& Operator s Manual Copyright Sure-Feed Engineering, Inc. 2003. All rights reserved. (Ver. 4.1) -1-
Table of Contents Topic Page Safety Statement and Recommendations 1 General Operation and Set-Up 4 Control Panel Operation 5 Stop Interrupt Operation 6 Integrated Control Panel 8 Set Up and Operation 9 Set Up Feeder Configuration 9 Side Guide and Back Wedge Selection and Installation 12 Material Alignment in Feeder 16 Long Transport Cover (FeedMax-S) 17 Feeder Separator Wheel Adjustment 18 Back Wedge Adjustment 19 Extend Roller, In-Feed Conveyor 19 Long Side Guide, In-Feed Conveyor 20 Short Side Guide, In-Feed Conveyor 22 Height Sensor Setting 22 FeedMax-S, Set-Up and Adjustments 23 Trailer Arm Adjustment 24 Ball Rack and Belt Alignment 25 Ball Rack Height Adjustment 26 Ball Rack Skew Adjustment 28 FeedMax-S Alignment to Old Style Bases 30 General Cleaning and Maintenance 32 Installation and Wiring 35 Wiring Diagrams 41 (Ver. 4.1) -2-
The FeedMAX and the FeedMAX S are designed to feed a variety of materials at a high capacity. Both models of the FeedMAX can be set up and operated in either, straight in-line or right angle configurations. Sure-Feed Engineering Inc. also offers a Left 90 degree Angle configuration FeedMAX and FeedMAX-S as a special order item. Depending on the specific model, the FeedMAX can be interfaced with several different types of ink jets, folders, tabbers and inserters as well as stand-alone applications. Both FeedMAX models come with an adjustable six (6) foot in-feed conveyor that will accommodate a variety of different size stock. Safety Statement and Recommendations The following recommendations for safe operation and maintenance of the FeedMAX and the FeedMAX-S are as follows: Any persons designated to operate, work on or near the FeedMAX or FeedMAX-S should be fully trained by a factory-authorized representative. Do not operate or perform any type of maintenance on the FeedMAX or FeedMAX-S while under the influence of drugs or alcohol. Do not operate or perform any type of maintenance on the FeedMAX or FeedMAX-S in or around freestanding water. Do not wear loose or baggie fitting shirts, shirts with bellowing sleeves, bracelets, rings, necklaces, neckties or other loose apparel that may come into close proximity with moving parts of the FeedMAX or FeedMAX-S. Do not attempt to increase the operating height of the FeedMAX or FeedMAX-S by putting wood 2X4 s, wood blocks, bricks, stacks of cardboard, stacks of paper, postal trays or any other objects or devices not known to the manufacturer, under the FeedMAX or FeedMAX-S. (The FeedMAX and FeedMAX-S are manufactured with adjustable leveler pads designed to provide an adjustable operating height range of plus five and one quarter inches [+ 5-1/4 ]. Increasing the operating height of the FeedMAX or FeedMAX-S beyond these specifications is not recommended by the manufacturer and other companies connected with the promotion and sale of the FeedMAX and FeedMAX-S. The manufacturer and other companies connected with the promotion and sale of the FeedMAX and FeedMAX-S do not assume any responsibility for any damage to the FeedMAX or the FeedMAX-S or product and shall be held harmless for any damages and / or injuries resulting from this practice.) Wear protective safety eyeglasses or goggles and use a particle mask or similar device when cleaning off the FeedMAX or FeedMAX-S with compressed air. Alert all other persons in the area to stand a minimum of thirty (30) feet from the area where compressed air is put to such use. All persons having hair greater than shoulder length who operate, work on or near the FeedMAX or FeedMAX-S should keep their hair pulled back in ponytail fashion then pinned up or otherwise contained to the top of their head or confined under the back of their shirt. Turn off the main power to the FeedMAX or FeedMAX-S before performing any maintenance. Any persons working near any of the electrical motors of the FeedMAX or FeedMAX-S should use caution. Electrical motors give off heat; contact with or exposure to bare skin may result in burns. The FeedMAX and the FeedMAX-S was designed to feed, transport and convey paper or paper products. Do not attempt to feed and / or run materials made of or containing glass, metal, wood, plastics, liquids, foods, powders, gasses, explosives or toxic and hazardous chemicals on the FeedMAX or the FeedMAX-S. (Note: The manufacturer recognizes and acknowledges that the FeedMAX and the FeedMAX-S are capable of successfully running and / or feeding compact disk and audio cassettes, however the manufacture and other companies connected with the promotion and sale of the FeedMAX and the FeedMAX-S do not assume any responsibility for any damage to the FeedMAX and / or the FeedMAX-S or product and shall be held harmless for any damages and / or injuries resulting from this practice.) (Ver. 4.1) -3-
& General Operation & Set-Up (Ver. 4.1) -4-
Control Panel Operation The power switch for the Conveyor and feeder are separate, both however are located on the main control panel, found mounted to the conveyor bed. (Special Note: FeedMax and FeedMax-S models that have been purchased as part of an ink jet system, will find only one power switch and one speed control knob on the control panel. These will control the conveyor only. The power and speed control for the feeder will be found on the control panel of the ink jet base.) To engage the conveyor power, depress the right side of the red rocker style switch, labeled Conveyor Power. The switch will illuminate when the power is on. Depressing the left side of this switch will turn the power off. To adjust the speed of the conveyor belts, turn the speed control knob labeled, Conveyor Speed in a clock-wise direction to increase the running speed. Turn the knob counter clock-wise to decrease the running speed. To engage the feeder power, depress the right side of the red rocker style switch, labeled Feeder Power. The switch will illuminate when the power is on. Depressing the left side of this switch will turn the power off. To adjust the speed of the feeder, turn the speed control knob labeled, Feeder Speed in a clock-wise direction to increase the running speed. Turn the knob counter clock-wise to decrease the running speed. To operate the Stop Interrupt button, depress the black button (One Time Only), located on the top of the Stop Interrupt module. This will stop the feeder only, the conveyor will stop automatically when the material going into the feeder raises enough to block the height sensor. (Note: Depressing the stop interrupt button a second time will re-start the feeder) Conveyor Speed Control Knob Feeder Speed Control Knob Feeder Power Switch Feeder Stop / Interrupt Button Conveyor Power Switch (Fig. 1) (Ver. 4.1) -5-
Operation of the Stop Interrupt Button The Stop Interrupt button mounted to the FeedMax and / or FeedMax-S with magnetic strips. The cable connecting it to the control panel is approximately ten (10) feet long. This enables the operator to position this button anywhere along the conveyor bed or the base of the machine the FeedMax is running material into. The Stop interrupt button can also be used in a hand held position, see figure 2. This is a helpful feature when setting up the feeder. (Note: If you are using the stop interrupt as a hand held item while setting up the feeder do not leave the cable laying on top of the conveyor or [transport of the FeedMax-S]. The cable could get caught in moving belts and become damaged, avoid this by passing the cable under the conveyor, see figure 3.) Stop Interrupt shown in Hand Held use (Fig. 2) Feeder Set-Up Positioṇ Operator s Position Direct the Stop Interrupt button cable UunderU the conveyor. (Fig. 3) Warning: Do not lay the stop interrupt button cable over the top of any machinery. (Ver. 4.1) -6-
The Stop Interrupt can be remove from the FeedMax / FeedMax-S by performing the following: a. Turn the retaining ring found on the Stop Interrupt button cable plug, located under the control panel, in a counter clock-wise direction to loosen. b. Pull the plug free from the receptacle. c. Cut the plastic retaining strap that secures the By-Pass Plug to the Stop interrupt cable, see figure 4. d. Insert the By-Pass Plug into the receptacle, align the pins in the plug to the holes in the receptacle and press firmly until seated, see figure 5. e. Secure the By-Pass Plug with the retaining ring by turning it in a clock-wise direction using light to moderate force. (Note: Do not over tighten the retaining ring.) (Fig. 4) To disengage the Stop Interrupt button, clip the plastic retaining strap (as shown) on the by-pass plug. Unplug the Stop Interrupt button cable and plug the by-pass plug into the same receptacle Selector switch for feeder demand signal Plug receptacle for Stop Interrupt Button / By-Pass Plug (Fig. 5) (Ver. 4.1) -7-
Power Switch and Speed Control The FeedMax models (only) that have been purchased as part of a new ink jet system, will have only one power switch and one speed control knob. These will control the conveyor only. The power and speed control for the feeder will be found on the control panel of the ink jet base. Operation of the Control Panel Integrated with a New Ink Jet System To engage the conveyor power, depress the right side of the red rocker style switch, labeled Conveyor Power. The switch will illuminate when the power is on. Depressing the left side of this switch will turn the power off. To adjust the speed of the conveyor belts, turn the speed control knob labeled, Conveyor Speed in a clock-wise direction to increase the running speed. Turn the knob counter clock-wise to decrease the running speed. Conveyor Speed Control Knob (Fig. 6) Conveyor Power Switch FeedMax control panel shown as it appears as an integrated component of an ink jet system. Note the absence of the feeder speed control knob and power switch. Demand Signal Switch The FeedMax and FeedMax-S come with a demand signal selector switch located on the bottom, left side of the control panel. This feature will isolate the type of demand signal that the base unit your running it with may provide. The control panel can receive the following types of signals: 24 Volt DC 24 Volt AC 24 Volt Dry Contact Depressing the back side, (closest to the in-feed conveyor) of the selector switch prompts the feeder for a 24 Volt Dry Contact single Depressing the front side of the selector switch prompts the feeder for a 24 Volt AC or DC signal. Selector switch for feeder demand signal (Fig. 7) Note: See page, for Installation Kit and wiring instructions. (Ver. 4.1) -8-
Set Up and Operation of the FeedMAX Set the feeder to the conveyor for either right angle or in line configuration by performing the following: 1. Turn the power off to the FeedMAX and / or FeedMAX-S. 2. Loosen the ratchet lock handle located to the right of the roller extension knob by turning it in a counter clock-wise direction, see figure 8. 3. Retract the front conveyor rollers by turning the adjustment knob in a clock-wise direction until the front rollers are completely retracted, see figure 8. Shown below is the FeedMAX S model with the long transport belt Adjustable Lock Handle and knob to extend / retract the front rollers of the conveyor (Fig. 8) Position of feeder assembly alignment holes in support deck 4. Using a Phillips head screwdriver, remove the paper guide located on the exit end of the in-feed conveyor, see figure 9. (Note: The paper guide is only used when running the Feed Max in a right angle configuration and must be removed before lifting the feeder up to re-position for straight in-line operation.) (Warning: Lifting the feeder with out removing the paper guide may result in damage to the machine as well as possible personal injury.) (Ver. 4.1) -9-
Remove these two (2) Phillips head screws and remove the paper guide. (Fig. 9) Remove socket head Allen screw Feeder Retaining Clamp Special Note: These retaining clamps are only found on FeedMAX-S models Loosen ratchet lock handle 5. FeedMAX-S (Only) remove the two (2) feeder retaining clamps located at the bottom of the feeder, see figure 9. to remove the two (2) retaining clamps, perform the following: a. Loosen the ratchet lock handle locate at the bottom of each retaining clamp. b. Using a 5/32 Allen wrench, remove the socket head Allen screw located on the side of the retaining clamp. (Note:These retaining clamps are designed to prevent the feeder from tipping in the event the long transport is not properly supported.) 6. Lift the feeder assembly straight up until the alignment pins are free of the feeder support deck. (Warning: The FeedMAX feeder assembly weighs 39 pounds, the FeedMAX S feeder assembly weighs 58 pounds, practice safe lifting techniques while performing this step or request assistance for lifting the feeder assembly.) (Ver. 4.1) -10-
7. Set the feeder assembly alignment pins in selected holes of the feeder support deck that best accommodates the configuration, (Straight or right angle) for the stock size you wish to run, see figure 10. (Note: Make sure all alignment pins are seated in holes, do not let the feeder assembly over hang the support deck. When performing this step with the FeedMAX S model, make sure the long transport belt assembly is supported at all times. Failure to support the long belt transport may result in damage to the machine.) Alignment holes for Straight In-Line configuration Direction In-Line Feed Direction of Right Angle Feed Conveyor Alignment holes for Right Angle configuration (Fig. 10) Set up the feeder section by performing the following: 1. Turn the power on to the feed max base and the ink jet base. 2. Select the side guide / guides, center guide and back wedge that best fit the material and configuration of the set up you are preparing to run. To change the center guide, perform the following: a. Remove the 3 or 4 Phillips head screws located at the bottom of the center guide. (Note: The center guide used for right angle operation has 3 Phillips head screws, the center guide used for straight in line operation has 4 Phillips head screws) b. Align the holes in the newly selected center guide to the center holes in the bridge tram bar of the feeder and secure it using the screws that were removed in step [a]. (Note: To avoid stripping out the threads in the bridge tram bar, do not over tighten the Phillips head screws.) (Ver. 4.1) -11-
To change the side guide / guides, perform the following: a. Remove the 2 Phillips head screws located on the current side guide / guides near the bridge tram bar. (Note: Do not loosen the front thumb lock or adjustable lock handle on the current side guide at this time, use care to prevent dropping the side guide or screws) Once the existing side guide has been removed the side clamp should still be secured to the bridge tram bar. b. Mount the newly selected side guide / guides to the side guide clamp using the Phillips head screws removed in step [a]. (Note: To avoid stripping out the threads in the side guide clamp, do not over tighten the Phillips head screws.) To change the back wedge, perform the following: c. Remove the thumb lock screw that secures the current back wedge to the agitator plate by turning it in a counter clock-wise direction, then lift up on the current back wedge until it is clear of the roll pin, see figure. d. Place the newly selected back wedge (slotted side down), onto the roll pin in the agitator feed plate and secure it with the thumb lock screw removed in step [c]. (Note: To avoid stripping out the threads in the mount block, located under the agitator feed plate, do not over tighten the thumb lock screw.) Special Note: The FeedMAX comes with a variety of back wedge guides, side guides and center guides. These are designed to accommodate most standard size stocks for either straight in-line or right angle configuration, see figures 11 through 19. Center Guide to run in line with the In-feed conveyor (Fig.11) Center Guide to run at 90-degree right angle with the in-feed conveyor (Ver. 4.1) -12-
Large product side guides for catalog size material. (Use both for running in-line with the in-feed conveyor, use the one shown on the left to run at a 90-degree right angle with the in-feed conveyor) (Fig. 12) Cut for height sensor eye when running straight in-line Standard product side guides for letter size material. (Use both for running in-line with the in-feed conveyor, use the one shown on the left to run at a 90-degree right angle with the in-feed conveyor) (Fig. 13) Side guide Clamps Shown with thumb lock and adjustable ratchet handle. (Fig. 14) In-feed conveyor paper guide Used only when running in right angle configuration (Fig. 15) (Ver. 4.1) -13-
Wide feeder back wedge Typically used for catalog size material (Fig. 16) Standard feeder back wedge Typically used for letter size material (Fig.17) Forward tilt back wedge Typically used to run flat sheets (8-1/2 X 11) with feeder set to run in an in-line configuration (Fig.18) Small feeder back wedge Typically used for business card or similar size material (Fig.19) (Note: For back wedge installation orientation, see figure 20 and 21, page 13, also see Back Wedge adjustment for set-up, page 17.) (Ver. 4.1) -14-
Running direction of material Separator Wheels Paper Standard back angle, back wedge Thumb Lock Screw Agitator Feed plate Alignment Roll Pin (Fig. 20) Back wedge slide block Separator Wheels Running direction of material Paper Thumb Lock Screw Agitator Feed plate Alignment Roll Pin Back wedge slide block (Fig. 21) Front Tilt back angle, back wedge (Runs 8-1/2X11, inline only feeding paper long-wise) (Ver. 4.1) -15-
3. Fold one sample piece of the material your going to run in half from leading edge to trailing edge, forming a center crease, see figure 22. Center Crease Run Direction Post Card To John Q. Public Letter To John Q. Public $ Run Direction Center Crease (Fig. 22) 4. Set the creased sample in the feeder and align the crease with the Phillips head screws in the center of the stainless steel shroud of the separator wheels, see figure 23. Align the center crease in the sample, to the center screws on the feeder shroud Move the side guide until it just touches the material Feed Max-S shown set up in right angle configuration (Fig. 23) (Ver. 4.1) -16-
5. Loosen the front thumb lock and the adjustable ratchet handle on the side guide / guides. When running in a right angle configuration, slid the side guide over until it just touches the material, then tighten the front thumb lock and adjustable handle using light to moderate force. In the event you are setting up the FeedMAX or FeedMAX-S for straight in line running, adjust both side guides to within a 1/8 of the material, see figure 23. (Note: Do not over tighten the thumb lock or the adjustable handle.) 6. Lift up on the separator wheel using the separator lift bar and slide the set up sample under the separator wheels and release the lift bar, see figure 26. (Helpful Tip: The lift bar can be utilized in two ways; First method; Push down on the lift bar, using it as a lever to lift the separator wheels. Second method; lift up on the lift bar, lifting the separator wheels at the same time.) [Special Note for FeedMAX-S operators: In order to use the Second method of lifting the lift bar, the clear lexan cover must be raised, to do this use a 1/8 Allen wrench and remove the button head screw, located at the bottom of each (two) retaining brackets, found on each side, at the exit end of the long transport and lift cover, see figures 24 and 25.] Remove these two (2) button head Allen screws to lift the lexan cover (Fig. 24) Warning: To avoid damage turn locking ratchet handles on feeder side guides away from cover before opening Open lexan cover from exit end of the long transport (Fig. 25) Special Warning: After the set-up is complete, be sure to re-secure the clear lexan cover to the exit end of the long transport using the button head screws previously removed in step # 6. The manufacture and other companies connected with the promotion and sale of the FeedMAX and FeedMAX-S do not recommend running the FeedMAX or FeedMAX-S with the clear lexan cover loose or removed. (Ver. 4.1) -17-
Lift up on Lift Bar to raise the Separator Wheels for sample placement during set-up To change the height of the separator wheels, turn the adjustment knob clock-wise to raise, counter clock-wise to lower (Fig. 26) 7. Adjust the height of the separator wheels by turning the adjustment knob (Clock-wise to raise, counter clockwise to lower) until light resistance is felt when pulling on the set up sample, see figure 26. (Ver. 4.1) -18-
8. Adjust the back wedge to create a slight angle to the stack of material. (Note: Generally, the more back wedge is under the stack of material, the less critical the separator wheel adjustment becomes, the less back wedge is under the material, the more critical the separator wheel adjustment becomes. Exceptions to this may depend on the characteristics of the material you are running.) Helpful Tip: All adjustments to the back wedge should be made to accommodate the characteristics of the material you wish to run. For the purpose of a basic starting point, try the following: For ridged stock, place the lead edge of a sample of the stock your setting up under the separator wheels at 6 o clock, position the lowest point of the back wedge so that it is just touching the trailing edge of the sample piece. For flimsy stock, place the lead edge of a sample of the stock your setting up under the separator wheels approximately half an inch beyond the 6 o clock position and set the back wedge so that the trailing edge of the sample is about a half to one inch up the incline from the lowest point of the back wedge. For stock containing static, place the lead edge of a sample of the stock your setting up under the separator wheels at 6 o clock, position the back wedge so the trailing edge of the sample is mid-way between the lowest and highest point of the back wedge. Note: These are basic starting points for a set-up Further adjustments may be required. 9. Jog / inch the ink jet base forward to check the feeder set up. (Note: If the feeder is set up correctly, the material should feed onto the ink jet base one piece at a time. More adjustment to the separator wheels or back wedge may be required at this time.) (Special Note for FeedMAX-S Operators: In the event you notice the material lagging or hesitating between the Red Gum Friction Belts and the Long Green Transport Belts, then make an adjustment to the Trailer Arm. To adjust the trailer arm, see page 21.) 10. Stack some material in the feeder so the height is just a little higher than the in-feed conveyor. 11. Extend the in-feed conveyor exit roller until it is almost touching the stack of material placed in the feeder in step # 10. This is done by performing the following: a. Loosen the adjustable ratchet handle by turning it counter clock-wise, see figure 27. b. Extend the in-feed conveyor exit roller by turning the silver knob counter clock-wise, see figure 27. c. Tighten the adjustable ratchet handle by turning it clock-wise. (Caution: Do not over tighten the adjustable ratchet handle.) (Ver. 4.1) -19-
Extend / Retract Extend conveyor by turning this knob clock-wise, retract by turning counter clock-wise Adjustable ratchet handle (Fig. 27) 12. Set the in-feed conveyor side guide to create a free path for material to glide into the feeder. This is done by performing the following: a. Loosen both lock knobs that secure the long conveyor side guide to the conveyor bed, by turning them in a counter clock-wise direction, see figure 28. b. Adjust the conveyor side guide nearest the feeder so the inside surface is in line with the inside surface of the feeder side guide (when set up to run in a straight in-line configuration) or to the surface of the feeder center guide (when set up to run in a right angle configuration). (Helpful Tip: Use a sample of the material you are setting up, as a straight edge to assist you with this adjustment, see figure 28) c. Tighten the lock knob, nearest the feeder, by turning it in a clock-wise direction, to hold the side guide in position. It is important that the material, tracks straight on the conveyor belts. To ensure straight tracking, the long conveyor side guide must be parallel to the edge of the conveyor bed. To do this, perform the following: d. Measure the distance between the back surface of the side guide and the edge of the conveyor bed nearest the feeder. (Again, this can be done using a sample of the material you are running. Simply hold one end of the material sample against the back side of the conveyor side guide near the lock knob tightened in step - c. and crease it at the point where it bends over the back edge of the conveyor bed. e. Set the trailing end of the side guide to match the measurement taken in step d, us the sample previously creased as a reference, then secure the lock knob by turning it in a counter clock-wise direction. Once the rail is in position, tighten the trailing end lock knob by turning it in a clock-wise direction. (Ver. 4.1) -20-
Place sample along these two surfaces to align conveyor side guide with the feeder guide Turn Counter Clockwise to loosen Turn Clockwise to tighten (Fig. 28) The short side guide helps to control material as it travels from the conveyor to the feeder. Properly set, it should barely touch the material 13. Once the exit roller of the in-feed conveyor has been extended and the in-feed conveyor long side guide has been set, manually draw the material from the top of the stack, placed in to the feeder in step # 10, onto the in-feed conveyor, see figure 29. Manually over fill the feeder, then draw the material back over the in-feed conveyor. This will establish a natural radius for the material to follow and provide a starting reference point to position the height sensor. (Fig. 29) (Ver. 4.1) -21-
14. Set the height sensor to monitor the height of the material in the feeder by manually changing the contour of the adjustable cable housing, see figure 30. (Note: When the material height drops below the level of the sensor, the in-feed conveyor will be automatically triggered to run. More material will advance into the feeder until the sensor is blocked.) 15. Set the short side on the conveyor by performing the following: a. Loosen the lock knob by turning it in a counter clock-wise direction, see figure 28. b. Position the short side guide so that it is just barely touching the edge of the material that was drawn onto the conveyor in step # 13. (Note: There are two [2] rows of threaded holes providing six [6] different positions for the lock knob. The short side guide has a 1.50 slot in it, these two factors allow for a wide range of positions the short side guide can be placed in.) c. Once the short side guide has been properly positioned, tighten the lock knob by turning it in a clock-wise direction. Set height sensor to the top of the material stack in the feeder, below the level of the conveyor roller as shown Special Note: When the exit roller is adjusted correctly, the material coming off of the conveyor into the feeder will appear to have an even radius creating a waterfall effect Adjust roller until it almost touches the material in feeder... Extend / Retract. Adjustable ratchet handle In-feed conveyor exit paper guide. Used for right angle configuration only Extend conveyor by turning this knob counter clock-wise, retract by turning clock-wise (Fig. 30) (Ver. 4.1) -22-
Set-Up & Adjustments (Ver. 4.1) -23-
FeedMAX-S (Only) In the event the material you are running lags or hesitates between the red friction gum belts and the green transport belts, adjust the trailer arm by performing the following: 1. Open the clear lexan cover over the transport as shown in step # 6 on page 17, figures 24 and 25, basic set up. 2. Using a 5/32 Allen wrench, loosen the socket head Allen screw, located forward of the separator wheels in the slotted height adjustment bar, by turning it in a counter clock-wise direction, see figure 31. 3. Manually lift the bearing rollers locate at the end of the trailer arm and place a sample of the material you are running under the trailer arm bearing rollers, see figure 31. 4. Release the bearing rollers, allowing them to rest on the sample piece under their own spring tension. (Note: You should notice a moderate amount of resistance when pulling on the sample piece.) 5. Using a 5/32 Allen tighten the socket head screw, (loosened in step #2), by turning it in a clock-wise direction. Loosen the sockethead screw using a 5/32 Allen wrench (Fig. 31) Lift up on the bearing rollers, place sample between bearing rollers and green transport belt. Release bearing rollers so that they rest on the sample under their own spring tension (Ver. 4.1) -24-
FeedMAX-S (Only) Belt Alignment and Adjusting the Transport Ball Rack The ball rack is designed to control and maintain orientation of the material as it travels the length of the transport assembly. The transport belts and ball rack may need to be adjusted to accommodate the dimensions and thickness of the stock your running. These adjustments can be made by performing the following: 1. Turn off the power to the FeedMAX or FeedMAX-S. 2. Open the lexan cover over the transport assembly by performing the following: a. Use a 1/8 Allen wrench and remove the button head screw, located at the bottom of each (two) retaining brackets, found on each side, at the exit end of the long transport, see figure 24. b. Lift the lexan cover from the exit end of the transport assembly. See figure 25. 3. Manually drive one piece out of the feeder by turning the shaft at the exit end of the feeder, with the red gum friction belts, in a clock-wise direction, see figure 32. 4. Manually position the transport belts to support the material you are running. Take the roller and transport belt together between your thumb and forefinger and slid them to the desired position, see figure 32. (Helpful Tip: Running common flat stock, the outer edges should be supported evenly supported as well as the center. Running perforated, die-cut, hammer scored or end folded stock, the outer edges should still be evenly supported, however the center belts may be off set to compensate for weight or drag created by the material.) Manually position the transport belts to support the material you are running. Take roller and belt together between thumb and forefinger then slide it to the desired position. Special Note: One roller and belt must be left directly under the trailer arm With the power UOFFU, manually turn this shaft until the lead edge of one piece is over the green transport belts Ball Rack Adjustment Knob (Fig. 32) This roller and transport belt will move with the ball rack, when the ball rack adjustment knob is turned. Ball Rack (Ver. 4.1) -25-
5. Set the height of the Ball Rack to accommodate the thickness of the material you are running by performing the following: a. Set a sample piece under each end of the ball rack, see figure 33. b. Using a 1/8 Allen wrench, loosen the three (3) button head screws located on the back side of the silver ball rack guide bracket, see figure 33. c. Let the ball rack rest on the sample pieces, under it s own weight, (DO NOT push down on the ball rack), tighten the button head screws loosen in step (a.). d. Test this setting by sliding one sample piece, under the ball rack, from end to end. (Note: If the ball rack is properly set, there should be no variation of drag felt.) Loosen these three (3) button head screws to adjust Ball Rack height Shown without lexan cover (Fig. 33) Place sample piece at each end of the Ball Rack 6. Set the placement of the ball rack by performing the following: a. Manually drive one piece out of the feeder, just as described in step #3 of this section, see figure 32. b. Turn the Ball Rack Adjustment Knob, clock-wise to move the ball rack towards the center of the transport or counter clock-wise to move the ball rack towards the side of the transport, see figures 32 and 33. (Note: When the ball rack is adjusted correctly, the material should not touch the inside of the ball rack side guide until it is at the exit end of the long transport, see figures 34 and 35.) (Ver. 4.1) -26-
Gap between the edge of the stock and the side guide of the ball rack When correctly set, the stock should enter the ball rack but not touch the side guide of the ball rack, see inset. (Fig. 34) The edge of the stock touches the ball rack side guide When correctly set, the stack should touch the ball rack side guide at the exit end of the transport assembly, see inset. (Fig. 35) (Ver. 4.1) -27-
In the event it becomes necessary to adjust the skew of the ball rack, do so by performing the following: 1. Turn the FeedMax-S power off. 2. Open the lexan cover as described in step # 6 on page 17 figures 24 and 25. 3. Using an 1/8 Allen wrench, remove the four (4) button head Allen screws located in the top of the side cover, see figure 36. (Note: To prevent the cover from falling or being dropped, support the side cover when removing the retaining screws.) Remove these four (4) button head screws to remove the side cover (Fig. 36) 4. Using both hands, one at each end, remove the cover by lifting up just a little then pull the cover away from the long transport assembly, see figure 37. (Caution: There are two drive belts under this cover, use caution when removing the cover to prevent damage to the belts.) Loosen these two (2) set screws when adjusting the ball rack skew... Access the set screws, from inside the belt radius (Fig. 37) (Ver. 4.1) -28-
4. Using a 5/64 Allen wrench, loosen the two (2) set screws in the pulley located at the exit end of the transport assembly, see figure 37. (Helpful Tip: Gain access to the setscrews by slowly turning the ball rack adjustment knob. Loosen the setscrews as they appear inside the radius of the belt.) 5. Hold the exit end of the ball rack and slowly turn the ball rack adjustment knob to alter the factory set skew. (Helpful Tip: Turn the adjustment knob clock-wise to move the entry end of the ball rack towards the center of the transport assembly, counter clock-wise to move the entry end of the ball rack towards the side of the transport assembly) (Note: The ball rack skew should never be less than ¼, measure from the side frame of the transport directly over the threaded shaft at the entry end of the ball rack, then measure from the side frame directly over the threaded shaft at the exit end of the ball rack to ensure the accuracy of the recommended tolerance.) Special Note: While the ball rack adjustment knob was being turned as described in step # 5, the pulley loosened in step # 4 will also turning freely on the threaded shaft at the exit end of the transport assembly. After the desired adjustment has been made to the ball rack skew, it may be necessary to turn the adjustment knob a little more to gain access to the set screws in the free spinning pulley. If this dramatically alters your adjustment, manually turn the threaded shaft at the exit end of the transport to retain your adjustment before tightening the first setscrew. The adjustment knob can then be turned to gain access to the second set screw with out altering the ball rack skew. (Note: Be sure to align the set screws with the flats of the shaft. Caution: To avoid scarring the shaft, do not over tighten the setscrews.) 6. Re-assemble the transport by following steps # 4 through # 1 in reverse order. (Ver. 4.1) -29-
Special Note: When setting up the FeedMax-S with an older shuttle feed style ink jet bases, it is recommended to align the FeedMax-S by using the ball rack side guide as the reference. This can be done by performing the following: 1. Set up the FeedMax-S as described in this manual. 2. Line up the silver side guide of the ball rack parallel to the small gap between the shuttle and deck of the ink jet base. (Note: This will result in a slightly skewed appearance between the ink jet base and the FeedMax-S) To align the FeedMax-S to an old style ink jet base, perform the following: a. Lift up on the exit end of the long transport just enough to break the suction of the support feet cups, see figure 38. b. Place a piece of chip board, single ply card board or index card under each support foot cup, see figure 38. (Note: This is an important step, it prevents suction from occurring allowing for free movement of the exit end of the long transport.) (Warning failure to perform this step as described may result in damage to the support feet cups.) c. Stand at the back end of the in-feed conveyor and nudge the FeedMax-S right or left until the desired alignment is obtained, see figure 39. (Warning: The FeedMax-S has a shipping weight of 300 pounds, use caution when performing this step or ask for assistance to avoid injury.) d. When the desired alignment has been obtained, remove the chip board or card board pieces that were placed under the support feet cups in step (b). Lift this end of the transport to break the suction of the support feet cups Ball Rack lines up parallel to the gap between the shuttle and deck of the old style ink jet base Place chip board or index card under each support foot cup (Fig. 38) (Ver. 4.1) -30-
See Figure 31 for close up illustration Operator s Position Note: The Ball Rack has an adjustable skew as described on page 23. You will no longer see a 90-degree relationship between the FeedMax-S and the old style ink jet base after using the Ball Rack as the alignment reference. o o 90 + 90 - Nudge this end of the FeedMax-S to align (Fig. 39) (Ver. 4.1) -31-
& General Cleaning & Maintenance (Ver. 4.1) -32-
Maintenance and Care of the FeedMax and FeedMax-S General Cleaning of the FeedMax and FeedMax-S Blow off the feeder and conveyor using compressed air to fee it of paper dust and debris. (Warning: Wear protective safety eyeglasses or goggles and use a particle mask or similar device when cleaning off the FeedMAX or FeedMAX-S with compressed air. Alert all other persons in the area to stand a minimum of thirty (30) feet from the area where compressed air is put to such use) The conveyor belts may pick up residual ink off of printed material and may be cleaned with Simple Green or Isopropyl Alcohol. Both items can be purchased at most local grocery stores. To clean the Conveyor Belts, perform the following: 1. Turn off the conveyor and feeder power switches. 2. Apply a liberal amount of Simple Green or Isopropyl Alcohol to a clean cloth. 3. Wipe down that portion of the conveyor belts visible on the top side of the conveyor bed. (Warning: Do not reach under the conveyor bed to clean belts) 4. Turn the conveyor power switch back on and advance the conveyor until approximately four (4) feet of unclean conveyor belt becomes visible on the top side of the conveyor bed. (Helpful Tip: It may be necessary to position the feeder material height sensor away from the feeder to advance the conveyor) (Note: Repeat steps 1 through 3 until the total length of the conveyor belts have been cleaned.) (Warning: Do not attempt to clean conveyor belts while the machine is running.) The friction belts in the feeder may pick up residual ink off of printed material and may be cleaned with Simple Green or Isopropyl Alcohol. Both items can be purchased at most local grocery stores. To clean the Feeder Friction Belts, perform the following: 1. Turn off the conveyor and feeder power switches. 2. Apply a liberal amount of Simple Green or Isopropyl Alcohol to a clean cloth. 3. Wipe down that portion of the feeder friction belts visible on the top side of the feeder. 4. Advance the feeder manually, as stated on page 25, figure 32. (Note: Repeat steps 2 through 4 until the total length of the feeder friction belts have been cleaned.) (Warning: Do not attempt to clean feeder friction belts while the machine is running.) (Ver. 4.1) -33-
Lubrication The FeedMax and FeedMax-S are assembled with sealed bearings that require no lubrication. Only the adjustment rack and slid shafts that extend and retract the front roller of the in-feed conveyor need to be lubricated with a Lithium based multi-purpose grease. This grease can be purchased at most local automotive parts stores. To lubricate these parts, perform the following: 1. Turn the power off to the in-feed conveyor. 2. Retract the front roller of the in-feed conveyor as described on page 17 and shown in figure 27 on page 18. 3. Apply a liberal amount of Lithium based multi-purpose grease to the slide shafts and adjustment rack, see figure 40. Under side view of In-Feed Conveyor (Fig. 40) (Ver. 4.1) -34-
& Installation & Wiring (Ver. 4.1) -35-
Hard Wire Installation The FeedMax and FeedMax-S Installation Kit comes with the following items One 120 Volt AC Power Cable with stripped and tinned ends One Dry Contact Interface Cable with By-Pass Plug One Conveyor Interface Cable with 24 Volt AC / DC Interface One Stop Interrupt Button with By-Pass Plug The feeder used on the FeedMax and FeedMax-S are designed with the following interfaces: 24 Volt DC Interface 24 Volt AC Interface Dry Contact or Normally Open Interface 120 Volt AC connect cable (Hard wire the feeder to an older style ink jet base) Item A Item B Item C Item A B C Interface Item Description 120 Volt AC Power cable with stripped and tinned Ends Conveyor interface cable with 24 Volt AC / DC Interface Dry Contact Interface cable with additional by-pass Plug attached (Fig. 40) (Ver. 4.1) -36-
120 Volt AC Interface Use (item B) cable from In-Feed Conveyor Item A Connect the 120 volt AC power cable plug from In-Feed Conveyor or (See figures BK-1 to BK-3 for 120 Volt wiring to Buskro) (Fig. 41) Connect the dry contact by-pass plug from Item C Selector switch for feeder demand signal Depress the Back side of the select switch, (closest to the infeed conveyor) for Dry Contact Mode to use 120 Volt Interface (Fig. 42) (Ver. 4.1) -37-
Dry Contact interface Use (item B) cable from In-Feed Conveyor Use existing 120 volt AC power cable plug from In-Feed Conveyor Item C Connect the dry contact (Fig. 43) Selector switch for feeder demand signal Depress the Back side of the select switch, (closest to the in-feed conveyor) for Dry Contact Mode to use Dry Contact Interface (Fig. 44) (Ver. 4.1) -38-
24 Volt AC / DC Interface Item B Connect plug marked Feeder, Connect plug marked Conveyor to existing cable plug at In-Feed Conveyor. (See figure CH-1 for 24 Volt DC wiring to Cheshire) Use existing 120 volt AC power cable plug from In-Feed Conveyor Connect the dry contact by-pass plug from Item C (Fig. 45) Selector switch for feeder demand signal Depress the Front side of the select switch, (closest to the infeed conveyor) for 24 Volt Mode to use 24 Volt Interface (Fig. 46) (Ver. 4.1) -39-
Wiring for FeedMax / FeedMax-S to Cheshire (Fig. CH-1) (Ver. 4.1) -40-
Wiring for FeedMax / FeedMax-S to Buskro (Fig. BK-1) (Ver. 4.1) -41-
Wiring for FeedMax / FeedMax-S to Buskro (Fig. BK-2) (Ver. 4.1) -42-
Wiring for FeedMax / FeedMax-S to Buskro (Fig. BK-3) (Ver. 4.1) -43-
Notice This manual is a work in progress and is subject to change. This manual is updated frequently to accommodate changes, modifications and updates made to the FeedMax or FeedMax-S, software and / or other electronics. As these changes are made the version number of the manual will also change. (Ver. 4.1) -44-