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Extend-O-Feed Lead Edge Feeder Table of Contents

Foreword ...................................................................................... 2

How the System Works ................................................................. 3

Operating the System

Stroke Setting ............................................................................ 4

Feed Gate Setting ....................................................................... 7

Backstop Setting......................................................................... 7

Vacuum Pressure ................................................................ 8

Vacuum Door Setting .................................................................. 8

Maintenance ................................................................................. 9

Trouble Shooting ........................................................................ 13

Illustrations and Assemblies ......................................................... 22

© Copyright 2009, Rev.01, Sun Automation, Inc. All rights reserved.

© Copyright 2010, Rev.01.1, Sun Automation, Inc. All rights reserved.
© Copyright 2011, Rev.01.2, Sun Automation, Inc. All rights reserved.

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 Foreword

On today’s flexo-folder gluers, rotary die cutters, printer slotters, and other finishing
presses, lead edge feeders have become the standard. Among different types of lead
edge feeders, the rotary-motion Extend-O-Feed is widely recognized as the best in
performance and in reliability. Advantages of Extend-O-Feed over a conventional kicker
bar feeder are listed below.

The overwhelming benefit of the lead edge feeder is fewer jams. There are other
advantages, but none as beneficial as the dramatic reduction in jams and the resulting
savings in scrap and lost productivity time. The basic concept of utilizing a large area
of low vacuum pressure to grip the sheet is much more effective than the kicker bar
arrangement. Extend-O-Feed uses this method for positive sheet control without
sacrificing registration accuracy.

E-flute, cross-corrugated, and low quality board will tend to buckle when pushed by a
kicker bar. These jobs can be fed effectively with a lead edge feeder.

Quicker set-up is another advantage of lead edge feeders, especially on orders that
require the kicker bar to be changed for board caliper.

Some advantages of Extend-O-Feed over other lead edge feeders are:

Less board crush. Since lead edge feeders have a larger and stronger vacuum area than
kicker bar feeders, greater feed roll pressure may be required to pull the sheet over the
vacuum area. However, Extend-O-Feed allows for continued feeding beyond the feed
rolls.

Direct Drive, totally enclosed, maintenance-free, oil-bath-lubricated transmission with

variable stroke for more control of board.

Low-friction metal grate runners last for years.

Auto indexing hunting ratio assures even wheel tread wear for maximum feed element
life.

Extremely rugged and precise construction for maximum rigidity and minimum
vibration. Custom-engineered for smooth integration within your existing finishing
machine.

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How the System Works

Extend-O-Feed feeds the sheet into the machine through a precise movement of
wheels and wheel box grates working in conjunction with a properly sized vacuum hold-
down. The transmission, which is a totally enclosed oil bath system, houses all gears
and cams as well as the grate lifting mechanism and interrupter mechanism. The
transmission, which is virtually maintenance free, controls the wheel speed in time with
the grate up/down movement.

The feed wheels have a soft urethane outer cover, which has a high coefficient of
friction with the sheet. During machine idle (Interrupt period), the sheet is not
contacting the wheels because the grate is in the up position. Once the feed cycle has
begun, the grate, which supports the sheet in the area around the wheels, is lowered.
This allows the sheet to come into contact with the wheels. Wheel velocity at the
beginning of the feed cycle is nearly zero, but increases quickly to 100% of machine
tangent velocity and remains there for the entire feed stroke.

Extend-O-Feed does not merely feed the sheet to the feed rolls like kicker bar systems
and other lead edge feeder systems. The feed wheels extend the feeding motion
beyond the feed rolls for nearly the entire length of the sheet. This extended feeding
motion helps solve crush problems on feed rolls and assures accurate registration.

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 Operating the System

Stroke setting – Proper use of the Extend-O-Feed’s adjustable stroke feature can
reduce board crush, reduce feed roll wear, and improve register.

In order to truly understand the adjustable stroke feature, the reader should first
understand the relationship between the Feeder wheels and the Stack support (Grate)
movement. Observe the feeder as it runs without feeding any boards. Notice that the
Stack support (Grate) lowers when the wheels slow down to minimum velocity. This is
the point when the sheet would first contact the wheels. This relationship (timing) is
internally set during the construction of the transmission. The point when the Stack
support (Grate) raises is determined by the stroke setting. For minimum stroke, the
Stack support (Grate) lowers for just a short time. For maximum stroke, the Stack
support (Grate) lowers for approximately three (3) times as long as minimum. In short,
the longer the Stack support (Grate) is down, the longer the Feeder wheels contact the
sheet.

Stroke adjustment – The feed stroke adjustment is located on the outside of the
Extend-O-Feed transmission (see Illustration 1). In order to change the stroke settings
follow these instructions:

 Turn the machine off with the feeder in the interrupt mode. The interrupt mode is
when the stack support runners (Grate) are locked in the “Up” position.

 Open the machine, if necessary, to get access to the transmission. Loosen, but do
not remove, the two hex head bolts near the dial.

 Turn the flywheel until the dial reads the desired setting. The numbers on the dial
correspond to the sheet width (measured in the direction of feed).

 Tighten the stroke adjustment bolts.

Stroke setting – basic rules – As previously stated, the stroke setting can be
adjusted every time the sheet size changes. The higher the setting, the more the board
is fed beyond the feed rolls. In general, the dial should be set to correspond to the
sheet width. In other words, referring to “D” (see Illustration 1); these numbers
correspond to the sheet size (in direction of feed). Below is a list of guidelines:

 If possible, set the stroke to correspond to the sheet width.

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 The stroke dial should never be set at a number greater than the sheet width
(unless you are feeding a sheet that is slightly smaller than the lowest number on the
dial, in which case the lowest number is acceptable).

 If the sheet is larger than the maximum dial setting, then set the stroke at the
maximum setting.

Stroke setting – Helpful hints - the following tips will enable Extend-O-Feed to hold
registration when the corrugator score is passing through the feed rolls:

 If possible, always set the feed stroke so that the corrugator score is through the
feed rolls before the feeder wheels lose contact with the sheet. Referring to Illustration
2, “F” should be greater than “S” provided “W” is smaller than “D” from Illustration 1.

 Referring to Illustration 3, if possible let the sheet be fed all the way to the first
print unit pull rolls before losing contact with the feeder wheels. On some machines the
pull rolls are located in front of the print cylinder so this can be done easily.

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Feed Gate Setting – unlike a kicker bar feeding system, the lead edge feeder
requires very accurate front gate settings.

 Feed gates should be positioned wide enough to keep board parallel to feed rolls,
usually as wide as possible but not wider than the width of wheel box.

 The gap between the top of the wheel box and the bottom edge of the feed gates
should be exactly the same on both feed gates and should only exceed the board
thickness by a small amount.

Backstop Setting – The trailing edge of boards should slide down on backstop front
lip and should be sitting against front wall of the backstop channel.

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Vacuum Pressure – All machines have a standard vacuum gauge that is located on
the bed of the lead edge feeder. This gauge measures in inches of H20. Most orders
should be able to run accurately with approximately 17 inches of H20. However,
severely warped sheets may require more pressure. For machines with a kPa gauge,
the reading should be approximately –4.5 kPa.

Vacuum Door Setting – (see Vacuum Door illustration) Vacuum doors are set open
or closed depending on the width of the board (length of board across the machine). If
the board is wider than the wheel box vacuum area, all the doors will be in the open
position. If the board is not as wide as the wheel box vacuum area, one door on each
side of the wheel box should be closed corresponding to the width of the board. To
avoid vacuum leakage, vacuum is shut off within the width of the sheet. This ensures
that as much of the sheet as possible will be pulled down by the vacuum, and that none
of the vacuum will be lost due to leaks in the area that the sheet is not covering.

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 Maintenance
Do not attempt to perform any preventative maintenance on the Extend-O-
Feed Lead Edge Feeder system without first being sure that all electrical
power has been turned off. Always use caution when performing any work
on the machine.

Mechanical:

Between Orders

– Remove scrap paper (loose liners etc.) from vacuum area of feed table between
orders or no less frequently than at the end of the shift.

Daily

– Check the dust container on the Dust Collector (optional equipment) container
unsnaps from the lid and easily snaps back on. Empty as it becomes filled half way.

Weekly

– Wheel Shaft Bearings

Location: Top of feed table within vacuum area.
The wheel shaft roller bearings should be greased with LITHIUM NLGI GRADE 2 or
DRYDENE 4000 grease. Use a hand-operated grease gun in order to avoid damage
to the bearing grease seals. It should take no more than three to five pumps to fully
lubricate these bearings.

– Rocker Shaft Wheel Box Bushing

Location: In front of wheel box (not on all models).
The rocker shaft mounting bushings should be lubricated with LITHIUM NLGI GRADE
2 or DRYDENE 4000.

– Rocker Drive Lever Bushings

Location: On transmission rocker drive lever.
The rocker drive lever bushings should be lubricated with LITHIUM NLGI GRADE 2 or
DRYDENE 4000.

– Rocker Shaft Transmission Bushing

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Location: On transmission.
The rocker drive lever bushings should be lubricated with LITHIUM NLGI GRADE 2 or
DRYDENE 4000.

– Filter Regulator Lubrication

The filter regulator should be kept filled with #10 SPINDLE OIL.

– Wheel Covers
Location: On wheel box.
Inspect the condition of the feed wheels for excessive wear and replace as needed.

NOTE: SEVERAL WORN OR DAMAGED FEED WHEELS DO NOT NECESSITATE

IMMEDIATE REPLACEMENT. SINCE IT IS RECOMMENDED THAT FEED
WHEELS BE REPLACED IN COMPLETE SETS, WE SUGGEST THAT THESE PARTS
BE REPLACED AT REGULAR INTERVALS.

Wheel Cover Replacement instructions:

– Move Feed section away from rest of machine so as to allow access to back of wheel
box.

– Turn off power to machine.

– Remove side bed covers.

– (Mark before removing to ensure proper re-assembly.) Loosen screw in wheel shaft
couplings.

– Insert wedge into split line of coupling and slide toward frame until couplings are free
to slide on the transmission stub shafts.

– (Mark before removing to ensure proper re-assembly.) Remove wheel box lips.

– Remove springs located on top of grates.

– (Mark before removing to ensure proper re-assembly.) Remove grates.

– Remove bearing mounting bar caps.

– Remove wheel box frame caps.

– Lift out wheel shafts.

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NOTE: WITH WHEEL SHAFTS REMOVED, THIS IS A GOOD TIME TO CLEAN
OUT THE WHEEL BOX. IF DUST COLLECTS IN THE BOTTOM OF THE WHEEL
BOX, THE VACUUM DOORS WILL NOT OPEN AND CLOSE PROPERLY.

– Remove worn wheel treads and replace with new wheel tread covers, making sure
that each new wheel tread is fully seated in aluminum wheel core (this can be
accomplished by tapping wheel treads with a rawhide or plastic hammer or rolling
entire shaft on a hard surface).

– Re-assemble by reversing the above procedure, making sure that grease holes in
bearing are properly aligned with grease fitting in their perspective caps.

– Re-grease wheel shaft bearings.

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Monthly

– It is recommended that the feed table (wheel box) lips be removed so that board dust
and scrap paper that may have become trapped in the vacuum area is removed.

– Filters on the Dust Collector (optional equipment) need to be inspected and cleaned
as required. Replace if they become damaged.

Semi-annually

Caution: Extend-O-Feed Transmission is shipped without oil. Be sure to fill

prior to initial start-up.

– Transmission Oil Level

The Extend-O-Feed transmission is furnished with a “bulls-eye” type of oil level sight
gauge. The level should be checked when the unit is stopped, at which time the oil
level should reach the center of the sight glass. During oil changes this “bull’s eye” can
be removed for cleaning.

Oil Change:

An oil change is required every 2000 hours of operation, or every six months whichever
occurs first. Where operating conditions are severe, such as: rapid rise and fall in
temperature of the transmission housing (which results in the formation of sludge), or
where operation is in moist and dusty atmospheres, or in the presence of chemical
fumes, it may be necessary to change the oil in intervals of one to three months.

Type of oil:

Lubricating oils for use in an Extend-O-Feed transmission should be high quality, well-
refined petroleum oils, or synthetic lubricants with extreme pressure additives. They
may be subject to high operating temperatures, so they must have good resistance to
oxidation. The following is a list of approved lubricants for use in Extend-O-Feed
transmission.
MOBILUBE 46 SAE 90 (MOBIL OIL)
MOBILGEAR 630 (MOBIL OIL)
OMALA 220 (SHELL OIL)
MEROPA 220 (TEXACO OIL)
MOBILUBE 220 (MOBIL OIL)
SCL LUBRIANT SAE 90 (AMERICAN OIL)
(See Engineering Bulletin #61 for more information)

Trouble Shooting

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Symptom Mechanical:

Mis-feeding – Sheet advances squarely but not in register.

 Vacuum blower not running – Turn on blower.

 Too much or too little vacuum – Adjust vacuum doors, adjust speed of blower if
Adjustable Frequency Drive is supplied.

 Backstop not properly adjusted – Set backstop so that boards are not wedged
between the feed gates and backstop.

 Pile height too high (too much weight in hopper) – Reduce pile height.

 Improper feed roll pressure – Increase feed roll pressure, replace worn rolls.

 Not enough wheel tread in contact with sheets – Replace feed wheels.

Sheet Skewing – There are three opportunities for a sheet to become skewed when
passing through the feed section. The sheet could be presented to the Lead Edge
feeder skewed, the Lead Edge feeder could transfer the sheet to the feed rolls skewed,
or the feed rolls may skew the sheet as it is pulled through the machine.

 Vacuum blower not running – Blower motor fuses blown (replace fuses), turn
blower to “ON” position.

 Not enough vacuum (blower running but not generating enough vacuum) – Blower
turning wrong direction, adjust speed of blower (if Adjustable Frequency Drive is
supplied).

 Feed gates not parallel – Shim feed gates so that they are parallel to the feed rolls.

 Feed gate height not set properly (one side tighter than the other) – Re-adjust
feed gate height.

 Vacuum not distributed evenly – Adjust vacuum doors so that vacuum is

distributed evenly.

 Grates (up/down bars) not parallel to top of wheel box lips – Level grates.

 Feed rolls not parallel – Level feed rolls.

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 Grates do not lift parallel – Clean out scrap from wheel box.

 Perform skew test(s) to determine other causes (see below).

Test A will deal with the Lead Edge feeder transferring the sheet to the feed rolls
skewed. Test B will deal with each way the sheet is being skewed.

Test “A”

 Select a sheet that is as wide as the vacuum wheel box and about 50% of the
machine printing circumference in depth. See illustration shown below.

 Move the side guides out of the way and position the feed gates near the ends of
the sheet, as shown below.

 Insert the test sheet behind the feed gates approximately one inch, and open the
feed rolls, as shown below.

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 Make sure the stroke setting is less than the sheet size.

 Make sure the vacuum doors are set correctly.

 Turn on the vacuum blower.

 Using the feed gates as a straight edge, draw a crisp, fine line in front of each
feed gate, as shown below.

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 Turn the machine on, let the sheet advance one cycle, and draw a second set of
lines as shown below. Note: One cycle means the grate (up/down bars) lowers
only once.

 Measure the distance between lines, on each end, and compare. If they are not
the same, consider the possible causes listed below:

– The grate (up/down bars) may not be level across the machine. If so, follow the
Grate leveling procedure.

– The wheel treads may be worn or they may not be level across the machine.

– One of the feed gates may be dragging on the sheet.

– The vacuum doors may not be set correctly.

– Some of the grate springs may be missing, or broken.

– The linkage, which moves the grate up and down, may have worn out bushings.

– Too much scrap may have collected inside the wheel box preventing the grate
from moving freely.

Test “B”

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 Place a pen behind the feed gates, as shown below, such that it will draw a line on
the sheets as they pass under. Be careful to secure the pen so it will not be
accidentally run through the machine.

 By careful examination of the line we can determine where the skewing occurs. If
the sheets pass through the Feed section without skewing, a straight line parallel to the
flutes will appear, as shown below.

 For case 1, described as follows, the line would be straight – but not parallel to
the flutes – see below.

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 For case 2, described as follows, the line would start to curve slightly. Then, once
the sheet reached the feed rolls, the line would slant back – see below.

 For case 3, described as follows, the line would start straight. Then, once the
sheet reached the feed rolls, the line would start to slant – see below.

Case 1

– The sheets may not be pushed up against the feed gates squarely.

– The feed gates may not be parallel to the feed roll.

– The trail support may not be parallel to the feed gates and feed rolls.

– The side guides may not let the sheets drop freely.

– The sheets may not be cut square from the corrugator.

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Case 2

– The wheel box assembly may not be parallel to the feed rolls.

– The feeder wheels may be at different heights along the wheel box.

– The grates (up/down bars) may not be level across the wheel box.

– The grates (up/down bars) may not move freely because the rocker shaft or
rocker drive lever needs to be greased. It is critical that both these items are greased.

– The springs between the wheel box lips and grates may be missing or damaged.

– Something may be rubbing or touching the sheet on one side of the machine –
such as the bottom of one feed gate or side guide.

Case 3

– The feed rolls may not be parallel to the print cylinder.

– The feed rolls may not be the same diameter across the length of the roll.

– The gap between the feed rolls may not be the same across the machine.

– The sheet could be rubbing, or touching something on one side of the machine.

Feed Interrupt - Feed interrupt not functioning

 No incoming air supply – Set regulator to 40-60psi or 275-415kPa, check air lines
for leaks.

 Feed interrupter switch damaged – Replace switch.

 Proximity switch damaged – Replace switch.

 Sync Logic Module not functioning – Tighten connections/replace.

 Solenoid defective – Replace solenoid.

 Air cylinder defective – Replace air cylinder.

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 Wheel box (vacuum area) jammed with scrap – Remove lips and clean out vacuum
area.

 Interrupter lever worn – Adjust interrupter stud and/or replace interrupter lever.

Symptom Electrical:

No Feed Interrupt in Skip Feed - Feed interrupt not functioning properly

 Air lines mixed up – Reverse the air lines on the air cylinder.

No Feed Interrupt - Feed interrupt not functioning properly

 Proxi switch too far from target – Move the proxi switch closer to the target so
that when the target is in front of the proxi switch the L.E.D. on the proxi switch is
illuminated.

 Air cylinder does not engage – Check electrical circuit, check the air lines, check air
pressure 50psi/345kPa to engage.

Electrical Descriptions:

Proxi Switch - The proxi switch is used to let the sync logic module know when the
transmission is on high cam. High cam is when the grates (up/down bars) are on the
up position. A metal target is located on the back of the transmission stroke
adjustment wheel. The proxi switch holder is also installed on the transmission. If you
rotate the shaft while watching the proxi target, you will notice the target will be in
front of the proxi switch holder just when the grates move to the up position.

Feed Interrupt – Feed is interrupted by an electrical switch that engages the air
cylinder on the transmission to lock the grates in the up position. If the power is
interrupted, feeding will cease. This arrangement can be reversed by moving the
jumper on the sync logic module to the other position. However, it is preferred to have
power interrupt feed.

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Skip Feed – The skip feed switch acts like a jumper between terminals H3 and H4 on
the sync logic module. When the switch is in the skip feed position the air cylinder
should interrupt feeding every other cycle.

Summary – When the switch is moved to the interrupt position, the sync logic module
waits for high cam and then engages the air cylinder on the transmission. The air
cylinder locks the grates in the up position. When the switch is moved back to the feed
position, the sync logic module waits for high cam to unlock the grates.

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 Illustrations and Assemblies

Lead Edge Feeder

Extend-O-Feed .............................................................PMNL-EOF

Transmission Section........................................................PMNL-TRA

Wheel Drive Section ......................................................... PMNL-WD

Grate Mechanism .............................................................. PMNL-GM

Vacuum Door Components ................................................ PMNL-VD

Trail Support Components .................................................. PMNL-TS

Vacuum System Assembly ................................................PMNL-VAC

Beds & Tie-ins .................................................................. PMNL-BM

Electrical Controls .............................................................. PMNL-EP

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