P.A. SRF-48 User manual

Form 1189 SRF-48 ROLL FEED 4/1/2009
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TABLE OF CONTENTS
DESCRIPTION PAGE
1. INSTALLATION.........................................................................................................................................................3
1.1. MECHANICAL INSTALLATION.....................................................................................................................3
1.2. ELECTRICAL INSTALLATION ......................................................................................................................4
1.3. LOADING THE FEED......................................................................................................................................5
1.4. THREADING THE TOOL................................................................................................................................7
1.5. RUNNING THE FEED.....................................................................................................................................8
1.6. PNEUMATIC PILOT RELEASE.....................................................................................................................9
2. MAINTENANCE......................................................................................................................................................10
3. MECHANICAL PARTS...........................................................................................................................................11
3.1. PARTS LIST....................................................................................................................................................15
4. WARNING................................................................................................................................................................17
5. SAFETY PROGRAM..............................................................................................................................................17
6. WARRANTY............................................................................................................................................................17

Form 1189 SRF-48 ROLL FEED 4/1/2009
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1. INSTALLATION
1.1. MECHANICAL INSTALLATION
The SRF-48 Roll Feed is supplied with an adjustable mounting bracket. The feed should be securely mounted to the
press frame. (A transition bracket is sometimes required in certain applications.) The feed should be centered, square,
and perpendicular to the pass line of the press. It should be mounted at a height that will accommodate the appropriate
die sets.
The feeder may be used to push or pull strip stock through the die.
The electro-pneumatic piloting will need another cam switch for controlling feed roll opening and closing.

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1.2. ELECTRICAL INSTALLATION
The Ultra Control has been designed to make electrical connections quickly and easily. All that is required is a "clean"
source that must be connected to the main disconnect switch.
The inputs and outputs to your press control (i.e. Emergency Stop, Feed Cam Signal, Pilot Release Cam Signal, Reset
Cam Signal) must also be connected for proper operation.
Note, that if your feed is supplied with P/A PLS (Programmable Limit Switch) you don’t have to wire Feed and Reset
Cam signals.
The motor connects to the electrical control by factory installed "Amphenol" (Military Specifications) Quick connectors.
The optional PLS connects to the electrical controls by factory installed Military Quick connector.
IMPORTANT!
A GROUNDING CONDUCTOR MUST BE INSTALLED FOR PROPER MACHINE GROUNDING.
NOTE:
All connections should be made in accordance with National Electrical Code (NEC) requirements and must
comply with all local ordinances.
NOTE:
A word about electrical “noise” - Most pressroom environments contain considerable electrical noise. It is
emitted from electro-mechanical press relays, contacts, and solenoids. While the Ultra Control is designed to
minimize “self generated” electrical noise, it is difficult to provide protection for all applications. If erratic
system behavior is experienced, then the source of the "noise" must be suppressed with either a
resistive/capacitive type of suppressor on AC coils, or “Avalanche” type diodes on DC coils.
NOTE:
The Ultra Control is fully protected by line circuit breakers.
NOTE:
The electrical control enclosure is supplied with a stand/support, which may be placed in any convenient location.
The enclosure may also be mounted in any fixed location as long as the cabling is adequate to reach the feed. It is
not recommended that the electrical enclosure be mounted directly to the press. The vibrations caused by the
punch press can result in damage to the control system

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1.3. LOADING THE FEED
FIGURE 3
Prior to this step, the electrical control must be powered up and all needed parameters are loaded.
(Refer to the Ultra Operating Manual.)
NOTE:
This example is based on using PLS (Programmable Limit Switch), but all PLS timing notes can be easily
translated to other forms of timing.
1. Put the Ultra control into “MANUAL MODE”. Record the present settings of the Feed Cam, Reset Cam, and
Pilot Release Cam into a job set-up record sheet for future reference to the job.

Form 1189 SRF-48 ROLL FEED 4/1/2009
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FIGURE 3A
2. Adjust for the material thickness using the (2) Cylinder Thickness Adjustment dials. Adjust the dials to the
required setting for your material. (0-3mm range) Refer to the FIGURE 3A for proper setting
3. Open the feed rolls by selecting Open on the jog pendant. Insert the material through the feed rolls and close
the feed rolls by selecting Close on the jog pendant.
4. Using the Jog Forward button on the jog pendant, advance the material up to the entrance of the die (far
enough where the punches would not pierce the material).
5. Check the vertical alignment of the strip. If necessary, adjust the pass line of the feeder so that the material is at
the proper height.
6. Assuming that the press shut height and the tool are set up properly, jog the press one or two strokes without the
feed working.
7. Jog the press down slowly observing when the longest pilot would engage the pilot hole in the material if the
material were there. (Refer to Figure 4.) Note the press positional readout and put this setting into your
Programmable Limit Switch (PLS) for the ‘Pilot Release On’ setting. The ‘Pilot Release Off’ setting, in most
cases, should be 180º. (See Figure 5.) Some drawing applications require the rolls to remain open past 180º.

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FIGURE 4
8. Continue to jog the press slowly until the longest pilot just comes out of the material. Note the press positional
readout and put this setting into your PLS for the ‘Feed Cam On’ setting. Set the ‘Feed Cam Off’ point so that
there is enough time to complete the feed length and enough time to stop the press, if there is a feed fault. (See
Figure 5.)
9. Set the ‘Reset Cam On’ for 180 degrees and ‘Reset Cam Off’ for 200 degrees. This setting should never need
changing. (See Figure 5.)
1.4. THREADING THE TOOL
For a comprehensive description, refer to the Ultra Servo Roll Feed Operation Manual.
NOTE ABOUT CAMS:
The Feed Cam (open tool): The feed system uses this press cam for timing the feeder to the press crankshaft.
Although no shafting or belts actually connect the press to the feeder, the feed must be “told” when it is safe to
move the strip and when the feed move must be completed.
This “connection” is an electrical one, and not a mechanical one. This gives the Operator/set-up personnel
total flexibility in deciding when the feed progression should take place.
Each die set can have a unique ‘Feed Angle’. This ‘Feed Angle’ is dependent upon many variables; pilot and
punch length, press stroke, strip forming in the die, etc.
Put the Ultra Control into “JTL” mode. All the adjustments to the feed system and press have now been made.
The press is at Top Dead Center (TDC) and ready for automatic cycling. Proceed by advancing the material
using Jog Forward button on the jog pendant until WAITING FOR PRESS is seen in the display and inch the
press through another stroke, verifying that things are happening at the correct time (Roll Release, etc.). If the
system is operating properly, you can make a few more “hits”, checking your parts.

Form 1189 SRF-48 ROLL FEED 4/1/2009
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1.5. RUNNING THE FEED
Put the Ultra Control into “Auto”mode and press the Cycle Start button. The Ultra Control
will now follow the press until it is stopped by the Operator, counter, emergency stop, or feed
error.
TYPICAL 180 DEGREE FEED ANGLE (FROM 260 DEGREES TO 80
DEGREES) WITH MECHANICAL PILOT RELEASE:
FIGURE 5

Form 1189 SRF-48 ROLL FEED 4/1/2009
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NOTES ABOUT ‘POSSIBLE PROBLEM TOOLING’: *
oA tight die, one that is not square, or has other tooling problems, will cause
significant difficulty and downtime. Accuracy in feeding is directly related to how
easily the feeder can position the strip in the die. Binding, bad part ejection, or
sticking parts may cause the material to "jam" in the die.
oThe Ultra Control will "try" to overcome the "jam-up" by applying more power to
the rolls.
ONE OF FOUR OUTCOMES WILL RESULT:
1. The feed will continue to try to move the strip (if the rolls do not slip) until the Feed
Cam opens. A SYNC FAULT Error will occur and the press will be stopped by the
feeder.
2. The feed will apply more power to the rolls, causing them to slip on the material.
This produces a "short-feed". In reality the feeder did not "miss-feed". The rolls
were positioned properly, the strip did not keep up, causing the die to close and a
miss-hit is produced.
3. The feed applies more power to a thin strip, causing the material to buckle
somewhere between the feed and the die set. The feeder positioned the strip
accurately, it just did not occur in the die set.
4. The feed tries to apply so much power to a heavy strip in order to move it, that
excessive current is drawn by the servo drive. This results in the drive shutting down
to protect itself and in doing so stops the press.
NOTE: The feed detected a problem and emergency-stopped the press before the die
closed. In using the Ultra Control, you in fact have added a "die protection" system to
your tooling.
*A tooling problem is a problem caused by tooling and not the Feeder itself.
1.6. PNEUMATIC PILOT RELEASE
During operations such as forming or using pilots, the purpose of the Pneumatic Pilot Release is to
release the strip from being held by the feeder rolls. This allows the material to be adjusted slightly
any time during the press cycle.
The pneumatic pilot release is controlled by a solenoid valve connected to (2) pneumatic cylinders.
Once the material thickness is set correctly (Ref Figure 3A) no further action is required.
The Pilot Release system requires hook up of outside air and electrical connections.
The pilot release is operated by applying the appropriate voltage signal from the Ultra Control to
actuate the 3-way solenoid valve to open the feeder rolls. The activation signal can come from a
source such as a rotary cam switch mounted on the press.
The solenoid valve, located on top of the servo feed, is provided with a cable attached to the solenoid
valve for connecting the power signal leads.

Form 1189 SRF-48 ROLL FEED 4/1/2009
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Air pressure of 80-100 PSI is required for proper operation of the release. A 3/8” tubing fitting is
provided for the air supply connection.
2. MAINTENANCE
The Ultra Advantage Servo Roll Feed needs very little maintenance to keep the system operating at its optimum
performance.
oThis precision equipment must be kept as clean as possible. This is especially important if
large amounts of air suspended oil mists in combination with “dirty metals” are used. The
resulting abrasive dust can attach itself to the feed rolls and other surfaces, leading to
premature wear on many parts.
oThe roll release system requires a clean, dry air supply.
oSome bearings used on the feeder are fully sealed and maintenance-free roller ball bearings.
The exceptions are provided with standard “zerk” type grease fittings. They should be
lubricated with a good grade of high pressure bearing grease. The frequency of lubrication will
depend on the overall usage of the system. A small “shot” once a day is a good starting point.
The feed roll gears set should be coated with a small amount of open gear grease.
oThe main drive belt should be checked periodically for tightness. It can be adjusted by
loosening the two fasteners on the motor adjuster plate, applying downward pressure on the
motor adapter plate, and retightening. ERRATIC MOTOR BEHAVIOR WILL BE
EXPERIENCED IF THE DRIVE BELT IS LOOSE!
oAll fasteners should be checked for tightness at regular intervals.
oThe electrical system also requires very little maintenance. Keep the enclosure clean and
replace any burned indicator bulbs. Do not expose the electrical enclosure to constant high
temperatures. Possible system failure could result.
oThe Feeder’s electrical enclosure door is sealed to prevent oil and contaminants from entering
inside. However, small gaps can be found around some sealing surfaces and faceplates. It is a
good idea, therefore, to keep the console free of stamping oils and fluids, which could "seep
into" the enclosure. Most often, these oils are carried by the Operator’s hands or by air mist
lubrication etc.
oAll of the above guidelines should be added to your existing pressroom Preventive
Maintenance (PM) Program.

Form 1189 SRF-48 ROLL FEED 4/1/2009
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3. MECHANICAL PARTS

Form 1189 SRF-48 ROLL FEED 4/1/2009
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Form 1189 SRF-48 ROLL FEED 4/1/2009
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Form 1189 SRF-48 ROLL FEED 4/1/2009
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Form 1189 SRF-48 ROLL FEED 4/1/2009
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3.1. PARTS LIST
PART NUMBER
DESCRIPTION
QTY
DIN-125-M16
M16, WASHER, FLAT, REG,ZINC PLATED STEEL
6
DIN-125-ZY-M5
M5, WASHER, FLAT, REG,ZINC PLATED YELLOW
2
DIN-128-A-M8
CURVED SPRING WASHER
10
DIN-71412-A-M6
LUBRICATING NIPPLE, CONED TYPE A
2
DIN-7991-M5x10
M5x10MM LG, FHSCS, ZINC PLATED
7
DIN-912-M10x30
M10x30MM LG, SHCS, BLACK
22
DIN-912-M10x35
M10x35MM LG, SHCS, BLACK
4
DIN-912-M10x40
M10x40MM LG, SHCS, BLACK
4
DIN-912-M16x65
M16x65MM LG, SHCS, BLACK
6
DIN-912-M5x16
M5x16MM LG, SHCS, BLACK
8
DIN-912-M6x16
M6x16MM LG, SHCS, BLACK
6
DIN-912-M8x16
M8x16MM LG, SHCS, BLACK
2
DIN-912-M8x20
M8x20MM LG, SHCS, BLACK
12
DIN-912-M8x25
M8x25MM LG, SHCS, BLACK
4
DIN-912-M8x30
M8x30MM LG, SHCS, BLACK
8
DIN-912-M8x35
M8x35MM LG, SHCS, BLACK
4
DIN-934-M8
M8, HEX NUT, BLACK
2
DIN-9427-M6X12
M6x12MM LG, BHCS, BLACK
23
R-SRF-1300-009
SIDE PLATE, LEFT
1
R-SRF-1300-010
SIDE PLATE, RIGHT
1
R-SRF-1300-011
DRIVE ROLL
1
R-SRF-1300-012
BEARING COVER
2
R-SRF-1300-013
EXIT COVER
1
R-SRF-1300-014
PIVOT SHAFT CAP
1
R-SRF-1300-015
UPPER EXIT PLATE
1
R-SRF-1300-016
LOWER EXIT PLATE
1
R-SRF-1300-017
EXIT GUIDE
1
R-SRF-1300-018
REAR PLATE
1
R-SRF-1300-019
ENTRANCE PLATE
1
R-SRF-1300-020
CASCADE MTNG BLOCK
2
R-SRF-1300-021
ENTRANCE COVER
1
R-SRF-1300-022
TOP PLATE
1
R-SRF-1300-023
FILTER REGULATOR MTG PLATE
1
R-SRF-1300-024
TOP COVER
1
R-SRF-1300-025
CYL MTNG BLOCK
4
R-SRF-1300-026
PIVOT SHAFT COVER
1
R-SRF-1300-027
PIVOT, LEFT
1
R-SRF-1300-028
PIVOT, RIGHT
1
R-SRF-1300-029
PIVOT SHAFT SUPPORT BRACKET
2
R-SRF-1300-030
PIVOT SHAFT BUSHING
2
R-SRF-1300-031
PIVOT SHAFT PLATE BUSHING
1
R-SRF-1300-032
CYL BUSHING
4
R-SRF-1300-032
SPROCKET
1
R-SRF-1300-033
SPROCKET, DRIVE
1
R-SRF-1300-034
UPPER ROLL
1

Form 1189 SRF-48 ROLL FEED 4/1/2009
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R-SRF-1300-034U
UPPER ROLL, URETHANE (OPTIONAL)
1
R-SRF-1300-035
PIVOT SHAFT
1
R-SRF-1300-036
GEAR RETAINING CAP
1
R-SRF-1300-037
SPRING BUSHING
2
R-SRF-1300-037
CYL MTNG BLOCK KEY
4
R-SRF-1300-038
CYL CLEVIS MNT
2
R-SRF-1300-039
SPRING
2
R-SRF-1300-040
CLEVIS BUSHING
2
R-SRF-1300-041
PRESS MOUNTING KEY
2
R-SRF-1300-042
CYLINDER ASSEMBLY
2
R-SRF-1300-043
FILTER REGULATOR
1
R-SRF-1300-044
FILTER REGULATOR BRACKET
1
R-SRF-14
REARING, 6206ZZ
8
16532-02
ROLLER, MATERIAL GUIDE
2
DIN-1587-ZP-M12
M12, DOME NUT, ZINC PLATED
8
DIN-7980-M12
M12, WASHER, LOCK, SPRING STEEL
16
DIN-912-M5x25
M5x25MM LG, SHCS, BLACK
4
DIN-912-M5x30
M5x30MM LG, SHCS, BLACK
4
R-SRF-1300-001
CASCADE SIDE PLATE
2
R-SRF-1300-002
CASCADE ROLL
4
R-SRF-1300-003
CASCADE ROLLER SHAFT
4
R-SRF-1300-004
CASCADE TNUT GUIDE RAIL
2
R-SRF-1300-005
CASCADE T-NUT RAIL MTNG BLOCK
2
R-SRF-45
T-NUT
2
DIN-912-M10x40
M10x40MM LG, SHCS, BLACK
4
DIN-912-M8x30
M8x30MM LG, SHCS, BLACK
2
DIN-933-M16x130
M16x130MM LG, HEX HD SCR, BLACK
2
DIN-934-M16
M16, HEX NUT, BLACK
2
R-SRF-1300-006
PRESS MOUNTING PLATE
1
R-SRF-1300-007
PRESS MOUNTING PLATE ADJUST BLOCK
2
R-SRF-1300-008
PRESS MOUNTING BLOCK KEY
2
PART NUMBER
DESCRIPTION
QTY

4. WARNING
This equipment offers various means of operating or controlling machines. The operator must not be in or near the point-of-
operation of the machine, or the operating parts of any equipment installed on the machine, or bodily injury could result. The
EMPLOYER must post adequate warning signs onto the machine with proper warnings for his machine and the specific application
to which the machine and equipment are being applied.
Occupational Safety and Health Act (OSHA) Sections 1910.211, 1910.212, and 1910.217 contain installation information on the
distance between danger points and point-of-operation guards and devices. No specific references have been made to which
paragraph of OSHA 1910.211, 1910.212, 1910.217 or any other applicable sections because the paragraphs may change with each
edition of the publication of OSHA provisions.
All equipment manufactured by us is designed to meet the construction standards of OSHA in effect at the time of sale, but the
EMPLOYER installs the equipment so the EMPLOYER is responsible for installation, use, application, training, and maintenance,
as well as adequate signs on the machine onto which this equipment will be installed.
Remember, OSHA says that the EMPLOYER must use operating methods designed to control or eliminate hazards to operating
personnel.
It shall be the responsibility of the EMPLOYER to establish and follow a program of periodic and regular inspections of his machine
to insure that all their parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment. Each machine
should be inspected and tested no less than weekly to determine the condition of the machine. Necessary maintenance or repair of
both shall be performed and completed before the machine is operated. The EMPLOYER shall maintain records of these
inspections and the maintenance work performed.
Our Company is not responsible to notify the user of this equipment of future changes in State or Federal laws, or construction
standards.
5. SAFETY PROGRAM
Accident free operation will result from a well developed, management sponsored and enforced safety program. Of vital importance
to any successful program is the proper selection of guards and devices. However, there is no safety device that will bring
“automatic” safety to your operation.
Of equal importance to this proper selection of the guard and the device is the training of your personnel. Each person must be
trained as to the operation of the guard or safety device, highlighting why they have been provided on the equipment. Rules for safe
operating should be written and enforced at all times. A final major concern of an effective safety program is regularly scheduled
inspection and maintenance of all of the equipment.
To ensure continued safety at all times, top management, line supervision, safety engineers and all employees must assume their
proper share of the responsibility in the program. Only as a group, one that knows your own operation and its problems, can you
carry out an effective safety program.
To assist you in the development of and continued use of safety programs, many safety minded groups have made guidelines
available to you. However, you must know when and how to apply these guidelines. The manufacturer provides information to
assist you in properly adjusting and maintaining your equipment. There is no short cut to proper safety; therefore, it is
recommended that you comply with their recommendations at all times.
6. WARRANTY
We warrant our new parts against defects under normal use and service for a period of 12 months after date of shipment. Our
obligation under this warranty is limited to replacing or repairing (at our option) the defective part without charge, F.O.B. our plant
in Bloomfield, Connecticut. The defective part must be forwarded to our plant, freight prepaid, for our inspection prior to
replacement or repair. EXCEPT AS EXPRESSLY PROVIDED HEREIN, THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. Furthermore, the seller does not warrant or represent that the equipment complies with the provisions of
any law, particularly including the Occupational Safety and Health Act of 1970, and regulations promulgated thereunder. In no
event shall we be liable for special, indirect incidental or consequential damages, however rising.