SERVO FEED WITH CUT-TO-LENGTH
OPERATING INSTRUCTIONS
MODELS
100, 200 & 300 SERIES
RAPID-AIR CORPORATION
4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925
Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.com
1
RAPID-AIR START UP SECTION
SERVO FEED—CUT TO LENGTH
100, 200, 300 Series
Rev. C
Congratulations on purchasing a Rapid-Air Servo Cut-To-Length. Not only did you
receive a complete servo unit but also telephone support by one of our engineering
staff to guide you on using the new servo to its maximum capability.
In order to maximize your learning time and trouble shoot any interface problems, we
would like to request that the following items be complete before calling us:
1. Servo unit should be completely installed and aligned to a die on the press.
2. 220 Vac electrical wiring should be in place and unit turned on.
3. All interface switches should be wired and tested.
4. Air if needed should be connected and ready to be used.
5. All servo interface questions should be directed to Rapid Air prior to a start-up visit.
Please call 815-397-2578 and ask to have these questions directed to the proper
personnel.
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TABLE OF CONTENTS
CHARTS AND DRAWINGS DIRECTORY pg. 4
INTRODUCTION pg. 5
INSTALLATION pg. 6
ELECTRICAL CABLES AND AIR LINE pg. 7
INTERFACING SERVO FEED WITH CUTTER pg. 8
PRETEST WRITE UP pg. 9
LOADING MATERIAL pg. 10
SERVO INTERFACING EXPLANATION pg. 11
PROGRAMMING PR OCEDURE pg. 15
DRIVE ROLL PARALLELISM ADJ. pg. 21
TROUBLESHOOTING pg. 22
OPERATIONAL MAINTENANCE PROCEDURES pg. 24
PRECAUTIONS AND SAFETY pg. 28
WARRANTY pg. 29
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CHARTS AND DRAWINGS
PLAN 100 SERIES pg. 30
PLAN 200 SERIES pg. 31
PLAN 300 SERIES pg. 32
ELECTRICAL PANEL LAYOUT pg. 33
OPERATORS TERMINAL LAYOUT pg. 34
INTERFACE SCHEMATICS - 953 pg. 35
INTERFACE SCHEMATICS - 953 pg 36
INTERFACE SCHEMATICS– 953 120 VAC pg 37
CUTTER MAINTENANCE pg. 38
CUTTER BASE LAYOUTS pg. 39
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INTRODUCTION
The Rapid Air Servo Cut-To-Length Feed system carries with it the quality and
reliability you have grown to expect from a Rapid Air product. The motion control
system is a programmable industrial computer and this advanced technology,
combined with a highly engineered precision roll feed, is an unchallenged combination
in the press industry.
The compact mechanical package, direct coupled with a brushless servo drive motor,
offers response and feed speed accuracy unparalleled in any other powered roll feed.
Operator interface is so simplified, a typical setup person can have the servo feed
programmed and running in a matter of minutes. A step by step prompt appears on a
four line 88-character display, which asks simple questions of the operator. Entry of
feed length, cutter dwell time, and % maximum speed are all that is required for a new
setup. Routine jobs can be stored, recalled, changed and saved or run with a simple 2
digit job number entry. Up to 99 jobs may be stored and recalled at will.
A resolver, direct coupled to the servo drive motor for precise digital position feedback,
enable roll positioning accuracy to +/- .0025 for any programmed feed length or speed.
Operator programmed feed length, up to 999.999 inches and % max speed selection
along with full jog features on a pendant unit, allow the operator to thread the material
and inch it into position. The inch feature enables the operator to jog the servo feed
forward or reverse at a slow rate. The operator can select jog to length or jog
continuous to aid in threading up material.
The Rapid Air Servo Roll Feed has been designed to mount on a free-standing table
as close as possible to the cutter.
The precision mechanical roll feed unit has been designed for compactness, ease of
setup and installation. Three cables with twist lock connectors, two cables for the
servo, one connected to the cutter, and one air line are the only external connections
required. The electrical controls are housed in a small cabinet which should be
mounted close to the press working area. The operator keypad and display are
mounted on top of the control cabinet.
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INSTALLATION AND MECHANICAL SETUP OF SERVO AND CUTTER
If you purchased the servo/cutter combination already mounted on a base then the
servo and cutter were aligned at the factory. A good practice is to check all hold down
bolts to be sure that they did not come loose during shipment.
If you purchased the servo and cutter and are going to mount it on a base at your
facility, then a base should be selected that will hold the weight of the servo and the
cutter and also the cycling shocks incurred during production.
When mounting the two devices. The pass line height of the cutter and the servo roller
center line should be equal. Even more critical is the parallelism between the two
devices. The cutter should be mounted first then the servo center line should be
aligned to the cutter center line with the servo rollers parallel to the cutter blade.
The servo should be mounted as close to the cutter as possible and depending on
thickness of the material a bridge should be installed between the servo and cutter to
minimize material droop or buckling during feed.
Although the cutter and servo weights can be located in other sections of the manual.
The following is a list of the weights.
Servo
104 Servo—78 lbs. 204 Servo—119 lbs. 306 Servo—241 lbs.
108 Servo—87 lbs. 208 Servo—159 lbs. 312 Servo—312 lbs.
112 Servo—101 lbs. 212 Servo—187 lbs. 318 Servo—339 lbs.
118 Servo—115 lbs. 218 Servo—203 lbs. 336 Servo—493 lbs.
Cutter
4” Cutter—47 lbs.
6” Cutter—72 lbs.
8” Cutter—110 lbs.
12” Cutter—213 lbs.
The unit is now assembled and the next step is to attach the electrical and air lines to
the servo and cutter.
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ELECTRICAL CABLES AND AIR LINE
120 VAC INPUT
The alternate input voltage to the control is 120 Vac, 1 Ph, 60 Hz. The max amperage
needed is 7.5 amps and the control has a circuit breaker with a trip amperage of 10
amps..
230 VAC INPUT
The required input voltage to the control is 230 Vac, 3 Ph, 60 Hz. The amperage
needed is 10-20 amps depending on the motor size. If unsure of the amperage
needed, the name plate on the side of the Pacific Scientific drive will give the number
of the control or check the disconnect fuses for the correct fuse size.
460 VAC INPUT
If your plant has only 460 Vac power then a step down transformer is needed in order
to run the servo feed. If you purchased the transformer from Rapid Air, then all that is
needed is to connect and wire the 460 volt line to the transformer. If you did not
purchase a transformer from Rapid Air then a transformer, 3 KVA for the 100S and
200S servos and 6KVA for the 300S servos, 460/230 VAC 3PH, 60HZ step down
transformer is needed before proceeding with the electrical portion of the installation.
The electrical control enclosure is shipped completely ready to be connected to the
mechanical feed. Connected to the bottom of the enclosure are (2) cables with keyed
screw type connectors for connection to the motor. If the series 200 or 300 was
purchased, (1 or 2) push-on connectors for connection to the air valves for solenoid
actuation of the pilot release and or anti-backup valve are included. The third
connector is used to interface the cutter to the controls.
Position the electrical enclosure at a convenient location near the mechanical feed and
attach the cables. The motor cables are easily identifiable by the amount of pins in the
plugs. The solenoid cables if any can now be attached and checked for proper
location when the feed is up and running.
An air line must be connected from the shop air to the air inlet of the servo feed. The
air should be at least 80 PSI continuous and should be dry filtered andlightly lubricated
for the best operation of the servo feed. The air inlet on the servo feed is a 3/8-18 NPT
pipe tap. The minimum air line size requirement is 1/2”ID hose. - (2 CFM)
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INTERFACING SERVO FEED WITH A CUTTER
The Servo Drive unit is programmed to feed each time a signal is received from the
cutter switch. The servo will feed one progression and wait for the next signal before it
will feed again in automatic mode.
The command is in the form of a normally open contact from a proximity switch,
located on the cutter and is activated when the cutter is returned.
If the feed/cutter was purchased complete then the interfacing was done for you. If
not, then Rapid Air has provided wiring to a terminal block for interconnection
purposes. The interface schematic provides the wire numbers and how to connect the
cutter to the feed.
This completes the initial setup of the servo feed to the cutter or other device. The
servo is now ready to run as intended.
If more complete interfacing is needed, please refer to the section (interfacing ) in this
manual for an explanation of inputs and ouputs available.
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PRETEST FOR SERVO FEED AND CUTTER WITHOUT MATERIAL
Now that your servo/cutter combination is in place, and the cables have been attached,
you can proceed with testing the unit. The first step is to turn on the main disconnect
switch on the electrical enclosure. Next, at the operator’s console, pull the power onoff button to the on position. The button should illuminate to indicate that there is
power to the system.
The Pacific Scientific drive performs an initial sequence to check its internal program.
At this time the display should show the Rapid Air screen for 5 seconds before starting
the main setup program. If you are comfortable with programming a job then continue,
it not, please refer to the “Programming Procedure” located in this manual.
Follow the programming sequence for the operators terminal to input parameters into
job storage. Your servo feed has been fully tested before it was shipped to your facility
and this procedure is merely a test to insure that all functions are still functional and the
cables are properly seated.
Once you have programmed the required parameters, select the manual mode of
operation. If the option of air regulated upper feed roll was purchased, check that the
main air is at least 80 psi and check that the roll pressure gage is functional by
adjusting the pressure up and down, This is accomplished by turning the pressure
adjusting knob. If you did not purchase the air regulated roll option then check that you
have enough tension on the material to avoid slipping during feeding. Open and close
the feed and anti-backup rolls electrically and/or manually. Visually inspect that the
rolls open and close as you press the appropriate keys on the keypad or when using
the manual levers.
Select the “inch” function (F2 on keypad) on the manual mode screen. Visually check
that the rolls rotate both forward and reverse with the corresponding key. The speed is
preset to creep the rolls at a slow speed for manual positioning of the material.
CAUTION: Do not attempt to place your fingers or any foreign material into the rolls.
Injury to the operator or damage to the servo rolls could result.
After you have verified that the rolls and air logic are operational, you can experiment
with the single cycle moves. The procedure is outlined in the programming section of
this manual.
After all the checks have been made and you feel comfortable with the programming
of the servo controller, place the servo in automatic mode. Now cycle the press in
either the inch, single stroke or continous run, the servo feed should react upon the
closure of the press window and signal and simulate a feed progression of material.
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LOADING MATERIAL INTO THE SERVO FEED
Upon the satisfactory completion of all the tests, you should be ready to load a strip of
material into the servo feed.
Step number one is to select the manual mode of operation on the operators console.
Then choose “Operate Rolls”. This will allow you to open the feed rolls and antibackup rolls to accept the material but only if you have purchased the option. You
could also open the rolls manually by lifting the lever mounted on the side of the servo
feed. Position the leading edge of the material with the center of the material near the
center of the entry rolls. Adjust the edge guides on the cascade rolls to the proper
width setting. Open the feed rolls and or anti-backup rolls. Hand feed the material into
the servo unit until it protrudes out of the feed rolls and starts into the guide on the
cutter. Close the anti-backup rolls (if purchased) to capture the material, then close the
feed rolls.
Check the roller force pressure to be sure that there is enough pressure to prevent
slippage but not too much to induce camber into the material. The pressure setting is
the amount of force necessary to move the material into the press at the speed and
feed programmed. You may find it necessary to readjust the force as you finalize the
setup procedure. The amount of force needed will vary depending on the width and
type of material being fed. Make a note of the final setting to aid in the setup of the
servo feed the next time the same material is run.
You are now ready to begin testing the complete system under power. To check the
progression, cycle the servo and cutter first in the manual mode then in the single cycle
mode . If the progression is correct, no further adjustments are necessary. If the
progression is either short or long, go to the troubleshooting chart and perform the
sequences described there for inaccurate feeding, once the feed progression has been
accurately set and the repeatability is satisfactory, you are ready for full automatic
mode.
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SERVO INTERFACING EXPLANATION
A. TAUT STOCK INPUT (J52)TBI-3)
This is a normally open contact from a switch or device that monitors the loop of
material prior to the servo feed. When the material reaches a point that it trips the
switch, a taut stock has been reached. This input, when received, immediately drops
the automatic which stops the feed in progress. The material should be repositioned in
the die before restarting the automtaic sequence, as the progression was lost when the
taut stock occurred.
This input also could be used as a “No Stock” switch that would monitor whether or not
there is material available to feed.
B. ANTI-BACKUP INPUT (J52)TBI-4) (series 200 servos only)
Whether the anti-backup rolls were purchased with the unit or came on the unit
standard, they can be activated to raise in the automatic cycle. The anti-backup rolls,
by design, keep the material from sliding back during the pilot operation. They can
become a hinderance if the material tends to walk to one side or the other during the
feed cycle.
C. ENABLE INPUT (J4-Pin 5 & 6))
The enable input is shipped from the factory, jumpered, so that the Pac-Sci unit is
ready to work after the initialization procedure is complete.
If it is desired that the servo controls are not functional until other equipment or safety
source is activated then a normally open contact can be interfaced to this input. If at
any time during the feed cycle the input changes state then the feed will stop at this
position. If feeding stock, the reference will be lost and the stock will have to be
manually repositioned to the correct location. The automatic cycle will be dropped and
have to be restarted.
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D. ENABLE OUPUT (J52)TB2-22)
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output is high
whenever the enabled input is activated.
E. CUTTER OUTPUT (J52)TB2-21)
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output goes high at
the end of every feed cycle and stays high for programmed cut time before going low.
To adjust this time, go to programming the job number and adjust the time needed for
the cutter.
F. AUTOMATIC OUTPUT (J52)TB2-20
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output goes high
whenever automatic is selected on the program panel. Any faults will cause the
automatic ouput to go low.
H. KEYPAD AND DISPLAY INTERFACE (RS232 PORT)
The keypad/display is the interface between the operator and the resident program.
The Pacific Scientific drive is purchased with a great many capabilities, none of which
can be used unless a program is written to utilize these capabilities. Rapid-Air put a
great deal of time making a program that is user friendly and yet gets the job done
efficiently. We took all the questions and constructive criticism and came up with a
program that would cover all the applications, yet be easy to interface and program by
a customer.
If an operator reads the programming procedure in this manual and then reads the
screen parameters listed as they are displayed and acts on them by inputting data as
needed, the servo can be up and running in a very short time.
1. Select a job number.
2. Input or review parameter for that job number.
3. Thread up material in manual mode.
4. If properly interfaced, go into automatic mode.
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RESET JOB PARAMETERS
The reset job parameters routing should be used with special caution. We
incorporated it as a user function for two reasons.
The first reason is if a problem caused the displayed parameters to be garbled
because of a program glitch, then by resetting the job parameters the problem could
be cleared.
The second reason is if there were a number of different jobs in memory that were
no longer required, then by resetting the job parameters, all the job numbers would
be reset to their default values, which includes putting all zeros in the feed length
and strokes per minute area of the program.
CAUTION!! CAUTION!! CAUTION!!
Keep a hard copy record of program numbers and data associated with them for
reference if needed. If this function is used in a way other than what it was designed
for then all previous data is lost and cannot be recovered.
To enter this function, turn off the program by depressing the master stop button.
Turn on the program again and push and hold the “clear entry” key, once the
program has started the following screen will be displayed.
**DEFAULT VALUE SETUP
PRESS F1 TO RESET TO
DEFAULT VALUES, PRESS
F4 TO IGNORE CHANGES
**Once F1 has been pressed then all data that had been entered will be reset.
PROGRAM NUMBER DISPLAY
Each servo unit that is shipped has a program number assigned to it. If a problem
occurs and cannot be solved by reloading the program then you will be asked the
program number associated with this servo.
To view the program number, press and hold the “back space” key during the power
up sequence. The program number will be displayed for about 30 seconds. Please
find and write down the program number in case it is needed in the future.
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TO HELP YOU ENTER A JOB FROM THE KEYPAD LET’S CREATE AN EXAMPLE:
We will use a feed length of three inches and want to run the feed rate at 100 percent .
The main menu is currently displayed. First we select the job number and we will use job
#1.
1. Press F1 to select the job number.
2. Enter job number “01” - press the F4 key when finished.
3. The job number screen shows two choices:
A. F1 = program parameters. This choice is used if a job has already been
programmed and you would like to adjust the parameters that were preset for the
job or if entering a new job number.
To move around in this screen, press the “enter” key in the lower right corner of the
key pad. Once the feed length and strokes per minute are entered, then the F4 key to
exit the screen. The program now calculates the accel/decel and speed for the
parameters entered. At this time the “F4 key” review parameter should be used to
check to be sure that you entered the correct parameters.
B. F4 = don’t alter parameters. Run the job as previously entered
4. Press “F2” to select the manual mode.
A. Press F1 to select the “inch” or jog mode. This mode will move the material
slowly forward or reverse to position the material at it’s proper location. F2 being
used for forward and F3 for reverse movement. Press F4 to leave the “inch”
mode.
B. Press F2 to select the “single feed” mode. At this time each press on the F1 key
will rotate the rolls to move the material three inches, the feed length that was
entered, at the same feed rate as the feed would move the material in the
automatic mode. Press the F4 key {exit} to leave this screen.
5. Press “F3” to select automatic cycle. In this mode the servo can be run in the batch
or continuous mode.
A. Press F1 to select the batch mode. In the batch mode, the servo will feed each
time it is commanded until the batch count reaches “0”, then the automatic cycle
drops out.
B. Press F2 to select the continuous mode. In the continuous mode, the servo will
feed each time it is commanded until the command stops or the operator presses
the “F4” return key.
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OPERATOR INPUT TERMINAL - PROGRAMMING PROCEDURE-STANDARD
SOFTWARE
The intent of this section is to familiarize the operator with the program flow and what
to expect with every keypress. Each screen on the display will be reviewed with
special comments to help clarify what is being asked on the screen. The program flow
is broken down into 5 sections with the main menu being the home postion.
The first screen to be displayed on the operator terminal will look like this
RAPID-AIR CORPORATION
4601 KISHWAUKEE STREET
ROCKFORD, IL 61109
815-397-2578
After a few seconds, the display will clear and the following display will appear:
MAIN SELECTION MENU
F1=JOB NUM F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
SELECT F1=JOB #
The first step in programming the servo feed is to select a job number which will be
used to store the parameters the operator inputs or recall the parameters which have
been previously loaded into the servo controller program. When the operator selects
F1 on the keypad, the screen will change to:
JOB # SELECTION MENU
ENTER IN NEW JOB #=XX
PRESS F4 KEY AFTER
CORRECT # IS ENTERED
The operator must enter a 2 digit number before proceeding to any other function. If
the job number the operator has entered has been previously stored in memory, or
entering a new job, the folowing display will appear:
JOB NUMBER-01 LOADED
F1=PROGRAM PARAMETERS
F4=DON'T ALTER VALUES
THAT ARE PROGRAMMED!
If entering in a new job then select (F1) “program parameters” and follow the
directions.
15
The job number screen displays (2) choices for the operator. In the first choice,
F1=Program new values, the operator can enter or change the, pilots, feed length, %
of max speed and cut time. This then calculates the optimum speed of the material
movement. The second choice, F4= Don’t alter values that are programmed, puts the
job number entered in memory for running at this time. If F1 was selected the following
display would appear.
FEED ADVISOR JOB#=00
FEED LENGTH=000.000
CUT = .XXX % RATE=100
F4=EXIT FEED ADVISOR
This window is displayed during job setup calculations.
CALCULATING THE FEED
SPEED, ACCEL VALUES
PLEASE WAIT FOR MAIN
MENU TO BE DISPLAYED
Pressing the F4 key at any time returns you to the main menu.
MAIN SELECTION MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
In order to advance material into the die, using the servo feed, the operator has to be
in the manual mode. Pressing the F2 on the keypad will cause the screen to change to
the manual mode screen. (Cycle rolls with keys) - If the keypad has keys with open
rolls or close rolls on it then the keys are active at this time and the rolls can be
electrically released for inserting the material into the servo feed.
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F1=INCH MODE
Pressing the F1 key will let the operator select a jog mode type, continuous or jog to
length. In the continuous mode, the servo will run at a slow rate of speed until the
button is released. In the jog to length mode, the servo will run at a slow rate of speed
until the job number feed length is reached then it will stop. The key has to be
released and depressed to jog again.
Depressing the F2 key will direct the servo to feed forward and pressing the F3 key will
direct the servo to feed in reverse.
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JOG! TYPE=CONTINUOUS
F1=ALTER TYPE OF JOG
F2=FORWARD F3=BACKUP
F4=EXIT (INCH MODE)
Pressing the F4 key once will reset the program to the jog mode screen so that jog is
now active. Pressing the F4 key twice will reset the program to the manual mode
screen. If the F4 key was pressed twice then the following screen is displayed.
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F2=SINGLE FEED
If the operator presses F2 then the following screen is displayed. The single feed
mode is active and every time the F1 key is pressed then the feed will cycle and move
the distance indicated on the feed length line.
JOB#=00 FL=000.000
F1=FEED SINGLE LNGTH
F2=CUT F3=SINGLE CYC
F4=EXIT (SINGLE FEED)
Pressing F4 once resets the program to the manual mode display. Pressing the F4
key twice resets the program to the main menu display. If the F4 key was pressed
twice the following screen is displayed.
MAIN SELECTION MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
You can now select between batch or continuous mode
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
F2=CONTINUOUS
17
If the F2 key was pressed then the servo will be in the auto total mode and the
following screen appears.
AUTOMATIC TOT=000000
JOB# =00 CUT=0.150
FL=000.000 SPEED=100
ACCEL=001% F4=RETURN
Pressing the F4 key, stops the automatic cycle and the main menu screen appears.
MAIN SELECTION MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
If the feed has been properly set up, tested in manual, press electrically interlocked
with feed, feed and pilot switches wired to the correct terminals, then pressing the F3
key will display the following screen.
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
F1=BATCH
If the F1 key was pressed then the servo will be in the auto batch mode and the
following screen appears.
BATCH SETTING=000000
BATCH COUNTER=000000
F1=RESET BATCH COUNT
F4=CONTINUE WITH COUNT
If F1 (reset batch count) is pressed then the batch count will be reset to it’s preset
valve. If F4 (continue with count) is pressed the batch count will remain at its present
value. Either F1 or F4 will lead to the following screen.
AUTOMATIC BATCH=000000
JOB#=XX CUT=0.XXX
FL=XXX.XXX SPEED=XXX%
ACCEL=XXX% F4=RETURN
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Pressing the F4 key, stops the automatic cycle and the main menu screen appears.
When the automatic screen is displayed, all keys except the F4 key are inactive. Every
time the press cycles and trips the feed switch, the feed will cycle once per the
parameters displayed on the screen. If the feed encounters excessive material drag
while feeding or the material being moved encounters a restriction that stops the
material forward movement then a servo fault can occur. If this happens then the
following screen is displayed.
DRIVE FAULT OCCURED
NOTE TYPE OF FAULT— (xxx)
Example of fault - (2) = motor over temperature
Look up fault code printout listed in this manual.
To reset the fault, the master on-off switch has to be cycled which will reset the
controller. The material path should be checked for obstruction and parrallelism to the
die. If all this seems to be satisfactory and another fault occurs the factory should be
consulted.
MAIN SELECTION MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
The last section to be covered is the ramp/counters section. To get into this mode,
press the ramp push-button and the following screen appears.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ACCEL/DECEL RAMPS
F4=EXIT TO MAIN MENU
F1=BATCH/TOTAL COUNTS
Pressing the F1 key will bring up the batch/total screen, which is used for presetting
the batch count or resetting the total count. The following screen appears.
BATCH COUNTER=000000
TOTAL COUNTER=000000
SET:F1=BATCH F2=TOT
F4=RETURN TO RAMP COUNT
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Pressing the F1-batch counter key allows the operator to preset a batch count.
Pressing the F2-total counter key resets the total count to zero. This cannot be
undone so be sure that the counter should be reset to zero before pressing F2 key.
Pressing the F4 key brings up the following screen.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ACCEL/DECEL RAMPS
F4=EXIT TO MAIN MENU
The only section that has not been covered in this write-up is the ramp adjust mode.
The ramp adjusts how fast the servo motor gets up to speed and how fast it stops.
This feature is an asset that is seldom adjusted but can be a sure cure if material
slippage seems to be a problem. With the main menu screen displayed the key
labeled ramp is active. Pressing the ramp key produces this display.
RAMP PARAMETER MODE
F1=ACCEL% F2=DECEL%
F3=PERCENT MAX SPEED
F4=RETURN RAMP/COUNT
PRESS F1 OR F2
Pressing the F1 or F2 keys will produce one of the following displays. The lower the
number entered, the longer the ramp cycle. Press F1 or F2 now.
ENTER IN %ACCEL RATE ENTER IN %DECEL RATE
MAX%=75000 RPM/SEC MAX%=75000 RPM/SEC
MAX ACCEL%=XXX% MAX DECEL% = XXX%
F4=EXIT %ACCEL MENU F4=EXIT %DECEL MENU
The ramp usually is factory set at .015 on the series 100 drives and .035 on the series
200 & 300 drives. There is some deviation to this when the factory runs the unit, but
this is a basic starting point.
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DRIVE ROLL PARALLELISM ADJUSTMENT
Every servo feed has an eccentric adjustment screw to adjust the upper roller to be in
parallel to the lower roller. The maximum adjustment is .008” on the eccentric.
The adjustment screw is located behind the belt cover and is held fast by a 10-32
socket head cap screw. The acutal adjustment screw is a slotted eccentric pin which is
turned clockwise or counter-clockwise to raise or lower one end of the upper roll.
The parallel adjustment is factory set when the unit is manufactured but if material
tracking seems to be a problem then this could be a way of solving the problem. To
test if the rolls need adjustment, do the following.
1. Remove the front and rear roll covers.
2. Raise the anti-backup rolls. (If any) main rolls should be closed.
3. Shine a light from the rear of the feed toward the main rollers.
4. Inspect from the main rolls side to see if the rollers are parallel. If they are then the
material could be the cause of the material walking. If they are not parallel then an
adjustmet has to be made.
5. To make the adjustment:
a. Remove manual roll release arm by removing roll pin.
b. Remove belt cover.
c. Locate eccentric screw and loosen 10-32 screw.
d. Turn slotted eccentric screw while viewing rolls until the rolls are parallel.
e. Tighten 10-32 screw and reassemble parts, then retry running material.
For a more accurate adjustment use a feeler gage to check the parallelism.
This completes the eccentric adjustment write-up, if there are further questions, please
call the factory.
* Before attempting to solve a possible roll parallelism problem by readjusting the rolls
or calling the factory, perform the following test.
Step 1) A 3 to 5 foot length of material should be cut from the storage loop preceeding
the servo feed.
Step 2) Lay the material next to a straight line to see if the material is cambered. If it is
then this could be the reason that the material is walking. If not, then turn the material
upside down from the way it was being fed and insert into the feed. If the material
walks in the opposite direction then the material could be to blame.
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TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
No power indication Disconnect off Turn disconnect on
Blown fuse Check/replace fuse
Master button in Pull button out
No display on Program fault Check lights on P.C.
operators console Faulty wiring Check plug on
console
Power on-no motion Program fault Check lights on drive
Drive fault Check lights on servo
drive readout
Program error Check parameters
No roll action No air Check air line
Low air pressure Check air regulator
Material will not Anti-backup closed Open rolls
enter rolls Feed roll adjusting Open adjustment
mechanism too close mechanism
Material too thick Check servo parameters
Material will not feed Low roller force Raise roller pressure
Oily material Clean material
Program fault Check parameters
Obstruction in die Check die
Material feeds short Accel to fast Lower accel speed
Low roller force Raise roller pressure
Oily material Clean material
Obstruction in die Check die
Feed signal to close to Move feed signal input so
pilot release rolls are closed to feed.
Material feeds long High % max speed Lower % max feed speed
Material slippery Lower % Decell
Decell set too high Lower % Decell
Material camber High roller force Lower roller pressure
Bad stock Check stock at input
for camber
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TROUBLESHOOTING CHART (cont.)
PROBLEM CAUSE REMEDY
Material feeds off Edge guides not set Set edge guides
center properly
Material not centered Center material
to feed
Bad Material Try new roll of material
No automatic cycle No press signal Check limit switch
input to servo control
Controller fault Check lights on drive
Servo fault Check lights on drive
Program error Check parameters
on display
Servo squeals while Servo velocity gain Consult factory
too high
Belt too loose or tight Readjust belt tension
Fault signal on Pac-Sci Servo fault Recycle power
is displayed Material jam Check die
Power surge/failure Check/recycle power
Cannot program unit Program fault Check Pac-Sci &
from display call factory.
Data Instruments Check Data Instruments
interface jumper loose connection
Mechanical pilot release Too much overtravel Restrict travel of
sticks down mechanical actuating
arm
Broken spring Remove plate and check
springs
Needs lube Remove plate and
lubricate release bar
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MOTOR SERVICE
The servo motor is flanged mounted and secured with four socket head cap screws.
The motor removal has to be done in a sequence as described below.
1. The manual roll release handle has to be removed. The inner roll pin holds the
handle to the shaft. Once this is removed the handle should slide off the shaft.
2. The belt guard has to be removed. It is fastened with four 1/4-20 socket head cap
screws on the 100 & 200 servos and five 5/16-18 socket head capscrews on the 300B.
3. Remove the belt tension then remove the motor.
4. Install new motor and reassemble in reverse order of the previous instructions.
5. When reinstalling the belt, the tension on the belt should be 1/64” deflection per
inch distance between the center lines of the pulleys using 1.5 to 2 lbs. force to cause
the deflection. The best way is to tension the belt and try running the servo for a few
cycles. If you get a high vibration on the belt when the feed stops then you have to
readjust the belt tension. It will have to have more or less tension to stop the vibration
of the belt.
MANIFOLD ASSEMBLY
The manifold assembly was designed to give the customer easy access to the
components. The valve for the electric roll release and if supplied, the anti-backup
valve is mounted on the side of the feed. The air regulator and pressure gauge is
mounted on the input side of the feed. All can be easily replaced if needed.
ROLLER AND GEAR BOX ASSEMBLY
At this stage of disassembly, all field maintenance components are exposed and easily
accessible. No further field service should be necessary on the roller and gear box
assembly unless the gear train is suspected of a malfunction. The drive rolls should be
checked for erroneous wear pattern while they are exposed and cleaned before
reassembly.
MAINTENANCE PROCEDURES
DAILY WEEKLY MONTHLY
Wipe off feed rolls Check wear pattern of rolls Check oil level
Clean any dirt from Check cables for cuts
servo unit or wear
Clean any dirt from
operators pendant
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SERVO FAULT DISPLAY
The Pacific Scientific drive has a list of internal faults and displays the number of that fault on
it’s readout located on the front of the drive. Rapid Air now displays the fault on the keypad
display. If a fault occurs the screen will display the number and the name of the fault, but
there will not be an explanation accompanying the fault. This is a tool to help you to trouble
shoot if the servo fails to perform when commanded.
If a fault was displayed the servo controller will have to be turned off and restarted to clear the
fault. If the fault is still present when the Pacific Scientific unit is restarted, the fault may not
be displayed on the keypad screen as the fault will not let the internal program restart. The
control panel will have to be opened to view the fault again.
A list of probable faults and some explanation is included in this section. If more help is
required, then Rapid Air will have to be contacted.
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FAULT CODE
(Predefined Variable, Integer, Status Variable, Read-Only)
Guidelines - 0 means the drive is not faulted and not enabled, while 8 means the drive is not
faulted and enabled. Alternating 8.> means actively inhibiting CW motion and alternating
8.< means actively inhibiting CCW motion
STATUS LED VALUE FAULT MEANING
(Blinking) 1 1 Velocity feedback (VelFB) over speed
(Blinking) 2 2 Motor Over-Temp
(Blinking) 3 3 Drive Over-Temp
(Blinking) 4 4 Drive I*t
(Blinking) 5 5 1-n Fault (9x3)
(Blinking) 6 6 Control ±12 V supply under voltage
(Blinking) 7 7 Output over current or bus over voltage
(Blinking) 9 9 Not Assigned
(Blinking) A 10 Bus OV detected by DSP
(Blinking) b 11 Auxiliary +5V Low
(Blinking) C 12 Not assigned
(Blinking) D 13 Not assigned
(Solid) E* 14 Processor throughput fault
(Blinking) E* 14 Power Up Self Test Failure
(Alternating) E1 225 Bus UV, Bus Voltage VBUSTHRESH
(Alternating) E2 226 Ambient Temp Too Low
(Alternating) E3 227 Encoder commutation align failed
(Only CommSrc=1)
(Alternating) E4 228 Drive software incompatible with NV
memory version
(Alternating) E5* 229 Control Card hardware not compatible with
drive software version
(Alternating) E6 230 Drive transition from unconfigured to
configured while enabled
(Alternating) E7 231 Two AInNull events too close together
(Alternating) F1 241 Excessive Position Following Error
(Alternating) F3 243 Parameter Checksum Error (Memory Error)
*FaultReset cannot reset these faults.
See ExtFault for further information on Blinking E, Blinking 1 and Alternating F3.
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REASSEMBLY OF UNIT
Prior to assembly, attention must be given to three points of contact that require an
application of Moly-Cote, Lubriplate or other suitable heavy grease.
The three points are:
1. The antibackup piston which is located at the feed entrance.
2. The main roll piston and the spiral pins in the main roller tie plate which can be seen
by viewing straight down through the center of the feed at approximately half way from
the inlet to the exit roller. The piston is positioned horizontally at the base of the feed
and approximately in the center of the feed if viewing from the gear box to the belt
cover.
3. The mechanical roll release shaft located at the exit side of the feed. Three screws
have to be removed and then the keeper plate can be removed. The inner shaft
should be thoroughly greased to prevent sticking.
Do not apply excessive grease as it may fall onto the drive rollers and cause
misfeeding due to material slippage. All bearings are sealed and need no additional
lubrication.
LUBRICATION
The gear box oil must be kept up to sight gauge level and changed after every 2000
hours of use. Recommended oil is Mobil #SHC630 or equivalent. The oil reservoir
capacity is 3.5 oz. The oil can be drained by removal of the drain plug located near
the base of the gear housing cover, just below the sight gauge. The oil reservoir is
filled through the pipe thread port occupied by the air breather plug near the upper
edge of the gear housing cover.
NOTE: THE ORIGINAL BREAK-IN OIL IN THE GEAR BOX SHOULD BE CHANGED
AFTER 100 HOURS OF CYCLE TIME AND EXAMINED FOR CHIPS OR FOREIGN
MATTER. REPLACE THE BEAR BOX OIL PER INSTRUCTIONS.
The anti-backup rollers have been lubricated at the factory and should need no further
attention. If they are found to slip in the reverse direction, consult the factory for further
assistance.
PINCH ROLL & ANTI-BACK UP ACTUATING PISTONS
Periodically grease with lubriplate or equivalent grease to anti-backup & pinch roll
actuating piston nose where it contacts the pressure plate.
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PRECAUTIONS & SAFETY
NEVER - Put screwdrivers or foreign materials in feed rolls
NEVER - Hold onto material as it is being fed through the servo
NEVER - Wear neckties around the servo feed rolls
NEVER - Force the rolls open by prying on them
NEVER - Modify the mechanical aspects of the servo feed
CAUTION - Contact the factory before drilling any holes in the unit
CAUTION - Wear proper eye protection when working around the servo
CAUTION - Do not wear loose clothing around the servo feed rolls
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WARRANTY
ALL SALES BY THE COMPANY ARE MADE SUBJECT TO THE FOLLOWING
TERMS AND CONDITIONS. PLEASE READ.
WARRANTY - The Company warrants, for a period of one year from date of shipment
by the Company, that the product shipped is free from defects in material and
workmanship. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL IMPLIED
WARRANTIES IN LAW, INCLUDING MERCHANT - ABILITY. The Company
obligation under this warranty is limited to repairing or replacing, F.O.B. Madison, SD,
any part or parts proved to have been defective when shipped. In no event shall the
Company be liable for special or consequential damages. Provisions set forth in
specifications are descriptive and subject to change and are not intended as
warranties.
CUSTOMER LICENSE AGREEMENT
The RAPID-AIR CORPORATION reserves the rights in it’s software. The software
program is licensed by RAPID-AIR to the original purchaser of the equipment which
contains the software for use only on the terms set forth in this license.
You may use the program only on the programmable servo computer furnished with
the system and only in conjunction with the servo feed supplied with the system.
You may not without expressed permission from Rapid-Air:
A. Copy, distribute, or document the program for others.
B. Modify or merge any portion of the program for use on non compatible hardware.
C. Make alterations to the program.
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