Rapid-Air 100C, 100D User Manual
SERVO FEED
OPERATING INSTRUCTIONS
MODELS
100C SERIES
(INCLUDES 100D 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
TAblE OF CONTENTS
SERVO COMPONENTS ............................................................................................................................... pg. 3
START-UP ..................................................................................................................................................... pg. 4
INTRODUCTION .......................................................................................................................................... pg. 4
INSTALLATION AND MECHANICAL SETUP ........................................................................................... pg. 5
INSTALLATION OF MOUNTING BRACKET ............................................................................................. pg. 5
MECHANICAL ROLL RELEASE SETUP ..................................................................................................... pg. 6
ELECTRICAL CABLES AND AIR LINE ....................................................................................................... pg. 6
INTERFACING FEED WITH PRESS ........................................................................................................... pg. 7
PRETEST WRITE UP ................................................................................................................................... pg. 8
LOADING MATERIAL .................................................................................................................................. pg. 9
SERVO INTERFACING EXPLANATION ..................................................................................................... pg. 10
RESET PARAMETERS ................................................................................................................................. pg. 11
ENTER JOB EXAMPLE ............................................................................................................................... pg. 12
FEED ARC...................................................................................................................................................... pg. 13
PROGRAMMING PROCEDURE ................................................................................................................. pg. 14-16
DRIVE ROLL PARALLELISM ADJ. ............................................................................................................. pg. 17
TROUBLESHOOTING .................................................................................................................................. pg. 18-20
OPERATIONAL MAINTENANCE PROCEDURES ..................................................................................... pg. 21-22
PRECAUTIONS AND SAFETY .................................................................................................................... pg. 23
WARRANTY ................................................................................................................................................. pg. 24
CHARTS AND DRAWINGS PLAN 100 SERIES ........................................................................................ pg. 25
SERVO BRACKET SIDE 100 SERIES ......................................................................................................... pg. 26
ELECTRICAL PANEL LAYOUT .................................................................................................................... pg. 27
OPERATORS TERMINAL LAYOUT ............................................................................................................ pg. 28
PROGRAMMING MAP ............................................................................................................................... pg. 29
JOB INPUT SEQUENCE .............................................................................................................................. pg. 30
MANUAL SEQUENCE ................................................................................................................................. pg. 31
AUTOMATIC SEQUENCE............................................................................................................................ pg. 32
PRESS-FEED AND PILOT SWITCH SETTINGS ....................................................................................... pg. 33
INTERFACE SCHEMATICS ......................................................................................................................... pg. 34-35
JOB RECORD SHEET .................................................................................................................................. pg. 36
100D ENVELOPE DRAWING ...................................................................................................................... pg. 37
2
SERVO FEED (100 SERIES) COmPONENTS
(100C – SERIES SHOWN)
3
START-UP AND INTRODUCTION
Rapid-Air Start-Up Section (100C & D Series Servo)
Congratulations on purchasing a
Rapid-Air Servo. 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
Introduction
The Rapid-Air servo feed 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
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.
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. 120 vac electrical wiring should be
in place and unit turned on.
3. All interface switches should
A step by step prompt on the four
line 80 character display asks simple
questions of the operator. Entry of
feed length, strokes per minute, %
maximum speed and pilot 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.
Operator programmed feed length, up
to 999.999 inches and % max speed
selection along with full jog features,
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
be wired and tested.
4. Air if needed should be connected
and ready to be used.
5. All servo interface questions
should first be directed to your
distributor, then to Rapid-Air.
Please call 815-397-2578 and
ask to have these questions
directed to the proper personnel.
at a slow rate. He can select jog to
length or jog continuous to aid him in
the threading up of material.
The precision mechanical roll feed
unit has been designed for compactness, ease of setup and installation.
A 120 VAC receptacle is all that is
required of the customer. Two cables
with twist lock plugs are supplied
with the control and need only be
connected to the proper locations
on the motor. 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 area.
4
INSTAllATION AND mEChANICAl SET-UP
Installation and Mechanical Set-Up of Servo Feed
The shipping container should contain:
1 Mechanical Servo Feed: –Standard
1 Console Complete: –Standard
1 Cascade Assembly: –Optional
(100 Series)
1 Servo Mounting Bracket: –Optional
1 Guide Support Assembly: –Optional
If a mounting bracket was purchased
then it should be installed at this time.
There are mounting bracket prints in
the back of the manual for hole
location dimensions and a bracket
mounting instruction section can be
found later in this section.
If a mounting bracket was not
purchased then the feed should be
positioned with the centerline of the
drive roller in line with the centerline
of the die entrance and at the proper
pass line height to the die. Aligning
the feed to the die (Parallelism) is very
important to the accuracy of the feed.
Drag due to misalignment can cause
short feeds and servo faults.
If the feed is positioned as such that
the material has to move unsupported
from the exit side of the feed to the
die and the material being moved is
allowed to droop or buckle during
a move, a short feed can occur.
A guide should then be built
between the feed and the die to
solve this problem.
The following chart lists the servo size
with the proper bolt size.
SERVO BOLT QUANTITY
Series 100 All 3/8-16 4
The servo mounting bolts should
not penetrate into the servo body by
more than .625”.
Installation and Mechanical Set-Up of Mounting Bracket
The cast mounting bracket is
available for mounting the servo
feed directly to the bolster plate of
the press. There are several sets
of mounting holes in the bracket to
afford the setup person an efficient
means of mounting the bracket.
Mounting holes are located on the
top and front for securing the bracket
firmly. It is very important that the
servo bracket and the servo feed be
secured and not allowed to float
or vibrate.
NOTE: It is very important that the
end of the bolster plate, where the
servo feed is to be mounted, be
perpendicular to the top surface of
the bolster plate within +-.005 to assure the servo feed will be aligned for
proper feeding.
Align the servo feed bracket with the
center line of the bolster plate and transfer the mounting holes on the top face.
There are two 1/2” holes on this bracket.
Once the bracket has been aligned
and secured to the bolster plate, the
servo feed can now be put in place.
The slotted holes in the mounting
bracket allow for accurate alignment
of the servo feed in the x – y axis.
There is an elevating screw to
position the servo feed to the proper
tooling pass line height.
When the servo feed has been
aligned and mounted to the bracket,
loosen the elevator locking screws
and position the servo to match the
tooling pass line height. This is
accomplished by turning the adjusting
screw provided. When the servo is
correctly positioned, tighten the
elevator locking screws to prevent
the unit from moving. There are 2
locking screws on the this bracket.
The unit is now assembled and the next
step will be to attach the electrical and
air, if used, to the servo feed unit.
Material alignment is critical. The
servo feed rolls are so precise that
they will move the material in whatever direction that they are presented
to the die. The feed and die must be
in line and square to one another. The
servo feed does not have the power
of a press driven roll feed so the feed
will fault out if misaligned. This is a
good warning and if corrected could
result in better tool life.
5
ROll RElEASE SET-UP AND CAblING
Mechanical Roll Release Set-Up
All the 100 feeds have an optional
mechanical pilot release. If the
mechanical pilot release is used,
(we recommend this for press speeds
faster than 250 SPM) then a bracket
has to be manufactured and attached
to the press ram to actuate the pilot
release mechanism.
NOTE:
The roll release height
adjustment screw should be
backed off all the way to prevent
jamming when using the
mechanical release.
The bracket should be made adjustable for tuning to the press position in
which the roll release should occur.
Some attention should be given to
the bracket stroke length so that the
release mechanism is not jammed into
the feed during the press stroke.
The 100 series pilot release actuator
has a 1” stroke to full open with an
additional .750” overtravel before
bottoming out.
We do not offer any manufactured
bracket to assist you because there
are as many combinations for stroke
and clearance as there are presses
manufactured today.
We do, however, ask that the
bracket be designed to withstand
considerable resistance as the
mechanism has to defeat the roller
pressure spring force.
OPTIONAL MANUAL PILOT RELEASE
The optional manual pilot release
should be ordered at the time of
purchase but can be added at a later
date. Rapid-Air would like to perform
the installation if at all possible.
OPTIONAL ELECTRIC PILOT RELEASE
The optional pilot release package consists of a valve, fitting, relay
and solenoid cable. A switch signal
from the press has to be wired to the
control panel and an air line has to be
connected to the valve from the main
shop air. The relay and solenoid cable
will have to be mounted and wired in
the electric cabinet if it is to be used
with the program.
Electrical Cables and Air Line
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.
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.
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 and lightly 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)
6
INTERFACING FEED wITh PRESS
Interfacing Servo Feed With A Press
The Servo Drive unit is a slave to the
press therefore it needs a command
from the press to operate in the
automatic mode.
The command is in the form of a
normally open contact from a limit
switch, cam switch or an electronic
feed interface device that can be
programmed.
The contact should be commanded
or activated at 270 degrees of the
press stroke or when the tooling is
clear of the material and released or
turned off at around 350 degrees of
the press stroke. The significance of
the release position is to insure that
the feed switch is released with the
press top stopped. Once the program
senses a closure of the feed input,
it will command a move and will
complete the move regardless of
the switch position.
The air operated pilot release also
has to have a signal input to
operate. The pilot signal should be
set to turn on when the point of the
pilot is entering the hole. This signal
them commands air roll release to
raise and release the material, letting
the pin pull the material forward into
position. The release should be
then commanded to turn off at
approximately 180 degrees letting the
rollers return to a holding position for
the next move.
The roll release stop adjustment
screw is located at the entrance
of the feed. (See drawing for your
servo). The screw is used to limit the
travel of the roller during release.
Adjustment may be necessary if
using air pilot release at a somewhat
high speed with the pilot release
deactivating and feed switch
activating at a close proximity with
each other in degrees of press stroke.
To adjust, insert material into the feed,
lower rolls, adjust screw, using 3/16
hex wrench, to full in. Release rolls
and adjust screw so the material is
free to be pulled in by the pilot pin.
The adjustment is now complete.
(NOTE: This adjustment does limit
the manual roll release travel.
If this causes a problem back off
the adjustment a little.)
The schematic in the back of this
manual points out the switch or
contact connections for wiring the
interface. Locate the feed input and
wire per print. This input is brought
down to a terminal strip for your
convenience. The feed input
number is (J52)TB1-2) and the pilot
input number is (J52)TB1-4).
This completes the initial setup of
the servo feed to the press 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.
7
PRETEST wRITE UP
Pretest For Servo Feed And Press Without Material
Now that your servo feed unit has
been mounted 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, turn on the
on-off switch. The button should
illuminate to indicate that there is
power to the system.
The drive performs an initiate
sequence to check it’s 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; if 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 you
are using air, check that the main
air is at least 80 PSI. Open and close
the feed 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.
Now you can cycle the press and
watch the rolls to verify that the
signal from the press window switch
signal is functional and actuating
at the proper time.
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.
8
lOADING mATERIAl
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. 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 hand
feed the material into the servo unit
until it protrudes out of the feed rolls
and starts into the guide on the press,
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
press in the single cycle mode with
the servo feed in the automatic 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 accuratelly set
and the repeatability is satisfactory,
you are ready for full automatic mode.
9
SERVO INTERFACING
Servo Interfacing Explanation
A. TAUT STOCK INPUT
(J52)TB1-6)
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 automatic 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. 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 before the
servo can function 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 referance 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.
C. ENABLE OUPUT
(J52)TB2-15)
This output must be tied to a solid
state relay to interface to the ouside
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.
END OF FEED OUTPUT
D.
(J52)TB2-13)
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 and stays
high for programmed amount of time
before going low. To program the
time, with the menu display on, push
the period on the keypad - follow the
instructions and enter the time in
milli-seconds. The time entered will
add to the total feed cycle time and
if programmed to last longer than the
time from the actual end of feed and
the actual tripping of the feed switch
then the program will not see the feed
switch being tripped, you will then get
two hits per feed.
E. AUTOMATIC OUTPUT
(J52)TB2-11)
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 output to go low.
STANDARD PROGRAM -
F.
DATA INSTRUMENTS INTERFACE
(J52)TB1-14)
With the jumper in place, the
standard program is active. Remove
the jumper, recycle power and the
Data Instruments program is active.
Only the manual mode will work
with the keys at this time.
G. 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 into 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.
10
RESET PARAmETERS
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.
11
ENTER jOb ExAmPlE
Servo
To help you to enter a job from the
keypad, let’s create an example.
We will use a feed length of three
inches and want to run at 100 strokes
per minute. We have a pilot pin on
the die, so pilots will have to be used.
The max feed arc will be 180 degrees.
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 al
ready been programmed and
you would like to adjust the
parameters that were preset for
the job.
B. F2 = feed-advisor-calc. This
should be used when entering a
new job number. The two main
inputs are the feed length and
strokes per minute. The third
input is to enter a “1” or a “0”
for pilots. We will put in a “1”
for “yes for pilots”. The fourth
input is the feed arc. This is
preprogrammed as 180 degrees
and need not be changed to set
up a job unless specific move
parameters in relation to press
stroke position is required. 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.
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.
12
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