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
FEED ARC
Feed Arc Relationship
To explain how the “feed arc” is
related to the servo feed calculation,
we must first explain what the feed
arc is in relation to a press.
The press has a die that has two
halves. The lower half is stationary
and the top half is moveable in an up
and down motion which is one cycle
from the full open to the full closed to
the full open again. The component
that makes all of this happen is named
“crankshaft”. The crankshaft makes
a 360 degree revolution for one cycle
of the die from open to close to open
again. When the die is fully open, the
crankshaft would be at “0” degree
position. When the die is fully closed
the crankshaft is at 180 degrees or
one-half of a revolution.
We ask that a switch be set at 270
degrees to activate the feed because
at this position, the die is completely
clear of the material. This is also a
good starting point to explain the
“feed arc” portion of the auto
calculation in the Rapid Air program.
If the feed input switch was tripped
at 270 degrees of the total revolution
of the crankshaft and the arc calculation was 180 degrees then the servo
feed would complete it’s feed by 90
degrees of the press cycle or 180
degrees past the 270 degree mark.
The feed arc could be set at 90
degrees so the feed cycle would be
complete by 360 degrees or when the
press was at the top of the stroke.
The feed arc could be set at 270
degrees so the feed cycle would be
complete when the press was at 180
degrees. This example would not
work if the feed cycle started at
270 degrees as the feed would still be
trying to move the material when the
die was closed or together. To use a
270 degree feed arc the feed would
have to start at 230 degrees or 240
degrees to be finished moving the
material before the die was closed
or together. This example could not
be possible if the die had pilot pins
installed in it for precise locating of
the stamped part. The cam switch
drawing in the back of the manual
will help you visualize the above feed
arc explanation.
In essence, the larger the feed arc
number up to 270 degrees, the lower
the acceleration/deceleration rate.
The smaller the feed arc the higher
the acceleration/deceleration rate
and the fewer strokes per minute for
a given feed length.
13
PROGRAmmING PROCEDURE
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. Reviewing the flow
chart in the back of this manual will
help in understanding the sections.
SECTION1 — F1=JOB ENTRY
SECTION2 — F2=MANUAL MODE
SECTION3 — F3=AUTOMATIC
SECTION4 — F4=REVIEW JOB PARAMETERS
SECTION 5 — RAMP=ADJUST ACCELLERATION
AND DECELLERATION
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 MENU
F1=JOB 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 JOB NUMBER=XXX
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 following display will appear:
JOB NUMBER= XXX
F1=PROGRAM PARAMETERS
F2=FEED ADVISOR-CACL
F4=DON’T ALTER VALUES
If entering in a new job then select
(F2) feed advisor first as Rapid-Air can
preset the Accel/Decel & max speed
according to the feed length, feed arc
and spm entered.
The job number screen displays (3)
choices for the operator. In the first
choice, F1=Program parameters, the
operator can enter or change the
pilots, feed length, strokes per minute
that the press is running and speed of
the material movement. In the second
choice, F2=Feed Advisor-Calc, the
operator can enter or change the pilots,
feed length, strokes per minute that
the press is running and feed arc (free
travel of the press in which the feed
can move material without a problem).
This then calculates the optimum
speed of the material movement. The
third choice, F4=Exit, puts the job number entered in memory for running at
this time. If F1 or F2 was selected one
of the following displays will appear:
MANUAL PROG--JOB #=XX
LGTH=XXX.XXX SPM=XXX
PILOTS=X %SPEED=XXX
ACC/DEC=XXX% F4=EXIT
Input or change data at
curser. When complete, press
F4 to exit. Fault window
will appear if feed length
is too long for SPM.
FEED ADVISOR JOB#=XX
LGTH=XXX.XXX SPM=XXX
PILOTS=X FEED ARC=XXX
F4=EXIT FEED ADVISOR
Input or change data at
curser. When complete, press
F4 to exit. Fault window
will appear if feed length
is too long for SPM. Feed
arc is “press free travel” for
feeding material. Minimum
arc=10, max=300 degrees.
The % of speed is then
automatically calculated.
*Use the manual program parameters
to massage the parameters or to
check what the actual feed speed
and accel/decel percents are.
This is the fault window that is
displayed if the feed length and
strokes per minute are not within
minimum parameters.
FEED PARAMETER OUT
OF RANGE. THE LENGTH
IS TOO LONG FOR FEED
ARC OR SPM F4=NEXT
F4=Next this command returns to
the previous screen so that the new
parameters can be entered.
14
PROGRAmmING PROCEDURE – (CONTINUED)
Operator Input Terminal – Programming Procedure – Standard Software
Pressing the F4 key at any time
returns you to the main menu.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
SELECT F2=MANUAL
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 (see below). “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=INCH key will display
the following screen. Pressing and
holding the F2 and F3 key will command
the servo to move the material at a slow
rate of speed for the amount that was
entered for the feed length programmed
for the job number. You may press and
release the key as many times as you
wish to get the feed length.
JOG: TYPE=JOG-LENGTH
F1=ALTER TYPE OF JOG
F2=FWD F3=REV
F4=EXIT (MANUAL MODE)
F1=ALTER TYPE OF JOG
Pressing the F1=alter type of jog will
allow the operator to change the
current “jog to length” to “continuous”.
See below. Pressing and holding the
F2 and F3 key will command the servo
to move the material at a slow rate of
speed for as long as the key
is pressed.
JOG: TYPE=CONTINUOUS
F1=ALTER TYPE OF JOG
F2=FWD F3=REV
F4=EXIT (MANUAL MODE)
Pressing the F4 key once will
reset the program to the manual
mode screen.
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.
SINGLE FEED MODE
FEED LENGTH=XXX.XXX
F1=FEED SINGLE LNGTH
F4=EXIT (MANUAL MODE)
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 MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
F3=AUTOMATIC CYCLE
If the feed has been properly set up
and tested in manual and the press
has been electrically interlocked
with the 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
F2=CONTINUOUS
If the F2 key was pressed then the
servo will be in the auto total mode
and the following screen appears.
AUTOMATIC TOTAL=000000
JOB #=XX PILOTS=NO
LGTH=XXX.XXX SPM=XXX
SPEED=XXX% F4=RETURN
Pressing the F4 key, stops the
automatic cycle and the main menu
screen appears.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
F3=AUTOMATIC CYCLE
If the feed has been properly set up
and tested in manual and the press
has been electrically interlocked
with the 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
15
PROGRAmmING PROCEDURE – (CONTINUED)
Operator Input Terminal – Programming Procedure – Standard Software
If the F1 key is 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 the F1 “reset batch count” is
pressed then the batch count will be
reset to preset or if the F4 “continue
with count” is pressed then either
way the following screen appears.
The only difference is that if F1 is
pressed, then the count starts over
and if F4 is pressed, then it continues
with existing batch count on counter.
AUTOMATIC BATCH=000000
JOB #=XX PILOTS=NO
LGTH=XXX.XXX SPM=XXX
SPEED=XXX% F4=RETURN
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.
A DRIVE FAULT HAS OCCURRED
NOTE TYPE OF FAULT
( )
*Example of fault
#2 Motor over temperature
Look up fault code printout listed in
this manual .
If this screen is displayed then the
control cabinet has to be opened and
the Pac-Sci drive has to be checked.
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 parallelism to the die. If all this
seems to be satisfactory and
another fault occurs the factory
should be consulted.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
The last section to be covered is the
ramp/counters section. To get into
this mode, press the ramp pushbutton
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=TOTAL
F4=RETURN TO RAMP COUNT
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
MAX%=75000 RPM/SEC
MAX ACCEL%=XXX%
F4=EXIT %ACCEL MENU
ENTER IN %DECEL RATE
MAX%=75000 RPM/SEC
MAX DECEL% = XXX%
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.
16
DRIVE ROll PARAllElISm ADjUSTmENT
Drive Roll Parallelism Adjustment Procedure
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
actual 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.
NOTE: Before attempting to solve a
possible roll parallelism problem by
readjusting the rolls or calling the
factory, the following test should be
performed.
Step one:
A 3 to 5 foot length of material
should be cut from the storage loop
preceeding the servo feed.
Step two:
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.
17
TROUblEShOOTING
Problem Cause Remedy
No power indication
No display on operator’s console
Power on – no motion
No roll action
Material will not enter rolls
Material will not feed
Material feeds short
– 120 vac circuit tripped
– Blown fuse
– Master button off
– Program fault
– Faulty wiring
– Program fault
– Drive fault
– Program error
– No air
– Low air pressure
– Plugged air muffler
– Feed roll adjusting mechanism too close
– Material too thick
– Low roller force
– Oily material
– Program fault
– Obstruction in die
– Accel to fast
– Low roller force
– Oily material
– Obstuction in die
– Feed signal to close to pilot release
– Reset CB
– Check/replace fuse
– Turn master button on
– Check lights on drive
– Check plug on console
– Check lights on drive
– Check lights on servo drive readout
– Check parameters
– Check air line
– Check air regulator
– Clean muffler
– Open adjustment mechanism
– Check servo parameters
– Raise roller pressure
– Clean material
– Check parameters
– Check die
– Lower accel speed
– Raise roller pressure
– Clean material
– Check die
–
Move feed signal input so rolls are close to feed
Material feeds long
Material camber
Material feeds off center
No automatic cycle
Servo squeals while stopped
Fault signal on Pac-Sci is displayed
Cannot program unit from display
Mechanical pilot release sticks down
– High % max. speed
– Material slippery
– Decell set too fast
– High roller force
– Bad stock
– Edge guides not set properly
– Material not centered to feed
– Bad material
– No press signal
– Controller fault
– Servo fault
– Program error
– Servo velocity gain too high
– Belt too loose or tight
– Servo fault
– Material jam
– Power surge/failure
– Program fault
– Data Instruments interface jumper loose
– Too much overtravel
– Broken spring
– Needs lube
– Lower % max. feed speed
– Lower % decel
– Lower % decel
– Lower roller pressure
– Check stock at input for camber
– Set edge guides
– Center material
– Try new roll of material
– Check limit switch input to servo control
– Check lights on drive
– Check lights on drive
– Check parameters on display
– Consult factory
– Re-adjust belt tension
– Recycle power
– Check die – recycle power
– Check – recycle power
– Check Pac-Sci and call factory
– Check Data Instruments connection
– Restrict travel of mechanical actuating arm
– Remove plate and check springs
– Remove plate and lubricate release bar
18
TROUblEShOOTING
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 troubleshoot 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.
19
TROUblEShOOTING
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
(Blinking) 2
(Blinking) 3
(Blinking) 4
(Blinking) 5
(Blinking) 6
(Blinking) 7
(Blinking) 9
(Blinking) A
(Blinking) b
(Blinking) C
(Blinking) D
(Solid) E*
(Blinking) E*
1
2
3
4
5
6
7
9
10
11
12
13
14
14
Velocity feedback (VelFB) over speed
Motor Over-Temp
Drive Over-Temp
Drive l*t
1-n Fault (9x3)
Control ±12 V supply under voltage
Output over current or bus over voltage
Not Assigned
Bus OV detected by DSP
Auxiliary ±5V Low
Not assigned
Not assigned
Processor throughput fault
Power Up Self Test Failure
(Alternating) E1
(Alternating) E2
(Alternating) E3
(Alternating) E4
(Alternating) E5*
(Alternating) E6
(Alternating) E7
(Alternating) F1
(Alternating) F3
* FaultReset cannot reset these faults.
See ExtFault for further information on Blinking E, Blinking 1 and Alternating F3.
225
226
227
228
229
230
231
241
243
Bus UV, Bus Voltage VBUSTHRUSH
Ambient Temp Too Low
Encoder commutation align failed (Only CommSrc=1)
Drive software incompatible with NV memory version
Control Card hardware not compatible with drive software version
Drive transition from unconfigured to configured while enabled
Two AlnNull events too close together
Excessive Position Following Error
Parameter Checksum Error (Memory Error)
20
OPERATIONAl mAINTENANCE PROCEDURES
Motor Service
The servo motor is flanged mounted
and secured with four socket head cap
screws. The motor removal has to be
done in the sequence described below.
1) The exit side roll guard should
be removed. The reason for this
will become evident when
reassembly of the handle to the
shaft is being accomplished.
2) The motor release handle has to
be removed. The inner roll pin
holds the handle to the shaft. The
roll pin has to be driven out as it
is a very tight fit. Once this is
removed then the handle
should slide off the shaft.
3) The belt guard has to be removed.
It is fastened with four 1/4-20
socket head cap screws.
4) Remove the belt tension by
loosening the 2 motor bracket
screws and let the motor slide
down to the bottom of the slot in
the bracket. Remove the motor
belt and then the motor.
5) The new motor should already
have the belt sheeve installed,
so exchange the motors on the
mounting bracket.
6) Reassemble the unit in reverse
order of the previous instructions.
Roller And Gear Box Assembly
7) When reinstalling the belt, the
tension on the belt should be 1/64”
deflection per 1 inch distance be tween the center line of the pulleys
using 1.5 to 2 lbs. force to cause the
deflection. Tension the belt so that
there is no slack and then run the
servo feed for a few cycles. If you
get a high belt vibration which
causes the servo unit to hum loudly
when the unit is sitting idle after a
feed, then the tension will have to
be readjusted by either tightening or
loosening the belt. This operation
may have to be performed 2 to 3
times to get it right. Once the servo is
running satisfactorily, this operation
will not have to be performed again.
Maintenance Procedures
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.
DAILY:
a) Wipe off feed rolls.
b) Clean any dirt from servo unit.
c) Clean any dirt from operators
keypad.
WEEKLY:
a) Check wear pattern of rolls.
MONTHLY:
a) Check oil level (100C).
b) Check cables for cuts or wear.
21
OPERATIONAl mAINTENANCE PROCEDURES
Reassembly Of Unit
Prior to assembly, attention must be
given to points of contact that require
an application of Moly-Cote, Lubriplate or other suitable heavy grease.
The points are:
1. 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.
2. The mechanical roll release shaft
located at the exit side of the feed.
Lubrication (100C only, 100D no oil bath)
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
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.
chips or foreign matter. Replace the
gear box oil per instructions.
PINCH ROLL ACTUATING PISTONS
Periodically grease with lubriplate or
equivalent grease to pinch roll actuating piston nose where it contacts the
pressure plate.
22
PRECAUTIONS & SAFETy
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
23
wARRANTy
Warranty Terms & Conditions
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
Rapid-Air reserves the rights in its 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.
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Loading...