Rapid-Air 104CJ, 108CJ, 106CJ, 112CJ User Manual
SERVO FEED
OPERATING INSTRUCTIONS
MODELS
CJ SERIES
(5-07)
104 & 108 CJ
(not available after 5-07)
106 & 112 CJ
(available after 5-07)
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
INTRODUCTION .......................................................................................................................................... pg. 3
INSTALLATION, MECHANICAL & ELECTRIC PILOT RELEASE
PROGRAMMING PROCEDURE ................................................................................................................. pg. 5-6
FATAL FAULT ERROR CODES ..................................................................................................................... pg. 6
NO MESSAGE FAULTS
SCHEMATICS ............................................................................................................................................... pg. 8-16
............................................................................................................................... pg. 7
............................................................. pg. 4
2
INTRODUCTION
The CJ Servo
The CJ servo has many features found
in the more expensive models. Some of
it’s features are:
Input:
120 VAC, 50/60 HZ
Amperage required at input:
10 amps maximum.
Accuracy:
.0025 per feed length at the rolls.
Maximum feed length input:
999.999 inches.
Job storage:
99 jobs
Display:
4 rows by 80 characters, backlit
Fault type:
Displayed on the drive if a fault occurs
otherwise an “8.” is displayed.
Rolls:
Hardened and Ground.
Drive roll parallelism adjustment:
Used to tune the rolls to the material if
needed.
The Rapid-Air CJ feed uses the same
type of programming procedures as it
has in it’s more expensive models. Input
a feed length, strokes per minute, and a
feed arc and the program will adjust the
servo acceleration/deceleration and
maximum servo speed parameters
to the requirement needed to keep up
to the press strokes per minute.
The precision mechanical roll feed has
been designed for compactness, ease
of setup and installation. A 120 VAC
receptacle is all that is required of the
customer. Two cables are supplied with
the control and need to be connected
to the proper locations of the motor.
The electrical controls are housed in a
small box that can be mounted on the
press or if purchased, on a post that
can be positioned close to the press.
Note:
4 KEYS WERE CHOSEN TO HAVE A
DOUBLE MEANING, ARROWS AND
“F” KEYS. THE ARROWS WERE
BROUGHT OUT AS THE PRIMARY
INSTEAD OF THE “F” KEYS. IF YOU
WOULD BEAR WITH US, WE ARE
LOOKING AT A CORRECTION.
KEYPAD
3
INSTAllATION, mEChANICAl & ElECTRIC PIlOT RElEASE
Installation
The Rapid-Air servo was run and fully
tested before being shipped from our
plant. Carefully inspect all parts when
uncrating them. If you find any damaged parts, please report it to the
carrier that delivered the servo drive
and at the same time, report the damage to your distributor.
The servo feed container should
contain:
1 servo feed-- standard
1 console-- standard
Mechanical Pilot Release
All CJ servo feeds are manufactured to
accept an optional mechanical pilot release kit. If the mechanical pilot release
is used, (we recommend it for press
speeds of 250 or greater strokes
per minute.) An adjustable actuator must
be mounted to the press and timed to
1 console stand-- optional
1 servo mounting bracket-- optional
1 cascade roller assembly-- optional
Please contact someone at your
facility to verify what options were
purchased.
If a mounting bracket was purchased
then it should be mounted first being
careful that the center line of the
bracket lines up with the center line
of the die area. The servo can then be
mounted on the bracket. A print of the
open the rolls when needed. Rapid-Air
offers such an actuator but only in one
style and one length. If after inspecting
the print dimensions and it is found that it
would work for you then contact your
distributor to purchase the actuating
arm. If the arm doesn’t seem like it will
bracket can be found in the back of
this manual.
If a bracket was not purchased then
the servo will have to be mounted on
the press bed or customer provided
bracket. Line up the rolls to be centered and perpendicular to the center
line of the die area. Included in the
back of this manual is a hole pattern
layout print for the CJ servo.
work then manufacturing your own arm
is your only recourse. The only
dimension that has to be closely
watched is the travel of the mechanical
actuating arm attached to the feed. The
maximum travel of this arm is .800 before
bottoming out (.250 for 106 & 112 CJ).
Electric Pilot Release
The optional electric pilot release is
mounted on top of the servo with 4
bolts which are included in the kit.
The kit also includes the valve and
the roll release stop for setting the
maximum movement of the roll opening. It is the customers responsibility
to interface the pilot release
valve with the customer supplied,
press mounted, activating switch. The
4
air requirements for the release to
work correctly is 80 to 120 PSI, dry fil
tered and lightly lubricated air. There
should be a minimum of 2 CFM available at all times.
-
PROGRAmmING PROCEDURE
Operator Input Section
The intent of this section is to familiarize the operator with the flow of
the program and what to expect with
each key press. Each program screen
of the servo will be displayed
and also comments to clarify possible
questions. There are four sections
that will be explained and they are as
follows
SECTION 1 — JOB NUMBER
SECTION 2 — MANUAL MODE
SECTION 3 — AUTOMATIC MODE
SECTION 4 — REVIEW PARAMETERS
When the servo is first started, and
has performed its startup procedure,
the first screen displayed should look
like this.
MAIN SELECTION MENU:
F1=JOB NUM F2=MANUAL
F3=AUTOMATIC (CYCLE)
F4=REVIEW PARAMETERS
* SELECT F1=JOB NUM
The first step in programming a job is
to select a two digit job number which
will be used to store the parameters
that the operator inputs or to recall
an existing job number that was
previously loaded. When the operator
presses F1 on the keypad, the screen
will change to:
JOB SELECTION MENU
ENTER JOB NUMBER=____
PRESS F4 KEY AFTER
CORRECT # IS ENTERED
JOB NUMBER = ______
F1=PROG. PARAMETERS
F4=DON’T ALTER VALUES
Pressing the “F1 PROG. PARAM
ETERS” key initiates the following
screen. Key in the required parameters.
FEED LENGTH=_________
PRESS SPEED=_________
FEED ANGLE=__________
* ONCE THE PARAMETERS HAVE
BEEN ENTERED, THE PROGRAM WILL
COMPLETE THE MATH ROUTINE
WHICH SELECTS THE PROPER ACCEL/DECELL AND MOTOR SPEED FOR
THE PARAMETERS LISTED AND THEN
THE MAIN MENU IS DISPLAYED
AGAIN.
*SELECT F2 MANUAL
If the operator elects to move the
material from the feed to the die
electrically, the manual mode has to
be selected. Pressing the F2 key will
bring up the manual mode screen.
MANUAL LENGTH=_______
F1=SINGLE_FEED
F2=GO TO INCH MODE
F4=RETURN
Each time the F1 key is pressed, the
servo will move the material the feed
length entered for the job number.
The material will move at the speed
required to keep up with the programmed press strokes per minute.
-
INCH MODE:
F1=JOG FORWARD
F2=JOG REVERSE
F4=RETURN
When the F1 key is pressed, the feed
will advance the material at a slow
rate of speed. When the F2 key is
pressed, the feed will reverse the
material and run at a slow rate of
speed. Press F4 to return to the main
screen.
With the main menu displayed and
Pressing the “F3 AUTOMATIC (CYCLE)”, the following screen appears.
AUTOMATIC JOB=01
FEED LENGTH=______
PRESS SPEED=______
F4=RETURN
In the automatic mode, the feed
length and operator entered press
speed will be displayed. Whenever
the press mounted feed switch is
activated, the servo will feed the
feed length displayed on the screen.
Because there is not an interface in
the control for the pilot release it will
be up to the customer to wire the pilot
release switch to the solenoid that
operates the raising of the rolls.
Press F4 button to return to the main
menu and deactivate the automatic
control.
Press F4 again and the final mode is
review parameters, the parameters
for the job number will then be displayed.
The next screen lets you program
parameters or exit with the existing
parameters.
If the operator would like the material
to move a slower rate then the inch
mode should be selected. Press F2
now to display the inch mode screen.
5
The last function on the keypad is the
“RESET JOB PARAMETERS”. This
function should be used with special
Operator Input Section (cont.)
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