Rapid-Air 100, 200, 300 User Manual

SERVO FEED WITH CUT-TO-LENGTH

OPERATING INSTRUCTIONS

MODELS

100, 200 & 300 SERIES

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

Phone: [phone] • Fax: [phone] • Web Site: www.rapidair.com

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RAPID-AIR START UP SECTION

SERVO FEED—CUT TO LENGTH

100, 200, 300 Series

Rev. C

Congratulations on purchasing a Rapid-Air Servo Cut-To-Length. Not only did you
receive a complete servo unit but also telephone support by one of our engineering
staff to guide you on using the new servo to its maximum capability.

In order to maximize your learning time and trouble shoot any interface problems, we
would like to request that the following items be complete before calling us:

1. Servo unit should be completely installed and aligned to a die on the press.

2. 220 Vac electrical wiring should be in place and unit turned on.

3. All interface switches should be wired and tested.

4. Air if needed should be connected and ready to be used.

5. All servo interface questions should be directed to Rapid Air prior to a start-up visit.
Please call 815-397-2578 and ask to have these questions directed to the proper
personnel.

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TABLE OF CONTENTS

CHARTS AND DRAWINGS DIRECTORY pg. 4

INTRODUCTION pg. 5

INSTALLATION pg. 6

ELECTRICAL CABLES AND AIR LINE pg. 7

INTERFACING SERVO FEED WITH CUTTER pg. 8

PRETEST WRITE UP pg. 9

LOADING MATERIAL pg. 10

SERVO INTERFACING EXPLANATION pg. 11

PROGRAMMING PR OCEDURE pg. 15

DRIVE ROLL PARALLELISM ADJ. pg. 21

TROUBLESHOOTING pg. 22

OPERATIONAL MAINTENANCE PROCEDURES pg. 24

PRECAUTIONS AND SAFETY pg. 28

WARRANTY pg. 29

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CHARTS AND DRAWINGS

PLAN 100 SERIES pg. 30

PLAN 200 SERIES pg. 31

PLAN 300 SERIES pg. 32

ELECTRICAL PANEL LAYOUT pg. 33

OPERATORS TERMINAL LAYOUT pg. 34

INTERFACE SCHEMATICS - 953 pg. 35

INTERFACE SCHEMATICS - 953 pg 36

INTERFACE SCHEMATICS– 953 120 VAC pg 37

CUTTER MAINTENANCE pg. 38

CUTTER BASE LAYOUTS pg. 39

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INTRODUCTION

The Rapid Air Servo Cut-To-Length Feed system carries with it the quality and
reliability you have grown to expect from a Rapid Air product. The motion control
system is a programmable industrial computer and this advanced technology,
combined with a highly engineered precision roll feed, is an unchallenged combination
in the press industry.

The compact mechanical package, direct coupled with a brushless servo drive motor,
offers response and feed speed accuracy unparalleled in any other powered roll feed.
Operator interface is so simplified, a typical setup person can have the servo feed
programmed and running in a matter of minutes. A step by step prompt appears on a
four line 88-character display, which asks simple questions of the operator. Entry of
feed length, cutter dwell time, and % maximum speed are all that is required for a new
setup. Routine jobs can be stored, recalled, changed and saved or run with a simple 2
digit job number entry. Up to 99 jobs may be stored and recalled at will.

A resolver, direct coupled to the servo drive motor for precise digital position feedback,
enable roll positioning accuracy to +/- .0025 for any programmed feed length or speed.

Operator programmed feed length, up to 999.999 inches and % max speed selection
along with full jog features on a pendant unit, allow the operator to thread the material
and inch it into position. The inch feature enables the operator to jog the servo feed
forward or reverse at a slow rate. The operator can select jog to length or jog
continuous to aid in threading up material.

The Rapid Air Servo Roll Feed has been designed to mount on a free-standing table
as close as possible to the cutter.

The precision mechanical roll feed unit has been designed for compactness, ease of
setup and installation. Three cables with twist lock connectors, two cables for the
servo, one connected to the cutter, and one air line are the only external connections
required. The electrical controls are housed in a small cabinet which should be
mounted close to the press working area. The operator keypad and display are
mounted on top of the control cabinet.

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INSTALLATION AND MECHANICAL SETUP OF SERVO AND CUTTER

If you purchased the servo/cutter combination already mounted on a base then the
servo and cutter were aligned at the factory. A good practice is to check all hold down
bolts to be sure that they did not come loose during shipment.

If you purchased the servo and cutter and are going to mount it on a base at your
facility, then a base should be selected that will hold the weight of the servo and the
cutter and also the cycling shocks incurred during production.

When mounting the two devices. The pass line height of the cutter and the servo roller
center line should be equal. Even more critical is the parallelism between the two
devices. The cutter should be mounted first then the servo center line should be
aligned to the cutter center line with the servo rollers parallel to the cutter blade.

The servo should be mounted as close to the cutter as possible and depending on
thickness of the material a bridge should be installed between the servo and cutter to
minimize material droop or buckling during feed.

Although the cutter and servo weights can be located in other sections of the manual.
The following is a list of the weights.

Servo
104 Servo—78 lbs. 204 Servo—119 lbs. 306 Servo—241 lbs.
108 Servo—87 lbs. 208 Servo—159 lbs. 312 Servo—312 lbs.
112 Servo—101 lbs. 212 Servo—187 lbs. 318 Servo—339 lbs.
118 Servo—115 lbs. 218 Servo—203 lbs. 336 Servo—493 lbs.

Cutter
4” Cutter—47 lbs.
6” Cutter—72 lbs.
8” Cutter—110 lbs.
12” Cutter—213 lbs.

The unit is now assembled and the next step is to attach the electrical and air lines to
the servo and cutter.

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ELECTRICAL CABLES AND AIR LINE

120 VAC INPUT
The alternate input voltage to the control is 120 Vac, 1 Ph, 60 Hz. The max amperage
needed is 7.5 amps and the control has a circuit breaker with a trip amperage of 10
amps..

230 VAC INPUT
The required input voltage to the control is 230 Vac, 3 Ph, 60 Hz. The amperage
needed is 10-20 amps depending on the motor size. If unsure of the amperage
needed, the name plate on the side of the Pacific Scientific drive will give the number
of the control or check the disconnect fuses for the correct fuse size.

460 VAC INPUT
If your plant has only 460 Vac power then a step down transformer is needed in order
to run the servo feed. If you purchased the transformer from Rapid Air, then all that is
needed is to connect and wire the 460 volt line to the transformer. If you did not
purchase a transformer from Rapid Air then a transformer, 3 KVA for the 100S and
200S servos and 6KVA for the 300S servos, 460/230 VAC 3PH, 60HZ step down
transformer is needed before proceeding with the electrical portion of the installation.

The electrical control enclosure is shipped completely ready to be connected to the
mechanical feed. Connected to the bottom of the enclosure are (2) cables with keyed
screw type connectors for connection to the motor. If the series 200 or 300 was
purchased, (1 or 2) push-on connectors for connection to the air valves for solenoid
actuation of the pilot release and or anti-backup valve are included. The third
connector is used to interface the cutter to the controls.

Position the electrical enclosure at a convenient location near the mechanical feed and
attach the cables. The motor cables are easily identifiable by the amount of pins in the
plugs. The solenoid cables if any can now be attached and checked for proper
location when the feed is up and running.

An air line must be connected from the shop air to the air inlet of the servo feed. The
air should be at least 80 PSI continuous and should be dry filtered andlightly lubricated
for the best operation of the servo feed. The air inlet on the servo feed is a 3/8-18 NPT
pipe tap. The minimum air line size requirement is 1/2”ID hose. - (2 CFM)

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INTERFACING SERVO FEED WITH A CUTTER

The Servo Drive unit is programmed to feed each time a signal is received from the
cutter switch. The servo will feed one progression and wait for the next signal before it
will feed again in automatic mode.

The command is in the form of a normally open contact from a proximity switch,
located on the cutter and is activated when the cutter is returned.

If the feed/cutter was purchased complete then the interfacing was done for you. If
not, then Rapid Air has provided wiring to a terminal block for interconnection
purposes. The interface schematic provides the wire numbers and how to connect the
cutter to the feed.

This completes the initial setup of the servo feed to the cutter or other device. The
servo is now ready to run as intended.

If more complete interfacing is needed, please refer to the section (interfacing ) in this
manual for an explanation of inputs and ouputs available.

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PRETEST FOR SERVO FEED AND CUTTER WITHOUT MATERIAL

Now that your servo/cutter combination is in place, and the cables have been attached,
you can proceed with testing the unit. The first step is to turn on the main disconnect
switch on the electrical enclosure. Next, at the operator’s console, pull the power on­off button to the on position. The button should illuminate to indicate that there is
power to the system.

The Pacific Scientific drive performs an initial sequence to check its internal program.
At this time the display should show the Rapid Air screen for 5 seconds before starting
the main setup program. If you are comfortable with programming a job then continue,
it not, please refer to the “Programming Procedure” located in this manual.

Follow the programming sequence for the operators terminal to input parameters into
job storage. Your servo feed has been fully tested before it was shipped to your facility
and this procedure is merely a test to insure that all functions are still functional and the
cables are properly seated.

Once you have programmed the required parameters, select the manual mode of
operation. If the option of air regulated upper feed roll was purchased, check that the
main air is at least 80 psi and check that the roll pressure gage is functional by
adjusting the pressure up and down, This is accomplished by turning the pressure
adjusting knob. If you did not purchase the air regulated roll option then check that you
have enough tension on the material to avoid slipping during feeding. Open and close
the feed and anti-backup rolls electrically and/or manually. Visually inspect that the
rolls open and close as you press the appropriate keys on the keypad or when using
the manual levers.

Select the “inch” function (F2 on keypad) on the manual mode screen. Visually check
that the rolls rotate both forward and reverse with the corresponding key. The speed is
preset to creep the rolls at a slow speed for manual positioning of the material.

CAUTION: Do not attempt to place your fingers or any foreign material into the rolls.
Injury to the operator or damage to the servo rolls could result.

After you have verified that the rolls and air logic are operational, you can experiment
with the single cycle moves. The procedure is outlined in the programming section of
this manual.

After all the checks have been made and you feel comfortable with the programming
of the servo controller, place the servo in automatic mode. Now cycle the press in
either the inch, single stroke or continous run, the servo feed should react upon the
closure of the press window and signal and simulate a feed progression of material.

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LOADING MATERIAL INTO THE SERVO FEED

Upon the satisfactory completion of all the tests, you should be ready to load a strip of
material into the servo feed.

Step number one is to select the manual mode of operation on the operators console.
Then choose “Operate Rolls”. This will allow you to open the feed rolls and anti­backup rolls to accept the material but only if you have purchased the option. You
could also open the rolls manually by lifting the lever mounted on the side of the servo
feed. Position the leading edge of the material with the center of the material near the
center of the entry rolls. Adjust the edge guides on the cascade rolls to the proper
width setting. Open the feed rolls and or anti-backup rolls. Hand feed the material into
the servo unit until it protrudes out of the feed rolls and starts into the guide on the
cutter. Close the anti-backup rolls (if purchased) to capture the material, then close the
feed rolls.

Check the roller force pressure to be sure that there is enough pressure to prevent
slippage but not too much to induce camber into the material. The pressure setting is
the amount of force necessary to move the material into the press at the speed and
feed programmed. You may find it necessary to readjust the force as you finalize the
setup procedure. The amount of force needed will vary depending on the width and
type of material being fed. Make a note of the final setting to aid in the setup of the
servo feed the next time the same material is run.

You are now ready to begin testing the complete system under power. To check the
progression, cycle the servo and cutter first in the manual mode then in the single cycle
mode . If the progression is correct, no further adjustments are necessary. If the
progression is either short or long, go to the troubleshooting chart and perform the
sequences described there for inaccurate feeding, once the feed progression has been
accurately set and the repeatability is satisfactory, you are ready for full automatic
mode.

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SERVO INTERFACING EXPLANATION

A. TAUT STOCK INPUT (J52)TBI-3)
This is a normally open contact from a switch or device that monitors the loop of
material prior to the servo feed. When the material reaches a point that it trips the
switch, a taut stock has been reached. This input, when received, immediately drops
the automatic which stops the feed in progress. The material should be repositioned in
the die before restarting the automtaic sequence, as the progression was lost when the
taut stock occurred.

This input also could be used as a “No Stock” switch that would monitor whether or not
there is material available to feed.

B. ANTI-BACKUP INPUT (J52)TBI-4) (series 200 servos only)
Whether the anti-backup rolls were purchased with the unit or came on the unit
standard, they can be activated to raise in the automatic cycle. The anti-backup rolls,
by design, keep the material from sliding back during the pilot operation. They can
become a hinderance if the material tends to walk to one side or the other during the
feed cycle.

C. ENABLE INPUT (J4-Pin 5 & 6))
The enable input is shipped from the factory, jumpered, so that the Pac-Sci unit is
ready to work after the initialization procedure is complete.

If it is desired that the servo controls are not functional until other equipment or safety
source is activated then a normally open contact can be interfaced to this input. If at
any time during the feed cycle the input changes state then the feed will stop at this
position. If feeding stock, the reference will be lost and the stock will have to be
manually repositioned to the correct location. The automatic cycle will be dropped and
have to be restarted.

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D. ENABLE OUPUT (J52)TB2-22)
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output is high
whenever the enabled input is activated.

E. CUTTER OUTPUT (J52)TB2-21)
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output goes high at
the end of every feed cycle and stays high for programmed cut time before going low.
To adjust this time, go to programming the job number and adjust the time needed for
the cutter.

F. AUTOMATIC OUTPUT (J52)TB2-20
This output must be tied to a solid state relay to interface to the outside world. The
solid state relay must have a D.C. coil and should have a rating of 3-30 VDC. The
Rapid-Air #69100165 is recommended for this application. This output goes high
whenever automatic is selected on the program panel. Any faults will cause the
automatic ouput to go low.

H. KEYPAD AND DISPLAY INTERFACE (RS232 PORT)
The keypad/display is the interface between the operator and the resident program.
The Pacific Scientific drive is purchased with a great many capabilities, none of which
can be used unless a program is written to utilize these capabilities. Rapid-Air put a
great deal of time making a program that is user friendly and yet gets the job done
efficiently. We took all the questions and constructive criticism and came up with a
program that would cover all the applications, yet be easy to interface and program by
a customer.

If an operator reads the programming procedure in this manual and then reads the
screen parameters listed as they are displayed and acts on them by inputting data as
needed, the servo can be up and running in a very short time.

1. Select a job number.

2. Input or review parameter for that job number.

3. Thread up material in manual mode.

4. If properly interfaced, go into automatic mode.

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