Rapid-Air 200T, 200TX User Manual

SERVO FEED

OPERATING INSTRUCTIONS

MODELS

S, X, HT SERIES

(INCLUDES 100T & TX, 106T & TX THROUGH 118T & TX, 200T & TX.

220VAC, 3PH, 60HZ)

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

RAPID-AIR START UP SECTION (100-200-300 S SERIES)

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 it’s 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 your distributor first then to
Rapid-Air. 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. 3
INTRODUCTION pg. 4
INSTALLATION AND MECHANICAL SETUP pg. 5
INSTALLATION OF MOUNTING BRACKET pg. 6
MECHANICAL ROLL RELEASE SETUP pg. 7
ELECTRICAL CABLES AND AIR LINE pg. 8
INTERFACING FEED WITH PRESS pg. 9

PRETEST WRITE UP pg. 10
LOADING MATERIAL pg. 11
SERVO INTERFACING EXPLANATION pg. 12-13
RESET JOB PARAMETERS pg. 14
PROGRAM NUMBER DISPLAY pg. 14
PROGRAMMING PR OCEDURE pg. 17
DRIVE ROLL PARALLELISM ADJ. pg. 24
TROUBLESHOOTING pg. 25-26
FAULT DISPLAY - FAULT CODE pg. 27-28
OPERATIONAL MAINTENANCE PROCEDURES pg. 29

PRECAUTIONS AND SAFETY pg. 31
WARRANTY pg. 32

100 SERIES WIRING DIAGRAM pg. 33
100 SERIES ENVELOPE DRAWING pg. 34
200 SERIES ENVELOPE DRAWING pg. 35
100 SERIES – EXPLODED VIEW AND PARTS LIST FOR SERVO FEED pg. 36-37

100 SERIES – EXPLODED VIEW AND PARTS LIST FOR CABINET pg. 38
100 SERIES – EXPLODED VIEW AND PARTS LIST FOR CASCADE ASSEMBLY pg. 39

200 SERIES – EXPLODED VIEW AND PARTS LIST FOR SERVO FEED pg. 40-41
200 SERIES – EXPLODED VIEW AND PARTS LIST FOR CONTROL CABINET pg. 42
200 SERIES – EXPLODED VIEW AND PARTS LIST FOR CASCADE ASSEMBLY pg. 43

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CHARTS AND DRAWINGS

PLAN 100 SERIES

PLAN 200 SERIES

PLAN 300 SERIES

SERVO BRACKET SIDE 100 SERIES
200/300 SERIES - 4&8”

ELECTRICAL PANEL LAYOUT

OPERATORS TERMINAL LAYOUT

PROGRAMMING MAP

JOB INPUT SEQUENCE

MANUAL SEQUENCE

AUTOMATIC SEQUENCE

STROKES PER MINUTE VS. FEED WINDOW

PRESS-FEED AND PILOT SWITCH SETTINGS

INTERFACE SCHEMATICS - 752

SERVO PARTS BREAKDOWN

WIRING SCHEMATIC

100T & TX ENVELOPE DRAWING

200T & TX ENVELOPE DRAWING

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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 unchallanged 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 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 at a slow rate. The operator can select jog to length or jog continuous to aid in
threading up material.

The precision mechanical roll feed unit has been designed for compactness, ease of
setup and installation. A 230 volt, 3 phase supply and an air line are all that is required
of the customer. Two cables with twist lock plugs and one or two cables for the air
valve control are supplied with the control and need only be connected to the proper
locations. 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 SETUP OF SERVO FEED

The shipping container should contain:
1 Mechanical Servo Feed -Standard
1 Console Complete -Standard
1 Cascade Assembly -Optional (100 Series) (Standard 200-300 Series)
1 Servo Mounting Bracket -Optional
1 Guide Support Assy. -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
Series 200 4&8” Wide 3/8-16 4
12” Wide 1/2-13 4
Series 300 All 1/2-13 4

The servo mounting bolts should not penetrate into the servo body by more
than .625".

5

INSTALLATION AND MECHANICAL SETUP 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 the smaller bracket and 3
1/2” holes on the large 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 small bracket and 3 locking screws on the
large bracket.

The unit is now assembled and the next step will be to attach the electrical and air 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.

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MECHANICAL ROLL RELEASE SETUP

All Rapid-Air feeds are set up to add a mechanical pilot release. If the mechanical pilot
release is used, and we recommend this for press speeds faster than 250 SPM, then
a bracket must be fabricated 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.

The series 200 and series 300 pilot release actuator has a 2” 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 or overcome the incoming air pressure or
roller pressure spring force depending on which servo unit you purchased.

ELECTRIC PILOT RELEASE
If an electric pilot release is used and the servo is a series 200 or series 300 then a
switch from the press has to be wired into the control box to control when the release
has to take place. If a series 100 was purchased then an optional pneumatic pilot
release has to be purchased.

OPTIONAL PILOT RELEASE #10900449 (100 series)
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.

Optional Mechanical Pilot Release - 100 series #10900483
Optional Mechanical Pilot Release - 200 series #10900489
Optional Mechanical Pilot Release - 300 series #10900490

7

ELECTRICAL CABLES AND AIR LINE

230 VAC INPUT
The required in put voltage to the control is 230 Vac, 3 Ph, 60 Hz. The amperage
needed is 6 amps for 752 control and 10 amps for the 753 control. 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 you 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 and 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.

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)

8

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 and 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 then commands the 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 and pilot signal input and wire per print. The
feed input number is (J52)TBI-2) and the pilot input number is (J52)TBI-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.

9

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, 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 preforms an initial 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,
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.

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.

10

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
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 press. 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 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.

11

SERVO INTERFACING EXPLANATION

A. TAUT STOCK INPUT (J52)TBI-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 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-8)
Whether the anti-backup rolls where 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 tend to walk to one side or the other during the
feed cycle.

The anti-backup switch can be used as a solution. If the material walking problem is
being experienced then a switch or a cam switch with a normally open contact can be
wired in from the press. Usually this switch is activated when the press is at 180
degrees or when the die is closed to be sure that the material is being held in position.
The rolls will raise for the amount of degrees that the switch is activated, letting the
material reposition itself in line with the die. It is crucial that this switch is not activated
for too long a time as when the die releases the material, the material will slide back
which will cause a misfeed. This feature has to be used in conjunction with the main
rolls being raised or it will not give the desired results as one of the rolls will be holding
the material from moving.

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.

12

D. ENABLE OUPUT (J52)TB2-15)
This output must be tied to a solid state relay to interfact 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.

E. END OF FEED OUTPUT (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 main screen menu displayed, 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.

F. 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 ouput to go low.

G. STANDARD PROGRAM- DATA INSTRUMENTS INTERFACE (J52)TB1-14)
With the jumper in place, the standard program is active. Remove jumper, recycle
power and the Data Instruments program is active. Only the manual mode will work
with the keys at this time.

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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