CABINET REEL
OPERATING INSTRUCTIONS
MODELS
15, 25, 40 & 60 SERIES
RAPID-AIR CORPORATION
4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925
Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.com
REEL MANUAL INDEX
1. Installation
2. Reel diagram
3. Reel electric component diagrams for series 15, 25, 40 & 60
4. Reel specifications and maintenance chart
5. Dancer arm functions and diagrams
6. Taut stock functions and diagram
7. Coil load and unload
8. Trouble shooting
9. RAMM motor drive board operating instructions
10. KBRG motor board operating instructions
11. Electrical diagrams and reel parts breakdown
OPERATING INSTRUCTIONS FOR CABINET REEL
SERIES 15, 25, 40, 60
INSTALLATION
1. The reel that you have just received is fully assembled and ready to be put into
position. Due to shipment vibration, the reel should be checked to be sure that all
screws and bolts are tight and that all electrical components are in place inside the
cabinet; visually inspect the reel for damaged parts due to shipment. If the reel was
damaged in shipment, contact the carrier first to report the damage and then your
distributor.
2. Install the reel on a level surface with sufficient clearance for loading and
unloading the coils.
3. Wiring
The series 15, 25, & 40 reel is completely self contained and needs only to be
plugged into a 20 amp, 120 volt, 60 Hz outlet. If an extension cord is used as a
source to the reel, it should be a minimum #12 gauge wire to keep the voltage loss
down and for electrical safety reasons.
The series 60 reel or series 40 reel with a 3 hp motor, although completely wire,
requires a 240 volt, 1 pH, 60 Hz input. Rapid Air has provided a point of connection
in the form of a fused disconnect box for this purpose. Once the input wiring is
complete, the reel should be ready to run electrically.
The following pages are intended to familiarize you with the reel no matter what the
size. If, after reading the manual, you have questions on the operation on the reel,
we would appreciate hearing from you.
START UP PROCEDURE
Prior to applying power to the machine the operator should review all the controls on
the machine. A brief summary of the controls is listed below.
MAIN CONSOLE & CONTROLLER
The main control console & controls are mounted on the end of the cabinet. Located
on the face of the console are eight switches, on potentiometer, push-button and 2
reset switches, which are explained below.
1. DIRECTION CONTROL - (CW-CCW) - CAUTION: DO NOT REVERSE MOTOR
WHEN THE REEL IS RUNNING! - The direction control switch select the direction the
reel will turn, clockwise or counter clockwise. Once switched there is a time delay
before resuming normal operation. This is a built in safety for the machine.
2. % SPEED POT - The % speed pot adjusts the maximum speed that the reel will
rotate and should be set to maintain a constant feed rate.
3. ON/OFF SWITCH - This illuminated switch is the main power switch for the
controller. It must be “ON” for the machine to function.
4. PAYOUT/REWIND SWITCH - The payout rewind switch selects whether the dancer
arm will cause the reel to function at a low speed at the bottom of the arc and increase
the reel speed as the arm raises. (Payout); or cause the reel to function at a low speed
at the top of the arc and increase the reel speed as the arm lowers. (Rewinds)
5. RUN/STOP/JOG SELECTOR SWITCH - The switch selects between Run& Jog. If
in Run and the control arm is moved the coil plate will turn. If in Jog, the Jog button
has to be depressed for the coil plate to turn.
6. JOG BUTTON - Used for intermittent movement of the coil plate, mainly for set up,
speed is adjusted on the 69100076 board by potentiometer R3 on the electrical control
sub panel.
7. DANCER ARM LOOP HEIGHT & RANGE ADJUSTMENT -
a. Loop Range - The loop range switch adjusts the amount of travel the dancer arm will
move to provide the full range of speed of the pallet reel.
b. Loop Height - This switch is used for setting the start position of the control arm.
The setting determines when the reel will start turning. Each position will move the
operating angle of the arm so that top-to-bottom travel is adjusted to accommodate
specific material and loop height requirements.
8. LOOP ARM LEFT/RIGHT SWITCH
The loop arm left right switch selects the control which side of the reel the dancer arm
is controlling from. If the switch is in the wrong position the reel will run continuously at
full speed.
9. LOOP ARM/ARM EXTERNAL SWITCH
This switch selects either dancer arm (internal ) or “D” connector (external) speed
control functions.
10. RESET BUTTONS
a. 15 amp - This is the main circuit breaker for the reel.
b. 3 amp - this is the circuit protection for the “D” connector. Any shorts or over
loads would trip this breaker.
11. REMOTE INTERFACE PORT “D” CONNECTOR
This connector is used to communicate with external loop control equipment.
CAUTION: Never plug any type of computer or non Rapid-Air equipment into this
plug or severe damage will result. Always consult with the factory when installing
new external controls for compatibility and wiring information.
ELECTRICAL COMPONENT DESCRIPTION
69100034 board - proportional control board
69100076 board - component interface board
69100014 Motor control board (RAMM) - D.C. motor board
69100196 Motor control board (KBRG) - D.C. motor board
69100185 Motor control board (KBRG) - D.C. motor board 3 hp
REEL SPECIFICATIONS AND MAINTENANCE
REEL CAPACITY VALUES
----------------------------------------------------------------------------------------------------------------SERIES 15 25 40 60
------------------------------------------------------------------------------------------------------------------
COIL CAPACITY (LB.) 1500 2500 4000 6000
-----------------------------------------------------------------------------------------------------------------RPM (STANDARD) 23 23 23 17
-----------------------------------------------------------------------------------------------------------------STANDARD STOCK WIDTH 6 &12” 6, 12 &18” 12, 18 &24” 12, 18 &24”
-----------------------------------------------------------------------------------------------------------------COIL I.D. 14 - 22” 16 - 24” 16 - 24” 18 - 25”
-----------------------------------------------------------------------------------------------------------------MAX COIL O.D. STANDARD 36” 36” 36” 48”
----------------------------------------------------------------------------------------------------------------- OPTION 48” 48” 48” 60”
----------------------------------------------------------------------------------------------------------------- OPTION 60” 60” 72”
-----------------------------------------------------------------------------------------------------------------INPUT VOLTAGE (1 PH) 120VAC 120VAC 120VAC 240VAC
-----------------------------------------------------------------------------------------------------------------MOTOR VOLTAGE 90VDC 90VDC 90VDC 180 VDC
-----------------------------------------------------------------------------------------------------------------MOTOR SIZE 1/2 HP 1 HP 1 1/2 HP 2 HP
-----------------------------------------------------------------------------------------------------------------LUBRICATION (GEAR BOX) 32 OZ. 32 OZ. 32 OZ. 70 OZ.
------------------------------------------------------------------------------------------------------------------
LUBRICATION
Type: Gear transmission oil - Use Mobil 600W cylinder oil or equivalent. Fill to the bottom
edge of the oil fill hole. The capacity is listed above.
** The oil should be changed every 1000 hours
REEL DANCER ARM FUNCTIONS
All the reels manufactured by Rapid-Air have the capability of being run by proportional
control {dancer arm} or non-contact loop control {electronic loop sensing}. We
designed the electrical circuit so that a switch, mounted on the operator control panel,
can be selected to designate internal or external control.
If the internal was selected and the reel was in the “payout” mode then the dancer arm
would provide the means of controlling the speed of the reel. The higher the dancer
arm was raised from the rest position, the faster the reel would rotate. When the loop,
between the reel and the device it was feeding, reached the correct depth the reel
would stop and wait until the arm was raised again. Reels, whether they are vertical or
horizontal have one function and that is to unwind or rewind coils of material. The
vertical reels, if they are correctly adjusted and maintained accomplish this task very
well. Rapid Air has incorporated some adjustment means, that if set properly, can
have the reel paying out continuously without starting and stopping.
There are two switches and a potentiometer that are associated with the dancer arm.
One switch, labeled height, is used to control the distance that the dancer arm has to
move before activating the reel. This function becomes valuable if the material is thick
and will not let the dancer arm down to it’s rest position. Moving the selector switch to
the next height position will give the dancer arm more control because it will have to be
raised higher to activate.
Second switch, labeled range, provides a means of adjusting the distance the dancer
arm has to travel to achieve it’s maximum speed potential. With this switch set to the
lowest number the dancer arm has to travel very little to attain the maximum speed of
the motor. If the switch is adjusted to the next highest number then the dancer arm will
have to travel farther in it’s arc to achieve the maximum speed of the motor, etc.
The two previous switches, although very important, will not completely remove the
start-stop workings conditions of the reel. The third component which is very important
is the percent speed potentiometer. This device limits the maximum speed that the
reel can run regardless of the dancer arm position. The significance of this device
becomes apparent if long feed lengths are run and the dancer arm is raised high
enough to signal the reel to run at it’s maximum speed and then drops because the
loop is now sufficient. This causes the reel to work very hard for nothing. If by
adjusting the percent speed potentiometer to 50% of the maximum speed of the reel
and the material loop is sufficient to provide enough material for the next feed length
and the reel does not stop trying to provide the material then the reel controls are set
correctly. We want the reel to run as continuously as possible, without starting or
stopping between feed
cycles. The percent speed potentiometer should have it’s final settings set when the
coil is at it’s lowest point before running out of material. When a new coil is then put on
the reel, the reel will run somewhat on and off until the coil becomes smaller. The reel
speed will then even out until it is running continuously again. The previous example
will work only if the same feed length and coil O.D. is repeated for the conditions that
the reel was set up for. If a different coil O.D. or different feed length is used, then the
previous settings may have to be altered.
The following diagrams provide a means of visually helping you understand how the
dancer arm function affects the motor response. The diagram also exhibits how the
reel performs on payout and rewind mode and orientation of the material so that it can
be threaded under the dancer arm before going to it’s destination to be formed or cut.
DANCER ARM POSITION EXPLANATION
The dancer arm was designed to operate from either side of the reel. The main reason
for this was so the reel controls could be lined up on same as the press controls.
To switch the dancer arm to operate on the opposite side that it is currently located on,
first remove the counterweight if equipped with one. Turn the locking knob to
disengage the lock on the dancer arm hub. Remove the dancer arm and relocate it to
the other side. Turn the hub 60 degrees and insert the dancer arm into the slot and set
it to the desired position. Turn the locking knob until tight on the dancer arm, Replace
the counterweight if so equipped. Switch the loop arm selector slide switch from left to
right side or right to left side position as required. The dancer arm is now ready for
production running.
TO LOAD OR UNLOAD A COIL
The Rapid Air reel is manufactured using a three arm mandrel with manual
expansion as standard for all models. This coupled with three inner keeper arms or
one inner coil plate and three outer keeper arms complete the coil retaining
capabilities. The mandrel adjustment is accomplished by turning a crank handle
located on the outer end of the mandrel.
To load a coil, turn the crank handle in a counter-clockwise rotation until the mandrel
is collapsed enough to accept the inner coil diameter. Position the material coil with
the back of the coil in contact with the inner coil or keeper arms. While keeping the
coil weight off of the mandrels, turn the mandrel crank adjust handle in a clockwise
rotation until the mandrels have tension on the I.D. of the coil. Adjust the position of
the coil and recheck the coil mandrel tension. Retighten if necessary. Place the
three outer coil keepers on the mandrels and fasten them down using the automatic
tightening handle to make sure that they are secure. Fold the crank handle back
into itself for storage. The reel is now ready for production.
To unload a coil ring, remove the three outer coil keepers and then turn the crank
handle in a counterclockwise rotation until the coil is released Unload the coil.
Reinsert the coil keepers on the mandrel and fold the crank handle back into itself
for storage.
Once the coil has been loaded and secured and before breaking the band on the
coil, the reel should be checked so that it will operate correctly.
Turn the main power switch and select the jog function. Push in the jog button and
check that the reel is rotating in the direction that the material will be feeding. If
using a dancer arm for reel speed control, then set the loop arm switch to internal
control. Check that the dancer arm left/right switch is in the correct position. Put the
run-stop-jog selector switch in the run position and slowly raise the dancer arm to
see if it is controlling the reel speed and that it is not operating too fast from zero to
maximum speed for the amount of dancer arm movement. If need to be, reset the
height and range switch to get a smooth transition of motor speed to dancer arm
movement.
Turn off the reel and cut the coil band. Turn on the reel and jog the reel until some
material has payed out. Put the reel in the run mode and have the material payout
under the dancer arm to the press feed or other feeding device. This completes
your reel setup.
TROUBLE SHOOTING GUIDE
MAIN SWITCH ON BUT NOT LIT
1. CB tripped
a. Reset CB
2. Unit not plugged into main power
a. Plug into main power source
3. No power in incoming line.
a. Check outlet.
b. Check power cord.
4. Loose wiring
a. Check terminals and connections.
MOTOR CREEPS IN STOP POSITION
1. R1 & R3 pot on 69100034 board not correctly adjusted.
a. Reajust pots so table stops. Call factory.
2. Dancer arm bent.
a. Readjust R1 & R3 on 61000033 board.
b. Straighten dancer arm.
UNIT TURNS ON BUT WON”T JOG
1. Selector switchnot in jog position.
a. Select jog.
2. Jog pot on 69100076 board not adjusted correctly.
a. Adjust pot on 69100075 board. Call Factory.
3. Maximum speed pot on Ramm board set too low.
a. Adjust pot.
UNIT ON BUT MOTOR WON’T RUN. (ARMATURE VOLTAGE PRESENT - ON
RAMM BOARD)
1. Check motor wiring and fuse.
a. Replace motor cord or correct motor wiring. Call Factory.
2. Check motor.
a. Worn brushes or motor defective. Call Factory.
UNIT ON BUT MOTOR WON’T RUN. (NO ARMATURE VOLTAGE ON RAMM
BOARD)
1. Selector switch not in run position.
a. Turn selector switch to run position.
2. If running with a dancer arm control.
a. Check that the external/loop arm switch is in the external position.
3. If running with external control.
a. Check that the external/loop arm switch is in the external position.
4. Height switch setting too high.
a. Set height setting to “O”.
5. Percent speed pot set too low.
a. Adjust percent speed pot to 100%.
6. Fuses blown.
a. Check fuses & circuit breaker.
7. No AC voltage at DC drive board.
a. Check wiring.
8. Check signal voltage between P2 to I2 on DC drive.
0-6 VDC - Ramm
0-9 VDC - Regen Drive
While moving the dancer arm.
a. If there is a signal, check continuity between I1 & I2
If no continuity, replace D.C. drive or call factory.
9. Check line voltage input of 69100033 board, 120 VAC, TB-1.
a. Check wiring. Call factory.
10. Check pico fuse 6910033 board (f1).
a. Replace fuse, 1 amp pico fuse - call factory.
11. Check for 0-12 VDC between pin #1 (+V) and pin #2 (GND) of panduit connec-
tor TC3 on board #69100033.
a. If no voltage present call factory.
12. Check for DC voltage between pin #6 (V0) and pin #2 GND of panduit connector
TC3, on board #69100033, while moving the dancer arm from minimum to
maximum position.
a. If voltage is present, turn power off and check the ribbon cable
connections between panduit connector #TC3 of 69100033 board and pan
duit connector TB-4 of 6910076 board. This should be a continuity check for
tight connections. Call factory for assistance.
b. If voltage is not present move on to step 12.
13. Check voltage between pin #5 of B-6 & pin #3 of B-5 on 6910007 board while
moving the dancer arm from minimum to maximum position.
a. If voltage varies 2.5- volt from minimum to maximum position, the dancer
arm pot is OK, but the 69100076 board could be defective. Call factory.
b. If voltage does not vary when moving the dancer arm from minimum to
maximum position - call the factory for assistance.
69100034 TAUT STOCK OUTPUT
The 69100034 - proportional control board has a taut stock output. This output must
be wired to a solid state relay as the Max current draw is 20 ma. The solid state
relay’s contact can then be incorporated into the electrical control circuitry.
The output can be wired so that the relay is either on or off with the dancer arm down.
When the dancer arm reaches the set point for taut stock, the relay switches state.
The taut stock height set point is set by raising the dancer arm to a position that the
material is taut and then adjusting pot R7 so the output changes state. Lower and
raise the dancer arm a few times to check that the set point repeats and then the task
is finished.
The potentiometer that is located just below the taut stock terminal strip is used for
presetting the Max voltage output requirement for a particular drive. A Ramm DC
drive board needs 6 VDC for Max motor sped so turn the pot fully counter—
clockwise. A minarik drive board needs 10 VDC for Max motor speed so turn the pot
fully clockwise.
The following is a brief wiring diagram for the taut stock.
3 GRD.
2 10 VDC out with dancer arm down
1 0 VDC out with dancer arm down
If the existing taut stock is being used, do not change anything. This change was
incorporated so that the straighteners and other equipment without the direction
board have a taut stock option.
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