Rapid-Air AIR FEED User Manual

AIR FEED / CUT-TO-LENGTH

WITH KEYPAD

OPERATING INSTRUCTIONS

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

Air Feed/Cut-to-Length with Keypad

Table of Contents

Charts and Drawings Directory pg. 2

Installation pg. 3

Cutter Data pg. 4

Air Feed Progressions Setup pg. 5

Electrical Setup pg. 8

Pretest Without Material pg. 8

Loading Material pg. 9

Interfacing pg. 10

Programming pg. 11

Troubleshooting Electrics pg. 16

Troubleshooting Air Feed pg. 18

1

CHART AND DRAWINGS

Programming Map pg. 20

Manual Sequence pg. 21

Auto Sequence pg. 22

Rapid Master Layout pg. 23

Rapid Master Panel Layout pg. 24

Operator Keypad pg. 25

Electrical Diagram pg. 26

2

Operating Instructions
Cut to Length Machine

INSTALLATION:

The Cut to Length (CTL) that you have just received is fully assembled and ready to
be put into production. Due to shipment vibration and handling, the machine should
be checked to ensure all screws and bolts are tight. Remove the cover to the
electrical controls and visually inspect that all parts are in place and secure. If the
machine was damaged in shipment, contact the carrier first to report the damage and
then Rapid-Air.

CAUTION — The CTL machine is top heavy when not sitting on its base legs.
Use extreme caution when moving this machine.

Install machine on a level surface with sufficient clearance for loading and unloading
process material. The machine should be secured to the floor through the 4 holes
provided in the feet of the machine using 7/16 tie-down bolts. Or, can be installed
using 1/2-13 leveling bolts and machine pads. The pads keep the machine from
walking during operation and also act as a noise reduction device.

The machine has two other requirements that need attention before putting the CTL
into production.

1) The customer must provide minimum CFM—RE: chart, at 75 to 120 PSI of dry air to
the machine. Connect a minimum of 5/8” ID hose into the filter regulator provided on
the machine. The inlet to the F-R-L is a NPT female thread.

2) The customer must provide 120 volt, 20 amp, 60 cycle electrical power. If an
extension cord is used between the source and the machine, it should be a minimum
12 gauge wire to keep the voltage loss down and for electrical safety reasons.

3

SMALL CUTTER

Cutter Data:

See specific cutter specifications.

Operations:

The solenoid valve, which is remote mounted, is attached to the cutter (item #3) by a
plastic hose and advances the cutter into the material. Compression springs return the
blade to the raised position. The cutter raised position is monitored by a proximity
switch mounted on the rear of the cutter. (item 4)

Adjustments:

The cutter blade may be lowered manually by pushing down on the head of the cutter.
The upper half of the cutter is attached to an adjustable slide. The cutter clearance can
be adjusted by loosening 2 screws (item #1) and rotating the hex nuts (item #2). To
adjust, loosen one side and tighten the opposite side corresponding to the side you
want to adjust in order to line up the blades. Retighten the top screws (item #1). When
greasing, use Mobilux No. 2 or equivalent.

LARGE CUTTER

Cutter Data: Material opening item #1; See specific cutter specifications.

Operations:
The solenoid valve (item #2) advances the cutter into the material and the compression
springs return the blade to the raised position.

Adjustments:
The blade may be lowered manually with an eccentric cam screw (item #6) located on
the upper blade assembly just under the solenoid valve. The lower half of the cutter is
attached to an adjustable slide (item #3). The cutter clearance is adjusted by looseing
(2) hex screws (item #4) on the adjusting slides and turning (2) knurled knobs (item #5)
to move the lower blade horizontally in & out.

4

AIR FEED PROGRESSION SET UP

The feed guide rollers are adjustable by loosening the machine screws and moving the
rollers to the desired position. For best results the stock should be centrally located in
the feed.

The notches in the guide rails provide for coarse feed adjustment of the stop block. The
final feed adjustment for stroke length is made by the screw in the center of the stop
block. The final feed adjustment is aided by the use of accurately dimensioned spacers
or gage blocks placed between the adjusting screw and the main cushion bolt, and with
the air pressure turned on to keep the slide block tight against the main body.

With the air pressure off, the material is then inserted between the guide rollers and
passed under the feed clamp. Lift the stock clamp and push the material through to the
starting position. Turn on the air (75-120 PSI) and the feed is ready to operate.

The last adjustment, if necessary, would be the speed adjusting valve. The valve
adjustment is located on top of the main body on the opposite side of the actuating
valve. Adjust the screw for minimum impact by turning clockwise and for faster speed
by turning counterclockwise. When the impact is high, slippage is possible resulting in
poor repeatability and also part fatigue. Refer to the diagram below.

MAINTENANCE
The ram head assembly requires very little maintenance. There are four dynamic “O”
rings that would need to be replaced on the rare occasion of an air leak. These are as
follows per Rapid Master head assembly drawing #24000001 parts list.
item 43, part no. 60108212 1 req.
item 45, part no. 60108234 1 req.
item 90, part no. 60108269 2 req.
To absorb mechanical shock, reduce noise and prolong machine life, a rubber bumper
is incorporated into the assembly. Some stroke accuracy could be affected by rubber
deterioration. Stroke adjustment will compensate for any small overall stroke increase.

The rubber bumper (item 52, part no 35900037), should bbe examined during any “O”
ring maintenance procedure.

5

LUBRICATION
For a general guide for the Rapid Master, the lubricator oil release adjustment should
be set to one drop of oil for each 50-80 strokes. (See insert on lubrication of “O” rings.)

LUBRICATION OF “O” RINGS

The “O” Rings furnished with Rapid-Air feeds are made of a Buna N Compound
designed to give long life on service with air, oil and water. This rubber compound
features high abrasiion resistance and good dimensional stability if the
recommendations listed below are followed.

A filter and lubricator should be used; the filter to remove grit that would otherwise act
as an abrasive, and the lubricator to provide an adequate quantity of oil. For best
results, avoid excess of oil.

Parafifin base oils in general will give the best service. The viscosity should be 140­170 S.S.U., the API gravity 29.5 minimum and the aniline point between 150 F and
210F. Variation of the aniline point from the limits given is likely to cause either
shrinkage or stretching of the “O” Rings.

Detergent motor oils and all other oils designed for automotive use are generally
unreliable in chemical makeup for use with rubber compounds. Spindle oils are
too low in viscosity.

The group of oils listed below are generally recommended for Buna N compound 366Y
“O” Rings. This grouping is given in good faith but, because of the constant changes
made in oils by the manufacturers, we cannot guarantee any consistency of chemical
makeup. All of these oils have an aniline point of 210, and API gravity of 29.5 minimum
and a viscosity of 140-170 S.S.U. The base stock is paraffin.

Recommended:
Cities Service Oil Co. Pacemaker #1 (Standard hydraulic oil)
Standard Oil of Indiana #5 Hydraulic Oil
Sun Oil Co. Sunvix #916
Texaco Regal A, R & O
Shell Oil Co. Tellus #27
Turbo #27
Sinclair Oil Co Rubilene Extra Light
Atlanta Refining Co. Hytherm Oil #C
New Jersey Lubricant Co A-88/HNR
Standard Oil of Ohio Sohivis #43
Mobil DTE 10W Hydraulic

6