CUT-TO-LENGTH
WITH MULTI-STROKE
OPERATING INSTRUCTIONS
RAPID-AIR CORPORATION
4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925
Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.com
Cut to Length with Multi Stroke Program
Cut to Length with Multi Stroke Program
The standard multi-stroke program is a multiple feed length program within a
specified job number. The different programmed feed lengths will be referred
to as sequences. Each sequence can be repeated many times with 0 being
entered for no repeats. Although this is the standard program, Rapid Air can
program other configurations in any combination to meet the customer’s
requirements.
The standard multi-stroke program has 10 jobs with 10 programmable
sequences per job. Each sequence can be a different feed length which can
be repeated multiple times. The following chart depicts the previous write-up.
GAG FEED
TOTAL JOBS 10
TOTAL SEQUENCES 10
TOTAL REPEATS 10
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The job, sequence and repeats are software programmable.
TABLE OF CONTENTS
CHARTS AND DRAWINGS DIRECTORY pg. 4
INTRODUCTION pg. 5
INTERFACING FEED WITH CUTTER 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
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SERVO INTERFACING EXPLANATION pg. 11
PROGRAMMING PROCEDURE pg. 15
DRIVE ROLL PARALLELISM ADJ. pg. 23
TROUBLESHOOTING pg. 24
OPERATIONAL MAINTENANCE PROCEDURES pg. 26
PRECAUTIONS AND SAFETY pg. 30
WARRANTY pg. 31
LISTING OF CHARTS AND DRAWINGS
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time, are all that is required for a new setup. Routine jobs can be stored,
recalled, changed, saved or run with a simple 2 digit job number entry. Up to
10 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 can program feed lengths, 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
and ease of setup and installation. Three cables with twist lock connectors,
two cables for the servo and one connected to the cutter including one air line
are the only external connections required. The electrical controls are housed
in a small cabinet which have been mounted close to the working area. The
operator keypad and display are mounted on top of the control cabinet.
INSTALLATION AND MECHANICAL SETUP OF SERVO AND CUTTER
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drive will give the number of the control also 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 RapidAir then it is required to connect and wire the 460 volt line to the enclosure. If
you did not purchase a transformer from Rapid-Air then a 3 KVA, 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. 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.
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
and lightly 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 outputs available.
PRETEST FOR SERVO FEED AND CUTTER WITHOUT MATERIAL
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Once the 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 on-off button to the on position. The button should
illuminate to indicate that there is power to the system.
The Pacific Scientific drive performs an initiate 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 80psi and check that the roll
pressure gage is functional by adjusting the pressure up and down. This is
accomplished by turning the pressure adjust 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 antibackup rolls electrically 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.
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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. The
servo will feed and when done the cutter will cycle. This will verify that the unit
is working correctly.
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/cutter combination.
Step number one is to select the manual mode of operation on the operators
console. If you purchased the series 100 servo and added the air operated
roll release option then choose “Operate Rolls”. This will allow you to open
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the feed rolls and anti-backup 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 near the center of the entry
rolls and adjust the edge guides on the cascade rolls to the proper width
setting. Open the feed rolls and 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 feed rolls to capture the material.
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 feed and then cut or use 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.
SERVO INTERFACING EXPLANATION
A. TAUT STOCK INPUT (J52)TB1-6)
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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 automatic
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)TB1-8)
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 antibackup rolls, by design, keep the material from sliding back during the pilot
operation. They can become a hindrance if the material tend to walk to one
side or the other during the feed cycle.
The anti-backup switch was designed in for this program. If this 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 because 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.
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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 before this unit can function 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.
D. ENABLE OUTPUT (J52)TB2-15)
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)TB2-13)
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 the amount of
time programmed by the operator when the job number was programmed.
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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 output to go low.
G. 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.
H. STANDARD PROGRAM-INSTRUMENTS INTERFACE (J52)TB1-14)
With the jumper in place, the standard program is active. Remove jumper,
recycle power and the Data Instruments is active. Only the manual mode will
work with the keys at this time.
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.
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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.
RESET JOB PARAMETERS
The reset job parameters routing should be used with special caution. We
incorporated it as a user function for two reasons.
The first reason is if a problem caused the displayed parameters to be garbled
because of a program glitch, then by resetting the job parameters the problem
could be cleared.
The second reason is if there were a number of different jobs in memory that
were no longer required, then by resetting the job parameters, all the job
numbers would be reset to their default values, which includes putting all
zeros in the feed length and strokes per minute area of the program.
CAUTION! CAUTION! CAUTION!
Keep a hard copy record of program numbers and data associated with them
for reference if needed. If this function is used in a way other than what it was
designed for then all previous data is lost and cannot be recovered.
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To enter this function, turn off the program by depressing the master stop
button. Turn on the program again and push and hold the “clear entry” key,
once the program has started the following screen will be displayed.
**DEFAULT VALUE SETUP
PRESS F1 TO RESET TO
DEFAULT VALUES, PRESS
F4 TO IGNORE CHANGES
**Once F1 has been pressed then all data that had been entered will be reset.
PROGRAM NUMBER DISPLAY
Each servo unit that is shipped has a program number assigned to it. If a
problem occurs and cannot be solved by reloading the program then you will
be asked the program number associated with this servo.
To view the program number, press and hold the “back space” key during the
power up sequence. The program number will be displayed for about 30
seconds. Please find and write down the program number in case it is needed
in the future.
TO HELP YOU ENTER A JOB FROM THE KEYPAD LET’S CREATE AN
EXAMPLE
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We will use a feed length of three inches and want to run at a reasonable
cycles per minute.
The main menu is currently displayed. First we select the job number and we
will use job #1.
1. Press F1 to select the job number
2. Enter job number (01) - press the F4 key when finished.
3. The job number shows two choices:
a) Program parameters - This should be used when programming or
changing job parameters. The three inputs are feed length spm and cut
time. Enter in the three inch feed length putting zeros where needed.
(003.000) when finished, press the enter key and the selection underline
moves to the spm input.
Enter is a stroke per minute. We will use 150 spm (0.150). Press the
enter key again. The underline moves to the cut time selection. To start
with, put in (0.150). This will cut the material in at a high rate and may not be
enough time for thicker stock.
b) Don’t alter parameters - this will just load the existing parameters
without any changes. Exits to the main menu.
4. Press “F2” to select the manual mode.
a) Press F1 to select the “inch” or jog mode. This mode will move the
material slowly forward or reverse to position the material at it’s proper
location. F2
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being used for forward and F3 for reverse movement. Press F4 to
leave the “inch” mode.
b) Press F2 and the cutter will cycle for the max amount of time
entered. Press F3 and the roll will move the material the feed length
entered and then cut the material when the move is finished.
5. Press “F3” to select automatic cycle. In this mode the servo can be run in
the batch or continuous mode.
a) Press F1 to select the batch mode. In the batch mode, the servo
will feed each time it is commanded until the batch count reaches “0”, then the
automatic cycle drops out.
b) Press F2 to select the continuous mode. In the continuous mode,
the servo will feed each time it is commanded until the command stops
or the operator presses the “F4” return key.
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DRIVE ROLL PARALLELISM ADJUSTMENT
Every servo feed has an eccentric adjustment screw to adjust the upper roller
to be in parallel to the lower roller. The maximum adjustment is .008” on the
eccentric.
The adjustment screw is located behind the belt cover and is held fast by a 1032 socket head cap screw. The actual adjustment screw is a slotted eccentric
pin which is turned clockwise or counter-clockwise to raise or lower one end of
the upper roll.
The parallel adjustment is factory set when the unit is manufactured but if
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material tracking seems to be a problem then this could be a way of solving
the problem. To test if the rolls need adjustment, do the following.
1. Remove the front and rear roll covers.
2. Raise the anti-backup rolls. (If any) main rolls should be closed.
3. Shine a light from the rear of the feed toward the main rollers.
4. Inspect from the main rolls side to see if the rollers are parallel. If they are
then the material could be the cause of the material walking. If they are not
parallel then an adjustment has to be made.
5. To make the adjustment:
a. Remove manual roll release arm by removing roll pin.
b. Remove belt cover.
c. Locate eccentric screw and loosen 10-32 screw.
d. Turn slotted eccentric screw while viewing rolls until the rolls are parallel.
For a more accurate adjustment use a feeler gage to check the parallelism.
e. Tighten 10-32 screw and reassemble parts, then retry running material.
This completes the eccentric adjustment write-up, if there are further
questions, please call the factory.
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TROUBLESHOOTING CHART
PROBLEM CAUSE REMEDY
No power indication Disconnect off Turn
disconnect on
Blown fuse
Check/replace fuse
Master button in Pull button
out
No display on Program fault Check lights on P.C.
operators console Faulty wiring Check plug
on
console
Power on-no motion Program fault Check lights on P.C
Drive fault Check
lights on
drive
Program error Check
parameters
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No roll action No air Check air
line
Low air pressure Check air
regulator
Material will not Anti-backup closed Open rolls
enter rolls Feed roll adjusting Open
adjustment
mechanism too close
mechanism
Material too thick Check
servo parameters
Material will not feed Low roller force Raise roller
pressure
Oily material Clean
material
Program fault Check parameters
Obstruction in cutter Check
cutter
Material feeds short Accel to fast Lower accel
speed
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Low roller force Raise roller
pressure
Oily material Clean
material
Obstruction in cutter Check
cutter
Material feeds long High % max speed Lower % max
feed speed
Material slippery Lower
Decell speed
Decell set too fast Lower
Decell speed.
Material camber High roller force Lower roller
pressure
Bad stock Check
stock at input
TROUBLESHOOTING CHART (cont.)
PROBLEM CAUSE REMEDY
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Material feeds off Edge guides not set Set edge
guides
center properly
Material not centered Center
material
in feed
No automatic cycle No cutter returned signal Check limit
switch
input to
servo control
Controller fault Check
lights on P.C.
Servo fault Check
lights on drive
Program error Check
parameters
Servo squeals while Servo velocity gain Consult
factory
in position too high
Belt too loose or tight Readjust
belt tension
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Fault signal on Pac-Sci Servo fault Recycle
power
is displayed Material jam Check cutter
Power surge/failure
Check/recycle power
Cannot program unit Program fault Check Pac-Sci &
Call
factory.
Mechanical pilot release Too much overtravel Restrict travel of
sticks down mechanical
actuating
arm
Broken spring Remove
plate and check
springs
Needs lube Remove
plate
and
lubricate release bar
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MOTOR SERVICE
The servo motor is flanged mounted and secured with four socket head cap
screws. The motor removal has to be done in a sequence as described
below.
1. The manual roll release handle has to be removed. The inner roll pin holds
the handle to the shaft. Once this is removed the handle should slide off the
shaft.
2. The belt guard has to be removed. It is fastened with four 1/4-20 socket
head cap screws.
3. Remove the belt tension then remove the motor.
4. Install new motor and reassemble in reverse order of the previous
instructions.
5. When reinstalling the belt, the tension on the belt should be 1/64”
deflection per inch distance between the center lines of the pulleys using 1.5
to 2 lbs. force to cause the deflection. The best way is to tension the belt and
try running the servo for a few cycles. If you get a high vibration on the belt
when the feed stops then you have to readjust the belt tension. It will have to
have more or less tension to stop the vibration of the belt.
MANIFOLD ASSEMBLY
The manifold assembly was designed to give the customer easy access to the
components. The valve for the electric roll clamp and if supplied, the antibackup valve are mounted on the side of the feed. The air regulator and
pressure gauge is mounted on the input side of the feed. All can be easily
replaced if needed.
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ROLLER AND GEAR BOX ASSEMBLY
At this stage of disassembly, all field maintenance components are exposed
and easily accessible. No further field service should be necessary on the
roller and gear box assembly unless the gear train is suspected of a
malfunction. The drive rolls should be checked for erronious wear pattern
while they are exposed and cleaned before reassembly.
MAINTENANCE PROCEDURES
DAILY WEEKLY
MONTHLY
Wipe off feed rolls Check wear pattern of rolls Check oil
level
Clean any dirt from Check
cables for cuts
servo unit or wear
Clean any dirt from
operators pendant
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SERVO FAULT DISPLAY
The Pacific Scientific drive has a list of internal faults and displays the number
of that fault on it’s readout located on the front of the drive. Rapid Air now
displays the fault on the keypad display. If a fault occurs the screen will
display the number and the name of the fault, but there will not be an
explanation accompanying the fault. This is a tool to help you to trouble shoot
if the servo fails to perform when commanded.
If a fault was displayed the servo controller will have to be turned off and
restarted to clear the fault. If the fault is still present when the Pacific
Scientific unit is restarted, the fault may not be displayed on the keypad
screen as the fault will not let the internal program restart. The control panel
will have to be opened to view the fault again.
A list of probable faults and some explanation is included in this section. If
more help is required, then Rapid Air will have to be contacted.
FAULT CODE
(Predefined Variable, Integer, Status Variable, Read-Only)
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Guidelines - 0 means the drive is not faulted and not enabled, while 8 means
the drive is not faulted and enabled. Alternating 8.> means actively inhibiting
CW motion and alternating
8.< means actively inhibiting CCW motion
STATUS LED VALUE FAULT MEANING
(Blinking) 1 1 Velocity feedback (VelFB) over speed
(Blinking) 2 2 Motor Over-Temp
(Blinking) 3 3 Drive Over-Temp
(Blinking) 4 4 Drive I*t
(Blinking) 5 5 1-n Fault (9x3)
(Blinking) 6 6 Control ±12 V supply under voltage
(Blinking) 7 7 Output over current or bus over voltage
(Blinking) 9 9 Not Assigned
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(Blinking) A 10 Bus OV detected by DSP
(Blinking) b 11 Auxiliary +5V Low
(Blinking) C 12 Not assigned
(Blinking) D 13 Not assigned
(Solid) E* 14 Processor throughput fault
(Blinking) E* 14 Power Up Self Test Failure
(Alternating) E1 225 Bus UV, Bus Voltage VBUSTHRESH
(Alternating) E2 226 Ambient Temp Too Low
(Alternating) E3 227 Encoder commutation align failed
(Only CommSrc=1)
(Alternating) E4 228 Drive software incompatible with NV
memory version
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(Alternating) E5* 229 Control Card hardware not compatible
with drive software version
(Alternating) E6 230 Drive transition from unconfigured to
configured while enabled
(Alternating) E7 231 Two AInNull events too close together
(Alternating) F1 241 Excessive Position Following Error
(Alternating) F3 243 Parameter Checksum Error (Memory Error)
*FaultReset cannot reset these faults.
See ExtFault for further information on Blinking E, Blinking 1 and Alternating F3.
REASSEMBLY OF UNIT
Prior to assembly, attention must be given to three points of contact that
require an application of Moly-Cote, Lubriplate or other suitable heavy grease.
The three points are:
1. The antibackup piston which is located at the feed entrance.
2. The main roll piston and the spiral pins in the main roller tie plate which can
be seen by viewing straight down through the center of the feed at
approximately half way from the inlet to the exit roller. The piston is positioned
horizontally at the base of the feed and approximately in the center of the feed
if viewing from the gear box to the belt cover.
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3. The mechanical roll release shaft located at the exit side of the feed.
Three screws have to be removed and then the keeper plate can be
removed. The inner shaft should be thoroughly greased to prevent sticking.
Do not apply excessive grease as it may fall onto the drive rollers and cause
misfeeding due to material slippage. All bearings are sealed and need no
additional lubrication.
LUBRICATION
The gear box oil must be kept up to sight gauge level and changed after every
2000 hours of use. Recommended oil is Mobil #SHC630 or equivalent. The
oil reservoir capacity is 3.5 oz. The oil can be drained by removal of the drain
plug located near the base of the gear housing cover, just below the sight
gauge. The oil reservoir is filled through the pipe thread port occupied by the
air breather plug near the upper edge of the gear housing cover.
NOTE: THE ORIGINAL BREAK-IN OIL IN THE GEAR BOX SHOULD BE
CHANGED AFTER 100 HOURS OF CYCLE TIME AND EXAMINED FOR
CHIPS OR FOREIGN MATTER. REPLACE THE BEAR BOX OIL PER
INSTRUCTIONS.
The anti-backup rollers have been lubricated at the factory and should need
no further attention. If they are found to slip in the reverse direction, consult
the factory for further assistance.
PINCH ROLL & ANTI-BACK UP ACTUATING PISTONS
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Periodically grease with lubriplate or equivalent grease to anti-backup (if
purchased) & pinch roll actuating piston nose where it contacts the pressure
plate.
PRECAUTIONS & SAFETY
NEVER - Put screwdrivers or foreign materials in feed rolls
NEVER - Hold onto material as it is being fed through the servo
NEVER - Wear neckties around the servo feed rolls
NEVER - Force the rolls open by prying on them
NEVER - Modify the mechanical aspects of the servo feed
CAUTION - Contact the factory before drilling any holes in the unit
CAUTION - Wear proper eye protection when working around the servo
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CAUTION - Do not wear loose clothing around the servo feed rolls
WARRANTY
ALL SALES BY THE COMPANY ARE MADE SUBJECT TO THE
FOLLOWING TERMS AND CONDITIONS. PLEASE READ.
WARRANTY - The Company warrants, for a period of one year from date of
shipment by the Company, that the product shipped is free from defects in
material and workmanship. THIS WARRANTY IS EXCLUSIVE AND IN LIEU
OF ALL IMPLIED WARRANTIES IN LAW, INCLUDING MERCHANT ABILITY. The Company obligation under this warranty is limited to repairing
or replacing, F.O.B. Madison, SD, any part or parts proved to have been
defective when shipped. In no event shall the Company be liable for special
or consequential damages. Provisions set forth in specifications are
descriptive and subject to change and are not intended as warranties.
CUSTOMER LICENSE AGREEMENT
The RAPID-AIR CORPORATION reserves the rights in it’s software. The
software program is licensed by RAPID-AIR to the original purchaser of the
equipment which contains the software for use only on the terms set forth in
this license.
You may use the program only on the programmable servo computer
furnished with the system and only in conjunction with the servo feed supplied
with the system.
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You may not without expressed permission from Rapid-Air:
A. Copy, distribute, or document the program for others.
B. Modify or merge any portion of the program for use on non compatible
hardware.
C. Make alterations to the program.
OPERATOR INPUT TERMINAL - PROGRAMMING PROCEDURE-
STANDARD SOFTWARE
The intent of this section is to familiarize the operator with the program flow
and what to expect with every keypress. Each screen on the display will be
reviewed with special comments to help clarify what is being asked on the
screen. The program flow is broken down into 5 sections with the main menu
being the home postion. Reviewing the flow chart in the back of this manual
will help in understanding the sections.
SECTION1 —- F1=JOB ENTRY
SECTION2 —- F2=MANUAL MODE
SECTION3 —- F3=AUTOMATIC
SECTION4 —-F4=REVIEW JOB PARAMETERS
SECTION 5 —-RAMP=ADJUST ACCELLERATION AND DECELLERATION
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The first screen to be displayed on the operator terminal will look like this:
RAPID-AIR CORPORATION
4601 KISHWAUKEE STREET
ROCKFORD, IL 61109
815-397-2578
After a few seconds, the display will clear and the following display will
appear:
MAIN MENU
F1=JOB F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
SELECT F1=JOB #
The first step in programming the servo feed is to select a job number which
will be used to store the parameters the operator inputs or recall the
parameters which have been previously loaded into the servo controller
program. When the operator selects F1 on the keypad, the screen will change
to:
JOB SELECTION MENU
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ENTER JOB NUMBER=XX
PRESS F4 KEY ONCE
CORRECT # IS ENTERED
The operator must enter a 2 digit number before proceeding to any other
function. If the job number the operator has entered has been previously
stored in memory, or entering a new job, the following display will appear:
JOB NUMBER-01 LOADED
F1=PROGRAM NEW VALUES
F4= DON’T ALTER VALUES
THAT ARE PREPROGRAMMED
The job number screen displays (2) choices for the operator. In the first
choice, F1=Program new values, the operator can enter or change the
number of sequences, repeats per sequence, pilots, feed length, strokes per
minute that the press is running and feed arc angle. (Free travel of the press
in which the feed can move material without a problem) this then calculates
the optimum speed of the material movement. The second choice, F4= Don’t
alter values that are programmed, puts the job number entered in memory for
running at this time. If F1 was selected the following display would appear.
JOB NUMB=XX ENTER IN
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NUMB OF SEQUENCES=XX
PRESS F4 KEY ONCE
CORRECT # IS ENTERED
By definition a sequence is an event. Within a specific job number there is a
maximum of 10 sequences or events. A different sequence could be a new
feed length or a different output or both. After choosing the amount of
sequences then press the F4 key and the following screeen appears.
FEED ADVISOR JOB#=00
FL=000.000 SPM=000
TIME OF CUT = .XXX
F4=EXIT FEED ADVISOR
Input or change data at cursor. At this time, the longest feed length and the
maximum strokes per minute for this job should be entered to test if the feed
parameters are within the specifications of what the feed can perform. When
complete press F4 to exit. A fault window will appear if the feed length is too
long for SPM. Feed arc is press free travel for feeding material. Max feed arc
=300 degrees. The % of speed and then % accel rate is automatically
calculated.
This is the fault window that is displayed if the feed length and strokes per
minute are not within maximum parameters.
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FEED PARAMETER OUT
OF RANGE. THE LENGTH
IS TOO LONG FOR FEED
ARC OR SPM F4=REPEAT
F4=Repeat this command returns to the previous screen so that the new
parameters can be entered.
Pressing the F4 key at any time returns you to the main menu.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
SELECT F2=MANUAL
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After pressing the F4 key and the parameters are within the operating range,
the following screen appears.
JOB#=00 SEQUENCE=00
FL=000.000 REPS-0000
PUSH ENTER TO SELECT
F4=PROGRAM NEXT STEP
This screen will repeat for all the sequences selected. Press enter key to
move from FL, repeat, outputs and pilots. Press F4 key when all sequence
parameters have been entered. When complete, the main menu will appear.
If a feed rate is entered that is too long for the SPM then a fault screen will
appear as previously described.
In order to advance material into the cutter, using the servo feed, the operator
has to be in the manual mode. Pressing the F2 on the keypad will cause the
screen to change to the manual mode screen. (Cycle rolls with keys) - If the
keypad has keys with open rolls or close rolls on it then the keys are active at
this time and the rolls can be electrically released for inserting the material into
the servo feed.
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
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F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F1=INCH MODE
Pressing the F2 key will only let the operator make a forward movement the
amount that was programmed for the feed lengths of the job. Pressing F1 will
display the following Jog Mode screen.
JOG MODE
F1=FORWARD
F2=REVERSE - OR USE
EXTERNAL JOG PENDANT
F4=EXIT (INCH MODE)
F4=EXIT
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Pressing the F4 key once will restart the program to the jog mode screen so
that jog is now active. Pressing the F4 key twice will reset the program to the
manual mode screen. If the F4 key was pressed twice then the following
screen is displayed.
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F2-SINGLE FEED
Pressing the F4 key once will reset the program to the jog mode screen so
that jog is now active. Pressing the F4 key twice will reset the program to the
manual mode screen. If the F4 key was pressed twice then the following
screen is displayed.
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MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F2=SINGLE FEED
If the operator presses F2 then the following screen is displayed. The single
feed mode is active and every time the F1 key is pressed then the feed will
cycle and move the distance indicated on the feed length line.
JOB#=000 FL=000.000
SEQ#=00
F1=FEED F2=CUT
F3=FEED/CUT F4=EXIT
Pressing F4 once resets the program to the manual mode display. Pressing
the F4 key twice resets the program to the main menu display. If the F4 key
was pressed twice the following screen is displayed.
MAIN MENU
F1=JOB # F2=MANUAL
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F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
If the feed has been properly set up, tested in manual, press electrically
interlocked with feed, feed and pilot switches wired to the correct terminals,
then pressing the F3 key will display the following screen.
START AUTOMATIC FROM
F1=SEQUENCE NUMBER 1
F2=PREVIOUS SEQUENCE
AND REPEATS POSITION
After selecting one of the above choices the following screen appears.
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
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F2=CONTINUOUS
If the F2 key was pressed then the servo will be in the auto total mode and the
following screen appears.
AUTOMATIC TOTAL=000000
JOB #=XX PILOTS=NO
LGTH=XXX.XXX SPM=XXX
SPEED=XXX% F4=RETURN
Pressing the F4 key, stops the automatic cycle and the main menu screen
appears.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
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F3=AUTOMATIC
CYCLE
If the F2 key was pressed then the servo will be in the auto total mode and the
following screen appears.
AUTOMATIC MODE
JOB =00 NUMBER OF SEQ=00
TOTAL COUNTER=000000
F4=EXIT (AUTO CYCLE)
Pressing the F4 key, stops the automatic cycle and the main menu screen
appears.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
If the feed has been properly set up, tested in manual, press electrically
interlocked with feed, feed and pilot switches wired to the correct terminals,
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then pressing the F3 key will display the following screen.
START AUTOMATIC FROM
F1=SEQUENCE NUMBER 1
F2=PREVIOUS SEQUENCE
AND REPEATS POSITION
After selecting one of the above choices the following screen appears.
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
F1=BATCH
If the F1 key was pressed then the servo will be in the auto batch mode and
the following screen appears.
BATCH SETTING=000000
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BATCH COUNTER=000000
F1=RESET BATCH COUNT
F4=COINTINUE WITH COUNT
If F1 (reset batch count) is pressed then the batch count will be reset to it’s
preset valve. If F4 (continue with count) is pressed the batch count will remain
at its present value. Either F1 or F4 will lead to the following screen.
AUTOMATIC CYCLE MODE
JOB =00 NUMBER OF SEQ=00
BATCH COUNTER=000000
F4=EXIT (AUTO CYCLE)
Pressing the F4 key, stops the automatic cycle and the main menu screen
appears. When the automatic screen is displayed, all keys except the F4 key
are inactive. Every time the press cycles and trips the feed switch, the feed
will cycle once per the parameters displayed on the screen. If the feed
encounters excessive material drag while feeding or the material being moved
encounters a restriction that stops the material forward movement then a
servo fault can occur. If this happens then the following screen is displayed.
DRIVE FAULT OCCURED
NOTE TYPE OF FAULT—-
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(xxx
*example of fault
2 - motor over temperature
If this screen is displayed then the control cabinet has to be opened and the
Pac-Sci drive has to be checked. To reset the fault, the master on-off switch
has to be cycled which will reset the controller. The material path should be
checked for obstruction and parrallelism to the die. If all this seems to be
satisfactory and another fault occurs the factory should be consulted.
MAIN MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F4=JOB REVIEW
Pressing the F4 key will display the following screen. This screen asks for a
sequence number to be reviewed or modified. The program only allows
reviewing of a sequence in the job that is currently active. For an example, if
job #1 had 4 sequences and sequence 1 was not functioning correctly then
put in 01 at this time.
REVIEW OR MODIFY SEQ
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JOB NUMB=00 ENTER IN
THE SEQ=00 THEN
PRESS F4 TO CONTINUE
Pressing the F4 key will display the following screen.
JOB#=00 SEQUENCE#=00
FL=000.000 REPEAT=00
SPEED=000 ACCEL=000
F4=EXIT TO MAIN MENU
The above screen displays the job number and the sequence that was
selected. If all that was needed was to look at the sequence to verify that it
was correct then pressing the F4 key will return you to the main menu. If
there was a problem with this particular
sequence, like a length change, then the length could be adjusted now and
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the sequence would be changed in the job memory for any future running of
the job. The repeats, outputs, pilots, speed and accel can also be adjusted at
this time. When finished, press the F4 key and the main menu screen will be
displayed.
The last section to be covered is the ramp/counters section. To get into this
mode, press the ramp pushbutton and the following screen appears.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ALTER ACCEL/SPEED
F4=EXIT TO MAIN MENU
F1=BATCH/TOTAL COUNTS
Pressing the F1 key will bring up the batch/total screen, which is used for
presetting the batch count or resetting the total count. The following screen
appears.
BATCH COUNTER=000000
TOTAL COUNTER=000000
SET:F1=BATCH F2=TOTAL
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F4=RETURN TO RAMP COUNT
Pressing the F1-batch counter key allows the operator to preset a batch count.
Pressing the F2-total counter key resets the total count to zero. This cannot
be undone so be sure that the counter should be reset to zero before pressing
F2 key. Pressing the F4 key brings up the following screen.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ALTER ACCEL/SPEED
F4=EXIT TO MAIN MENU
The only section that has not been covered in this write-up is the ramp adjust
mode. The ramp adjusts how fast the servo motor gets up to speed and how
fast it stops. This feature is an asset that is seldom adjusted but can be a
sure cure if material slippage seems to be a problem. Pressing the F2 (alter
accel/speed) key produces this display.
RAMP PARAMETER MODE
F1=CHANGE % OF ACCEL
F2= CHANGE % OF SPEED
F4=RETURN RAMP/COUNT
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PRESS F1 OR F2
Pressing the F1 or F2 keys will produce one of the following displays. The
lower the number entered, the longer the ramp cycle. Press F1 or F2 now.
ENTER ACCEL RAMP % JOB NUMB=00 ENTER IN
MAX%=75000 RPM/SEC PERCENT MAX VEL=000%
MAXIMUM ACCEL %=002% PRESS F4 KEY ONCE
F4=EXIT (RAMP MENU) CORRECT # IS ENTERED
Multi-stroke Program Explanation
The Multi-stroke program is a cut-to-length program with the option of cutting
different lengths with different quantities for each length within the same
program or job
number.
The program consists of 10 jobs with 10 sequences per job. Each sequence
has multiple repeats with a programmable timed output to the cutter.
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The servo feed gets it’s “go” signal to feed from the cutter returned switch and
it in turn, the servo gives the cutter it’s “go” signal in the cut time section of the
programming. The cut time is actually how long the cut signal is to be
energized or have the cutter valve turned on.
The program asks for a two digit job number and then the number of
sequences required. This would be the number of different parts to be cut
within the job number. The next step is the feed advisor section when the
operator enters in the longest feed length at the strokes per minute required
and the cut time. The stokes-per-minute usually is not the actual strokes-perminute entered as the time required for the operation of each output varies
with the actual operation of each component but this sets up the accel/decel
and max speed of the servo motor.
The program then displays a window for each sequence with a feed length
and repeats or number of parts required for that feed length.
The program then can be run in manual or automatic (continuous or batch)
until the job is finished.
The Multi-stroke program remembers all aspects of the 10 jobs except for the
batch section which has to be changed for each job. Each sequence within
the job can be revised in the Review Parameters section so the job does not
have to be completely reentered for a change in any one sequence.
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Example of sequences within a job.
Job 01, 4 sequences
sequence 1
5.0 inch rep-100
sequence 2
8.0 inch rep-25
sequence 3
12.0 inch rep-10
sequence 4
28.500 inch rep-2
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