Rapid-Air D 100, 1000 User Manual
dual swivel reel
with display keypad
operating instructions
MODELS
100 & 1000 SERIES
RAPID-AIR CORPORATION
4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925
Phone: (815) 397-2578
• Fax: (815) 398-3887 • Web Site: www.rapidair.com
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table of contents
OPERATING INSTRUCTIONS .................................................................................................................... pg. 3
MECHANICAL OPERATING PROCEDURES ............................................................................................. pg. 4
DANCER ARM LOOP ................................................................................................................................... pg. 5
START-UP PROCEDURE ............................................................................................................................. pg. 6
TROUBLESHOOTING GUIDE ..................................................................................................................... pg. 7
SAFETY - MOTOR SPEED CONTROL ........................................................................................................ pg. 8
INTRODUCTION - MOTOR SPEED CONTROL ......................................................................................... pg. 9-10
ADJUSTMENTS AND CONTROL FUNCTIONS ....................................................................................... pg. 11
WARRANTY ................................................................................................................................................. pg. 12
PUSHBUTTON CONTROL REEL (1000 SERIES) DUAL SWIVEL (1/2 HP - 3 HP) DIAGRAMS ........... pg. 13-16
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operating instructions
CAUTION: DISCONNECT ELECTRICAL POWER
BEFORE PERFORMING ANY
SERVICE TO THIS MACHINE.
Installation
1. The machine that you have just
received is fully assembled and
ready to be put into position. Due
to shipment vibration the machine
should be checked to be sure all
screws and bolts are tight.
Visually inspect the machine for
damaged parts due to shipment.
If the machine is damaged in
shipment, contact the carrier
first to report the damage, and
then Rapid-Air.
2. Install the machine on a level
surface with sufficient clearance
for loading and unloading coils.
3. The machine is completely self contained and need only be
plugged into a 20 amp, 120 volt,
60 HZ outlet. If an extension cord
is used as the source to the
machine, it should be a minimum
#12 wire to keep the voltage loss
down and for electrical safety
reasons.
The main control unit is located
behind the pushbutton cover.
Below is an illustration of the
layout of the control panel. This
diagram lists all the components
and the approximate location of
each that could be used for troubleshooting the machine if a problem
should occur. The reel is shipped
with – 120 VAC (1 phase) input.
Visually check all electrics before
starting the reel.
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mechanical operating procedure
To Load Or Unload A Coil Ring
A) If your reel has a fixed center
shaft go to Step 1.
B) If your reel has an adjustable
center shaft go to Step 2.
Step 1:
Release and remove the outer coil
retainer from the shaft. Load or
unload the coil ring. Replace and
secure the outer coil retainer. The
reel is now ready for production.
Step 2:
Release and remove the outer coil
retainer from the shaft. If unloading, adjust the centering arms to a
position that they have released the
coil. Remove the coil ring. If loading,
place the coil ring on the adjustable
centering arms, adjust the centering
arms until they are tight on the coil.
Replace and secure the outer coil
retainer. The reel is now ready for
production.
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 the
same side as the punch controls.
slot. Set to desired length. Turn the
locking knob until tight on the dancer
arm. Then replace counter weight, if
so equipped.
Turn on the main power switch and
select “LV” for loop arm vertical at
“loop Type” on the pushbuttons.
Turn off the main power switch, press
and hold the “Run/Stop/Jog” button
while turning the main power switch
on. The first screen you see will
display the jog speed percentage.
JOG SPEED 23% +
NEXT -
If you want the jog speed faster
then press the “Reel Speed “+ ““
pushbutton. If you want the jog speed
slower then press the “Reel Speed
“-” “ pushbutton. The jog speed is
shown in percent of max jog speed.
If the jog speed is “OK “ then push the
Run/Stop/Jog button once for next.
The next screen asks if you want to
set up the sensor? As before the percent speed buttons are used for the
yes-no. Select “yes”! And then next.
SENSOR LOW SETPOINT
SAVE XXX
The next screen is for setting the high
set point. Raise the dancer arm to
its upper stop position and press the
save or Stop/Run /Jog button once.
SENSOR HIGH SETPOINT
SAVE XXX
The next screen is to set the offset of
the program. Potentiometers are hard
to get set from left to right so we built
in an offset. If you set the low and
high range and go into run, and the
reel runs for no reason, then an offset
has to be put in. Go through the setup
procedure again and put in an offset
of –3 to –5 and now the pot is zero.
LOW OFFSET + 0 +
NEXT -
You have now set the dancer arm
limits. The next screen is to exit the
setup and start working
EXIT SETUP? YES
NO
To switch the dancer arm to operate
on the opposite side that it is currently
located on, first remove the counter
weight if equipped with one, then 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
SETUP SENSOR YES
NEXT NO
The next screen asks you to set the
low set point. If the dancer arm is at
“No Material Rest” then just save
the setting by pushing the Stop/Run/
Jog pushbutton.
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Choose yes and next and the next
screen appears .
SHUT OFF POWER TO
SAVE AND EXIT
The dancer arm is now ready for
production running.
dancer arm loop
Dancer Arm Loop Height Adjustment
Eight different loop sensing arm
operating positions can be selected
during set-up. The material thickness
determines the dancer arm rest
position. Once the material is
threaded up and the dancer arm
is resting on the material and the
reel runs in the rest position then
select a higher number on the height
adjustment until the reel stops
rotating. The zero point of the dancer
arm is raised from its no material rest
position to the current rest position
angle shown (as indicated 0-8). The
dancer arm will start the material
dereeling from the new rest position
selected. The function is active and
can be changed in the run mode.
Dancer Arm Loop Range Function
The loop range function selects the
degree of arm movement to achieve
maximum motor speed selected. If a
loop range of “0” was selected then
the arm would only have to move
approximately 10 degrees to have the
reel at full speed whereas if the loop
range “8” was selected then the arm
would have to move almost the full
travel or approximately 90 degrees to
get to full speed. The function is active
and can be changed in the run mode.
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