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
1
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
2
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.
3
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.
4
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.
5
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 pushbutton control box is
mounted on the top of the reel frame.
Located on the face of the console
are eleven pushbuttons, one display,
one on/off switch, one circuit breaker,
one external loop plug and inside
the box is motor board and one
potentiometer when required, all
of which are explained below.
1. DIRECTIONAL CONTROL –
(CW/CCW)
CAUTION: DO NOT REVERSE MOTOR
WHEN THE REEL IS RUNNING!
The direction control function selects
the direction the reel will turn,
clockwise or counterclockwise.
To find which way it should be
programmed, stand facing the coil
side and decide which way the coil
should wind or unwind, clockwise
or counter-clockwise. Push the
appropriate button until the correct
rotation is displayed on the display.
CW= clockwise and CCW= counterclockwise. Adjust in stop mode only.
2. % SPEED POT
The % speed function adjusts the
maximum speed that the reel will
rotate and should be set to maintain
a constant feed rate. Adjustable in
the run mode.
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
The payout/rewind function 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 (Rewind). Adjust in stop
mode only.
5. RUN/STOP/JOG
This function selects between Run,
Stop and 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. If
in Stop, there should be no movement
of the coil plate, even if the dancer
arm is raised or lowered or the jog
pushbutton is pressed.
6. JOG BUTTON
Used for intermittent movement of
material on the coil plate, mainly for
set up or rewinding excess material.
Active in jog mode only.
7. DANCER ARM LOOP HEIGHT
& RANGE ADJUSTMENT
a. Loop Range – The loop range
function adjusts the amount the
dancer arm will travel to provide
the full range of speed of the reel.
There are eight positions available.
b. Loop Height – The loop height
function 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 start position
up from the home position to
accommodate specific material
rest height requirements.
8. LOOP ARM/EXTERNAL SWITCH
This switch selects either dancer arm
(internal) by displaying “LV” for loop
arm vertical reel or “LH” for loop arm
horizontal reel (PMD) or external loop
control by displaying “RT” for the
RTB and ”RS” for the RS_1. The RLL
will work on the “RT” selection.
9. RESET BUTTONS
A. 15 amp – This is the main circuit
breaker for the reel.
10. 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
69100804 board – main reel control
board
69100014 (RAMM) – D.C. motor board
69100218 dancer arm potentiometer
69100578 circuit breaker
69100315 rocker switch
6
troubleshooting 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. “Min” speed pot on RAMM
board out of adjustment.
UNIT TURNS BUT WON’T JOG
1. Jog function was not selected
a. Select jog.
2. Jog speed has not been set up
a. Call factory.
UNIT ON BUT MOTOR WON’T RUN.
(ARMATURE VOLTAGE PRESENT –
ON RAMM BOARD)
1. Check motor wiring
a. Replace motor cord or correct
motor wiring. Call factory.
2. Check motor
a. Worn brushes or motor
defective. Call factory.
b. Check for oil in motor, gear box
seal could have ruptured.
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 function is in the loop
arm position.
3. If running with external control.
a. Check that the external/loop
arm function is in the
external position.
4. Loop height switch setting
too high.
a. Set height setting to “0”.
5. Percent speed function set
too low.
a. Adjust percent speed
function 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 P1 on DC drive.
0-6 VDC—RAMM
0-9 VDC—Regen Drive
while moving 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 pico fuse on 69100804
board (F1).
a. Replace fuse, 1 amp pico
fuse—call factory.
7
safety warning – please read carefully
RAMM Solid State DC Motor Speed Control
This product should be installed and
serviced by a qualified technician,
electrician or electrical maintenance
personnel familiar with its operation
and the hazards involved. Proper in
stallation (see instruction information
which accompanies product), which
includes wiring, mounting in proper
enclosure, fusing or other overcurrent
protection and grounding, can reduce
the chance of electrical shocks, fires
or explosion in this product or prod
ucts used with this product, such
as electric motors, switches, coils
solenoids and/or relays. Eye protec
tion must be worn when working with
control under power. This product is
constructed of materials (plastics,
metals, carbon, silicon, etc.) which
may be a potential hazard. Individual
material safety data sheets (MSDS)
are available upon request. Proper
shielding, grounding and filtering of
-
-
-
this product can reduce the emission
of radio frequency interference (RFI)
which may adversely affect sensitive
electronic equipment. If information is
required on this product, contact our
factory. It is the responsibility of the
ultimate user of this product to read
and comply with this safety warning.
(SW effective 1/89)
***IMPORTANT***
YOU MUST READ THESE
INSTRUCTIONS BEFORE
OPERATING CONTROL
1. Be sure AC line voltage
corresponds to control voltage.
TABLE 1: NOMINAL TRIMPOT SETTINGS
MIN (minimum speed): 15% CL (current limit/torque): 65%
MAX (maximum speed): 65% ACCEL (acceleration start): 20%
IR (IR compensation): 25% DECEL (deceleration stop): 20%
2. Install the correct Plug-In
Horsepower Resistor according
to armature voltage and motor
horsepower.
3. Recheck connections: AC line to
L1 and L2; armature to A+ and
A– and field (Shunt motors only
to F+ and F-.) (NOTE: If motor runs
in improper direction, interchange
armature leads.)
4. Install proper AC line fuse and
armature fuse as required.
5. Nominal trimpot settings are as
follows (expressed in % of full
CW rotation):
Plug In Horsepower Resistor
A Plug-In Horsepower Resistor
must be installed
to match the
RAMM to the
motor horsepower and volt
age. See table 2
for the correct
value. Plug-In
Horsepower
Resistors are
stocked by your
distributor.
-
TABLE 2: PLUG IN HORSEPOWER RESISTOR CHART
MOTOR HORSEPOWER RANGE **
Armature Voltage
90-130 VDC
1/4
1/2
3/4
1**
* Motor horsepower and armature voltage must be specified when ordering so that proper resistor will be supplied.
** For overlapping motor horsepower range use lower value Plug-In Horsepower Resistor.
*** Auxiliary heat sink must be used to achieve HP rating.
Armature Voltage
180 VDC
1/2
1
1-1/2
2***
8
Plug-in
Horsepower
Resistor Resistance
Value (ohms)
.05
.025
.015
.01
Rapid-Air
P/N
69100529
69100530
69100534
69100531
introduction
RAMM Full Wave Solid State DC Motor Speed Control
The RAMM Full Wave Solid State DC
Motor Speed Control represents the
latest state-of-the-art design achiev
able through modern technology.
FEATURES INCLUDE:
Integrated Circuitry
Used to control and amplify
command and reference levels
with both closed and open loop
feedback to provide superior
motor regulation. (Speed changes
due to load, line voltage, or
temperature variations are held to
minimum levels).
High Quality Components
Selected and tested for proven
dependability.
-
3. Follow the recommended supply
wire sizes as per table 3.
4. Follow the NEC and other
electrical codes that apply.
TABLE 3: MINIMUM SUPPLY WIRE SIZE REQUIREMENTS
Max.
Motor
Amps
(DC Amps)
6.0
12.0
16.0
* Maximum recommended wire size.
Max.
Motor
HP
90V
1/2
1
1-1/2
Max.
Motor
HP
180V
1
2
3
CAUTION: SEPARATE BRANCH
PROTECTION MUST BE PROVIDED
ON 240V CIRCUITS.
5. Connect control in accordance
to connection diagram.
Max.
Motor
Run
16
14
12
Minimum
Wire Size (AWG)
Cu only)
Max. Motor Run
14
12*
12
Transient Protection
Used to prevent failure of the
power bridge circuit caused by
voltage spikes on the AC line.
High Reliability
When used in accordance with
instructions in this manual, the
RAMM will provide years of
trouble free operation.
A. INITIAL SETUP AND WIRING
General Instructions
1. Install proper size Plug-In
Horsepower Resistor. (see table 2)
2. The RAMM can be connected
to a standard 120V or 240V
50/60 Hz AC line (be sure the
AC input voltage corresponds
to the control voltage rating and
the motor rating). (e.g. 90-130 VDC
motor on 120VAC and 180 VDC
motor on 240 VAC)
FIGURE 1: BASIC RAMM CONNECTION DIAGRAM
CAUTION: DO NOT BUNDLE
POTENTIOMETER CONNECTIONS
(P1, P2, P3) AND INHIBIT
CONNECTIONS (I1, I2) WITH
AC LINE OR MOTOR WIRES.
B. VOLTAGE FOLLOWING
All models can be controlled with an
isolated analog reference voltage
(0-6VDC) in lieu of the main speed
potentiometer. The voltage is con
nected to P2 (+) and F-. The control
output voltage will linearly follow the
-
input voltage. The source impedance
of the input should be 10K ohms or
less. The Min trimpot can be used to
provide an offset speed. If an offset is
not required, adjust the Min to 0+ or
0– speed as desired. The Max trimpot
is rendered inoperative in the voltage
following mode. Use auxiliary trimpot
to limit the control range. If the input
signal is not isolated, or is a current
signal (4-20 MA), the RASI240D Signal
Isolator must be used. It will allow
direct connection to process control
lers and microprocessors.
-
9
introduction (continued)
RAMM Full Wave Solid State DC Motor Speed Control
CAUTION:
1. The voltage feeding P2 and
F– must be isolated from the AC
line. Do not ground P2 or F– to set
up a zero ground reference.
2. Do not bundle signal wires to P2
and F– with AC line motor
connections. If signal wires are
over 18”, use shielded cables.
C. FUSING
The RAMM has provision for a built
in AC line fuse and armature fuse.
The AC line fuse protects the control
against catastrophic failure– if the
fuse blows, the control is miswired,
the motor is shorted or grounded, or
the RAMM control is defective. The
armature fuse provides overload
protection for the motor and control.
Choose the proper size armature fuse
by multiplying the maximum DC motor
amps by 1.7. On domestic 240 Volt
AC lines, separate branch circuit
protection for each line must be
used. All fuses should be normal blow
ceramic 3AG or ABC or equivalent.
1. AC Line Fuse is chosen according
to the maximum rating of the
control:
– 12 AMP fuse for all motors up
to 3/4 HP-90V and 1-1/2 HP 180VDC.
– 25 AMP fuse for all motors 1
and 1-1/2 HP-90V and 2 and
3 HP-180VDC.
(Use Buss ABC, Littlefuse
326 ceramic fuse or equivalent.)
TABLE 4: ARMATURE FUSE CHART
Horsepower
90 VDC
Motor
1/4
1/2
3/4
1
1-1/2
* Also used as AC line fuse.
Horsepower
180 VDC
Motor
1/2
1
1-1/2
2
3
2. Armature Fuse can be chosen
in accordance with the fuse chart.
Note: The armature fuse is
calculated based on the
approximate full load DC current
rating of the motor times a form
factor of 1.5. If motor has
characteristics not consistent
with these approximations, a
different fuse value may have to
be used. Fuses are available from
your distributor.
Approx.
DC Motor Current
(Amps)
2.5
5.0
7.5
10.0
15
Fuse
Rating
(AC Amps)
4
8
12*
15
25*
10
adjustments and control functions
RAMM Adjustments And Control Functions
WARNING: IF ADJUSTMENTS ARE
MADE UNDER POWER, INSULATED
ADJUSTMENT TOOLS MUST BE
USED AND EYE PROTECTION MUST
BE WORN.
The RAMM has been factory adjusted
to provide 0-full speed using the
speed control knob. Minimum and
Maximum speed trimpots are provid
ed to change the speed from other
than 0- full speed. The Acceleration
(ACCEL) trimpot is provided to allow
for a smooth start over an adjustable
time period each time the AC power is
applied or the speed pot is rotated.
The DECEL trimpot controls the amount
of ramp-down when the speed pot
is adjusted to a lower speed. The
Current Limit (CL, or torque output)
adjustment is factory set to approxi
mately 1-1/2 times the motor rating.
The IR Compensation (IR) is factory
adjusted to provide excellent motor
regulation under normal operation.
NOTE: In order for the IR comp and
CL trimpot settings to be correct, the
proper Plug-in Horsepower Resistor
must be installed for the particular
motor and input voltage being used.
Do not attempt to change the settings
of the trimpots unless absolutely nec
essary since they are factory adjusted
to near optimum settings.
-
-
-
A. Acceleration Start. The ACCEL
is factory set at approximately
.2 seconds. To readjust to
different times, set the knob to the
desired position as indicated in Fig 2.
B. Deceleration. The DECEL is
factory set to provide a ramp
down time of .2 seconds. To
change the ramp-down time,
adjust the DECEL trimpot as
indicated in Fig 2.
C. Minimum Speed Adjustment. If a
higher than zero minimum speed
is desired, readjust the minimum
speed by turning the speed control
knob to zero setting (full CCW
position). Then adjust the Min.
Speed trimpot to the desired setting.
NOTE: The min. speed adjustment
will affect the max. speed setting.
Therefore, it is necessary to readjust
the max. speed after the min. speed is
adjusted.
D. Maximum Speed Adjustment. Turn
Speed Control Knob to full speed
(maximum CW position). Adjust max.
speed trimpot to new desired setting.
NOTE: Do not attempt to adjust the
max. speed above the rated motor
RPM since unstable motor operation
may occur. For moderate changes in
the max. speed, there will be a slight
effect on the min. speed setting.
trimpot to full CCW position.
2. Connect a DC ammeter in series
with the armature lead.
3. Lock shaft of motor (be sure CL
pot is in full CCW position).
Apply power and rotate CL pot CW
slowly until DC ammeter reads 1.5
times motor rating (do not exceed 2
times motor rating, Max. CW position.)
NOTE: If only an AC ammeter is avail
able, it can be installed in series with
the AC line. Follow above instructions;
however, set AC amperage at .75
times motor rating.
F. IR Compensation Adjustment. IR
compensation is provided to sub stantially improve load regulation.
If the load presented to the motor
does not vary substantially, the
IR adjustment may be set at a
minimum level (approximately 1/4
of full setting). The control is
factory adjusted to approximately
3% regulation. If superior perfor mance is desired (less than 1%
speed change of base speed
from 0 to full load), then the IR
comp. Should be adjusted as follows:
NOTES: 1. Excessive IR comp. will
cause control to become unstable,
which causes motor cogging.
2. For tach feedback applications the
IR comp can be set to minimum rota
tion (full CCW).
-
-
The following procedure, presented in
order of adjustment sequence, should
be used when readjusting all trimpot
functions.
FIGURE 2: ACCEL/DECEL
TRIMPOT ADJUSTMENT
E. Current Limit (CL Torque Adjust ment). CL circuitry is provided to
protect the motor and control
against overloads. The CL also limits
the in rush current to safe level
during startup. The CL is factory
set to approximately 1.5 times the
full load range of the motor. (CL
trimpot is nominally set to ap-
proximately 65% of full CW rotation).
To set the CL to factory specifications
adjust as follows:
1. Set speed control knob at approxi mately 30-50% CW rotation. Set CL
11
1. Set IR comp. trimpot at approxi mately 25% of CW rotation. Run
motor unloaded at approximately
1/3 speed and record RPM.
2. Run motor with maximum load and
adjust IR comp. trimpot so that
the motor speed under load equals
the unloaded speed per step 1.
3. Remove load and recheck
unloaded RPM. If unloaded RPM
has shifted, repeat procedure for
more exact regulation.
The RAMM is now compensated to
provide minimal speed change under
large variations of applied load.
warranty
Limited Warranty – RAMM 125, 225, 225D
For a period of one (1) year from date of original purchase Rapid-Air Corporation will repair or replace without charge
devices which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not
been tampered with by unauthorized persons, misused, abused or improperly installed and has been used in accordance
with the instructions and/or ratings supplied. The foregoing is in lieu of any other warranty or guarantee expressed or
implied, and we are not responsible for any expense (including installation and removal), inconvenience, or consequential
damage, including injury to any person, caused by items of our manufacture and/or sale. Some states do not allow certain
exclusions or limitations found in this warranty so that they may not apply to you. In any event, Rapid-Air Corporation’s total
liability, under all circumstances, shall not exceed the full purchase price of this unit.
12
Pushbutton Control Reel 1000 Series Dual Swivel – 1/2-1 HP
13
Pushbutton Control Reel 1000 Series Dual Swivel – 1-1/2 HP
14
Pushbutton Control Reel 1000 Series Dual Swivel – 2 HP
15
Pushbutton Control Reel 1000 Series Dual Swivel – 3 HP
16
Loading...