Rapid-Air KBX User Manual

SERVO FEED

OPERATING INSTRUCTIONS

MODELS

KBX SERIES

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

RAPID-AIR START UP SECTION (100-200-300 S SERIES)

Congratulations on purchasing a Rapid-Air Servo. Not only did you receive a complete
servo unit but also telephone support by one of our engineering staff to guide you on
using the new servo to it’s maximum capability.

In order to maximize your learning time and trouble shoot any interface problems. We
would like to request that the following items be complete before calling us.

1. Servo unit should be completely installed and aligned to a die on the press.

2. 220 VAC electrical wiring should be in place and unit turned on.

3. All interface switches should be wired and tested.

4. Air if needed should be connected and ready to be used.

5. All servo interface questions should be directed to your distributor first then to
Rapid-Air. Please call 815-397-2578 and ask to have these questions directed to the
proper personnel.

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TABLE OF CONTENTS

CHARTS AND DRAWINGS DIRECTORY pg. 3

INTRODUCTION pg. 4

INSTALLATION AND MECHANICAL SETUP pg. 5

INSTALLATION OF MOUNTING BRACKET pg. 6

ELECTRICAL CABLES AND AIR LINE pg. 7

INTERFACING FEED WITH PRESS pg. 8

PRETEST WRITE UP pg. 9

LOADING MATERIAL pg. 10

SERVO INTERFACING EXPLANATION pg. 11-12

RESET JOB PARAMETERS pg. 13

PROGRAM NUMBER DISPLAY pg. 13

PROGRAMMING PR OCEDURE pg. 16

DRIVE ROLL PARALLELISM ADJ. pg. 23

TROUBLESHOOTING pg. 24-25

FAULT DISPLAY - FAULT CODE pg. 26-27

OPERATIONAL MAINTENANCE PROCEDURES pg. 28

PRECAUTIONS AND SAFETY pg. 30

WARRANTY pg. 31

STRAIGHTENING INSTRUCTIONS pg. 34

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CHARTS AND DRAWINGS

104KBX

108KBX

MOUNTING BRACKET

KBX STRAIGHTENER LAYOUT

ELECTRICAL PANEL LAYOUT

OPERATORS TERMINAL LAYOUT

PRESS-FEED AND PILOT SWITCH SETTINGS

ELECTRICAL & INTERFACE SCHEMATICS - 953

SERVO PARTS BREAKDOWN

WIRING DIAGRAM

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INTRODUCTION

The Rapid-Air servo feed carries with it the quality and reliability you have grown to
expect from a Rapid-Air product. The motion control system is a programmable
industrial computer and this advanced technology combined with a highly engineered
precision roll feed coupled with a straightener is an unchallanged combination in the
press industry.

The compact mechanical package, direct coupled with a brushless servo drive motor,
offers response and feed speed accuracy unparalleled in any other powered roll feed.
Operator interface is so simplified, a typical setup person can have the servo feed
programmed and running in a matter of minutes. A step by step prompt on the four
line 80 character display asks simple questions of the operator. Entry of feed length,
strokes per minute, % maximum speed and pilot are all that is required for a new
setup. Routine jobs can be stored, recalled, changed and saved or run with a simple 2
digit job number entry. Up to 99 jobs may be stored and recalled at will.

Operator programmed feed length, up to 999.999 inches and % max speed selection
along with a jog feature allowing the operator to thread the material and inch it into
position. The inch feature enables the operator to jog the servo feed forward at a slow
rate. The operator can select jog to length or jog continuous to aid in threading up
material.

The precision mechanical roll feed unit has been designed for compactness, ease of
setup and installation. A 230 volt, 3 phase supply and an air line are all that is required
of the customer. Two cables with twist lock plugs and one or two cables for the air
valve control are supplied with the control and need only be connected to the proper
locations. The electrical controls are housed in a small cabinet which should be
mounted close to the press working area. The operator keypad and display are
mounted on top of the control area

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INSTALLATION AND MECHANICAL SETUP OF SERVO FEED

The shipping container should contain:
1 Mechanical Servo Feed/Straightener -Standard
1 Console Complete -Standard
1 Cascade Assembly -Optional (100 Series) (Standard 200-300 Series)
1 Servo Mounting Bracket -Optional
1 Guide Support Assy. -Optional

If a mounting bracket was purchased then it should be installed at this time. There are
mounting bracket prints in the back of the manual for hole location dimensions and a
bracket mounting instruction section can be found later in this section.

If a mounting bracket was not purchased then the feed should be positioned with the
centerline of the drive roller in line with the centerline of the die entrance and at the
proper pass line height to the die. Aligning the feed to the die (Parallelism) is very
important to the accuracy of the feed. Drag due to misalignment can cause short feeds
and servo faults.

If the feed is positioned as such that the material has to move unsupported from the
exit side of the feed to the die and the material being moved is allowed to droop or
buckle during a move, a short feed can occur. A guide should then be built between
the feed and the die to solve this problem.
The following chart lists the servo size with the proper bolt size.

SERVO BOLT QUANTITY
Series KBX 3/8-16 4

The servo mounting bolts should not penetrate into the servo body by more
than .625".

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INSTALLATION AND MECHANICAL SETUP OF MOUNTING BRACKET

The cast mounting bracket is available for mounting the KBX feed directly to the bolster
plate of the press. Mounting holes are located on the top and front for securing the
bracket firmly. It is very important that the servo bracket and the KBX feed be secured
and not allowed to float or vibrate.

Note: It is very important that the end of the bolster plate where the servo feed is to be
mounted, be perpendicular to the top surface of the bolster plate within +-.005 to
assure the KBX feed will be aligned for proper feeding.

Align the KBX feed bracket with the center line of the bolster plate and transfer the
mounting holes on the top face. There are two 1/2” holes on the smaller bracket and 3
1/2” holes on the large bracket.

Once the bracket has been aligned and secured to the bolster plate, the KBX feed can
now be put in place. The slotted holes in the mounting bracket allow for accurate
alignment of the servo feed in the x-y axis. There is an elevating screw to position the
servo feed to the proper tooling pass line height.

When the KBX feed has been aligned and mounted to the bracket, loosen the elevator
locking screws and position the servo to match the tooling pass line height. This is
accomplished by turning the adjusting screw provided. When the servo is correctly
positioned, tighten the elevator locking screws to prevent the unit from moving. There
are 2 locking screws on the small bracket and 3 locking screws on the large bracket.

The unit is now assembled and the next step will be to attach the electrical and air to
the servo feed unit.

Material alignment is critical. The KBX feed rolls are so precise that they will move the
material in whatever direction that they are presented to the die. The feed and die must
be in line and square to one another. The servo feed does not have the power of a
press driven roll feed so the feed will fault out if misaligned. This is a good warning
and if corrected could result in better tool life.

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ELECTRICAL CABLES AND AIR LINE

230 VAC INPUT
The required input voltage to the control is 230 Vac, 3 Ph, 60 Hz. The amperage
needed is 10 amps for 953 control. If unsure of the amperage needed, the name plate
on the side of the Pacific Scientific drive will give the number of the control or 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 Rapid-Air then all that is
needed is to connect and wire the 460 volt line to the transformer. If you did not
purchase a transformer from Rapid-Air then a transformer, 3 KVA for the control is
needed. 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.

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. The solenoid cables if any can now be attached and checked for proper
location when the feed is up and running.

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INTERFACING SERVO FEED WITH A PRESS

The KBX unit is a slave to the press therefore it needs a command from the press to
operate in the automatic mode.

The command is in the form of a normally open contact from a limit switch, cam switch
or an electronic feed interface device that can be programmed.

The contact should be commanded or activated at 270 degrees of the press stroke or
when the tooling is clear of the material and released and turned off at around 350
degrees of the press stroke. The significance of the release position is to insure that
the feed switch is released with the press top stopped. Once the program senses a
closure of the feed input, it will command a move and will complete the move
regardless of the switch position.

The schematic in the back of this manual points out the switch or contact connections
for wiring the interface. Locate the feed signal input and wire per print. The feed input
number is (J52)TBI-1).

This completes the initial setup of the servo feed to the press or other device. The
KBX 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 ouputs available.

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PRETEST FOR KBX FEED AND PRESS WITHOUT MATERIAL

Now that your KBX feed unit has been mounted 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 on­off button to the on position. The button should illuminate to indicate that there is
power to the system.

The Pacific Scientific drive preforms an initial 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.

Select the “inch” function (F2 on keypad) on the manual mode screen. Visually check
that the rolls rotate forward when pressing the inch forward 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 are operational, you can experiment with the single
cycle moves. The procedure is outlined in the programming section of this manual.

Now, you can cycle the press and watch the rolls to verify that the signal from the
press window switch signal is functional and actuating at the proper time.

After all the checks have been made and you feel comfortable with the programming
of the servo controller, place the controller in automatic mode. Now cycle the press in
either the inch, single stroke or continous run, the servo feed should react upon the
closure of the press window and signal and simulate a feed progression of material.

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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.

Step number one is to select the manual mode of operation on the operators console.
Open the rolls manually by lifting the lever mounted on the side of the servo feed then
open the straightener cover. Position the leading edge of the material with the center
of the material near the center of the entry rolls. Adjust the edge guides on the
cascade rolls to the proper width. Hand feed the material into the KBX unit until it
protrudes out of the feed rolls and starts into the guide on the press. Close the
straightener rolls to capture the material, then close the feed rolls.

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 press in the single cycle mode with the servo feed in the
automatic 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
accuratelly set and the repeatability is satisfactory, you are ready for full automatic
mode.

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