multi-stroke control
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
1
tAble of contents
INTRODUCTION .......................................................................................................................................... pg. 3
BOARD COMPONENTS AND TROUBLESHOOTING .............................................................................. pg. 4
AIR FEED PROGRESSION SET-UP ............................................................................................................ pg. 4
MAINTENANCE ........................................................................................................................................... pg. 5
LUBRICATION AND LUBRICATION OF “O” RINGS .............................................................................. pg. 5
TROUBLESHOOTING .................................................................................................................................. pg. 6-7
MULTI-STROKE CONTROL ELECTRICAL DIAGRAM .............................................................................. pg. 8
MULTI-STROKE CONTROL ILLUSTRATION ............................................................................................. pg. 9
WARRANTY ................................................................................................................................................. pg. 10
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introduction
Multi-Stroke Control Introduction
The Multi-Stroke Control, when
coupled with a Rapid-Air feed,
increases the feed length by up
to 9 times the original feed length
capability.
The control is completely self-contained and requires only 3 interface
points, which are provided on the
outside of the electrical enclosure.
1. A cable connection that should
be connected to the solenoid
of the air feed.
2. A normally closed reset signal
device, to reset the multi-stroke
cycle.
3. An isolated, normally open
contact which is provided for
customer interface of a work
device, such as a solenoid or relay
that can be activated upon
completion of a feed cycle.
Reset Signal Device:
The reset signal device should be
a limit switch mounted on external
equipment.
CAUTION – DO NOT STOP
ON THE RESET SWITCH
The diagram 85500131, illustrates
the proper interface connection
of the switch to the controller at
position (S2).
CAUTION – NO VOLTAGE
SHOULD BE APPLIED TO THIS
CONNECTION
Isolated Normally Open Contact:
At the completion of the feed cycle,
a solid state relay is energized. The
normally open contact provides a
path to allow an external device to
operate. The solid state relay will
remain until the reset switch is
tripped. The contact is rated at
0.5 AMPS/120 VAC.
The diagram 85500131, illustrates
the proper interface connection at
position (S1).
WARNING – THE CONTROLLER
WAS NOT DESIGNED TO
WORK WITH ANY DEVICES
OTHER THAN A FEED PRESS
COMBINATION. IF CONNECTED
TO OTHER THAN A FEED PRESS
COMBINATION, RAPID-AIR WILL
NOT BE RESPONSIBLE FOR
WARRANTY OR INJURY
SUSTAINED BY THIS ACT.
The front of the multi-stroke unit has
(9) components.
1. START/STOP POWER BUTTON:
Depressing the “START” button
activates the unit.
Depressing the “STOP” button
deactivates the unit.
2. STOP/RUN/START SELECTOR
SWITCH:
In the STOP mode there should be
a motion or reset signal recognized
by the circuitry. If the unit is
cycling and the switch is turned to
stop, the cycle in process will
finish before stopping.
In the RUN mode, the multi-stroke
can be started by turning the
selector to start and then
releasing it.
3. FEED STROKES PER CYCLE
SELECTOR SWITCH
The position of the selector switch
determines how many feed cycles
are completed before the solid
state relay is energized to allow
the work cycle to begin. The
minimum cycles is (1) and the
maximum is (9).
4. FEED/CUT DELAY
POTENTIOMETER
The feed rate potentiometer is a
single turn potentiometer. By
turning the knob clockwise, the
cycle time will be shortened
causing more strokes per minute.
By turning the knob counter clockwise, the cycle time will be
lengthened resulting in fewer
cycles per minute. If the rate is
set too high (trying to cycle the
feed at 200 strokes per minute
when the feed is only capable
of 160 strokes per minute) then
severe misfeeding will result.
Cycling the feed too slow will
simply reduce the parts per
minute produced. Once the
best setting is determined, note
the setting for future reference.
There is a formula to calculate the
maximum parts per minute (PPM) for
a given feed.
The formula is PPM=X/(2N-1).
X = The maximum recommended
cycles per minute of the feed.
N = The required number of feed
cycles per part.
Example:
If it is desired to cut a 24” long part,
having the feed adjusted to an 8”
progression, the counter would be set
for 3 progressions and the maximum
recommended number of cycles per
minute is 100. The maximum number
of parts per minute would be
100/(2x3-1) or 20m parts per minute.
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b0Ard comPonents And troubleshootinG
There are two switches on the
board for changing the operation
of the cut-to-length.
1. The first switch is a bat or toggle
switch. It is located just above
the transformer on the board.
When the switch position is to the
left of the board, then the air feed
will run at a normal speed.
When the switch position is to
the right of the board or facing
the board connector, then the
speed of the cycle with the feed
rate potentiometer set at “low”
would be equal to the normal
setting with the feed rate
potentiometer set at “high”.
A. Set bat switch left and turn
feed rate potentiometer to
high. Record cycles per
minute.
B. Set bat switch right and
turn feed rate
potentiometer to low. Cycles
per minute should be
about the same as in “A”.
Turn feed rate to high and
record cycles per minute.
2. The second switch is a slide
switch. It is located in the upper
middle of the board. When the
switch is set to the lower
position, the control can be
started by turning the selector
switch from stop to start and then
releasing it, or by an input from
the feed switch to start the cycle.
If the slide switch is set to the
upper position, the control can
only be started by a machine
movement and that is not possible
on an economy cut-to-length unit.
There are 5 lights on the board for
trouble shooting purposes.
1. Light (L1) is the cycling light,
whenever it is on, the air feed
solenoid should be energized.
2. Light (L2) is the selector switch
in run mode light. Whenever the
selector switch is in the run
position this light will be on.
3. Light (L3) is the selector switch
in start mode light. Whenever
the selector switch is in the
start position this light will
be off.
4. Light (L4) is the reset signal
device input. If the unit is in run
mode and the reset signal is
activated, the light will be out
for as long as the reset signal
is present.
5. Light (L5) is the preset count
complete. Whenever the preset
count, set with strokes per cycle
selector switch has been
reached, the light will be on and
stay on until the reset signal has
been activated.
There are 2 fuses on the board
1. Fuse (F1) is the fuse for the air
feed solenoid and is a 5 amp
Pico fuse.
2. Fuse (F2) is the main board fuse
and is a 5 amp Pico fuse.
Air feed ProGression set-uP
The feed guide rollers are adjustable
by loosening the machine screws and
moving the rollers to the desired position. For best results the stock should
be centrally located in the feed.
The notches in the guide rails provide
for coarse feed adjustment of the stop
block. The final feed adjustment for
stroke length is made by the screw in
the center of the stop block. The final
feed adjustment is aided by the use
of accurately dimensioned spacers
or gage blocks placed between
the adjusting screw and the main
cushion bolt. The air pressure should
be turned on to keep the slide block
tight against the main body.
With the air pressure turned off, the
material is then inserted between the
guide rollers and passed under the
feed clamp. Lift the stock clamp and
push the material through to the starting position. Turn on the air (75-120
PSI) and the feed is ready to operate.
The last adjustment, if necessary,
would be the speed adjusting
valve. The valve adjustment is
located on top of the main body
4
on the opposite side of the actuating
valve. Adjust the screw for
minimum impact by turning
clockwise. For faster speed
turn counterclockwise.
When the impact is high, slippage
is possible resulting in poor
repeatability as well as part fatigue.
Refer to the diagram below.
mAintenAnce
The air feed needs very little
maintenance. The most important
part to watch is the air. Too much
oil or water in the air can cause
the air feed to start running erratic.
Screws should be checked
lubricAtion
As a general guide for the air feed,
the lubricator oil release adjustment
should be set to one drop of oil for
each 50-80 strokes. (See insert on
lubrication of “O” rings.)
LUBRICATION OF “O” RINGS
The “O” rings furnished with
Rapid-Air feeds are made of a
Buna N Compound designed to
give long life on service with air,
oil and water. This rubber compound
features high abrasion resistance
and good dimensional stability if
the recommendations listed below
are followed.
A filter and lubricator should be used;
the filter to remove grit that would
otherwise act as an abrasive, and
the lubricator to provide an adequate
quantity of oil. For best results, avoid
excess oil.
Paraffin base oils in general will give
the best service. The viscosity should
be 140-170 S.S.U., the API gravity
29.5 minimum, and the aniline point
between 150F and 210F. Variation of
the aniline point from the limits given
is likely to cause either shrinkage or
stretching of the “O” rings.
periodically to be sure they are tight.
This includes the switch mounting
brackets, if present, as they can
loosen up over time due to the
vibration and high impact movement
of the air feed. A visual check of the
Detergent motor oils and all other
oils designed for automotive use
are generally unreliable in chemical
makeup for use with rubber
compounds. Spindle oils are too
low in viscosity.
The group of oils listed below are
generally recommended for Buna
N compound 366Y “O” rings. This
grouping is given in good faith, but
because of the constant changes made
in oils by the manufacturers, we cannot
guarantee any consistency of chemical makeup. All of these oils have an
aniline point of 210, and API gravity of
29.5 minimum, and a viscosity of 140170 S.S.U. The base stock is paraffin.
Recommended:
Cities Service Oil Co.
– Pacemaker #1
(Standard hydraulic oil)
Standard Oil of Indiana
– #5 Hydraulic Oil
Sun Oil Co.
– Sunvix #916
Texaco
– Regal A, R & O
Shell Oil Co.
– Tellus #27
– Turbo #27
air feed every morning before
running it will help assure many
hours of running time. If small
problems are left unchecked,
they can turn into large problems
and down time.
Sinclair Oil Co.
– Rubilene Extra Light
Atlanta Refining Co.
– Hytherm Oil #C
New Jersey Lubricant Co.
– A-88/HNR
Standard Oil of Ohio
– Sohivis #43
Mobil DTE
– 10W Hydraulic
RECOMMENDED LUBE FOR
ASSEMBLY OF RAPID-AIR
FEEDS: MIXTURE OF LUBRIPLATE
AND MOLYKOTE
No. 105 Lubriplate
– Fiske Bros. Refining Co.
Newark, NJ - Toledo, OH
Molykote
– Powder (Molybdenum disulfide
Dow Corning Corp.
Midland, Michigan
To a 2 lb coffee can filled with
lubriplate, add 2 tablespoons of
molykote and mix thoroughly.
Loctite sealant is used on threaded
parts, type AV.
5
troubleshootinG
Problem Possible Cause Remedy
Feed and stock clamps work, but
slide block does not move when
actuating valve is depressed.
Excessive leakage of air from
exhaust hole beneath speed
adjusting screw when actuating
valve is in up position.
Excessive leakage of air from
exhaust hole, also sluggish
operation of feed clamp pistons,
actuating valve up.
Excessive leakage of air from
exhaust hole when actuating valve
is in down position. (NOTE: that a
slight amount of leakage is normal
in this position.)
Stock clamp does not move up
and down when actuating valve
is depressed. Other operations
appear normal.
– Pilot operated valve is stuck.
– Poppet not seating on bottom
of valve hole.
– Leaking of “O” rings #85, 83, 84,
88, 90 and 100.
– Leaking of “O” rings #85 and 90.
– Tight “O” rings or grit around pilot
operated valve may prevent it from
moving its full stroke.
– Worn poppet.
– Poppet in backwards.
– Worn “O” rings #96 around O.D.
of stock clamp pistons.
– Check for grit, swollen nylon or
swollen “O” rings.
– Check for grit or chips.
– Check “O” rings #85, 83, 84, 88,
90 and 100. See assembly drawing
for 106 location.
– Check “O” rings #85 and 90. See
assembly drawing for 106 location.
– Clean grit, cycle feed manually
to break in “O” rings.
– Insert new poppet.
– See feeds parts list #106 for location.
– Replace “O” rings. See assembly
drawing #106.
Excessive leakage of air from
actuating valve vent hole when
actuating valve is in up position.
Gradually reduced speed.
Excessive leakage of air from
pilot operated valve vent hole
on side of feed.
Cushion pistons act too slow and
provide too much cushion.
Mist of oil coming from exhaust hole.
– “O” rings #103 beneath actuating
valve retainer #31C is leaking.
– Lack of oil.
– Low viscosity oil.
– Speed adjusting screw turned
in too far.
– Oversized poppet.
– Leaking of “O” rings #100, 101 or 102.
– Excessive oil, reduce supply.
– Excessive oil, reduce supply.
– Install “O” rings beneath retainer -
not in air groove. See assembly
drawing #106.
– Adjust air/oil mixture.
– Use lighter weight oil.
– Readjust screw.
– Clean poppet area; check for
free fit.
– Check “O” rings #100, 101 and 102.
See assembly drawing for #106
location.
– Adjust air/oil mixture.
– Adjust air/oil mixture.
6
troubleshootinG (continued)
Problem Probable Causes Remedy
Feed has difficulty pushing last
part of progression.
Over feeding.
Under feeding.
– Feed is not inline with die.
– Stock excessively dirty or oily.
– Feed is operating too fast.
– Stock and feed clamps may be loose.
– Insufficient air pressure.
– Stock has large slitting burr.
– Stock clamp and feed clamps
are loose.
– Feed is not lubricated.
– Stock excessively dirty.
– Feed may be feeding before
punches are clear from stock or die.
– Feed may be operating too slow.
– A slight angular adjustment of the
feed will reduce the binding of the
stock on the die guides.
– Clean unit and stock. Run and retest.
– Turn speed adjusting screw clockwise
to slow down.
– Although nuts are self locking, they
can in time work themselves loose;
retighten the nuts.
– Adjust air pressure between 80
and 100 PSI.
– Check clearance between clamps
and stock.
– Although nuts are self locking they
can in time work themselves loose;
retighten them.
– Check lubricator in air inlet, there
should be oil in the bowl.
– Clean away dirt which may be
present between slide block and
main body area.
– Adjust the amount of depression of
the actuating valve.
– Turn speed adjusting screw counter clockwise to increase speed.
Slide block will move out okay, but
will not return without hesitation.
Feed acts sluggish on start up.
Okay after running for a while.
– Check speed adjusting screw.
– Check pilot operated valve.
Swollen “O” ring could be binding,
until pressure build up breaks it free.
Check poppet valve.
– Check pilot operated valve for
“O” rings binding. Valve should
move freely in cartridge
7
– Adjust for smooth operation.
– Check moisture content in air lines.
Change “O” rings.
– This usually occurs after a period
of non-running. After running unit for
a while the unit usually frees up okay.
FEED ACTUATION. MISFEEDING WILL RESULT.
CAUTION: TOO FAST OF A SETTING WILL CAUSE IMPROPER
ISOLATED NORMALLY OPEN CONTACT PROVIDED
TO CUSTOMER. THE CONTACT WILL CLOSE WHEN
THE PRESET COUNT OF THE MULTI-STROKE UNIT
HAS BEEN REACHED (MAX 120 VAC).
NORMALLY CLOSED LIMIT SWITCH (SUPPLIED
BY CUSTOMER) TO BE MOMENTARILY OPENED
AFTER WORK CYCLE OF THE EXTERNAL
EQUIPMENT TO PROVIDE A RESET SIGNAL.
NOTE-1: IF THE RESET SWITCH IS ALLOWED TO
BE HELD OPEN THEN AN UNCONTROLLED START
CYCLE COULD BE INITIATED.
NOTE-2: THE MULTI-STROKE UNIT CYCLE IS
CONTROLLED BY THE PRESS CYCLE. TURNING
OFF THE MULTI-STROKE UNIT BEFORE THE
PRESS CYCLE IS COMPLETE COULD ALLOW THE
PRESS TO CONTINUE CYCLING.
SEQUENCE OF OPERATION
1. SUPPLY 120 VAC TO MULTI-STROKE UNIT THROUGH POWER CORD PROVIDED.
2. PUSH GREEN “ON” PORTION OF POWER PUSHBUTTON.
3. TURN “STOP-START” SELECTOR SWITCH TO THE “START” POSITION, AND RELEASE IT. IT WILL SPRING
RETURN TO THE RUN POSITION.
4. THE FEED WILL BEGIN TO CYCLE FOR THE NUMBER OF STROKES SET ON THE “FEED STROKES PER
CYCLE” ROTARY SWITCH.
5. THE FEED WILL CYCLE AT THE RATE DETERMINED BY THE SETTING ON THE “FEED RATE” POT. (THE
FEED RATE CAN BE DOUBLED THROUGH A TOGGLE SWITCH LOCATED ON THE PRINTED
CIRCUIT BOARD.)
6. AFTER THE FEED HAS OPERATED FOR THE PRESET NUMBER OF STROKES THE FEED WILL STOP
AND THE MULTISTROKE WILL ACTUATE THE SOLID STATE RELAY, PROVIDING THE CUSTOMER WITH AN
ISOLATED CONTACT OUTPUT FOR USE IN HIS EXTERNAL CONTROLS.
7. AFTER THE WORK CYCLE OF THE EXTERNAL EQUIPMENT, A NORMALLY CLOSED LIMIT SWITCH (OR
CONTACT) MUST BE OPENED MOMENTARILY TO PROVIDE A RESET SIGNAL TO THE
MULTISTROKE CONTROL.
8. TURNING THE “START - STOP - RUN” SELECTOR SWITCH TO THE STOP POSITION WILL ALLOW THE
PRESENT FEED STROKE CYCLES TO COMPLETE THE PRESET NUMBER OF STROKES HOWEVER, A
SEQUENCE CAN BE INITIATED BY EITHER THE CONSOLE PUSHBUTTON OR THE EXTERNAL RESET SIGNAL.
RESET SIGNAL WILL NOT ACTUATE ANOTHER MULTISTROKE PROGRESSION CYCLE.
9. SLIDING THE INITIATE SWITCH TO THE “A” POSITION ALLOWS THE MULTI-STROKE CONTROL TO BE
ACTUATED BY THE EXTERNAL RESET SIGNAL ONLY. IF THE SLIDE SWITCH IS IN THE “B” POSITION THE
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9
wArrAnty
Warranty Terms & Conditions
ALL SALES BY THE COMPANY ARE MADE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS. PLEASE READ.
WARRANTY
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.
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.
- The Company warrants, for a period of one year from date of shipment by the Company, that the product
The Company obligation under this warranty is limited to
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