Rapid-Air PMD35, PMD50. 115VAC User Manual

PALLET MASTER (PMD)

OPERATING INSTRUCTIONS

MODELS

(INCLUDES PMD35 & PMD50. 115VAC, 1PH, 60HZ)

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

Rapid Air Corporation

OPERATING INSTRUCTIONS

PMD 35 &50

INSTALLATION

The machine that you have just received was disassembled for shipping
purposes. Please check all parts for shipping damage. If damage has occurred,
contact the carrier first and then Rapid Air to report the damage.

Upon opening the shipping crate, you will find the main base table control arm,
drum, and a counter weight. Release all the components from the hold down
position and put them in the location that the pallet reel will be assembled.

Locate the electrical wires to determine where the control arm will be mounted.
Attach the control arm to the table base with the (4) 1/2-13x3/4 hex head screws
provided.

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Remove the access cover of the control arm and route the electrical wires from
the base into the electrical control area. Attach the wires to the terminals
provided.

See fig. below.

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CONTROL ARM SETUP & INSTALLATION

Determine the direction of rotation in which the material shall decoil as it leaves
the pallet reel. Position the pallet reel in line with the entrance side of the press.

Install the control arm assembly in the control head hub such that the counter
weight is pointing toward the turntable. Position the control head and arm and
check that it is locked before proceeding

The following sketches will show some basic arrangements of the pallet reel. The
choice depends upon such factors as loading ease, clockwise or counter clockwise
wound coils, and floor space available.

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Locate the proportional control arm and the knurled adjustable knob on the back
of the push button unit. Loosen the nut and slide the square drum rod into the slot
provided behind the knurled knob, making sure that the drum rod is between the
two stops provided. Attach the drum to the drum rod and the counter weight onto
the rod provided.

See Drawing (Fig. RA-4)

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DANCER ARM LOOP HEIGHT ADJUSTMENT

Eight different loop sensing arm operating positions are selected manually during
set-up. By incrementing the thumbwheel height switch, the zero point of the
dancer arm is raised from its rest position to the angle shown (as indicated 0-7).
The dancer arm will move from rest position to the angle selected before the
pallet reel begins to rotate.

DANCER ARM LOOP RANGE FUNCTION

30 degree— Loop sensing arm travels through a full 30 degree arc to vary

turntable rotation speed from slow to full speed as controlled by % speed pot.

20 degree— Loop sensing arm travels through a 20 degree arc to vary turntable
speed from slow to full speed as controlled by % speed pot.

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10 degree— Loop sensing arm travels through a 10 degree arc to vary turntable
rotation speed from slow to full speed as controlled by % speed pot.

5 degree— Only the first 5 degrees of loop sensing arm travel is required to
control turntable rotation from slow through full speed as controlled by % speed
pot.

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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

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The main control console & controls are mounted on the end of the raised
extended arm of the machine. It was installed to keep the operator clear of the
coil plate. Located on the face of the console are seven switches and one
potentiometer, which are explained below.

1. DIRECTIONAL CONTROL - The direction control switch selects the
direction the pallet reel will rotate, clockwise or counterclockwise.

2. % SPEED POT - The % speed pot adjusts the maximum speed that the pallet
reel will rotate and should be set to maintain a constant feed rate.

3. ON/OFF SWITCH - This illuminated switch is the main power switch for the
controller. It must be “ON” for the pallet reel to function.

4. L↔R SWITCH - (Stock Arm Direction Switch) - Stock feeds to the press
over the table. The Left-Right switch determines from which side of the table the
drum is operated. (See Control Arm Setup & Installation).

5. RUN/STOP/JOG SELECTOR SWITCH - The switch selects between Run
& 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.

6. JOG BUTTON - Used for intermittent movement of the coil plate, mainly for

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set up. Speed is adjusted on the 69100053 terminal board on the electrical control
sub-panel.

7.

DANCER ARM LOOP HEIGHT & RANGE ADJUSTMENT -

a. Loop Range - The loop range thumbwheel adjusts the amount of travel the
dancer arm will move to provide the full range of speed of the pallet reel.

b. Loop Height - This thumbwheel 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 angle of the arm so that top-to-bottom travel is
adjusted to accommodate specific material and loop height requirements.

ELECTRICAL COMPONENT DESCRIPTION

69100034 board—proportional control board

69100035 board—rotational isolation board

69100053 board—terminal board

PC control board (Ramm) - D.C. motor board

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TAUT STOCK

The TAUT STOCK feature monitors the loop between the PMD and the external
equipment. If the loop gets small enough to possibly cause damage to the PMD,
the interface contacts change state and stops the PMD.

If it is desired to monitor the PMD, then the following write up will explain how
to connect and adjust this feature.

The TAUT STOCK feature is built into the Rapid-Air board #69100035 and
wired to external terminals 7-8-9. The terminal #9 is common and from terminal
8 to 9 is a normally closed contact with power on the unit. Terminal 7 to 9 is a
normally open contact with power on the unit. These contacts are from “relay 2”
chip. See diagram. This relay has to be in place for taut stock to work. There is
also a 4 prong post labeled “JUMP” that has to be connected so that relay 2 can
be activated. To correctly apply the jumper, locate the post and then locate the
plastic 2 prong jumper. Insert the jumper so that the left 2 vertical posts are
covered. Once this is in place, the taut stock feature can be tuned.

To tune the taut stock, check that there are no connections on the terminals 7-8 &
9, except those that were factory connected. Attach an OHM meter to terminal 9
& 7 with the meter set to OHMS.

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Start the reel and raise the dancer arm so that the reel is running maximum speed.
Raise the dancer arm up to a point that the stock would be taut. Hold the dancer
arm at this position and adjust the pot R9 of board 69100034 until the contact
changes state. Release the dancer arm. The contact should return to normal
state. Raise and lower the dancer arm 2 to 3 times to ensure that the contact
functions properly. Disconnect the OHM meter and connect the customer
interface. CAUTION! The contact rating of the relay is 10VA@ 0.5 amps max.

POWER

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