Rapid-Air RLL User Manual

RAPID LIGHT LOOP

OPERATING INSTRUCTIONS

MODELS

RLL

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

OPERATING INSTRUCTIONS

RLL (RAPID LIGHT LOOP)

Part number 10900462 and 10900463

INSTALLATION:

The RLL unit, when received, should be checked for shipping damage. If damage has
occurred, contact the carrier that handled the shipment first and then Rapid-Air to report
the damage.
The RLL unit is shipped pretested, set to a working height of 30”, and set for payout
operation. It should be set in place on a level surface, although each stand is provided
with (4) base thru holes for 7/16 bolts if the unit is to be bolted to the floor.
Each RLL unit assembled is prewired with an Amp 14 pin circular or 25 pin D sub
connector that matches a connector output on every Rapid-Air device capable of
running from an external loop controller. Optional cord adapters are available for
interfacing each style. Contact Rapid-Air for details. The RLL gets its 115 VAC power
from the controlled device. Once the plug is attached, the RLL is ready to run.
Fig RLL-1 is a drawing of the RLL unit.

The RLL unit (10900462 and 10900463) consists of the following major components.

1. Infrared Transmitter part # 69100087 (4 required)

2. Infrared Receiver part # 69100089 (4 required)

3. Control Interface pwb. part #69100091

4. Jog Pushbutton part # 69100257
5a. Cable Assy: 28900226 for 10900462 14 pin Amp
5b. Cable Assy: 28900227 for 10900463 25 pin
Refer to Fig RLL-2

INFRARED TRANSMITTER ASSY:
Each transmitter assy. transmits a beam of light to the receiver assy. If the beam is
interrupted by material the receiver will send the appropriate control signal to the
interface control pwb. There are no adjustments or user replaceable components on
this assy.

INFRARED RECEIVER ASSY:
Each receiver assy. receives the light beam from the transmitter assy. and sends the
appropriate control signal to the interface pwb if material interrupts the light. There is
one factory adjustment on this assy. and should never need to be field adjusted. In the
event of complete receiver replacement, a field alignment of this assy. maybe required.
Please contact Rapid-Air for details prior to any adjustments

CONTROLLER INTERFACE PWB ASSY.

1

The interface board contains a Payout/Rewind switch and user adjustable Max. output
and Jog speed potentiometers. Refer to the adjustments section prior to changing
these setpoints. The RLL is factory set for (Payout) mode and will send a 6 VDC
output to the controlled unit when the material is at the top of the loop. All loop control
functions are fixed and never need adjustment. See the adjustment section prior to
selecting the Rewind mode. There is one user replaceable fuse.
Power down prior to any service to the fuse or while performing any maintenance.
Qualified electrical personnel should perform service to this equipment. 115 VAC is
present on this PWB.
CAUTION:::

JOG PUSHBUTTON:
The Jog Pushbutton is used to assist the operator in the initial thread up of material.
The jog speed is adjustable and can be tuned to match the needs of the specific
operation. For location of this potentiometer, refer to the adjustments section.

CABLE ASSEMBLY:
The cable assembly was designed to make the installation of the RLL to a Rapid-Air
Reel, Straightener, or Rapid Roll as easy as possible. The power and control
connection is accomplished through one of two types of connectors. Optional adapter
cables are available for the two conversions when required. Contact Rapid-Air for
details or assistance for this and also when interfacing non Rapid-Air equipment.

OPERATION:
PAYOUT MODE:

With the RLL in place and electrically connected to a Reel, Straightener, etc, that is
powered, the RLL is ready for loop control operation. The top light beam (ON), if
interrupted by material will give the full speed signal to the controlled device. The
(Ramp Up) light beam if interrupted by material will give an increase in speed from
previous. The Ramp Down light beam if interrupted by material will give a decrease in
speed from previous. The bottom light beam if interrupted by material will fully stop the
motor. The Ramp Up or Ramp Down and Hold functions are not affected by the full on
or full off functions. In this manner the loop window will be controlled between the
Ramp Up and Ramp Down light beams.
To start thread up, press the jog button. The controlled device will run at jog speed,
paying out material for the operator to work with. With the material held between the
light posts walk material to the controlled device and thread up. The controlled device
will stop when the bottom beam is interrupted by material. The RLL and the controlled
device are now ready to run material.
As the loop depth diminishes the RLL will automatically increase the motor speed
keeping the loop depth fairly constant at 9 to 15 inches above the floor.

OPERATION:
REWIND MODE

2

CAUTION:

Keep clear of rotating hardware during thread up. Turn power off of take up reel during
thread up or place take up reel in the JOG mode. Make certain material is taut and
above RLL upper beam prior to power up.

Set the Payout/Rewind switch to Rewind on the Control Pwb of the RLL. This will
automatically switch light beam operation to give full speed at the bottom of the loop
and the motor to be full off if the top light beam is interrupted by material. Caution:
Remember to keep material taut in this mode during tread up keeping the motor of the
controlled device off. As the loop depth now becomes lower the motor speed will
increase and eventually the loop will be controlled between 12 and 18 inches from the
floor.

Turn on power on take up reel or place in run mode. The RLL will start auto control as
the material falls below the top light beam.

ADJUSTMENTS

RECEIVER BOARD 69100089 ASSY.

Refer to Fig. RLL-2

There is one potentiometer on each of the receiver boards. This is factory adjusted for
a 5 micro second pulse width TP-3 to TP-4. This alignment will need to be made only
if a receiver is damaged, replaced or if a support post is bent. Static adjustment in the
field maybe accomplished with a DVM. Adjust pot for 7.90 to 7.97 VDC as measured
between TP-3 and TP-4 on the receiver pwb. Please contact Rapid-Air prior to making
this adjustment.

INTERFACE CONTROL PWB 69100091 ASSY.
Refer to Fig. RLL-2

There are 2 user adjustable setpoints and 1 mode select switch on this assy. There
are 2 factory set pots on this assy. R43 is a Preset Ramp Voltage. R25 is a Ramp
Null.
Do not adjust R43 or R25.

JOGSPEED POTENTIOMETER R39

Adjust this pot to increase or decrease jog speed. Jog speed is attenuated by the % of
speed potentiometer on the controlled device.

3

MAX. VOLTAGE OUTPUT. R33
This pot is set for normal 6 VDC operation. Adjust this pot to increase voltage to 10
VDC only if required by controlled device drive.

PAYOUT/REWIND MODE SELECT
Select either payout or rewind mode from this switch. Payout mode is selected by
setting the toggle switch towards the interior of the board.

TROUBLESHOOTING ELECTRONIC CIRCUITRY

69100089 RECEIVER BOARD

1. Place in payout mode. Block bottom light beam. Controlled device motor should
stop if on. Block top light beam with material. Motor should run approx. 95 % full
speed. Block second to bottom light beam. Motor will slow to approx half speed.
Continue to Ramp down motor speed by blocking second to bottom light beam. Ramp
up motor speed by blocking second to top light beam. If any of these functions do not
work check appropriate receiver alignment using 2 below as a guide.

2. Each receiver should respond to a blocked beam by sending a high (no pulses)
signal to the interface control pwb. Check TP-3 to TP-4 with a scope. Align pwb for 5
micro second pulse width TP-3 to TP-4 with no material blocking beam. Approx. 7.92
to 7.97 VDC with a DVM, if a scope is not available.

3. If each of the receivers are checked for proper alignment and a function still doesn't
work, the problem is most likely a defective control pwb 69100091.

4. There is one fuse on the main pwb, Fl. This is a PICO 1 amp Little fuse. Turn
power off before removal. 115 VAC is present in this circuit.

5. Contact Rapid-Air for assistance, if fuse is checked and problem still persists.

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