Rapid-Air SBX, SCX, SD User Manual

STRAIGHTENER

OPERATING INSTRUCTIONS

MODELS

SBX, SCX & SD SERIES

(4-02)

RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

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

INDEX

1. Straightener Layout Sheet SBX Pg. 3

2. Straightener Layout Sheet SCX Pg. 4

3. Platen Adjustment Bulletin Pg. 5

4. Specifications Pg. 6

5. Installation Pg. 7

6. Start-Up Procedure Pg. 8

7. Electrical Controls Layout Pg. 10

8. Dancer Arm Adjustment Explanation Pg. 12

9. Standard and Optional Components Pg. 13

10. Operations Pg. 14

11. Maintenance Pg. 15

12. Trouble Shooting Guide Pg. 16

13. Taut Stock Explanation Pg. 18

14. Electrical Schematics Pg. 28

15. Mechanical Parts List SBX Pg. 33

16. Mechanical Parts List SCX Pg. 35

17. Typical Stamping Layout Pg. 41

SBX SERIES POWERED STRAIGHTNER

INSTALLATION

The straightener that you just received is fully assembled and tested and ready to be put into po­sition. CAUTION: Due to shipment vibration, the straightener should be checked to be sure
that all screws and bolts are secure and all electrical components are in place inside the cabinet.
Visually inspect the complete machine for physical damage due to shipment and handling. If
the straightener was damaged in shipment, contact the carrier first and then Rapid Air.

Install the straightener on a level surface with sufficient clearance for loading the material and
adjusting the roller pressure for straightening. Align and center the straightener to the device
that it will be supplying the straightened stock. The straightener should then be bolted to the
floor especially when used to pull stock from a non-powered reel.
CAUTION: Before bolting the straightener down, check for the longest feed length to be run.
The straightener should be set so that there will be about two or three feed lengths in storage in
the loop without re-inducing coil set in the material.

The standard speed straightener is completely self contained and only needs to be plugged into
a 20 amp, 120 VAC, 60 HZ outlet. If an extension cord is used as a source to the straightener
power, it should be a minimum 12 gauge wire to keep the voltage losses down and also for elec­trical safety reasons.

Please check your local safety codes.

The medium and high speed straighteners require 230 VAC, 60 HZ, 1PH as the supply voltage.
Please refer to the schematics in the manual for required fuse sizes.

Please check your local safety codes.

Turn on the main power button and run a test cycle checking the jog (using the jog button) and
run (using the dancer arm to test that the speed varies if using the proportional control). Test all
electrical features before continuing.

START UP PROCEDURE

Prior to applying power to the straightener, all the controls on the machine should be reviewed.
A brief summary is listed on the next page.

MAIN CONSOLE AND CONTROLLER

The main control console with controls is mounted on the cabinet of the straightener. Located
on the face of the console are five switches, one potentiometer, one push-button and one or two
circuit breaker reset switches, which are explained below.

1. ON/OFF SWITCH

This illuminated switch is the main power switch for the controller. On the 120 VAC
straighteners, it will be a toggle switch and on the 230 VAC version it will be a mushroom
push-button. It must be “ON” for the straightener to function.

2. RESET BUTTONS (circuit breaker)

120 VAC.
A. 15 amp—This is the main circuit breaker for the straightener.

B. 3 amp—This is the main circuit breaker for the “D-SUB” (25 pin) connector.
Any shorting or overloads would trip this breaker.

240 VAC.
A. 3 amp—This is the main circuit breaker for the “D-SUB” connector. Any shorting

or overloads would trip this breaker.

3. RUN/STOP/JOG SELECTOR SWITCH

A. If “RUN” was selected and the dancer control arm was raised, the straightener rolls would

rotate.

If “STOP” was selected then none of the functions would work.

If “JOG” was selected then the jog button has to be depressed to have the straightener rolls ro­tate.

4. JOG BUTTON

Used for intermittent movement of the straightener rolls and mainly for setup. The jog speed
can be adjusted by rotating the R3 potentiometer on the 69100079 board in the control sub-
panel.

5. % SPEED POTENTIOMETER

The % speed potentiometer adjusts the maximum speed that the straightener rolls can rotate re­gardless of the dancer arm height. It should be set to maintain a constant material feed rate
through the straightener.

6. DANCER ARM LOOP HEIGHT AND RANGE ADJUSTMENT

A. Loop Range—The loop range switch adjusts the amount of travel that the dancer arm will

move to provide the full range of speed on the straightener. It has three positions with a “0” as
the least travel from slowest to fastest speed and a “2” has the most movement between slowest
to fastest speed.

B. Loop Height—The loop height switch is used for setting the start position of the control
arm. It has three positions with the “0” setting having the start position at the dancer arm rest
position and the “2” having the start position somewhat higher than the dancer arm rest posi­tion. This setting will determine the dancer arm angle that the reel will start turning. This func­tion is used to accommodate different thickness of material which would have a different bend
radius thus requiting the dancer arm to be at a height somewhat above the home position when
at rest.

7. LOOP ARM / EXTERNAL SWITCH

This switch is used to select whether the material loop is controlled by the dancer arm or an ex­ternal loop control. If LOOP ARM is selected then the control will monitor the dancer arm
movement. If EXTERNAL is selected then the control will monitor whatever is plugged into
the “D-SUB” (25 pin) connector.

8. REMOTE INTERFACE PORT “D” CONNECTOR

This 25 pin connector, located on the lower portion of the console is used to communicate with
external loop equipment. The RSB, RTB, & RTA will plug into the port and can immediately
be implemented.

CAUTION: NEVER PLUG ANY TYPE OF COMPUTER OR NON RAPID-AIR
EQUIPMENT INTO THIS PLUG OR SEVERE DAMAGE COULD RESULT. AL­WAYS CONSULT THE FACTORY WHEN INSTALLING DIFFERENT EXTERNAL
CONTROLS FOR ADVICE ON COMPATIBILITY AND WIRING INFORMATION.

9. PANEL MOUNTED ELECTRICAL COMPONENT DESCRIPTION

69100034 board—proportional control board
69100076 board—component interface board
69100014 board—(RAMM) D.C. motor control board [ 120 VAC, 1 PH ]
69100038 board—(RAMM) D.C. motor control board [ 240 VAC, 1 PH ]

DANCER ARM LOOP HEIGHT ADJUSTMENT

Three different loop sensing arm operating positions are selected manu­ally during set-up. By selecting the higher number, the zero point of
the dancer arm is raised from it’s rest position to the angle shown (as
indicated 0-2). 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 travel through a 20 degree arc to vary
turntable speed from slow to full speed as controlled by % speed pot.

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.

STANDARD STRAIGHTENER COMPONENTS

CURVE UP/DOWN ADJUSTMENT

Some applications have dies that cannot accept anything but flat stock and other dies run better
with the material curving up or down to miss the built in edge required in the die. Before this
feature was added, operators would under straighten or over straighten the material to suit their
needs but in doing so would severely change the material entering the die. This not only caused
feeding problems but part quality problems. With this feature, curve up or down can be accom­plished by changing the position of the rolls without stressing the material.

ENTRANCE GUIDE ROLL BLOCK

All straighteners are shipped with an entrance guide roll. This contains a roller and two adjust­able edge guides.

OPTIONAL STRAIGHTENER COMPONENTS

ENTRANCE CASCADE ROLL

The entrance cascade roll assembly is used to maintain a support arc for stock entering a feed.
The cascade roll has three extra rollers to help the material flow better.

EXIT CASCADE ROLL

The straightener is shipped with the exit side pre-drilled for the cascade roll or guide roll
block. The entrance and exit use the same components.

ANGLE BRACKET

Rapid Air offers this accessory that mounts between the straightener head and the base. It an­gles the exit side of the straightener twelve degrees lower than the entrance side. This feature
works very well when using the straightener to pull off a non powered reel.