servo feed / rapid master
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
INSTALLATION, SET-UP, AND CABLING ................................................................................................. pg. 4
PRETEST ....................................................................................................................................................... pg. 5
INTERFACING .............................................................................................................................................. pg. 6
JOB PARAMETERS ..................................................................................................................................... pg. 7
LOADING MATERIAL .................................................................................................................................. pg. 8
PROGRAM PROCEDURES .......................................................................................................................... pg. 9-11
PARALLELISM ............................................................................................................................................. pg. 12
TROUBLESHOOTING .................................................................................................................................. pg. 13-14
MOTOR SERVICE AND FAULT DISPLAY .................................................................................................. pg. 15
TROUBLESHOOTING .................................................................................................................................. pg. 16
REASSEMBLY AND LUBRICATION .......................................................................................................... pg. 17
PRECAUTIONS AND SAFETY .................................................................................................................... pg. 18
WARRANTY ................................................................................................................................................. pg. 19
106 SERVO CTL ............................................................................................................................................ pg. 20
MECHANICAL SET-UP OF DIE OR PUNCH .............................................................................................. pg. 21
ELECTRICAL SCHEMATIC .......................................................................................................................... pg. 22
KEYPAD DISPLAY ....................................................................................................................................... pg. 23
100 SERIES RAPID MASTER SC953 SERVO WIRING DIAGRAM ......................................................... pg. 24
RAPID MASTER INTER-CONNECT WIRING DIAGRAM ....................................................................... pg. 25
JOB TICKETS ............................................................................................................................................... pg. 26
2
introduction
The Rapid Master
The Rapid Master that you have just received is fully assembled and ready to
be put into production. Due to shipment
vibration and handling, the machine
should be checked to ensure all screws
and bolts are tight. Remove the cover
to the electrical controls and visually
inspect that all parts are in place and
secure. If the machine was damaged
in shipment, contact the carrier first to
report the damage and then Rapid-Air.
CAUTION:
THE RAPID MASTER MACHINE IS TOP
HEAVY WHEN NOT SITTING ON ITS
BASE LEGS. USE EXTREME CAUTION
WHEN MOVING THIS MACHINE!
Install machine on a level surface
with sufficient clearance for loading
and unloading process material. The
machine should be secured to the floor
through the four holes provided in the
feet of the machine using 7/16 tie-down
bolts. Or, can be installed using 1/2-13
leveling bolts and machine pads. The
pads keep the machine from walking
during operation and also act as a noise
reduction device.
The machine has two other requirements that need attention before putting the Rapid Master into production.
1) The customer must provide
minimum CFM Air, at 75 to 120 PSI
of clean, dry, lightly lubed air to the
machine. Connect a minimum of
5/8” ID hose into the filter regulator
provided on the machine. The inlet
to the FRL is a NPT female thread.
2) The customer must provide
120 volt, 20 amp, 60 cycle
electrical power. If an extension
cord is used between the source
and the machine, it should be a
minimum 12 gauge wire to keep the
voltage loss down and for electrical
safety reasons.
In order to maximize your learning
time and troubleshoot 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, if required,
should be in place and unit
turned on.
3. Air should be connected
and ready to be used.
4. All servo interface questions
should be directed to Rapid-Air prior
to a start-up visit. Please call
815-397-2578 and ask to have
these questions directed to the
proper personnel.
The Servo Feed / Rapid Master Feed System
The Rapid-Air Servo / Rapid Master
Feed system 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, is
an unchallenged 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
appears on a four line 88-character
display, which asks simple questions of
the operator. Entry of feed length, cutter
dwell time, and % maximum speed 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.
A resolver, direct coupled to the servo
drive motor for precise digital position
feedback, enable roll positioning
accuracy to +/- .0025 for any
programmed feed length or speed.
Operator programmed feed length, up
to 999.999 inches and % max speed
selection along with full jog features
on a pendant unit, allow the operator
to thread the material and inch it into
position. The inch feature enables the
operator to jog the servo feed forward
or reverse at a slow rate. The operator
can select jog to length or jog continuous to aid in threading up material.
The Rapid-Air Servo Roll Feed has been
designed to mount on a free-standing
table as close as possible to the press
The precision mechanical roll feed unit
has been designed for compactness,
ease of setup and installation. Three
cables with twist lock connectors, two
cables for the servo, one connected to
the cutter, and one air line are the only
external connections required. 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 cabinet.
3
installation, set-up, and cabling
Installation And Mechanical Set-Up Of Servo And Press
If you purchased the Servo/Rapid
Master combination already mounted
on a base then the servo and press
were aligned at the factory. A good
practice is to check all hold down
bolts to be sure that they did not come
loose during shipment.
If you purchased the servo and
press and are going to mount it on
a base at your facility, then a base
Electrical Cables And Air Line
120 VAC INPUT
The alternate input voltage to the
control is 120 Vac, 1 Ph, 60 Hz. The
max amperage needed is 7.5 amps
and the control has a circuit breaker
with a trip amperage of 10 amps.
230 VAC INPUT
The required input voltage to the
control is 230 Vac, 3 Ph, 60 Hz. The
amperage needed is 10-20 amps
depending on the motor size. 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.
should be selected that will hold the
weight of the servo and the press
and also the cycling shocks incurred
during production.
When mounting the two devices.
The pass line height of the press
and the servo roller center line
should be equal. Even more critical
is the parallelism between the
two devices. The press should be
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 100S
and 200S servos and 6KVA for the
300S servos, 460/230 Vac 3 Ph, 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. If the series 200 was purchased,
(1 or 2) push-on connectors for connection to the air valves for solenoid
actuation of the pilot release and or
mounted first then the servo center
line should be aligned to the press
center line with the servo rollers
parallel to the press blade.
The servo should be mounted as
close to the press as possible and depending on thickness of the material
a bridge should be installed between
the servo and press to minimize material droop or buckling during feed.
anti-backup valve are included. The
third connector is used to interface
the press to the controls.
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.
An air line must be connected from
the shop air to the air inlet of the servo feed. The air should be at least 80
PSI continuous and should be dry filtered
and lightly lubricated for the best operation of the servo feed. The air inlet on the
servo feed is a 3/8-18 NPT pipe tap. The
minimum air line size requirement
is 1/2” lD hose. - (2 CFM)
4
pretest
Pretest For Servo Feed And Press Without Material
Now that your servo/press combination is in place, and the cables have
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
on-off button to the on position. The
button should illuminate to indicate
that there is power to the system.
The Pacific Scientific drive performs
an initial sequence to check its
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, if 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.
Once you have programmed the
required parameters, select the
manual mode of operation. If the
option of air regulated upper feed roll
was purchased, check that the main
air is at least 80 psi and check that the
roll pressure gauge is functional by
adjusting the pressure up and down,
this is accomplished by turning the
pressure adjusting knob. If you did not
purchase the air regulated roll option
then check that you have enough tension on the material to avoid slipping
during feeding. Open and close the
feed and anti-backup rolls electrically
and/or manually. Visually inspect that
the rolls open and close as you press
the appropriate keys on the keypad or
when using the manual levers.
Select the “inch” function (F2 on
keypad) on the manual mode screen.
Visually check that the rolls rotate
both forward and reverse with the
corresponding 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 and air logic are operational,
you can experiment with the single
cycle moves. The procedure is
outlined in the programming section
of this manual.
After all the checks have been made
and you feel comfortable with the
programming of the servo controller,
place the servo in automatic mode.
Now cycle the press in either the
inch, single stroke or continuous run,
the servo feed should react upon
the closure of the press window
and signal and simulate a feed
progression of material.
5
interfacing
Servo Interfacing Explanation
A. TAUT STOCK INPUT (J52)TBI-3)
This is a normally open contact from
a switch or device that monitors the
loop of material prior to the servo
feed. When the material reaches a
point that it trips the switch, a taut
stock has been reached. This input,
when received, immediately drops
the automatic which stops the feed
in progress. The material should
be repositioned in the die before
restarting the automatic sequence,
as the progression was lost when
the taut stock occurred.
This input also could be used as a
“No Stock” switch that would monitor
whether or not there is material
available to feed.
B. ENABLE INPUT (J4-Pin 5 & 6)
The enable input is shipped from
the factory, jumpered, so that the
Pac-Sci unit is ready to work after the
initialization procedure is complete.
If it is desired that the servo controls
are not functional until other
equipment or safety source is activated then a normally open contact can
be interfaced to this input. If at any
time during the feed cycle the input
changes state then the feed will stop
at this position. If feeding stock, the
reference will be lost and the stock
will have to be manually repositioned
to the correct location. The automatic
cycle will be dropped and have to
be restarted.
C. ENABLE OUTPUT (J52)TB2-22)
This output must be tied to a solid
state relay to interface to the outside
world. The solid state relay must
have a D.C. coil and should have a
rating of 3-30 VDC. The Rapid-Air
#69100165 is recommended for this
application. This output is high
whenever the enabled input
is activated.
D. PRESS OUTPUT (J52)TB2-21)
This output must be tied to a solid
state relay to interface to the outside
world. The solid state relay must have
a D.C. coil and should have a rating
of 3-30 VDC. The Rapid-Air #69100165
is recommended for this application.
This output goes high at the end of
every feed cycle and stays high for
programmed press time before going
low. To adjust this time, go to
programming the job number and
adjust the time needed for the press.
E. AUTOMATIC OUTPUT (J52)TB2-20
This output must be tied to a solid
state relay to interface to the outside
world. The solid state relay must have
a D.C. coil and should have a rating
of 3-30 VDC. The Rapid-Air #69100165
is recommended for this application. This output goes high whenever
automatic is selected on the program
panel. Any faults will cause the automatic output to go low.
F. KEYPAD AND DISPLAY
INTERFACE (RS232 PORT)
The keypad/display is the interface
between the operator and the resident program. The Pacific Scientific
drive is purchased with a great many
capabilities, none of which can be
used unless a program is written to
utilize these capabilities. Rapid-Air
put a great deal of time making a
program that is user-friendly and yet
gets the job done efficiently. We took
all the questions and constructive
criticism and came up with a program
that would cover all the applications,
yet be easy to interface and program
by a customer.
If an operator reads the programming
procedure in this manual and then
reads the screen parameters listed
as they are displayed and acts on
them by inputting data as needed,
the servo can be up and running in
a very short time.
1. Select a job number.
2. Input or review parameter for
that job number.
3. Thread up material in manual
mode.
4. If properly interfaced, go into
automatic mode.
6
job parameters
Reset Job Parameters
The reset job parameters routing
should be used with special caution.
We incorporated it as a user function
for two reasons.
The first reason is if a problem caused
the displayed parameters to be
garbled because of a program glitch,
then by resetting the job parameters
the problem could be cleared.
The second reason is if there were
a number of different jobs in memory
that were no longer required, then
by resetting the job parameters,
all the job numbers would be reset
to their default values, which
includes putting all zeros in the
feed length and strokes per minute
area of the program.
CAUTION!! CAUTION!! CAUTION!!
Keep a hard copy record of program
numbers and data associated with them
for reference if needed. If this function
is used in a way other than what it was
designed for then all previous data is
lost and cannot be recovered.
To enter this function, turn off the program by depressing the master stop
button. Turn on the program again and
push and hold the “clear entry” key,
once the program has started the
following screen will be displayed.
**DEFAULT VALUE SETUP
PRESS F1 TO RESET TO
DEFAULT VALUES, PRESS
F4 TO IGNORE CHANGES
**Once F1 has been pressed then
all data that had been entered
will be reset.
PROGRAM NUMBER DISPLAY
Each servo unit that is shipped
has a program number assigned
to it. If a problem occurs and
cannot be solved by reloading
the program then you will be
asked the program number
associated with this servo.
To view the program number, press
and hold the “back space” key during
the power up sequence. The program
number will be displayed for about
30 seconds. Please find and write
down the program number in case
it is needed in the future.
To Help You Enter A Job From The Keypad, Let’s Create An Example:
We will use a feed length of three
inches and want to run the feed rate
at 100 percent.
The main menu is currently displayed.
First we select the job number and we
will use job #1.
1. Press F1 to select the job number.
2. Enter job number “01” - press
the F4 key when finished.
3. The job number screen shows
two choices:
A. F1 = program parameters. This
choice is used if a job has
already been programmed and
you would like to adjust the
parameters that were preset
for the job or if entering a new
job number.
To move around in this screen,
press the “enter” key in the lower
right corner of the keypad. Once
the feed length and strokes per
minute are entered, then press the
F4 key to exit the screen. The
program now calculates the accel/
decel and speed for the
parameters entered. At this time
the “F4 key” review parameter
should be used to check to be sure
that you entered the correct
parameters.
B. F4 = don’t alter parameters. Run
the job as previously entered.
4. Press “F2” to select the manual
mode.
A. Press F1 to select the “inch”
or jog mode. This mode will
move the material slowly
forward or reverse to position
the material at its proper
location. F2 being used for
forward and F3 for reverse
movement. Press F4 to leave
the “inch” mode.
B. Press F2 to select the “single
feed” mode. At this time
each press on the F1 key
7
will rotate the rolls to move
the material three inches,
the feed length that was
entered, at the same feed rate
as the feed would move the
material in the automatic mode.
Press the F4 key {exit} to leave
this screen.
5. Press “F3” to select automatic
cycle. In this mode the servo
can be run in the batch or
continuous mode.
A. Press F1 to select the batch
mode. In the batch mode, the
servo will feed each time it is
commanded until the batch
count reaches “0”, then the
automatic cycle drops out.
B. Press F2 to select the
continuous mode. In the
continuous mode, the servo
will feed each time it is
commanded until the command
stops or the operator presses
the “F4” return key.
loading material
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. Then choose “Operate Rolls”. This will allow you to open
the feed rolls and anti-backup rolls
to accept the material but only if you
have purchased the option. You could
also open the rolls manually by lifting
the lever mounted on the side of the
servo feed. 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 setting. Open the feed rolls and or anti-
backup rolls. Hand feed the material
into the servo unit until it protrudes
out of the feed rolls and starts into the
guide on the press. Close the antibackup rolls (if purchased) 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
servo and press first in the manual
mode then in the single cycle 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 accurately set
and the repeatability is satisfactory,
you are ready for full automatic mode.
8
programming procedure
Operator Input Terminal – Programming Procedure – Standard Software
The intent of this section is to
familiarize the operator with the
program flow and what to expect
with every keypress. Each screen
on the display will be reviewed with
special comments to help clarify
what is being asked on the screen.
The program flow is broken down
into 5 sections with the main menu
being the home position.
The first screen to be displayed on the
operator terminal will look like this
RAPID-AIR CORPORATION
4601 KISHWAUKEE STREET
ROCKFORD, IL 61109
815-397-2578
After a few seconds, the display will
clear and the following display will
appear:
MAIN SELECTION MENU
F1=JOB NUM F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW PARAMETERS
SELECT F1=JOB #
The first step in programming the
servo feed is to select a job number
which will be used to store the
parameters the operator inputs or
recall the parameters which have
been previously loaded into the
servo controller program. When the
operator selects F1 on the keypad,
the screen will change to:
JOB # SELECTION MENU
ENTER IN NEW JOB #=XX
PRESS F4 KEY AFTER
CORRECT # IS ENTERED
The operator must enter a 2-digit
number before proceeding to any
other function. If the job number the
operator has entered has been
previously stored in memory, or
entering a new job, the following
display will appear:
JOB NUMBER-01 LOADED
F1=PROGRAM PARAMETERS
F4=DON’T ALTER VALUES
THAT ARE PROGRAMMED!
If entering in a new job then select
(F1) “program parameters” and follow
the directions.
The job number screen displays (2)
choices for the operator. In the first
choice, F1=Program new values, the
operator can enter or change the,
pilots, feed length, % of max speed
and cut time. This then calculates the
optimum speed of the material
movement. The second choice,
F4= Don’t alter values that are
programmed, puts the job number
entered in memory for running at this
time. If F1 was selected the following
display would appear.
FEED ADVISOR JOB#=00
FEED LENGTH=000.000
CUT = XXX % RATE=100
F4=EXIT FEED ADVISOR
This window is displayed during job
setup calculations.
CALCULATING THE FEED
SPEED, ACCEL VALUES
PLEASE WAIT FOR MAIN
MENU TO BE DISPLAYED
Pressing the F4 key at any time
returns you to the main menu.
MAIN SELECTION MENU
F1=JOB # F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
In order to advance material into the
die, using the servo feed, the operator
has to be in the manual mode.
Pressing the F2 on the keypad will
cause the screen to change to the
manual mode screen. (Cycle rolls
with keys) - If the keypad has keys
with open rolls or closed rolls on it
then the keys are active at this time
and the rolls can be electrically
released for inserting the material into
the servo feed.
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F1=INCH MODE
Pressing the F1 key will let the
operator select a jog mode type,
continuous or jog to length. In the
continuous mode, the servo will
run at a slow rate of speed until the
button is released. In the jog to length
mode, the servo will run at a slow rate
of speed until the job number feed
length is reached then it will stop.
The key has to be released and
depressed to jog again.
Depressing the F2 key will direct the
servo to feed forward and pressing
the F3 key will direct the servo to
feed in reverse.
JOG! TYPE=CONTINUOUS
F1=ALTER TYPE OF JOG
F2=FORWARD F3=BACKUP
F4=EXIT (INCH MODE)
Pressing the F4 key once will reset
the program to the jog mode screen
so that jog is now active. Pressing the
F4 key twice will reset the program to
the manual mode screen. If the F4 key
was pressed twice then the following
screen is displayed.
9
programming procedure (continued)
Operator Input Terminal – Programming Procedure – Standard Software
MANUAL MODE F1=INCH
F2=SINGLE FEED MODE
F4=EXIT MANUAL MODE
CYCLE ROLL WITH KEYS
F2=SINGLE FEED
If the operator presses F2 then the
following screen is displayed. The
single feed mode is active and every
time the F1 key is pressed then the
feed will cycle and move the distance
indicated on the feed length line.
JOB#=00 FL=000.000
F1=FEED SINGLE LNGTH
F2=CUT F3=SINGLE CYC
F4=EXIT (SINGLE FEED)
Pressing F4 once resets the program
to the manual mode display. Pressing
the F4 key twice resets the program
to the main menu display. If the F4
key was pressed twice the following
screen is displayed.
MAIN SELECTION MENU
F1=JOB# F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
You can now select between batch or
continuous mode
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
F2=CONTINUOUS
If the F2 key was pressed then the
servo will be in the auto total mode
and the following screen appears.
AUTOMATIC TOT=000000
JOB#=00 CUT=O.150
FL=000.000 SPEED=100
ACCEL=OO1% F4=RETURN
Pressing the F4 key, stops the
automatic cycle and the main menu
screen appears.
MAIN SELECTION MENU
F1=JOB# F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
F3=AUTOMATIC CYCLE
If the feed has been properly set up,
tested in manual, press electrically
interlocked with feed, feed and pilot
switches wired to the correct
terminals, then pressing the F3 key
will display the following screen.
SELECT CONTINUOUS OR
BATCH CYCLE F1=BATCH
F2=CONTINUOUS CYCLE
F4=EXIT TO MAIN MENU
F1 =BATCH
If the F1 key was pressed then the
servo will be in the auto batch mode
and the following screen appears.
BATCH SETTING=000000
BATCH COUNTER=000000
F1=RESET BATCH COUNT
F4=CONTINUE WITH COUNT
If F1 (reset batch count) is pressed
then the batch count will be reset
to its preset valve. If F4 (continue
with count) is pressed the batch
count will remain at its present
value. Either F1 or F4 will lead to the
following screen.
AUTOMATIC BATCH=000000
JOB#=XX CUT=0.XXX
FL=XXX.XXX SPEED=XXX%
ACCEL=XXX% F4=RETURN
Pressing the F4 key, stops the
automatic cycle and the main menu
screen appears.
When the automatic screen is
displayed, all keys except the F4 key
are inactive. Every time the press
cycles and trips the feed switch,
the feed will cycle once per the
parameters displayed on the screen.
If the feed encounters excessive
material drag while feeding or the
material being moved encounters
a restriction that stops the material
forward movement then a servo fault
can occur. If this happens then the
following screen is displayed.
DRIVE FAULT OCCURED
NOTE TYPE OF FAULT––
(xxx)
Example of fault – (2) = motor over
temperature.
Look up fault code printout listed in
this manual.
To reset the fault, the master on-off
switch has to be cycled which will
reset the controller. The material path
should be checked for obstruction and
parallelism to the die. If all this seems
to be satisfactory and another fault occurs the factory should be consulted.
MAIN SELECTION MENU
F1=JOB# F2=MANUAL
F3=AUTOMATIC CYCLE
F4=REVIEW JOB PROGRAM
10
programming procedure (continued)
Operator Input Terminal – Programming Procedure – Standard Software
The last section to be covered is
the ramp/counters section. To get
into this mode, press the ramp
push-button and the following
screen appears.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ACCEL/DECEL RAMPS
F4=EXIT TO MAIN MENU
F1 =BATCH/TOTAL COUNTS
Pressing the F1 key will bring up the
batch/total screen, which is used
for presetting the batch count or
resetting the total count. The
following screen appears.
BATCH COUNTER=000000
TOTAL COUNTER=000000
SET:F1=BATCH F2=TOT
F4=RETURN TO RAMP COUNT
Pressing the F1-batch counter key
allows the operator to preset a
batch count.
Pressing the F2-total counter key
resets the total count to zero. This
cannot be undone so be sure that the
counter should be reset to zero before
pressing F2 key.
Pressing the F4 key brings up the
following screen.
SELECT RAMP/COUNTERS
F1=BATCH/TOTAL COUNT
F2=ACCEL/DECEL RAMPS
F4=EXIT TO MAIN MENU
The only section that has not been
covered in this write-up is the ramp
adjust mode. The ramp adjusts how
fast the servo motor gets up to
speed and how fast it stops. This
feature is an asset that is seldom
adjusted but can be a sure cure if
material slippage seems to be
a problem. With the main menu
screen displayed the key labeled
ramp is active. Pressing the ramp
key produces this display.
RAMP PARAMETER MODE
F1=ACCEL% F2=DECEL%
F3=PERCENT MAX SPEED
F4=RETURN RAMP/COUNT
PRESS F1 OR F2
Pressing the F1 or F2 keys will produce
one of the following displays. The
lower the number entered, the longer
the ramp cycle. Press F1 or F2 now.
ENTER IN %ACCEL RATE
MAX%=75000 RPM/SEC
MAX ACCEL%=XXX%
F4=EXIT %ACCEL MENU
ENTER IN %DECEL RATE
MAX%=75000 RPM/SEC
MAX DECEL% = XXX%
F4=EXIT %DECEL MENU
The ramp usually is factory set at .015
on the series 100 drives and .035 on the
series 200 & 300 drives. There is some
deviation to this when the factory runs
the unit, but this is a basic starting point.
11
parallelism
Drive Roll Parallelism Adjustment
Every servo feed has an eccentric
adjustment screw to adjust the upper
roller to be in parallel to the lower
roller. The maximum adjustment is
.008” on the eccentric.
The adjustment screw is located
behind the belt cover and is held fast
by a 10-32 socket head cap screw.
The actual adjustment screw is a
slotted eccentric pin which is
turned clockwise or counter-clockwise
to raise or lower one end of the
upper roll.
The parallel adjustment is factory
set when the unit is manufactured
but if material tracking seems to
be a problem then this could be
a way of solving the problem.
To test if the rolls need adjustment,
do the following.
1. Remove the front and rear
roll covers.
2. Raise the anti-backup rolls.
(If any) main rolls should be closed.
3. Shine a light from the rear of the
feed toward the main rollers.
4. Inspect from the main rolls side to
see if the rollers are parallel. If they
are then the material could be the
cause of the material walking.
If they are not parallel then an
adjustment has to be made.
5. To make the adjustment:
a. Remove manual roll release arm
by removing roll pin.
b. Remove belt cover.
c. Locate eccentric screw and
loosen 10-32 screw.
d. Turn slotted eccentric screw
while viewing rolls until the rolls
are parallel.
e. Tighten 10-32 screw and
reassemble parts, then retry
running material.
For a more accurate adjustment use a
feeler gauge to check the parallelism.
This completes the eccentric adjustment write-up, if there are further
questions, please call the factory.
* Before attempting to solve a
possible roll parallelism problem
by readjusting the rolls or calling
the factory, perform the following
test.
Step 1) A 3 to 5 foot length of material
should be cut from the storage loop
proceeding the servo feed.
Step 2) Lay the material next to a
straight line to see if the material is
cambered. If it is then this could be the
reason that the material is walking. If
not, then turn the material upside down
from the way it was being fed and
insert into the feed. If the material
walks in the opposite direction then
the material could be to blame.
12
troubleshooting
Problem Cause Remedy
No power indication
No display on operators console
Power on – no motion
No roll action
Material will not enter rolls
– Disconnect off
– Blown fuse
– Master button in
– Program fault
– Faulty wiring
– Program fault
– Drive fault
– Program error
– No air
– Low air pressure
– Anti-backup closed
– Feed roll adjusting mechanism
too close
– Material too thick
– Turn disconnect on
– Check / replace fuse
– Pull button out
– Check lights on P.C.
– Check plug on console
– Check lights on drive
– Check lights on servo drive readout
– Check parameters
– Check air line
– Check air regulator
– Open rolls
– Open adjustment mechanism
– Check servo parameters
Material will not feed
Material feeds short
Material feeds long
Material camber
– Low roller force
– Oily material
– Program fault
– Obstruction in die
– Accel to fast
– Lower roller force
– Oily material
– Obstruction in die
– Feed signal to close to pilot release
– High % max speed
– Material slippery
– Decel set too high
– High roller force
– Raise roller pressure
– Clean material
– Check parameters
– Check die
– Lower accel speed
– Raise roller pressure
– Clean material
– Check die
– Move feed signal input so rolls
are closed to feed
– Lower % max feed speed
– Lower % decel
– Lower % decel
– Lower roller pressure
– Bad stock
– Check stock at input for camber
13
troubleshooting (continued)
Problem Cause Remedy
Material feeds off center
No automatic cycle
Servo hum
Fault signal on Pac-Sci is displayed
Cannot program unit from display
– Edge guides not set properly
– Material not centered to feed
– Bad material
– No press signal
– Controller fault
– Servo fault
– Program error
– Servo velocity gain too high
– Belt too loose or tight
– Servo fault
– Material jam
– Power surge / failure
– Program fault
– Set edge guides
– Center material
– Try new roll of material
– Check limit switch input to
servo control
– Check lights on drive
– Check lights on drive
– Check parameters on display
– Consult factory
– Readjust belt tension
– Recycle power
– Check die
– Check / recycle power
– Check Pac-Sci & call factory
Mechanical pilot release
sticks down
– Data Instruments interface
jumper loose
– Too much overtravel
– Broken spring
– Needs lube
– Check Data Instruments connection
– Restrict travel of mechanical
actuating arm
– Remove plate and check springs
– Remove plate and lubricate
release bar
14
motor service and fault displaY
Servo Motor Service
The servo motor is flanged mounted
and secured with four socket head
cap screws. The motor removal has
to be done in a sequence as
described below.
1. The manual roll release handle
has to be removed. The inner roll
pin holds the handle to the
shaft. Once this is removed the
handle should slide off the shaft.
2. The belt guard has to be
removed. It is fastened with four
1/4-20 socket head cap screws
on the 100 & 200 servos and five
5/16-18 socket head capscrews
on the 300B.
3. Remove the belt tension then
remove the motor.
4. Install new motor and
reassemble in reverse order
of the previous instructions.
5. When reinstalling the belt, the
tension on the belt should be
1/64” deflection per inch
distance between the center
lines of the pulleys using 1 .5 to
2 lbs. force to cause the
deflection. The best way is to
tension the belt and try running
the servo for a few cycles. If
you get a high vibration on the
belt when the feed stops then
you have to readjust the belt
tension. It will have to have more
or less tension to stop the
vibration of the belt.
MANIFOLD ASSEMBLY
The manifold assembly was
designed to give the customer
easy access to the components.
The valve for the electric roll release
and if supplied, the anti-backup valve
is mounted on the side of the feed.
The air regulator and pressure
gauge is mounted on the input side
of the feed. All can be easily
replaced if needed.
ROLLER AND GEAR BOX ASSEMBLY
At this stage of disassembly, all field
maintenance components are exposed
and easily accessible. No further field
service should be necessary on the
roller and gear box assembly unless
the gear train is suspected of a
malfunction. The drive rolls should
be checked for erroneous wear
pattern while they are exposed and
cleaned before reassembly.
MAINTENANCE PROCEDURES
DAILY
Wipe off feed rolls.
Clean any dirt from servo unit.
Clean any dirt from operators pendant.
WEEKLY
Check wear pattern of rolls.
MONTHLY
Check oil level.
Check cables for cuts or wear.
Servo Fault Display
The Pacific Scientific drive has a list
of internal faults and displays the
number of that fault on its readout
located on the front of the drive.
Rapid-Air now displays the fault on the
keypad display. If a fault occurs the
screen will display the number and
the name of the fault, but there will not
be an explanation accompanying the
fault. This is a tool to help you
to troubleshoot if the servo fails to
perform when commanded.
If a fault was displayed the servo controller will have to be turned off and restarted to clear the fault. If the fault is
still present when the Pacific Scientific
unit is restarted, the fault may not be
15
displayed on the keypad screen as the
fault will not let the internal program
restart. The control panel will have to
be opened to view the fault again.
A list of probable faults and some
explanation is included in this section.
If more help is required, then Rapid-Air
will have to be contacted.
troubleshooting
Fault Code
(Predefined Variable, Integer, Status Variable, Read-Only)
Guidelines - 0 means the drive is not faulted and not enabled, while 8 means the drive is not faulted and enabled.
Alternating 8.> means actively inhibiting CW motion and alternating 8.< means actively inhibiting CCW motion
Status LED Value Fault Meaning
(Blinking) 1
(Blinking) 2
(Blinking) 3
(Blinking) 4
(Blinking) 5
(Blinking) 6
(Blinking) 7
(Blinking) 9
(Blinking) A
(Blinking) b
(Blinking) C
(Blinking) D
(Solid) E*
(Blinking) E*
1
2
3
4
5
6
7
9
10
11
12
13
14
14
Velocity feedback (VelFB) over speed
Motor Over-Temp
Drive Over-Temp
Drive l*t
1-n Fault (9x3)
Control ±12 V supply under voltage
Output over current or bus over voltage
Not Assigned
Bus OV detected by DSP
Auxiliary ±5V Low
Not assigned
Not assigned
Processor throughput fault
Power Up Self Test Failure
(Alternating) E1
(Alternating) E2
(Alternating) E3
(Alternating) E4
(Alternating) E5*
(Alternating) E6
(Alternating) E7
(Alternating) F1
(Alternating) F3
* FaultReset cannot reset these faults.
See ExtFault for further information on Blinking E, Blinking 1 and Alternating F3.
225
226
227
228
229
230
231
241
243
Bus UV, Bus Voltage VBUSTHRESH
Ambient Temp Too Low
Encoder commutation align failed (Only CommSrc=1)
Drive software incompatible with NV memory version
Control Card hardware not compatible with drive software version
Drive transition from unconfigured to configured while enabled
Two AlnNull events too close together
Excessive Position Following Error
Parameter Checksum Error (Memory Error)
16
reassemblY and lubrication
Reassembly Of Unit
Prior to assembly, attention must be
given to three points of contact that
require an application of Moly-Cote, Lubriplate or other suitable heavy grease.
The three points are:
1. The antibackup piston which
is located at the feed entrance.
2. The main roll piston and the
spiral pins in the main roller tie
plate which can be seen by
Lubrication Of Unit
The gear box oil must be kept
up to sight gauge level and changed
after every 2000 hours of use.
Recommended oil is Mobil #SHC63O
or equivalent. The oil reservoir
capacity is 3.5 oz. The oil can be
drained by removal of the drain
plug located near the base of the
gear housing cover, just below the
sight gauge. The oil reservoir is
filled through the pipe thread port
occupied by the air breather plug
viewing straight down through
the center of the feed at
approximately halfway from the
inlet to the exit roller. The piston
is positioned horizontally at the
base of the feed and
approximately in the center of
the feed if viewing from the
gear box to the belt cover.
3. The mechanical roll release shaft
located at the exit side of the
near the upper edge of the gear
housing cover.
NOTE: THE ORIGINAL BREAK-IN
OIL IN THE GEAR BOX SHOULD BE
CHANGED AFTER 100 HOURS OF
CYCLE TIME AND EXAMINED
FOR CHIPS OR FOREIGN MATTER.
REPLACE THE BEAR BOX OIL
PER INSTRUCTIONS.
The anti-backup rollers have been
feed. Three screws have to be
removed and then the keeper
plate can be removed. The inner
shaft should be thoroughly
greased to prevent sticking.
Do not apply excessive grease as
it may fall onto the drive rollers and
cause misfeeding due to material
slippage. All bearings are sealed and
need no additional lubrication.
lubricated at the factory and should
need no further attention. If they
are found to slip in the reverse
direction, consult the factory for
further assistance.
PINCH ROLL & ANTI-BACK UP
ACTUATING PISTONS
Periodically grease with lubriplate or
equivalent grease to anti-backup and
pinch roll actuating piston nose where
it contacts the pressure plate.
17
precautions & safetY
Precautions & safety
NEVER – Put screwdrivers or foreign materials in feed rolls
NEVER – Hold onto material as it is being fed through the servo
NEVER – Wear neckties around the servo feed rolls
NEVER – Force the rolls open by prying on them
NEVER – Modify the mechanical aspects of the servo feed
CAUTION – Contact the factory before drilling any holes in the unit
CAUTION – Wear proper eye protection when working around the servo
CAUTION – Do not wear loose clothing around the servo feed rolls
18
warrantY
Warranty Terms & Conditions
ALL SALES BY THE COMPANY ARE MADE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS. PLEASE READ.
WARRANTY – The Company warrants, for a period of one year from date of shipment by the Company, that the product
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. The Company obligation under this warranty is limited to
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.
CUSTOMER LICENSE AGREEMENT – The RAPID-AIR CORPORATION reserves the rights in it’s software. The software
program is licensed by RAPID-AIR to the original purchaser of the equipment which contains the software for use only on
the terms set forth in this license.
You may use the program only on the programmable servo computer furnished with the system and only in conjunction
with the servo feed supplied with the system.
You may not without expressed permission from Rapid-Air:
A. Copy, distribute, or document the program for others.
B. Modify or merge any portion of the program for use on non compatible hardware.
C. Make alterations to the program.
19
Rapid-Master/106 Servo CTL
20
set-up
Mechanical Set-Up Of Die Or Punch
1) Secure the die set to the bolster
plate.
2) The piston adjustment sleeve
(item #1), establishes the stroke to
a maximum of .50 inches when fully
extended. The stroke is reduced by
1.8 inches with each full inward
rotation, using the 3-3/4 spanner
wrench provided. The piston stroke
adjustment sleeve is locked in place
with a nylon tipped set screw (item #2).
3) Lift the punch holder plate and
loosely connect it to the inner shaft
ram adjustment screw with the two
half shell clamps (item #3) provided.
4) Adjust the inner shaft (item #4) for
proper open height, using the
wrench provided.
5) Tightly secure the punch holder
plate to the inner shaft.
6) Lower the piston, piston shaft and
piston sleeve by rotating the
adjustment screw on top of the
head assembly (item #5) with the
crank provided. This is done to
check the full stroke set up. If all
adjustment are within limits, the top
adjustment screw should be
retracted to fully raise the piston
and ram assembly.
7) Lock the upper adjustment screw
(item #6) in the up position.
21
Electrical Schematic
22
on options purchased.
** Keypad shown with all options .
Left 2 rows may vary depending
Keypad
23
100 Series Rapid Master – SC953 Servo Wiring Diagram
24
Inter-Connect Wiring Diagram
25
26
Loading...