Rapid-Air SERVO FEED User Manual
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
Loading...