Rapid-Air SMS2, SMS4, SMS8 User Manual
smart mini servo feed
cut-to-length
oPerating instructions
MODELS
SMS2, SMS4, SMS8
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, INSTALLATION AND SET-UP ..................................................................................... pg. 3
ADJUSTMENT, CABLING AND INTERFACING ...................................................................................... pg. 4
PRETEST WITHOUT MATERIAL AND LOADING MATERIAL ................................................................ pg. 5
TROUBLESHOOTING .................................................................................................................................. pg. 6-7
MAINTENANCE PROCEDURES, PRECAUTIONS AND SAFETY ........................................................... pg. 7
CUTTER MAINTENANCE ........................................................................................................................... pg. 8
FSC8/SMS8 CONTROL ASSEMBLY .......................................................................................................... pg. 9
RSC14/SMS2 SERVO CONTROL ASSEMBLY .......................................................................................... pg. 10
PROGRAMMING PROCEDURE ................................................................................................................. pg. 11-13
TROUBLESHOOTING .................................................................................................................................. pg. 14-15
LED STATUS SYMBOLS ............................................................................................................................. pg. 16-18
SMS - CTL FEED DIAGRAM ....................................................................................................................... pg. 19
SMS - CTL SERVO FEED DIAGRAM ......................................................................................................... pg. 20
SMS WITH CUTTER CONTROL PANEL ASSEMBLY .............................................................................. pg. 21
SMS WITH CUTTER WIRING SCHEMATIC ............................................................................................. pg. 22
WARRANTY ................................................................................................................................................. pg. 23
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introduction, installation and set-uP
Smart Mini Servo Feed With Cut-To-Length Introduction
The Rapid-Air Servo Cut-To-Length
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
80-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 99.999 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 cutter.
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.
Installation And Mechanical Setup Of Servo And Cutter
If you purchased the servo/cutter
combination already mounted on a
base then the servo and cutter 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 cutter
and are going to mount it on a base
at your facility, then a base should
be selected that will hold the weight
of the servo and the cutter and also
the cycling shocks incurred during
production.
When mounting the two devices,
the pass line height of the cutter
and the servo roller center line should
be equal. Even more critical is the
parallelism between the two devices.
The cutter should be mounted first
then the servo center line should
be aligned to the cutter center line
with the servo rollers parallel to the
cutter blade.
The servo should be mounted as
close to the cutter as possible and depending on thickness of the material
a bridge should be installed between
the servo and cutter to minimize
material droop or buckling during feed.
3
adjustment, cabling and interfacing
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
opposite the belt cover and is held
fast by a socket head cap screw.
The actual adjustment screw is an
eccentric sleeve 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. Shine a light from the rear
of the feed toward the
main rollers.
3. 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.
4. To make the adjustment:
a. Locate eccentric screw
and loosen socket head
lock screw.
b. Turn slotted eccentric
sleeve while viewing rolls
until the rolls are parallel.
c. 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
preceding 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.
Electrical Cables And Air Line
120 VAC INPUT
The 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.
The electrical control enclosure is
shipped completely ready to be
connected to the mechanical feed.
Connected to the enclosure are (2)
cables with keyed screw type
connectors for connection to the
motor. The third connector is used to
interface the cutter 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
Interfacing Servo Feed With A Cutter
The Servo Drive unit is programmed
to feed each time a signal is received
from the cutter switch. The servo will
feed one progression and wait for the
next signal before it will feed again in
automatic mode.
The command is in the form of a
normally open contact from a proximity switch, located on the cutter and is
activated when the cutter is returned.
If the feed/cutter was purchased
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
is NPT pipe tap. The minimum
air line size requirement is 1/2” ID
hose. - (2 CFM)
complete, then the interfacing was
done for you.
This completes the initial setup of the
servo feed to the cutter or other device.
The servo is now ready to run as intended.
4
Pretest and loading material
Pretest For Servo Feed And Cutter Without Material
Now that your servo/cutter combination is in place, and the cables have
been attached, you can proceed
with testing the unit. The first step
is to turn on the main switch on the
electrical enclosure.
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 Operator Interface Terminal 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. Check that
you have enough tension on the
material to avoid slipping during
feeding. Open and close the feed rolls
manually. Visually inspect that the
rolls open and close when using the
manual levers.
Select the “inch” function (F1 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 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.
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. You 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. Hand
feed the material into the servo unit
until it protrudes out of the feed rolls
and starts into the guide on the cutter.
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 cutter 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.
5
troubleshooting
Problem Cause Remedy
No power indication
No display on operators console
Power on – no motion
Material will not enter rolls
Material will not feed
– Disconnect off.
– Blown fuse.
– Master button in.
– Program fault.
– Faulty wiring.
– Program fault
– Drive fault
– Program error.
– Feed roll adjusting mechanism
too close.
– Material too thick.
– Low roller force.
– Oily material.
– Program fault.
– Obstruction.
– 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.
– Open adjustment mechanism.
– Check servo parameters.
– Raise roller pressure.
– Clean material.
– Check parameters.
– Check path.
Material feeds short
Material feeds long
Material camber
– Accel to fast.
– Low roller force.
– Oily material.
– Obstruction in path.
– High % max speed.
– Material slippery.
– Decell set too high.
– High roller force.
– Bad stock.
– Lower accel speed.
– Raise roller pressure.
– Clean material.
– Check path.
– Lower % max feed speed.
– Lower % decell.
– Lower % decell.
– Lower roller pressure.
– Check stock at input for camber.
6
troubleshooting (continued)
Problem Cause Remedy
Material feeds off center
No automatic cycle
Servo squeals
Fault signal on drive is displayed
Cannot program unit from display
– Edge guides not set properly.
– Material not centered to feed.
– Bad material.
– No cutter 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 cutter prox. SW. input to
servo control.
– Check lights on drive.
– Check parameters on display.
– Consult factory.
– Readjust belt tension.
– Recycle power.
– Check cutter.
– Check / recycle power.
– Check drive and call factory.
maintenance Procedures, Precautions and safety
Maintenance Procedures Precautions And Safety
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 cables for cuts or wear.
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.
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