Rapid-Air PLAN 100 Series Operating Instructions Manual Download Page 1

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RAPID-AIR CORPORATION

4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925

Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.com

CUT-TO-LENGTH

WITH MULTI-STROKE

OPERATING INSTRUCTIONS

Summary of Contents for PLAN 100 Series

Page 1: ...RAPID AIR CORPORATION 4601 KISHWAUKEE ST ROCKFORD IL 61109 2925 Phone 815 397 2578 Fax 815 398 3887 Web Site www rapidair com CUT TO LENGTH WITH MULTI STROKE OPERATING INSTRUCTIONS ...

Page 2: ...for no repeats Although this is the standard program Rapid Air can program other configurations in any combination to meet the customer s requirements The standard multi stroke program has 10 jobs with 10 programmable sequences per job Each sequence can be a different feed length which can be repeated multiple times The following chart depicts the previous write up GAG FEED TOTAL JOBS 10 TOTAL SEQ...

Page 3: ...F CONTENTS CHARTS AND DRAWINGS DIRECTORY pg 4 INTRODUCTION pg 5 INTERFACING FEED WITH CUTTER pg 6 ELECTRICAL CABLES AND AIR LINE pg 7 INTERFACING SERVO FEED WITH CUTTER pg 8 PRETEST WRITE UP pg 9 LOADING MATERIAL pg 10 file C Web_develop cut_to_length_with_multi_stroke_ htm 2 of 66 12 10 2001 3 44 57 PM ...

Page 4: ...GRAMMING PROCEDURE pg 15 DRIVE ROLL PARALLELISM ADJ pg 23 TROUBLESHOOTING pg 24 OPERATIONAL MAINTENANCE PROCEDURES pg 26 PRECAUTIONS AND SAFETY pg 30 WARRANTY pg 31 LISTING OF CHARTS AND DRAWINGS file C Web_develop cut_to_length_with_multi_stroke_ htm 3 of 66 12 10 2001 3 44 57 PM ...

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Page 7: ...he 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 and ease of setup and installation Three cables with twist lock connector...

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Page 10: ...ady 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 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 th...

Page 11: ...was purchased complete then the interfacing was done for you If not then Rapid Air has provided wiring to a terminal block for interconnection purposes The interface schematic provides the wire numbers and how to connect the cutter to the feed This completes the initial setup of the servo feed to the cutter or other device The servo is now ready to run as intended If more complete interfacing is n...

Page 12: ...nput 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...

Page 13: ...ned 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 The servo will feed and when done the cutter will cycle This will verify that the unit is working correctly LOADING MATERIAL INTO THE SERVO FEED Upon the satisfactory completion of all the tests you should be ready...

Page 14: ... 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 syste...

Page 15: ...ng back during the pilot operation They can become a hindrance if the material tend to walk to one side or the other during the feed cycle The anti backup switch was designed in for this program If this problem is being experienced then a switch or a cam switch with a normally open contact can be wired in from the press Usually this switch is activated when the press is at 180 degrees or when the ...

Page 16: ...omatic cycle will be dropped and have to be restarted D ENABLE OUTPUT J52 TB2 15 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 E CUTTER OUTPUT J52 TB2 13 This output...

Page 17: ... 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 H STANDARD PROGRAM INSTRUMENTS INTERFACE J52 TB1 14 With the jumper in place the...

Page 18: ...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 numbe...

Page 19: ...set 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 ...

Page 20: ...re needed 003 000 when finished press the enter key and the selection underline moves to the spm input Enter is a stroke per minute We will use 150 spm 0 150 Press the enter key again The underline moves to the cut time selection To start with put in 0 150 This will cut the material in at a high rate and may not be enough time for thicker stock b Don t alter parameters this will just load the exis...

Page 21: ... 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 ...

Page 22: ...he 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 file C Web_develop cut_to_length_with_multi_stroke_ htm 21 of...

Page 23: ... 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 For a more accurate adjustment use a feeler gage to check the parallelism e ...

Page 24: ...k replace fuse Master button in Pull button out No display on Program fault Check lights on P C operators console Faulty wiring Check plug on console Power on no motion Program fault Check lights on P C Drive fault Check lights on drive Program error Check parameters file C Web_develop cut_to_length_with_multi_stroke_ htm 23 of 66 12 10 2001 3 44 57 PM ...

Page 25: ...sting Open adjustment mechanism too close mechanism Material too thick Check servo parameters Material will not feed Low roller force Raise roller pressure Oily material Clean material Program fault Check parameters Obstruction in cutter Check cutter Material feeds short Accel to fast Lower accel speed file C Web_develop cut_to_length_with_multi_stroke_ htm 24 of 66 12 10 2001 3 44 57 PM ...

Page 26: ...rial feeds long High max speed Lower max feed speed Material slippery Lower Decell speed Decell set too fast Lower Decell speed Material camber High roller force Lower roller pressure Bad stock Check stock at input TROUBLESHOOTING CHART cont PROBLEM CAUSE REMEDY file C Web_develop cut_to_length_with_multi_stroke_ htm 25 of 66 12 10 2001 3 44 57 PM ...

Page 27: ...o cutter returned signal Check limit switch input to servo control Controller fault Check lights on P C Servo fault Check lights on drive Program error Check parameters Servo squeals while Servo velocity gain Consult factory in position too high Belt too loose or tight Readjust belt tension file C Web_develop cut_to_length_with_multi_stroke_ htm 26 of 66 12 10 2001 3 44 57 PM ...

Page 28: ...recycle power Cannot program unit Program fault Check Pac Sci Call factory Mechanical pilot release Too much overtravel Restrict travel of sticks down mechanical actuating arm Broken spring Remove plate and check springs Needs lube Remove plate and lubricate release bar file C Web_develop cut_to_length_with_multi_stroke_ htm 27 of 66 12 10 2001 3 44 57 PM ...

Page 29: ...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 be...

Page 30: ... the gear train is suspected of a malfunction The drive rolls should be checked for erronious wear pattern while they are exposed and cleaned before reassembly MAINTENANCE PROCEDURES DAILY WEEKLY MONTHLY Wipe off feed rolls Check wear pattern of rolls Check oil level Clean any dirt from Check cables for cuts servo unit or wear Clean any dirt from operators pendant file C Web_develop cut_to_length_...

Page 31: ...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 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 faul...

Page 32: ...tively inhibiting CCW motion STATUS LED VALUE FAULT MEANING Blinking 1 1 Velocity feedback VelFB over speed Blinking 2 2 Motor Over Temp Blinking 3 3 Drive Over Temp Blinking 4 4 Drive I t Blinking 5 5 1 n Fault 9x3 Blinking 6 6 Control 12 V supply under voltage Blinking 7 7 Output over current or bus over voltage Blinking 9 9 Not Assigned file C Web_develop cut_to_length_with_multi_stroke_ htm 31...

Page 33: ...cessor throughput fault Blinking E 14 Power Up Self Test Failure Alternating E1 225 Bus UV Bus Voltage VBUSTHRESH Alternating E2 226 Ambient Temp Too Low Alternating E3 227 Encoder commutation align failed Only CommSrc 1 Alternating E4 228 Drive software incompatible with NV memory version file C Web_develop cut_to_length_with_multi_stroke_ htm 32 of 66 12 10 2001 3 44 58 PM ...

Page 34: ...SSEMBLY 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 viewing straight down through the center of the feed at ...

Page 35: ...eservoir 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 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 ...

Page 36: ...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 file C Web_develop cut_to_length_wit...

Page 37: ...son 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 ...

Page 38: ...e 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 postion Reviewing the flow chart in the back of this manual will help in understanding the sections SECTION1 F1 JOB ENTRY SECTION2 F2 MANUAL MODE SE...

Page 39: ...N MENU F1 JOB F2 MANUAL F3 AUTOMATIC CYCLE F4 REVIEW JOB PROGRAM 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 file C...

Page 40: ...or the operator In the first choice F1 Program new values the operator can enter or change the number of sequences repeats per sequence pilots feed length strokes per minute that the press is running and feed arc angle Free travel of the press in which the feed can move material without a problem this then calculates the optimum speed of the material movement The second choice F4 Don t alter value...

Page 41: ...put or change data at cursor At this time the longest feed length and the maximum strokes per minute for this job should be entered to test if the feed parameters are within the specifications of what the feed can perform When complete press F4 to exit A fault window will appear if the feed length is too long for SPM Feed arc is press free travel for feeding material Max feed arc 300 degrees The o...

Page 42: ...Repeat this command returns to the previous screen so that the new parameters can be entered Pressing the F4 key at any time returns you to the main menu MAIN MENU F1 JOB F2 MANUAL F3 AUTOMATIC CYCLE F4 REVIEW JOB PROGRAM SELECT F2 MANUAL file C Web_develop cut_to_length_with_multi_stroke_ htm 41 of 66 12 10 2001 3 44 58 PM ...

Page 43: ...f a feed rate is entered that is too long for the SPM then a fault screen will appear as previously described In order to advance material into the cutter 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 close rolls on it then the key...

Page 44: ...t the operator make a forward movement the amount that was programmed for the feed lengths of the job Pressing F1 will display the following Jog Mode screen JOG MODE F1 FORWARD F2 REVERSE OR USE EXTERNAL JOG PENDANT F4 EXIT INCH MODE F4 EXIT file C Web_develop cut_to_length_with_multi_stroke_ htm 43 of 66 12 10 2001 3 44 58 PM ...

Page 45: ... following screen is displayed MANUAL MODE F1 INCH F2 SINGLE FEED MODE F4 EXIT MANUAL MODE CYCLE ROLL WITH KEYS F2 SINGLE FEED 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 file C Web_develop cut_to_leng...

Page 46: ... pressed then the feed will cycle and move the distance indicated on the feed length line JOB 000 FL 000 000 SEQ 00 F1 FEED F2 CUT F3 FEED CUT F4 EXIT 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 MENU F1 JOB F2 MANUAL file C Web_develop cut_...

Page 47: ...hes wired to the correct terminals then pressing the F3 key will display the following screen START AUTOMATIC FROM F1 SEQUENCE NUMBER 1 F2 PREVIOUS SEQUENCE AND REPEATS POSITION After selecting one of the above choices the following screen appears SELECT CONTINUOUS OR BATCH CYCLE F1 BATCH F2 CONTINUOUS CYCLE F4 EXIT TO MAIN MENU file C Web_develop cut_to_length_with_multi_stroke_ htm 46 of 66 12 1...

Page 48: ...llowing screen appears AUTOMATIC TOTAL 000000 JOB XX PILOTS NO LGTH XXX XXX SPM XXX SPEED XXX F4 RETURN Pressing the F4 key stops the automatic cycle and the main menu screen appears MAIN MENU F1 JOB F2 MANUAL F3 AUTOMATIC CYCLE F4 REVIEW JOB PROGRAM file C Web_develop cut_to_length_with_multi_stroke_ htm 47 of 66 12 10 2001 3 44 58 PM ...

Page 49: ...0 F4 EXIT AUTO CYCLE Pressing the F4 key stops the automatic cycle and the main menu screen appears MAIN 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 file C Web_develop cut_to_length_with_multi_stroke_ htm 48 of 6...

Page 50: ...TION After selecting one of the above choices the following screen appears 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 file C Web_develop cut_to_length_with_multi_stroke_ htm 49 of 66 12 10 2001 3 44 58 PM ...

Page 51: ... 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 mat...

Page 52: ...ms to be satisfactory and another fault occurs the factory should be consulted MAIN MENU F1 JOB F2 MANUAL F3 AUTOMATIC CYCLE F4 REVIEW JOB PROGRAM F4 JOB REVIEW Pressing the F4 key will display the following screen This screen asks for a sequence number to be reviewed or modified The program only allows reviewing of a sequence in the job that is currently active For an example if job 1 had 4 seque...

Page 53: ...AIN MENU The above screen displays the job number and the sequence that was selected If all that was needed was to look at the sequence to verify that it was correct then pressing the F4 key will return you to the main menu If there was a problem with this particular sequence like a length change then the length could be adjusted now and file C Web_develop cut_to_length_with_multi_stroke_ htm 52 o...

Page 54: ...p counters section To get into this mode press the ramp pushbutton and the following screen appears SELECT RAMP COUNTERS F1 BATCH TOTAL COUNT F2 ALTER ACCEL SPEED 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...

Page 55: ...TERS F1 BATCH TOTAL COUNT F2 ALTER ACCEL SPEED 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 Pressing the F2 alter accel speed key produces this ...

Page 56: ...2 PRESS F4 KEY ONCE F4 EXIT RAMP MENU CORRECT IS ENTERED Multi stroke Program Explanation The Multi stroke program is a cut to length program with the option of cutting different lengths with different quantities for each length within the same program or job number The program consists of 10 jobs with 10 sequences per job Each sequence has multiple repeats with a programmable timed output to the ...

Page 57: ...er minute usually is not the actual strokes per minute entered as the time required for the operation of each output varies with the actual operation of each component but this sets up the accel decel and max speed of the servo motor The program then displays a window for each sequence with a feed length and repeats or number of parts required for that feed length The program then can be run in ma...

Page 58: ...le of sequences within a job Job 01 4 sequences sequence 1 5 0 inch rep 100 sequence 2 8 0 inch rep 25 sequence 3 12 0 inch rep 10 sequence 4 28 500 inch rep 2 file C Web_develop cut_to_length_with_multi_stroke_ htm 57 of 66 12 10 2001 3 44 58 PM ...

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