AIR FEED / CUT-TO-LENGTH WITH KEYPAD OPERATING INSTRUCTIONS RAPID-AIR CORPORATION 4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925 Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.
Air Feed/Cut-to-Length with Keypad Table of Contents Charts and Drawings Directory pg. 2 Installation pg. 3 Cutter Data pg. 4 Air Feed Progressions Setup pg. 5 Electrical Setup pg. 8 Pretest Without Material pg. 8 Loading Material pg. 9 Interfacing pg. 10 Programming pg. 11 Troubleshooting Electrics pg. 16 Troubleshooting Air Feed pg.
CHART AND DRAWINGS Programming Map pg. 20 Manual Sequence pg. 21 Auto Sequence pg. 22 Rapid Master Layout pg. 23 Rapid Master Panel Layout pg. 24 Operator Keypad pg. 25 Electrical Diagram pg.
Operating Instructions Cut to Length Machine INSTALLATION: The Cut to Length (CTL) 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.
SMALL CUTTER Cutter Data: See specific cutter specifications. Operations: The solenoid valve, which is remote mounted, is attached to the cutter (item #3) by a plastic hose and advances the cutter into the material. Compression springs return the blade to the raised position. The cutter raised position is monitored by a proximity switch mounted on the rear of the cutter. (item 4) Adjustments: The cutter blade may be lowered manually by pushing down on the head of the cutter.
AIR FEED PROGRESSION SET UP The feed guide rollers are adjustable by loosening the machine screws and moving the rollers to the desired position. For best results the stock should be centrally located in the feed. The notches in the guide rails provide for coarse feed adjustment of the stop block. The final feed adjustment for stroke length is made by the screw in the center of the stop block.
LUBRICATION For a general guide for the Rapid Master, the lubricator oil release adjustment should be set to one drop of oil for each 50-80 strokes. (See insert on lubrication of “O” rings.) LUBRICATION OF “O” RINGS The “O” Rings furnished with Rapid-Air feeds are made of a Buna N Compound designed to give long life on service with air, oil and water. This rubber compound features high abrasiion resistance and good dimensional stability if the recommendations listed below are followed.
RECOMMENDED LUBE FOR ASSEMBLY OF RAPID-AIR FEEDS MIXTURE OF LUBRIPLATE AND MOLYKOTE No. 105 Lubriplate Fiske Bros. Refining Co. Newark, NJ - Toledo, OH Molykote Powder (Molybdenum disulfide) Dow Corning Corp. Midland, Michigan To a 2 lb coffee can filled with lubriplate, add 2 tablespoons of moly kote and thoroughly mix. Loctite sealant is used on threaded parts type AV.
ELECTRICAL SET-UP 1. MASTER POWER ON/OFF BUTTON Mushroom push/pull lighted pushubtton. Pull to turn on the power and push to turn off the power. 2. DOOR CLOSED SWITCHES There is one door closed switch on the slide unit. The slide door has to be closed in the automatic mode. 3. POSITION SWITCHES There are two position switches on the air feed, any failure on any of these switches could stop the running of the complete unit. 4. PRE-OPERATION CHECK * Check that the air is connected and turned on.
Once you have programmed the required parameters. Select the manual mode of operation. After you have verified that the feed and cutter are operational, you can experiment with single cycle moves. The procedure is outlined in the programming section of this manual. Now, you can cycle the cutter and watch the feed to verify that the signal from the cutter switch is functional and actuating at the proper time.
INTERFACING EXPLANATION A. TAUT STOCK INPUT This is a normally open contact from a switch or device that monitors the loop of material prior to the air 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.
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 onthe display will be reviewed with special comments to help clarify what is being asked on the screen. The program flow is broken down into sections with the main menu being the home position. Reviewing the flow chart in the back of this manual will help in understanding the sections.
1. When pressing the F4 key the display reverts back to the main menu. 2. All manual keys are now active. Pressing any labeled key will activate a movement. Caution: Make sure there is air to the cutter before cycling or the system will lock up. To unlock, the main power has to be cycled. 3. Pressing the “Feed Button” will cause the feed to move the number of cycles that was entered. 4. Pressing the “Cut Button” will cause the cutter to cycle one time. 5.
Each time the switch changes state, the screen switches to off or on. If the switch is energized, the screen displays on. If the switch is de-energized, the screen displays off. 10. Press the “Count Display Button” and the following screen appears. PART COUNT DISPLAY TOTAL COUNT=XXXXXX BATCH COUNT=XXXXXX F4=EXIT Pressing the F4 “Exit” key and the screen reverts back to the previous screen. Press the F4 exit key until the main menu screen appears.
At this time the operator can choose to run auto total or exit. If exit is chosen then the previous screen is displayed. If run is chosen then the following screen is displayed. ** AUTO TOTAL MODE ** FEED PER CYCLE = XX TOTAL COUNT = XXXXXX F4=STOP CYCLE The unit is now in full automatic. Whenever an input for feed is received, the air feed will feed the cycles programmed and increment the counter by one count.
Once the number has been entered, the previous screen appears. Press F2 run current batch and the following screen appears and cycling begins. AUTO BATCH F4=STOP FEED PER CYCLE = XX BATCH COUNT=XXXXXX TOTAL COUNT=XXXXXX The batch count will decreemnt while the total count increments. Once the batch size gets to zero, the auto cycle stops. Pressing F4 at any time stops the cycle and the following screen appears.
TROUBLESHOOTING ELECTRICS PROBLEM POSSIBLE CAUSE The attempt is made to start * No power at source the machine by pulling the mushroom start button but no lights illuminate. * The machine is not plugged into the source power. REMEDY *Check building recept. for voltage. *Plug cord into 120 volt-1Ph recept. *Fuse blown on the control. *Look for burn spots to see what caused the blown fuse - replace fuse. The attempt is made to cycle the feed but the slide will not move.
PROBLEM PROBABLE CAUSES REMEDY The attempt is made to *Loose wiring or defective cycle the Cutter, but it won’t solenoid valve. move. *Check wiring. The unit drops out of *Door closed switch is automatic at random times. improperly adjusted. *Readjust swtich. *Loose wiring. *Check for loose wires or screws. The total count counter will not increment. *Check that auto total or auto batch has been selected. Select auto total or auto batch. The total batch counter will not increment.
Characteristics and Possible Causes of Troubles with Rapid-Air Feeds PROBLEM POSSIBLE CAUSES REMEDY Feed and stock clamps work, but slide block does not move when actuating valve is depressed. *Pilot operated valve is stuck *Check for grit, swollen nylon or swollen “O” rings Excessive leakage of air from exhuast hole beneath speed adjusting screw when acutating valve is in up position. * Poppet not seating on bottom of *Check for grit or chips valve hole.
PROBLEM PROBABLE CAUSES REMEDY Feed has difficulty pushing last part of progression. *Feed is not inline with die. *A slight angular adjustment of the feed will reduce the binding of the stock on the die guides. Over feeding *Stock excessively dirty or oily. *Clean unit and stock. Run and retest. *Turn speed adjusting screw clockwise to slow down *Although nuts are self locking, they can in time work themselves loose; retighten the nuts *Feed is operating too fast.
