CUT-TO-LENGTH WITH MULTI-STROKE OPERATING INSTRUCTIONS RAPID-AIR CORPORATION 4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925 Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.
Cut to Length with Multi Stroke Program Cut to Length with Multi Stroke Program The standard multi-stroke program is a multiple feed length program within a specified job number. The different programmed feed lengths will be referred to as sequences. Each sequence can be repeated many times with 0 being entered for no repeats. Although this is the standard program, Rapid Air can program other configurations in any combination to meet the customer’s requirements.
Cut to Length with Multi Stroke Program The job, sequence and repeats are software programmable. TABLE OF CONTENTS CHARTS AND DRAWINGS DIRECTORY INTRODUCTION INTERFACING FEED WITH CUTTER pg. 4 pg. 5 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_.
Cut to Length with Multi Stroke Program SERVO INTERFACING EXPLANATION pg. 11 PROGRAMMING PROCEDURE pg. 15 DRIVE ROLL PARALLELISM ADJ. TROUBLESHOOTING OPERATIONAL MAINTENANCE PROCEDURES PRECAUTIONS AND SAFETY WARRANTY pg. 23 pg. 24 pg. 26 pg. 30 pg. 31 LISTING OF CHARTS AND DRAWINGS file:///C|/Web_develop/cut_to_length_with_multi_stroke_.
Cut to Length with Multi Stroke Program time, are all that is required for a new setup. Routine jobs can be stored, recalled, changed, saved or run with a simple 2 digit job number entry. Up to 10 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 can program feed lengths, up to 999.
Cut to Length with Multi Stroke Program drive will give the number of the control also 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. If you purchased the transformer from RapidAir then it is required to connect and wire the 460 volt line to the enclosure.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program Once the 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 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 initiate sequence to check it’s internal program.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program the feed rolls and anti-backup rolls to accept the material. 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 near the center of the entry rolls and adjust the edge guides on the cascade rolls to the proper width setting. Open the feed rolls and anti-backup rolls.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program C. 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 before this unit can function then a normally open contact can be interfaced to this input.
Cut to Length with Multi Stroke Program F. AUTOMATIC OUTPUT (J52)TB2-11) 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. G.
Cut to Length with Multi Stroke Program 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. RESET JOB PARAMETERS The reset job parameters routing should be used with special caution. We incorporated it as a user function for two reasons.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program We will use a feed length of three inches and want to run at a reasonable cycles per minute. 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 shows two choices: a) Program parameters - This should be used when programming or changing job parameters. The three inputs are feed length spm and cut time.
Cut to Length with Multi Stroke Program being used for forward and F3 for reverse movement. Press F4 to leave the “inch” mode. b) Press F2 and the cutter will cycle for the max amount of time entered. Press F3 and the roll will move the material the feed length entered and then cut the material when the move is finished. 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.
Cut to Length with Multi Stroke Program 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 1032 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.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program TROUBLESHOOTING CHART PROBLEM CAUSE No power indication disconnect on Disconnect off REMEDY Turn Blown fuse Check/replace fuse Master button in Pull button out No display on operators console on Program fault Check lights on P.C. Faulty wiring Check plug console Power on-no motion Program fault Drive fault Check lights on P.C Check lights on drive Program error parameters file:///C|/Web_develop/cut_to_length_with_multi_stroke_.
Cut to Length with Multi Stroke Program No roll action line No air Check air Low air pressure Check air Material will not Anti-backup closed Open rolls enter rolls adjustment Feed roll adjusting Open regulator mechanism too close mechanism Material too thick Check servo parameters Material will not feed pressure Low roller force Oily material Raise roller Clean material Program fault Obstruction in cutter Check parameters Check cutter Material feeds short speed Accel to fast file:/
Cut to Length with Multi Stroke Program Low roller force Raise roller Oily material Clean Obstruction in cutter Check pressure material cutter Material feeds long feed speed High % max speed Lower % max Material slippery Lower Decell set too fast Lower Decell speed Decell speed. Material camber pressure High roller force Bad stock Lower roller Check stock at input TROUBLESHOOTING CHART (cont.) PROBLEM CAUSE file:///C|/Web_develop/cut_to_length_with_multi_stroke_.
Cut to Length with Multi Stroke Program Material feeds off guides center Edge guides not set Set edge properly Material not centered Center material in feed No automatic cycle switch No cutter returned signal Check limit input to servo control Controller fault Check Servo fault Check Program error Check lights on P.C.
Cut to Length with Multi Stroke Program Fault signal on Pac-Sci power Servo fault Recycle is displayed Material jam Check cutter Power surge/failure Check/recycle power Cannot program unit Program fault Check Pac-Sci & Call factory. Mechanical pilot release Too much overtravel Restrict travel of sticks down actuating arm mechanical Broken spring Remove plate and check springs Needs lube plate and lubricate release bar file:///C|/Web_develop/cut_to_length_with_multi_stroke_.
Cut to Length with Multi Stroke Program 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. 3. Remove the belt tension then remove the motor. 4.
Cut to Length with Multi Stroke Program 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 erronious wear pattern while they are exposed and cleaned before reassembly.
Cut to Length with Multi Stroke Program SERVO FAULT DISPLAY The Pacific Scientific drive has a list of internal faults and displays the number of that fault on it’s 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 trouble shoot if the servo fails to perform when commanded.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program (Blinking) A 10 Bus OV detected by DSP (Blinking) b 11 Auxiliary +5V Low (Blinking) C 12 Not assigned (Blinking) D 13 Not assigned (Solid) E* 14 Processor 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 memo
Cut to Length with Multi Stroke Program (Alternating) E5* with 229 Control Card hardware not compatible drive software version (Alternating) E6 230 Drive transition from unconfigured to configured while enabled (Alternating) E7 231 Two AInNull events too close together (Alternating) F1 241 Excessive Position Following Error (Alternating) F3 243 Parameter Checksum Error (Memory Error) *FaultReset cannot reset these faults.
Cut to Length with Multi Stroke Program 3. The mechanical roll release shaft located at the exit side of the 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.
Cut to Length with Multi Stroke Program Periodically grease with lubriplate or equivalent grease to anti-backup (if purchased) & pinch roll actuating piston nose where it contacts the pressure plate.
Cut to Length with Multi Stroke Program CAUTION - Do not wear loose clothing around the servo feed rolls WARRANTY 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.
Cut to Length with Multi Stroke Program 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. OPERATOR INPUT TERMINAL - PROGRAMMING PROCEDURESTANDARD SOFTWARE The intent of this section is to familiarize the operator with the program flow and what to expect with every keypress.
Cut to Length with Multi Stroke Program 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 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
Cut to Length with Multi Stroke Program ENTER JOB NUMBER=XX PRESS F4 KEY ONCE 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 NEW VALUES F4= DON’T ALTER VALUES THAT ARE PREPROGRAMMED The job number screen displays (2) choices for the operator.
Cut to Length with Multi Stroke Program NUMB OF SEQUENCES=XX PRESS F4 KEY ONCE CORRECT # IS ENTERED By definition a sequence is an event. Within a specific job number there is a maximum of 10 sequences or events. A different sequence could be a new feed length or a different output or both. After choosing the amount of sequences then press the F4 key and the following screeen appears. FEED ADVISOR JOB#=00 FL=000.000 SPM=000 TIME OF CUT = .XXX F4=EXIT FEED ADVISOR Input or change data at cursor.
Cut to Length with Multi Stroke Program FEED PARAMETER OUT OF RANGE. THE LENGTH IS TOO LONG FOR FEED ARC OR SPM F4=REPEAT F4=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_.
Cut to Length with Multi Stroke Program After pressing the F4 key and the parameters are within the operating range, the following screen appears. JOB#=00 SEQUENCE=00 FL=000.000 REPS-0000 PUSH ENTER TO SELECT F4=PROGRAM NEXT STEP This screen will repeat for all the sequences selected. Press enter key to move from FL, repeat, outputs and pilots. Press F4 key when all sequence parameters have been entered. When complete, the main menu will appear.
Cut to Length with Multi Stroke Program F4=EXIT MANUAL MODE CYCLE ROLL WITH KEYS F1=INCH MODE Pressing the F2 key will only let 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_.
Cut to Length with Multi Stroke Program Pressing the F4 key once will restart 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. 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.
Cut to Length with Multi Stroke Program 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#=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.
Cut to Length with Multi Stroke Program 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. START AUTOMATIC FROM F1=SEQUENCE NUMBER 1 F2=PREVIOUS SEQUENCE AND REPEATS POSITION After selecting one of the above choices the following screen appears.
Cut to Length with Multi Stroke Program F2=CONTINUOUS If the F2 key was pressed then the servo will be in the auto total mode and the following 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_.
Cut to Length with Multi Stroke Program F3=AUTOMATIC CYCLE If the F2 key was pressed then the servo will be in the auto total mode and the following screen appears. AUTOMATIC MODE JOB =00 NUMBER OF SEQ=00 TOTAL COUNTER=000000 F4=EXIT (AUTO CYCLE) Pressing the F4 key, stops the automatic cycle and the main menu screen appears.
Cut to Length with Multi Stroke Program 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 F1=BATCH If the F1 key was pressed then the servo will be in the auto batch mode and the following screen appears.
Cut to Length with Multi Stroke Program BATCH COUNTER=000000 F1=RESET BATCH COUNT F4=COINTINUE WITH COUNT If F1 (reset batch count) is pressed then the batch count will be reset to it’s 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 CYCLE MODE JOB =00 NUMBER OF SEQ=00 BATCH COUNTER=000000 F4=EXIT (AUTO CYCLE) Pressing the F4 key, stops the automatic cycle and the main menu screen appears.
Cut to Length with Multi Stroke Program (xxx *example of fault 2 - motor over temperature If this screen is displayed then the control cabinet has to be opened and the Pac-Sci drive has to be checked. 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 parrallelism to the die. If all this seems to be satisfactory and another fault occurs the factory should be consulted.
Cut to Length with Multi Stroke Program JOB NUMB=00 ENTER IN THE SEQ=00 THEN PRESS F4 TO CONTINUE Pressing the F4 key will display the following screen. JOB#=00 SEQUENCE#=00 FL=000.000 REPEAT=00 SPEED=000 ACCEL=000 F4=EXIT TO MAIN 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.
Cut to Length with Multi Stroke Program the sequence would be changed in the job memory for any future running of the job. The repeats, outputs, pilots, speed and accel can also be adjusted at this time. When finished, press the F4 key and the main menu screen will be displayed. The last section to be covered is the ramp/counters section. To get into this mode, press the ramp pushbutton and the following screen appears.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program 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.
Cut to Length with Multi Stroke Program The servo feed gets it’s “go” signal to feed from the cutter returned switch and it in turn, the servo gives the cutter it’s “go” signal in the cut time section of the programming. The cut time is actually how long the cut signal is to be energized or have the cutter valve turned on. The program asks for a two digit job number and then the number of sequences required. This would be the number of different parts to be cut within the job number.
Cut to Length with Multi Stroke Program Example 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_.
