SERVO FEED WITH PILOT RELEASE OPERATING INSTRUCTIONS MODELS KBX SERIES RAPID-AIR CORPORATION 4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925 Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.
RAPID-AIR START UP SECTION (100-200-300 S SERIES) Congratulations on purchasing a Rapid-Air Servo. Not only did you receive a complete servo unit but also telephone support by one of our engineering staff to guide you on using the new servo to it’s maximum capability. In order to maximize your learning time and trouble shoot 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.
TABLE OF CONTENTS KBX with Pilot Release CHARTS AND DRAWINGS DIRECTORY pg. 3 INTRODUCTION pg. 4 INSTALLATION AND MECHANICAL SETUP pg. 5 INSTALLATION OF MOUNTING BRACKET pg. 6 ELECTRICAL CABLES AND AIR LINE pg. 7 INTERFACING FEED WITH PRESS pg. 8 STRAIGHTENER OPERATION pg. 9-10 PRETEST WRITE UP pg. 12 SERVO INTERFACING EXPLANATION pg. 13-14 RESET JOB PARAMETERS pg. 15 PROGRAM NUMBER DISPLAY pg. 15 PROGRAMMING EXAMPLE pg. 16 FEED ARC EXPLANATION pg. 17 PROGRAMMING PROCEDURE pg.
CHARTS AND DRAWINGS 104KBX W/ ROLL RELEASE 108KBX W/ ROLL RELEASE MOUNTING BRACKET KBX STRAIGHTENER LAYOUT ELECTRICAL PANEL LAYOUT OPERATORS TERMINAL LAYOUT PRESS-FEED AND PILOT SWITCH SETTINGS INTERFACE SCHEMATICS - 953 SERVO PARTS BREAKDOWN WIRING DIAGRAM 3
INTRODUCTION The Rapid-Air servo feed 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 coupled with a straightener is an unchallanged combination in the press industry.
INSTALLATION AND MECHANICAL SETUP OF SERVO FEED The shipping container should contain: 1 Mechanical Servo Feed/Straightener -Standard 1 Console Complete -Standard 1 Cascade Assembly -Optional 1 Servo Mounting Bracket -Optional 1 Guide Support Assy. -Included If a mounting bracket was purchased then it should be installed at this time. There are mounting bracket prints in the back of the manual for hole location dimensions and a bracket mounting instruction section can be found later in this section.
INSTALLATION AND MECHANICAL SETUP OF MOUNTING BRACKET The cast mounting bracket is available for mounting the KBX feed directly to the bolster plate of the press. Mounting holes are located on the top and front for securing the bracket firmly. It is very important that the servo bracket and the KBX feed be secured and not allowed to float or vibrate.
ELECTRICAL CABLES AND AIR LINE 230 VAC INPUT The required input voltage to the control is 230 Vac, 3 Ph, 60 Hz. The amperage needed is 10 amps for 953 control. 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.
INTERFACING SERVO FEED WITH A PRESS The KBX unit is a slave to the press therefore it needs a command from the press to operate in the automatic mode. The command is in the form of a normally open contact from a limit switch, cam switch or an electronic feed interface device that can be programmed. The contact should be commanded or activated at 270 degrees of the press stroke or when the tooling is clear of the material and released and turned off at a maximum of 350 degrees of the press stroke.
KBX Servo Straightener OPERATION For set up only, place a short length of stock about four feet on bottom rolls, between the pinch rolls. Set the entrance guide rolls before lowering the cover. Make sure the top rolls are retracted to prevent stock deformation. Apply light pinch roll force on the stock to insure adequate assisting pulling force on the stock and to prevent slippage of the stock over the straightener rolls. Never overload the pinch rolls.
Straightener Section The whole concept of the KBX with pilots is that the servo can feed and straighten at the same time while shortening up the whole stamping process line. Should the pilot or roll release be required, the servo and straightener rolls will release for the duration in degrees set on the pilot release switch input. The straightener, although it had been designed for quite some time, had to then be redesigned to operate with the servo as one unit.
PRETEST FOR KBX FEED AND PRESS WITHOUT MATERIAL Now that your KBX feed unit has been mounted 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 preforms an initial sequence to check it’s internal program.
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. Open the rolls manually by lifting the lever mounted on the side of the servo feed then open the straightener cover. Position the leading edge of the material with the center of the material near the center of the entry rolls.
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 and also drops the automatic output.
F. STANDARD PROGRAM- DATA INSTRUMENTS INTERFACE (J52)TB1-7) With the jumper in place, the standard program is active. This means that a job number can be programmed from the keypad. Remove jumper, recycle power and the Data Instruments or Link program is active. Only the manual mode will work with the keys at this time as the job programming is preformed on the Data or Link systems and sent to the Rapid Air control and displayed on job number 99. G.
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.
SERVO To help you to enter a job from the keypad, let’s create an example. We will use a feed length of three inches and want to run at 100 strokes per minute. We have a pilot pin on the die, so pilots will have to be used. The max feed arc will be 180 degrees. 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.
FEED ARC To explain how the “feed arc” is related to the servo feed calculation, we must first explain what the feed arc is in relation to a press. The press has a die that has two halves. The lower half is stationary and the top half is moveable in an up and down motion which is one cycle from the full open to the full closed to the full open again. The component that makes all of this happen is named “crankshaft”.
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 on the display will be reviewed with special comments to help clarify what is being asked on the screen. The progarm flow is broken down into 5 sections with themain menu being the home postion. Reviewing the flow chart in the back of this manual will help in understanding the sections.
The job number screen displays (3) choices for the operator. In the first choice, F1=Program parameters, the operator can enter or change the feed length, strokes per minute that the press is running and speed of the material movement.
In order to advance material into the die, using the servo feed, the operator has to be in the manual mode. Pressing F2 on the keypad will cause the screen to change to the manual mode screen. MANUAL MODE F1=INCH F2=SINGLE FEED MODE F4=EXIT MANUAL MODE CYCLE ROLL WITH KEYS F1=INCH MODE Pressing the F1 key will allow the operator to change the current “jog to length” to “continuous”. Pressing and holding the F2 and F3 button will command the servo to move the material one programmed feed length.
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. SINGLE FEED MODE FEED LENGTH=XXX.XXX F1=FEED SINGLE LNGTH F4=EXIT (MANUAL MODE) 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.
If the feed has been properly set up and tested in manual and the press has been electrically interlocked with the feed, feed switch is wired to the correct terminals, then pressing the F3 key will display the following screen. 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.
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. MAIN MENU F1=JOB # F2=MANUAL F3=AUTOMATIC CYCLE F4=REVIEW PARAMETERS The last section to be covered is the ramp/counters section.
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. With the main menu screen displayed the key labeled “ramp” is active. Pressing the ramp key produces this display.
DRIVE ROLL PARALLELISM ADJUSTMENT Every KBX 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 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.
TROUBLESHOOTING CHART PROBLEM CAUSE REMEDY No power indication Disconnect off Blown fuse Master button in Turn disconnect on Check/replace fuse Pull button out No display on operators console Program fault Faulty wiring Check lights on P.C.
TROUBLESHOOTING CHART (cont.
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.
FAULT CODE (Predefined Variable, Integer, Status Variable, Read-Only) 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.
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 on the 100 & 200 servos and five 5/16-18 socket head capscrews on the 300B. 3.
REASSEMBLY 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 two points are: 1. 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 approximately half way from the inlet to the exit roller.
PRECAUTIONS & SAFETY 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 32
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. The Company obligation under this warranty is limited to repairing or replacing, F.O.B.
34
