Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Rapid-Air Manuals
  4. Cutter
  5. PLAN 100 Series
  6. Operating instructions manual

Rapid-Air PLAN 100 Series Operating Instructions Manual

Cut-to-length with multi-stroke
Hide thumbs

Advertisement

Quick Links

Download this manual
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.com

Advertisement

loading
Need help?

Need help?

Do you have a question about the PLAN 100 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Rapid-Air PLAN 100 Series

  • Page 1 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.com...
  • Page 2 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.
  • Page 3 Cut to Length with Multi Stroke Program The job, sequence and repeats are software programmable. TABLE OF 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.

  • Page 4: Table Of Contents

    Cut to Length with Multi Stroke Program SERVO INTERFACING EXPLANATION pg. 11 PROGRAMMING 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]...
  • Page 7 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.
  • Page 10 Air then it is required to connect and wire the 460 volt line to the enclosure. If you did not purchase a transformer from Rapid-Air then a 3 KVA, 460/230 VAC 3PH, 60HZ step down transformer is needed before proceeding with the electrical portion of the installation.
  • Page 11 If the feed/cutter 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.
  • Page 12 The Pacific Scientific drive performs an initiate sequence to check it’s internal program. 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, it not, please refer to the “Programming...
  • Page 13 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.

  • Page 14: Servo Interfacing Explanation

    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.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 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.
  • Page 19 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...
  • Page 20 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.
  • Page 21 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.

  • Page 22: Drive Roll Parallelism Adj

    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 10- 32 socket head cap screw.
  • Page 23 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.
  • Page 24 Cut to Length with Multi Stroke Program TROUBLESHOOTING CHART PROBLEM CAUSE REMEDY No power indication Disconnect off Turn disconnect on Blown fuse Check/replace fuse Master button in Pull button No display on Program fault Check lights on P.C. operators console Faulty wiring Check plug console...
  • Page 25 Cut to Length with Multi Stroke Program No roll action No air Check air line Low air pressure Check air regulator Material will not Anti-backup closed Open rolls enter rolls Feed roll adjusting Open adjustment mechanism too close mechanism Material too thick Check servo parameters Material will not feed...

  • Page 26: Troubleshooting

    Cut to Length with Multi Stroke Program Low roller force Raise roller pressure Oily material Clean material Obstruction in cutter Check cutter Material feeds long High % max speed Lower % max feed speed Material slippery Lower Decell speed Decell set too fast Lower Decell speed.
  • Page 27 Cut to Length with Multi Stroke Program Material feeds off Edge guides not set Set edge guides center properly Material not centered Center material in feed No automatic cycle No cutter returned signal Check limit switch input to servo control Controller fault Check lights on P.C.
  • Page 28 Cut to Length with Multi Stroke Program Fault signal on Pac-Sci Servo fault Recycle power 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 mechanical actuating...
  • Page 29 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.
  • Page 30 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.
  • Page 31 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.
  • Page 32 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.< means actively inhibiting CCW motion STATUS LED VALUE FAULT MEANING...
  • Page 33 Cut to Length with Multi Stroke Program (Blinking) A Bus OV detected by DSP (Blinking) b Auxiliary +5V Low (Blinking) C Not assigned (Blinking) D Not assigned (Solid) E* Processor throughput fault (Blinking) E* Power Up Self Test Failure (Alternating) E1 Bus UV, Bus Voltage VBUSTHRESH (Alternating) E2 Ambient Temp Too Low...
  • Page 34 Cut to Length with Multi Stroke Program (Alternating) E5* Control Card hardware not compatible with drive software version (Alternating) E6 Drive transition from unconfigured to configured while enabled (Alternating) E7 Two AInNull events too close together (Alternating) F1 Excessive Position Following Error (Alternating) F3 Parameter Checksum Error (Memory Error) *FaultReset cannot reset these faults.
  • Page 35 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.

  • Page 36: Precautions And Safety

    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. 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...

  • Page 37: Warranty

    CUSTOMER LICENSE AGREEMENT The RAPID-AIR CORPORATION reserves the rights in it’s software. The software program is licensed by RAPID-AIR to the original purchaser of the equipment which contains the software for use only on the terms set forth in this license.
  • Page 38 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.
  • Page 39 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...
  • Page 40 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...
  • Page 41 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.
  • Page 42 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...
  • Page 43 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.
  • Page 44 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.
  • Page 45 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.
  • Page 46 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.
  • Page 47 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...
  • Page 48 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.
  • Page 49 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.
  • Page 50 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...
  • Page 51 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.
  • Page 52 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.
  • Page 53 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.
  • Page 54 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.
  • Page 55 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.
  • Page 56 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. ENTER ACCEL RAMP % JOB NUMB=00 ENTER IN MAX%=75000 RPM/SEC PERCENT MAX VEL=000%...
  • Page 57 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.
  • Page 58 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_.htm (57 of 66) [12/10/2001 3:44:58 PM]...

This manual is also suitable for:

Plan 200 seriesPlan 300 series