CABINET REEL OPERATING INSTRUCTIONS (Rev. 1) RAPID-AIR CORPORATION 4601 KISHWAUKEE ST. • ROCKFORD, IL 61109-2925 Phone: (815) 397-2578 • Fax: (815) 398-3887 • Web Site: www.rapidair.
OPERATING INSTRUCTIONS CABINET REEL (Revision 1—2/94) INSTALLATION 1. The machine that you have just received is fully assembled and ready to be put into position. Due to shipment vibration the machine should be checked to be sure all screws and bolts are tight and that all electrical components are in place inside cabinet. Visually inspect the machine for damaged parts due to shipment. If the machine was damaged in shipment, contact the carrier first to report the damage, and then Rapid-Air. 2.
The main control unit is located behind the side access cover. Fig. Man 28 is an illustration of the layout of the control panel. This diagram lists all the components and the approximate location of each that could be used for troubleshooting the machine if a problem should occur. The reel is shipped with—120 VAC (1 phase) input. Visually check all electrics before starting the reel.
Mechanical Operating Procedure To Load or Unload a Coil Ring A) If your reel has a fixed center shaft go to Step - 1 B) If your reel has an adjustable center shaft go to Step - 2 Step 1: Release and remove the outer coil retainer from the shaft. Load or unload the coil ring. Replace and secure the outer coil retainer. The reel is now ready for production. Step 2: Release and remove the outer coil retainer from the shaft. If unloading, adjust the centering arms to a position that they have released the coil.
DANCER ARM LOOP HEIGHT ADJUSTMENT Three different loop sensing arm operating positions are selected manually during set-up. By selecting the higher number, the zero point of the dancer arm is raised from it’s rest position to the angle shown (as indicated 0-2). The dancer arm will move from rest position to the angle selected before the pallet reel begins to rotate.
START UP PROCEDURE Prior to applying power to the machine the operator should review all the controls on the machine. A brief summary of the controls is listed below. MAIN CONSOLE & CONTROLLER The main control console & controls are mounted on the end of the cabinet. Located on the face of the console are eight switches, one potentiometer, pushbutton and 2 reset switches, which are explained below. 1.
9. LOOP ARM/EXTERNAL SWITCH This switch selects either dancer arm (internal) or “D” connector (external) speed control functions. 10. RESET BUTTONS A. 15 amp - This is the main circuit breaker for the reel. B. 3 amp - This is the circuit protection for the “D” connector. Any shorts or over loads would trip this breaker. 11. REMOTE INTERFACE PORT “D” CONNECTOR This connector is used to communicate with external loop control equipment.
REEL SPECIFICATIONS AND MAINTAINCE CAPACITY SERIES COIL CAPACITY STANDARD STOCK WIDTH MAX COIL O.D. 20 75 LBS 4” 18” 24” 30” 30 150 LBS 4” 24” 30” 36” 40 250 LBS 6” 30” 36” 50 500 LBS 6” 36” 48” ELECTRIC MOTORS R20 to R30 are furnished with 1/4 hp, 2500 rpm permanent magnet d.c. motors. R45 to R58 are furnished with 1/2 hp, 2500 rpm permanent magnet d.c. motors. All motors are 90 V.D.C. unless otherwise specified. All brushes on the motors should be checked every 1500 to 2000 hours.
TROUBLE SHOOTING GUIDE MAIN SWITCH ON BUT NOT LIT 1. CB tripped a. Reset CB 2. Unit not plugged into main power. a. Plug into main power source. 3. No power in incoming line. a. Check outlet. b. Check power cord. 4. Loose wiring a. Check terminals and connections. MOTOR CREEPS IN STOP POSITION 1. R1 & R3 pot on 69100034 board not correctly adjusted. a. Readjust pots so table stops. Call factory. UNIT TURNS BUT WON’T JOG 1. Selector switch not in jog position. a. Select jog. 2.
5. Percent speed pot set too low. a. Adjust percent speed pot to 100%. 6. Fuses blown. a. Check fuses & circuit breaker. 7. No AC voltage at DC drive board. a. Check wiring. 8. Check Signal voltage between P2 to I2 on DC drive. 0-6 VDC—Ramm 0-9 VDC—Regen Drive while moving dancer arm. a. If there is a signal, check continuity between I1 & I2. If no continuity, replace D.C. drive or call factory. 9. Check line voltage input of 69100034 board, 120 VAC, TB-1 a. Check wiring. Call factory. 10.
RAPID-AIR CORPORATION RAMM SOLID STATE DC MOTOR SPEED CONTROL SAFETY WARNING—PLEASE READ CAREFULLY This product should be installed and serviced by a qualified technician, electrician or electrical maintenance personnel familiar with its operation and the hazards involved.
PLUG IN HORSEPOWER RESISTOR A Plug-In Horsepower Resistor must be installed to match the RAMM to the motor horsepower and voltage. See table 2 for the correct value. Plug-In Horsepower Resistors are stocked by your distributor. TABLE 2. PLUG IN HORSEPOWER RESISTOR CHART* MOTOR HORSEPOWER RANGE ** Armature Voltage 90-130 VDC Armature Voltage 180 VDC Plug-in Horsepower Resistor Resistance Rapid-Air Value (ohms) P/N 1/4 1/2 3/4 1*** 1/2 1 1-1/2 2*** .05 .025 .015 .
INTRODUCTION The RAMM Full Wave Solid State DC Motor Speed Control represents the latest state of the art design achievable through modern technology. Features Include: Integrated Circuitry Used to control and amplify command and reference levels with both closed and open loop feedback to provide superior motor regulation. (Speed changes due to load, line voltage, or temperature variations are held to minimum levels). High Quality Components Selected and tested for proven dependability.
Fig. 1. Basic RAMM Connection Diagram CAUTION: Do not bundle potentiometer connections (P1, P2, P3) and inhibit connections (I1, I2) with AC line or motor wires. B. VOLTAGE FOLLOWING. All models can be controlled with an isolated analog reference voltage (0-6VDC) in lieu of the main speed potentiometer. The voltage is connected to P2 (+) and F-. The control output voltage will linearly follow the input voltage. The source impedance of the input should be 10K ohms or less.
1. AC Line Fuse is chosen according to the maximum rating of the control: 12 AMP fuse for all motors up to 3/4 HP-90V and 1 1/2 HP-180VDC. 25 AMP fuse for all motors 1 and 1 1/2 HP-90v and 2 and 3 HP-180VDC. (Use Buss ABC, Littlefuse 326 ceramic fuse or equivalent.) 2. Armature Fuse can be chosen in accordance with the fuse chart. Note: The armature fuse is calculated based on the approximate full load DC current rating of the motor times a from factor of 1.5.
NOTE: In order for the IR comp and CL trimpot settings to be correct, the proper Plug-in Horsepower Resistor must be installed for the particular motor and input volt age being used. Do not attempt to change the settings of the trimpots unless absolutely necessary since they are factory adjusted to near optimum settings. The following procedure, presented in order of adjustment sequence, should be used when readjusting all trimpot functions. Fig 2. ACCEL/DECEL TRIMPOT ADJUSTMENT A. Acceleration Start.
To set the CL to factory specifications adjust as follows: 1. Set speed control knob at approximately 30-50% CW rotation. Set CL trimpot to full CCW position. 2. Connect a DC ammeter is series with the armature lead. 3. Lock shaft of motor (be sure CL pot is in full CCW position). Apply power and rotate CL pot CW slowly until DC ammeter reads 1.5 times motor rating (do not exceed 2 times motor rating, Max. CW position.
LIMITED WARRANTY—RAMM 125, 225, 225D For a period of one (1) year from date of original purchase Rapid-Air Corporation will repair or replace without charge devices which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused or improperly installed and has been used in accordance with the instructions and/or ratings supplied.
