PALLET MASTER (PMD) HIGH SPEED OPERATING INSTRUCTIONS MODELS 35, 50 & 100 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 Corporation Operating Instructions Pallet Master - PMD 25, 35, 50 & 100 High Speed POWER The system is designed to operate on 120 VAC 50/60 HZ power. The unit is provided with a power cord that distributes the power to a terminal strip located under the pallet reel dial plate. The power is then distributed to the proper control panel. The distributed power is circuit breaker protected and is intended as a power source for the Pallet Reel and any additional Rapid-Air accessory.
Pre-Operation Check Before placing any material on the turntable ensure that all functions are in the correct mode for machine operation. i.e. 1. Switch “OFF” 2. Run/Stop/Jog “stop” position. 3. Control arm arranged with counter weight toward the turntable at its max. extension. 4. Lock the control head. 5. Rotation directions switch to agree with the decoiling direction of the material on the pallet that is ready to be loaded onto the PMD. 6. Loop range at maximum 3”. 7. Loop height—0. 8.
Operation 12. Place the coiled stock on the turntable. Center the material on the turntable within 1/2 inch from center. 13. Rotate the table slowly by pushing the control arm toward the turntable. Unwind the first coil until the material can be threaded around the roller and back toward the press. The control arm and turntable will, now, operate automatically. 14. Slowly walk the material to the press.
Electronic loop height adjustment Eight different loop sensing arm operating positions are selected manually during set-up. In operation, the desired position is monitored and maintained electronically. Each separate position will move the operating angle of the arm so that top-to-bottom travel is located to accommodate specific material and loop height requirements.
Instruction for wiring Pallet Master Decoiler after shipping 1. See drawing (fig RA-1) 2. Feed wires from base through hole in control arm. 3. Bolt control assembly to base with (4) 1/2-13 x 3/4 screws provided. 4. Take off control sub-panel access cover by removing (14) screws. 5. See drawing (fig RA-4) for 230 V system See drawing (fig RA-5) for 110 V system 6. Connect wiring shown on drawing (fig RA-4) or (fig RA-5) which ever applies. 7. Replace cover. 8.
The TAUT STOCK feature is built into the Rapid-Air board #69100035 and wired to external terminals 10-11-12. The terminal #12 is common and from terminal 11 to 12 is a normally open contact with power on the unit. Terminal 10 to 12 is a normally closed contact with power on the unit. These contacts are from “relay 2” chip. See diagram. This relay has to be in place for taut stock to work. There is also a 4 prong post labeled “JUMP” that has to be connected so that relay 2 can be activated.
Rapid-Air Corp. Minarik Adjustable Speed Control models RG100UC and RG200UC Specifications Input voltage RG100UC 115 vac, 50/60 hertz, single phase RG200UC 230 vac, 50/60 hertz, single phase Maximum input current 15.0 amperes Output armature voltage RG100UC 0-90 vdc RG200UC 0-180 vdc Output armature current 10.0 amperes Output Field Voltage RG100UC 100 vdc RG200UC 200 vdc Output field current 1.0 ampere Weight 3.
Safety Warning - Please Read Carefully Improper installation practices can cause equipment malfunction or serious physical injury. This equipment must be installed, adjusted, and serviced by qualified electrical maintenance personnel familiar with the construction and operation of the equipment and the hazards involved. It is the responsibility of the individual installing the control to take diligent care during installation.
Line Starting and Line Stopping Connect a jumper between terminals 9 and 12. When AC line power is removed, the motor will coast to a stop. When power is re-applied, the motor will accelerate to the set speed at a rate determined by the Accel Adjustment trim pot setting. Unidirectional Operation For unidirectional operation, disconnect the reverse end of the speed pot from terminal 6 and connect it to terminal 3.
Regen Run-Brake Switch The Regen Run-Brake switch is optional. When the switch is in the open position, the motor will run. When the switch is closed, the motor will be regeneratively braked to a stop. NOTE: The Run/Brake switch acts as an inhibit function and will not unlatch the Start/Stop pushbutton circuit. Tachogenerator Feedback Tachogenerator feedback is optional. Without tachogenerator feedback, load regulation is approximately 8% of base speed with a speed range of 10 to 1.
OPERATION Before operating the control, carefully check that all connections are correct. Check that there are no wire chips or other foreign material on the printed circuit boards. Make sure that the input voltage is the same as listed on the control nameplate. FIRST TIME STARTUP 1. Set the direction select Speed Adjust Pot to approximately its center position. If this pot is wired for unidirectional operation, set the pot to full CCW. Apply AC power to the unit. 2.
IMPORTANT: A non-metallic screwdriver must be used when setting the trimpots to avoid any possibility of the screwdriver’s blade contacting live circuitry and shorting the circuitry or allowing contact with any dangerous or fatal voltages. Eight trim pots, located on the PC board, are provided for tuning the control to obtain optimum performance. Two unlabeled trimpots have been added to the logic board. They are used only in the factory calibration procedure.
Troubleshooting The printed circuit boards in these controls are built utilizing the surface mount technology and are not considered to be field repairable. However, few problems originate from the printed circuit board. By following the procedures listed below, a trained service technician can troubleshoot and solve most problems. Basic Considerations Before proceeding check the following: 1) AC input power must be the same voltage as shown on the control nameplate.
b) If line fuse does not blow but motor will not run: 1) Direction select speed adjust pot or unidirectional speed adjust pot may be defective. 2) Control switches may be defective IV. Motor will not reach desired speed. a) MAX SPEED trim pot may be set incorrectly. b) FWD TORQUE OR REV TORQUE trim pot may be set too low. c) If in tachogenerator mode, R! may be incorrect value. V. Motor surges or pulsates. a) IR COMP trim pot may be set too high. Tachogenerator Feedback Mode I.
LIMITED WARRANTY - RG100UC/RG200UC 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 prove 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.
