Straightener rapid-roll operating inStructionS by liwenting

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									Straightener / rapid-roll
 operating inStructionS

                             ModeLs
           sa3 - sd with coMpact contRoL
                                 (5-07)




                        Rapid-aiR coRpoRation
           4601 KishwauKee st. • RocKfoRd, iL 61109-2925
 phone: (815) 397-2578 • fax: (815) 398-3887 • web site: www.rapidair.com
                                    
table of contentS
  Straightener Layout Sheet SBX ............................................................................................................... pg. 3
  Straightener Layout Sheet SCX ................................................................................................................ pg. 4
  Platen Adjustment Bulletin ...................................................................................................................... pg. 5
  Specifications ............................................................................................................................................. pg. 6
  Installation ................................................................................................................................................... pg. 7
  Start-Up Procedure .................................................................................................................................... pg. 8
  Electrical Controls Layout ........................................................................................................................ pg. 9-10
  Dancer Arm Adjustment Explanation ..................................................................................................... pg. 11
  Standard and Optional Components ....................................................................................................... pg. 12
  Operations.................................................................................................................................................... pg. 13
  Maintenance ............................................................................................................................................... pg. 13
  Troubleshooting Guide .............................................................................................................................. pg. 14
  Taut Stock Explanation.............................................................................................................................. pg. 15
  RAMM Board Explanation ........................................................................................................................ pg. 16-19
  Warranty....................................................................................................................................................... pg. 20
  Electrical Schematics ............................................................................................................................... pg. 21-23
  Mechanical Parts List SBX ................................................................................................................... pg. 24-27
  Mechanical Parts List SCX .................................................................................................................... pg. 28-33
  Typical Stamping Layout ........................................................................................................................... pg. 34
  Straightener SA3 - SB4 ............................................................................................................................. pg. 35-36
  Rapid Roll .................................................................................................................................................... pg. 37-38




                                                                                      


                                                      If the straightener is made to correct a clockwise        To more easily explain the concept, Figure 8
                                                      curvature, it is often impossible to correct a            shows a three-roll combination with the upper
                                                      counterclockwise curvature. The only available            roll forward and Figure 9 shows a three-roll
                                                      adjustment is the variation of the degree of bend         combination with the upper roll to the rear.
                                                      at each station. This is true even for straighteners      Figure 8                   Figure 9
                                                      that have banked upper rolls that pivot for
                                                      two-point adjustment.

    Adjustable Platen                                 six-way upper roll adjustment: After
                                                      manufacturing straighteners with vertically               Notice that the sharpest bend occurs where two
   Stock Straighteners                                adjustable rolls for many years, Rapid-Air                rolls are in close proximity. When the upper
                                                      developed and patented the adjustable platen
            vs.                                       type straightener as illustrated in Figure 3.
                                                                                                                roll is forward, the curvature will be up and
                                                                                                                when the forward roll is adjusted to the rear,
   Straighteners with                                  Figure 3                                                 the bend will be down. The degree of bend can
                                                                                                                be adjusted by a combination of vertical and
        Traditional                                                                                             horizontal adjustments.
       Vertical Roll                                                                                            adVantages: The high degree of flexibility
       Adjustment                                                         Forward/Back                          afforded by the adjustable platen design provides
                                                                                                                a predictable straightening method for a wide
                                                                                                                variety of materials and takes a lot of the “Black
concept: The concept behind a movable                                                                           Magic” out of pressroom straightener setup.
platen containing the upper bank of rolls for                                                                   The reduction in the flexing and distortion of
straighteners can be somewhat difficult to                                  Up/Down
                                                                                                                the strip of material and the reduction of the
grasp, but once the principles are understood                                                                   straightening power required allows effective-
the superiority of this system becomes obvious.                                                                 ness with heavy materials. Additionally, the ability
To explain the differences between the adjust-                                                                  to place rolls in a proper close proximity allows
able platen system and one that uses traditional                                                                effective straightening with very thin materials.
single-point vertical roll adjustment, we are
                                                                         Up/Down Slant                          roll diameter: The smaller the roll
describing both types of systems here.
                                                      This design mounts the upper rolls in a platen            diameter in a straightener the better it is able to
Vertically adjustable upper rolls:                    which can be adjusted for degree of bend as               remove distortions in the strip of material, but
For centuries the bending of materials has been       illustrated in Figure 4 and Figure 5                      this factor is compromised by the requirement
                                                                                                                of larger rolls in wider models of straighteners
done by variations of a three-roll arrangement as
                                                       Figure 4                               Less deflection   in order to prevent deflection of the rolls
illustrated in Figure 1.                                                                                        themselves. Rapid-Air straighteners are designed
Figure 1                                                                                                        to optimize all factors (including number
                                                                                                                of rolls, diameter and position) within the
                                                                                                                published material capacities and specifications
                                                                             Light material distortion          for each model.
                   Downward curvature of material      Figure 5                           Deeper deflection
                        to remove coil set                                                                      swing-open top: Rapid-Air developed and
Bending occurs when one roll is forced into the                                                                 introduced the swing-open top for straighteners
space between the other two rolls for downward                                                                  in order to facilitate the cleaning of rolls and the
curvature of the material to remove coil set.                                                                   threading of a new strip of material through the
Pressroom straighteners add multiple three-roll
                                                                             Heavy material distortion          straightening rolls. For convenience and safety,
combinations in order to level the material in        and for curvature direction as shown in                   each top is counterbalanced and held in the
small increments at each stage. This method can       Figure 6 and Figure 7.                                    open position until it is clamped for operation.
provide acceptable results for some materials,                                                                  Roll adjustment settings are maintained when the
but is limited because correction of material          Figure 6                                                 top is closed and locked.
curvature is effective in only one direction as
illustrated in Figure 2.                                                                                        aVailability: All models of Rapid-Air straight-
                                                                                                                eners are presently available with the adjustable
 Figure 2                                                                  Rolls forward – curve up             platen design with an expanded range of models
                                                                                                                being introduced in the coming months.
                                                       Figure 7




                    Material curvature is effective
                        in only one direction                                 Rolls back – curve down




                                                                               
  SA                        SB                               SBX                                        SCX                                           SD
  Series                    Series                           Series                                     Series                                        Series




SpecificationS
                Max                Effective                      Max                           Straightening             Pinch                Drive         Input
               Material          Straightening                   Speed                              Rolls                Rolls (2)             Motor        Power
Model           Width                Range                      per min            Speed           No., Dia.               Dia.                (HP)        (vac/ph)

sa3            3” (76mm)     .002” - .030” (.051-.76mm)        700” (1778cm)      Standard     11, 3/8 (9.53mm)        1-1/2 (38.1mm)           1/4            115/1
sa3M           3” (76mm)     .002” - .030” (.051-.76mm)      1,400” (3556cm)      Medium       11, 3/8 (9.53mm)        1-1/2 (38.1mm)           1/2            115/1

sB4           4” (102mm)    .003” - .050” (.076-1.27mm)        700” (1778cm)      Standard     11, 5/8 (15.86mm)       1-1/2 (38.1mm)           1/2            115/1
sB4M          4” (102mm)    .003” - .050” (.076-1.27mm)      1,400” (3556cm)      Medium       11, 5/8 (15.86mm)       1-1/2 (38.1mm)           1/2            115/1

sBX4          4” (102mm)     .004” - .080” (.10-2.03mm)        825” (2100cm)      Standard     9, 7/8 (22.23mm)        1-3/4 (44.45mm)          3/4            115/1
sBX8          8” (203mm)     .004” - .070” (.10-1.78mm)        825” (2100cm)      Standard     9, 7/8 (22.23mm)        1-3/4 (44.45mm)          3/4            115/1
sBX12        12” (305mm)     .004” - .060” (.10-1.52mm)        825” (2100cm)      Standard     9, 7/8 (22.23mm)        1-3/4 (44.45mm)          3/4            115/1

sBX4M         4” (102mm)     .004” - .080” (.10-2.03mm)      1,650” (4200cm)      Medium       9, 7/8 (22.23mm)        1-3/4 (44.45mm)          1              115/1
sBX8M         8” (203mm)     .004” - .070” (.10-1.78mm)      1,650” (4200cm)      Medium       9, 7/8 (22.23mm)        1-3/4 (44.45mm)          1              115/1
sBX12M       12” (305mm)     .004” - .060” (.10-1.52mm)      1,650” (4200cm)      Medium       9, 7/8 (22.23mm)        1-3/4 (44.45mm)          1              115/1

scX6          6” (152mm)     .006” - .100” (.15-2.54mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          1              115/1
scX12        12” (305mm)     .006” - .090” (.15-2.29mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          1              115/1
scX18        18” (457mm)     .006” - .080” (.15-2.03mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          1              115/1
scX24        24” (610mm)     .006” - .065” (.15-1.65mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          1              115/1

scX6M         6” (152mm)     .006” - .100” (.15-2.54mm)      1,650” (4200cm)      Medium       9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
scX12M       12” (305mm)     .006” - .090” (.15-2.29mm)      1,650” (4200cm)      Medium       9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
scX18M       18” (457mm)     .006” - .080” (.15-2.03mm)      1,650” (4200cm)      Medium       9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
scX24M       24” (610mm)     .006” - .065” (.15-1.65mm)      1,650” (4200cm)      Medium       9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1

scX6h         6” (152mm)     .006” - .080” (.15-2.03mm)     4,100” (10400cm)      High         9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          3              230/1
scX12h       12” (305mm)     .006” - .070” (.15-1.78mm)     4,100” (10400cm)      High         9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          3              230/1
scX18h       18” (457mm)     .006” - .060” (.15-1.52mm)     4,100” (10400cm)      High         9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          3              230/1
scX24h       24” (610mm)     .006” - .055” (.15-1.40mm)     4,100” (10400cm)      High         9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          3              230/1

sd6           6” (152mm)     .006” - .125” (.15-3.18mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
sd12         12” (305mm)     .006” - .125” (.15-3.18mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
sd18         18” (457mm)     .006” - .100” (.15-2.54mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1
sd24         24” (610mm)     .006” - .090” (.15-2.29mm)        825” (2100cm)      Standard     9, 1-3/8 (34.93mm)      1-3/4 (44.45mm)          2              230/1

                       A right-to-left material flow direction is standard for above models –– left-to-right optional at no additional cost.

sc4           4” (102mm)     .015” - .085” (.38-2.13mm)        825” (2100cm)      Standard     9, 1-1/4 (31.75mm)      1-1/4 (31.75mm)          1              115/1




           Model SC4 Straightener with individually adjustable upper                           A noTe on RoLL DiAMeTeR AnD qUAnTiTy:
           rolls. This 4” x .085” capacity straightener with its coun-                         The smaller the roll diameter in a straightener the better
           terbalanced swing-open top is a Rapid-air original and                              it is able to remove distortions in the strip of material.
           continues to be available due to customer acceptance and                            Rapid-Air straighteners are designed to optimize all
           demand. Dial-type indicators for roll settings are optional.                        factors (including number of rolls, diameter and position)
                                                                                               within the published material capacities and specifica-
                                                                                               tions for each model.
           Model SC4
                                                                       
inStallation
Operating Instructions For Straighteners / Rapid Roll
Align the Rapid Roll with the feed al-     its center. Adjust parallelism of the      any final adjustment. Tighten the
lowing sufficient space for free stock     rolls by loosening the center screw        trunion lock screw. Raise the pinch
for the feed. The loop control arm         and rotating the trunion through 180       roll to allow clearance for the next
roller rests on the stock between the      degrees. A wide blade screwdriver          setup procedure.
Rapid Roll and the press. The Rapid        and allen wrench may be used. Use a
Roll should be bolted to the floor, es-    feeler gauge to check for equal spac-      The main control unit is located behind
pecially when used to pull stock from      ing on either side of the pinch rolls.     the side access cover. on pages 9 &
a non-powered reel.                                                                   10 is an illustration of the layout of the
                                           Perform a visual check by lifting the      control panel. This diagram lists all
The pinch rolls must be parallel in the    cover and placing a white piece of         the components and the approximate
lateral (horizontal plane to insure that   paper in front of the pinch rolls to re-   location of each that could be used for
there will be equal pinch force along      flect light through the space between.     troubleshooting the machine if a problem
the full width of the stock). An upper     Tighten the pinch roll knob so the rolls   should occur. The reel is shipped with
pinch roll adjustable eccentric trunion    just touch. observe the slit of reflect-   - 120 vac (1 phase) input. Visually check
is slotted with a locking screw in         ed light between the rolls and make        all electrics before starting the reel.




                                                              
Start up procedure
Prior to applying power to the straightener, all the controls on the machine should be reviewed.
A brief summary is listed below.


Main Console And Controller
The main control console with con-        4. JOG BUTTON                              would have a different bend radius
trols is mounted on the cabinet of the    Used for intermittent movement of          thus requiting the dancer arm to
straightener. Located on the face of      the straightener rolls and mainly for      be at a height somewhat above the
the console are five switches, one po-    setup. The jog speed can be adjusted       home position when at rest.
tentiometer, one push-button and one      by rotating the R3 potentiometer on
or two circuit breaker reset switches,    the 69100079 board in the control          7. LOOP ARM / EXTERNAL SWITCH
which are explained below.                sub panel.                                 This switch is used to select whether
                                                                                     the material loop is controlled by the
1. ON/OFF SWITCH                          5. % SPEED POTENTIOMETER                   dancer arm or an external loop con-
This illuminated switch is the main       The % speed potentiometer adjusts          trol. if LooP ARM is selected then the
power switch for the controller.          the maximum speed that the straight-       control will monitor the dancer arm
on the 120 VAC straighteners, it          ener rolls can rotate regardless           movement. if eXTeRnAL is selected
will be a toggle switch and on the        of the dancer arm height. it should be     then the control will monitor whatever
230 VAC version it will be a mushroom     set to maintain a constant material        is plugged into the “D-SUB” (25 pin)
push-button. it must be “on” for the      feed rate through the straightener.        connector.
straightener to function.
                                          6. DANCER ARM LOOP HEIGHT                  8. REMOTE INTERFACE
2. RESET BUTTONS (circuit breaker)           AND RANGE ADJUSTMENT                        PORT “D” CONNECTOR
                                                                                     This 25 pin connector, located on the
120 VAC.                                  a. Loop Range – The loop range             lower portion of the console is used
a. 15 amp – This is the main circuit      switch adjusts the amount of               to communicate with external loop
breaker for the straightener.             travel that the dancer arm will            equipment. The RSB, RTB, & RTA will
b. 3 amp – This is the main circuit       move to provide the full range of          plug into the port and can immediately
breaker for the “D-SUB” (25 pin)          speed on the straightener. it has          be implemented.
connector. Any shorting or overloads      three positions with a “0” as the
would trip this breaker.                  least travel from slowest to               CAUTION: never plug any type of
                                          fastest speed and a “2” has the            computer or non Rapid-Air equipment
240 VAC.                                  most movement between slowest              into this plug or severe damage could
a. 3 amp – This is the main circuit       to fastest speed.                          result. Always consult the factory
breaker for the “D-SUB” connector.                                                   when installing different external
Any shorting or overloads would trip      b. Loop Height – The loop height           controls for advice on compatibility
this breaker.                             switch is used for setting the             and wiring information.
                                          start position of the control arm.
3. RUN/STOP/JOG                           it has three positions with the “0”        9. PANEL MOUNTED ELECTRICAL
     SELECTOR SWITCH                      setting having the start position at          COMPONENT DESCRIPTION
a. if “RUn” was selected and the          the dancer arm rest position and           69100034 board – proportional control
dancer control arm was raised, the        the “2” having the start position          board
straightener rolls would rotate. if       somewhat higher than the dancer            69100076 board – component inter-
“SToP” was selected then none of          arm rest position. This setting will       face board
the functions would work. if “JoG”        determine the dancer arm angle             69100014 board – (RAMM) D.C. motor
was selected then the jog button has      that the reel will start turning. This     control board [120 VAC, 1 PH]
to be depressed to have the straight-     function is used to accommodate            69100038 board – (RAMM) D.C. motor
ener rolls rotate.                        different thickness of material which      control board [240 VAC, 1 PH]




                                                             

0
dancer arm loop
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 its rest position to
the angle shown (as indicated
0-2). The dancer arm will move
from rest position to the angle
selected before the straightener
rolls begin to rotate.




Dancer Arm Loop Range Function

                              30 degree — Loop sensing arm travels through a full 30 degree arc to vary
        3                     rotation speed from slow to full speed as controlled by % speed pot.




                              20 degree —Loop sensing arm travel through a 20 degree arc to vary
        2                     speed from slow to full speed as controlled by % speed pot.




                              10 degree — Loop sensing arm travels through a 10 degree arc to vary
        1                     rotation speed from slow to full speed as controlled by % speed pot.




                                                              
Standard Straightener componentS
Curve Up/Down Adjustment                                                            Entrance Guide Roll Block
Some applications have dies that cannot accept anything but flat stock and          All straighteners are shipped with an
other dies run better with the material curving up or down to miss the built in     entrance guide roll. This contains a
edge required in the die. Before this feature was added, operators would            roller and two adjustable edge guides.
under straighten or over straighten the material to suit their needs but in doing
so would severely change the material entering the die. This not only caused
feeding problems but part quality problems. With this feature, curve up or down
can be accomplished by changing the position of the rolls without stressing
the material.




optional Straightener componentS
Entrance Cascade Roll                      Exit Cascade Roll                        Angle Bracket
The entrance cascade roll assembly         The straightener is shipped with         Rapid-Air offers this accessory that
is used to maintain a support arc for      the exit side pre-drilled for the        mounts between the straightener
stock entering a feed. The cascade         cascade roll or guide roll block.        head and the base. it angles the
roll has three extra rollers to help the   The entrance and exit use the            exit side of the straightener twelve
material flow better.                      same components.                         degrees lower than the entrance
                                                                                    side. This feature works very well
                                                                                    when using the straightener to pull
                                                                                    off a non-powered reel.




                                                             
operation
once the straightener has been              of the material. Adjust the second              Thread the material from the reel
tested and all the functions work,          idler roll knob so it is lightly on the roll.   through the straightener, under the
then it should be tested for what it        Run the material to check that the exit         dancer arm, and into the pulling
was designed to do and that is to           pinch roll is not slipping on the mate-         device leaving ample loop between
remove coil set.                            rial, readjust if necessary. This piece         the straightener and the pulling
                                            will still have coil set in the first two       device. if the material thickness is
Retract all of the idler rolls and the      feet of the material as it was not run          such that when exiting the straight-
exit pinch roll to a position so when       through the complete straightening              ener, it will not let the dancer arm
the cover is closed the material is         cycle. At this time, this piece could be        down to the rest position, then
not being deformed. open the cover          rerun and checked for straightness or           either lengthen the dancer arm
of the straightener and position the        a new piece could be cut and run and            or adjust the loop height until the
edge guides for maximum width. Cut          then be checked.                                straightener stops feeding.
and place about a four foot length of
the material onto the straightener          A good check is to guide the exiting            Set the % speed potentiometer
rolls with the exit end of the mate-        material, keeping it parallel to the rolls,     to 50% for a starting position and
rial extending through the exit pinch       until the run is complete and then hold         start the pulling device to have the
rolls and centered from side to side        one end of the material in the air while        material feeding. if the straightener
in the straightener. Close the cover        peering down the length of the mate-            gets finished and stops before
and latch it. Adjust the exit pinch roll    rial. if the material still has “coil set”      material is needed again then
enough to grip and hold the material.       then readjust roll pressure on the last         the straightener is set to feed too
Adjust the edge guides so that they         roll, towards the exit end but before the       fast, slow it down by adjusting
just touch the material.                    pinch roll, until the material is straight.     the % speed potentiometer. The
                                            Run one or more short length setups             ideal straightening is to have the
Adjust the first idler roll knob, this is   while making final adjustments. once            straightener slightly exceed the
the one nearest the entrance of the         the proper setting has been deter-              feed rate required. This minimizes
straightener, so that it deforms the        mined, the quick release top maintains          the starting and stopping and
material no more than the thickness         the adjustment during loading.                  resultant stock deformation.




maintenance
Lubrication
Gear transmission                           Rolls                                           Drive belt
The reservoir oil capacity is about         Although the rolls should be cleaned            At the oil change interval, check for
4 oz. The reservoir oil should be           periodically they never have to                 belt tension and wear.
changed every 2000 hours and should         be greased as all the rolls have
be filled to the oil level site gauge.      permanently lubricated bearings.
Use MoBiLe 600W cylinder oil or
equivalent. This is a non-synthetic oil.




                                                                 
troubleShooting guide
MAIN SWITCH ON BUT NOT LIT                      a. Turn selector switch to               12. Check for DC voltage between
1. CB tripped.                                     run position.                             pin #6 (Vo) and pin #2 (GnD) of
   a. Reset CB.                           2.    if running with a dancer arm                 panduit connector TC3, on board
2. Unit not plugged into main power.            control.                                     69100034, while moving the dancer
   a. Plug into main power source.              a. Check that the external/loop              arm from minimum to maximum
3. no power in incoming line.                      switch is in the loop arm position.       position.
   a. Check outlet.                       3.    if running with external control.            a. if voltage is present, turn power
   b. Check power cord.                         a. Check that the external/loop                 off and check the ribbon cable
4. Loose wiring.                                   arm switch is in the                         connections between panduit
   a. Check terminals and connections.             external position.                           connector #TC3 of 69100034
                                          4.    Height switch setting too high.                 board and panduit connector
MOTOR CREEPS IN STOP POSITION                   a. Set height setting to “0”.                   #TB-4 of 69100076 board. This
1. R1 & R3 pot on 69100034 board not      5.    Percent speed pot set too low.                  should be a continuity check for
   correctly adjusted.                          a. Adjust percent speed                         tight connections. Call factory
   a. Readjust pots so rollers stop.               pot to 100%.                                 for assistance.
      Call factory.                       6.    Fuses blown.                                 b. if voltage is not present move
                                                a. Check fuses & circuit breaker.               on to step 13.
UNIT TURNS BUT WON’T JOG                  7.    no AC voltage at DC drive board.         13. Check voltage between pin #5 of
1. Selector switch not in jog position.         a. Check wiring.                             TB-6 & pin #3 of TB-5 on 69100076
   a. Select jog.                         8.    Check Signal voltage between                 board while moving the dancer
2. Jog pot on 69100076 board not                P2 to i2 on DC drive.                        arm from minimum to maximum
   adjusted correctly.                          0-6 VDC—Ramm                                 position.
   a. Adjust pot. Call factory                  0-9 VDC—Regen Drive                          a. if voltage varies 2.5-4 volt from
3. Maximum speed pot on Ramm                    while moving dancer arm.                        minimum to maximum position,
   board set too low.                           a. if there is a signal, check                  the dancer arm pot is oK, but
   a. Adjust pot.                                  continuity between i1 & i2.                  the 69100076 board could be
                                                b. if no continuity, replace D.C.               defective. Call factory.
UNIT ON BUT MOTOR WON’T RUN.                       drive or call factory.                    b. if voltage does not vary when
(ARMATURE VOLTAGE PRESENT –               9.    Check line voltage input of                     moving the dancer arm from
ON RAMM BOARD)                                  69100034 board, 120 VAC, TB-1.                  minimum to maximum
1. Check motor wiring and fuse.                 a. Check wiring. Call factory.                  position — call the factory
   a. Replace motor cord and correct      10.   Check pico fuse 69100034                        for assistance.
   motor wiring. Call factory.                  board (f1).
2. Check motor.                                 a. Replace fuse, 1 amp pico
   a. Worn brushes or motor                        fuse — call factory.
      defective. Call factory.            11.   Check for 0-12 VDC between
                                                pin #1 (=V) and pin #2 (GnD)
UNIT ON BUT MOTOR WON’T RUN.                    of panduit connector TC3 on
(NO ARMATURE VOLTAGE ON                         board #69100034.
RAMM BOARD)                                     a. if no voltage present, call
1. Selector switch not in run                      factory.
   position.




                                                                
69100034 taut StocK output
The 69100034—Proportional control        The taut stock height set point is set    drive. A RAMM DC drive needs
board has a taut stock output. The       by raising the dancer arm to a posi-      6 VDC for max motor speed so turn
output must be wired to a solid state    tion that the material is taut and then   the pot fully counter clockwise.
relay as the max current draw is 20      adjusting pot R7 so the output chang-     A minarik drive board needs 10 VDC
MA. The solid state relay’s contact      es state. Lower and raise the dancer      for max motor speed so turn the
can then be incorporated into the        arm a few times to check that the set     pot fully clockwise.
electrical control circuitry.            point repeats and then the set point      The following is a brief wiring diagram
                                         repeats and then the task is finished.    for the taut stock.
The output can be wired so that
the relay is either on or off with the   The potentiometer that is located just    3 GRD
dancer arm down. When the dancer         below the taut stock terminal strip is    2 10 VDC out with dancer arm down
arm reaches the set point for taut       used for presetting the max voltage
stock, the relay switches state.         output requirement for a particular       1 0 VDC out with dancer arm down




                                                           
Safety warning – pleaSe read carefully
RAMM Solid State DC Motor Speed Control
This product should be installed and             this product can reduce the emission                     2. install the correct Plug-in
serviced by a qualified technician,              of radio frequency interference (RFi)                       Horsepower Resistor according
electrician or electrical maintenance            which may adversely affect sensitive                        to armature voltage and motor
personnel familiar with its operation            electronic equipment. if information is                     horsepower.
and the hazards involved. Proper in-             required on this product, contact our
stallation (see instruction information          factory. it is the responsibility of the                 3. Recheck connections: AC line to
which accompanies product), which                ultimate user of this product to read                       L1 and L2; armature to A+ and
                                                 and comply with this safety warning.                        A– and field (Shunt motors only
includes wiring, mounting in proper
                                                 (SW effective 1/89)                                         to F+ and F-.) (Note: if motor runs
enclosure, fusing or other overcurrent
                                                                                                             in improper direction, interchange
protection and grounding, can reduce
                                                 ***IMPORTANT***                                             armature leads.)
the chance of electrical shocks, fires
                                                 YOU MUST READ THESE
or explosion in this product or prod-                                                                     4. install proper AC line fuse and
                                                 INSTRUCTIONS BEFORE
ucts used with this product, such                                                                            armature fuse as required.
                                                 OPERATING CONTROL
as electric motors, switches, coils                                                                       5. nominal trimpot settings are as
solenoids and/or relays. eye protec-             1. Be sure AC line voltage                                  follows (expressed in % of full
tion must be worn when working with                 corresponds to control voltage.                          CW rotation):
control under power. This product is
constructed of materials (plastics,
metals, carbon, silicon, etc.) which             TABLE 1: NOMINAL TRIMPOT SETTINGS
may be a potential hazard. individual                Min (minimum speed):                 15%                CL (current limit/torque):           65%
material safety data sheets (MSDS)                   MAX (maximum speed):                 65%                ACCeL (acceleration start):          20%
are available upon request. Proper                   iR (iR compensation):                25%                DeCeL (deceleration stop):           20%
shielding, grounding and filtering of




Plug-In Horsepower Resistor
A Plug-in Horse-      TABLE 2: PLUG-IN HORSEPOWER RESISTOR CHART*
power Resistor
must be installed       MoToR HoRSePoWeR RAnGe **                                                     Plug-in
to match the                                                                                          Horsepower
RAMM to the             Armature Voltage                    Armature Voltage                          Resistor Resistance             Rapid-Air
motor horse-            90-130 VDC                          180 VDC                                   Value (ohms)                    Part number
power and volt-                                             1/2                                       .05
                        1/4                                                                                                            69100529
age. See table 2                                            1                                         .025
                        1/2                                                                                                            69100530
for the correct                                             1-1/2                                     .015
                        3/4                                                                                                            69100534
value. Plug-in                                              2***                                      .01
                        1***                                                                                                           69100531
Horsepower
Resistors are
                       * Motor horsepower and armature voltage must be specified when ordering so that proper resistor will be supplied.
stocked by your        ** For overlapping motor horsepower range use lower value Plug-in Horsepower Resistor.
distributor.           *** Auxiliary heat sink must be used to achieve HP rating.




                                                                          
introduction
RAMM Full Wave Solid State DC Motor Speed Control
The RAMM Full Wave Solid State DC        3. Follow the recommended supply           CAUTION: SePARATe BRAnCH
Motor Speed Control represents the          wire sizes as per table 3.              PRoTeCTion MUST Be PRoViDeD
latest state of the art design achiev-                                              on 240V CiRCUiTS.
able through modern technology.          4. Follow the neC and other                5. Connect control in accordance
                                            electrical codes that apply.               to connection diagram.
FEATURES INCLUDE:

Integrated Circuitry                     TABLE 3: MINIMUM SUPPLY WIRE SIZE REQUIREMENTS
    Used to control and amplify            Max.               Max.          Max.       Max.           Minimum
    command and reference levels           Motor              Motor         Motor      Motor          Wire Size (AWG)
    with both closed and open loop         Amps               HP            HP         Run            Cu only
    feedback to provide superior           (DC Amps)          90V           180V                      Max. Motor Run
    motor regulation. (Speed changes
    due to load, line voltage, or          6.0                1/2           1           16            14
    temperature variations are held to     12.0               1             2           14            12*
    minimum levels).                       16.0               1-1/2         3           12            12
                                         * Maximum recommended wire size.
High Quality Components
   Selected and tested for proven
   dependability.

Transient Protection
   Used to prevent failure of the
   power bridge circuit caused by
   voltage spikes on the AC line.

High Reliability
   When used in accordance with
   instructions in this manual, the
   RAMM will provide years of
   trouble free operation.               FIGURE 1: BASIC RAMM CONNECTION DIAGRAM

A. INITIAL SETUP AND WIRING              CAUTION: Do noT BUnDLe                     input voltage. The source impedance
                                         PoTenTioMeTeR ConneCTionS                  of the input should be 10K ohms or
General Instructions                     (P1, P2, P3) AnD inHiBiT                   less. The Min trimpot can be used to
1. install proper size Plug-in           ConneCTionS (i1, i2) WiTH                  provide an offset speed. if an offset is
   Horsepower Resistor (see table 2).    AC Line oR MoToR WiReS.                    not required, adjust the Min to 0+ or
                                                                                    0– speed as desired. The Max trimpot
2. The RAMM can be connected             B. VOLTAGE FOLLOWING                       is rendered inoperative in the voltage
   to a standard 120V or 240V                                                       following mode. Use auxiliary trimpot
   50/60 Hz AC line (be sure the         All models can be controlled with an       to limit the control range. if the input
   AC input voltage corresponds          isolated analog reference voltage          signal is not isolated, or is a current
   to the control voltage rating and     (0-6VDC) in lieu of the main speed         signal (4-20 MA), the RASi240D Signal
   the motor rating). (e.g. 90-130 VDC   potentiometer. The voltage is con-         isolator must be used. it will allow
   motor on 120VAC and 180 VDC           nected to P2 (+) and F-. The control       direct connection to process control-
   motor on 240 VAC).                    output voltage will linearly follow the    lers and microprocessors.
                                                             
introduction (cont.)
CAUTION:                                 1. AC Line Fuse is chosen according           2. Armature Fuse can be chosen
1. The voltage feeding P2 and               to the maximum rating of the                  in accordance with the fuse chart.
   F– must be isolated from the AC          control:                                      Note: The armature fuse is
   line. Do not ground P2 or F– to set                                                    calculated based on the
   up a zero ground reference.               – 12 AMP fuse for all motors up              approximate full load DC current
2. Do not bundle signal wires to P2             to 3/4 HP-90V and 1-1/2 HP-               rating of the motor times a form
   and F– with AC line motor                   180VDC.                                    factor of 1.5. if motor has
   connections. if signal wires are          – 25 AMP fuse for all motors 1               characteristics not consistent
   over 18”, use shielded cables.              and 1-1/2 HP-90V and 2 and                 with these approximations, a
                                               3 HP-180VDC.                               different fuse value may have to
C. FUSING                                    (Use Buss ABC, Littlefuse                    be used. Fuses are available from
                                             326 ceramic fuse or equivalent.)             your distributor.
The RAMM has provision for a built
in AC line fuse and armature fuse.
The AC line fuse protects the control
against catastrophic failure– if the
fuse blows, the control is miswired,
the motor is shorted or grounded, or     TABLE 4: ARMATURE FUSE CHART
the RAMM control is defective. The
armature fuse provides overload            Horsepower                   Horsepower   Approx.                 Fuse
protection for the motor and control.      90 VDC                       180 VDC      DC Motor Current        Rating
Choose the proper size armature fuse       Motor                        Motor        (Amps)                  (AC Amps)
by multiplying the maximum DC motor        1/4                          1/2          2.5                     4
amps by 1.7. on domestic 240 Volt          1/2                          1            5.0                     8
AC lines, separate branch circuit          3/4                          1-1/2        7.5                     12*
protection for each line must be           1                            2            10.0                    15
used. All fuses should be normal blow      1-1/2                        3            15.0                    25*
ceramic 3AG or ABC or equivalent.        * Also used as AC line fuse.




                                                                 
adjuStmentS and control functionS
RAMM Adjustments And Control Functions
WARNING: if adjustments are made         A. Acceleration Start. The ACCeL                trimpot to full CCW position.
under power, insulated adjustment           is factory set at approximately           2. Connect a DC ammeter in series
tools must be used and eye protection       .2 seconds. To readjust to                   with the armature lead.
must be worn.                               different times, set the knob to the      3. Lock shaft of motor (be sure CL
                                            desired position as indicated in Fig 2.      pot is in full CCW position).
The RAMM has been factory adjusted                                                    Apply power and rotate CL pot CW
to provide 0-full speed using the        B. Deceleration. The DeCeL is                slowly until DC ammeter reads 1.5
                                            factory set to provide a ramp-            times motor rating (do not exceed 2
speed control knob. Minimum and
                                            down time of .2 seconds. To               times motor rating, Max. CW position.)
Maximum speed trimpots are provid-          change the ramp-down time,
ed to change the speed from other           adjust the DeCeL trimpot as               NOTE: if only an AC ammeter is avail-
than 0-full speed. The Acceleration         indicated in Fig 2.                       able, it can be installed in series with
(ACCeL) trimpot is provided to allow                                                  the AC line. Follow above instructions;
for a smooth start over an adjustable    C. Minimum Speed Adjustment. if a            however, set AC amperage at .75
time period each time the AC power is       higher than zero minimum speed            times motor rating.
applied or the speed pot is rotated.        is desired, readjust the minimum
The DeCeL trimpot controls the amount       speed by turning the speed control        F. IR Compensation Adjustment. iR
of ramp-down when the speed pot             knob to zero setting (full CCW               compensation is provided to sub-
is adjusted to a lower speed. The           position). Then adjust the Min.              stantially improve load regulation.
                                            Speed trimpot to the desired setting.        if the load presented to the motor
Current Limit (CL, or torque output)
adjustment is factory set to approxi-                                                    does not vary substantially, the
                                         NOTE: The min. speed adjustment                 iR adjustment may be set at a
mately 1-1/2 times the motor rating.     will affect the max. speed setting.             minimum level (approximately 1/4
The iR Compensation (iR) is factory      Therefore, it is necessary to readjust          of full setting). The control is
adjusted to provide excellent motor      the max. speed after the min. speed is          factory adjusted to approximately
regulation under normal operation.       adjusted.                                       3% regulation. if superior perfor-
                                         D. Maximum Speed Adjustment. Turn               mance is desired (less than 1%
NOTE: in order for the iR comp and                                                       speed change of base speed
CL trimpot settings to be correct, the      Speed Control Knob to full speed
                                            (maximum CW position). Adjust max.           from 0 to full load), then the iR
proper Plug-in Horsepower Resistor                                                       comp. Should be adjusted as follows:
                                            speed trimpot to new desired setting.
must be installed for the particular
motor and input voltage being used.      NOTE: Do not attempt to adjust the           NOTES: 1. excessive iR comp. will
Do not attempt to change the settings    max. speed above the rated motor             cause control to become unstable,
of the trimpots unless absolutely        RPM since unstable motor operation           which causes motor cogging.
necessary since they are factory         may occur. For moderate changes in           2. For tach feedback applications the
adjusted to near optimum settings.       the max. speed, there will be a slight       iR comp can be set to minimum rota-
                                         effect on the min. speed setting.            tion (full CCW).
The following procedure, presented in
order of adjustment sequence, should     e. Current Limit (CL/Torque Adjust-          1. Set iR comp. trimpot at approxi-
be used when readjusting all trimpot        ment). CL circuitry is provided to            mately 25% of CW rotation. Run
                                            protect the motor and control                 motor unloaded at approximately
functions.
                                            against overloads. The CL also limits         1/3 speed and record RPM.
                                            the inrush current to safe level          2. Run motor with maximum load and
                                            during startup. The CL is factory             adjust iR comp. trimpot so that
FIGURE 2: ACCEL/DECEL                       set to approximately 1.5 times the            the motor speed under load equals
Trimpot ADJUSTMENT                          full load rating of the motor. (CL            the unloaded speed per step 1.
                                            trimpot is nominally set to ap-           3. Remove load and recheck
                                            proximately 65% of full CW rotation).         unloaded RPM. if unloaded RPM
                                                                                          has shifted, repeat procedure for
                                         To set the CL to factory specifications          more exact regulation.
                                         adjust as follows:                           The RAMM is now compensated to
                                         1. Set speed control knob at approxi-        provide minimal speed change under
                                             mately 30-50% CW rotation. Set CL        large variations of applied load.
                                                            
warranty
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. The foregoing is in lieu of any other warranty or guarantee expressed or
implied, and we are not responsible for any expense (including installation and removal), inconvenience, or consequential
damage, including injury to any person, caused by items of our manufacture and/or sale. Some states do not allow certain
exclusions or limitations found in this warranty so that they may not apply to you. in any event, Rapid-Air Corporation’s total
liability, under all circumstances, shall not exceed the full purchase price of this unit.




                                                              0
      Wiring Diagram for STD Speed Straighteners (1-HP)





      Wiring Diagram for High Speed Straighteners (3-HP)





      Wiring Diagram for Medium Speed Straighteners (2-HP)





      Standard Speed SBX Series 4” Straightener





      Standard Speed SBX Series 4” Straightener





      Standard Speed SBX Series 4” Straightener





      Standard Speed SBX Series 4” Straightener





      SCX-6 Straightener Standard Speed





      SCX-6 Straightener Standard Speed





      SCX-6 Straightener Standard Speed




0
      SCX-6 Straightener Standard Speed





      SCX-6 Straightener Standard Speed





      SCX-6 Straightener Standard Speed





      Typical Stamping Layout





Straightener Sa3 - Sb4
OPERATION                                     the stock with only slight deformation        resultant stock deformation.
For set up only, place a short length         (crease) at the station. observe the
of stock about four feet on the               degree of deformation at this first sta-      CAUTION: Lateral adjustment, gener-
bottom rolls, between the pinch rolls.        tion by lifting the cover and noting the      ally, requires no more than two or three
Set the entrance guide rolls before           pattern of light reflecting off the stock     turns either side of center. never
lowering the cover. Make sure the             surface. Rotate the vertical entrance         force idler rolls against the powered
top rolls are retracted to prevent            knob 1/4 turn down and lock in place.         rolls. This will deform the stock.
stock deformation. Apply light pinch
roll force on the stock to insure             Close the cover, hand hold in place           CAPACITY
adequate assisting pulling force on           while lowering the exit knob. Continu-        The model SA3 is designed for 3”
the stock and to prevent slippage of          ously observe the changing deforma-           maximum width and .005 to .020
the stock over the straightener rolls.        tion pattern until all but the last station   thick material. The SB4 is designed
never overload the pinch rolls. This          reflects a change. The stock should           for 4” maximum width and .007 to
could damage the stock by extrusion           reflect a diminishing deformation             .035 thick material. The maximum
causing permanent deformation.                pattern until the final set of exit rolls     feed rate for SA3 and SB4 is 700
                                              afford no deformation. Lock the exit          inches per minute. The maximum
With the cover down and the stock in          knob. Close the cover and latch.              feed rate for SAM3 and SBM4 is
place, position the idler rolls such that                                                   1400 inches per minute.
they are mid-way between the drive            The dancer arm position for height
rolls. The windows in the side of the         and range is operator selectable              ELECTRIC MOTOR
cover are visual indicators of the idler      through the settings of thumbwheels.          SA3 and SB4 straighteners are
rolls relative position to the drive rolls.   The speed of the straightener rollers         furnished with a 1/4 HP - 2500 RPM
                                              is automatically controlled by the            permanent magnet motor. input
Do not lock the cover down at this            position of the dancer arm. As the            power is single phase, 115 volt A.C.
time. With the cover held down firmly         dancer arm is raised, the straight-           rotation must be CW as viewed from
by hand, lower the vertical entrance          ener rollers increase in speed. This          shaft end. SAM3 and SBM4 have
knob until the first idler roll contacts      minimizes starting and stopping and           a 1/2 HP motor.




                                                                 
Straightener Sa3 - Sb4
Lubrication
Gear transmission oil - Use Mobil 2000 SSU 100 degree F 600W cylinder oil or equivalent.
SA3 & SB4 Worm Gear Case (above motor) 4 oz. capacity.
SA3 Spur Gear Case (straightener side) 4 oz. capacity.
SB4 Spur Gear Case (straightener side) 6 oz. capacity.
Change oil every 1000 hours.




1.   Loop Control Arm
2.   Pinch Roll Knob
3.   eccentric Trunion
4.   Cover Latch
5.   exit Adjustment Knob
6.   entrance Adjustment Knob
7.   Visual indicator Window
8.   Lateral Adjustment Knob
9.   entrance Guide Rolls




                                                            
rapid roll
OPERATION                               The speed of the Rapid Roll rollers is   ELECTRIC MOTOR
For set up only, place a short length   automatically controlled by the posi-    P1V, P4V, and P8V Rapid Rolls
of stock about four feet long on the    tion of the dancer arm.                  are furnished with a 1/4 HP -
bottom rolls, between the pinch                                                  2500 RPM permanent magnet
rolls. Set the entrance guide rolls     As the dancer arm is raised the Rapid    motor. input power is single
to maintain stock position. Make        Roll rollers increase in speed. This     phase, 115 volt A.C. Rotation
sure the top rolls are retracted. To    minimizes starting and stopping and      must be clockwise as viewed
prevent stock deformation apply         resultant stock deformation.             from shaft end. The P1M, P4M &
light pinch roll force on the stock                                              P8M have a 1/2 HP motor.
to insure adequate assisting            CAPACITY
pulling force on the stock and to       The model P1V is designed for 1.5”       LUBRICATION
prevent slippage of the stock while     maximum width and .0005 to .075 thick    Gear transmission oil – Use
operating. never overload the pinch     material. The P4V is designed for 4”     Mobil 2000 SSU, 100 degree F 600 W
rolls. This could damage the stock      maximum width and .0005 - .060 thick     cylinder oil or equivalent. Rapid Roll
by extrusion causing permanent          material. The P8V is designed            worm gear case (above motor) 4 oz.
deformation.                            for 8” maximum width and .0005 - .050    capacity (fill to level plug). Change
                                        thick material. The maximum feed rate    every 1000 hours of operation.
The dancer arm position for height      for P1V, P4V & P8V is 700 inches per
and range is operator selectable        minute. The maximum feed rate for        GREASE FITTINGS
through the setting of thumbwheels.     P1M-P8M is 1400 inches per minute.       Use Mobilux number 2 or equivalent.




                                                          
1.   Loop Control Arm
2.   Pinch Roll Knob
3.   Grease Zircs
4.   eccentric Trunion
5.   entrance Guide Rollers
6.   D.C. Drive Motor




                              

								
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