100D CTL/100T w/Flat Stock Cutter - Rapid
Contents
1. 1060 Assembly Drawing 22 FSC12 Assembly Drawing 24 1120 Assembly Drawing 27 FSC18 Assembly Drawing 29 1180 Assembly Drawing 34 1 Page SPECIFICATIONS Mechanical Max Material Width 106D FSC6 1120 5 12 1180 5 18 Max Thickness Capacity at Full Width 106D FSC6 1120 5 12 1180 5 18 Max Feed Roll Cutter Blade Opening 106D FSC6 112D FSC12 118D FSC18 Roll Position Repeatability Roll Type Blade Type Stock Entrance Options 6 152mm 12 304mm 18 457mm 0 046 1 17mm 0 060 1 52mm 0 045 1 14mm based on low carbon steel commercial grade 0 150 3 81mm 0 100 2 54mm 0 150 3 81mm 0 0025 8620 C R S Hardened amp Ground M2 DCF Tool Steel Heated amp Tempered to 62 65 Rc Cascade Rollers and Edge Guides Standard Pneumatic Operated Roller Release Special Rolls Contact Factory Self Centering Edge Guides Carbide Cutter Blades 2 Page SPECIFICATIONS Electrical Line Voltage Rated Input Current Max Inrush Current Max Operating Temperature Controller AC Servo Drive Display Enclosure Rating Dimensions Inputs Outputs Options Pneumatic Shop Air 120 VAC 10 50 60 Hz 9 9 Amps 10 0 Amps 30 C Ambient Trio Motion Coordinator MC302X Kollmorgen 00606 Beijer H T60b S IP65 24 x 18 x 10 610mm x 457mm x 254mm Use PNP se2. 5 5 DGA YOLSISSY MOvaa 34 0333 61 Jadzii 2 2 001 8 88 8 B 2 D T D 8 8 8800 20 20 00 2 1 0025 081020 5 CORPORATION ROCKFORD IL 100D CUT TO LENGTH PART WIRING SCHEMATIC SHEET 1 OF 2 POWER CIRCUIT 85500336 1 2014 ev ee 16 Page 5 WWHON 0333 03385 5 L_ 2 STOJ OOF LAWL 72015 10114 09 138 311 3 47193 ON Ti wyo 4001 RAPID AIR CORPORATION ROCKFORD 1000 CUT TO LENGTH WIRING SCHEMATIC SHEET 2 OF 2 VO CIRCUIT MAY 2014 eo 85500336 2 17 Page O90909 2 COW 19 202126 09 23244 120VAC SERVICE N C N 85500333 1000 WIRING SCHEMATIC version N S 69340036 26 FERRULE 69340037 20 GA FERRULE 69340039 16 GA FERRULE 69340040 14 GA FERRULE 69300048 CNTRLR DISPLAY CABLE N S 69300047 CNTRLR DRIVE CABL
3. 13 1 31702175 CAM PLATE 1 31702174 SHAFT PLATE 1 32900873 SHAFT 1 31702173 PLATE NOTE FSCI2S FOR SERVO C T L CONTROL VERSION 24 VALVE PNP SENSOR 25500076 PISTON ASSEMBLY 30100297 PISTON HOUSING 30100296 UPPER BLADE HOUSING RAPID AIR CORPORATION ROCKFORD IL MADISON SD 1 31702170 SIDE PLATE 5 125 CUTTER 1 1 31702169 PLATE SENSOR FOR SERVO C T L EF SHEET 3 a 1 SNL SECTION DD IMPORTANT MOTOR TERMINALS POSITION UNLESS OTHERWISE SPECIFIED RAPID AIR CORPORATION ROCKFORD IL MADISON SD 4 FRAME CONSTRUCTION PRE EYE N 27 Page 83 1 62900004 PLUG 1 31702417 SCREW PLATE 81 31500479 5 0 GUIDE 4 65920100 5 5 1 4 20 X 1 79 16 66620050 BHSCS 1 4 20 x 1 2 78 4 65912075 5 5 10 32 3 4 6 66512037 5 5 810 32 x 3 8 76 12 65931075 5 5 5 16 18 3 4 75 2 66631037 5 5 5 16 18 x 3 8 1 4 20 X 5 8 73 2 65936100 5 5 3 8 16 X 1 66612050 BHSCS 10 32 X 1 2 71 4 66612037 BHSCS 810 32 x 3 8 70 6 65101032 NUT 10 32 69 1 65113716 NUT 3 8 16 68 1 65118814 NUT 7 8 14 67 1 66700056 OVAL POINT SET SCREW
4. L CONTROL SHEET 1 OF 3 24 VALVE PNP SENSOR FSC12S FOR SERVO C NOTE VERSION SECTION EE 11300380 ROCKFORD IL MADISON SD 50125 CUTTER RAPID AIR CORPORATION SENSOR FOR SERVO C T L VIEW BB SECTION DD FSC12S FOR SERVO C T L CONTROL VERSION 24 V D C VALVE PNP SENSOR NOTE SHEET 3 LOCTITE RK 5555 lt 535525255254 STRIPPER PLATE 070 MANUFACTURING SET 2222 2 22 227 022252 90 35022 PAR 2 SECTION AA 259200 ORR 257262200 OA 2222 9 52 4 22 2 lt gt 55555555506 SR 555555555 SERRE X 1 69400065 BALL PLUNGER 80 2 34700066 j 79 1 69280240 VALVE PLUG 78 65908125 5 5 48 32 X 11 4 THREADED INSERT DRIVE SCREW SERIAL TAG BLADE POSITION LABEL STOCK GUIDE NUT STOCK GUIDE ROLLER SLEEVE STOCK GUIDE ROLLER 69 1 67100145 TUBING 1 4 67 1 67100142 PIPE ELBOW 3 8 NPT FEMALE 66 1 67100159 PIPE 3 8 NPT FEMALE 65 1 63130500 PIPE PLUG 1 2 NPT 64 2 34100348 spaci PIPE PLUG 1 4 NPT HEX NIPPLE 3 8 NPT SHCS 174 20
5. NUT 3 8 16 68 1 65118814 NUT 7 8 14 67 1 66700056 OVAL POINT SET SCREW 66 1 66700072 SET SCREW 65 2 66300250 DRIVE SCREW 1 39900051 S N TAG RAPIDAIR LOGO INLET LABEL 60910050 RETAINING RING 60910078 RETAINING RING H 60910087 RETAINING RING 6090016 5 RETAINING RING 60930043 GRIP RING 60108208 70 RING 1 60108228 40 RING 5412 40 RING 37500107 SPRING 62425075 ROLL PIN 1 4 X 3 4 51 1 62419075 ROLL 3 16 X 3 4 501 6213150 5 PIN 491 62500002 TAPER 48 1 62318050 DOWEL PIN 3 16 X 1 2 47 8 62331075 DOWEL PIN 5 16 X 3 4 46 2 62225050 DOWEL PIN 1 4 X 1 2 45 1 62325062 DOWEL PIN 1 4 X 5 8 441 36800005 KEY 36800013 69000047 MOTOR 41 2 34700082 WASHER 40 2 64520028 THRUST WASHER 39 4 34700117 THRUST WASHER 38 1 64510001 THRUST BEARING 37 2 64600054 BALL BEARING 36 2 64500061 NEEDLE BEARING 64100073 BUSHING 36100099 ADJUSTING SCREW ae m SECTION BB 261818 100320 UPPER ROLLER SPACER 34100372 SPACER 29 1 34100318 SPACER 28 2 33900264 BEARING SLEEVE 27 1 36600035 HANDLE 1 36500044 HANDLE at 36500043 32900854 ECCENTRIC SHAFT 23 1 32900962 SHAFT 2211 32500003 TIMING BELT 1 32500030 BUSHING FOR 32500029 ALUMINUM PUL
6. 0 250 LENGTH in 0 000 LENGTH in 0 000 CANCEL On the NEW job parameter screen the feed length defaults to inches Use the F1 amp F2 to toggle between entering the length in inches or millimeters On the EDIT screen the feed length units will be whatever the job was originally defined as but it may be changed the same way Note when changing between inches and millimeters on an existing job the previous length is not converted to the new units For example if the previously length was 1 25 inches and the units are changed to millimeters the length does not become 31 75 mn it is now 1 25 mm Enter the approximate number of cycles the amount of time the cut off solenoid is energized and the required feed length The controller will then compute the move parameters based ona standard trapezoidal move If the move cannot be made with the given parameters a warning message will be displayed Acknowledge the message and re enter the parameters INVALID PARAMETERS The requested cycle rate is too fast Either decrease the cycles minute or decrease the cut duration ACKNOWLEDGE If the move parameters are accepted but when the move is tested with material and it is apparent the move is too hard so the rolls slip or other problems are caused then edit the job and reduce the number of CYCLES per MINUTE It will be trial and error to find the rate that works best for your particular applicatio
7. 66 1 66700072 SET SCREW 65 2 66300250 DRIVE SCREW 1641 39900051 5 TAG 63 1 39900245 RAPIDAIR LOGO 62 1 39900175 INLET LABEL ZDA RETAINING RING 60910078 RETAINING RING RETAINING RING 5 RETAINING RING 60930043 GRIP RING 56 2 60108208 RING TAPER INSTALLATION DRAWING 55 1 60108228 0 RING SET SCREW 1 4 20 X 3 8 5412 70 RING SHCS 1 4 20 X 3 4 37500107 SPRING 62425075 ROLL PIN 1 4 X 3 4 51 1 62419075 ROLL 3 16 X 3 4 501 6213150 5 PIN 491 62500002 TAPER 48 1 62318050 DOWEL PIN 3 16 X 1 2 47 8 62331075 DOWEL PIN 5 16 X 3 4 46 2 62225050 DOWEL PIN 1 4 X 1 2 45 1 62325062 DOWEL PIN 1 4 X 5 8 441 36800005 KEY 43 1 36800013 KEY 69000047 41 2 34700082 WASHER 40 2 64520028 THRUST WASHER 39 4 34700117 THRUST WASHER 38 1 64510001 THRUST BEARING 37 2 64600054 BALL BEARING 36 2 64500061 NEEDLE BEARING 64100073 BUSHING 36100099 ADJUSTING SCREW a SECTION BB 34100320 UPPER ROLLER SPACER 34100372 SPACER 29 1 34100318 SPACER 28 2 33900264 BEARING SLEEVE 27 36600035 HANDLE 26 1 36500044 HANDLE 36500043 32900854 SHAFT 23 1 32900960 SHAFT 2211 32500003 TIMING BELT 1 32500030 BUSHING FOR 32500029 ALUMINUM PULLEY 32
8. 1 62325050 DOWEL 26 2 34400315 TUBE 25 1 32900533 5 24 2 32900532 ADJUSTING SHAFT 518 32900531 GUIDE SHAFT 36500032 21 4 25500073 PISTON 20 1 21900138 REAR GUARD ASSEMLY 19 1 51500137 FRONT GUARD ASSEMBLY 18 o n n 69400052 SPRING PLUNGER 114 1 31701444 SHAFT MOUNTING PLATE 113 1 31701443 CAM ACTUATING PLATE 1 31702184 MANIFOLD PLATE j 11 4 31701441 PISTON WEAR PLATE 1 31701606 STRIPPER PLATE j 31701605 TEE SLOT PLATE 2 8 31701604 BLADE SUPPORT PLATE 7 31701437 BEARING PLATE 6 5 n st 1 31701436 LH BEARING PLATE 31701435 RH SIDE PLATE 4 1 31701434 LH SIDE PLATE 2 30100300 PISTON HOUSING 30100180 BLADE HOUSING 1 11 30100179 BASE HOUSING RAPID AIR CORPORATION ROCKFORD IL MADISON SD w 29 VIEW SECTION HNN 555555555555 55555555555 iS R AER SRR SECTION VIEW FROM SHEET 1 RAPID AIR CORPORATION ROCKFORD IL MADISON SD FSCI8S CUTTER 5 185 FOR SERVO C T L CONTROL VERSION 24 V D C VALVE PNP SENSOR NOTE SENSOR FOR SERVO T L 11300381 13 SHEET 2 OF 5 SS
9. 69280200 CORDGRIP 69300002 120VAC LINE CORD 14 3 1 1 69300041 MOTOR POWER CABLE 2 69280248 METRIC LOCKNUT M32 2 2 69280247 SPLIT CORDGRIP GROMMET 1 69300042 MOTOR FEEDBACK CABLE 8 65100632 HEX NUT 6 32 4 66506062 FHSCS 6 32 2 69100643 VENT COVER amp FILTER 1 39900243 LOGO LABEL ROCKFORD IL PART 100D SERVO CONTROL ASSEMBLY ww To m a 28900431 19 Page 11300379 So SERVES MADISON SD 5 65 CUTTER SENSOR RAPID AIR CORPORATION FOR SERVO C T L AX 507 SECTION EE _ _______ ww ___ lt gt 252 2755 55522 222020 gt SECTION 22 222 CESS 2220 5522 gt 2222 227 22227 222 2 77 29 KA 2 57 SDR 2227 2 AOL ZR 2 22 2 2 222 KA AKA 4 22 2 X lt gt 22 SECTION 74 z 1 gt a 4 L VERSION 24 V D C VALVE PNP SENSOR NOTE 62337075 DOWEL 3 8 X 3 4 6 65936100 5 5 3 8 16 1
10. 7418 66700057 LOW HEAD 5 5 659362255 5 3 8 16 X 2 1 4 MRIS LES EINE 72 2 65500005 5 NUT 71 65936150 lt 3 8 16 1 1 2 k 22220 70 4 6595 200 5 5 172 13 69 4 66520100 5 5 1 4 20 1 68 8 65931175 SHCS 5 16 18 X 1 3 4 on 65931125 5 5 5 16 18 X 1 1 4 6613 66520050 5 5 174 20 X 172 65 8 65931100 5 5 5 16 18 X 1 64 66612037 10 32 X 3 8 63 65912125 SHCS 10 32 X 1 1 4 62 61 62331075 DOWEL 5 16 X 3 4 76 lt lt O 229 22922 22222222 59222 lt R gt gt SS SIT SSS 55555559 x lt 69100348 PROX SWITCH PNP 62325050 DOWEL PIN 1 4 X 1 2 3 63130125 PIPE PLUG 1 8 NPT 59 2 63130375 PLUG 3 8 69200032 VALVE 24 57 1 67200001 MUFFLER 56 65920150 1 4 20 X 11 2 55 2 60 08014 70 RING 67200007 MUFFLER 53 55 55555 ES NS RS DSSS 67100142 90 ELBOW 67100141 NIPPLE 31702182 EXHAUST MANIFOLD 31500445 QUICK EXHAUST COVER 6 QUICK EXHAUST 31900641 QUICK EXHAUST MTG BRKT 47 1 36300009 QUICK EXHAUST FITTING 2202 46 1 39900175 INLET LABEL BRON 451 9900 48 ADJUST LABEL SEES 15411 169400052 SPRING PLUNGER PRO SRA SECTION 51 62
11. NUMBER elele This screen is used to define a new job edit an existing job or recall an existing job Up to 99 jobs can be created and stored Until a valid job number is entered the RECALL NEW and EDIT pushbuttons are not enabled F5 is the only function key used on this screen Use the F5 key to return to the SPLASH screen without changing any job information RECALL This pushbutton recalls a previously set up job and makes it the CTL active job any invalid job number is entered you will get fault message Simply acknowledge the message and try again When the recall is successful you will be returned to the SPLASH screen NEW amp EDIT Both of these pushbuttons will cause a new screen to appear allowing you to enter the job s parameters If you ve forgotten what job numbers have been set up and you enter a used number and then push NEW you will get a fault message This action is intended to keep the operator from accidentally changing a stored job Similarly if you enter a job number that does not exist and try to EDIT it you will get a fault message Simply acknowledge the message and try again JOB NUMBER NOT FOUND ALREADY EXISTS ACKNOWLEDGE ACKNOWLEDGE 7 Page SERVO FEED OPERATION NEW EDIT CYCLES MINUTE 1 CUT TIME Sec CYCLES MINUTE JOB 0 INCH CUT TIME Sec METRIC 0 250
12. is turned on some of the components must boot up much like a computer During this period the display will show a clock so you can recognize the control is in the process of getting ready If the control is turned on immediately after the incoming service is restored you will notice a longer boot up time is required The display is a touch screen Touch the screen in the general area of an object when it is necessary to enter numbers push pushbuttons or reset values The screen has a built in screen saver function whereby it blanks after a predetermined time of inactivity Touch the screen anywhere to bring back it to life On the right hand side of the display there are 5 programmable function keys These keys have different functions depending on the active screen The F5 key is typically the EXIT or CANCEL key The keys are always active If you forget a key s function you can press the MENU button and the function key menu for the active screen will slide out The slide out menu is also a touch key so you can either touch the appropriate menu choice or press the F key itself Once a choice is made the slide out menu will close You can also close the slide out menu by pressing the MENU button a second time As you become accustomed to the operation of the CTL you will probably find yourself calling for the slide out menu less and less The CTL will power up with the last job used as the active job This means th
13. 13000592 E SECTION DD TERMINALS POSITION UNLESS OTHERWISE SPECIFIED IMPORTANT MOTOR 83 1 62900004 PLUG 1 31702417 ADJ SCREW PLATE 81 fe 31500471 stock GUIDE 4 65920100 5 5 1 4 20 X 1 79 12 66620050 BHSCS 1 4 20 1 2 4 65912075 5 5 10 32 x 3 4 77 4 66512037 FHSCS 10 32 x 3 8 76 12 65931075 5 5 5 16 18 3 4 75 2 66631037 5 5 5 16 18 x 3 8 1 4 20 5 8 73 2 65936100 5 5 378 16 X 1 172 66612050 BHSCS 10 32 x 1 2 71 4 66612037 BHSCS 810 32 x 3 8 70 4 65101032 NUT 10 32 69 1 65113716 NUT 3 8 16 68 1 65118814 NUT 7 8 14 67 1 66700056 OVAL POINT SET SCREW 66 1 66700072 SCREW 65 2 66300250 DRIVE SCREW 16411 39900051 5 TAG 63 1 39900245 RAPIDAIR LOGO 5412 40 RING 37500107 SPRING 62425075 ROLL PIN 1 4 X 3 4 51 1 62419075 ROLL 3 16 X 3 4 501 6213150 5 PIN 491 62500002 TAPER 48 1 62318050 DOWEL PIN 3 16 X 1 2 47 8 62331075 DOWEL PIN 5 16 X 3 4 46 2 62225050 DOWEL PIN 1 4 X 1 2 45 1 62325062 DOWEL PIN 1 4 X 5 8 441 36800005 KEY 36800013 69000047 MOTOR 41 2 34700082 WASHER 40 2 64520028 THRUST WASHER 39 4 34700117 THRUST WASHER 38 1 64510001 THRUST BEARING 37 2 64600054 BALL BEARING 36
14. 2 64500061 NEEDLE BEARING 64100073 BUSHING 36100099 ADJUSTING SCREW 36300008 AIR INLET FITTING 34400533 AIR_ TUBE 34100320 UPPER ROLLER SPACER 34100372 SPACER 29 1 34100318 SPACER 28 2 33900264 BEARING SLEEVE 27 1 36600035 HANDLE HANDLE ECCENTRIC SHAFT PIVOT SHAFT TIMING BELT BUSHING FOR 32500029 ALUMINUM PULLEY MOTOR PULLEY GEAR 17 STEEL GEAR 16 1 25500071 PISTON ASSEMBLY 15 31500426 BELT COVER 14 1 31500425 PISTON COVER 113 1 21900325 EXIT GUARD ASSEMBLY 12 1 21900324 ENTRANCE GUARD ASSEMBLY 1 34200365 UPPER ROLLER 10 1 34200364 LOWER ROLLER 30100284 PISTON HOUSING 30100283 BEARING HOUSING 7 31900636 UPPER ROLLER BRACKET E 31702088 HANDLE SUPPORT PLATE 31702086 MOTOR MOUNTING PLATE 1 31702416 PLATE 1 31702415 SIDE PLATE 1 31702414 SIDE PLATE BOTTOM PLATE DESCRIPTION TAPER PIN INSTALLATION DRAWING SET SCREW 1 4 20 X 3 8 5 5 1 4 20 3 4 SECTION OOA SECTION SHEET OF 2 RAPID AIR CORPORATION ROCKFORD IL MADISON SD 1060 SERVO W VERSIDN CONTROL 4 HOUSING CONSTRUCTION 23 Page RAPID AIR CORPORATION MADISON SD FSCI2S CUTTER SENSOR FOR SERVO C T L
15. 3275 SHCS 1 2 13 X 2 3 4 31500440 9 EXHAUST COVER 2 65936400 5 5 3 8 16 4 65 4 36300009 QUICK EXHAUST FITTING 83 8 66700054 LOW SHCS 1 2 13 11 4 64 68000000 EXHAUST i 81 1 67200001 MUFFLER 63130375 PIPE PLUG 3 8 NPT 4 65936100 5 5 3 846 1 63130250 PLUG 1 4 79 1 68419150 ROLL 3 6 11 2 60 1 63130750 PIPE PLUG 3 4 NPT 7 59 58 57 56 15511 69200032 VALVE 24 V D C 541 69280240 PLUG 53 1 69100348 PROX SWITCH 52 2 36200023 51 34200159 STOCK GUIDE ROLLER 50 2 33900237 ROLLER SLEEVE 49 1 133900238 SLEEVE 48 2 65600005 INSERT hele 4612 62418100 ROLL 4514 62337075 44 12 62250150 PULL DOWEL 62437150 ROLL 42 4 62150200 SPIRAL PIN 41 2 60108110 40 1 31701623 SWITCH MOUNTING PLATE 2 60108329 0 RNG 2814 lenost RING 37 4 60108349 12 RING 36 2 60910050 RETAINING RING 60900250 RETAINING RING 65912300 SHCS 810 32 X 3 EEE 11 lt 4 64100052 BUSHING 2 36600020 hanme 67 2 39900175 INET LABEL 29 1 39900051 NAMEPLATE 28811 39900235 ADJUST LABEL e7
16. 412075 ROLL 1 8 X 3 4 58 60910031 RETAINING RING 69280240 PLUG Sie 4 31701441 PISTON WEAR PLATE 37500013 SPRING 37500128 SPRING 60108109 0 RING 60108241 0 RING 13312 5 0 GUIDE NUT 32 2 133900243 5 GUIDE SLEEVE E 34200240 5 GUIDE ROLLER 6600024 HANDLE 2514 6 BUSHING 27 2 65600007 INSERT 26 2 36700040 KNOB 4 36500037 32900600 BLADE ADJ SHAFT 32900599 SHAFT 531 20 2 32900598 SHAFT 19 25500077 PISTON 18 35900045 LOWER BUMPER 17 25900044 UPPER BUMPER 16 1 31701617 MOUNTING PLATE 15 31701616 CAM SHAFT MOUNTING PLATE lt NOTE FSC6S FOR SERVO C T L CONTROL VERSION 24 VALVE PNP SENSOR 9 31702209 BLADE SUPPORT PLATE T SLOT PLATE 7 31701612 RH BEARING PLATE 6 31701611 BEARING PLATE SHT OF 2 5 30100303 BLADE HOUSING RAPID AIR CORPORATION 31701609 L H SIDE PLATE 5 65 CUTTER SENSI FOR SERVO C T L 31702207 BASE PLATE SS 21 Page 11300379 ROCKFORD IL MADISON SD_ 1060 SERVO W VERSIDN CONTROL lt 4 PIECE HOUSING CONSTRUCTION RAPID AIR CORPORATION eis ex
17. 500005 MOTOR PULLEY 18 1 32600231 UHMW GEAR 17 1 32602600 STEEL_GEAR 16 1 25500071 PISTON ASSEMBLY 15 31500426 BELT COVER 14 1 31500425 PISTON COVER 1 21900329 EXIT GUARD ASSEMBLY 1 21900328 ENTRANCE GUARD ASSEMBLY SS 34200367 UPPER ROLLER 1 34200966 LOVER ROLLER 9 1 30100284 PISTON HOUSING 222222 7 31900637 UPPER ROLLER BRACKET 31702088 HANDLE SUPPORT PLATE 31702086 MOUNTING PLATE SHEET 2 OF 2 RAPID AIR CORPORATION 1120 SERVO SECTION OO me E 28 Page 78115 65931150 SHCS 5 16 18 X 1 1 2 77 6 66520050 5 5 174 20 x 1 2 9514 6520200 5 5 1 4 20 x 2 5 5 10 32 X 3 8 5415 6590 5 5 48 32 11 8 75 2 66300250 SCREW 165936275 5 5 3 8 16 X 2 3 4 74 6 65920175 5 5 1 4 20 X 1 3 4 15319 81 11 NOTE 5 185 FOR SERVO C T L CONTROL suosio RINE easeoor7 THRUST WASHER VERSION 24 VALVE PNP SENSOR soe EDL RUST 67100141 PIPE NIPPLE 71 RING 7012 8 4 66520125 5 5 1 4 20 X 1 1 4 67100142 90 ELBOW 68 67 6611 87 4 65936150 5 5 3 8 16 X 1 1 2 31702186 QUICK EXHAUST MANIFOLD RH 86 4 65961500 shes 5 8 1 5 31702185 QUICK EXHAUST MANIFOLD LH 5 3 6595
18. 55 SPIRAL 5 BACK lt gt PLACES KR RSA 2555 SER 55250 RR TRS SS SEIS 5555 55509 LENO SKA SECTION VIEW DD FROM SHEET 1 ROCKFORD IL MADISON SD 5 85 CUTTER RAPID AIR CORPORATION SENSOR FOR SERVO C T L SECTION FF a 2 2 gt o gt gt 99 uz gt FROM SHEET 1 113 sm E SHEET 5 OF 5 SECTION DD 76 LOWER 4 208 SCREWS 34 IMPORTANT MOTOR wali 162500004 TPLUG 32500042 TAPER PIN INSTALLATION DWG TERMINALS POSITION 1 131702417 8 SCREW PLATE 66220037 SCREW 1 4 20 3 8 UNLESS OTHERWISE 2 21500482 GUIDE 87 2 65920075 5 5 1 4 20 x 3 4 SPECIFIED 80 4 65920100 SHCS 1 4 20 X 1 79 20 66620050 BHSCS 1 4 20 X 1 2 17814 65912075 5 5 410 32 x 3 4 77 66512037 FHSCS 10 32 x 3 8 76 12 65931075 5 5 5 16 18 3 4 75 2 66631037 5 5 5 16 18 x 3 8 1 4 20 5 8 73 2 65936100 5 5 378 16 X 1 172 66612050 BHSCS 10 32 X 1 2 71 4 66612037 BHSCS 810 32 x 3 8 70 8 65101032 HEX NUT 10 32 69 1 65113716
19. 555552 S NO 55 22 lt lt 2 SECTION EE FROM SHEET 1 555555555555 WNW SISSON ISN 55555555 SSIS 51 PERN SS 4 c RSS SECTION QQ 2 ju KEDY OOP 49 VIEW GG FROM SHEET 1 X NOTE 5 185 FOR SERVO C T L CONTROL VERSION 24 VALVE PNP SENSOR RAPID AIR CORPORATION MADISON SD FSCI8S CUTTER W PNP SENSOR FOR SERVO C T L B 31 SHEET OF 11300381 RAPID AIR CORPORATION ROCKPORD IL MADISON SD 5 185 CUTTER W PNP SENSOR FOR SERVO C T L SS SN SONNET ETT 1 1 31 6 CONTROL PNP SENSOR T L BLADE ADJUSTMENT E 5 185 FOR SERVO VERSION 24 V D C VALVE 5 5 2 SECTION LL SECTION 8 9 2 VE 5555 S 7 OS es be gt 5 SES SNS SRR SS 723 SRI BS 5555 SOILS SO 5555
20. E 28 1 69101008 RESISTOR 25 1 39900310 120VAC DISCONNECT WIRING LABEL 69101002 4 FUSE CLASS 21 1 69100748 1 WIRE DUCT COVER 20 1 69100749 1 x 2 WIRE DUCT 2 4 5 3 1 19 1 69100819 CONTACTOR 18 2 69100775 GROUND TERMINAL 17 5 69100773 TERMINAL JUMPERS 16 1 69100771 TERMINAL END BARRIER 6 14 4 69100772 TERMINAL END ANCHORS 11 69100827 SERVO CONTROLLER 69101005 REGEN RESISTOR 69100769 DIN RAIL 6 38 69101006 DISCONNECT SHORTING LINK 6 1 69100584 DISCONNECT SHAFT sonne 69100582 DISCONNECT 30A 600VAC 3 1 69100769 95 69280249 GROUND LUG 38900199 SUBPANEL aja Blu 52 CXS ITEM DESCRIPTION RAPID AIR_ CORPORATION ROCKFORD IL er ee 100D SERVO CONTROL SUBPANEL ASSEMBLY oj ww APRIL 2014 28900430 D 18 Page 10900601 100 amp 200 SERVO CNTRL STAND 1 1 69280216 INSULATED SLEEVE CLAMP 1 60940015 RETAINER 1 69100583 DISCONNECT HANDLE 1 69100829 OPERATOR INTERFACE 4 66006175 5 6 32 1 39900188 PUSHBUTTON NAMEPLATE 1
21. LEY 32500005 MOTOR PULLEY 18 1 32600231 UHMW GEAR 17 1 32602600 STEEL GEAR 16 1 25500071 PISTON ASSEMBLY 15 31500426 BELT COVER 14 1 31500425 PISTON COVER 13 1 21900331 EXIT GUARD ASSEMBLY 12 1 21900330 ENTRANCE GUARD ASSEMBLY 11 34200381 UPPER ROLLER 10 1 34200380 LOWER ROLLER 30100284 PISTON HOUSING aa 30100283 BEARING HOUSING 7 31900638 UPPER ROLLER BRACKET 31702088 HANDLE SUPPORT PLATE svi PATE ERE fo aur KATE SECTION e 2 1 31702414 RH SIDE PLATE ee ameua PLATE 35 lt
22. Rapid AIr Operating Instructions C T L w 100D Series Servo Feed Control Ver s n 133095 amp Later 4601 Kishwaukee Street Rockford IL 61109 815 397 2578 www rapidair com Thank you for purchasing Rapid Air Cut to Length CTL system The system is configured from our proven line of servo feeds and stock cutters Rapid Air Corp designed and built its first servo driven roll feed and cutter combination in 1994 As with the whole Rapid Air product line there has been an ongoing program of product improvement Our roots are in stamping and our engineering expertise is extensive Many of our earliest products remain in use today in small shops and large factories worldwide Some of these products are still manufactured with only slight modifications to the original design allowing for modern manufacturing technologies to be used in their production All Rapid Air products are built right here in our own U S factory No inconsistent design differing parts or sourcing problems Just the same reliable quality renowned support and lasting value you can always expect from Rapid Air TABLE OF CONTENTS Specifications 2 Mechanical Set Up 4 Servo Feed Operation 5 Troubleshooting 13 Flat Stock Cutter Operation 14 Waranty 15 Electrical Schematic 16 Electrical Assembly Drawing 18 FSC6 Assembly 20
23. X 1 3 4 RETAINING RING 3 8 SHCS 3 8 16 X 1 3 4 58 5 5 5 16 18 2 1 4 ae BHSCS 810 32 X 3 8 56 2 6593125 5 5 5 16 18 X 1 1 4 65931100 5 5 5 16 18 X 1 65908175 5 48 32 X 1 3 4 HOLE PATTERN FOR F SERIES AIR FEEDS 5313 65520050 174 20 X 1 8 3984 REED HOLE PATTERN FOR H SERIES AIR FEEDS HOLE PATTERN FOR J SERIES AIR FEEDS 66520075 5 5 174 20 X 3 4 8 HOLE PATTERN L SERIES AIR FEEDS se 65936150 SHCS 3 8 16 X 11 2 SHCS 1 2 13 11 4 49 1 62419100 ROLL 3 16 X 1 14811 62425075 ROLL PIN 1 4 3 4 47 DOWEL PIN 1 4 X 1 2 46 SPIROL PIN 1 2 X 2 1 4 45 DOWEL PIN 1 2 X 1 44 DOWEL 3 8 3 4 MUFFLER SPRING SPRING CENTURY 872486 BUSHING AA 1807 2 ROLL PIN 1 8 X 1 37 1 69100348 SWITCH PNP 36 1 69200032 VALVE 24 VDC 0000 1 8 BE 10 RING 5 50 LD X 210 5215 1939691286 516 1X 18 60108109 70 RING 5 16 LD X 103 31 15 60108207 70 RING 9 16 LD X 139 30 32900874 ADJUSTING SHAFT 29 28 36700019 KNOB 36800039 7 4 36300009 QUICK EXHAUST FITTING 26 1 31500435 SECTION 31702178 MTG PLATE 19 32000013 BLADE 18 2 31702177 PISTON WEAR PLATE 17 1 31702176 STRIPPER PLATE HOLD DOWN BOLTS 5 8 11 FROM TOP 3 4 10 FROM BOTTOM lt 4 HOLES
24. arranty The Company warrants for a period of one year from the date of shipment by the Company that the product shipped is free from defects in material and workmanship THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL IMPLIED WARRANTIES IN LAW INCLUDING MERCHANTABILITY The Company obligation under this warranty is limited to repairing or replacing F O B Rockford IL any part or parts proved to have been defective when shipped In no event shall the Company be liable for special or consequential damages Provisions set forth in specifications are descriptive and subject to change and are not intended as warranties Customer License Agreement Rapid Air reserves the rights in its 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 You may use the program only on the programmable servo controller furnished with the system and only in conjunction with the servo feed supplied with the system 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 15 Page 35 341 1 1 43MOd YLL ZOL 1 1
25. e servo feed via hardwired pushbuttons If the CTL was not ordered with a remote jog pendant it is possible to field install JOG FWD and JOG REV pushbuttons See page 2 of 2 of the included electrical schematic Like the HMI jog buttons the hardwired pushbuttons will only be active when the display is on the manual function screen 9 SERVO FEED OPERATION cont d AUTOMATIC Two modes of operation are available in the automatic mode One mode is continuous In this mode the CTL will run until the operator stops the cycle There is a TOTAL COUNT indicator that will indicate how many cycles have been run This counter may be RESET at any time When run in the continuous mode the screen changes and the BATCH start and count display will not be visible 0 000 in 0 CYCLES MINUTE 0 000 in 0 CYCLES MINUTE starr BATCHED COUNT other mode of operation is batch mode You can enter on the BATCH COUNT the number of pieces you want to make start the machine and it will automatically stop after the count is complete Once started in the batch mode the screen changes and the continuous mode start stop pushbutton is not visible The TOTAL count display remains visible allowing the operator to see how many cycles have happened and at the same time the BATCH counter will display the number of cycles remaining The BATCH counter will reset automatically between batches but the TOTAL counte
26. ere is no need to load the same job number day after day 5 Page SERVO FEED OPERATION SPLASH SCREEN www rapidair com Once the control is booted up and ready to go the Rapid Air logo will be displayed This is called the SPLASH screen The SPLASH screen is the main menu F1 JOB SELECT Go to this screen to set up the desired job F2 AUTOMATIC Go to this screen to start making parts MANUAL Go to this screen to manually control individual functions F4 JOB REVIEW Go to this screen to quickly see what the active job is and its parameters F5 ABOUT Go to this screen for information about the CTL You can change to any screen listed no particular order is required For purposes of explaining the controls we will describe how to enter a new job number and the job parameters A typical sequence would be JOB SELECT Enter job number JOB CONFIG After selecting a job number you are automatically sent to the JOB CONFIG screen to either confirm the job choice or to enter the new job parameters You could also choose to go to the JOB CONFIG screen to edit an existing job s values MANUAL Allows you to test settings and position the material for production You are automatically sent to this screen after the JOB CONFIG screen AUTOMATIC Ready for production waiting for the feed initiate signal 6 Page SERVO FEED OPERATION JOB SELECT ENTER JOB
27. gh the material then when compared to 0 030 cold rolled steel Each job recipe allows for a different CUT TIME If maximizing the cycle rate is not important you may find one CUT TIME works well for all of your setups A suggested starting value is 0 250 second Each blade has four cutting edges When a blade dulls rotate it 90 for a sharp edge When all four edges have been used flat grind the large faces on both sides of the blade After reinstalling the blades it may be necessary to adjust the clearance between the blades Blade Adjustment The upper blade may be lowered manually with the eccentric cam located at the top center of the cutter The purpose for this manual operation is for horizontal blade clearance adjustment Blade clearance affects the quality of the cut The CTL is shipped with the cutter s blades clearance set at the factory To adjust the blade clearance Cam the upper blade down Loosen lower blade holder lock screws Move lower blade in or out with knurled knobs When desired clearance is achieved lock lower blade holder screws Check adjustment by manually cutting bond paper The upper blade is mounted with a 2 shear angle 2506 item 71 FSC12 item 51 FSC18 item 85 FSC6 item 26 FSC12 item 29 FSC 18 item 31 14 Page Warranty Terms Conditions ALL SALES BY THE COMPANY ARE MADE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS PLEASE READ W
28. loting CTL application there is no reason to adjust the pilot release stop Roll Release Handle The roll release handle is located on the side of the servo feed If the PILOT RELEASE STOP has not been set then the handle can travel full stroke and lock in the fully open position This is the max feed roll opening of 0 060 If the pilot release stop has been set then the handle will only travel enough to open the rolls to the amount set by the pilot release stop The handle will not lock in this position do not force beyond this point Roll Pressure The roll pressure knob is located on the entrance side of the servo feed and is a knurled knob with a locking nut located right behind it It is positioned parallel to the inlet face and uses a compression spring for adjusting roll pressure Adjust so there is only enough pressure applied to properly feed the stock Exerting too much pressure can result in fluting of the edges or cause camber Entrance Guide The entrance guide s adjustable rollers should be adjusted to maintain the incoming stock centered on the feed rolls Similar guides are available as an option for the exit side of the feed rolls By having a set of guides on each side of the servo feed the setup time for aligning the material in the feed is decreased considerably as you will know that the material is straight through the feed before entering the die 4 Page SERVO FEED OPERATION When the control
29. n The number of cycles per minute entered will only be an approximation of what is actually produced Once a job is entered with valid parameters the operator will be returned to the SPLASH screen 8 Page SERVO FEED OPERATION MANUAL The manual mode is to aid in job setup and for maintenance You can jog forward JOG FWD and you can jog reverse JOG REV The jog speed can be changed via the JOG SPEED and JOG SPEED pushbuttons The speed can vary from 1 to 20 These numbers do not relate to anything like inches sec they are just a reference so you can return to a particular speed during future setups When either jog speed change button is pushed the speed changes a small amount initially The longer the button is held the more rapid the change becomes The SINGLE CYCLE pushbutton will cause 1 feed length to be fed at the normal production speed and accel decel rates The JOG LENGTH pushbutton will jog forward just like the JOG FWD button except it will only feed up to the programmed feed length and then the POSITION REFERENCE indicator needs to be reset to 0 000 before it will jog again Touch the POSITION REFERENCE box to reset it will toggle the rollers open and closed if the servo feed is equipped with air operated rollers F2 will cycle the cut off mechanism 0 000 in MANUAL SINGLE 0 000 in MANUAL TOGGLE OPENICLOSH 206 sil SPEED LE FEEDROLLS It is possible to jog th
30. nsor or isolated contact Min 3 5 VDC Max 30 VDC Min 2 mA Max 15 mA Sourcing 24VDC 250 mA max 460 VAC 30 50 60 Hz AC Cooled Enclosure Adjustable Mounting Stand Filtered and lightly lubricated Working Pressure 80 120 PSI Maximum Pressure 150 PSI 3 Mechanical Setup Installation Since the servo feed and the flat stock cutter have already been mounted on a common base no further mechanical component installation or alignment is required The CTL cabinet may need to be leveled to steady the entire assembly or optionally it can be anchored to your shop floor Four 12 13 threaded holes are provided in the cabinet base for this purpose It will be necessary to bring a compressed air and an electrical service drop to the area you intend to locate the CTL See the specification pages for requirements Gear Train The gear train is located on the same side as the roll release handle It is a non lubricated gear train so it is essentially maintenance free Pilot Release Stop Our 100D series servo feeds are equipped with a pilot release stop as standard In a press feeding application higher speed applications may benefit from adjusting the pilot release stop By limiting the amount the rolls can open time is not wasted by the rolls traveling full open and close The pilot release stop adjustment is mounted next to the roll pressure knob and should be set to let the rolls open about 0 005 010 to free the material during pi
31. r assistance with your CTL you may be requested to provide the Rapid Air serial number or other programming information You find this information on the ABOUT screen Because the display or other parts may not be working when you need to contact us please record the information in the space provided below 106D SERVO FEED ver SIN 50 00 CONTROLLER PROG 85700312 DISPLAY PROG 85700313 MOTOR PARAMETERS 857000 Rapid Air Corp Rockford IL 61109 815 397 2578 www rapidair com Servo Feed Model Number Serial Number S N Shop Order Number S O Controller Prog Number 12 Page TROUBLESHOOTING If the servo drive faults out it is reported back to the controller as a general fault condition and the controller is not able to annunciate the specific cause The operator interface will display the following message UNKNOWN DRIVE FAULT servo drive is faulted and the reason and observe There is a 2 character LED display on the front panel of the drive The left character will be F as in fault and the right side displays the 3 digit fault number as follows 1 9 1 break for example 13 Page FLAT STOCK CUTTER OPERATION The cutter operates by air pressure down spring return Different material types and thicknesses will require different amounts of time for the cutter valve to be energized For example 0 010 foil will require less time for the blades to cut throu
32. r has to be manually reset 0 000 in 0 0000 in 0 CYCLES MINUTE 0 CYCLES MINUTE TOTAL CYCLES CONT BATCHED COUNT BATCH 0 10 Page SERVO FEED OPERATION cont d AUTOMATIC cont d When operated in the BATCH mode and the batch count is complete the CTL will stop cycling and the following screen will appear When this screen is acknowledged you are returned to the start of the automatic function At this point you can start another batch change batch quantity and start another batch or operate in a continuous mode The CTL control has an input dedicated for a TAUT stock sensor A user supplied sensor wired to this input will cause the CTL to stop cycling if the input is triggered The feed will continue to feed the length in progress when the input is triggered so it must be adjusted to allow enough stock in the loop to allow the completion of that feed length TAUT STOCK INPUT ACTIVE INSUFFICIENT STOCK TO CONTINUE CYCLE STOPPED ACKNOWLEDGE 11 JOB REVIEW When the CTL is powered up the last job used edited or recalled is the active job by default If you do not remember what that job is you can review it by pressing F4 JOB REVIEW on the SPLASH screen ACTIVE JOB IS 0 FEED LENGTH 0 000 CYCLES MINUTE 0 CUT DURATION 0 000 ABOUT If you contact Rapid Air Corp to request parts or seek othe
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