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CABINET REEL OPERATING INSTRUCTIONS CABINET REEL
OPERATING INSTRUCTIONS
RAPID-AIR CORPORATION
4601 KISHWAUKEE ST. ROCKFORD, IL 61109-2925
Phone: (815) 397-2578 Fax: (815) 398-3887 Web Site: www.rapidair.com
MODELS
15, 25, 40 & 60 SERIES REEL MANUAL INDEX


1. Installation

2. Reel diagram

3. Reel electric component diagrams for series 15, 25, 40 & 60

4. Reel specifications and maintenance chart

5. Dancer arm functions and diagrams

6. Taut stock functions and diagram

7. Coil load and unload

8. Trouble shooting

9. RAMM motor drive board operating instructions

10. KBRG motor board operating instructions

11. Electrical diagrams and reel parts breakdown OPERATING INSTRUCTIONS FOR CABINET REEL
SERIES 15, 25, 40, 60

INSTALLATION

1. The reel that you have just received is fully assembled and ready to be put into
position. Due to shipment vibration, the reel should be checked to be sure that all
screws and bolts are tight and that all electrical components are in place inside the
cabinet; visually inspect the reel for damaged parts due to shipment. If the reel was
damaged in shipment, contact the carrier first to report the damage and then your
distributor.

2. Install the reel on a level surface with sufficient clearance for loading and
unloading the coils.

3. Wiring

The series 15, 25, & 40 reel is completely self contained and needs only to be
plugged into a 20 amp, 120 volt, 60 Hz outlet. If an extension cord is used as a
source to the reel, it should be a minimum #12 gauge wire to keep the voltage loss
down and for electrical safety reasons.

The series 60 reel or series 40 reel with a 3 hp motor, although completely wire,
requires a 240 volt, 1 pH, 60 Hz input. Rapid Air has provided a point of connection
in the form of a fused disconnect box for this purpose. Once the input wiring is
complete, the reel should be ready to run electrically.

The following pages are intended to familiarize you with the reel no matter what the
size. If, after reading the manual, you have questions on the operation on the reel,
we would appreciate hearing from you. START UP PROCEDURE

Prior to applying power to the machine the operator should review all the controls on
the machine. A brief summary of the controls is listed below.

MAIN CONSOLE & CONTROLLER
The main control console & controls are mounted on the end of the cabinet. Located
on the face of the console are eight switches, on potentiometer, push-button and 2
reset switches, which are explained below.

1. DIRECTION CONTROL - (CW-CCW) - CAUTION: DO NOT REVERSE MOTOR
WHEN THE REEL IS RUNNING! - The direction control switch select the direction the
reel will turn, clockwise or counter clockwise. Once switched there is a time delay
before resuming normal operation. This is a built in safety for the machine.

2. % SPEED POT - The % speed pot adjusts the maximum speed that the reel will
rotate and should be set to maintain a constant feed rate.

3. ON/OFF SWITCH - This illuminated switch is the main power switch for the
controller. It must be ON for the machine to function.

4. PAYOUT/REWIND SWITCH - The payout rewind switch selects whether the dancer
arm will cause the reel to function at a low speed at the bottom of the arc and increase
the reel speed as the arm raises. (Payout); or cause the reel to function at a low speed
at the top of the arc and increase the reel speed as the arm lowers. (Rewinds)

5. RUN/STOP/JOG SELECTOR SWITCH - The switch selects between Run& Jog. If
in Run and the control arm is moved the coil plate will turn. If in Jog, the Jog button
has to be depressed for the coil plate to turn.

6. JOG BUTTON - Used for intermittent movement of the coil plate, mainly for set up,
speed is adjusted on the 69100076 board by potentiometer R3 on the electrical control
sub panel.

7. DANCER ARM LOOP HEIGHT & RANGE ADJUSTMENT -
a. Loop Range - The loop range switch adjusts the amount of travel the dancer arm will
move to provide the full range of speed of the pallet reel.
b. Loop Height - This switch is used for setting the start position of the control arm.
The setting determines when the reel will start turning. Each position will move the
operating angle of the arm so that top-to-bottom travel is adjusted to accommodate
specific material and loop height requirements.

8. LOOP ARM LEFT/RIGHT SWITCH
The loop arm left right switch selects the control which side of the reel the dancer arm
is controlling from. If the switch is in the wrong position the reel will run continuously at
full speed. 9. LOOP ARM/ARM EXTERNAL SWITCH
This switch selects either dancer arm (internal ) or D connector (external) speed
control functions.

10. RESET BUTTONS
a. 15 amp - This is the main circuit breaker for the reel.
b. 3 amp - this is the circuit protection for the D connector. Any shorts or over
loads would trip this breaker.

11. REMOTE INTERFACE PORT D CONNECTOR
This connector is used to communicate with external loop control equipment.

CAUTION: Never plug any type of computer or non Rapid-Air equipment into this
plug or severe damage will result. Always consult with the factory when installing
new external controls for compatibility and wiring information.

ELECTRICAL COMPONENT DESCRIPTION
69100034 board - proportional control board
69100076 board - component interface board
69100014 Motor control board (RAMM) - D.C. motor board
69100196 Motor control board (KBRG) - D.C. motor board
69100185 Motor control board (KBRG) - D.C. motor board 3 hp REEL SPECIFICATIONS AND MAINTENANCE



REEL CAPACITY VALUES
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SERIES 15 25 40 60
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COIL CAPACITY (LB.) 1500 2500 4000 6000
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RPM (STANDARD) 23 23 23 17
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STANDARD STOCK WIDTH 6 &12 6, 12 &18 12, 18 &24 12, 18 &24
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COIL I.D. 14 - 22 16 - 24 16 - 24 18 - 25
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MAX COIL O.D. STANDARD 36 36 36 48
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OPTION 48 48 48 60
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OPTION 60 60 72
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INPUT VOLTAGE (1 PH) 120VAC 120VAC 120VAC 240VAC
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MOTOR VOLTAGE 90VDC 90VDC 90VDC 180 VDC
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MOTOR SIZE 1/2 HP 1 HP 1 1/2 HP 2 HP
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