Cameron Opti-Rip 415A-M1 Manual Download Page 2

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Table of Contents

INTRODUCTION ...................................................................5

Company Introduction .......................................................................... 6

Limited Warranty ................................................................................... 7

Machine Requirements and Layout ..................................................... 8

RULES FOR SAFE OPERATION .........................................9

Types of Warnings .............................................................................. 10

General Safety Rules ...........................................................................11

Machine Safety Decals ....................................................................... 12

INSTALLATION ...................................................................14

Receiving & Unpacking ..................................................................... 15

Opti-Rip Assembly .............................................................................. 16

Initial Placement........................................................................................... 16

Install the Belt Tracks .................................................................................. 16

Position the Roller Arms or Infeed Chains ................................................ 17

Install the Laser Stand ................................................................................. 17

Final Positioning .......................................................................................... 18

Position the Laser Stand ............................................................................. 18

Lag the Machine to the Floor ...................................................................... 18

Install the Lasers.......................................................................................... 18

Mount the Computer Stand ......................................................................... 19

Mount the Measuring Sensors .................................................................... 19

Connect Hoses and Wires ........................................................................... 19

Power Connection ....................................................................................... 20

Check Motor Rotation .................................................................................. 20

Movable Saw Connection (Optional) .......................................................... 20

Setting an Initial Saw Location ................................................................... 21

Set up a Simple Arbor ................................................................................. 21

Setting the Feed Delay ................................................................................ 21

Achieving Parallel Feed............................................................................... 22

Laser Setup .................................................................................................. 22

Final Alignment ............................................................................................ 23

Dismantling: ................................................................................................. 24

Machine Disposal: ....................................................................................... 24

OPERATION .......................................................................25

Safety & Training ................................................................................. 26

TABLE OF CONTENTS

Summary of Contents for Opti-Rip 415A-M1

Page 1: ...130 Salt Point Turnpike Poughkeepsie NY 12603 Tel 845 452 3780 Fax 845 452 0764 Email info cameronautomation com Web http www cameronautomation com Model 415A M1 SN ...

Page 2: ...Infeed Chains 17 Install the Laser Stand 17 Final Positioning 18 Position the Laser Stand 18 Lag the Machine to the Floor 18 Install the Lasers 18 Mount the Computer Stand 19 Mount the Measuring Sensors 19 Connect Hoses and Wires 19 Power Connection 20 Check Motor Rotation 20 Movable Saw Connection Optional 20 Setting an Initial Saw Location 21 Set up a Simple Arbor 21 Setting the Feed Delay 21 Ac...

Page 3: ...rchived Orders Report 37 Export Archived Orders 37 Edit System Parameters 37 Calibrating the Width Measuring Sensors 43 Simulate Production Run 43 Production Analysis and Reports 44 Width Distribution Report 47 Arbor Setup Report 47 Bundle Report 48 Bundle Summary Report 48 Pack Report 48 Part Names 48 Memory Stick 49 Arbor Optimization 50 Yield Distribution Report 51 Getting the Most with your Lu...

Page 4: ...Operational Troubleshooting 58 MJ SR2 Error Messages 61 MAINTENANCE 62 Daily Maintenance 63 Monthly Maintenance 64 PARTS SERVICE 65 Recomended Spare Parts 72 Parts Order Form 73 ...

Page 5: ...5 INTRODUCTION INTRODUCTION INTRODUCTION ...

Page 6: ... Opti Rip We urge you to read it carefully to become familiar with the components and features it describes Following these recomendations will make your cameron machine as trouble free and productive as possible This manual is intended for use by anyone working with this machine It should be kept available for immediate reference so that all operations can be performed with maximum efficiency and...

Page 7: ...of parts or other losses or for ex pense of repairs made outside of its factory except when made pursuant to Cameron Automation s PRIOR written consent Cameron Automation does not guarantee equipment furnished by us but manufactured by others such as belts electric motors starters controls or other electrical equip ment or accessories as they are guaranteed separately by their respective manufactu...

Page 8: ...of a common configuration 16 Bundle of Lumber 16 0 8 3 4 6 20Amps 220V 1 2 Air LIne 6 Bar Poughkeepsie N Y U S A Scale Material James L Taylor Mfg Co Layout Layout Cameron Rip System 1 48 9 3 14 jdg Saw Control Cabinet 4 2 7 9 8 1 90 Amps 460 3 Phase 60HP 1 2 Air Line 90psi Dust Collection 2 8 Duct 1 4 Duct 34H Quick Rip 413B 18 Cameron Rip Saw ...

Page 9: ...9 RULES FOR SAFE OPERATION RULES FOR SAFE OPERATION 415 R1 RULES FOR SAFE OPERATION ...

Page 10: ...lamation point This indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING in black letters on a safety orange background with a safety orange exclamation point This indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION in black letters on a safety yellow background with a safety yel...

Page 11: ...chine Wear eye protection See the plant supervisor to determine what protective equipment each job requires Follow electrical and fire codes Do not wear loose clothing jewelry or long hair around operating equipment Keep guards in protective position when machine is operating Keep clear of belts chains and moving parts DANGER Lockout ALL energy sources before servicing ...

Page 12: ...Cameron Automation 130 Salt Point Turnpike Poughkeepsie NY 12603 Tel 845 452 3780 Fax 845 452 0764 E mail info cameronautomation com WARNING Keep Hands Clear Lock power off before removing guards PLA80 2556 DANGER Hazardous Voltage Lock power off before servicing PLA80 2558 Part Number PLA80 2556 Description Chain Warning Sticker Location Chain Guards Part Number PLA80 2558 Description Voltage War...

Page 13: ...art Number PLA 190 Description Crush Hazard Location On Idle Roller Frames Part Number PLA34 252 Description Pinch Roll Warning Location Upper Beam on Pinch Roll Frame Part Number PLA34 523 Description Laser Warning Location On the outside of the last belt track ...

Page 14: ...14 INSTALLATION INSTALLATION 415 R1 8 15 18 JR INSTALLATION ...

Page 15: ...ed at our factory then disassembled for compact shipping The Laser Stand has been strapped to the top of the machine and the Computer and its mount have been removed and packed away Depending on the size and configuration of the machine belt tracks and infeed chains optional may be packaged on a separate skid The Opti Rip comes in several configurations The maximum size for each skid will be 210 l...

Page 16: ...cks make sure to loop a belt over each belt track before bolting it in place Otherwise you will not be able to attach the belts Each belt track attaches to the infeed legs and outfeed legs with the shallow side up Note that the tracks are numbered When mounting track number 1 also install the light curtain mounting brackets in their proper position When mounting track number 3 also mount the guard...

Page 17: ...Stand Position the Laser Stand in front of the belt area of the machine as shown in the photo Attach the operator controls to the horizontal tube These controls should be positioned side to side so that the lasers cover the entire section of the belts It should be positioned front and back so that the back of the controls are 10 from the belt track On machines with movable lasers be sure to positi...

Page 18: ...te that the board will be raised off of the belts by 3 3 8 before it is fed into the saw Make sure the polyurethane rollers are perfectly square with the feed of the saw If the ripsaw has any kind of fence on its infeed this should first be removed Position the Laser Stand Position the laser stand so that the back of the box enclosing the operator controls is 9 3 4 from the first belt track Lag th...

Page 19: ...r Motor Black Black Black Green Jog Encoder Red Black Shield White Green 121 127 67 68 110V Control Stand Wires Black Green Red Blue 43 Orange 44 50 51 48 31 GND Hot Contact Coil Chains Blue 24V Control Stand Cable Wire 6 Wire 5 Wire 2 Wire 1 Wire 3 Wire 4 87 88 89 90 91 92 24VDC Process Deduct Next Original Auto 31 61 50 129 Black White Green Lasers 62 30 1K Ω Lineal Encoder Green Black Shield Re...

Page 20: ... Operator Controls Also press the power button on the computer Make sure that the air pressure regulator is set in the range between 60 psi and 80 psi Check Motor Rotation Select Inputs and Outputs from the Diagnostics menu on the computer Press the 5 key while in the diagnostics screen and the roller feed motor should run The roller should rotate in the proper direction to feed a board into the r...

Page 21: ...tion for an arbor setup as explained in the operation section of this manual Create a setup with a single 1 3 8 rip Build an arbor for your saw for a 1 3 8 rip using two blades Any size rip will work if your saw can t be set to a 1 3 8 rip Make sure Auto Skew is turned off Setting the Feed Delay Select Edit System Parameters from the Special menu Set the Feed Delay to 250 DO NOT change any other i...

Page 22: ...just before the bottom rollers reach their topmost position Also make sure the feed of the saw is perpendicular to the pinch rollers Lumber with internal stress will be difficult to feed consistently Laser Setup Make a setup board by finding a 16 board with VERY STRAIGHT AND PARALLEL edges cut on it Scribe a line on the board exactly one inch in from the leading edge Press the Set Lasers button on...

Page 23: ... kerf in the computer setup matches the actual saw kerf of the blades in the saw Put the setup board against the stops and click the Set Lasers button again This time align a laser to each position presented in the laser setup procedure Place a board on the stops the socket head screws and press the process button The Opti Rip should move the board under the lasers and display where the board shou...

Page 24: ...antle the machine reverse the Installation Assembly instructions Machine Disposal The components used in the construction of an Opti Rip are not hazardous or harmful When the machine has completed it s life cycle dispose of the materials according to local regulations ...

Page 25: ...25 OPERATION OPERATION 415 R1 8 15 18 JR OPERATION ...

Page 26: ...S RESPONSIBILITY to Permit only trained and authorized employees to operate equipment Inspect and maintain guards safety devices and start stop controls Instruct train and supervise the safe method of work Be sure personnel are properly trained and safety rules are clearly understood before operating or performing maintenance ...

Page 27: ... in front of the operator station It then repositions the board under the laser lines at the operators command Finally the belt conveyor moves the board from the laser area to the pinch rollers The pinch rollers pick the board up off the belt conveyor and feed it into the rip saw The control box houses the servo drive and various other electrical components The operator controls are located in a s...

Page 28: ...the process time of the job currently in process Edit Setups By clicking on the Setup button or the 1 key the operator can edit one of the 500 setups available Setups are numbered from 1 to 500 The reference number of the current setup is displayed in the title bar of the setup screen Before information can be entered into the setup editing window a saw arbor must first be configured To switch fro...

Page 29: ...and grade of lumber being processed Misc Space for any additional information pertaining to the job Saw Kerf The amount of wood in inches removed by each of the saw blades This is determined by tooth width Thickness Identifies in inches the lumber thickness being processed Auto Deduct The amount in inches that the computer automatically deducts from every board width prior to calculating the best ...

Page 30: ...equipped with Auto Skew Piece Count Lineal Feet Board Feet This offers the choice of displaying the tallies and required quantities of ripped widths on the operation screen as either piece count lineal feet or board feet Width The widths of the ripped stock that the machine will produce during this setup For rip saws with movable blades you may enter a random range For example entering 2 4 in the ...

Page 31: ...e active orders Each material to be processed will be listed separated automatically by thickness Note that if you stock your lumber in different grades you must designate the grade in the material name along with the species The Materials window also indicates the square footage remaining to be processed for each material Note that this total square footage is a totaled from all of your active or...

Page 32: ...e inch in from the straight edge Press the Set Lasers button to choose Laser Setup The computer will then prompt you to put the setup board on the stops against the socket head screws Once the setup board is in place against the stops press the OK button The setup board will be dropped onto the belts and moved underneath the lasers For fixed lasers slide the laser so that it is centered on the lin...

Page 33: ... Rips with no infeed chains this switch does nothing Process Button This button causes the board currently under the lasers to be moved to the pinch rollers and fed into the saw At the same time the next board is positioned under the lasers Next Pattern This button should be pressed when the operator is trying to rip around a defect in the board This button tells the computer to move the board und...

Page 34: ...he measured width of the board The board however may need to be shifted to one side of the other to obtain the best rip pattern The belts move the same speed and direction as the knob is turned The operator should NOT use the knob to move the board to another rip pattern If the operator does this the board will still rip where the lasers last indicated but the computer will think the board is stil...

Page 35: ...e to run a different job and switch back to the original setup to resume the first job To create a new setup or switch to a different setup click the Setup List button on either the main screen or from within the Edit Setup screen A list of available setups will be displayed To create a new setup click on one of the setups in the list then click the Duplicate button to duplicate it To select an ex...

Page 36: ...eate a new species and or grade entry Enter the Thickness of the lumber to be ripped inches the Width of the part to be produced inches and the Quantity of that rip width Note that you can specify the appropriate Units to properly describe the quantity Any one order may have material specified in different units Pieces Lineal Ft Bd Ft or Sq Ft Use the Notes field to designate part numbers or any o...

Page 37: ...peration of the machine Keep in mind that misadjustment of these values can render the machine unusable so great care should be taken when editing them The values that can be changed are as follows Arbor Length The usable length of the saw arbor where the saws are installed This value is only used for fixed arbor saws Saw 1 Near This should be checked if the saw furthest in on the arbor is nearest...

Page 38: ...tem Machine Type This should be set to the type of machine Opti Rip Quick Rip Skew that the software is operating It will change the software slightly to match the machine Clicking on the Edit Machine button will bring up additional system parameters specific to that machine see below Saw Type This should be set to match the type of saw that the Opti Rip is feeding For moving blade saws the Edit S...

Page 39: ...how far the saw moves when commands are given The Saw Script contains scripts for homing and move commands Laser System Type This should be set to match the laser system on the machine If it is set to movable lasers The Edit Lasers button will bring up another window with additional system parameters pertaining to the lasers The number of fixed and movable lasers in this window should match what i...

Page 40: ... the Quick Chop Label Printer IP Address This is the IP address of a label printer that is on the network with the Opti Rip The label printer can be used to produced bundle labels for labeling bundles of finished rips Machine Specific System Parameters The Edit Machine button brings up additional system parameters specific to the type of machine the software is controlling The following parameters...

Page 41: ... a board on the belts before they come up again In general this value should be set to 1 First Stops Delay for Automated Opti Rip Only This value determines how long the first stops that separate one board from the inventory of boards stay down when separating boards If this value is set too high multiple boards may be released before the stops return to their up positions This value should be use...

Page 42: ...ith the flow control valves on the skewing cylinder Pinch Start Delay After the board to be fed is in position this value determines amount of time in seconds from when the pinch rollers actuate until the feed belts are once again free to move for positioning the next board in front of the operator Lower Pinch Delay During over under feeding this delay in seconds defines how long the machine shoul...

Page 43: ...the board has been measured under the Special menu select Calibrate Sensors When prompted for a password enter 1234 Next enter the exact width of the board that was just measured and click on the Calibrate button The computer will use the values obtained from scanning the board as well as the entered width to calibrate the sensors Simulate Production Run When editing a setup the Simulate button ca...

Page 44: ...hs times their respective value divided by the actual measured width of the board Deduct The value assigned to the deduct function in the current setup Process Time The amount of accumulated time that has elapsed during a production run since starting the new batch Any pause in board measurement exceeding five 5 minutes causes the clock to stop return to the point of its last board measurement and...

Page 45: ...e The difference between the product value and product cost which represents the gross profit or loss of this production run This gain or loss does not include any overhead or processing costs Therefore these expenses must be subtracted from this figure to get an accurate representation of the financial results of this production run The Opti Rip Production Report is invaluable for maintaining inv...

Page 46: ...46 OPERATION OPERATION 415 R1 8 15 18 JR ...

Page 47: ... can also be a valuable tool for verifying that purchased lumber hasn t been pre sorted and picked through for particular widths Arbor Setup Report The arbor setup report shows the information necessary to set up the Opti Rip software and the rip saw for a particular job If the software is used off line to optimize jobs this report can be printed and given to the rip saw operator so that he knows ...

Page 48: ...un This report can be exported to a tab delimited file that can be read into a spreadsheet by choosing Export Bundle Summary under the File menu Pack Report The Pack Report shows statistical information regarding the incoming lumber from your supplier When you generate this report you are prompted to begin a new pack Pressing cancel will allow you to see the current status of the report without cl...

Page 49: ...otely Your Opti Rip software includes the ability to view certain production data from a web browser If Opti Rip computer has been properly networked you can access a general report for the current setup by using the syntax http 10 0 0 75 21000 report A general report can be accessed for a specific setup number as well For example to access setup 5 use http 10 0 0 75 21000 report 5 You can also se...

Page 50: ...des as determined the setting of the Rip For Req d field In the first mode when Rip For Req d is unchecked the Opti Rip optimizes an arbor for yield or value given the desired rip widths When the values are all set to the same number yield is maximized In the second mode when Rip For Req d is checked the optimizer configures an arbor that will produce approximately the required number or lineal fe...

Page 51: ...ll optimize the arbor and then simulate a production run and produce a production report When looking at the report look specifically at the yield and the quantities of each rip produced When using a saw with movable blades you will need to click on the Edit Saw button to see how the software arranged the fixed blades on the arbor Yield Distribution Report When editing a setup clicking on the Yiel...

Page 52: ...g lumber takes full advantage of the flexibility and features offered by Opti Rip By combining the computer s ripping solutions and laser line guidance with the operators insight of the quality requirements and defect limitations of the ripped stock being produced the primary goal to recover the maximum amount of clear ripped stock with minimum waste can be achieved Opti Rip s multiple laser line ...

Page 53: ...ws which results in the next highest product value of the combined rips These alternatives calculated by the Next Pattern switch are presented in order of descending value and NOT in order of descending dimensional yield It is very possible that this next solution is actually wider than the previous solution and of a higher board yield while the value has declined If the proposed combination is st...

Page 54: ...N RW1 RW2 RWN The average PRODUCT VALUE PVA which is printed on the report is the running average of all the processed boards It is calculated PVA PV1 PV2 PVZ Z 2 Value M Value M displayed on the screen is the value of the board currently being processed This single board value BV is calculated BV RW1 V1 RW2 V2 RWN VN BW 3 Average Lumber Value The average lumber value LVA is displayed as AVER VALU...

Page 55: ...Rip simulation is useful in understanding the operation of the Opti Rip and creating the optimal arbor design Once setups are created on the simulator they can be transferred to the machine via a memory stick or over an ethernet network To simulate running the Opti Rip press the Process button in the Simulation window The boards should be processed just as if you were running the actual machine ...

Page 56: ...56 TROUBLESHOOTING TROUBLESHOOTING 415 R1 8 15 18 JR TROUBLESHOOTING ...

Page 57: ...nt up The Width Count counts when the belts are moved This should count up when the belts move a board toward the saw and down when moving away from the saw The width sensors each show three values The first value changes from 0 to 1 whenever the beam is broken The remaining values are the servo counter values for the leading and trailing edge of the most recently measured board Outputs Outputs ca...

Page 58: ...something between the measuring sensors while you press A on the keyboard The belts should move and the Sensor Counts item on the screen should count up If it counts up whenever the belt moves regardless of whether the sensor beam is broken then the sensor transmitter and receiver may not be aligned properly There are LED s on the sensor itself that indicate when the sensors are aligned If boards ...

Page 59: ...eters If the boards are feeding into the saw consistently cocked by the same amount adjust the stops socket head screws by the appropriate amount to change the angle that the board is fed into the saw The lasers will have to be realigned after this is done Make sure all of the upper and lower rollers are touching the surface of the board being fed Boards feed straight but are consistently off to o...

Page 60: ...wear Lineal Measurement doesn t work Go into the diagnostics screen and make sure the Encoder Counts value increases when you trip the board present light curtain and spin the roller with the encoder on it The encoder counts value will not count unless the curtain is tripped Lineal Measurement isn t accurate In the system parameters the Pulses Per Inch value must be calibrated properly Increasing ...

Page 61: ...ll appear in the message box Indicates that a moving saw blade servo has tripped out or has been shut off Check the status of the Gang Rip saw servo drives Error when commanding saw to move Communication with the moving saw blade servo drive has been established but it is returning an error Check the error code on the gang rip saw servo drive Timed Out while waiting for drives to home We have been...

Page 62: ...the receiver and trying to find the position in which the LED completely switches off or shows a weak light Then temporarily fix the emitter in this position 4 Correct the direction of the receiver by observing its red LED until it is completely switched off or shows a weak light Then temporarily fix the receiver in this position 5 Repeat points 3 4 until when you reach alignment It s important to...

Page 63: ...63 MAINTENANCE MAINTENANCE 415 R1 8 15 18 JR MAINTENANCE ...

Page 64: ... 15 18 JR Daily Maintenance Photocopy for daily use Daily Maintenance Checklist Keep interlocks clean and tested Keep the keyboard clean and clear of sawdust Keep sensor clean and clear of sawdust Backup to Memory Stick Comments Date By ...

Page 65: ... Checklist Keep the belts tightened just enough so the belts hang 1 8 below the bottom of the belt track Overtightening may damage the belts Grease all bearings Check all bearing set screws for tightness on shafts Check all cylinder clevises for wear Check all pivoting and moving parts for wear Comments Date By ...

Page 66: ...66 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR PARTS SERVICE ...

Page 67: ...ngs disk under PLC projects This will set the IP Address to 10 0 0 78 Leave the dip switches at the factory default RS 232 Use a 9 pin serial extension cable to connect the Digi One to the bottom of the B B RS 232 to RS 485 converter which is located inside the MJ control box Cut the Digi One power cable and connect the Digi One end of the cable to the 24V DC power supply located inside the MJ con...

Page 68: ...9 05 AS NZS5 3548 Digi One SP Immunity EN 55024 1998 EN61000 6 2 1999 LED Color State Indicates Power Red labeled PWR On Power detected Steady blinking Waiting for an IP address Blinking 1 1 1 Starting the EOS Blinking 1 3 1 Starting the TFTP process Blinking 1 5 1 Configuration returned to factory defaults Blinking 9 1 1 Contact Tech Support 1 952 912 3444 Off No power detected Link Green On Phys...

Page 69: ...69 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR ...

Page 70: ...70 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR ...

Page 71: ...71 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR ...

Page 72: ...72 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR ...

Page 73: ...73 PARTS SERVICE PARTS SERVICE 415 R1 8 15 18 JR ...

Page 74: ...ntime of your automated opti rip to a minimum Quantity Part No Description 1 SWITCHPU 52 Black Head N O Contact Switch 1 SENSOR 35 Diffuse Laser Sensor 1 VALVE 76 Single Unit Valve 1 VALVE06FC 2 3 8 Flow Control Valve 1 VALVE06FC 3 3 8 BIMBA Flow Control Valve 1 VALVE06QE 2 3 8 QE3 Quick Exhaust Valve 1 ENCODER 20 Red Lion Encoder 1 LASER 14 Laser Light ...

Page 75: ...hone ___________________________ Fax ______________________________ Purchase Order ___________________ 2 Ship to Company __________________________ Address ___________________________ Address ___________________________ City _______________________________ State _____ Zip ____________________ Attention __________________________ Phone ___________________________ Fax _____________________________ P...

Page 76: ...Machinery Basic Concepts General Principles for Design pr EN 1050 Principles for Risk Assesment EN 294 Safety distances to prevent danger zones being reached by upper limbs EN 60204 Electrical equipment for industrial machinery EN 349 Safety distances to avoid crushing of human body EN 60529 Touch distances for electrical equipment following the provisions of the following directives 89 392 EEC 91...

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