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Summary of Contents for iREL Systems

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Page 2: ...1 iREL Systems Material Handling Reference Information REL Inc 57640 North Eleventh Street Calumet MI 49913 Phone 906 337 3018 Fax 906 337 2930 www relinc com ...

Page 3: ...ead this manual thoroughly The information in this document is subject to change without notice and should not be construed as a commitment by REL Inc REL Inc assumes no responsibility for any errors that may appear in this manual In no event shall REL Inc be liable for incidental or consequential damages arising from use of this manual or of the software and hardware described in this manual For ...

Page 4: ...eral Safety 17 Chapter 5 Preventive Maintenance 18 Introduction 18 Routine Maintenance 18 Chapter 6 Illustrated Parts Breakdown 19 Corner Turn Tipple Conveyor 19 Ramp Conveyor 21 Paint Conveyor 22 Straight Conveyor 25 High Speed Tipple 26 Board Flipper 1 32 High Speed Corner Transfer 35 High Speed Tenoner Transfer 38 Board Accumulator Conveyor 38 Tipple Conveyor 42 Flipper Accumulator 44 Turntable...

Page 5: ...r Included in this project is a new board dryer that was supplied and installed by others The conveying system is designed to process boards from 30 x 60 to 52 x 120 Following is a brief description of each piece of equipment supplied and built by REL Corner Turn Tipple Conveyor The REL Corner Turn Tipple Conveyor is manufactured to smoothly transition the board to either the new paint line or to ...

Page 6: ...ollers on these conveyors Straight Conveyors The REL Straight Conveyors are manufactured to move the board in the conveying process Edge guides are provided as needed to control product flow The board rides on lineshaft driven rollers on these conveyors High Speed Tipple The REL High Speed Tipple Conveyor consists of a tipple frame that incorporates two sets of driven belt beds It is designed to s...

Page 7: ...rd and stop the infeed belts when the leading edge of the board reaches the pivot point of the flipper arm mechanism The lifting arm side of the flipper tilts the board to approximately 90 degrees allowing the board to transfer to the lowering arm side of the flipper The lowering arm then pivots down to the horizontal position and leaves the board on the outfeed belt bed which moves the panel on t...

Page 8: ...eyor The REL Tipple Conveyor is built to move the board running on this line back onto the existing conveyor line The conveyor consists of a powered belt conveyor mounted on a tipple frame that pivots at the infeed end lowering the outfeed end to the height of the existing conveyor line elevation The tipple frame nests with the existing power curve With the tipple raised board will travel through ...

Page 9: ...ch motor will be green if it is running grey if it is off or red if it is faulted Servo Motor Status o The servo motors will be green if they are ready and grey if they are off or faulted Alarm faulted motors servos o In the event that a motor faults an alarm will be triggered and it will turn red on the Overview screen o All active alarms will scroll across the bottom of the Overview screen and a...

Page 10: ...E LOCAL Mode selection o This button is security protected you have to be logged in to change it o During normal run the line will be in REMOTE mode o In REMOTE mode the line will be started stopped from the main plant DCS Control System o In LOCAL mode the line can be started stopped from the 2 local HMIs A START SYSTEM button will be visible in Local mode PRODUCT SIZE selection o This button is ...

Page 11: ...ge Pressing the Login button on any screen allows the user to select Access Level and login and logout Entering an incorrect password will cause the system to logout of the current Access Level Figure 2 Overview Screen Figure 3 Login Screen ...

Page 12: ...f the screen is where alarms just for that respective zone will scroll The status box next to each motor reflects the mode that each motor is in which are described below Grey à Set to Auto Mode à Off Green à Set to Auto Mode à On Orange à Set to Manual Mode à Off Yellow à Set to Manual Mode à On Red à Fault The Zone 0 screen also has indication for the signal between our control system and the ma...

Page 13: ... about this signal this signal will turn on the dryer out feed motor B7 as long as our system is powered up Signals from our system out to the plant 70 40 MODE this indicates that our system is ready to accept board from the plant This signal will drop out anytime there is a problem in one of our zones ACCUMLATOR STACKING indicates that we are accumulating board stacking it up ACCUMLATOR FEEDING i...

Page 14: ...d manually turn on off the paint motors The Zone 5 screen has the same features as the other screen with the ability to reset faulted servos and turn the blowers on and off If a servo remains grey instead of starting with the rest of the servos it can be reset by pressing on the servo and pressing the reset button on the popup screen Figure 6 Zone 7 Figure 7 Zone 1 ...

Page 15: ... can be acknowledged by selecting them on this screen The text for acknowledged alarms will be yellow and turn to green once the alarm trigger has become false To delete specific alarms select the alarm and press the Delete Selected Acknowledged Alarm button To clear all alarms press the Clear button Figure 8 Zone 5 Figure 9 Alarm Screen ...

Page 16: ...ual Off Auto MOA screens can be viewed by pressing on the motor icon for the desired motor When a motor is in Auto mode you cannot change its speed If the motor is in Off or Manual mode a numeric input box will appear Press on the box to change the motor speed Figure 10 Zone 0 Motors Figure 11 Zone 0 Motors ...

Page 17: ... section of this manual Proper housekeeping cleanliness will ensure trouble free operation All belt idler sheaves have lube for life sealed ball bearings The drive shafts conveyor rollers and servo pivot shafts have pillow block style bearings with zerk fittings for lubrication A routine belt inspection would include a quick visual and noise inspection once a month A more complete inspection shoul...

Page 18: ...aintenance personnel and service personnel must know that safety practices are a vital part of the job Whenever maintenance or repair is performed on any part of the Line all equipment must be in a zero energy state and proper lockout tagout procedures must be performed When putting equipment in a zero energy state the operator may encounter the following energy sources Electrical power Pressurize...

Page 19: ... attempt to perform any maintenance on equipment until all safety instruction have been reviewed and all power sources are locked out as described in Chapter 3 Safety Routine Maintenance Lubrication of Bearings All of the mounted bearings require grease lubrication Gear Box Oil See manufactures recommendations regarding changing oil in the drive motor gearbox UHMW Wear Strips on conveyors The wear...

Page 20: ...www relinc com iREL Systems 19 Chapter 6 Illustrated Parts Breakdown Corner Turn Tipple Conveyor Figure 13 Corner Turn Tipple Conveyor Figure 14 Corner Turn Tipple Conveyor ...

Page 21: ...educer 1 4 Polychain Belt roller drive 1 5 Pillow block bearing 24 6 Flange bearing 2 bolt 22 7 Flange bearing 2 bolt 2 8 Motor 2hp 230 460V Premium 1 9 Gear reducer 1 10 Polychain Belt roller drive 1 Fenner Drives 1 2 round urethane belting 11 Fenner Drives 3 8 round urethane belting 11 Figure 15 Corner Turn Tipple Conveyor Figure 16 Power Curve ...

Page 22: ...www relinc com iREL Systems 21 Ramp Conveyor Figure 17 Ramp Conveyor Figure 18 Ramp Conveyor ...

Page 23: ...s List Paint Conveyor Item Description Qty 1 Motor 2hp 230 460V Premium 1 2 Gear reducer 1 3 Polychain Belt 1 4 Polychain Belt 1 5 Flange bearing 2 bolt 4 6 Flange bearing 2 bolt 36 Fenner Drives 3 8 round urethane belting 18 Figure 19 Paint Conveyor ...

Page 24: ...www relinc com iREL Systems 23 Figure 20 Paint Conveyor Figure 21 Paint Conveyor ...

Page 25: ...30 460V Premium 1 2 Gear reducer 1 3 Flange bearing 2 bolt 8 4 Flange bearing 2 bolt 12 5 Fenner A twin round urethane belting 10 6 Wear strip out feed end 15 7 Polychain Belt 2 8 Polychain Belt 1 9 Wear strip in feed end 15 Fenner Drives 3 8 round urethane belting 3 Figure 22 Paint Conveyor ...

Page 26: ...www relinc com iREL Systems 25 Straight Conveyor Figure 23 Straight Conveyor Figure 24 Straight Conveyor ...

Page 27: ...arts List High Speed Tipple Item Description Qty 1 Motor 2hp 230 460V Premium 1 2 Gear reducer 1 3 Polychain Belt 1 4 Flange bearing 2 bolt 2 5 Flange bearing 2 bolt as req d Fenner Drives 38 round urethane belting as req d Figure 25 High Speed Tipple ...

Page 28: ...www relinc com iREL Systems 27 Figure 26 High Speed Tipple Figure 27 High Speed Tipple ...

Page 29: ...ock bearing 2 3 Wear strip 30 5 Servo motor 460V 1 6 Servo gear box 1 7 Spherical Bearing sealed 4 8 Timing Belt 1 9 Polychain Belt lower belts drive 1 10 Motor 2hp 230 460V Premium 1 11 Gear reducer 1 12 Drive sheave assembly 20 13 Fenner A twin round urethane belt 10 14 Polychain Belt coupling belt 1 15 Flange bearing 2 bolt 2 Figure 28 Corner Transfer Overpass ...

Page 30: ...www relinc com iREL Systems 29 Figure 29 Corner Transfer Overpass Figure 30 Corner Transfer Overpass ...

Page 31: ...www relinc com iREL Systems 30 Figure 31 Corner Transfer Overpass Figure 32 Corner Transfer Overpass ...

Page 32: ... 6 8 Flange bearing 2 bolt 6 9 Flange bearing 2 bolt 64 10 Fenner A twin round urethane belt 6 11 Idler sheave assembly 24 12 Crowned Idler sheave assembly 6 13 Drive sheave assembly 6 14 Servo motor 460V 1 15 Servo gear box 1 16 Spherical Bearing sealed 2 17 Thrust washer 2 18 Wear strip 6 19 Spherical Bearing sealed 4 Fenner Drives 3 8 round urethane belting 64 Oil resistant vibration dampener s...

Page 33: ...www relinc com iREL Systems 32 Board Flipper 1 Figure 34 Board Flipper 1 Figure 35 Board Flipper 1 ...

Page 34: ...www relinc com iREL Systems 33 Figure 36 Board Flipper 1 Figure 37 Board Flipper 1 ...

Page 35: ...er 1 6 Pillow block bearing 6 7 2 bolt flange bearing 20 8 Bumper Pad 5 9 Idler sheave assembly 32 10 Drive sheave assembly 16 11 Pillow block bearing 6 12 Rod end female 10 13 Belt wear strip 32 14 Rod end male 10 15 Idler sheave assembly 16 16 Fenner A twin round urethane belt 16 17 Servo motor 460V 1 18 Servo gear box 1 19 Rod end female 3 20 Spherical bearing 1 Figure 38 Board Flipper 1 ...

Page 36: ...www relinc com iREL Systems 35 High Speed Corner Transfer Figure 39 High Speed Corner Transfer Figure 40 High Speed Corner Transfer ...

Page 37: ...www relinc com iREL Systems 36 Figure 41 High Speed Corner Transfer Figure 42 High Speed Corner Transfer ...

Page 38: ... urethane belting 6 8 Flange bearing 2 bolt 4 9 Servo motor 460V 1 10 Servo gear box 1 11 Spherical Bearing sealed 4 12 Spherical Bearing sealed 2 13 Thrust washer 2 14 Pillow block bearing 2 15 Drive sheave assembly 6 16 Idler sheave assembly 12 17 Motor 5hp 230 460V 1 18 Polychain Belt belt drive 1 19 Wear plate 1 2 1 20 Fenner A twin round urethane belt 6 21 Wear plate 1 2 1 22 Wear strip 1x3 1...

Page 39: ...www relinc com iREL Systems 38 High Speed Tenoner Transfer Board Accumulator Conveyor Figure 45 Board Accumulator Figure 44 High Speed Tenoner Transfer ...

Page 40: ...www relinc com iREL Systems 39 Figure 46 Board Accumulator Figure 47 Board Accumulator ...

Page 41: ...www relinc com iREL Systems 40 Figure 49 Board Accumulator Figure 48 Board Accumulator ...

Page 42: ... Belt roller drive 1 4 Pillow block bearing 2 5 Flange bearing 4 bolt 4 6 Pillow block bearing tapped base 28 7 Air cylinder 1 8 Air cylinder 1 9 2 bolt flange bearing 2 10 Servo motor 2 11 Helical bevel reducer 2 12 Wear plate 1 2 x 2 28 13 Wear plate 1 2 x 2 4 14 Flange bearing 4 bolt 4 Fenner Drives 1 2 round urethane belting 14 ...

Page 43: ...www relinc com iREL Systems 42 Tipple Conveyor Figure 50 Tipple Conveyor Figure 51 Tipple Conveyor ...

Page 44: ... 1 Motor 2hp 230 460V 2 2 Gear reducer 2 3 Flange bearing 2 bolt 10 4 Polychain Belt 1 5 Polychain Belt 1 6 Flange bearing 2 bolt 20 7 Fenner A twin round urethane belt 6 8 Wear strip 3 4 x 2 24 9 Air cylinder 1 Fenner Drives 38 round urethane belting 9 Figure 52 Tipple Conveyor ...

Page 45: ...www relinc com iREL Systems 44 Flipper Accumulator Figure 53 Flipper Accumulators ...

Page 46: ...www relinc com iREL Systems 45 Turntable Detail A Design Engineering Example Figure 54 REL s attention to design engineering detail ...

Page 47: ...pply to accessories or damage caused where repairs have been made or attempted by others This warranty gives you specific rights and you may have others rights which vary by state or province IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LIABILITY FOR LOSS OF PROFITS ARISING FROM THE SALE OR USE OF THIS PRODUCT SOME STATES IN THE U S AN...

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