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REL iREL Systems Manual

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  • Page 2 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 All rights reserved. Printed in the United States. This document and parts thereof may not be reproduced or copied without the written permission of REL, Inc. Contents of this manual must not be distributed to a third party nor be used for any unauthorized purpose. Warning and Disclaimer Correct usage of this machine is important to assure the expected machine functionality as well as operator safety. Read 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 questions, comments, or concerns please contact REL, Inc. during normal business hours: Monday through Friday, 8:00 am to 5:00 pm EST. REL, Inc. 57640 North Eleventh Street Calumet, MI 49913 Phone: (906) 337-3018 Fax: (906) 337-2930 www.relinc.com...

  • Page 4: Table Of Contents

    www.relinc.com iREL Systems Contents Chapter 1 – Overview ..................4 Chapter 2 – Operation ..................8 Getting Started ................................ 8 Overview .................................. 8 Login Page ................................10 Zone Screens ................................11 Alarm Summary ..............................14 Motor MOA Screens ............................. 15 Chapter 3 – Maintenance ................16 Chapter 4 – Safety ..................... 17 Hazardous Materials............................17 General 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 .

  • Page 5: Chapter 1 - Overview

    Chapter 1 – Overview Figure 1: Example Overall Line Layout REL, Inc. builds conveyor systems for manufacturing processes. This example project consists of a new corner turn tipple, ramp conveyor, paint conveyor, powered corner turn and straight conveyors, high speed tipple, two flipper conveyors, two high speed corner transfer conveyors, a board accumulator, and tipple conveyor. 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 by-pass the paint line and continue to the existing main line. The board rides on lineshaft driven rollers on this conveyor.
  • Page 6 The REL Ramp Conveyor is manufactured to smoothly transition the board from the 70” elevation of the Quarter Turn Power Curve to the 42” height of the Paint Conveyor. The board rides on lineshaft driven rollers on this conveyor. Paint Conveyor The REL Paint Conveyor has driven infeed and outfeed belt beds with a gap provided to accept the curtain coater provided by others. The infeed and outfeed conveyors are linked with a timing belt to ensure constant speed through the paint conveyor. The paint is applied with the board completely flat. The corner turn conveyor following the paint conveyor is positioned such that the board will not start turning until the tail end has exited the paint stream.
  • Page 7 Corner Transfer/Overpass Conveyor The REL Corner Transfer/Overpass Conveyor is built to either feed the first board flipper or by-pass the first flipper and feed the second board flipper. The overpass portion of this conveyor consists of a stationary lineshaft driven roller bed that moves the board over the top of the corner transfer portion of this conveyor to feed the second board flipper. The corner transfer portion of this conveyor consists of a stationary lineshaft driven roller bed, and pop-up belt transfer with an integral vacuum system. The function of the corner transfer portion is to take board moving down the line and change its direction, exiting at a right angle to the infeed flow and depositing the board on the first board flipper. As the board enters the infeed end on the roller bed, sensors indicate position up against the stop fence. The belt bed then raises by way of a rotary servo motor, lifting the board off the rollers and transferring it off the conveyor. The vacuum assist on the belt bed helps in maintaining good...
  • Page 8 Tipple Conveyor 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...

  • Page 9: Chapter 2 - Operation

    www.relinc.com iREL Systems Chapter 2 – Operation Getting Started This line is controlled from two HMI screens. One is installed in the Paint Coater control panel, CP-2000, and the other is in the Main control panel, CP-1000. The Overview screen shows the status of each motor and allows you to select board size. Each Zone screen shows the speed of each motor in that zone and with security login, allows you to manually turn on all the motors in that zone. The Alarm Summary screen shows a list of alarms. It can be accessed by pressing the “Go To Alarm” button on the Overview screen. Overview The Overview screen is for monitoring the system and selecting the main control functions.
  • Page 10 www.relinc.com iREL Systems System Restart • o After ESTOP: • To restart the line after an ESTOP was pressed use the start zone ## motors button in all the zones starting with zone 7 and counting down o After Zone Fault: • To restart after a Zone fault start the zones that stopped from the highest number to the lowest o During a startup sequence: •...

  • Page 11: Login Page

    www.relinc.com iREL Systems Figure 2: Overview Screen Login Page 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 3: Login Screen...

  • Page 12: Zone Screens

    www.relinc.com iREL Systems Zone Screens The screens for Zone 0, Zone 3, Zone 4, Zone 6 and Zone 7 are all very similar. They show each motor in its respective zone, and the number below each motor represents the percentage at which it is running. The “Start/Stop Zone XX Motors” button allows users with access to start an individual zone. The box on the top of 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 Figure 4: Zone Screen The Zone 0 screen also has indication for the signal between our control system and the main plant control system upstream and downstream from this system. The signals will show gray when they are off and green when they are on.
  • Page 13 www.relinc.com iREL Systems Signals into our system from the plant: • 70/40 MODE – this is the main start/stop signal for REMOTE mode. This is also the signal that will shift the tipples down at the infeed and outfeed of the line • DOWNSTREAM LINE READY FOR PRODUCT – This is on when the downstream system is ready to accept product from our line. If this is not on the system will go into “STACK” mode on the accumulator • DRYER AT SET TEMPERATURE – This is a signal from the dryer that indicates that the dryer is at temperature • DRYER CONVEYORS RUNNING – This is a signal from the dryer that indicate the dryer conveyors are running o NOTE 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 – indicates that the accumulator is being unloaded, feeding the downstream system • ACCUMLATOR FEED THRU – indicates that the accumulator is not stacking or feeding/unloading, board is passing thru the accumulator •...
  • Page 14 www.relinc.com iREL Systems Figure 6: Zone 7 All of the above regarding Zone screens also applies to Zone 1. However, the Zone 1 screen also allows you to turn on the paint system and manually turn on/off the paint motors. Figure 7: Zone 1 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.

  • Page 15: Alarm Summary

    www.relinc.com iREL Systems Figure 8: Zone 5 Alarm Summary The Alarm Summary screen shows all alarms. The text of the alarm will initially be red. Alarms 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 9: Alarm Screen...

  • Page 16: Motor Moa Screens

    www.relinc.com iREL Systems Motor MOA Screens Users with access can manually operate each motor. The Manual-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: Chapter 3 - Maintenance

    Chapter 3 – Maintenance During the course of operation of all REL custom conveying equipment, some routine maintenance will be required. This includes such things as belt inspection, bearing lubrication, inspection of belt guides and edge guides, etc. Links to manufacturers’ recommendations are included in the appendix 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 should include such things as ensuring proper belt tension, alignment, drive component wear, etc. Inspect belts for wear or damage and replace as needed.

  • Page 18: Chapter 4 - Safety

    When putting equipment in a zero energy state, the operator may encounter the following energy sources: • Electrical power • Pressurized air • Components that can fall • Other potential hazards not listed here Integrated Safety Features: Figure 12: REL's integrated safety features- Proximity Sensors (left); Emergency Stops (middle); Light Curtains (right)

  • Page 19: Chapter 5 - Preventive Maintenance

    www.relinc.com iREL Systems Chapter 5 – Preventive Maintenance Introduction Preventive maintenance (PM) is essential for the proper operation of the Line. Elements of an effective PM program include documentation, verification of proper operation, routine maintenance, inspection, spare/replacement parts, and electrical maintenance. CAUTION! Do not 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 strips on each conveyor section should be inspected after every year of operation. Replace the wear strip if it shows signs of excessive wear.

  • Page 20: Chapter 6 - Illustrated Parts Breakdown

    www.relinc.com iREL Systems Chapter 6 – Illustrated Parts Breakdown Corner Turn Tipple Conveyor Figure 13: Corner Turn Tipple Conveyor Figure 14: Corner Turn Tipple Conveyor...
  • Page 21 www.relinc.com iREL Systems Figure 15: Corner Turn Tipple Conveyor Figure 16: Power Curve Corner Turn Tipple Conveyor Parts List Item # Description Air cylinder Motor, 2hp, 230/460V, Premium Gear reducer Polychain Belt, roller drive Pillow block bearing Flange bearing, 2-bolt Flange bearing, 2-bolt Motor, 2hp, 230/460V, Premium Gear reducer Polychain Belt, roller drive Fenner Drives 1/2"...

  • Page 22: Ramp Conveyor

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

  • Page 23: Paint Conveyor

    www.relinc.com iREL Systems Ramp Conveyor Parts List Item # Description Motor, 2hp, 230/460V, Premium Gear reducer Polychain Belt Polychain Belt Flange bearing, 2-bolt Flange bearing, 2-bolt Fenner Drives 3/8" round urethane belting Paint Conveyor Figure 19: Paint Conveyor...
  • Page 24 www.relinc.com iREL Systems Figure 20: Paint Conveyor Figure 21: Paint Conveyor...
  • Page 25 www.relinc.com iREL Systems Figure 22: Paint Conveyor Paint Conveyor Parts List Item # Description Motor, 2hp, 230/460V, Premium Gear reducer Flange bearing, 2-bolt Flange bearing, 2-bolt Fenner "A" twin round urethane belting Wear strip, out-feed end Polychain Belt Polychain Belt Wear strip, in-feed end Fenner Drives 3/8"...

  • Page 26: Straight Conveyor

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

  • Page 27: High Speed Tipple

    www.relinc.com iREL Systems Straight Conveyor Parts List Item # Description Motor, 2hp, 230/460V, Premium Gear reducer Polychain Belt Flange bearing, 2-bolt Flange bearing, 2-bolt as req'd. Fenner Drives 38" round urethane belting as req'd. High Speed Tipple Figure 25: High Speed Tipple...
  • Page 28 www.relinc.com iREL Systems Figure 26: High Speed Tipple Figure 27: High Speed Tipple...
  • Page 29 www.relinc.com iREL Systems High Speed Tipple Parts List Item # Description Shock absorber Flange bearing, 2-bolt Pillow block bearing Wear strip Servo motor, 460V Servo gear box Spherical Bearing, sealed Timing Belt Polychain Belt, lower belts drive Motor, 2hp, 230/460V, Premium Gear reducer Drive sheave assembly Fenner "A"...
  • Page 30 www.relinc.com iREL Systems Figure 29: Corner Transfer Overpass Figure 30: Corner Transfer Overpass...
  • Page 31 www.relinc.com iREL Systems Figure 31: Corner Transfer Overpass Figure 32: Corner Transfer Overpass...
  • Page 32 www.relinc.com iREL Systems Figure 33: Corner Transfer Overpass Corner Transfer/Overpass Parts List Item # Description Motor, 5hp, 230/460V, Premium Gear reducer Polychain Belt Motor, 2hp, 230/460V, Premium Gear reducer Polychain Belt Flange bearing, 2-bolt Flange bearing, 2-bolt Flange bearing, 2-bolt Fenner "A" twin round urethane belt Idler sheave assembly Crowned Idler sheave assembly Drive sheave assembly...

  • Page 33: Board Flipper #1

    www.relinc.com iREL Systems Board Flipper #1 Figure 34: Board Flipper #1 Figure 35: Board Flipper #1...
  • Page 34 www.relinc.com iREL Systems Figure 36: Board Flipper #1 Figure 37: Board Flipper #1...
  • Page 35 www.relinc.com iREL Systems Figure 38: Board Flipper #1 Board Flipper #1 Parts List Item # Description Motor, 5hp, 230/460V Gear reducer Polychain Belt, infeed belt drive Motor, 2hp, 230/460V Gear reducer Pillow block bearing 2-bolt flange bearing Bumper Pad Idler sheave assembly Drive sheave assembly Pillow block bearing Rod end, female Belt wear strip...

  • Page 36: High Speed Corner Transfer

    www.relinc.com iREL Systems High Speed Corner Transfer Figure 39: High Speed Corner Transfer Figure 40: High Speed Corner Transfer...
  • Page 37 www.relinc.com iREL Systems Figure 41: High Speed Corner Transfer Figure 42: High Speed Corner Transfer...
  • Page 38 www.relinc.com iREL Systems Figure 43: High Speed Corner Transfer High Speed Corner Transfer Parts List Item # Description Motor, 2hp, 230/460V Polychain Belt, roller drive Pillow block bearing Flange bearing, 3-bolt Idler roller assembly Idler sheave assembly Fenner Drives 1/2" round urethane belting Flange bearing, 2-bolt Servo motor - 460V Servo gear box Spherical Bearing, sealed...

  • Page 39: High Speed Tenoner Transfer

    www.relinc.com iREL Systems High Speed Tenoner Transfer Figure 44: High Speed Tenoner Transfer Board Accumulator Conveyor Figure 45: Board Accumulator...
  • Page 40 www.relinc.com iREL Systems Figure 46: Board Accumulator Figure 47: Board Accumulator...
  • Page 41 www.relinc.com iREL Systems Figure 48: Board Accumulator Figure 49: Board Accumulator...
  • Page 42 www.relinc.com iREL Systems Board Accumulator Parts List Item # Description Motor, 2hp, 230/460V Gear reducer Polychain Belt, roller drive Pillow block bearing Flange bearing, 4-bolt Pillow block bearing, tapped base Air cylinder Air cylinder 2-bolt flange bearing Servo motor Helical bevel reducer Wear plate, 1/2" x 2" Wear plate, 1/2"...

  • Page 43: Tipple Conveyor

    www.relinc.com iREL Systems Tipple Conveyor Figure 50: Tipple Conveyor Figure 51: Tipple Conveyor...
  • Page 44 www.relinc.com iREL Systems Figure 52: Tipple Conveyor Tipple Conveyor Parts List Item # Description Motor, 2hp, 230/460V Gear reducer Flange bearing, 2-bolt Polychain Belt Polychain Belt Flange bearing, 2-bolt Fenner "A" twin round urethane belt Wear strip, 3/4" x 2" Air cylinder Fenner Drives 38" round urethane belting...

  • Page 45: Flipper Accumulator

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

  • Page 46: Turntable Detail: A Design & Engineering Example

    Turntable Detail: A Design & Engineering Example Figure 54: REL's attention to design & engineering detail...

  • Page 47: Warranty

    Warranty REL will repair, without charge, any defects due to faulty materials or workmanship for one year from the date of purchase. This warranty does not cover part failure due to wear or tool abuse. For further detail regarding warranty coverage and/or warranty repair information, please call 1-906- 337-3018. This warranty does not apply 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. AND SOME CANADIAN PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENCIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

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