Cameron Opti-Rip 415A-M1 User manual

130 Salt Point Turnpike
Poughkeepsie, NY 12603
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: http://www.cameronautomation.com
Model - #415A-M1
SN -

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

TABLE OF CONTENTS
Opti-Rip Operation .............................................................................. 27
The Main Window......................................................................................... 28
Edit Setups ................................................................................................... 28
Conguring the Saw Arbor ......................................................................... 28
Setting Up A Job .......................................................................................... 29
Rip Width Table ............................................................................................ 30
"From Orders".............................................................................................. 31
Optimization and Simulation ...................................................................... 32
Laser Setup .................................................................................................. 32
Starting a Job............................................................................................... 32
Loading the Opti-Rip ................................................................................... 32
Operator Controls........................................................................................ 33
Printing a Report.......................................................................................... 34
Extra Feed..................................................................................................... 35
Setup List...................................................................................................... 35
Orders ........................................................................................................... 35
Edit Orders ................................................................................................... 36
Archive All Completed Orders.................................................................... 37
Archived 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 Lumber with Opti-Rip.................................... 52
Algebraic Expressions of Opti-Rip Calculations ...................................... 54
Opti-Rip Computer Software.............................................................. 55
TROUBLESHOOTING........................................................56
Diagnostics - Inputs and Outputs...................................................... 57
Inputs ............................................................................................................ 57
Outputs ......................................................................................................... 57

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

5
INTRODUCTION
INTRODUCTION
INTRODUCTION

6
INTRODUCTION
INTRODUCTION
Company Introduction
We at Cameron Automation would like to thank you and your company for selecting the
Cameron Automation Opti-Rip. With proper care, your Opti-Rip will provide you with many
years of reliable service.
This manual contains important information about the installation, operation and
maintenance of your 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
efciency and safety. Do not attempt to perform maintenance or operate this machine until
you have read and understand the information contained in this manual.

7
INTRODUCTION
INTRODUCTION
Limited Warranty
This supersedes all previous warranties
Cameron Automation guarantees all products of its manufacture to be free of defects in
workmanship or material when properly installed, serviced and maintained under normal
conditions. Cameron Automation’s obligation under this warranty is limited to repairing
or replacing any part or parts thereof which shall within one (1) year after shipment to the
original user, be returned to its factory, transportation charges prepaid, and which Cameron
Automation’s examination shall disclose to be defective.
Cameron Automation assumes no liability for labor charges incidental to the adjustment,
service, repairing, or removal or replacement of parts or other losses, or for expense 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 equipment
or accessories, as they are guaranteed separately by their respective manufacturers.
Cameron Automation assumes no liability what so ever for any of these parts claimed to
be defective or for damages or delays caused by defects beyond making such repair or
furnishing duplicate parts within the manufacturer’s warranty, nor shall we be liable for any
defective material repaired or replaced without our consent.
The foregoing shall constitute the fulllment of all of our obligations under this warranty and
there are no other warranties or guarantees, expressed or implied except as stated herein.

8
INTRODUCTION
INTRODUCTION
Machine Requirements and Layout
The Opti-Rip comes in many different congurations. Shown below is a representation of a
common conguration.
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

9
RULES FOR SAFE OPERATION
RULES FOR SAFE
OPERATION
#415-R1
RULES FOR SAFE
OPERATION

10
RULES FOR SAFE OPERATION
RULES FOR SAFE
OPERATION
#415-R1
Types of Warnings
This is the safety alert symbol. It is used to
alert you to potential injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury.
DANGER!
WARNING
!
CAUTION
!
!
DANGER in white letters on a safety red
background with a safety red exclamation
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 yellow
exclamation point.
This indicates a potentially hazardous
situation which, if not avoided, COULD result
in minor or moderate injury.

11
RULES FOR SAFE OPERATION
RULES FOR SAFE
OPERATION
#415-R1
General Safety Rules
• Follow lockout procedure before servicing.
• Read and understand manual before operating machine.
• Wear eye protection.
• See the plant supervisor to determine what protective equipment each job requires.
• Follow electrical and re 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.

12
RULES FOR SAFE OPERATION
RULES FOR SAFE
OPERATION
#415-R1
Machine Safety Decals
The following warning stickers are some that
are used on your machine. Over time, these
stickers can become worn and illegible.
New stickers can be obtained from:
Cameron Automation
130 Salt Point Turnpike
Poughkeepsie, NY 12603
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
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 Warning Sticker
Location: Control Cabinet Cover

13
RULES FOR SAFE OPERATION
RULES FOR SAFE
OPERATION
#415-R1
Part 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.

14
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
INSTALLATION

15
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
Receiving & Unpacking
Inspect the skid and its boxes for shipping
damage.
If any shipping damage has occurred, notify
the shipping company immediately.
The Opti-Rip has been quality inspected and
tested 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 conguration of the machine,
belt tracks and infeed chains (optional) may
be packaged on a separate skid.
The Opti-Rip comes in several
congurations. The maximum size for each
skid will be: 210" long x 97" wide x 62" high.
Max weight: 2150 lbs.

16
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
Opti-Rip Assembly
The Opti-Rip has been pre-assembled
and run at our factory, then broken into the
following major components: The machine
section, the laser stand, and the computer
enclosure.
Initial Placement
Position the machine in front of the rip
saw as shown in the layout located in the
"Introduction" section of this manual.
Install the Belt Tracks
On machines made for wider saws, the belt
tracks may have been removed for shipping.
If the belts are already in place, this step
should be skipped.
When installing the belt tracks, 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 for the drive
belt.
Tension the belts so that each belt hangs
down 1/8" below the bottom of the belt track
in the center. You may notice that there is
a 1/32" shim between the idler bracket and
the belt track on the bolt nearest the end of
the track. This will angle the idler out slightly
so that when the belt is in tension, it will
be pulled back square again. This shim is

17
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
important to keep the belt tracking properly.
Position the Roller Arms or Infeed Chains
For Quick-Rips, lower the Roller Arms into
position and attach them to the air cylinder
at the infeed end of the machine.
For Automated Opti-Rips, position the infeed
chains so that the belt track mounting holes
line up with the holes on the infeed section
legs.
Install the Laser 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 position the laser rack such that the
moving lasers can reach a position to shine
their line 1" from the roller drive guard. This
will be very close to the saw.
Note that the laser rack must be square with
the belt tracks.

18
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
Final Positioning
Position the machine in front of the rip
saw so that the polyurethane rollers are
approximately centered on the track of the
saw. Leave approximately 1/2" between
the brackets for the light curtain and the
infeed end of the rip saw. Check that the
saw has been leveled properly. Place shims
(provided) under the Opti-Rip feet such that
the bottom of the board will feed 1/8" above
the saw feed chain. If you swap the hoses
on the lower pinch rolls cylinder temporarily,
you can raise the lower rollers without
electrical power on the machine. Note 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
rst 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 rst belt track.
Lag the Machine to the Floor
Lag the legs and Laser Stand to the oor.
Lag the saw to the oor as well.
Install the Lasers
Mount the lasers on the laser rack. Plug
each laser into a power supply. Lasers will
be aligned later. Moving lasers should be
positioned toward the top of the laser rack
and xed lasers should be positioned near
the bottom where they can be easily reached
by the operator.
1/8"
1/2"
3 3/8"

19
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
Mount the Computer Stand
Mount the computer stand
onto the laser stand. Run the
ethernet cable and power cord
through the liquid tight tubing.
Plug one end of the ethernet
cable into the computer. The
other end will plug into the
main control box. Plug the
power adapter into the outlet
on the control stand.
Mount the Measuring
Sensors
On machines that
were shipped without the
belt tracks installed, the
measuring bar will also need
to be installed.
Mount the measuring sensor
bar to the chain section legs
using the bolts provided. The
sensors will point up toward the bottom of
the board. They are positioned between the
tracks so as not to interfere with them.
Connect Hoses and Wires
Connect the hoses, if any are loose, to the
control box. The hoses are color coded.
Connect the ethernet cable to the upper
connector on the right hand side of the
control box. Also, connect any loose wires
to the control box as well.
When running wires into the control box,
run them through the hole in the control box
closest to where each respective wire will
connect inside the control box. Connect the
292928281010 12121111 1313 15151414 3030
2929
Chain  Motor
Black
Black
Black
Green
{
Roller 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 6150
129
Black
White
Green
Lasers
{
62
30
1K
Ω
Lineal Encoder
Green
Black/
Shield
Red
{
70 7271
Cable A
Green
{
8182
Red
White
126
40 53 54 55 64
Chain Down
1st Stops
Upper Pinch
Auto Skew
38
1
235
56
Lower Pinch
4
Skip on -0C on -AS only
Terminal
Strip
Lower
Level
5
4
G
Laser Mover #3
3
1
2
{
233
6
252
234
253
237 238 239235 236
{
6
4
G
Measure Sensors Cable #1
3
1
2
{
6
4
G
Measure Sensors Cable #2
3
1
2
94 9599 100
105 106 107 108 109 110 111
104
6
4
G
Measure Sensors Cable #3
3
1
2
{
6
4
G
Measure Sensors Cable #4
3
1
2
{
96 97101 102
112 113 114 115 117 118 119
116
Board Present Sensor Receiver
Black
Blue
{Brown
74 75 76
White
122
123125
Board Present Sensor Sender
Black
Blue
Brown
White
{
124 122123 124
125
{
Laser Mover #1
Laser Mover #4
5
4
G
3
1
2
6
5
4
G
3
1
2
6
{
200 218
201 219
204 205 206202 203 252
267
253 268
256 257 258254 255
Laser Mover #2
Laser Mover #5
5
4
G
3
1
2
6
{
5
4
G
3
1
2
6
{
218 233
219 234
222 223 224220 221 267 268 271 272 273269 270
Terminal
Strip
Upper
Level
Terminal
Strip
Middle
Level
WBW B W B WB W B
Terminal
Strip
Lower
Level
Terminal
Strip
Middle
Level
40 41
41 49
49
128
128 129

20
INSTALLATION
INSTALLATION
#415-R1 8-15-18 - JR
wires as follows:
1. Run the two servo cables into the control box and attach them to the servo drive. One
cable plugs in, the other attaches to screws on the front of the drive. Match the labels on
the wires with the labels on the drive. You may need to detach the ends from the cables
briey to get them inside of the control box. Be certain to reassemble the cable ends
exactly as they were.
2. Connect the wires to the terminal strips located in the bottom right hand corner of the
control box. Follow the diagram at the right and connect the wires to the terminal strips.
Power Connection
Wire 208-240V, 3 phase power to the disconnect switch on the left hand side of the control
box. This power should be protected with 20A FRN, LPN, or equivalent fuses. Run the
incoming ground to the chassis of the control box, not to the disconnect switch. In order
to ensure that your machine is free from electrical noise, you should ground your machine
independently from other machinery. Contact your electrician if necessary.
Turn on the power and air and start the machine by depressing the green button on the
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 rip saw. On machines with infeed
chains, use the selector switch on the top of the control box to briey run the chains. If
either of these motors run in the wrong direction, remove power from the machine and
swap any two of the black wires connected to the terminal strip from the motor.
Movable Saw Connection (Optional)
Mereen-Johnson 312 "Select-A-Rip":
With power disconnected from the saw, mount the "Digi-One" (included) inside of the
Mereen-Johnson control box. Attach the power cable for the "Digi-One" to the 24VDC
power supply inside of the MJ Control Box. The wire with the white stripe should attach
to the positive (+) terminal and the all black wire should attach to the negative (-) terminal.
The Digi-One has been congured at the factory with the proper baud rate to communicate
with the saw. It has been set to communicate with the Opti-Rip using IP Address:
10.0.0.78. Run an ethernet cable (included) from the extra port on the back of the Opti-Rip