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Acer Wood Runner Manual

Acer Wood Runner Manual

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WOOD RUNNER MANUAL
SAFETY INSTALLATION OPERATION SERVICE PARTS
ACER INC.
MACHINE SERIAL NUMBER______________________
3/21/14
1
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Summary of Contents for Acer Wood Runner

  • Page 1 WOOD RUNNER MANUAL SAFETY INSTALLATION OPERATION SERVICE PARTS ACER INC. MACHINE SERIAL NUMBER______________________ 3/21/14...

  • Page 2: Table Of Contents

    Contents 1 WARRANTY ................................... 6 2 INTRODUCTION................................7 2.1 MACHINE INTRODUCTION ............................. 7 2.2 WHO SHOULD USE THIS MANUAL ......................... 7 2.3 PURPOSE OF THIS MANUAL ........................... 7 2.4 SYMBOLS ................................7 2.5 RELATED DOCUMENTATION ..........................8 2.6 TERMS USED IN THIS MANUAL ..........................8 3 SAFE OPERATING PROCEDURES ..........................
  • Page 3 8.7 ALIGNING THE BRAKE BEAMS ..........................46 8.8 ALIGNING THE LASER ............................46 8.9 SETTING THE LASER OFFSET IN SOFTWARE ......................47 8.10 GANTRY BRAKE ..............................47 8.11 BRAKE PAD REPLACEMENT ..........................49 9 TROUBLESHOOTING ..............................51 10 DETAILED PARTS IDENTIFICATION - WOOD RUNNER ....................55...
  • Page 4 10.1 RUNWAY ASSEMBLY ............................55 10.2 BELT SUPPORT ASSEMBLY ..........................57 10.3 RUNWAY DRIVE ASSEMBLY ..........................58 10.4 RUNWAY IDLER ASSEMBLY ..........................60 10.5 GANTRY ASSEMBLY ............................61 10.6 PICKING HEAD ASSEMBLY ..........................64 10.7 ELECTRICAL PANEL ASSEMBLY ........................... 68 10.8 GANTRY ENCLOSURE ASSEMBLY ........................

  • Page 6: Warranty

    All extra charges for expedited shipping shall be at the customer’s expense. ACER INC shall not be liable for any loss of use, loss of profits or damages based upon a claim for breach of warranty. This warranty shall be in lieu of any other warranty, expressed or implied, including but not limited to, any implied warranty of fitness for a particular purpose, all such other warranties being hereby expressly excluded.

  • Page 7: Introduction

    2.1 MACHINE INTRODUCTION The Wood Runner is a lumber delivery system designed to feed dimensional lumber to a saw or other production process. It has the capacity to dispense boards from multiple units of lumber. Each unit can be of a different size, length or grade.

  • Page 8: Related Documentation

    2.5 RELATED DOCUMENTATION Related documentation includes but is not limited to the following: 1. Safety – The following safety guides should be followed in addition to any safety rules listed in this guide.  OSHA  Local safety standards 2. Mechanical – The following mechanical guides are supplement manuals/guides that take secondary precedence to specifications list in this manual.
  • Page 9 Off position before servicing the machine. See the Safety section of this manual for more information.  I/O Cable - Cables that carry the control signals between various components of the Wood Runner.  Ethernet Cable - Cables that carry the Ethernet communication signal between various components of the Wood Runner.

  • Page 10: Safe Operating Procedures

    Serious injury or death may occur from moving machine parts inside this area. Never reset the safety system or enable the Wood Runner system unless you are sure all personnel are clear of the Hazardous Zone.

  • Page 11: Safety Requirements

    See the detailed Safety Section later in this manual. 3.3 PRECAUTION The Wood Runner was designed with safety in mind, but as with any machinery, safe operating procedures must be followed to prevent downtime, machine damage, personal injury or loss of life. It is...

  • Page 12: Lockout/Tagout

     EMERGENCY STOP BUTTON is located on the front of the Operators Console. It is red in color and should be used if any unsafe conditions are observed.  ACCESS COVERS must be in place at all times to prevent injury. If it is necessary to remove a cover the power must be locked out using proper OSHA methods.

  • Page 13: Emergency Stop

     Tag-out all controls and energy sources which cannot be locked out. All personnel affected must know about and understand all lockout tags.  Verify that all energy sources have been accounted for before performing any maintenance or service work. ...

  • Page 14: Laser Safety

     Do not override or bypass E-Stop  Always have electrical panel doors closed unless being serviced. 3.11 LASER SAFETY The Wood Runner is equipped with a Laser sensing device. Serious injury to eyes may result from looking directly at the beam.

  • Page 15: Installation Of Equipment

    It is important that the machine is lifted directly under the frame as shown. Some parts of the Wood Runner have a high center of gravity while being moved and could present a tipping hazard.

  • Page 16: Positioning And Anchoring

    4.3 POSITIONING AND ANCHORING  Careful consideration should be given to the site selected for the Wood Runner. Ample room must be provided to facilitate the loading of the machine and for service or maintenance. Once the site is chosen it will be necessary to securely anchor the machine to the floor.

  • Page 17: Final Assembly

    Plumbing the Guide Tubes  Locate and anchor the Operators Console guarding per the drawings.  The Lumber Cart guides and Perimeter Guarding should not be installed until the Gantry is positioned on the Runway. This is covered in the final assembly section. 4.4 FINAL ASSEMBLY CAUTION - SYSTEM IS INOPERABLE UNLESS THE GANTRY BRAKE SPRING IS UN-CAGED.
  • Page 18 Routing of wires and airline  Next connect the I/O cable and airline to Gantry as shown. Remove the protective tape or sleeve from the Ethernet cable end and route it through the aluminum connector on the Gantry enclosure. This connector must be taken apart to allow the cable to be placed in the slit in the rubber portion.
  • Page 19  Plug electrical connector into Gantry Enclosure Connector. Plugging in the Electrical Connection  Next connect the airline to Gantry as shown, pushing airline into fitting. Airline connection on Gantry  Loosely connect one end of the drive belt to the Gantry and thread the belt around the drive and idler pulleys.
  • Page 20 Connecting Drive Belt  Install the Picking Head cylinder positioning the ports so that they are closest to the air valve assembly. Leave the bolts loose until the cylinder shaft is connected to the Picking Head. The Picking head must be in the fully raised position before tightening the cylinder.
  • Page 21 Airline Connections on Cylinder  Connect the airline for the Infeed Deck and the I/O cable to the mating connector on the underside of the Main Electrical Enclosure.  Connect the wires for the Infeed Deck motors as shown in the diagram. These are the 4 wires in the flexible conduit.
  • Page 22 Infeed Deck Power Connection  Connect Ethernet and I/O wire between the Operators console and the Main Electrical Enclosure. Both ends of the Ethernet cable route through the same type of aluminum connect that was used on the Gantry. These wires are typically routed through the frame of the Infeed Deck. ...

  • Page 23: Pneumatic Connections

    4.5 PNEUMATIC CONNECTIONS Clean dry air is required for the machines operation. The Wood Runner is provided with a filter and automatic condensate trap in the Air Supply Assembly. A ½” shop air line should be connected to the ½” NPT female port on the Air Supply Assembly.

  • Page 24: Gantry Brake

    4.7 Gantry Brake Never attempt to operate the Wood Runner system unless the Gantry brake system is operational and has been tested for safe operation. Never remove or disable the brake system. Serious machine damage, injury or death may occur.

  • Page 25: Operating Instructions

    5 OPERATING INSTRUCTIONS You will need to familiarize yourself with the different screens available on the Wood Runner computer. Navigation to the various screens is selected by buttons on the Main screen. 5.1 MACHINE STARTUP  Check to see that you have completed all of the connections properly as outlined above and make...
  • Page 26  Check the Main screen for a low air warning in the upper left corner. See the Troubleshooting section if you have a warning.  Check to make sure that the Gantry is free from obstructions. Press the Home button on the screen and wait for the machine to travel to the end of the Runway and stop.

  • Page 27: Main Screen

    5.2 MAIN SCREEN This is the screen that displays when the machine is powered up. During operation the lumber sequence is shown as well as the status of the Infeed Deck. Homing can be done from this screen. Main Screen...

  • Page 28: Manual Controls Screen

    5.3 MANUAL CONTROLS SCREEN Troubleshooting and testing can be done from this screen. You will be able to see all of the inputs from the safety system, sensors and buttons. Outputs can be controlled from here. The outputs include the air valves, motors and Gantry movement.

  • Page 29: Settings Screen

    5.4 SETTINGS SCREEN Lumber sizes and types are assigned here to the various Lumber Carts and Magazines in the Wood Runner system. Settings Screen...

  • Page 30: Homing

    5.5 HOMING Homing the machine allows the Gantry to determine its exact position on the Runway. There is a homing switch located on the Runway close to the Main Electrical Panel. When the machine is instructed to home the Gantry will move slowly in the Home direction until the switch is energized and then reverse direction until the switch is de-energized.

  • Page 31: Safety System Description And Troubleshooting

    6 SAFETY SYSTEM DESCRIPTION AND TROUBLESHOOTING The Wood Runner system is equipped with several safety components to insure the safety of the operator and other personnel. These components make up the Safety system and work together to shut down the Wood Runner system when a dangerous condition exists.

  • Page 32: Emergency Stop Button

    6.2 EMERGENCY STOP BUTTON Located on the operators console next to the operators screen. Depressing the button causes an E-stop to be triggered. Twist the button clockwise and pull slightly to reset it. Emergency Stop Button & Keyed Safety Pre-reset Button Safety Reset Switch 6.3 KEYED SAFETY RESET SWITCH This switch has 3 positions.

  • Page 33: Brake Beams

    Obstruction Sensors. When any of these are triggered by the operator or an unsafe condition the relay shuts the Wood Runner system down and reports this to the PC. The PC can then display information on the screen relating to the source of the E-stop condition. The Safety Relay is equipped with 3 LED’s to help troubleshoot any problems.

  • Page 34: Safety Brake

    6.7 SAFETY BRAKE The Gantry safety brake stops the Gantry rapidly when an E-stop condition occurs. The brake is applied by a spring and is held in the released position by air pressure provided through the Brake Valve. An E-stop condition causes the air pressure in the Brake chamber to be released through the Brake Valve.

  • Page 35: Function Of The Safety System

    E-stop can be viewed here even if it was an intermittent problem. This is explained in the next section. Shown here is a diagram of the Wood Runner safety system. The main components and the interconnections between them and the system PC are detailed. This is not meant to be a wiring diagram;...

  • Page 38: Troubleshooting The Safety System

    Main screen and the LED indicating lights on the Safety Relay in the Operators Enclosure. The most common problem you may encounter is that the Wood Runner system cannot be enabled or is disabled by a random E-stop not caused by the operator. The random E-stop could be of an intermittent nature and would be hard to diagnose without understanding the Safety system.
  • Page 39 Check to see that it is not depressed. Check the wiring to the E-stop button for damage or E-stop button - disconnection. Replace the entire switch or both contact blocks on the switch if no wiring problem is found. First verify that both the Receiver and the Emitter have green LED lights lit. Check the wiring Light Curtain - for damage if one of the lights is not lit.

  • Page 40: Diagnosing An Intermittent E-Stop

    6.9b DIAGNOSING AN INTERMITTENT E-STOP No message will be retained at the top of the Main screen if the E-stop cause is intermittent. Navigate to the Manual screen and view the inputs for the Light Curtain, E-stop Button and Obstruction sensors. The input box will be red for the input that caused the last E-stop condition.

  • Page 41: Maintenance Section

    7 MAINTENANCE SECTION Proper maintenance will keep your Wood Runner working efficiently and minimize any downtime. Maintenance procedures are simple and require very little time. 7.1 DAILY  Inspect all safety guarding to make sure it is in place and fasteners are tight. Repair if problems are found.

  • Page 42: Adjustments

    8 ADJUSTMENTS 8.1 PICKUP SCREW REPLACEMENT Use a ¾” wrench to hold the Screw motor arbor and remove the collet nut with a 5/8” wrench. The screwdriver bit is free to fall out at this time. Insert the new screw into the collet nut and thread the nut onto the arbor while aligning the screw with the screwdriver bit.

  • Page 43: Drive Belt Alignment

    Drive Belt Tensioning – Board location Drive Belt Tensioning – ¼” sag 8.3 DRIVE BELT ALIGNMENT The pulleys must be properly aligned so that the belt tracks correctly on the pulleys. Poor tracking will damage the belt or pulley flange. This procedure is done from outside the Hazardous Zone (SEE SAFETY SECTION) while the Gantry is in Auto Cycle mode.

  • Page 44: Pressure Switch Adjustment

    The pressure switch is provided with an LED light that illuminates if the pressure is high enough for system operation and an output to the Wood Runner’s computer. Setting the pressure switch is a simple push button operation which is detailed below.

  • Page 45: Pickup Screw Depth Setting

    8.5 PICKUP SCREW DEPTH SETTING The depth that the Pickup screws thread into the board is adjustable. Depth is set at ¾” engagement at the factory. A switch on the Pressure Pad is set to trip at the correct depth and shut the screw motor off. See the instructions and picture below for the adjustment procedure.

  • Page 46: Aligning The Brake Beams

    3. Loosen the adjustment screws for the Receiver and rotate and tip it until the green LED is lit. Sweep it left to right and up and down to locate the midpoint of the “on” (green LED) before tightening the adjustment screws.

  • Page 47: Setting The Laser Offset In Software

    8.9 SETTING THE LASER OFFSET IN SOFTWARE The horizontal offset of the Laser from the centerline of the Pickup screws is adjustable in the software. The actual value measured and recorded in the above section 8.8 was measured to the closest side of the Picking Head horizontal bar.
  • Page 48 Inserting tool into the hole; aligning tabs with slots Brake Chamber end with slots  Insert release tool into the hole in the back of the brake chamber by aligning the tabs on the tool with the slots on the brake chamber. Turning release tool clockwise Tighten nut until spring is compressed ...

  • Page 49: Brake Pad Replacement

    Locknut Locknut and Pad Locations Loosen the locknut on brake chamber Brake Pad Material  Loosen the locknut on the brake chamber and unscrew the brake chamber by turning it counter-clockwise. The chamber should unscrew easily if the chamber spring is properly compressed. CAUTION! If it is difficult to turn, stop and check that the chamber spring has been properly caged.
  • Page 50  Reinstall the drive belt and tension it correctly.  Test the brake function as shown in the Safety section of this manual.

  • Page 51: Troubleshooting

    9 TROUBLESHOOTING See Section 6 SAFETY SYSTEM for troubleshooting information for the safety devices and safety system. SYMPTOM PROBLEM CAUSE/SOLUTION SYSTEM WILL NOT POWER UP NO INCOMING POWER OR HAVE ELECTRICIAN CHECK NO LIGHTS IN MAIN DISCONNECT SHUT OFF INCOMING POWER ENCLOSURE RESET CIRCUIT BREAKER CIRCUIT BREAKER FOR POWER...
  • Page 52 E-STOP CONDITION WILL NOT LIGHT CURTAIN NOT ALIGNED SEE LIGHT CURTAIN RESET- SEE SAFETY SYSTEM ALIGNMENT IN SAFETY SECTION OF MANUAL FOR SYSTEM SECTION DETAILED EXPLANATION OF SAFETY SYSTEM E-STOP SWITCH PUSHED IN PULL OUT SWITCH OR OR FAULTY REPLACE BRAKE BEAM NOT ALIGNED SEE BRAKE BEAM ALIGNMENT IN SAFETY SYSTEM SECTION...
  • Page 53 GANTRY HITS END STOP PROBLEM WITH HOME HOME SWITCH GAP SET WHEN HOMING SWITCH IMPROPERLY- RESET TO 1/16” CABLE UNPLUGGED OR FAULTY FAULTY SWITCH PICKUP SCREWS LASER ALIGNMENT RE-ALIGN LASER WITH LOAD CONSISTENTLY NOT BAR- COVERED IN CENTERED ON BOARD ADJUSTMENT SECTION OF MANUAL LUMBER PILES NOT SHOWN...

  • Page 55: Detailed Parts Identification - Wood Runner

    10 DETAILED PARTS IDENTIFICATION - WOOD RUNNER 10.1 RUNWAY ASSEMBLY...
  • Page 56 RUNWAY ASSEMBLY Description Part Number Runway Runway Foot Bump stop PC5019 Cable Carrier – 30 ft. PC5041-30 Cable Carrier – 40 ft. PC5041-40 Cable Carrier – 60 ft. PC5041-60 Runway Idler Assembly SA5042 3/8 Flat Washer ½ Flat Washer 3/8-16 X 1-1/4 Hex Bolt ½-13 X 1-1/2 Hex Bolt ½-13 Hex Nut Timing Belt –...

  • Page 57: Belt Support Assembly

    10.2 BELT SUPPORT ASSEMBLY BELT SUPPORT ASSEMBLY Description Part Number Roller Mount Bracket MC5378 Belt Roller MC5118 Idler Spacer MC5503 ½ Narrow Flat Washer ½-13 X 3 Hex Bolt ½-13 Hex Nut...

  • Page 58: Runway Drive Assembly

    10.3 RUNWAY DRIVE ASSEMBLY...
  • Page 59 RUNWAY DRIVE ASSEMBLY Description Part Number Mount Plate Gearbox MC5447 Motor w/Resolver EP5129 Shaft MC5448 Timing Belt Pulley – Drive MC5141 Power Lock Bushing PC5024 Key - Metric PC5102 5/16 Flat Washer 3/8 Flat Washer 5/16 Lock Washer ½ Lock Washer ½-13 X 1 Hex Bolt 3/8 Lock Washer M8 X 30 Metric Hex Bolt 3/8-16 X 1 Hex Head Bolt...

  • Page 60: Runway Idler Assembly

    10.4 RUNWAY IDLER ASSEMBLY RUNWAY IDLER ASSEMBLY Description Part Number Mount Plate Idler MC5091 Timing Belt Pulley – Idler MC5143 Bearing – Wheel PC5001 Shaft Idler – Runway MC5113 7/8 Shaft Collar PC5021 3/8-16 X 1 Socket Head Set Screw ¾-10 Nylock Nut...

  • Page 61: Gantry Assembly

    10.5 GANTRY ASSEMBLY...
  • Page 62 GANTRY ASSEMBLY...
  • Page 63 GANTRY ASSEMBLY Description Part Number Gantry Gantry Brake Assembly SA5074 Lower Wheel Link SA5011 Wheel MC5056 Wheel Bushing MC5293 Clamp Body PC5055 Sensor Arm MC5291 3/8 Flat Washer 1/2 Flat Washer Alum Shaft Collar PC5057 Laser w/Cable EP5000 Laser Adaptor MC5450 Laser Adaptor Mount Plate MC5451...

  • Page 64: Picking Head Assembly

    10.6 PICKING HEAD ASSEMBLY...
  • Page 65 PICKING HEAD ASSEMBLY...
  • Page 66 PICKING HEAD ASSEMBLY Description Part Number Motor Plate MC5137 Slide Block MC5135 Screw Cylinder PP5028 18MM Prox Switch EP5005 18MM Prox Nut Screw Bearing PC5025 3/8-16 Hex Nut ¼-20 Hex Nut ¼ Lock Washer 10-24 X 5/8 Socket Head Cap Screw 3/8 Flat Washer 5/16 Flat Washer Slide Washer...
  • Page 67 Straight Connector 1/8 G X ¼ Tube PP5048 Cylinder Mount Tube – Offset MC5563 Head Mount Bar MC5556 5/8 Flat Washer 3/8 SAE Flat Washer ¼-20 X 3-1/4 Hex Bolt 3/8-16 X 3-1/2 Hex Bolt 5/16-18 X 5 Hex Bolt 5/16-18 X 1/2 Socket Head Set Screw Valve PP5140...

  • Page 68: Electrical Panel Assembly

    10.7 ELECTRICAL PANEL ASSEMBLY...
  • Page 69 ELECTRICAL PANEL ASSEMBLY Description Part Number Back Panel EP5117 Wire Way – 17-3/4” Wire Way – 10-3/4” Wire Way – 4-1/4” Din Rail – 6” Din Rail – 8-1/4” Power Supply EP5045 2 Pole Breaker – Power Supply EP5046 3 Pole Breaker – Servo Amp EP5047 Disconnect Switch EP5118...

  • Page 70: Gantry Enclosure Assembly

    10.8 GANTRY ENCLOSURE ASSEMBLY...
  • Page 71 GANTRY ENCLOSURE ASSEMBLY Description Part Number Back Panel MC5550 Din Rail – 5-1/2” End Stop Wago EP1210 2 Conductor Wago Block – Gray EP1211 2 Conductor Wago Block – Orange EP1214 2 Conductor Barrier Wago – Gray EP1213 End Barrier - Orange EP1212 Ethercat Bus Coupler EP5127...

  • Page 72: Console Assembly

    10.9 CONSOLE ASSEMBLY...
  • Page 73 CONSOLE ASSEMBLY...
  • Page 74 CONSOLE ASSEMBLY Description Part Number Console Din Rail 18” End Stop Wago EP1210 2 Conductor Wago Block – Gray EP1211 2 Conductor Barrier Wago – Orange EP1212 2 Conductor Wago Block – Orange EP1214 Jumper EP1215 Relay Socket EP5087 2 Conductor Wago Block – Blue EP1213 Relay EP5135...

  • Page 75: Air Supply Assembly

    10.10 AIR SUPPLY ASSEMBLY...
  • Page 76 AIR SUPPLY ASSEMBLY Description Part Number Filter Regulator – Auto Drain PP5156 T-Bracket PP5159 Shutoff/Relief Valve PP5162 Adaptor Plate PP5157 Liquid Filled Gauge PP5155 Soft Start Dump Valve PP5161 U-Bracket PP5160 Pneumatic Distribution Block PP5163 Silencer PP5152 Hex Bushing PP5164 Straight Connector 1/2 NPT X 3/8 Tube PP5166 Straight Connector ¼...

  • Page 77: Gantry Valve Assembly

    10.11 GANTRY VALVE ASSEMBLY...
  • Page 78 GANTRY VALVE ASSEMBLY Description Part Number Valve Manifold PP5137 Port Adaptor MC5648 Regulator – Gauge & Bracket PP5093 Valve PP5140 Straight Connector 3/8 NPT X ½ Tube PP5052 Straight Connector 3/8 NPT X 3/8 Tube PP5079 Straight Connector ¼ G X 3/8 Tube PP5045 90°...

  • Page 79: Gantry Brake Assembly

    10.12 GANTRY BRAKE ASSEMBLY...
  • Page 80 GANTRY BRAKE ASSEMBLY Description Part Number Brake Backer MC5368 Brake Pad MC5371 Brake Shaft MC5446 Shoulder Screw ½ X 1-1/4 Compression Spring PC5076 Brake Chamber PC5054 Valve PP5098 Straight Connector 3/8 NPT x 3/8 Tube PP5079 Silencer PP5129 Reducing Tee ½ x 3/8 x ½ PP5099...

  • Page 81: Electrical Diagrams

    11 ELECTRICAL DIAGRAMS 11.1 SYSTEM OVERVIEW...

  • Page 82: Main Enclosure - Low Voltage

    11.2 MAIN ENCLOSURE – LOW VOLTAGE...

  • Page 83: Gantry Wiring - Low Voltage

    11.3 GANTRY WIRING – LOW VOLTAGE...

  • Page 84: I/O Chart

    11.4 I/O CHART...

  • Page 85: Infeed Wiring - Low Voltage

    11.5 INFEED WIRING – LOW VOLTAGE...

  • Page 86: Operators Console

    11.6 OPERATORS CONSOLE...

  • Page 87: Main Enclosure - High Voltage

    11.7 MAIN ENCLOSURE – HIGH VOLTAGE...

  • Page 88: Main Enclosure Receptacle Wiring

    11.8 MAIN ENCLOSURE RECEPTACLE WIRING...

  • Page 89: Safety Circuit Layout

    11.9 SAFETY CIRCUIT LAYOUT...

  • Page 90: Safety Circuit Diagram

    11.10 SAFETY CIRCUIT DIAGRAM...

  • Page 91: Brake Sensor Diagnosis

    11.11 BRAKE SENSOR DIAGNOSIS...

  • Page 92: Pneumatic Diagrams

    12 PNEUMATIC DIAGRAMS 12.1 SINGLE HEAD GANTRY...

  • Page 93: Double Head Gantry

    12.2 DOUBLE HEAD GANTRY...

  • Page 94: Infeed Deck

    12.3 INFEED DECK...

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