STEINEL HG ROOF Maintenance And Repair
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STEINEL HG ROOF Maintenance And Repair

STEINEL HG ROOF Maintenance And Repair

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HG ROOF
Maintenance
and Repair

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Summary of Contents for STEINEL HG ROOF

  • Page 1 HG ROOF Maintenance and Repair...

  • Page 2: Table Of Contents

    HG ROOF Maintenance and Repair Table of Contents Spare parts Switch Potentiometer Tools Needed Troubleshooting Start/Stop Switch Opening the Robot Power Cable Power Supply Motor Heat Tool Heating Element Wheels Guide Block Reassemble HG ROOF...

  • Page 3: Spare Parts

    HG ROOF Maintenance and Repair Spare Parts...

  • Page 4: Tools Needed

    HG ROOF Maintenance and Repair Tools Needed 3,4,5,6 mm Allen wrench Phillips #2 3,4,5,6 mm Allen wrench Torx TX20 8 mm socket Torx TX20 8 mm socket...

  • Page 5: Troubleshooting

    HG ROOF Maintenance and Repair Troubleshooting – Main Power Switch When the main power is turned on, the green control light should turn on and you should hear the fan. It is a “no volt release switch.” If there is power to the switch, it will click when pressed. If there is no power, the switch will not click.
  • Page 6 HG ROOF Maintenance and Repair Troubleshooting – Main Power Switch The housing is grounded and when tested from the plug to the case there should be less than 3 Ohm when used with a cable that is 5m in length.
  • Page 7 HG ROOF Maintenance and Repair Troubleshooting – Start / Stop switch When the toggle switch is in the up position and the speed is above 0, the welder should move forward. If the switch is in the down position, the tool must be placed in the run position and the welder will start...
  • Page 8 HG ROOF Maintenance and Repair Troubleshooting – Reed switch. X6. You can check continuity between red and black. When there is no magnet, it is open. When there is a magnet, there is continuity. You must first remove the wires from the terminal block for a...

  • Page 9: Opening The Robot

    HG ROOF Maintenance and Repair Opening the Robot 1. Use the 5 mm Allen and remove the two screws at the top of the handlebar. 2. Use the 8 mm socket to remove the guide arm. 3. Replace the nut so it does not get lost and so that the bearing and axle do not fall out when the housing...
  • Page 10 HG ROOF Maintenance and Repair Opening the Robot 4. Use the Torx to remove the back wheels. 5. Use the 5 mm hex to remove the heat tool. 6. Use the 4 mm Allen to remove the wheel. If you only loosen the screw the wheel will stay on and will spin.
  • Page 11 HG ROOF Maintenance and Repair Opening the Robot 7. Use Torx T20 and remove 5 housing screws. The screws on the bottom have a lock washer and aid in grounding the device. The screws on the sides do not have a lock washer.
  • Page 12 HG ROOF Maintenance and Repair Opening the Robot 10. Check the power connections on the switch. Tighten the connection contacts if necessary. 11. Check the power connections on the power supply unit.
  • Page 13 HG ROOF Maintenance and Repair Opening the Robot 12. Check the grounding wire and plug connection for ground. 13. The fan runs on 24v. Blue and Red wires. 14. The heat tool runs on 240v. Use #2 Phillips to tighten loose connections as needed.

  • Page 14: Pcb

    HG ROOF Maintenance and Repair Removing the PCB 1. Loosen the fan and power terminals from the power supply using a #2 Phillips. 2. Remove the power cable from the terminal block and remove the side with the fan and heat tool.
  • Page 15 HG ROOF Maintenance and Repair Removing the PCB 4. Remove the PCB...
  • Page 16 HG ROOF Maintenance and Repair Terminal block for the PCB X3 is the Speed Control Potentiometer 3 Blue 24v 2 White 10 kOhm adjustable resistor 1 Blue/white 0v X4 is the motor – all inputs are for the stepper motor...
  • Page 17 HG ROOF Maintenance and Repair X3 Testing the speed control potentiometer 1. Remove the wires from the block. 2. Check between blue and blue with white stripe. It should be 10 kOhm. 3. Check between white and blue/white and turn the potentiometer. You should get a variation between 0...
  • Page 18 HG ROOF Maintenance and Repair X1 Testing the start / stop switch 1. Remove the wires from the terminal. 2. Switch the switch and check for continuity change.
  • Page 19 HG ROOF Maintenance and Repair X2 Check Power Supply 1. Retighten the power input and 24v supply on the power supply. 2. Unplug the power supply input on the PCB and connect the voltage tester. Plug in the unit and check voltage between blue and blue/white. You should have 24v DC. If there is...
  • Page 20 HG ROOF Maintenance and Repair Replacing the PCB 1. Remove the wires and label or remove one wire at a time and immediately install in the new PCB because some of the wire colors are the same. 2. Reinstall the new PCB.

  • Page 21: Power Supply

    HG ROOF Maintenance and Repair Replacing the Power Supply 1. Remove all the wires from the power supply using a #2 Phillips. 2. Unplug the switch and ground. 3. Remove the housing using Torx TX20. There are 5 screws.
  • Page 22 HG ROOF Maintenance and Repair Torx TX10 Replacing the Power Supply 4. Lift off housing and set to the side. 5. Remove Power Supply: Remove 3 screws from the L bracket. The tool needed is Torx TX10.

  • Page 23: Motor

    HG ROOF Maintenance and Repair Remove the Motor 1. Cut zip tie. 2. Remove 2 screws with 4 mm Allen. 3. Remove motor and chain.
  • Page 24 HG ROOF Maintenance and Repair X4 Testing the motor 1. There are usually no problems with the motor (the PCB more often needs to be replaced) but there is a simple test for the motor. Place the chain on the sprocket and you can easily turn the motor.
  • Page 25 HG ROOF Maintenance and Repair Replace the Motor 1. Attach the chain over the motor sprocket and wheel sprocket. Insert screws and then press up until the chain is only slightly tight. Tighten down screws. 2. Reassemble the housing and connect the motor to the terminal block. The picture is showing the...

  • Page 26: Wheels

    HG ROOF Maintenance and Repair Remove Wheel 1. Remove the axle by first heating and then using a 3 mm punch or Allen through the hole in the axle. Turn the axle clockwise to remove. This is not the normal direction to loosen a screw.
  • Page 27 HG ROOF Maintenance and Repair Remove Wheel 2. Heat the sprocket and turn counter-clockwise. It is best to use an old chain and pliers to protect the sprocket and your fingers from heat. 3. You can now remove the wheel bearings by tapping the screw with a plastic hammer.

  • Page 28: Guide Block

    HG ROOF Maintenance and Repair Replace the Guide Block 1. Heat the two long screws and then remove. 2. Use a 4 mm Allen to unscrew.
  • Page 29 HG ROOF Maintenance and Repair Replace the Guide Block 3. Remove 2 short 4 mm Allen screws and 1 TX 20 from the front. 4. Remove and replace the reed switch.
  • Page 30 HG ROOF Maintenance and Repair Replace the Guide Block 5. Replace all screws and add Loctite to the long screws. 6. Reassemble the new guide bar and tighten.
  • Page 31 HG ROOF Maintenance and Repair Replace the Guide Block 7. The heat tool will eventually be connected to this part. 8. Make sure the end of the reed switch is out in front of the housing about 1/8”.

  • Page 32: Switch

    HG ROOF Maintenance and Repair Switch Replacement 1. Unplug wires. 2. Remove the old switch by pressing spring tabs on either side and then removing. 3. Insert new switch and press in so that the red button is on the top side and reconnect wires.
  • Page 33 HG ROOF Maintenance and Repair Switch Replacement...

  • Page 34: Potentiometer

    HG ROOF Maintenance and Repair Replace the Speed Control Potentiometer 1. Use a 1.5 mm Allen to loosen the screw on the bottom of the dial. 2. Remove the dial.
  • Page 35 HG ROOF Maintenance and Repair Replace the Speed Control Potentiometer 3. Use a 11 mm socket to unscrew the nut from the housing of the potentiometer.
  • Page 36 HG ROOF Maintenance and Repair Replace the Speed Control Potentiometer 4. Remove and replace the potentiometer. 5. Place the plastic insert by aligning the small slot at the bottom of the potentiometer. 6. Reinstall the new potentiometer in the reverse steps.

  • Page 37: Start/Stop Switch

    HG ROOF Maintenance and Repair Replace the Start / Stop Switch 1. Use a 22 mm wrench to loosen the lock nut. 2. Remove the old switch and replace with the new switch.
  • Page 38 HG ROOF Maintenance and Repair Replace the Start / Stop Switch 3. Notice that when installing the new switch, the blue wire is on the bottom. If you do not do this correctly the start stop will be backwards.

  • Page 39: Led

    HG ROOF Maintenance and Repair Replace the LED 1. Press springs on both sides and remove. 2. Press in new LED.

  • Page 40: Power Cable

    HG ROOF Maintenance and Repair Replace Power Cable 1. Remove the connectors from the switch. 2. Use a 22 mm wrench to loosen the nut.
  • Page 41 HG ROOF Maintenance and Repair Replace Power Cable 3. Loosen the compression fitting and remove the cable.
  • Page 42 HG ROOF Maintenance and Repair Replace Power Cable 4. Install new cable and compression fitting if needed. 5. Install spade connector and connect to switch. 4&5...

  • Page 43: Fan

    HG ROOF Maintenance and Repair Replace Fan 1. Cut zip ties. 2. Remove 4 2.5 mm Allen screws.
  • Page 44 HG ROOF Maintenance and Repair Replace Fan 3. Replace old fan with new fan and reinstall making sure the arrow is pointing down. The airflow should move from inside to outside. 4. Secure wires close to the power input cord with zip ties and trim.

  • Page 45: Heat Tool

    HG ROOF Maintenance and Repair Replace Heat Tool 1. Cut the cable length to 70 cm. 2. Strip the outer black insulation to 50 cm and crimp the ends with a 1 mm sleeve. 3. Cover with yellow insulation and zip tie.

  • Page 46: Heating Element

    HG ROOF Maintenance and Repair Change the Heating Element Important! Disconnect tool from power supply. 1. Undo welding nozzle clamping screw and remove nozzle. 2. Undo screw below the guide carriage. (5 mm Allen) 3. Pull hot air tool out of the guide carriage.
  • Page 47 HG ROOF Maintenance and Repair Change the Heating Element 4. Remove fastening screws from the left and right of the heat shield. (Torx T20) 5. Remove hot air tool from heat shield. 6. Remove 4 screws from outlet nozzle/heating element. (Phillips #2)
  • Page 48 HG ROOF Maintenance and Repair Change the Heating Element 7. Detach outlet nozzle and fit the new outlet nozzle. 8. Firmly screw outlet nozzle back on again. 9. Push hot air tool into heat shield and tighten fastening screws on the heat shield.
  • Page 49 HG ROOF Maintenance and Repair Change the Heating Element 10. Push hot air tool back into the guide carriage. 11. Lightly tighten screw below the guide carriage. 12. Reattach the welding nozzle.
  • Page 50 HG ROOF Maintenance and Repair Change the Heating Element 13. Take special care that the nozzle is flat and aligned, then tighten the nozzle. 14. Align the nozzle with the guide and the pressing wheel by sliding the tool along the guide carriage.

  • Page 51: Reassemble Hg Roof

    HG ROOF Maintenance and Repair Reassemble the HG ROOF 1. Place the cover back on. 2. Tighten cover screws. 3. All screws on the bottom cover have a lock washer to aid in grounding.
  • Page 52 HG ROOF Maintenance and Repair Reassemble the HG ROOF 4. Screws on the back do not have a washer. 5. Rewire the PCB. 6. Screw down the PCB with 3 screws.
  • Page 53 HG ROOF Maintenance and Repair Reassemble the HG ROOF 7. Rewire the power supply. 8. Connect the switch. 9. Connect the line voltage input.
  • Page 54 HG ROOF Maintenance and Repair Reassemble the HG ROOF 10. Connect the heat tool input. 11. Connect the fan. 12. Make sure all wires are connected to the power supply. Tuck wires and reassemble the side housing.
  • Page 55 HG ROOF Maintenance and Repair Reassemble the HG ROOF 13. Check that grounding is less than 3 Ohms. 14. Before screwing in the side, turn the unit on and test for functionality. The LED should turn on. 15. Ensure the fan is blowing.
  • Page 56 HG ROOF Maintenance and Repair Reassemble the HG ROOF 16. The run switch should make the wheels turn when in the start position. When in the stop position, if the reed switch is activated the wheels should turn. If the switch is open the wheels should stop.
  • Page 57 HG ROOF Maintenance and Repair Reassemble the HG ROOF 18. Attach the brace with the axle and housing. There is a screw on the side and bottom. 19. Attach the wheel to the axle. There is one screw on the side of the wheel.
  • Page 58 HG ROOF Maintenance and Repair Reassemble the HG ROOF 20. Install the back wheels. There are two screws. 21. The silicon tire can be replaced separately. 22. Install the handle with two screws.
  • Page 59 HG ROOF Maintenance and Repair Reassemble the HG ROOF 23. Install the side arm with one nut and washer. Take special care to align the notched hole on the side of the arm to the bolt extending out of the welder.
  • Page 60 HG ROOF Maintenance and Repair Reassemble the HG ROOF 25. Take special care that the nozzle is flat and aligned and then tighten the nozzle. 26. Align the nozzle with the guide and the pressing wheel. 27. Adjust the depth of welding as necessary and tighten the lock screw.
  • Page 61 HG ROOF Maintenance and Repair Reassemble the HG ROOF 28. The track can be replaced and tightened. 29. Reinstall the round belt by stretching it over the two pulley grooves. Note: Before shipping from the factory, all units are tested for 30 minutes at full temperature and speed.

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