Page 2 Equipment Manual RoofTracker II ™ Roof Truss Roller Press U.S. and other patents pending. MiTek Part Number 001100 Machinery Division Revision Date Revised 22 March 2012 301 Fountain Lakes Industrial Drive Created By R. Tucker St. Charles, MO 63301 Approved By M.
Page 3: Legal Notice
The trademark was applied for and obtained in the United States and in select foreign countries. It may not be reproduced, used, or otherwise exploited without written authorization from MiTek. Patents Made and sold under one or more of the following patents:* U.S.
Page 4 Notice of Change Use this page to record Service Bulletins and Notices that you receive to keep your manual updated. Equipment Manual RoofTracker II™ Roof Truss Roller Press Service Bulletin or Notice # Dated Title 001100 Rev. A Notice of Change...
Page 5: Table Of Contents
Contents Preliminary Pages Legal Noticeii Notice of Changeiii Contentsiv Safety (English) Safety Indicators: Signal Words ix Safety Rules x Lockout/Tagout xii Lockout/Tagout Guidelines xii Electrical Lockout/Tagout Procedures xiii Troubleshooting With an Energized Machine xv Safety Tests xvi Before Starting the Tests xvi Testing the Safety Controller xvii Testing the Light Curtains xviii Testing the Bumpers xx...
Page 6 Contents Additional Resources 3 Supplemental Documentation 3 Web Site 3 Contacting MiTek 3 Introduction to the Equipment 4 Purpose 4 Overview 4 What This Manual Covers 4 Main Components 5 Platform Options 5 Operating Options 6 General Specifications 7 Truss Terminology 8...
Page 7 Contents Assembling the Light Curtains & Beacon 23 Connecting the Laser Scanner (optional equipment) Startup Chapter 4 Checking Motor Rotation 25 Setting Pneumatic Pressure for Gantry Lifter 25 Safety Tests 25 Operation Chapter 5 Before You Begin 26 Understanding This Chapter 26 Important Notes 27 Stopping the Machine 28 Stopping During Normal Operation 28...
Page 8 Contents Replacing Guide Wheels 53 Pressure Wheels 54 Lubricating 54 Replacing Pressure Wheels 54 Take-Up Bearing 55 Lubricating 55 Adjusting 55 Chains 55 Lubricating the Chains 55 Adjusting Chain Tension 56 Replacing a Chain 58 Adjusting the Roller Height 59 Bumpers 61 Replacing a Bumper Plate (Weldment) 61 Replacing a Bumper Bearing 61...
Page 9 Contents Hour-Meter 87 Laser Scanner Indicator Lights 87 Graphics 88 General Graphics 88 Drive System and Wheels 89 Lubrication Graphics 91 Troubleshooting Appendix A 93 Mechanical Troubleshooting 94 Electrical and Perimeter Guarding Troubleshooting Safety Controller Diagnostics and Troubleshooting Safety Controller Diagnostics 99 Safety Controller Error Names and Solutions 102 Light Curtain Diagnostic Codes 106 Laser Scanner Diagnostic Codes 107...
Page 10: Safety (English)
Safety (English) Safety Indicators: Signal Words The following signal words and colors are used throughout this document to indicate safety hazards. Pay careful attention when you see them. The level of severity differs for Refiérase a la each signal word and color. página xx para español.
Page 11: Safety Rules
RoofTracker II™ Roller Press Safety Rules Because it is impossible to anticipate every circumstance that might involve a hazard, the safety information provided in this equipment manual and on the machine is not all- inclusive. If this machine is operated or serviced using a procedure not specifically recommended by the manufacturer, the procedure shall be approved by a professional engineer to ensure it will not render the equipment unsafe.
Page 12: Electrical Safety
RoofTracker II™ Roller Press Lockout/Tagout • Before performing maintenance on the pneumatic or hydraulic systems, bleed the lines to eliminate pressure. • Lockout/tagout all energized systems before performing maintenance on them. Refer to the Lockout/Tagout Guidelines section on page xii.
Page 13: Lockout/Tagout
RoofTracker II™ Roller Press Lockout/Tagout Lockout/Tagout Guidelines All lockout/tagout guidelines must be met according to OSHA 29 CFR 1910.147. A specific procedure should be included in your company’s energy control program. This manual is not intended to replace your company’s de- energizing or lockout/tagout procedure required by OSHA, but merely to provide general guidance.
Page 14: Electrical Lockout/Tagout Procedures
RoofTracker II™ Roller Press Electrical Lockout/Tagout Procedures When Working on a Machine Outside the Machine’s Main Electrical Enclosure If working on the electrical transmission line to the machine, follow the procedure on page xv. Before performing maintenance on any machine with electrical power, lockout/tagout the machine properly.
Page 15 RoofTracker II™ Roller Press Figure SAFETY-1: Sample of a Lockout/Tagout Mechanism on an Electrical Enclosure Sample of a Lock and Tag Attached to a Machine’s Electrical Enclosure 001100 Rev. A Safety (English)
Page 16: Troubleshooting With An Energized Machine
RoofTracker II™ Roller Press When Working on a Machine Inside the Machine’s Main Electrical Enclosure or in the Electrical Transmission Line to the Machine Before opening the main electrical enclosure, or attempting to repair or replace an electrical transmission line to the machine, lockout/tagout the machine properly. Follow your company’s approved lockout/tagout procedures which should include, but are not...
Page 17: Safety Tests
RoofTracker II™ Roller Press Safety Tests WARNING CRUSH HAZARD. Perform the safety tests described before operating the equipment at the initial startup, after performing any maintenance, and in accordance with the maintenance schedule. The following test procedure MUST be performed by qualified personnel after ANY maintenance, adjustment, or modification.
Page 18: Testing The Safety Controller
RoofTracker II™ Roller Press Testing the Safety Controller 1. Take precautions to ensure only the person performing the test will be near the machine during this test. Power must remain on to perform the test. 2. Verify that the safety controller (in the main enclosure) doesn’t have any faults (ERR/ALM red light, blinking or solid).
Page 19: Testing The Light Curtains
RoofTracker II™ Roller Press Testing the Light Curtains 1. Take precautions to ensure only the person performing the test will be near the machine during this test. Power must remain on to perform the test. 2. Ensure the disconnect handle is in the ON position.
Page 20 RoofTracker II™ Roller Press 13. Verify that the gantry head is still able to move in the opposite direction (away from the wooden T): a) Move the joystick away from the wooden T while also pressing the white button on the joystick.
Page 21: Testing The Bumpers
RoofTracker II™ Roller Press Testing the Bumpers 1. Lockout/tagout. 2. Check the location of each bumper flag in relation to its light bar sensor: a) Each bumper flag should be aligned with its light bar sensor so there is no space between the edge of the flag and the edge of the sensor.
Page 22 RoofTracker II™ Roller Press 4. Place a board (any 2-in. thick board) flat on the table in the same plane as the heavy object. See the image on page xx for clarification. The board is called a reference board in the remainder of this procedure.
Page 23 RoofTracker II™ Roller Press 9. Verify that the gantry head is still able to move in the opposite direction (away from the heavy object): a) Move the joystick away from the heavy object while also pressing the white button on the joystick.
Page 24 RoofTracker II™ Roller Press Testing the Laser Scanner (optional equipment) 1. Lockout/tagout. 2. Verify that all safety labels are legible. 3. Check for signs of external damage to the laser scanner, the guarded machine, the electrical cables and wiring. 4. Clean dust and fingerprints off the scan surface using a soft cloth and glass cleaner.
Page 25 RoofTracker II™ Roller Press 8. Start the gantry head moving toward the wooden T and: a) Verify that the green RIGHT READY light (located on the horn) turns off when the beam is interrupted. b) Press the RESET button on the operator control station.
Page 26: Restricted Zone
RoofTracker II™ Roller Press Restricted Zone DANGER Stay out of the restricted zone when equipment is in use. Serious injury or death may result if personnel are in the restricted zone. Always look for personnel in the restricted zone before operating equipment.
Page 27: Marking The Restricted Zone
The restricted zone must be marked so everyone near the equipment can clearly see the area where danger may exist. MiTek offers Restricted Zone Tape that is easy to apply and has text in English and Spanish. Some equipment comes with restricted zone tape. If your machine did not come with restricted zone tape, you may order it from MiTek Machinery Division Customer Service.
Page 28: Safety Symbol Definitions
RoofTracker II™ Roller Press Safety Symbol Definitions The safety symbols shown in this section can be found throughout the manual to indicate hazards that are related to this equipment.All personnel expected to operate or maintain this equipment should become familiar with these safety symbols and what they mean.
Page 29 RoofTracker II™ Roller Press Do not use sling equipment rated for less than ____ lbs/___kgs when lifting this equipment. Crush hazard from above Trip hazard! Pay attention when walking in this area. Keep hands and body clear. WARNING! ___ MAN LIFT REQUIRED TO SAFELY MOVE THIS EQUIPMENT.
Page 30 RoofTracker II™ Roller Press The operation of this equipment requires the use of PPE. Do not operate without wearing required protective clothing. 001100 Rev. A Safety (English) xxix...
Page 31 RoofTracker II™ Roller Press Refer to manual- After installation, read the user's guide carefully before operating. Follow all operating and other instructions carefully. Circuits are live -lockout/tagout the upstream disconnecting means prior to opening for service. Lockout in a de-energized state Lift Point - In order to reduce the likelihood of damage to the equipment, use only the lift points indicated in the manual.
Page 32 RoofTracker II™ Roller Press Consult material safety data sheet. Read all safety warnings and instructions before proceeding. Unplug equipment before servicing. Hazardous moving parts are located behind this access panel. Do not operate this equipment without all guards and covers in place.
Page 33 RoofTracker II™ Roller Press Do not use non-approved lubricants in this machine. Do not operate without guards and covers in place Do not weld Do not discard into municipal waste stream oil drop 001100 Rev. A Safety (English) xxxii...
Page 34: Declarations Of Conformity
RoofTracker II™ Roller Press Declarations of Conformity Gantry Standards All safety devices on this equipment are compliant with United States safety regulations and conform to current NEC, NFPA79, OSHA 21 CFR 1910, and UL regulations. Electrical components also adhere to international safety codes including, but not limited to, IEC 6149, EN 954 and/or ISO 13849.
Page 35: Light Curtain Standards
RoofTracker II™ Roller Press Light Curtain Standards The light curtains (PA4600), as a stand-alone unit, conforms to the following standards per OSTI 1109 PN99689-0010 Rev. L, page 42 (as of 12 October 2011): Figure SAFETY-5: Light Curtain Standards OMRON SCIENTIFIC TECHNOLOGIES INCORPORATED OMRON Scientific Technologies Incorporated (at 6550 Dumbarton Circle, Fremont, CA 94555-3605, U.S.A.),...
Page 36: Laser Scanner Standards
RoofTracker II™ Roller Press Laser Scanner Standards The laser scanner, model OS32C series, conforms to the following standards per OMRON STI Manual No. Z296-E1-04, page i (as of 12 October 2011): 1. This product is electro-sensitive protective equipment (ESPE) in accordance with European Union (EU) Machinery Directive Index Annex IV, B, Safety Components, Item 1.
Page 37 RoofTracker II™ Roller Press • IEC 61508-3 (Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems - Part 3: Software Requirements) • CAN/CSA-C22.2 No. 14 (Industrial Control Equipment) • CAN/CSA-C22.2 No. 0.8 (Safety Functions Incorporating Electronic Technology) d) JIS standards JIS B 9704-1:2006, JIS B 9704-3:2004 (Type3 ESPE) 3.
Page 38 RoofTracker II™ Roller Press The laser scanner, model OS32C series, also conforms to the following standards per OMRON STI Manual No. Z296-E1-04, page 137 (as of 12 October 2011): Figure SAFETY-6: Laser Scanner Conformity OMRON SCIENTIFIC TECHNOLOGIES INCORPORATED OMRON Scientific Technologies Incorporated (at 6550 Dumbarton Circle, Fremont, CA 94555-3605, U.S.A.),...
Page 39 RoofTracker II™ Roller Press 001100 Rev. A Safety (English) xxxviii...
Page 40: Seguridad (Español)
Seguridad (Español) Sea cuidadoso. Protéjase. 001100 Rev. A Seguridad (Español) xxxix...
Page 41: Indicadores De Seguridad Xl
RoofTracker II™ Roller Press Indicadores de seguridad Los siguientes símbolos de alerta de seguridad y palabras de advertencia se utilizan a lo largo de este documento para indicar riesgos de seguridad. Preste suma atención cuando los vea. Cada símbolo o palabra indica un nivel de gravedad diferente.
Page 42: Reglas De Seguridad Xli
RoofTracker II™ Roller Press Reglas de seguridad Debido a la imposibilidad de anticipar todas las circunstancias que podrían constituir un riesgo, la información de seguridad suministrada en este manual del equipo y sobre la máquina no es exhaustiva. Si se utiliza o realiza el mantenimiento de esta máquina utilizando un procedimiento no recomendado específicamente por el fabricante, el...
Page 43 RoofTracker II™ Roller Press • Proceda con precaución cuando levante piezas o materiales pesados. Procedimientos de Bloqueo/Etiquetado • Antes de realizar el mantenimiento de los sistemas neumáticos o hidráulicos, purgue las líneas para eliminar la presión. • Bloquee y etiquete todos los sistemas energizados antes de realizar tareas de mantenimiento en ellos.
Page 44 RoofTracker II™ Roller Press • Inspeccione periódicamente la calidad del producto terminado. Seguridad eléctrica • No utilice líquidos en el interior de los gabinetes eléctricos. • Cuando utilice disolventes sobre o alrededor de la máquina, desconecte la alimentación para eliminar las probabilidades de chispas, que pueden producir una explosión o incendio.
Page 45: Bloqueo/Etiquetado Xliv
RoofTracker II™ Roller Press Bloqueo/Etiquetado Pautas de bloqueo/etiquetado Deben cumplir con todas las pautas de bloqueo/etiquetado conforme a la norma OSHA 29 CFR 1910.147. El programa de control de energía de la compañía debe incluir un procedimiento específico. El objetivo de este manual no es reemplazar el procedimiento de desenergización o bloqueo/...
Page 46: Procedimientos De Bloqueo/Etiquetado Eléctricos Xlv
RoofTracker II™ Roller Press Procedimientos de bloqueo/etiquetado eléctricos Cuando trabaja en una máquina fuera del gabinete eléctrico principal de la máquina Si trabaja en la línea de transmisión eléctrica a la máquina, siga el procedimiento de la página xlvii. Antes de realizar el mantenimiento de cualquier máquina con alimentación eléctrica, bloquee y etiquete la máquina de forma adecuada.
Page 47 RoofTracker II™ Roller Press Figura SEGURIDAD-1: Bloqueo/etiquetado en el gabinete eléctrico principall Ejemplo de un candado y etiqueta fijados al gabinete eléctrico de una máquina 001100 Rev. A Seguridad (Español) xlvi...
Page 48 RoofTracker II™ Roller Press Cuando trabaje en una máquina dentro del gabinete eléctrico principal de la máquina o en la línea de transmisión eléctrica a la máquina Antes de abrir el gabinete eléctrico principal o intentar reparar o reemplazar una línea de transmisión eléctrica a la máquina, bloquee y etiqueta la máquina en forma adecuada.
Page 49: Solución De Problemas Con Una Máquina Energizada
RoofTracker II™ Roller Press Solución de problemas con una máquina energizada Sólo un electricista calificado que utilice el equipo de protección personal y siga los procedimientos recomendados en la norma NFPA 70E debe intentar realizar tareas de reparación o mantenimiento en un área o componente energizados de la máquina o en su proximidad.
Page 50: Pruebas De Seguridad Xlix
RoofTracker II™ Roller Press Pruebas de seguridad ADVERTENCIA RIESGO DE APLASTAMIENTO. Realice las pruebas de seguridad que se describen antes de utilizar el equipo por primera vez, después de cualquier tarea de mantenimiento y conforme con la frecuencia de mantenimiento establecida.
Page 51: Antes De Comenzar Las Pruebas L
RoofTracker II™ Roller Press Antes de comenzar las pruebas Suministros necesarios Para realizar esta prueba, usted necesitará: • 2 trozos de madera conectados en forma de T de manera que la T pueda mantenerse de pie, invertida, sin apoyo, y se vea así: •...
Page 52: Prueba Del Controlador De Seguridad Li
RoofTracker II™ Roller Press Prueba del controlador de seguridad 1. Tome precauciones para que únicamente la persona que realice la prueba esté cerca de la máquina durante esta prueba. Hay que mantener la máquina encendida para realizar la prueba. 2. Compruebe que el controlador de seguridad (en la caja principal) no tenga fallas (luz roja ERR/ALM, fija o intermitente).
Page 53: Prueba De Las Cortinas De Luz Lii
RoofTracker II™ Roller Press Prueba de las cortinas de luz 1. Tome precauciones para que únicamente la persona que realice la prueba esté cerca de la máquina durante esta prueba. Hay que mantener la máquina encendida para realizar la prueba.
Page 54 RoofTracker II™ Roller Press 12. Compruebe que la máquina no continúe moviéndose en la dirección de la T de madera mientras esté bloqueado el haz de luz: a) Presione el botón de RESET. El propósito de b) Mueva la palanca de mando hacia la T de madera mientras presiona el esta prueba es botón blanco en la palanca de mando.
Page 55: Prueba De Los Parachoques Liv
RoofTracker II™ Roller Press Prueba de los parachoques 1. Procedimiento de bloqueo/etiquetado. 2. Compruebe la localización de cada bandera del parachoques con respecto al sensor de su barra de luz. a) Cada bandera del parachoques debe estar alineada con el sensor de su barra de luz de manera que no haya espacio entre el borde de la bandera y el borde del sensor.
Page 56 RoofTracker II™ Roller Press 4. Coloque una tabla (cualquier tabla de 2 pulgadas de grosor) plana sobre la mesa al mismo nivel que el objeto pesado. Consulte la imagen en la página xx para aclarar dudas. La tabla se llamará tabla de referencia en el resto de este procedimiento.
Page 57 RoofTracker II™ Roller Press 9. Compruebe que la cabeza del pórtico todavía pueda moverse en la dirección contraria (lejos del objeto pesado): a) Mueva la palanca de mando en sentido contrario al objeto pesado mientras presiona el botón blanco en la palanca de mando.
Page 58: Prueba Del Escáner Láser (Equipo Opcional) Lvii
RoofTracker II™ Roller Press Prueba del escáner láser (equipo opcional) 1. Procedimiento de bloqueo/etiquetado. 2. Compruebe que todas las etiquetas de seguridad sean legibles. 3. Compruebe que no haya señales de daño externo al escáner láser, la máquina protegida, los cables eléctricos y el cableado.
Page 59 RoofTracker II™ Roller Press 8. Comience a mover la cabeza del pórtico hacia la T de madera y: a) Compruebe que la luz verde RIGHT READY (localizada en el claxon) se apague cuando se interrumpa el haz de luz. b) Presione el botón de RESET en la estación de control del operador.
Page 60: Zonas Restringida Lix
RoofTracker II™ Roller Press Zonas restringida PELIGRO Manténgase afuera de la zona restringida cuando el equipo esté en uso. Pueden producirse lesiones graves o incluso la muerte si el personal está en la zona restringida. Asegúrese que no haya personal en la zona restringida antes de operar el equipo.
Page 61: Marcar La Zona Restringida Lx
área donde pueda existir peligro. MiTek ofrece la cinta de zona restringida o “Restricted Zone Tape”, fácil de aplicar y con texto en inglés y en español. Algunos equipos traen la cinta de zona restringida. Si su máquina no trajo la cinta de zona restringida, puede pedirla a MiTek Machinery Division...
Page 62: General Information Chapter
General Information Chapter 1 This chapter introduces you to this manual and provides an Purpose of Purpose of overview of your equipment and the means to identify it. Chapter Chapter Introduction DANGER Read this manual completely before using this equipment! Do not operate this machine until you have a thorough understanding of all controls, safety devices, emergency stops, and operating procedures outlined...
Page 63 RoofTracker II™ Roller Press The graphics in Table 1-1 are used throughout the manual to quickly communicate a specific type of information. Table 1-1: Navigational Tools Used Throughout the Manual Graphic Explanation Important safety note! Indicates that you must lockout/tagout at the disconnect switch located on the equipment using approved methods described in OSHA 29 CFR 1910.147 before continuing...
Page 64: Additional Resources
Refer to these documents when you need more detailed information on highly-technical components. Web Site Visit the MiTek Web site at www.mii.com for up-to-date information on all MiTek equipment. View the latest revision of this manual and all Service Bulletins, or order parts on-line through our eStore...
Page 65: Introduction To The Equipment
MiTek Overview The RoofTracker II roof truss roller press system consists of a gantry head, which houses the roller that causes the initial embedment of the connector plates; a set of tables that holds and supports the truss and gantry head; a Stand-Alone Conveyor system; and a Finish Roller that completes the plate embedment process.
Page 66: Main Components
RoofTracker II™ Roller Press Main Components Table 1-2: Main Components of the RoofTracker II Press Component Description Part # to Order Moves across the tables for the initial plate Gantry Head embedment, includes operator platform and 67400-501-(xxx)V joystick control station...
Page 67: Operating Options
If your workflow builds multiple trusses on the same table line, you may want to install multiple gantry heads that use the same tables and conveyor system to give your plant more flexibility. The table design allows a RoofTracker II press to be used in conjunction with a ® RoofTracker press, RoofGlider...
Page 68: General Specifications
RoofTracker II™ Roller Press General Specifications Table 1-4: General Specification of the RoofTracker II Press Name of Spec Technical Data Speed up to 145 ft/min Direction of Movement Left and right (forward and reverse) Height Adjustment 4-1/2” up to 6” from table Roller Diameter 24”...
Page 69: Truss Terminology
RoofTracker II™ Roller Press Truss Terminology Table 1-5: Truss Terminology Length Types Height Types Overall length Board height Centerline length Centerline height Top length Centerline height Bottom length Centerline height Figure 1-3: Terminology Diagram Overall Length Top Length Bottom Length...
Page 70 RoofTracker II™ Roller Press Figure 1-4: Parts of a Truss 001100 Rev. A General Information...
Page 71: Prior To Installation Chapter
Each topic is explained in detail in the text following the table. If a MiTek representative is managing the installation of your equipment, the requirements in Table 2-1 must be satisfied before the scheduled installation date, or the installation may need to be rescheduled.
Page 72: Space Requirements
• Space between tables, between Stand-Alone Conveyors, and between components. • Adequate space for safe operation and maintenance of the equipment. Refer to the guidelines in this section when planning your space allocation. MiTek can provide help in plant layout and space utilization, on request.
Page 73: Space For The Equipment
Additional space is required for operation, maintenance, and optional equipment. Refer to your specific layout, provided by your MiTek representative for exact measurements. The dimensions in this manual is intended for general space planning...
Page 74: Location Requirements
This slab should be designed and installed in accordance with local building code requirements and, if required, under supervision of a professional engineer. Concrete should be a minimum of 6 in. thick under the RoofTracker II system. Five thousand (5000) psi concrete is recommended. Refer to your layout drawing.
Page 75: Customer-Supplied Parts
Allen wrenches: 1/8'', 5/32'' Sledge/mallet for concrete 1/2'' masonry drill bit anchors Shipping Information Table 2-5 shows the weight of the individual components of a typical RoofTracker II gantry head. Table 2-5: Shipping Information Contents of Shipment Weight Gantry Head approximately 10,000 lb 001100 Rev.
Page 76: Installation
Lift the equipment to remove the pallet, and gently place each unit in its new location. Equipment Layout The components of the RoofTracker II system must be located in specific locations. Refer to your own layout during installation for specific measurements. Your MiTek representative will provide your layout to you before the equipment is installed.
Page 77: Installing The Tables And Stand-Alone Conveyors
Installing the Gantry Head Installing the Parking Stands and Gantry Head Discuss with your MiTek representative when to install the parking stands. Your options vary depending on the amount of space available at either end of the tables for placing the gantry head.
Page 78: Releasing The Manual Brake
Representative for the correct dimensions. Releasing the Manual Brake The installation of the gantry head should be supervised by a MiTek representative. When sliding the gantry head onto the tables, it is necessary to manually release the brake. The manual brake lever is shown in Figure 6-2 in the Maintenance chapter.
Page 79: Festoon Cable Or Bus Bar
Depending on the length of your system and several other variables, a bus bar may be required. Discuss these options with your MiTek representative before installation. Overview of the Festoon Cable System If your system is using a festoon cable, the gantry head receives its power from a traveling cable running from the appropriate electrical enclosure to the top of the gantry head.
Page 80 RoofTracker II™ Roller Press Table 3-1: Wire Rope and Cable Trolley Requirements for a Festoon Cable System # of Cable Trolleys Length of Wire Rope # of Tables (See your layout for space (feet) required.) 001100 Rev. A Installation...
Page 81: Overview Of The Bus Bar System
RoofTracker II™ Roller Press Overview of the Bus Bar System If your system is using a bus bar system, the cable configuration will differ from that shown in Figure 3-1. Instead of the cable trolleys and wire rope, mount a junction box to the mast and the conductor bars that are attached to the ceiling.
Page 82 RoofTracker II™ Roller Press Figure 3-3: Components of a Bus Bar System Gang Bracket and Hanger Clamp Assembly Mounted on 5-Ft Centers Gang Bracket Mount Bus Bar (Customer-supplied) Collector (Mounted toward the rear) Collector (Mounted toward the front) Mast Gang Bracket Mount...
Page 83: Installing The Bus Bar System
RoofTracker II™ Roller Press Installing the Bus Bar System The customer must supply the hanging brackets. MiTek will provide drawings with the requirements for each bracket. The brackets consist of an upright, a gusset, and an adjustable foot. The instructions below address the installation of the components. The electrical needs are addressed in the Electrical section later in this chapter.
Page 84: Electrical
RoofTracker II™ Roller Press Electrical DANGER ELECTRICAL HAZARD. All electrical work must be performed by a qualified electrician. Follow approved lockout and tagout procedures (OSHA 29 CFR 1910.147). Connecting Power to the Gantry Head All electrical work is the customer’s responsibility and must be performed by a qualified electrician.
Page 85: Connecting The Laser Scanner (Optional Equipment)
RoofTracker II™ Roller Press The beacon and horn sounding device must also be attached to the gantry head during installation. Refer to electrical drawings for exact placement. Connecting the Laser Scanner (optional equipment) The laser scanner is an optional piece of equipment located under the operator platform on machines with a High Bottom-Chord Platform.
Page 86: Checking Motor Rotation
Chapter Chapter DANGER Do not attempt to start the system without a MiTek representative present. Serious injury and/or equipment damage may result. Checking Motor Rotation Check the motor rotation of the brake motor to ensure it is rotating in the same direction as the arrow on its housing.
Page 87: Operation
Before You Begin Understanding This Chapter Once the installation and startup procedures are complete, the equipment is ready to operate. The following sections provide instructions for everyday operation of the RoofTracker II press. 001100 Rev. A Operation...
Page 88: Important Notes
RoofTracker II™ Roller Press Important Notes Do not allow the gantry head to sit in one place for a long period of time after installing it on the table and parking stand assembly. This may cause flat spots to form on the polyurethane wheels.
Page 89: Stopping The Machine
RoofTracker II™ Roller Press Stopping the Machine Stopping During Normal Operation To significantly increase the life of machine components (such as brake pad, bearing, chain, wheels, motor, etc.), follow these guidelines when stopping the gantry head during normal operation: • To stop the gantry head during normal operation, release the joystick and let the gantry head coast to a stop.
Page 90: Laser Scanner
RoofTracker II™ Roller Press Laser Scanner The laser scanner is provided only if the equipment has the optional High Bottom-Chord Platform that is at the same height as the table tops. In this instance, a safety device scans Refer to page 79 for...
Page 91: Indicators
RoofTracker II™ Roller Press Indicators Figure 5-3: indicators on Light Stack and Horn Assembly Light Stack and Horn Light Stack There is a light stack located on top of the gantry head. It has 4 different beacon lights that visually show the status of the machine.
Page 92: Hour-Meter
RoofTracker II™ Roller Press Hour-Meter An hour-meter is located on the main enclosure. See Figure 5-4. It records the number of operating hours, which is the time the gantry head is in motion. Refer to this meter to determine a maintenance schedule.
Page 93: Operator Control Interface Mechanisms
Operator Control Interface Mechanisms Getting Familiar With the Operation Your RoofTracker II press is operated by a joystick. The joystick is mounted on a panel attached to the gantry head called the operator control station (or operator station). A platform is attached to the gantry head for the operator to stand on.
Page 94: Operator Platform
RoofTracker II™ Roller Press Joystick To operate the equipment with a joystick, press the blue RESET button on the operator control station. Then, press and hold the white button on the joystick handle while pushing the handle in the direction the gantry head should move. The operator must keep the white button on the joystick depressed for movement to continue.
Page 95: Operating Procedure
RoofTracker II™ Roller Press Operating Procedure Operating Under Normal Conditions 1. Turn the disconnect handle to the ON (vertical) position. 2. Set up the truss configuration and jigging. Refer to the Setting Up for Operation— Refer to... Jigging section. Figure 5-6 3.
Page 96 RoofTracker II™ Roller Press 6. Remove the truss from the table and place it on the Stand-Alone Conveyors. a) For systems without ejectors, manually slide the truss over onto the conveyors. b) For systems using pneumatic ejectors and receivers: 1) Remove all slider pads and ensure the gantry head is not parked on top of an ejector.
Page 97 RoofTracker II™ Roller Press Figure 5-6: Operating Procedure Turn on Disconnect Switch Set Up the Truss Verfiy That Path is Clear Press and Hold the Button While Pushing the Joystick to the Left or Right to Start Movement Release the Button and/or Joystick to Stop Movement...
Page 98: Restarting Operation
RoofTracker II™ Roller Press Restarting Operation If the machine stopped because you released the joystick, both Ready indicator lights should still be on. You can continue motion in either direction by pressing the joystick button and moving the joystick in the direction the gantry should go.
Page 99: Vfd And Brakes
RoofTracker II™ Roller Press VFD and Brakes Figure 5-7: VFD and Cards The VFD (variable frequency drive) is inside the VFD enclosure. It is the enclosure to the right of a bottom-chord operator platform. If the VFD experiences a fault, a fault...
Page 100: Other Vfd Faults
RoofTracker II™ Roller Press Other VFD Faults For other VFD faults, refer to your electrical schematic for VFD settings and jumper details. All VFD faults are explained in the VFD manual from the VFD manufacturer. The VFD manual was provided when your equipment was purchased and installed.
Page 101: Light Curtains
Light curtains are presence-sensing devices designed to guard personnel working around moving machinery. RoofTracker II presses use a two-beam light curtain set on both sides of the gantry head. Refer to Figure 5-1 on page 28 for a photograph of a light curtain. A light curtain set consists of a receiver bar and a transmitter bar.
Page 102: Maintenance
Certain operating environments may necessitate preventive maintenance at more frequent intervals. Because consistent preventive maintenance is so important for keeping mechanical equipment in good operating condition, MiTek recommends that you stock certain replacement parts to minimize downtime. The recommended parts list is in the Replacement Parts appendix.
Page 103: Safety Test
RoofTracker II™ Roller Press Refer to page 88 through page 92 for graphics that will assist with understanding this equipment. Safety Test The test procedure in the Safety Tests section on page xvi MUST be performed by qualified personnel after ANY maintenance, adjustment, or modification. Testing ensures that the light curtain, safety system, and machine control system work together to properly stop the machine.
Page 104: Brake Motor And Gearbox
RoofTracker II™ Roller Press Brake Motor and Gearbox The brake motor and gearbox allow the gantry head to start and stop motion. The VFD monitors the drive chain and is discussed later in this chapter. Certain preventive maintenance is required to keep the motor and gearbox in optimal Refer to the VFD working order.
Page 105: Using The Manual Brake Lever
RoofTracker II™ Roller Press Using the Manual Brake Lever Release the manual brake lever if you need to manually push the gantry head to a different location along the tables. See Figure 6-2. Replacing the Motor Figure 6-2: Brake Motor 1.
Page 106: Replacing A Brake Pad
RoofTracker II™ Roller Press Replacing a Brake Pad Figure 6-3: Steps 1 through 5 1. Unscrew the manual brake Brake handle extending from the side of the brake motor, if there is one. 2. Remove the fan cover. Slotted screwdriver 3.
Page 107: Maintaining The Air Gap
RoofTracker II™ Roller Press Maintaining the Air Gap NOTICE Adjusting the air gap improperly may damage motor. Do not attempt to make this adjustment unless the measured gap is outside the recommended allowance. Keeping the Correct Air Gap The air gap in the brake motor may need to be adjusted as the brake pad wears down. The air gap does not affect the stopping distance, but a worn break pad allows extreme friction on the metal components and will burn up the motor.
Page 108 RoofTracker II™ Roller Press 3. Using a feeler gauge, measure the gap between the armature disk and brake housing, shown in Figure 6-6. Measure completely around the brake and record any variations in the gap measurement. Figure 6-6: Measuring the Brake Disk Air Gap Armature Disc .016 - .043 in.
Page 109: Drive Wheels And Idler Wheels
RoofTracker II™ Roller Press Drive Wheels and Idler Wheels Drive wheels control the movement of the gantry head. They are driven by the drive chain. The idler wheels are in-line with the drive wheels and assist in supporting the gantry head.
Page 110: Replacing A Drive Wheel (Wheel Only)
RoofTracker II™ Roller Press Replacing a Drive Wheel (Wheel Only) Use this procedure to replace a drive wheel inside an existing drive wheel block. If you need to replace the entire wheel block, refer to the next section. Removing the Existing Wheel To replace an existing wheel, you must first disassemble the wheel block.
Page 111 RoofTracker II™ Roller Press 5. Gently pry the cover (63775-501) off of the wheel housing (63734). Figure 6-8 shows the wheel housing without a cover. a) Place a slotted screwdriver in the slots pointed out in Figure 6-8. b) Gently pry the cover off of the housing. Pry up gently and evenly on both sides to avoid damaging the housing.
Page 112 RoofTracker II™ Roller Press Installing a New Wheel in the Existing Wheel Block To replace the wheel in the wheel block, follow the procedure below. 1. Install the wheel assembly (63733-501) into the wheel housing (63734). This is a press fit. Use caution. The inside hole of the wheel must be in line with the outside diameter of the wheel housing while pressing.
Page 113: Replacing The Entire Drive Wheel Block
RoofTracker II™ Roller Press Replacing the Entire Drive Wheel Block 1. Park the gantry head in one of the parking areas so the wheel block is accessible from the inside of the gantry head, and the drive wheel chain master link is accessible.
Page 114: Guide Wheels
RoofTracker II™ Roller Press Guide Wheels Figure 6-9: Guide Wheel and Grease Fitting Refer to Figure 6-28 at the back of this chapter for a diagram of the wheels on the gantry head. Lubricating Guide wheels are necessary to keep the gantry head on a straight Refer to...
Page 115: Pressure Wheels
RoofTracker II™ Roller Press Pressure Wheels Refer to Figure 6-28 at the back of this chapter for a diagram of the wheels on the gantry head. Lubricating Pressure wheels keep the gantry head at a level position when it encounters the start of the truss on the tables.
Page 116: Take-Up Bearing
RoofTracker II™ Roller Press Take-Up Bearing Lubricating The take-up bearing allows the roller to turn, resulting in smooth embedment of the connector plates. It should be greased approximately every 150 working hours. Use a #2 lithium-based grease to lubricate the grease block for each take-up bearing. The Refer to...
Page 117: Adjusting Chain Tension
1/2 in. (1/4 in. movement to both sides of center). 3. Check the tension of the motor drive chain on the other end of the RoofTracker II. Repeat steps if the chain tension does not match the description in the optimum chain tension described above.
Page 118 RoofTracker II™ Roller Press Adjusting the Motor Drive Chain Tension 1. Loosen the top nuts on each of the jack bolts shown in Figure 6-12. 2. Raise the middle nut on each jack bolt to raise the motor plate. Ensure they are even and the motor plate is level.
Page 119: Replacing A Chain
RoofTracker II™ Roller Press Replacing a Chain Both of the drive wheel chains and the motor drive chain can be replaced using the following procedure. Refer to Figure 6-12 on page 57 for a close-up view of the motor drive chain and Figure 6-11 on page 56 for the drive wheel chain.
Page 120: Adjusting The Roller Height
RoofTracker II™ Roller Press Adjusting the Roller Height Check the roller setting with a standard 2x4 (1-1/2 in. thick) piece of lumber and 1/16 in. shim. The shim should slide between the bottom of the roller and the 1-1/2 in. thickness of the 2x4 at each end of the roller.
Page 121 RoofTracker II™ Roller Press Figure 6-14: Take-Up Bearing Adjustment Steps in Procedure Locking Nut Adjusting Nut Locking Bolt Hanger Bracket Bottom Nut (located behind frame) Take-Up Bearing 001100 Rev. A Maintenance...
Page 122: Bumpers
RoofTracker II™ Roller Press Bumpers Replacing a Bumper Plate (Weldment) 1. Remove the bumper plate hardware shown in Figure 6-15 and set aside the bumper plate. Keep all hardware. 2. Mount the new bumper plate with the original hardware. 3. Check the position of the bumper plate flag and the light curtain per Figure 6-15.
Page 123: Replacing A Gas Spring
RoofTracker II™ Roller Press Replacing a Gas Spring 1. Remove the gas-spring hardware and discard the damaged gas spring. 2. Mount the new gas-spring with the original hardware. 3. Check the position of the bumper plate flag and the light curtain per Figure 6-15.
Page 124: Adjusting The Bumper Flag
RoofTracker II™ Roller Press Adjusting the Bumper Flag The bumper flag, located above each bumper, interrupts the light curtain light beam sensor when the bumper compresses. To reduce the amount of time it takes to stop, each bumper flag should be aligned with its light bar sensor so there is no space between the edge of the flag and the edge of the sensor.
Page 125: Safety Controller
RoofTracker II™ Roller Press Safety Controller This information applies to the safety controller used in 2010. It can also be found in the Omron catalog number Z922-E1-01. This section contains text protected by Omron copyrights. The safety controller ensures that all safety features on this machine are working properly.
Page 126: Safety Controller Operating States
RoofTracker II™ Roller Press Safety Controller Operating States The indicator lights on the front of the safety controller show which Operating Mode the safety controller is in. Additional diagnostics are described on page 99 in the Troubleshooting appendix. Table 6-3: Operating Modes for the Laser Scanner System...
Page 127: Replacing The Safety Controller Or Memory Cassette
• Safety controller unit • Memory cassette Either part can be replaced, but they must be purchased through MiTek so the software and configuration can be installed first. To identify your safety controller model, refer to the nameplate described in Figure 6-17.
Page 128: Loading Software Upgrades
If updating the safety controller's configuration data is required due to a version upgrade of existing equipment, the new configuration data can be sent from MiTek on a new memory cassette. Follow the instructions on page 66 to insert the new cassette.
Page 129: Backing Up Data To The Memory Cassette
RoofTracker II™ Roller Press Backing Up Data to the Memory Cassette This section describes the conditions and procedures for backup. Backing up data needs to occur only if a new program is supplied for the memory cassette or safety controller.
Page 130 RoofTracker II™ Roller Press • Performing a backup overwrites the data on the memory cassette. Be sure to confirm that the memory cassette contains no required data before performing backup. • Formatting the memory cassette is not required. • The contents of the memory cassette can be checked by verifying the configuration ID to prevent setting incorrect configuration data when restoring data to the safety controller is performed from the memory cassette.
Page 131: Restoring Data To The Safety Controller
The device password for the safety controller must match the device password that is on the memory cassette. If the new cassette has a password that doesn’t match the safety controller unit, contact MiTek. • Prohibit Restore Setting Disabled The restore prohibition setting made for the safety controller was disabled before it was shipped to you or placed in the equipment.
Page 132: Managing Voltage Drops
RoofTracker II™ Roller Press • Operation will always start in restore waiting status when startup is performed with the memory cassette inserted into the safety controller using the default settings. Make sure the memory cassette is not inserted when downloading the configuration data from a computer.
Page 133: Vfd And Encoder
RoofTracker II™ Roller Press VFD and Encoder The VFD (Variable Frequency Device) is located in the main electrical enclosure. The VFD controls the speed that the gantry head travels and stops. A built-in PLC allows the VFD to monitor the drive chains motion during braking and alerts the operator when the gantry is not stopping as expected.
Page 134 RoofTracker II™ Roller Press Figure 6-19: Brake Reset Key (Main Electrical Enclosure) Hour-Meter Brake Reset Key a) Lock and tag the machine until maintenance is complete. It is most likely a loose drive chain or motor drive chain, but refer to the Troubleshooting section to determine the exact cause.
Page 135: Broken Chain Or Faulty Encoder
RoofTracker II™ Roller Press Broken Chain or Faulty Encoder When a chain breaks or the encoder does not register chain movement, the operator control station sends a message to the VFD that the gantry head should be moving, but the encoder sends a message to the VFD that the gantry head is not moving.
Page 136: Light Curtains
Components The RoofTracker II is equipped with 2 sets of light curtains, one set on each side of the gantry head. Each set consists of a transmitter bar and a receiver bar. The transmitter bar Refer to diagram transmits the signal for the light beam and the receiver bar receives the signal.
Page 137: Light Curtain Operating States
RoofTracker II™ Roller Press Light Curtain Operating States The indicators on the receiver bar tell the operator what operating state the light curtain set is detecting. The different operating states are described in Table 6-5. Table 6-5: Light Curtain Operating States...
Page 138: Light Curtain Diagnostic And Test Features
RoofTracker II™ Roller Press Light Curtain Diagnostic and Test Features DANGER ELECTROCUTION HAZARD. Disconnect power before opening end caps! Individual Beam Indicators (IBI) The light curtain system has a visible, red individual beam indicator (IBI) adjacent to each receiver bar infrared beam. An IBI will light when the infrared beam fails to meet the conditions necessary to remain in the machine-run state.
Page 139: Replacing Light Curtains
RoofTracker II™ Roller Press Replacing Light Curtains Light curtains can be replaced as a set of two, or just the transmitter or receiver may be ordered by itself. Refer to the Replacement Parts appendix for part numbers. 1. Determine if you need to replace a transmitter, receiver, or both. Locate the part number in the Replacement Parts appendix.
Page 140: Laser Scanner (Optional)
RoofTracker II™ Roller Press Laser Scanner (optional) Machines with a High Bottom-Chord Platform Figure 6-21: Laser Scanner are equipped with a laser scanner to sense people or obstacles that are in the path of the platform.When the scanner sensing something in its safety zone, the E-stop circuit causes the gantry head to stop moving.
Page 141: Laser Scanner Components
RoofTracker II™ Roller Press Laser Scanner Components Figure 6-22: Laser Scanner Components Table 6-6: Laser Scanner Components Defined Will turn ON when safety zone is clear and RUN indicator (green) OSSDs are ON Will turn ON when in interlock state, blink...
Page 142: Operating States Of Laser Scanner
RoofTracker II™ Roller Press Operating States of Laser Scanner Operating Mode After powering on, the laser scanner enters the interlock state if no fault or intrusion (object) is detected within the safety zone. Press the RESET button on the operator station to release the interlock state and enter the run (ON) state.
Page 143 RoofTracker II™ Roller Press Status/Diagnostic Display of Laser Scanner 1. When powered up, the Status/Diagnostic display area will display: Refer to Figure 6-22 a) The minimum object resolution on page 80 for • L3 = 30 mm location of scanner parts.
Page 144: Scanning Regions And Scanner Limitations
RoofTracker II™ Roller Press Scanning Regions and Scanner Limitations The boundaries of the scanned safety zone are configured by MiTek as shown in Figure 6-23. Keep the following points in mind when operating and maintaining the laser scanner: • The laser scanner scans directly underneath the platform when the gantry head is sitting still.
Page 145 RoofTracker II™ Roller Press Figure 6-23: Safety Zone Scanned by Laser Scanner 001100 Rev. A Maintenance...
Page 146: Replacing The Scan Window
Verify there are no obstructions (such as tools left out) in the scanner’s zone. c) Verify that dirt did not fall into the scanner when it was open. If it still will not function, calibration may be necessary. Call MiTek Machinery Customer Service to assist with laser scanner calibration. 001100 Rev. A...
Page 147: Multiple-Head Interlock
RoofTracker II™ Roller Press Multiple-Head Interlock Some truss assembly lines have more than one gantry head on a table line. When this occurs, a multiple-head interlock is attached to each head to prevent collisions. Even if the gantry head has a laser scanner under the platform, a multiple-head interlock is required.
Page 148: Indicator Lights And Sounding Device
RoofTracker II™ Roller Press Indicator Lights and Figure 6-24: Light Stack and Horn Sounding Device Light Stack Bulbs If a bulb in the light stack burns out, remove the appropriate beacon cover and replace the bulb. Refer to For more the Replacement Parts appendix for a part number.
Page 149: Graphics
RoofTracker II™ Roller Press Graphics General Graphics Figure 6-25: Electrical Enclosure and Safety Features, Operator End of Gantry Light Curtain Unit (4 places) Main Electrical Enclosure Bumper (2 or 4 places) 001100 Rev. A Maintenance...
Page 150: Drive System And Wheels
RoofTracker II™ Roller Press Drive System and Wheels Figure 6-26: Drive System on Outer Side of Gantry Head Drive Sprocket Drive Wheel Both ends Drive Wheel Tension Both ends Adjustment Both ends 001100 Rev. A Maintenance...
Page 151 RoofTracker II™ Roller Press Figure 6-27: Wheel Locations on Inner Side of Gantry Head Pressure Wheel 4 places each end Guid 4 plac Idler Wheel Block Mounting/ (not driven) Alignment Both ends (2 places each wheel block) Guard Guard Guard...
Page 152: Lubrication Graphics
RoofTracker II™ Roller Press Lubrication Graphics Figure 6-28: Wheel Locations and Chain Lubrication Points =Chain Lube Points Drive Wheels (2 with chain) Guide Wheels Pressure Wheels 001100 Rev. A Maintenance...
Page 153 RoofTracker II™ Roller Press Figure 6-29: Wheel and Bearing Lubrication Points Grease Block for Take-Up Bearing (only operator end) Grease every 150 working hours. Drive Wheel Bearing Drive Wheel Shaft Guide Wheel Grease Fitting Grease Fitting Grease Fitting (2 places each end)
Page 154: Troubleshooting
Troubleshooting Appendix A Navigating the Troubleshooting Appendix This appendix is divided into tables according to the nature of the issue that is being addressed. The tables are presented in the order listed below. Table A-1: Troubleshooting Appendix Quick Reference Guide Page # Troubleshooting Category page 94...
Page 155: Mechanical Troubleshooting
RoofTracker II Roller Press Mechanical Troubleshooting Table A-2: Troubleshooting the Mechanical System Problem Possible Cause Possible Solution Page Adjust the tension or Motor drive chain loose or broken replace chain Adjust the tension or Drive wheel chain loose or broken...
Page 156 RoofTracker II Roller Press Table A-2: Troubleshooting the Mechanical System (Continued) Problem Possible Cause Possible Solution Page Drive wheels are worn or damaged Gantry is sliding to a stop Track tube is slippery (may be due to lubricant residue) Drive Motor Chain tension is loose Adjust tension...
Page 157: Electrical And Perimeter Guarding Troubleshooting
RoofTracker II Roller Press Electrical and Perimeter Guarding Troubleshooting Check all bulbs on indicator lights to ensure they are still in working order before attempting to do any troubleshooting. Table A-3: Troubleshooting the Electrical System and Perimeter Guarding Problem Possible Cause...
Page 158 100mm away from any objects. any objects. Call MiTek if reconfiguration is necessary. Password is required! An additional measurement error Additional Error due to Reflective may need to be added due to...
Page 159 RoofTracker II Roller Press Table A-3: Troubleshooting the Electrical System and Perimeter Guarding (Continued) Problem Possible Cause Possible Solution Page The scanner will turn OFF if the zone set select input pattern does Call Customer Service to set the zone...
Page 160: Safety Controller Diagnostics And Troubleshooting
RoofTracker II Roller Press Safety Controller Diagnostics and Troubleshooting Safety Controller Diagnostics The indicators shown in Figure A-1, located on the front of the safety controller, communicates its status and Operating Mode. An explanation of each numbered row can be found on Refer to page 64 for maintenance information about the safety controller.
Page 161 RoofTracker II Roller Press Table A-4: Diagnostic Definitions for Safety Controller (Use With Figure A-1) Problem Status Possible Solution Normal Normal User testing has been completed, and normal operation is being operating status operating performed in automatic operating mode. No particular measures are...
Page 162 RoofTracker II Roller Press Table A-4: Diagnostic Definitions for Safety Controller (Use With Figure A-1) Problem Status Possible Solution A minor error (e.g., unsupported Unit mounted) from which recovery is possible has occurred. Check the following, confirm proper system configuration, and then cycle the power supply.
Page 163: Safety Controller Error Names And Solutions
RoofTracker II Roller Press Safety Controller Error Names and Solutions More information on the safety controller can be found in the Maintenance chapter, starting on page 64. Table A-5: Troubleshooting the Safety Controller Error Name Possible Cause Possible Solution A hardware error has been detected in hardware self- Cycle the power supply.
Page 164 RoofTracker II Roller Press Table A-5: Troubleshooting the Safety Controller (Continued) Error Name Possible Cause Possible Solution The memory cassette was With the power supply OFF, insert the Memory casette removed or removed during execution of a Memory Cassette again, and then turn ON access error memory cassette operation.
Page 165 RoofTracker II Roller Press Table A-5: Troubleshooting the Safety Controller (Continued) Error Name Possible Cause Possible Solution A logic error was detected in Function block status error Reference the safety controller’s manual function block execution. With the power supply off, check the...
Page 166 RoofTracker II Roller Press Table A-5: Troubleshooting the Safety Controller (Continued) Error Name Possible Cause Possible Solution Short-circuit detected at safety A fault in output signal lines was Check the external wiring. output detected. Contact made from output signal lines to positive side of power Check the external wiring.
Page 167: Light Curtain Diagnostic Codes
RoofTracker II Roller Press Light Curtain Diagnostic Codes Table A-6: Diagnostic Codes for the Light Curtain System Code Code Group Description of Diagnostic Code Number When powered-up, all of the segments are lit and then the software version 88/V# number is displayed...
Page 168: Laser Scanner Diagnostic Codes
RoofTracker II Roller Press Laser Scanner Diagnostic Codes Table A-7: Diagnostic Codes for the Laser Scanner System Code Status Description Corrective Action Number Power up indication Normal operation (guarded machine stop) Standby mode (guarded machine stop); blinking the rate of blinking depends on mode...
Page 169 RoofTracker II Roller Press Table A-7: Diagnostic Codes for the Laser Scanner System Code Status Description Corrective Action Number Affected by noise or disturbance light or Check the environment if any noise internal fault or disturbance light is coming in...
Page 170: Parts List
Parts List Appendix B Navigating the Parts List Appendix Finding the Part Number The parts list provided here shows spare parts that should be kept in stock at all times. Use one of the methods shown in Table B-1 to locate your part number. For a complete list of replacement parts, or if you’re unsure of which spare part you need and would like to see a picture, use the electronic Parts Guide for this machine.
Page 171 (OSHA 29 CFR 1910.147) before performing any maintenance on this equipment. NOTICE Only use the exact replacement parts that are specified by MiTek. Substitutions may harm your equipment. 001100 Rev. A Parts List...
Page 172: Part Numbers
RoofTracker II™ Roller Press Part Numbers Mechanical Parts Table B-3: Mechanical Replacement Parts Keep MiTek Part # Part Description Refer to Drawing # Stock Drive wheel chain, #80 554008 63750 or 63826 (Qty of 2 at 157" ea) 554008 Motor drive chain (Qty of 1 at 98")
Page 173: Electrical Parts
RoofTracker II™ Roller Press Electrical Parts Table B-4: Electrical Replacement Parts Keep Refer to MiTek Part # Part Description Drawing # Stock 208/230 V—516382 415/460 V—516388 Brake fuses (2) 90944 575 V—516383 208/230 V—516494 460 V—516491 Disconnect fuses (3) 90944 415/575 V—516490...
Page 174: Maintenance Checklists
These pages are supplied with the intent that you will photocopy them and document the date that maintenance is done on the copies, leaving the original in the manual for future use.  Press RoofTracker II Daily Checklist page 114 Weekly Checklist page 115...
Page 175: Daily Checklist
RoofTracker II Daily Checklist WARNING Lockout/tagout before performing any maintenance! If power is required, ensure all personnel are clear. Week of:_________________ Year:_________________ Action Shift 1 Lubricate the drive wheel chain Shift 2 (every 8 working hours) Shift 3 Shift 1...
Page 176: Weekly Checklist
RoofTracker II Weekly Checklist WARNING Lockout/tagout before performing any maintenance! If power is required, ensure all personnel are clear. Month: _____________ Year: _____________ Lockout/ Mechanical Actions Week 1 Week 2 Week 3 Week 4 Week 5 Tagout Check tension of the drive wheel chain—needs 1/2” play Check tension of the motor drive chain—needs 1/2”...
Page 177: Checklist By Working Hours
RoofTracker II Checklist by WARNING Working Hours Lockout/tagout before performing any maintenance! If power is required, ensure all personnel are clear. Year: _____________ WORKING Action Date HOURS Grease take-up bearing Grease gantry lifter bearings (if equipped with this option) Inspect and dust brake motor...
Page 178: Drawing Set
Drawing Set Appendix D Drawings may be in a separate binder accompanying this manual or at the end of this manual. Table D-1: Attached Drawings for a RoofTracker II System Drawing Description Drawing Number Parking stand assembly 63630-501 Drive wheel block assembly...
Page 179: Document Evaluation
Document Evaluation Appendix E A form is included in this appendix so you can provide MiTek with feedback on the usefulness of this manual. We make an ongoing effort to improve the value of our documentation, and your views are important to us.
Page 180 Document Evaluation Form We appreciate your comments on how we can make this document more useful. Document Identification: Equipment Manual ™ 001100 rev. A RoofTracker II General Ratings: Poor Fair Good Excellent Content     Organization  ...
Page 181 Date: Company Name: Address: Phone: E-mail: Please mail this form to: Or fax this form to: MiTek 636-328-9218 Machinery Operations Attn: Engineering Manager 301 Fountain Lakes Industrial Drive St. Charles, MO 63301 Attn: Engineering Manager If you do not receive a reply within 45 days, please call our Customer Service Department and ask for the Documentation Specialist or Engineering Manager: 800-523-3380.
Page 182: Glossary
Glossary actuate to activate, put into action aisle pad a type of jigging used when a connector plate needs to be embedded where the table surface gives way to a walk-through aisle amperage the strength of an electric current, expressed in amperes anchor plate a steel plate that holds the tables in place;...
Page 183 Glossary gantry head the entire traveling weldment that houses the roller to embed the connector plates hour-meter a gauge that tells the amount of time the motor is actually turning and the gantry head is moving idler wheel one of four wheels that assist the drive wheels but are not driven by the motor inner side refers to the end of the gantry head housing;...
Page 184 Glossary operator end also “motor end”, used to indicate which end of the gantry head is being discussed; the end of the gantry head that houses the motor and the user control interface OSSD Output Signal Switching Devise for safety scanner; provides “on” output when no object is interrupting the sensor within safety zone outer side refers to the end of the gantry head housing;...
Page 185 Glossary receiver bar the component of the light curtain that receives the signal from the transmitter bar; every light curtain set consists of a receiver bar and a transmitter bar regulator a component of the pneumatic system that connects to the main air source and regulates the air pressure allowed into the system roller the large roller inside the gantry head that initially embeds the plates...
Page 186: Index
Index disconnect switch document evaluation form drawing set beacon drive fault bearings drive system bumpers chain tension lubrication graphic take-up for press roller drive wheels bellows chains brake motor graphic bumpers lubrication overview replacing replacing safety test ejectors electrical chains enclosure adjusting tension disconnect...
Page 187 Index overview components guide wheels diagnostic codes graphic diagnostics lubrication installing replacing operating states and lights regions and limitations replacing window light bars operation horn light bulbs hour-meter light curtain diagnostic and test features diagnostic codes operation realigning and inspecting replacing xviii idler wheels...
Page 188 Index motor drive chain tension motors multiple-head interlock ready indicator lights Receiver Stands replacement parts electrical mechanical navigation restore data to safety controller operation restricted zone tape indicator lights restricted zones joystick return goods light curtain roller height options procedure quick start stopping time running...
Page 189 Index spare parts stackers stop motion, see E-stop tables take-up bearing adjusting diagram lubrication tension sprocket adjustment drive wheel chain graphic motor drive chain timing belt timing relay troubleshooting electrical problems mechanical problems perimeter guarding safety controller truss terminology Variable Frequency Drive, see VFD VFD (variable frequency drive) operation overview...
Page 190 001100 001100 001100 Rev. A Rev. A Rev. A...

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