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Mitek RoofTracker Operation And Maintenance Manual

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Operation and Maintenance Manual
RoofTracker
™
Roof Truss Roller Press
®
Copyright © 2005-2008 MiTek
. All rights reserved.
001075
Patented. See Legal Notice for list of patents.
Rev. F
001075 Rev. F
Prior to Installation
0

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  • Page 1 Operation and Maintenance Manual RoofTracker ™ Roof Truss Roller Press ® Copyright © 2005-2008 MiTek . All rights reserved. 001075 Patented. See Legal Notice for list of patents. Rev. F 001075 Rev. F Prior to Installation...
  • Page 2 Equipment Manual RoofTracker Roof Truss Roller Press U.S. and other patents pending MiTek Industries, Inc. 001075 Machinery Division Creation date 9 February 2004 Written by R.Tucker 301 Fountain Lakes Industrial Drive Approved by G. McNeelege St. Charles, MO 63301 Revision...

  • Page 3: Legal Notice

    Trademark 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 Holdings, Inc. 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™ Roof Truss Roller Press Service Bulletin or Notice # Dated Title 001075 Rev. F Notice of Change...

  • Page 5: Table Of Contents

    Corrección en caso de no pasar la prueba xxxiv General Information Chapter 1 Introduction 1 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 Components and Options 6...
  • Page 6 Contents Space Requirements 12 Space for the Equipment 12 Determining the Space Needed for Your System 13 Space for Operation and Maintenance 13 Location Requirements 13 Floor Structure 13 Environment 13 Electrical Requirements 14 Standard Electrical Requirements 14 Electric Cable or Bus Bar 14 Customer-Supplied Parts 15 Shipping Information 16 Installation Chapter 3...
  • Page 7 Contents Indicators 32 Indicator Lights 32 Indication of Movement (Beacon) 33 Hour-Meter 33 Operator Control Interface Mechanisms 34 Getting to Know Your Joystick Controller and Operator Platform 34 Getting to Know Your Pendant Control Station 36 Operating Procedure 37 Operating Under Normal Conditions 37 Restarting Operation 40 VFD 41 Brake Monitor 42...
  • Page 8 Contents Brake Monitor 68 Operating the Brake Monitor 68 Replacing the Brake Monitor 68 Motion Detector 70 Pendants and Joysticks 70 Maintaining the Joystick 70 Replacing Your User Control Interface 70 Limit Switches 71 Light Bars 72 Components 72 Realigning and Inspecting 72 Light Bar Operating States 73 Light Bar Diagnostic and Test Features 74 Replacing Light Bars 76...

  • Page 9: Safety (English)

    Safety (English) For safety information in Spanish, refer to page 11. Be Careful. Be Safe. 001075 Rev. F Safety (English)

  • Page 10: Safety Indicators

    RoofTracker Roller Press Safety Indicators The following safety alert symbols and signal words are used throughout this document to indicate safety hazards. Please pay careful attention when you see them. The level of severity differs for each symbol or signal word.

  • Page 11: Safety Rules

    RoofTracker 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 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 15. Keeping a Safe Environment •...

  • Page 13: Lockout/Tagout

    RoofTracker 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 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 18. Before performing maintenance on any machine with electrical power, lockout/tagout the machine properly.
  • Page 15 RoofTracker Roller Press Figure SAFETY-1: Lockout/Tagout on the Main Electrical Enclosure Sample of a Lock and Tag Attached to a Machine’s Electrical Enclosure 001075 Rev. F Safety (English) xiii...

  • Page 16: Troubleshooting With An Energized Machine

    RoofTracker 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 RoofTracker 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. Stackers Conveyors (Not Shown) Gantry Head Finish Roller Conveyors Tables Parking Stand 001075 Rev.

  • Page 18: Safety Test

    RoofTracker Roller Press Safety Test The following test procedure MUST be performed by qualified personnel after ANY maintenance, adjustment, or modification. Testing ensures that the light bar, safety system, and machine control system work together to properly stop the machine.
  • Page 19 RoofTracker Roller Press DANGER Never stand directly in front of the gantry head! If the gantry head fails to stop when expected, serious injury or death may occur. Testing the Light Bars 1. Ensure the disconnect handle is in the ON position.

  • Page 20: Correcting A Failed Test

    RoofTracker Roller Press 13. Repeat this test in the LEFT/ The purpose of this test is to ensure FORWARD direction. that the electrical system is wired correctly so motion stops when a 14. If any of the light bars fail this light bar beam is interrupted.
  • Page 21 RoofTracker Roller Press If the wiring does not match the drawing, correct it. If the wiring does match the drawing, refer to the Troubleshooting appendix. If a retracted bumper fails to stop the motion of the gantry head: 1. Examine the bumper for bent or damaged parts.

  • Page 22: Seguridad (Español)

    Seguridad (Español) Sea cuidadoso. Protéjase. 001075 Rev. F Seguridad (Español)

  • Page 23: Indicadores De Seguridad

    RoofTracker 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 24: Reglas De Seguridad

    RoofTracker 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 25 RoofTracker 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 26 RoofTracker 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 27: Bloqueo/Etiquetado

    RoofTracker 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 28: Procedimientos De Bloqueo/Etiquetado Eléctricos

    RoofTracker 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 19. Antes de realizar el mantenimiento de cualquier máquina con alimentación eléctrica, bloquee y etiquete la máquina de forma adecuada.
  • Page 29 RoofTracker Roller Press Figure SEGURIDAD-1: Bloqueo/etiquetado en el gabinete eléctrico principall Ejemplo de un candado y etiqueta fijados al gabinete eléctrico de una máquina 001075 Rev. F Seguridad (Español) xxvii...
  • Page 30 RoofTracker 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 31: Solución De Problemas Con Una Máquina Energizada

    RoofTracker 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 32: Zonas Restringida

    RoofTracker Roller Press Zonas restringida 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. Apiladores Bandas transportadoras (no ilustrados) Cabeza de caballete...

  • Page 33: Prueba De Seguridad

    RoofTracker Roller Press Prueba de seguridad El siguiente procedimiento de prueba DEBE ser realizado por personal calificado después de CUALQUIER tarea de mantenimiento, ajuste o modificación. La prueba permite verificar que la barra de luz, el sistema de seguridad y el sistema de control de la máquina funcionen bien juntos para detener la máquina en forma adecuada.
  • Page 34 RoofTracker Roller Press PELIGRO ¡No se pare nunca delante de la cabeza del caballete! Si ésta no se detiene en el momento adecuado, podría sufrir lesiones serias, o incluso la muerte. Prueba de las barras de luz 1. Asegúrese de que el mango de desconexión está en la posición ON (encendido).

  • Page 35: Corrección En Caso De No Pasar La Prueba

    RoofTracker Roller Press 13. Repita esta prueba en la dirección El propósito de esta prueba es LEFT/FORWARD asegurarse de que el sistema eléctrico esté correctamente 14. Si alguna de las barras de luz no conectado de modo tal que el pasa esta prueba, refiérase a la...
  • Page 36 RoofTracker Roller Press Si la cabeza del caballete se mueve en la dirección esperada, y sólo la barra de luz del lado opuesto la detiene: Inspeccione la conexión de la barra de luz con el plano correcto: Plano 90524 para máquinas de 2 cajas Plano 90544 para máquinas de 1 caja...

  • Page 37: 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 in this manual.
  • Page 38 RoofTracker 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 Explanatioin 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 39: Additional Resources

    The supplemental documentation is provided at the time of installation, or it may be found inside an electrical enclosure. Refer to these documents when you need more detailed information on these components than the MiTek manual provides.

  • Page 40: Introduction To The Equipment

    Overview The RoofTracker 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;...

  • Page 41: Operation Chapter

    RoofTracker Roller Press Figure 1-2: RoofTracker Press, Shown With a 2-Enclosure Electrical System Stand-Alone Conveyors Gantry Head Tables 001075 Rev. F General Information...

  • Page 42: Components And Options

    RoofTracker Roller Press Components and Options Main Components Table 1-2: Main Components of the RoofTracker Press Component Description Part # to Order Gantry Head WITHOUT Moves across the tables for the initial plate operator platform, 63750-501-(xxx)V embedment WITH pendant control station...

  • Page 43: Component Options

    RoofTracker Roller Press Component Options Table 1-3: Peripheral Components That May Be Used With the RoofTracker Press Component Description Part # to Order Receive the truss from the ejectors and Receiver Stands 63635-501 place it on the Stand-Alone Conveyors 66225-501...

  • Page 44: General Specifications

    RoofTracker Roller Press ® The table design allows a RoofTracker press to be used in conjunction with a RoofGlider press or an AutoPress machine to add capabilities to an existing press. A 12-ft gantry head is also available. Contact your MiTek Sales Representative for more information.

  • Page 45: Truss Terminology

    RoofTracker Roller Press Truss Terminology Table 1-6: 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 Center Line Length...
  • Page 46 RoofTracker Roller Press Figure 1-4: Parts of a Truss 001075 Rev. F General Information...

  • Page 47: 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 48: 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 below when planning your space allocation. MiTek can provide help in plant layout and space utilization, on request.

  • Page 49: Determining The Space Needed For Your System

    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 system. Five thousand (5000) psi concrete is recommended. Refer to your layout drawing.

  • Page 50: Electrical Requirements

    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 the installation date. 001075 Rev. F...

  • Page 51: Customer-Supplied Parts

    RoofTracker Roller Press Customer-Supplied Parts The customer must supply the parts shown in Table 2-4. Some must be installed before installation occurs and some must be available for use at the time of installation. Table 2-4: Customer-Supplied Parts Item Description...

  • Page 52: Shipping Information

    RoofTracker Roller Press Shipping Information Table 2-5 shows the weight of the individual components of a typical RoofTracker gantry head. Table 2-5: Shipping Information Contents of Shipment Weight Gantry Head 10,000 lb 001075 Rev. F Prior to Installation...

  • Page 53: Installation

    Delivery Unloading Even if a MiTek representative is present, it is the customer’s responsibility to provide equipment and labor for unloading, placement, and wiring of the RoofTracker gantry. Exercise extreme caution to avoid damage or misalignment during unloading. Do not apply pressure on any moving parts or fittings.

  • Page 54: Equipment Layout

    Roller Press Equipment Layout The components of the RoofTracker 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 55: Installing The Parking Stands And Gantry Head

    Roller Press 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. It may be necessary to install the gantry head before one of the parking stands is installed.

  • Page 56: Festoon Cable Or Bus Bar

    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 57: Installing The Festoon Cable

    RoofTracker Roller Press Figure 3-1. The cable is attached to a wire rope by trolleys that allow the cable to easily extend when the gantry head is at the opposite end of the table and neatly gather it to prevent it from hanging too low when the gantry head is at the end closest to the electrical enclosure.
  • Page 58 RoofTracker 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.) 001075 Rev. F Installation...

  • Page 59: Overview Of The Bus Bar System

    RoofTracker 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 60 RoofTracker 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 61: Installing The Bus Bar System

    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 62: Electrical

    Festoon Cable or Bus Bar Outgoing Wires to Outgoing Wires to RoofTracker Enclosure RoofTracker Enclosure Power is brought into the disconnect enclosure and connected to the terminals on top of the fuses. The wires are labeled Incoming Wires From Festoon Cable or Bus Bar in Figure 3-4.

  • Page 63: Connecting Power To A Bus Bar System

    RoofTracker Roller Press Connecting Power to a Bus Bar System If your system has a bus bar instead of a festoon cable, an additional enclosure mounts to the end of the conductor bars. Run cables from your power source to this enclosure.

  • Page 64: 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 65: Operation

    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 press. The terms defined in Table 5-1 will help you understand the instructions in the rest of this manual.

  • Page 66: Important Notes

    RoofTracker 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 67: Stopping The Machine

    RoofTracker Roller Press Stopping the Machine During normal operation, the gantry head decelerates to a stop when you release the directional button. For safety reasons, the following methods can also be used to stop the machine, or the disconnect switch can be used to turn off power when the machine is not in use.

  • Page 68: Disconnect Switch

    RoofTracker Roller Press Disconnect Switch Figure 5-2: Disconnect Turning the disconnect handle to the ON (vertical) position supplies electrical power to the entire machine. To remove power to the machine, turn the disconnect handle to the OFF (horizontal) position, as it is shown in Figure 5-2.

  • Page 69: Indication Of Movement (Beacon)

    RoofTracker Roller Press 3. The green RIGHT READY/ Figure 5-4: 3-Phase Electrical Enclosure REVERSE START light for a 2-Enclosure System indicates reverse direction is enabled. Beacon On a 2-enclosure system with a standard single- pendant control station, REVERSE is toward the...

  • Page 70: Operator Control Interface Mechanisms

    Getting to Know Your Joystick Controller and Operator Platform Your RoofTracker press is operated by a joystick or an optional pendant control station. The joystick is mounted on a panel attached to the gantry head. See Figure 5-5. If your machine has the optional pendant control station, it replaces the joystick and is discussed on page 18.
  • Page 71 RoofTracker Roller Press Operator Platform The operator platform is a standard feature with a joystick operator control interface. It is a raised platform connected to the operator end of the gantry head. The operator stands on the platform and rides along with the gantry head as it travels.

  • Page 72: Getting To Know Your Pendant Control Station

    RoofTracker Roller Press Getting to Know Your Pendant Figure 5-7: Pendant Control Station Control Station The pendant control station is an optional operator control interface that is shown in Figure 5-7 and Figure 5-8. It is a hand-held device connected to the machine by a cable.

  • Page 73: Operating Procedure

    RoofTracker 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 5-9 3.
  • Page 74 RoofTracker 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 75 Figure 5-9: Operating Procedure Turn on Disconnect Switch Set Up the Truss Press and Hold the Button While Pushing the Joystick to the Left or Right to Start Movement Verfiy That Path is Clear Release the Button and/or Joystick to Stop Movement Remove Slider Pads and Verify Gantry...

  • Page 76: Restarting Operation

    RoofTracker Roller Press Restarting Operation If the machine stopped because you released the joystick or directional button, both directional indicator lights should still be on. You can continue motion in either direction by pressing and holding the joystick or a directional button again.

  • Page 77: Vfd

    RoofTracker Roller Press The VFD (variable frequency drive) is inside the main electrical enclosure. If it experiences a fault, one of the fault numbers listed in Table 5-2 will appear in the LED display. Refer to Table 1-3 to remedy the faults.

  • Page 78: Brake Monitor

    RoofTracker Roller Press Brake Monitor The brake monitor informs the operator when the brake is getting worn and needs to be replaced. It is located on the motor end of the gantry head. When operating the machine, the key should be in RUN (vertical) position.
  • Page 79 RoofTracker Roller Press Table 5-3 describes the brake monitor’s indicator lights and operation. For information on specific errors or failcodes, refer to the Troubleshooting appendix. Table 5-3: Brake Monitor Operation Indicator or Button Function Indicates that the brake is released but the motor shaft is not Chain Break turning.

  • Page 80: Perimeter Access Guarding (Light Bars)

    RoofTracker presses shipped before 21 December 2006 use a three-beam light bar set on both sides of the gantry head. RoofTracker presses shipped on or after 22 December 2006 use a two-beam light bar set on both sides of the gantry head.

  • Page 81: Bumpers

    RoofTracker Roller Press Bumpers A bumper located on each corner of the gantry head provides additional safety control. One is shown in Figure 5-1. When a bumper collapses, it passes in front of the light bar and causes the machine to stop its motion in the direction associated with the collapsed bumper.

  • Page 82: 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 83: Safety Test

    RoofTracker Roller Press Safety Test The test procedure in the Safety Test section on page xvi MUST be performed by qualified personnel after ANY maintenance, adjustment, or modification. Testing ensures that the light bar, safety system, and machine control system work together to properly stop the machine.

  • Page 84: Brake Motor And Gearbox

    RoofTracker Roller Press Brake Motor and Gearbox The brake motor and gearbox allow the gantry head to start and stop motion. The motor is an integral motor attached to a Nord SK63 helical gearbox with triple reduction. Power output from the gearbox is 56 rpm. A brake monitor ensures the brake is working properly and is discussed later in this chapter.

  • Page 85: Replacing The Motor

    RoofTracker Roller Press Replacing the Motor Figure 6-2: Brake Motor 1. Lockout/tagout all power to the machine. 2. Verify that there is no load on the reducer so when the brake is Socket set (metric removed, the load is not and English) released.

  • Page 86: Replacing A Brake Pad

    RoofTracker Roller Press Replacing a Brake Pad Figure 6-3: Steps 1 through 5 Brake 1. Unscrew the manual brake handle extending from the side of the brake motor, if there is one. 2. Remove the fan cover. Slotted screwdriver 3. Remove the fan snap ring.

  • Page 87: Adjusting The Air Gap

    RoofTracker Roller Press Adjusting the Air Gap CAUTION Adjusting the air gap improperly may damage the motor. Do not attempt to make this adjustment unless the measured gap is outside the recommended allowance. If the brake monitor continually trips and other causes have been ruled out, the air gap in the brake motor may need to be adjusted.
  • Page 88 RoofTracker Roller Press d) Adjust the setting bolt as needed to reach the recommended gap. A 1/4 or 1/2 turn is usually sufficient for adjusting purposes. See Figure 6-7. Figure 6-7: Adjusting the Setting Bolt Turn setting bolt to adjust air gap.

  • Page 89: Drive Wheels

    Figure 6-26 movement of the gantry head. Drawing 63735 There are eight (8) drive wheels on the RoofTracker, four (4) on each end of the gantry head. The drive wheel bearings must be greased approximately every 300 working hours (according to the hour-meter) with a #2 lithium- based grease.
  • Page 90 RoofTracker 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 91 RoofTracker 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 92: Replacing The Entire Drive Wheel Block

    RoofTracker 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 93 RoofTracker Roller Press Figure 6-9: Drive Wheel Block on Outer Side of Gantry Head Drive Sprocket Drive Wheel Chain Nut on Tie Bolt Drive Wheel Sprocket Bearing QD Bushing Figure 6-10: Drive Wheel Block on Inner Side of Gantry Head...

  • Page 94: Guide Wheels

    There are either eight (8) or twelve (12) guide wheels on the RoofTracker, depending on when it was built. The guide wheel bearings must be greased approximately every 300 working hours.

  • Page 95: Pressure Wheels

    Pressure wheels keep the gantry head at a level position when it encounters the start of the truss on the tables. There are eight (8) pressure wheels on the RoofTracker, four (4) on each end of the gantry head. Your RoofTracker has either steel or Nylatron pressure wheels.

  • Page 96: Take-Up Bearing

    RoofTracker Roller Press Take-Up Bearing Graphics That Will Help... Lubricating Figure 6-26 Figure 6-28 The take-up bearing allows the Figure 6-29 roller to turn, resulting in smooth embedment of the connector plates. It should be greased approximately every 150 working hours.

  • Page 97: Adjusting The Chain Tension

    5. Re-tighten the mounting bolts on the tension sprocket take-up mechanism. 6. Check the tension of the motor drive chain on the other end of the RoofTracker. Repeat steps 1 through 5 if the chain tension does not match the description in the optimum chain tension described above.
  • Page 98 RoofTracker Roller Press Figure 6-13: Motor Drive Chain and Belt Tensioning Timing Belt Motor Drive Chain Mounting Tube Tension Tension Sprocket Bolts Tension Sprocket Take-Up Mechanism Figure 6-14: Drive Wheel Chain Tensioning Drive Wheel Chain Tension Sprocket Take-Up Mechanism Tension Bolts 001075 Rev.

  • Page 99: Replacing A Chain

    RoofTracker 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 6-13 on page 62 for a close-up view of the motor drive chain and Figure 6-14 on page 62 for the drive wheel chain.

  • Page 100: Maintaining The Belt

    RoofTracker Roller Press Maintaining the Belt There is little resistant force on this belt so no preventive maintenance is needed. If the belt is damaged or breaks and must be replaced, the part number can be found in the Replacement Parts appendix.

  • Page 101: Adjusting The Roller Height

    RoofTracker 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 102: Wipers

    RoofTracker Roller Press Figure 6-16: Take-Up Bearing Adjustment Steps in Procedure Locking Nut Adjusting Nut Locking Bolt Hanger Bracket Bottom Nut (located behind frame) Take-Up Bearing Wipers Figure 6-17: End of the Gantry Head, View From the Table Side A wiper is located in four...

  • Page 103: Safety Bumpers

    RoofTracker Roller Press Safety Bumpers If the entire bumper Figure 6-18: Replacing the Bumper must be replaced, follow the procedure below while referring to Figure 6- 18. Keep all original hardware until the replacement is complete. 1. Lockout/ tagout all...

  • Page 104: Brake Monitor

    RoofTracker Roller Press Brake Monitor Operating the Brake Monitor Refer to the Operation chapter for an explanation of the indicator lights and LED display. Figure 5-10 on page 42 and Table 5-3 on page 43 explain the indicator lights. Error codes are explained in the Troubleshooting chapter.
  • Page 105 RoofTracker Roller Press Figure 6-19: Brake Monitor Screw to Remove Front Cover (2 places) Wire Spade Terminals Connector Quick Disconnect Fitting Wire Running to Motion Detector 001075 Rev. F Maintenance...

  • Page 106: Motion Detector

    RoofTracker Roller Press Motion Detector A code on the brake monitor will indicate if the motion detector is malfunctioning. Refer to the Brake Monitor section of the Operation chapter for the error codes. Follow these steps while referring to Figure 6-20 on page 72 to replace the motion detector.

  • Page 107: Limit Switches

    RoofTracker Roller Press Limit Switches The only limit switch to maintain is located under the operator platform that is attached to some gantry heads. Generally, machines with joysticks have an operator platform. For the machine to operate, the bumpers must be in the center location so the limit switch remains untouched.

  • Page 108: Light Bars

    RoofTracker Roller Press Light Bars Components Figure 6-20: Motion Detector The RoofTracker is Motion equipped with two (2) sets Detector of light bars, one set on Electrical each side of the gantry Wire head. One set consists of a transmitter bar and a receiver bar.

  • Page 109: Light Bar Operating States

    RoofTracker Roller Press Light Bar Operating States The indicators on the receiver bar tell the operator what operating state the light bar set is detecting. The different operating states are described in Table 6-2. Table 6-2: Light Bar Operating States...

  • Page 110: Light Bar Diagnostic And Test Features

    RoofTracker Roller Press Light Bar Diagnostic and Test Features DANGER ELECTROCUTION HAZARD. Disconnect power before opening end caps! Individual Beam Indicators (IBI) The light bar 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 111: Diagnostic Display

    RoofTracker Roller Press Diagnostic Display The receiver unit has a two-digit numeric display that displays diagnostic codes identified by the internal control circuits. This display is visible from the front of the receiver bar. The diagnostic codes indicate normal operation, dipswitch setting faults, safety output faults, MPCE faults, and internal controller faults.

  • Page 112: Replacing Light Bars

    RoofTracker Roller Press Replacing Light Bars Light bars 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 113 RoofTracker Roller Press Figure 6-22: Dip Switch Settings MODE CODE CODE Transmitter (TX) Receiver (RX) RANGE SELECTION: 0.8-20 METER (1=OFF) SCAN CODE: C (2=OFF, 3=ON) SCAN CODE: C (2=OFF, 3=ON) AUX OUTPUT MODE: FOLLOW OSSD OUTPUT (1=ON) START MODE: START/RESTART INTERLOCK (1=OFF, 2=OFF)

  • Page 114: Indicator Lights And Sounding Device

    RoofTracker Roller Press Indicator Lights and Sounding Device Main Electrical Enclosure Figure 6-24: Electrical Enclosure on a 1-Enclosure System and Brake Monitor To remove the light cover, simply unscrew Beacon on Enclosure it. To replace the light bulb under the light cover, gently push in and turn the light bulb counterclockwise.

  • Page 115: Gantry Lifter

    RoofTracker Roller Press Gantry Lifter The gantry lifter is available only on end-eject systems. Adjusting the Height and Level of the Lifter 1. Lockout/tagout. 2. Level the track tube frame by adjusting the two (2) lower bolts. Refer to Drawing 83351.

  • Page 116: Replacing The Air Bags

    RoofTracker Roller Press 6. Restore power to the machine. 7. Build a truss and eject it from the tables normally. The truss should pass easily under the lifter. • If the truss does not pass easily under the lifter, lockout/tagout and readjust the set screws.

  • Page 117: Graphics

    RoofTracker Roller Press Graphics Figure 6-26: Wheels, Chains, and Belt (Machines Shipped Before 15 June 2006) Motor Drive Timing Belt Chain Drive Wheel Chain (1 on ea. end) Drive Wheels Guide Wheels Pressure Wheels (4 places) (4 places) (4 places) 001075 Rev.
  • Page 118 RoofTracker Roller Press Figure 6-27: Wheels, Chains, and Belt (Machines Shipped After 15 June 2006 Motor Drive Timing Belt Chain Drive Wheel Chain (1 on ea. end) Drive Wheels Pressure (4 places) Wheels (4 places) Guide Wheels (4 places) 001075 Rev. F...
  • Page 119 RoofTracker Roller Press Figure 6-28: Bearing Lubrication Points, One End of Gantry Head Grease Block for Take-Up Bearing Grease every 150 working hours. Drive Wheel Grease Fitting (4 places) Grease every 300 working hours. Guide Wheel Grease Fitting (4 places) Grease every 300 working hours.
  • Page 120 RoofTracker Roller Press Figure 6-29: Chain Lubrication Points Lubricate Motor Drive Chain Here Lubricate Drive Wheel Chain Here (same on other end of gantry ) Take-Up Bearing Grease Block (same on other end of gantry) Run the gantry head in the forward (or left) direction after lubricating these points.
  • Page 121 RoofTracker Roller Press Figure 6-30: Electrical Enclosure for a 1-Enclosure System 001075 Rev. F Maintenance...
  • Page 122 RoofTracker Roller Press Figure 6-31: Electrical Enclosures for a 2-Enclosure System LEFT ENCLOSURE (when facing the enclosure doors) Safety Relay Relay for Light Bars Timing When facing disconnect, bars on: Relay left right 24 VDC Control Power Relays (C) Supply...
  • Page 123 RoofTracker Roller Press Figure 6-32: Gantry Lifter Air Bags Support Roller Bearings Bearings 001075 Rev. F Maintenance...

  • Page 124: 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 Table Number Troubleshooting Category Table 1-1...
  • Page 125 RoofTracker Roller Press Table B-1: Troubleshooting the Mechanical System Problem Possible Cause Possible Solution Motor drive chain loose or broken Adjust the tension or replace chain Drive wheel chain loose or broken Adjust the tension or replace chain Check the perimeter of the gantry...
  • Page 126 RoofTracker Roller Press Table B-1: Troubleshooting the Mechanical System (Continued) Problem Possible Cause Possible Solution Roller height on one end differs Level the roller height from the opposite end Nail plates are not embedded Table surface is damaged Repair tabletop...
  • Page 127 RoofTracker Roller Press Check all bulbs on indicator lights to ensure they are still in working order before attempting to do any troubleshooting. Table B-2: Troubleshooting the Electrical System Problem Possible Cause Possible Solution Main disconnect switch is in OFF...
  • Page 128 RoofTracker Roller Press Table B-2: Troubleshooting the Electrical System (Continued) Problem Possible Cause Possible Solution Either LEFT READY/ FORWARD START or RIGHT READY/ REVERSE START Check timing relay for loose The timing relay has loose button is pressed, horn keeps...
  • Page 129 RoofTracker Roller Press Table B-3: VFD Fault Codes Fault Possible solution The thermostat on the dynamic brake resistor has tripped; wait for it to cool down and reset the VFD Auxiliary Input Check DB resistor wiring Monitor the incoming AC line for low voltage or line power...
  • Page 130 Alarm setting and continued to free run. Before counting stopped, power was removed from the brake monitor. Reset the brake monitor to clear this fault. EEPROM failure. Note the serial number of the unit and call MiTek. EEPROM failure. Note the serial number of the unit and call MiTek.

  • Page 131: Parts List

    Parts List Appendix C 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 2-1 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 132 RoofTracker Roller Press Ordering the Parts With Your Part Number There are three easy ways to order your part after you determine the part number. Each column in Table 2-2 describes one of the methods. Table C-2: How to Order Your Part Using the Part Number Using Our eStore™...
  • Page 133 RoofTracker Roller Press Safety Notes for Replacing Parts CAUTION Only use the exact replacement parts that are specified by MiTek. Substitutions may harm your equipment. WARNING CRUSH, CUT, AND PERSONAL INJURY HAZARD. Perform the safety tests described in the Safety Test section...

  • Page 134: Part Numbers

    RoofTracker Roller Press Part Numbers Mechanical Parts Table C-3: Mechanical Replacement Parts Keep Part Location Refer to MiTek Part # Part Description Category Drawing # Stock Drive wheel chain, #80 63750 or Drive System 554008 (Qty of 2 at 157" ea)

  • Page 135: Electrical Parts

    RoofTracker Roller Press Electrical Parts Table C-4: Electrical Replacement Parts Refer to Keep Part Location MiTek Part # Part Description Drawing Category Stock 208/230 V—none Fuses 460 V—516388 Brake fuses (2) 90544 575 V—516383 208/230 V—516494 Fuses 460 V—516491 Disconnect fuses (3) 90544 575 V—516490...

  • Page 136: 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 Daily Checklist page 11 Weekly Checklist page 12...

  • Page 137: Maintenance Checklist

    Maintenance Checklist Daily Checklist Week of:_________________ Year:_________________ Action Shift 1 Lubricate the drive wheel chain Shift 2 (every 8 working hours) Shift 3 Shift 1 Lubricate the motor drive chain Shift 2 (every 8 working hours) Shift 3 Shift 1 Inspect light bars Shift 2 Shift 3...

  • Page 138: Weekly Checklist

    Maintenance Checklist Weekly Checklist Month: _____________ Year: _____________ Action Week 1 Week 2 Week 3 Week 4 Week 5 Check tension of the drive wheel chain—needs 1/2” play Check tension of the motor drive chain—needs 1/2” play Notes Date 001075 Rev. F Maintenance Checklist...
  • Page 139 Maintenance Checklist Checklist by Working Hours Year: _____________ WORKING Action Date HOURS Grease take-up bearing Grease gantry lifter bearings (end-eject systems only) Inspect and dust brake motor Grease the drive wheels Grease the guide wheels Check oil level in brake motor Drain and change gearbox oil 10,000 Notes...

  • Page 140: Technical Information

    Technical Information Appendix F This appendix provides general information that will help you better understand how this equipment works. Understanding Overloads Purpose and Scope The information below has been collected to help you understand the role of an overload, how an overload works, and how to calculate the overload setting to protect the motor. The Importance of Protecting Your Motor The following statement describes the importance of protecting electric motors and is a good illustration of why we need overloads.

  • Page 141: Starting Current

    RoofTracker Roller Press What is an Overload? So, what is an overload? The term literally means that too much load (what the motor is driving) has been placed on the motor. A motor is designed to run at a certain speed, called its synchronous speed.
  • Page 142 RoofTracker Roller Press Figure F-1: Motor Inrush Curve Inrush Normal Current Operating Current 1000 Current A 300 % Overload .01 0.1 10 100 1000 Time (s) An overload condition will occur when the rotor has difficulty turning and draws more current than it normally would need to keep it turning.
  • Page 143 RoofTracker Roller Press • A design that meets the special protective needs of motor control circuits • Allow harmless temporary overloads, such as motor starting, without disrupting the circuit • Will trip and open a circuit if current is high enough to cause motor damage over a period of time •...
  • Page 144 Class 30 has a longer time delay to be used on high inertia loads that require a long acceleration or have shock loading that causes repetitive motor inrush. The overload class that MiTek normally specifies for equipment is a Class 10. Since it is possible to burn out a motor in less than 20 seconds, we have chosen to protect the motor with the highest degree of protection.

  • Page 145: Codes And Standards

    RoofTracker Roller Press Codes And Standards NFPA 79—Electrical Standard for Industrial Machinery, 2002 7.3.1.1 Motors. Motor overload protection shall be provided to each motor in accordance with Article 430, Part III, of NFPA 70, National Electrical Code. NEC 2002—National Electrical Code 430.32 (A) (1) Separate Overload Device.
  • Page 146 RoofTracker Roller Press Example 3 40 hp, 208V, 3 phase, wound rotor motor, FLA 118 amps. Overload Protection = 118 amps times 115%=136 amps The motor overloads must be calculated using the nameplate current and not from Tables 430-148 or 430-150 of the National Electrical Code.

  • Page 147: Insulation Class

    RoofTracker Roller Press Glossary of Overload Terms Full Load Amps (FLA) This is the current flow required by a motor during normal operation under normal loading to produce its designated horsepower. Motors having nothing attached to their shaft will draw less than the FLA current.
  • Page 148 RoofTracker Roller Press motor load. The motor load “seen” by a motor is dependant upon how the load is connected to the motor, the dimensions of the load, and the weight of the load. A load connected to a motor by a gearbox reduces the load by the square of the gear ratio.
  • Page 149 RoofTracker Roller Press NEMA Design Ratings NEMA ratings refer to the torque ratings. The following ratings apply to motors: NEMA B The NEMA B motor’s percentage of slip ranges from 2 to 4%. It has medium values for starting or locked rotor torque, and a high value of breakdown torque.
  • Page 150 RoofTracker Roller Press Class 20, and Class 30. Class 10, for example, has to trip the motor off-line in 10 seconds or less at 600% of the full load amps. This is usually sufficient time for the motor to reach full speed.

  • Page 151: Drive Faults

    Before troubleshooting a drive fault, determine whether the fault is a motor, drive, or application fault. Use the fault codes of the drive. If you are unable to locate the source of the fault, contact MiTek Customer Service. 001075 Rev. F...

  • Page 152: Drawing Set

    Drawing Set Appendix G Drawings are in a separate binder accompanying this manual. Figure G-1: Attached Drawings for a RoofTracker System Drawing Description Drawing Number Parking stand assembly 63630 Light beam mount 63718 Take-up bearing assembly 63721 Drive wheel block...

  • Page 153: Document Evaluation

    Document Evaluation Appendix H 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 154 Document Evaluation Form We appreciate your comments on how we can make this document more useful. Document Identification: Equipment Manual ™ 001075 RoofTracker General Ratings: Poor Fair Good Excellent Content     Organization     Accuracy ...
  • Page 155 Address: Phone: Email: Please mail this form to: Or fax this form to: 636-328-9218 MiTek Industries, Inc. Attn: Engineering Manager Machinery Operations 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 156: Glossary

    Glossary 1-enclosure system a RoofTracker press that has a gantry head with only 1 main electrical enclosure; the directional buttons are labeled LEFT and RIGHT and the indicator lights are labeled RIGHT READY and LEFT READY; this system has an hour-meter on the enclosure...
  • Page 157 RoofTracker uses a set of 3-beam or 2-beam light bars on both sides of the gantry head...
  • Page 158 RoofTracker Roller Press lubricator a device that allows controlled amounts of lubricants into the pneumatic system motor end also “operator end”, used to indicate which end of the gantry head is being discussed; the end of the gantry head that houses the motor and...
  • Page 159 RoofTracker Roller Press receiver bar the light bar that receives the signal from the transmitter bar; every light bar set consists of a receiver bar and a transmitter bar regulator a component of the pneumatic system that connects to the main air...

  • Page 160: Index

    Index air gap 51 danger logo ix alarm 42 delivery unloading 17 unpacking 17 directional buttons 36 disconnect switch 31 beacon 33 document evaluation form 118 bellows 67 drawing set 116 belts 63 drive fault 91 brakes disc 51 drive wheel block, see drive wheels monitor drive wheels failcodes 94...
  • Page 161 Index gantry head 3 laser projection 6 gearboxes 48 light bars diagnostic and test features 74 grease 47 operation 31 guide wheels realigning and inspecting 72 lubrication 58 replacing 76 replacing 58 light bulbs 78 lockout/tagout graphic 2 guidelines xii hazard indicator ix procedure xiii xxvii...
  • Page 162 Index pressure wheels lubrication 59 nail wiper 66 replacing 59 notice logo ix preventive maintenance 100 purpose of equipment 3 of manual 4 oil 47 one-enclosure system indicator lights 32 picture 85 Receiver Stands 6 operation replacement parts beacon or horn 33 electrical 99 brake monitor 42 mechanical 98...
  • Page 163 Index stackers 6 stop motion, see E-stop tables 18 take-up bearing adjusting 60 diagram 66 lubrication 60 tension sprocket drive wheel chain 62 motor drive chain 62 timing belt diagram 81 picture 62 replacing 64 timing relay 92 truss terminology 9 two-enclosure system indicator lights 32 picture 86...
  • Page 164 001075 001075 001075 Rev. F Rev. F Rev. F...

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