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RailRider ProTables

Operation and Maintenance Manual

®

Copyright © 2005 MiTek®. All rights reserved.Patented. See Legal Notice for list of patents. 001083

RailRider ProTables


MiTekMachinery Division301 Fountain Lakes DriveSt. Charles, MO 63301phone: 800-523-3380fax: 636-328-9218www.mii.com

001083Date created 07/07/2005Revision —Revision date —Print date 2/16/12Written by R. TuckerApproved byRevised by —Approved by —

Applicability: PN 63526-501, 63535-501, 63550-501

®

U.S. and other patents pending.

001083 Table of Contentsii

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiLegal Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivNotice of Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vSafety Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viGeneral Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiLockout/Tagout Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ixRestricted Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

General Information Chapter 1Introduction to This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction to This Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Purpose of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Overview of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Options and System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Identifying Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Prior to Installation Chapter 2MiTek’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Customer’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Location Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Pneumatic System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 12Shipping Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Customer-Supplied Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Training Provided . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation Chapter 3Responsibilities During Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Equipment Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Table and Gantry Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Installing the Tables and Gantry Head . . . . . . . . . . . . . . . . . . . . . 19Installing the Table Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Overview of Pneumatic Components . . . . . . . . . . . . . . . . . . . . . . 20Connecting the Pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Clamp Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Jigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Preliminary Pages

Table of Contents

001083 Table of Contentsiii

Startup Chapter 4Removing Lifting Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Filling the Lubricator Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Turning On the Air Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Operation Chapter 5Setting Up for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Laying Out the Truss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Using the Jigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pneumatic System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Operating Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Operating the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Deactivating Individual Pneumatic Components . . . . . . . . . . . . . . 32

Maintenance Chapter 6Introduction to Maintaining Your Equipment . . . . . . . . . . . . . . . . . 33Pneumatic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Understanding the Pneumatic System . . . . . . . . . . . . . . . . . . . . . 34Maintaining the Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Maintaining the Filter/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Maintaining the Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Replacing Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Jigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

TroubleshootingAppendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Parts ListAppendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance ChecklistsAppendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Document EvaluationAppendix D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Technical InformationAppendix E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Understanding Fluid Power: Hydraulic and Pneumatic System Basics . . . . . . . . . . . . . . . . . . . . 54Understanding Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Drawings are inserted in numerical order at the back of the manual. 70

Drawing SetAppendix F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Glossary 72

Index 76

Table of Contents

001083 Legal Noticeiv

TrademarkThe 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

Return Goods PolicyReturn goods cannot be accepted without prior authorization and are subject to a restocking charge. The Seller certifies the articles specified herein were produced in compliance with all provisions of the Fair Labor Standards Act of 1938, as amended, including Section 12.—Rev. 6/98

Recommending Documentation ImprovementsTo report errors or to recommend improvements to this manual, please complete the document evaluation form at the back of this document. Mail or fax the form to:

MiTek, Machinery Division301 Fountain Lakes Industrial DriveSt. Charles, MO 63301Attn: Engineering ManagerFax: 636-328-9218

Your support in helping MiTek provide unsurpassed machinery and support is appreciated.

Made and sold under one or more of the following patents:U.S. 37,797 U.S. 5,468,118U.S. 5,553,375 U.S. 6,079,325U.S. 6,145,684 U.S. 6,330,963U.S. 6,405,916 U.S. 6,651,306U.S. 6,807,903 Other Patents Pending

Legal Notice

001083 Notice of Changev

Use this page to record Service Bulletins and Notices that you receive to keep your manual updated.

Operation and Maintenance ManualRailRider® Pro

Floor Truss Roller Press

Service Bulletin or Notice # Dated Title

Notice of Change

001083 Safety Indicatorsvi

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 with each symbol or signal word. The definitions below may also be found in ANSI z535.4-2002.

Failure to comply with the accompanying instructions may result in property damage, personal injury, or even death. Personnel must follow all safety procedures and practices to ensure the safest possible operation and maintenance of this equipment. However, at no time is this document a substitute for common sense. Personnel must ensure that the work environment is safe and free of distractions.

DANGERIndicates an imminently hazardous situation which, if not avoided, will result in death or serious injury

WARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONWhen used with the safety alert symbol shown here, indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

When used without the safety alert symbol shown here, indicates a potentially hazardous situation which may result in equipment damage.

NOTICE NOTICECalls attention to information that is significant to understanding the operation at hand

ENVIRONMENTALApplies to conditions that may affect the environment but does not have an immediate, direct effect on personnel or equipment

!!!

Safety Indicators

ENVIRONMENTAL

NOTICE

001083 Safety Indicatorsvii

Because it is impossible to anticipate every circumstance that might involve a hazard, the safety information provided in this manual and on the machine are 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. Use extreme caution and common sense at all times!

1. All personnel shall read this manual completely before using or maintaining the equipment. Do not operate this machine unless you have a thorough knowledge of the controls, safety devices, emergency stops, and general operating procedures outlined in this manual.

2. All safety notes shall be read and observed before operating the machine or performing maintenance. Failure to comply with these instructions may result in economic loss, property damage, and/or serious personal injury including death.

3. Only qualified personnel shall operate, perform maintenance on, or be unsupervised near this equipment. “Qualified personnel” is defined as:

...a person or persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training, or experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work—ANSI B30.2-1983

...one who has skills and knowledge related to the construction and operation of the electrical equipment and installations and has received safety training on the hazards involved—NEC 2002 Handbook

4. Refer to the lockout/tagout guidelines on the following pages to safely perform maintenance and troubleshooting of this equipment.

5. Check that all safety devices are in working order before each shift starts. All protective guards and safety devices must be in place before and during use of the machine. Never disconnect or bypass any safety device or electrical interlock.

6. Observe and obey all safety labels. Replace worn labels immediately.

7. Check for worn or damaged parts regularly. Repair or replace them immediately.

8. Always wear safety glasses and hearing protection in an industrial environment.

9. Utilize a filtering facepiece (dust mask) when working near sawdust.

10. Use caution when lifting heavy parts or material.

11. Wear proper apparel and appropriate personal protective equipment. Do not wear loose clothing or jewelry. Confine long hair by tying it back.

General Safety Rules

001083 Safety Indicatorsviii

12. Keep children away. All visitors should be kept a safe distance from the work area. Hazards may not be apparent to individuals unfamiliar with the machine.

13. Keep work area clean and free of any trip or slip hazards.

14. Do not use any liquids in the interior of electrical cabinets.

15. When using solvents on and around the machine, remove power to the machine to eliminate the chance of sparking, which may result in explosion or fire. Wear a respirator approved for use with solvents. Wear protective clothing, gloves, and safety glasses.

16. Do not use in damp or wet locations, or expose the machine to rain or snow.

17. Keep work areas well lit.

18. Ensure that all tools and foreign objects are clear of the restricted zones before operating this equipment. The restricted zones are shown on page xi.

19. Periodically inspect the quality of the finished product to ensure it will perform its intended function safely. Use only materials certified for the intended use. Truss designs must be approved by a qualified design engineer. Qualification of design engineers is dictated by local, state, and federal regulations.

20. Use this equipment solely for the purpose described in this manual.

21. In case of machine malfunction, stop the machine immediately and report the malfunction to a supervisor.

22. Never leave the machine running unattended. Turn the power off! Do not leave the machine until all parts have come to a complete stop and all electrical power has been shut off.

23. Follow installation instructions completely. This equipment shall be installed following all guidelines in this manual.

24. This equipment must be installed, operated, and maintained in accordance with all current governing standards, including local, state, and national codes for the location in which it resides.

25. Keep the hydraulic, pneumatic, and electrical systems in good working order at all times. Repair leaks and loose connections immediately. Never exceed the recommended pressure or electrical power.

26. Before performing maintenance on the pneumatic or hydraulic systems, bleed the lines to eliminate pressure.

General Safety Rules

001083 Safety Indicatorsix

.

Lockout/Tagout

The term “lockout”, as used in this manual, means placing a lockout device on any and all energy sources to ensure that the energy isolating device and the equipment being controlled cannot be re-energized or operated until the lockout device is removed. The photos on the next page show where the electrical disconnects are located for this machine.

• Energy sources include electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

• In the case of electrical energy sources, the main power and control power to the machinery must be turned off and physically locked in the OFF position.

• In the case of hydraulic and pneumatic systems, bleed pressure from lines before attempting maintenance or repairs.

• A lockout device is usually a keyed padlock.• If more than one person is working in a restricted zone, use a group lockout device

that will allow each person to use a lock that can be removed only by the person performing the maintenance.

“Tagout” means that a prominent warning is securely fastened to an energy isolating device to indicate that the equipment shall not be operated.

Lockout/Tagout Guidelines

All lockout/tagout guidelines must be met according to OSHA 29 CFR 1910.147. Guidelines should be included in your company’s energy control program. This manual is not intended to replace your company’s de-energizing or lockout procedure required by OSHA, but merely to provide general guidance.

001083 Safety Indicatorsx

Performing Maintenance Outside a Machine’s Electrical Enclosures

When performing any maintenance or adjustments outside of the electrical enclosure, turn off the disconnect handle on the machine. Notify other personnel in the area that you are working on the machine by tagging and locking the disconnect handle in the off position as shown in the photo. If performing maintenance inside the electrical enclosure, refer to the next section.

Performing Maintenance Inside a Machine’s Electrical Enclosures

Before opening an electrical enclosure on a piece of equipment, turn off the machine’s disconnect handle and lockout/tagout the source of power. This is necessary because when the disconnect handle is turned off, power is still live between the power source and the disconnect switch’s enclosure. Because the routing of wires may not always be clear, you should lockout/tagout the source of power before opening any electrical enclosure.

The source of power is usually located in an electrical panel mounted on the building wall, similar to the panel shown in the photo. When you open the electrical enclosure, check the voltage inside the enclosure using a multimeter to ensure that there is no live power.

Troubleshooting With an Energized Machine

If a troubleshooting or repair activity can not be accomplished with the power turned off, refer to NFPA 70E for the personal protective equipment required. Any time maintenance is performed while the equipment is electrically energized, there is a potential electric arc flash hazard. Pneumatic and hydraulic components may move unexpectedly if not de-energized. Any components capable of movement should be physically restrained when working on or near those components. Every effort should be made to avoid energized areas, but when it is necessary, take every precaution possible.

De-Energizing Electrical Power at the Machine’s

Disconnect Switch

De-Energizing the Source of Electrical Power

Lockout/Tagout Guidelines

001083 Safety Indicatorsxi

All personnel must stay clear of the restricted zone when the equipment is in use. The operator shall check for personnel, equipment, and barriers within the restricted zone before starting the machine. The restricted zone is the red area shown in this graphic.

Restricted Zones

001083 General Information1

General Information

The purpose of the General Information chapter is to introduce you to this manual and to provide an overview of your equipment and how to identify it.

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.

All warnings must be read and observed. Failure to do so may result in economic loss, property damage, personal injury and/or death.

This manual must always be available to personnel operating and maintaining this equipment.

Chapter 1

RailRider® Pro Roller Press


Introduction to This Manual

Purpose of This Manual

This manual provides the information necessary to operate and maintain this equipment. In order for this manual to be useful, it must be kept with the machine so the operators and maintenance personnel have easy access to it.

Most maintenance, troubleshooting, and part number questions can be answered with the information in this manual. If you can not locate the answer or solution, contact the MiTek Machinery Division Customer Service Department using the contact information in Figure 1-1.

This manual addresses the RailRider® Pro tables, including the pneumatic clamps, pop-ups, and flippers. It does not address the gantry head or other components used with the tables.

Using This Manual

Review the table of contents to understand the structure of the chapters and appendices. The glossary and index are also valuable tools for getting the most out of your equipment.

To follow the procedures in this manual, you must first understand the formatting cues used. Table 1-1 describes how to read the cues provided in this text.

Table 1-1: How to Read the Formatting Cues

If Text Looks Like... It Indicates... Example in Text

All caps Key on keyboard or button on touch screen Press ENTER

Initial cap and italic Menu or field or virtual button that you must find or select

Click on the File menu

Initial cap only, no italics

Menu or field or virtual button when simply referring to it

While in the Main Menu

Plus sign (+) Hold buttons at the same time CTRL+ALT+DELETEGreater Than sign (>) Next selection File>Open

MiTek Machinery Division Customer Service Department301 Fountain Lakes Industrial DriveSt. Charles, MO 63301

Web Sitewww.mii.com/machinery

Technical AssistancePhone: 800-523-3380Fax: 636-328-9218

Parts Orders (with part number)eStore™ at http://estore.mii.comE-mail: [email protected]

Figure 1-1: Contacting MiTek



Introduction to This Equipment

Purpose of the Equipment

The primary function of the RailRider Pro floor truss roller press system is to completely embed connector plates into lumber to form strong connection points for floor trusses.

Overview of the Equipment

An entire system consists of a gantry head, which houses the roller that causes the embedment of the connector plates, a set of tables that holds and supports the truss and gantry head, and two (2) parking stands that support the gantry head while not in use. The main components are labeled in Figure 1-2. Refer to Figure 1-3 to see the system in greater detail.

Some systems may have RailRider Pro tables used with a RailRider gantry head.

Figure 1-2: Main Components



Figure 1-3: Getting to Know Your System



Main Components

Table 1-2 lists the main components that comprise this system.

Options and System Identification

Optional Components

Table 1-3 lists the options that are considered part of the table system. Table 1-4 lists optional components separate from the tables. Your system may have any combination of these options.

Table 1-2: Main Components

Component DescriptionGantry Head(not discussed in this manual)

Moves across the tables for the initial plate embedment

TablesSupports the truss material while being pressed by the gantry head; feature slotted tops for jigging, walk-through aisles, and several choices for ejection system configuration

Parking Stands Areas at each end of the table line to park the gantry head; allows entire working surface of the tables to be accessible during setup

Table 1-3: Optional Features on Tables

Table Side Component Description

Infeed Pop-Ups Lifts the truss straight up from the table for easy removal

Infeed Flippers Arms that flip the truss from the infeed side to the outfeed side

OutfeedSide-Eject Only Pop-Ups Lifts the truss straight up from the table for easy

removal

OutfeedEnd-Eject Only End-Eject Roller

Lifts the truss straight up from the table; contains a roller that allows the truss to easily move toward the end of the table line for easy removal

Infeed On-Table Splice Pad

Adjustable pad and supports that allow on-table splicing without using valuable table space

Table 1-4: Optional Additional Components

Component Description System Length Part #

Overhead Plate Rack

A free-standing rack that holds connector plates where the operators can easily reach them

40' System

60' System

64800-501

63527-501



Identifying Your System

The items in this section are the components and features listed on the original sales order. It is how MiTek identifies the system you have.

• The identification of the tables depends on the length and which of the features listed in Table 1-3 are included in your tables. See Table 1-5 for your table system part number.

• The identification of the pneumatic controls depends on the location of the controls. See Table 1-6.

Table 1-5: Available Table Systems

System Description Part #40-ft system with flippers and side-eject pop-ups 63535-50140-ft system with flippers and end-eject pop-ups 63550-50150-ft system TBD60 ft system with flipper and side-eject pop-ups 63526-50170-ft system TBD

Table 1-6: Available Pneumatic Control Systems

Location of Controls Ejection System Part #Pedestals“xx” indicates length of table system

Side- or End-Eject 64838-5xx

Overhead Rack“xx” indicates length of table system

Side-Eject 64844-5xx

Overhead Rack“xx” indicates length of table system

End-Eject 64845-5xx



General SpecificationsTable 1-7: General Specifications

PERFORMANCE AND CAPACITIESMax. truss width 24"Min. truss width 9-1/2"

Pressing area

40' system

50' system

60' system

70' system

42' x 7'

52' x 7'

62' x 7'

72' x 7'

Camber

40' system

50' system

60' system

70' system

21/32"

13-16"

31/32"

1-1/8"

PNEUMATIC SYSTEMFor air flow specs, see Table 2-3 in the Prior to Installation chapter.

Clamp Flipper Pop-Up End-Eject Roller

Number of cylinders per 20' table 8 3 2 4Number of cylinders per 10' table 4 2 1 2Cylinder bore (in.) 2-1/2 2-1/2 1-3/4 1-3/4Cylinder rod (in.) 5/8 5/8 1/2 1/2Cylinder stroke (in.) 18 16 3 1

DIMENSIONS OF SYSTEM COMPONENTSSee Table 2-2

WEIGHT OF SYSTEM COMPONENTSSee Table 2-6

001083 Prior to Installation8

MiTek’s Responsibilities

Prior to Installation

MiTek will provide the following items and information prior to the installation date:

1. A Prior to Installation package that provides the following information.

• Outlines this chapter and requests your signature of agreement.• Gives dates to expect shipment, delivery, and installation.• Explains the number of people required to help with installation.• Provides guidelines on providing an electrician, welder, and other specialists.• Describes payment information.

2. A layout of the equipment, specifically made for your building.

During Installation

MiTek Will Provide• A MiTek Customer Service Technician (CST) will be present to manage the

installation of your equipment.• The MiTek CST will train your personnel on how to operate and maintain the

equipment.• The MiTek CST will ensure that the Operation and Maintenance Manual is present.

One (1) printed manual is provided for every piece of equipment.

MiTek Will Not Provide• The MiTek CST is not responsible for providing tools or performing the work

during installation.• The MiTek CST is not responsible for training personnel on how to build a truss.

The purpose of the Prior to Installation chapter is to communicate what you must consider or complete before this equipment can be installed.

Prior to InstallationChapter 2



Customer’s ResponsibilitiesBefore the installation of your equipment, the items and procedures in this chapter must be arranged, purchased, or assembled. Table 2-1 provides an overview of the items that must be taken care of before your machine is installed. Each topic is explained in detail in the text following the table.

If these requirements are not satisfied before the scheduled installation date, the installation may need to be rescheduled. If travel arrangements have already been made for the CST, they will be the customer’s responsibility.

Table 2-1: Summary of the Customer’s Responsibility

Space Requirements

This equipment requires enough space to allow for the machine dimensions listed in Table 2-2, plus additional working space for operation and maintenance. Space should have adequate lighting.

Location Requirements

Concrete, a minimum of 6 in. thick 5000 psi, is required under the weight of the press head, tables, and parking stands.

Compressed Air Requirements See Table 2-3.

Shipping Weights See Table 2-6.Customer-Supplied Items Required

The customer is responsible for having the supplies listed in Table 2-7 at the time of installation.



Space Requirements

Refer to the guidelines described here when planning your space allocation. MiTek can provide help with plant layout and space utilization upon request.

Space for the Equipment

It is the customer’s responsibility to provide adequate space for the installation, operation, and protection of the equipment. The physical dimensions of the equipment are shown in Table 2-2. Additional space is required for operation, maintenance, and optional equipment.

Figure 2-1: Terminology Used for Dimensions (Applicable to all Roller Presses)

Table 2-2: Approximate Table System Dimensions

Dimension A Dimension B Dim. CGiven in feet only

Given in inches only

Given in feet only



Tables With Parking Stands

40' system 7' 84" 54' 648"approx.

30"50' system 7' 84" 64' 768"60' system 7' 84" 74' 888"



Space for Operation and Maintenance

Additional space must be allocated for operation and maintenance. Operation space should provide safety, freedom of movement, storage space, and free flow of raw and finished materials. There must also be adequate space for safe handling of the raw and finished materials throughout the process.

Location Requirements

Floor Structure

A level and structurally sound concrete slab must be provided for the installation of the equipment. 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 gantry head, tables, stand-alone conveyors, and Finish Roller. Five thousand (5000) psi concrete is recommended. Refer to your layout drawing.

Environment

It is recommended that these tables be located in a dry location.

Lighting should be adequate for safe operation and maintenance.



Pneumatic System Requirements

This equipment uses compressed air, also referred to as pneumatic power. The air source must be supplied and installed prior to the scheduled installation date of the MiTek equipment.

Table 2-3 describes the general pneumatic system requirements.

Table 2-4 and Table 2-5 describe the cubic feet per minute (CMF) that your system must be capable of providing. The columns indicate either a standard system, where the only pneumatic component is the clamp rail, or systems that include the infeed/outfeed pneumatic options.

Table 2-3: Pneumatic System Specifications

Air Source Connecting Air Source to System Pressure

Minimum of 60 gal

Minimum of 1-in. diameter tube between air source and FRL—connect to the FRL valve bank at the 3/4" NPT port. 80 psi

Table 2-4: Average CFM

Standard System

Pop-Up / Pop-Up

Flipper / Pop-Up

Flipper / End Eject

Pop-Up / End Eject

40' System 8.08 8.37 10.89 10.55 8.3250' System 11.06 10.46 13.81 13.38 10.4060' System 12.12 12.55 16.34 15.82 12.4870' System 14.14 14.64 19.26 18.66 14.56

Table 2-5: Instantaneous CFM

Standard System

Pop-Up / Pop-Up

Flipper / Pop-Up

Flipper / End Eject

Pop-Up / End Eject

40' System 126.43 132.88 164.77 163.70 131.8150' System 158.03 166.10 208.89 207.55 164.7660' System 189.64 199.32 247.16 245.55 197.7170' System 221.25 232.54 291.28 289.40 230.66



Shipping Information

When the equipment arrives, you must have the proper transport and lifting equipment available to remove it from the truck and place it in your facility. Table 2-6 shows the weight of the individual components of a typical system.

DANGER

!Transport and lifting equipment such as forklifts and cranes must be designed and rated for the load and application The weight of each major component is given in Table 2-6.

Inadequate transport equipment may result in property damage, personal injury, or death.

Table 2-6: Shipping Information

Possible Contents of Shipment Approximate Weight20' table (with pneumatic options attached) 10,000 lb eachParking stands (set of 2) 2,000 lb per set



Customer-Supplied Parts

The customer must supply the parts and equipment listed in Table 2-7. Some must be installed before installation occurs and some must be available for use at the time of installation.

Table 2-7: Customer-Supplied Parts

Item When Needed Description

Compressed Air

Air compressor that can meet the requirements in Table 2-3

Supply line from air compressor to FRL that meets the requirements in Table 2-3

Connector to connect air line from air source to 3/4-in. NPT port on the FRL

Electrical Equipment

All electrical requirements to provide power to the disconnect enclosure on the gantry head are the customer’s responsibility

Transport Equipment

A heavy-duty forklift is required to move the equipment during unloading and placement of the machine. The weight capacities are described in Table 2-6.

GeneralTools

Industrial hammer-drill

1/2” masonry drill bit

Tape measures (2)

Soft tape measures (2)(longer than total length of tables)

Adhesive tape

Thin rope, longer than the total length of tables

Pliers to cut skid bands

Chalk line

Hammers (2)

Pry bars, 6', wedge on one end (2)

Sockets: 3/4", 9/16"

Long hex head wrench 1-1/2"

Short hex head wrench 1-1/2"

Allen wrenches

C-clamps (2)

Sledge/mallet for concrete anchors



Training ProvidedIn the case where MiTek is overseeing the installation of your equipment, the MiTek representative will ensure that your operators and maintenance personnel understand how to operate and maintain this equipment. They will explain warranty information and ensure that the Operation and Maintenance Manual is present.

MiTek will NOT provide training related to building or engineering trusses.

001083 Installation16

Responsibilities During InstallationMiTek will provide installation supervision to ensure that the system is installed properly and operates correctly. We will also provide operating and maintenance training at the time the equipment is installed. You, as the customer, are responsible for providing all labor and equipment needed to complete the installation. These requirements are explained in the Prior to Installation chapter.

DeliveryRefer to the Prior to Installation chapter for information regarding preparing for the delivery.

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 equipment.

Unloading

Exercise extreme caution to avoid damage or misalignment during unloading. Do not apply pressure on any moving parts or fittings. Figure 3-2 shows how to lift and move the equipment safely.

Component weights are listed in. Table 2-6 in the Prior to Installation chapter.

The purpose of the Installation chapter is to describe the entire installation process in detail. The instructions assume that the prior-to-installation requirements are satisfied.

DANGER

!Transport and lifting equipment such as forklifts and cranes must be designed and rated for the load and application The weight of each major component is given in Table 2-6.

Lift the equipment only at the lift points indicated by MiTek!

If the equipment is transported incorrectly, equipment damage, personal injury, or death may result.

InstallationChapter 3



Unpacking

After successful unloading, remove any protective crating material. Detach and set aside all loose parts.

Equipment Layout

Each component must be located in specific locations. Your MiTek representative will provide your layout to you before the equipment is installed.

The tables must be placed in a pre-determined order for the camber rail to line up correctly. Align all tables so the camber rail on both sides of the table form a smooth curve away from the edge of the table, as shown in Figure 3-1. The parking stands are already attached to the end tables.

Figure 3-1: Correct Curve on the Camber Rail



Lifting

Two (2) lifting tubes are attached to each table to safely lift and move the tables. See Figure 3-2.

1. Using a forklift rated appropriately for the weight of the table, insert the forks into the lifting tubes.

2. Move the forklift forward as far as possible, without touching the edge of the table.

3. Slowly lift and move the table to the proper location.

4. Lower the forks gently until the table is resting solidly on the floor, and remove the forks from the lifting tubes.

Figure 3-2: Lift Points



Table and Gantry Installation

Installing the Tables and Gantry Head

Install anchor plates per your top level table assembly drawing.

Level and position the tables carefully.

Weld the tables to the anchor plates.

Place the gantry head on the tables.

Installing the Table Stop

Four (4) table stops are supplied to keep the gantry head from rolling off the end of the table system. Weld two (2) table stops to the end of each parking stand, approximately 5 in. from the outer edge. See Figure 3-3.

Figure 3-3: Location of Table Stops



Pneumatic SystemThe clamp rail on the table operates off of a pneumatic system that requires an air flow source. The optional flippers, pop-ups, and end-eject rollers use the same pneumatic system. You are responsible for supplying the air flow source and connections up to the FRL (filter/regulator/lubricator). Table 2-5 in the Prior to Installation chapter lists the specifications for the pneumatic air source, air lines, and connector.

Overview of Pneumatic Components

A description of each pneumatic component and its location is shown in Table 3-1 and Figure 3-4. This section covers all pneumatic options. Disregard the information about options your system doesn’t have.

Table 3-1: Components and Connections in the Pneumatic System

Component Purpose Location Connector

FRL (Filter/regulator/lubricator assembly)

Regulates air flow and lubrication to the pneumatic system

Under one parking stand

3/4" NPT port to connect to air source

Hoses connect 1 port to valve bank and 2 ports to control valves

Valve BankHouses directional valves for clamp rails and flippers

Under table, on end near FRL

Already connected to 28-mm and 22-mm piping

28-mm and 22-mm Piping

To transport compressed air to components

Under tables See the component

Control Valves

Actuates the clamp rails, flippers, pop-ups, and end-eject rollers

Both sets located on pedestals or overhead plate rack

See the component

Flipper assembly

To flip the truss from the infeed side to outfeed side of table

Flipper extends through slots in tables, cylinder is directly below it

Already connected to 22-mm piping with hose

Connect piping to control valve with hose

Clamp cylinder assembly

To hold the truss in place by clamping along the length of the truss

Center of table, one for the infeed side and one for the outfeed side

Already connected to 28-mm piping with hose

Connect piping to control valve with hose

Pop-up or end-eject roller assembly

To raise the truss off the table for easy removal

Extends through slots in the table, cylinder is directly below it

Already connected to plastic tubing

Connect tubing to control valve with hose



Figure 3-4: Location of Pneumatic Components



Connecting the Pneumatics

Connecting the Air Source to the FRL (Filter/Regulator/Lubricator)

Connect your air source to the FRL located under the table. It is shown in Figure 3-5 and Figure 3-6. The air source and the piping and connection to the FRL must be supplied by the customer.

Figure 3-5: Connecting the Air Source to the FRL

Figure 3-6: FRL



Connecting the Valve Bank

The valve bank directs compressed air to the clamp rails and flippers. The connections are shown in Figure 3-7 and described in Table 3-2.

Connecting the Control Valves

The pneumatic system is controlled by a set of control valves. Each side of the table has its own set of control valves. They are located one of two places:

Depending on the options purchased, your system may have one or two (1 or 2) control valves per table side. One valve controls the clamp rail. The optional second valve controls flippers, pop-ups, or end-eject rollers.

To connect the pneumatic system to the control valves on either the pedestals or overhead plate rack, refer to Figure 3-8 and Figure 3-9.

Table 3-2: Connection on Valve Bank

A Air in from FRLB ClampC FlipperD ClampE ClampF FlipperG ClampH Ports to individual cylinders

Table 3-3: Location of Pneumatic Controls

Location of Controls Location of Connectors on Side-Eject Systems

Location of Connectors on End-Eject Systems

Stationary pedestals(standard location)

Infeed side: centered along length of tables

Infeed side: centered along length of tables

Outfeed side: near end of tables where air enters system

Outfeed side: centered along length of tables

Overhead plate rack(optional location)

Infeed side: centered along length of plate rack

Infeed side: centered along length of plate rack

Outfeed side: near end of plate rack where air enters system

Outfeed side: centered along length of plate rack

Figure 3-7: Valve Plate Overview



Figure 3-8: Pedestal Connections

Figure 3-9: Control Valves on Overhead Plate Rack



Clamp RailsEach table has its own clamp rail, but they must move in unison to effectively clamp the truss. To ensure even movement of the entire length of the clamp rail, weld supporting braces between them as shown in Figure 3-10.

Figure 3-10: Connecting the Clamp Rails

JiggingA total of four (4) adjustable end stops are supplied with a 1-zone table system. Two (2) are right-hand end stops and two (2) are left-hand end stops. Use one end stop on each end of each truss. Refer to the Operation chapter for instructions on placing and adjusting them.

DANGER

! DO NOT ATTEMPT TO START THE SYSTEM WITHOUT A MITEK REPRESENTATIVE PRESENT!Serious injury and/or equipment damage may result.

001083 Startup26

Removing Lifting TubesOnce the tables are in place and permanently anchored to the floor, remove the lifting tubes that are shown in Figure 3-2 in the Installation chapter.

1. Remove the four (4) hex head cap screws from each tube.

2. You may discard the lifting tubes or keep them for future use. They are not required for any reason, except to move the tables.

Filling the Lubricator ReservoirRefer to Pneumatic System Maintenance in the Maintenance chapter to fill the FRL with lubricating oil. The customer must supply the oil.

Turning On the Air SourceBefore operating the tables, ensure that the air source for the pneumatic system is installed and hooked into the FRL.

DANGER

! DO NOT ATTEMPT TO START THE SYSTEM WITHOUT A MITEK REPRESENTATIVE PRESENT!Serious injury and/or equipment damage may result.

StartupChapter 4

001083 Operation27

The purpose of the Operation chapter is to describe the operating mechanisms on this equipment and the procedure to operate it in most circumstances.

DANGER



All warnings must be read and observed. Failure to do so may result in economic loss, property damage, personal injury and/or death.


DANGER

! Before turning on the equipment, make sure that all personnel and equipment are clear.

OperationChapter 5


001083 Operation28

Setting Up for OperationThis manual does not address the methods for building a truss. There are many other resources through MiTek and the components industry that address the proper way to build floor trusses. The information here describes how to operate the jigging and how the tables were designed to be used.

Laying Out the Truss

Lay the truss out on the tables as specified by your engineering drawings. The bottom chord must rest against the camber tube. The top chord will be contacted by the side clamp once it retracts.

1. Place the lumber as shown in Figure 5-1, building up from the bottom chord.

2. Place connector plates only on the side facing up.

3. Hold the connector plates in place by securing one corner of each plate with one strike of a hammer.

Figure 5-1: Setting Up the Truss


001083 Operation29

Using the Jigging

Use the adjustable end stops that came with your table system when setting up a truss. Place one end stop at each end of each truss on the table.

Placing and Adjusting the End Stops

To secure the end stops in place, refer to Figure 5-2 while completing these steps.

1. Place an end stop on the table with the bottom of the “L” facing the end of the truss to be fabricated.

2. Align the end stop so the closest adjusting holes in the camber rail show through the end stop’s slot.

3. Insert two (2) securing bolts through the slot in the end stop and thread them into the adjusting holes.

4. Before the bolts are completely tightened, slide the end stop to the exact location required.

5. When the proper length is achieved, tighten the securing bolts with a 3/8-in. allen wrench.

Accounting for Uneven Top and Bottom Chord Lengths

If the top chord and the bottom chord are different lengths, use a wooden block to compensate for the difference. Place the block against the end stop in place of the chord, and then place the chord to be fabricated against the block. This will create a structurally sound chord offset.

Figure 5-2: Right-Hand End Stop


001083 Operation30

Pneumatic System OperationRefer to the graphics in the General Information chapter to locate components.

Operating Overview

1. Set up the truss as described in the Setting Up for Operation section.

2. After all connector plates are in place on the applicable side, check the following:

• All personnel, tools, and equipment are at a safe distance from the equipment.

• All flippers, pop-ups, and end-eject rollers are retracted to their down position (if your system has these options).

3. Extend (close) the clamp rail by turning the control valve labeled Clamp to its closed position. See Figure 5-3.

4. Follow the manufacturer’s instructions for operating your particular gantry head to embed the plates with the gantry roller.

5. Park the gantry head on a parking stand.

6. Retract (open) the side clamp by turning the control valve labeled Clamp to its open position.

7. Place the truss on the outfeed side of the table.

a) If your system does NOT have pneumatic components on the infeed side, pick the truss up, turn it over, and place it plate-side down on the outfeed side.

CAUTIONCOLLISION HAZARD.

Before extending clamp rail:Retract flippers and end-eject rollers.

Before moving gantry head:Retract flippers.

Before raising flippers or end-eject rollers:Retract clamp rail and ensure gantry head is parked on a parking stand.

Figure 5-3: Control Valves for Pneumatic Components


001083 Operation31

b) If your system has pop-ups on the infeed side:

1) Raise the pop-ups on the infeed side by turning the control valve labeled Pop-Up to its up position.

2) Pick the truss up, turn it over, and place it plate-side down on the outfeed side of the table.

3) Lower the pop-ups by turning the control valve labeled Pop-Ups back to its down position.

c) If your system has flippers on the infeed side:

1) Make certain that the outfeed side is clear of material and personnel, the gantry head is parked clear of all flippers, and the clamp rail is retracted.

2) Extend the flippers on the infeed side by turning the control valve labeled Flipper to its up position.

The flippers will raise and turn the truss over so it falls plate-side down on the outfeed side of the table.

3) Lower the flippers by turning the control valve labeled Flipper back to its down position.

8. Place the connector plates in place on the second side of the truss.

9. Repeat step 2 through step 6.

10. Remove the truss from the table.

a) If your system does not have pneumatic components on the outfeed side, pick the truss up and remove it from the table.

b) If your system has pop-ups or end-eject rollers on the outfeed side:

1) Make certain that the clamp rail is retracted (open).2) Raise the pop-ups or end-eject rollers on the outfeed side by

turning the control valve labeled Pop-Up to its up position.3) Slide the truss off the tables.

If your system is end-eject, the gantry head must be parked completely on a parking stand for the truss to slide under the roller and exit the tables.

4) Lower the pop-ups or end-eject rollers by turning the control valve labeled Pop-Ups back to its down position.

CAUTIONCOLLISION HAZARD.

Before extending clamp rail:Retract flippers and end-eject rollers.

Before moving gantry head:Retract flippers.

Before raising flippers or end-eject rollers:Retract clamp rail and ensure gantry head is parked on a parking stand.


001083 Operation32

Operating the Control Valve

The control valves are three-position valves. The center position is neutral. It is not necessary to use the neutral position. It is acceptable to leave the valve in the down or open position when the pneumatic components are not in use.

Deactivating Individual Pneumatic Components

Each flipper has a shut-off valve that removes it from the setup. When the shut-off valve is closed, the flipper does not receive pneumatic pressure. It remains still when the pneumatic options handle is actuated and the other flippers extend. Figure 5-4 shows a shut-off valve in its open position. Turn the handle 90 degrees to close the shut-off valve.

The pop-ups and end-eject rollers do not have a shut off valve.

Figure 5-4: Flipper Shut-Off Valve in the Open Position

001083 Maintenance33

Introduction to Maintaining Your EquipmentThis manual contains sufficient information for proper operation and maintenance under most conditions. 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.

Review the Table of Contents and utilize the Index to locate the information you need. The following appendices will also assist in maintaining and repairing your equipment:

• Troubleshooting• Parts List• Maintenance Checklists• Drawing Set

Refer to Figure 1-3 in the General Information chapter for an overview of component locations that may require maintenance during the life of your equipment.

The purpose of the Maintenance chapter is to provide step-by-step instructions as well as information to help you understand how your equipment works to enable you to make repairs and perform preventive maintenance.

DANGER



All warnings must be read and observed. Failure to do so may result in economic loss, property damage, and/or personal injury.


MaintenanceChapter 6



Pneumatic System Maintenance

Understanding the Pneumatic System

The pneumatic system controls the ejectors on the tables and the receiver stands (on a side-eject system) at the stand-alone conveyors. You will find additional pneumatic system information in the Installation chapter. Maintenance information is in subsequent sections.

Understanding the FRL (Filter/Regulator/Lubricator)

The FRL is an assembly that consists of a filter, regulator, lubricator, and lockout valve for the pneumatic system. The air that provides pressure for the pneumatic system enters at the air source port labeled in Figure 6-1. The filter/regulator unit filters out contaminant and regulates the amount of air getting through to the system. As the air passes through the lubricator, a light fog of lubrication mixes with the compressed air. A more detailed graphic can be found in the Pneumatic System section in the Installation chapter.

Figure 6-1: FRL Overview

WARNING

!To avoid injury, bleed all pressure from the lines before performing any maintenance on the pneumatic components!

Do not remove the lubricator reservoir until all pressure is released. Ensure that the reservoir is securely attached to the lubricator body before returning pressure to the lines.



Understanding the Valve Bank

The valve bank directs compressed air to the clamp rails and flippers. The control valve for the clamp rail and flippers (located on the pedestal or overhead plate rack) is actually a pilot valve that actuates the valves in this valve bank. A more detailed graphic and explanation can be found in the Pneumatic System section in the Installation chapter.

Understanding the Control Valves

The control valves control all of the pneumatic functions of your system. All systems have control valves for both clamp rails. Additional control valves are required for the optional flippers, pop-ups, and end-eject rollers. The control valves are located either on pedestals or on the optional overhead plate rack. The infeed and outfeed sides of the table are controlled by separate control valves.

For the clamp rail and flippers, the applicable control valve actuates the valves on the valve bank to extend or retract the clamp rail or flippers. For pop-ups and end-eject rollers, the control valve directly actuates the pop-up or end-eject roller cylinders.

Figure 6-2: Control Valves on Pedestal



Maintaining the Lubricator

The lubricator is part of the FRL shown in Figure 6-1.

Checking the Lubricator’s Oil Reservoir

Check the oil level by viewing the sight gauge located on the reservoir. Check the oil level at least once a week. The sight glass turns red where the oil is contacting it. Refill or top off the oil every 2-3 months. The exact amount of time depends on the density of the fog injected into the system.

Filling the Oil Reservoir

Use a misting type oil rated 50 to 200 SSU that is compatible with the materials of construction.

WARNING

!To avoid injury, bleed all pressure from the lines before removing the reservoir.

Ensure that the reservoir is securely attached to the lubricator body before returning pressure to the lines.

Figure 6-3: Lubricator



1. Depressurize the system:

a) Close the lockout valve on the FRL by pushing the yellow slide down. It is shown in Figure 6-4.

b) Bleed the pressure from all the lines by opening all control valves and waiting a few minutes for the air to bleed out.

2. Remove the reservoir from the lubricator body by twisting approximately 1/4 turn clockwise while pushing up on the reservoir, then pull down and remove the reservoir from the body.

3. Pour the oil into the reservoir to the fill line.

4. Place the reservoir back onto the lubricator body by pushing up and turning counterclockwise. Make sure it is securely attached and the sight gauge can be easily viewed.

Adjusting the Density of the Lubricant Fog

The pneumatic system lubricator is a Micro-Fog Lubricator. It injects a finely divided fog of oil into a flowing stream of compressed air to provide internal lubrication. The density of the lubricant is controlled by the drip rate adjusting knob that is labeled “1” in Figure 6-3. Using a slotted screwdriver, turn the knob counterclockwise to increase the Micro-Fog density or clockwise to decrease it.

Performing Additional Required Maintenance

Proper preventive maintenance for the lubricator also includes replacing the O-rings, seals, and gaskets at regular intervals. We recommend that you replace these items every two (2) years. Contact the lubricator manufacturer to purchase the seal kit components.

WARNING

!To avoid injury, bleed all pressure from the lines before removing the filter guard.

Ensure that the filter guard is securely attached to the regulator body before returning pressure to the lines.

Figure 6-4: FRL Lockout Valve



Maintaining the Filter/Regulator

Replacing the Filter Element

The regulator uses a 40-micron filter element that must be replaced every six (6) months. This filter can be purchased from MiTek. Refer to the Parts List appendix for the part number.

1. Depressurize the system:

a) Close the lockout valve on the FRL by pushing the yellow slide down. It is shown in Figure 6-4.

b) Bleed the pressure from all the lines by opening all control valves and waiting a few minutes for the air to bleed out.

2. Remove the bowl from the regulator body by twisting approximately 1/4 turn clockwise while pushing up on the filter guard. Then pull down and remove the filter guard from the body.

3. Unscrew the filter element and remove it from the regulator. Be sure to keep the spring that is resting in the filter element.

4. Place the spring in the new filter element.

5. Screw the new filter element in its place.

6. Place the bowl back onto the regulator body by pushing up and turning counterclockwise. It must be secure before returning pressure to the lines.

Adjusting the Pressure

The operating pressure of the pneumatic system should be 80 psi. The pressure adjustment knob shown in Figure 6-5 controls the operating pressure. Do not adjust this knob to change the speed of the ejectors and receivers. Adjustments to individual cylinders can be made using the flow control valves on each cylinder. Refer to the Cylinders section for this procedure.

To adjust the system pressure to 80 psi:

1. Unlock the pressure adjustment knob on the regulator by pulling it straight up.

2. Turn the knob clockwise to increase pressure or counterclockwise to decrease it.

3. Once a pressure of 80 psi is achieved, push the knob down to lock it in place.

Figure 6-5: Regulator



Manual Drain

At the bottom of the regulator is a thumbscrew that operates a drain. Condensation can form in pneumatic lines due to temperature changes. When condensation gathers, it will show up in the bowl’s sight glass. Where the sight glass comes in contact with water, it turns red, indicating the water level. Open this drain periodically to drain fluid from the system. If condensation becomes a serious problem, an air dryer is available.

If the handle on the drain breaks, you can replace it by ordering the valve only. If the entire drain must be replaced, order the valve plus the valve body and O-ring. All three parts can be purchased by contacting the manufacturer directly.

Performing Additional Required Maintenance

If a regulator is not operating at its optimum capacity, we recommend cleaning the regulator and replacing the O-rings, gaskets, diaphragm, and valve assembly. You can order a service kit including these preventive maintenance parts from the manufacturer.

Maintaining the Control Valves

Preventive maintenance for the control valves consists of replacing the O-rings, seals, and valve head gasket when the quality of the air pressure begins to diminish.

Replacing a Handle Only

If the handle on a control valve breaks, remove the shoulder screw and replace the handle.

Refer to the Parts List appendix to locate the MiTek part number for the handle.

Replacing an Entire Control Valve

To replace a control valve:

1. Make note of which air lines are attached to which ports on the faulty valve.

2. Disconnect all air lines from the valve.

3. Remove the four (4) hex head cap screws from the front of the valve body.

4. Reconnect all air lines to the valve in the same manner they were previously connected.

If you need assistance with re-connecting the air lines, refer to the Installation chapter and the air schematic located with the drawings in the back of this manual.



Cylinders

Pneumatic cylinders control the clamp rail, flippers, pop-ups, and end-eject rollers.

Refer to the Parts List appendix to order new cylinders.

Adjusting the Cushion Valves

Some pneumatic cylinders have cushion valves to help decelerate the load and reduce potentially destructive energy. Refer to Table 6-1 to determine which components have a cushion valve.

If the components with a cushion adjustment seem to stop exceedingly hard, adjust the cushion using a slotted screwdriver in the set screw labeled in Figure 6-6.

Adjusting the Flow Control Valves

Both ends of the clamp rail cylinders and flipper cylinders have a flow control valve to adjust the speed that the clamp rail and flippers extend and retract. To adjust the flow control valve, use a slotted screwdriver in the set screw at the bottom of the valve. See Figure 6-6.

Turn the screw clockwise to slow the cylinder down and counterclockwise to speed the cylinder up.

Table 6-1: Determining If You Can Adjust a Cylinder

Component Flow Control Adjustment?

Cushion Adjustment?

Clamp Rails Yes MaybeFlippers Yes YesPop-Ups No NoEnd-Eject Rollers No No

NOTICEIt is important that all components work together in unison. The adjustment described here should rarely be required.

If you must make adjustments to a cylinder, ensure the timing of that component is working smoothly with all other components or the system will not operate properly!

Figure 6-6: Pneumatic Cylinder



Replacing Wear PadsPlastic wear pads located under the clamp rail help reduce friction between the clamp rail and the table surface. These pads eventually wear down and must be replaced. Replace all wear pads approximately once a year.

There is one (1) wear pad located near every cart.

To replace them:

1. Remove the 3/8-16x1 hex head cap screws labeled A in Figure 6-7 and remove every cart from one clamp rail.

2. Turn the clamp rail upside down to access the wear pads on the bottom.

3. Remove the two (2) flat head socket head screws holding each wear pad to the bottom of the clamp rail.

4. Place a new wear pad in place of each pad removed. Position them so that the flat head screws are countersunk into the holes.

5. Insert the screws that you removed from the old wear strips and tighten them so they are clearly countersunk at or below the surface of the wear strip.

6. After all wear strips have been replaced, turn the clamp rail back over and reattach the clamp rail to the carts, using the same hardware that was previously used.

7. Repeat the procedure for the second clamp rail.

Figure 6-7: Locating Wear Pads and Carts

Keep all hardware!



JiggingThe adjustable end stops are important components in building consistent floor trusses on this equipment. Keep your end stops in good condition.

It is a good idea to stock extra right-hand and left-hand end stops to prevent unnecessary down-time if an end stop is damaged. See the Parts List appendix for part numbers.

As part of your annual preventive maintenance, we recommend taking inventory of all jigging you are currently using or have in stock. Replace any damaged jigging at this time.

001083 Troubleshooting43

Navigating the Troubleshooting Appendix

This appendix is divided into tables according to the system or components that are showing troublesome symptoms. The tables are presented in the order listed here. The topics within each table are arranged according to this list.

Summary of Troubleshooting Information

System Showing Symptoms Table NumberPneumatic System Symptoms Table A-1

TroubleshootingAppendix A


001083 Troubleshooting44

Table A-1: Pneumatic System Symptoms

Problem Possible Cause Possible Solution

End fitting blown off of hose

Improper assembly procedures, improper skiving, incorrect hose-end series, mixing competitor’s components with Weatherhead�components

Ensure that the hose-end is the correct fitting and is properly installed; never intermix components

Hose end appears to have been pinched on one side Collet is becoming worn Replace the collet

Hose has burst or cracked

Abrasion, hose is twisted or kinked Remove possible abrasives and twists or kinks in the hose

Incompatible lubricant in lubricator Always use a recommended lubricant in lubricator

Excessive pressure Check pressure relief for damage or improper setting

Excessive heat Lubricator reservoir is low on oilFlippers/pop-ups/end-eject rollers are not raising simultaneously

Flow controls need adjustmentAdjust flow control valves on as few cylinders as possible to make their timing the same

A flipper is not working Shut off valve is blocking air flow Turn shut off valve on the flipper’s cylinder to the open position

Pop-ups or end-eject rollers do not have enough power to lift truss off table

System pressure set too low Increase pressure regulator to recommended 80 psi

Air loss in system Check all connections and hoses for air leaks

Air leak at pipe or hose fittings

Loose connectionEnsure system is depressurized. Disconnect tube from fitting and re-connect

O-ring damaged Replace fitting and remove burrs and sharp edges from tube

Loose connectionEnsure system is depressurized. Disconnect hose and ensure hose has clean 90° cut

Air leak in hose Hose damagedReplace hose; ensure area is free and clear of debris including nail plates

001083 Parts List45

Navigating the Parts List

This appendix is divided into sections which are presented in the order listed here. Each section is shown in its own table and sorted by the Part Location Categories column. Within each part location category, the part descriptions are arranged in alphabetical order.

Summary of the Parts List

System Requiring Parts Table Number Part Location Categories

Mechanical and Pneumatic Replacement Parts Table B-1

Clamp railControl valveEnd-eject rollerFlipperFRLJiggingPop-upTable

Parts ListAppendix B


001083 Parts List46

Table B-1: Mechanical and Pneumatic Replacement Parts

Part Location Category

Found on Drawing # Part Description MiTek Part #

Keep in

StockClamp rail 63529-501 Clamp cylinder assembly 63599-501Clamp rail 63599-501 Cylinder only, 2.58x18 423024Clamp rail 63599-501 Tubing, nylon 1/2 black 779122-38.00Clamp rail 63599-501 Tubing, nylon 1/2 black 779122-24.00Clamp rail 63571-501 Rod, clevis & nut for flipper and clamp 426070Control valve 64838 Control valve 434354 �

Control valve 64838 Control valve, handle only 434355Control valve — Control valve service kit TBDEnd-eject roller 63548-501 End-Eject assembly, without roller 64573-501End-eject roller 63548-501 End-Eject, roller, roller only 591060End-Eject roller 64573-501 End-Eject assembly 64573-501End-Eject roller 64573-501 End-Eject roller arm assembly 64575-501End-Eject roller 64573-501 End-Eject cylinder assembly 64579-501End-Eject roller 64573-501 Roller, conveyor, 2-1/2" diameter, 25" B.F. 591060Flipper 63529-501 Flipper assembly 24" truss 63562-501Flipper 63562-501 Flipper arm 63570Flipper 63571-501 Tubing, nylon, 1/2 black 779122-24.00Flipper 63571-501 Cylinder only 423009Flipper 63571-501 Rod, clevis & nut for flipper and clamp 426070Flipper 63571-501 Shutoff valve 430035Flipper 63571-501 Tubing, nylon, 1/2 black 779122-12.00Flipper 63571-501 Tubing, nylon, 1/2 black 779122-42.00FRL 64585-501 FRL mounting plate 63597FRL 64848-560 FRL plate assembly 64585-501FRL 62592 FRL plate assembly 64585-501FRL — Filter replacement element, 40 micron 438575 �

FRL 64585-501 Filter/regulator/lubricator (FRL) 438822FRL — Lubrication oil for FRL TBD �

Jigging 63526-501 LH end stop 66064-501 �

Jigging 63526-501 RH end stop 66069-501 �

Pop-up 63529-501 Pop-up, assembly 64563-501Pop-up — Cylinder only 423532Pop-up — Rod, clevis & nut 426070Pop-up — Tubing, frethane, 3/8 black 779125-48.00Table 63526-501 Anchor plate 26632Table 63529-501 Wear pad (replace all at same time) 63542


001083 Parts List47

Table 63526-501 Lifting tube 63553Table 63529-501 Cart assembly 63584-501Table 63526-501 Table stop 82120-501Table 63526-501 Anchor bolt 305022

Table B-1: Mechanical and Pneumatic Replacement Parts (Continued)

Part Location Category

Found on Drawing # Part Description MiTek Part #

Keep in

Stock

001083 Maintenance Checklists48

Checklists for Preventive Maintenance

Use the checklists in this appendix to schedule preventive maintenance. The checklists will guide you through all preventive maintenance tasks required to keep this equipment in top working condition.

These pages are supplied with the intent that you will photocopy them and document the date that maintenance is done, leaving the original in the manual for future use.

Checklists ProvidedWeekly Checklist page 49Periodic Checklist page 50

Maintenance ChecklistsAppendix C


Weekly ChecklistYear: _____________ Month: ________________

Preventive Maintenance Action(write dates at top of column) 1 2 3 4 5

Check oil level in air lubricator (FRL) and fill when necessary

Notes Date

Maintenance Checklist


Periodic ChecklistYear: _____________

Preventive Maintenance Action Sign and Date When Action is Performed

Replace regulator filter 6 months

Take inventory on jigging: replace or repaint as needed 6 months

Check that tables are still level 1 year

Install lubricator service kit (FRL) 2 years

Notes Date

Maintenance Checklist

001083 Document Evaluation51

This appendix contains a form to provide MiTek with feedback on the usefulness of this manual. Please follow the instructions on the form to provide us with comments or suggestions that will improve the quality of our documentation services.

Document EvaluationAppendix D


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001083

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001083 Technical Information54

This appendix provides general information that will help you better understand how this equipment works.

Understanding Fluid Power: Hydraulic and Pneumatic System Basics

Background

Fluid systems work by applying force at one point and transmitting that force to another point using either fluid (in hydraulic systems) or air (in pneumatic systems). These system are designed to use oil or air to create air tight systems and use a piston setup to generate force. The oil or air is routed to valves which control the direction of fluid flow and the amount of power produced by the cylinders. The cylinders power the system to complete the desired function. The force can be multiplied very easily by changing the size of the pistons. The system can be as basic or as complicated as your situation requires and there are many steps that need to be taken to keep your fluid system running smoothly.

Hydraulic Systems

Hydraulic systems use an incompressible fluid, called hydraulic fluid, to power their fluid system. When compared to pneumatic systems, hydraulic systems tend to last longer because a majority of the parts are protected by oil. They also create no exhaust, will work in sub-zero temperatures, are more portable, and have a greater performance to weight ratio.

Figure E-1 shows a basic hydraulic system schematic.

Pneumatic Systems

Pneumatic systems run on air pressure rather than hydraulic fluid. They use compressed air to System Components and are generally less expensive to build than hydraulic systems. They are also beneficial when hydraulic fluid could be harmful or contamination could be a problem.

A pneumatic system may have some of the same components as shown in Figure E-1.

Technical InformationAppendix E



Figure E-1: Basic Hydraulic System



Hydraulic Fluid

Hydraulic fluid, also called hydraulic fluid, is a requirement in all hydraulic systems.

There are four (4) functions of hydraulic fluid.

1. Create force and motion as flow is converted to pressure near the point of use.

2. Occupy the space between metal surfaces, the fluid forms a seal which provides a pressure barrier and helps exclude contaminate.

3. Lubricate metal surfaces.

4. Cool system components.

If one of these functions is impaired, the system will not function as designed. The fluid needs to be filtered to keep system running smoothly. When choosing a fluid, consider the system’s: maximum and minimum operating and ambient temperatures, type of pump used, operating pressures, operating cycle, loads encountered by various components, and type of control and power valves. There are two common terms used to describe hydraulic fluid. The ISO scale measures the viscosity grade of the oil. SUS (Saybolt Universal Seconds) are the units used to measure the operating viscosity at a certain temperature, usually stated at 100 degrees Fahrenheit.

Air Pressure

Pneumatic pressure, or air pressure, is a requirement in all pneumatic systems. Pneumatic systems are generally not as powerful as hydraulic systems and can be less expensive to setup. The air pressure generated in the compressor is carried throughout hoses to various pneumatic tools. Valves control how the tools operate and monitor the pressure in the hoses. Pressure is measured in psi or pounds per square inch. It can also be measured in scfm, or standard cubic feet per minute, but this scale can be deceptive due to the wide variety of “standards.” Be sure to verify the scfm information because the temperature of the standard varies from country to country.


System Components

Here is a list of commonly used parts of fluid power systems, why these parts are important, and different options available.

Accumulators

Accumulators store energy during slow periods. They also smooth pulsations that prematurely wear systems and reduce shocks caused by constantly starting and stopping pumps. The stored power can be used instantaneously if there is electrical failure. There are four types of accumulators and they are: diaphragm (bladder), hydro-pneumatic, weight-loaded piston, and spring. The last two types are rare and somewhat obsolete due to their size and weight.

Air Compressors

Compressors power many types of industrial machines including hydraulic systems.It is important to maintain systems as the cost benefit of powering tools with air can quickly be offset by the cost of repairing broken compression systems. There are two types of compressors including positive displacement and dynamic.

Air Dryers

Dryers are an important part of air compression system. They keep pneumatic parts free of moisture by lowering the dew point in and around the air circulating the compressor system. It is cheaper to dry compressed air than replacing rusted and broken parts due to water in the compression system.

Air Filters

Filters clean dust particles that are harmful to compression systems and help keep excess water vapor from condensing into liquid water.

Cartridge Valves

These valves are a form of hydraulic control. There are many different control figurations for: relief valves, sequence valves, pressure reducing valves, check valves, pilot operated valves load-control valves, counter balance valves, flow control valves, solenoid valves, electro-proportional direction, and specialty valves. A manifold with one or more cartridge valves is called a “valve package.”

Compressed Air Efficiency

It is commonly believed that compressed air is free but this could not be further from the truth. Compressed air isn’t free. It costs significant amounts of capital to compress air and this efficiency is reduced when there are air leaks in the system. Air leaks hurt production and are the primary cause of problems with compression control systems. 70-80% of leaks are inaudible and it is impossible to fix every leak. Leaks can be reduced by upwards of 80% which will increase production and extend the life of the compression system.

Cushion Valves

The cushion valve prevents the hydraulic motor from over pressurization due to a rapid stop. If it is set too low, the motor will never rotate. If it is set too high, motor stops may become sudden. The cushion valve is also known as a cross-over relief valve, cross-port relief valve, or break valve.

Cylinders

Cylinders produce linear motion for hydraulic or pneumatic systems. They also convert fluid pressure and flow to force and velocity, respectively. Most cylinders are double-acting meaning they route pressurized fluid into



the rod end of double acting cylinder causes piston to retract. When this occurs there is a reaction which routes pressurized fluid into the cap causes rod to extend. (fluid on the opposite end of the piston flows into the reservoir)

Directional Control Valves

Directional Control Valves, or DCV’s, are fluid flow controllers that allow or prevent pressurized fluid flow and alter flow direction. When permitting fluid flow, they are open and closed when the want to block flow.

Flow Control Valves

There are eight basic configurations of flow control valves that can be used to control flow rate according to fluid volume, weight, or mass. Because you can control multiple flow rates, it does not necessarily mean controlling gpm from a valve.

Flushing Procedures

Fluid velocity is critical to successfully remove all manufacturing and installation debris from hydraulic systems. It is important to flush system prior to operation because once system is sealed, the only debris you have to contend with can be eliminated with a filter. If installation debris exists, it is difficult to remove once operating and can harm the system.

Hydraulic Filtration

It is important to filter out dust, welding sag, rubber particles from hoses, sand, and other foreign materials. These impurities can cause surface wear if not eradicated. Also, it is important to filter out water because when it reaches 1-2% concentration in the oil, it changes the fluids viscosity and may cause malfunction.

Hydraulic Hoses

Hoses allow designers to bend around sharp corners, span long distances, and through tight spaces. When selecting the proper hose consider size, temperature, application, materials, pressure capabilities, hose ends and delivery. All of these decisions will guide your decision about the proper hose for your particular application.

Hydraulic Power Units

Hydraulic Power Units (HPUs) are self-contained units that sometimes house all or part of the hydraulic system components. Typically, the reservoir, motor, pump, and various valves are part of the HPU. Hoses and unattached components are usually not considered part of the HPU. The motors can be powered by air, electric, or gas. The HPU can even be mobile to suit your needs.



Hydraulic Pumps

These convert mechanical power into hydraulic energy. They generate flow with enough power to overcome pressure induced by the load. When it operates, it performs two functions: creates a vacuum at the pump inlet which allows atmospheric pressure to force liquid from the reservoir into the inlet line to the pump. Second, its mechanical action delivers this liquid to the pump outlet and forces it into the hydraulic system.

There are many types of pumps including: non-positive displacement pump, positive displacement pump, reciprocating pump, rotary pump, external gear pump, screw pump, internal gear pump, crescent seal pump, gerotor pump, vane pump, balanced and unbalanced vane pumps, piston pump, axial piston pump, inline piston pump, bent axis pump, radial piston pump, and plunger pump.

Motors

There are many different types of motors designed with a variety of functions in mind. Three of these designs are highlighted here.

The electric motor is the most common type of motor. Electric motors use magnets to generate their power with rotational motion. This motion creates the power and torque for which electric motors are known. Electric motors have finer-tuned speed controls, and they are not susceptible to torque and speed variations. They are also a good option if a compressed air source is not readily available.

Air motors produce continuous rotary power from compressed air system. They can be seen as superior to electrical motors because they require no electricity, have a higher power density, do not require auxiliary speed reducers, and generate less heat.

Hydraulic motors transform fluid energy into rotary mechanic power, which typically is applied to a load via a shaft. There are three types of motors including: vane, piston, and rotary abutment motors. When selecting a motor, consider horsepower, motor speed range, and torque required. Motors can malfunction because of improper fluid, poor maintenance, and improper operation.

Pressure Switches

Pressure switches accept pressure signals and, at a preselected pressure, open or close internal electrical switching elements. They may respond to rising or falling pressure, or a pressure differential. They are the most common electrical interface in fluid power systems. They are a low-cost alarm to protect operators, machinery, and work in progress by turning equipment off if it becomes too high or too low.

Relief Valves

Relief valves control and limit the forces inside a fluid power system. They are safeguards which limit maximum pressure in a system by diverting excess oil when



pressures get too high. There are many different kinds including: cracking pressure, directing-acting, poppet design, reverse flow, differential-piston design, and pilot-operated reliefs.

Solenoid

A solenoid is a type of valve that works in a similar manner as a relief valve. When an excessive amount of pressure is built up, the solenoid valve releases the dangerous pressure. With a proportional solenoid, the greater the pressure, the faster the valve releases the pressure.



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.

Proper Motor Protection Safeguards Your Investments

With electric motors driving the majority of today's manufacturing processes, proper motor protection is critical. Not surprisingly, a significant amount of effort and resources have recently been invested in motor protection technology, resulting in cost-effective solutions to many of today's common motor problems.

Motors fail for a number of reasons—moisture and contamination, short circuits, mechanical problems and old age—but the primary reason is excessive heat, caused by excess current (greater than normal motor full load current), high ambient temperatures, and poor ventilation of the motor. If a motor is continuously overheated by only 10 degrees, its life can be reduced by as much as 50%.

Steve ZimmermanControl EngineeringDecember 1, 1997



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. If the load on the motor increases, the motor draws more current to continue running at its synchronous speed.

It is quite possible to put so much load on a motor that it will draw more and more current without being able to reach synchronous speed. If this happens for a long enough period of time, the motor can melt its insulation and burn out, resulting in damage to the motor windings. This excessive load condition is called an overload.

In fact, the motor could stop turning altogether (called a locked rotor) under a large enough load. This is another example of an overload condition. Even though the motor shaft is unable to turn, the motor continues to draw current, attempting to reach its synchronous speed.

Although the running motor may not draw enough current to blow the fuses or trip circuit breakers, it can produce sufficient heat to burn up the motor. This heat, generated by excessive current in the windings, causes the insulation to fail and the motor to burn out. We use the term “locked rotor amps” to describe when the motor is in this state and is drawing the maximum amount of current.

Due to the possibility of excessive current draw, an overload protection device is required that does not open the circuit while the motor is starting, but opens the circuit if the motor gets overloaded.

Starting Current

When a motor is started, it must perform work to overcome the inertia of the rotating portion of the motor and the attached load. The starting current measured on the incoming line is typically 600% of full-load current when rated voltage and frequency is first applied to a NEMA B motor. The stationary portion of the motor current decreases to its rated value as the rotor comes up to speed.



Figure E-2: Motor Inrush Curve

An overload condition will occur when the rotor has difficulty turning and draws more current than it normally would need to keep it turning. When an overload occurs the current being drawn is usually between 2 to 6 times the normal operating current.

For example if a conveyor belt becomes jammed and does not allow the rotor to turn, the motor will draw about as much amperage as it would on startup to try to get the rotor to turn. As long as the rotor does not turn, this increased current will continue to flow. The key thing to remember in an overload condition is that the current flows through the normal circuit path. Continued overload current will cause excess heating in the motor and the motor circuit. If the over current protective device does not operate in a timely manner, the motor could short out a winding, or cause insulation damage to a winding which could lead to a short circuit later.

Overload Relays

The overload relay is the device used in starters for motor overload protection. It limits the amount of current drawn to protect the motor from overheating.

An overload relay consists of:

• A current sensing unit (connected in the circuit to the motor)• A mechanism to break the circuit, either directly or indirectly

Overload relays have the following features:

• A time delay which ignores harmless temporary overloads caused by normal motor starting, without breaking the circuit

• A means of resetting the circuit once the overload is removed



• 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• Can be reset once the overload is removed

Bimetallic Overload Relays

Overload protection is accomplished with the use of a bimetallic strip. This component consists of a small heater element wired in series with the motor and a bimetallic strip that can be used as a trip lever. A bimetallic strip is made of two dissimilar metals bonded together. The two metals have different thermal expansion characteristics, so the bimetallic bends at a given rate when heated.

Under normal operating conditions the heat generated by the heater element will be insufficient to cause the bimetallic strip to bend enough to trip the overload relay.

As current rises, heat also rises. The hotter the bimetallic becomes, the more it bends. In an overload condition the heat generated from the heater will cause the bimetallic strip to bend until the mechanism is tripped, stopping the motor.

If heat begins to rise, the strip bends, and the spring pulls the contacts apart, breaking the circuit, as shown in Figure E-3.

Figure E-3: The Warping Effect of the Bimetallic Strip

Once the tripping action has taken place, the bimetallic strip cools and reshapes itself, automatically resetting the circuit. The motor can be restarted even when the overload condition has not been cleared, and will trip and reset itself again and again. (This assumes an automatic reset and can also be equipped with a manual reset.)



Electronic Overload Relay

Electronic overload relays are another option for motor protection. The features and benefits of electronic overload relays vary but there are a few common traits. One advantage offered by electronic overload relays is heater-less design. This reduces installation cost and the need to stock a variety of heaters to match motor ratings. Electronic overload relays can detect a phase loss and disconnect the motor from the power source. This feature is not available on mechanical types of overload relays.

Overload Classifications

Overload relays also have an assigned trip class. The trip class is the maximum time in seconds at which the overload relay will trip when the carrying current is at 600% of its current rating. Bimetallic overload relays can be rated as Class 10, meaning that they can be counted on to break the circuit no more than ten seconds after a locked rotor condition begins. Melting alloy overload relays are generally Class 20.

American industry has standardized on Class 20 overload protection.The Europeans have standardized on Class 10.

Class 20 will give a nominal 590-second trip (9.83 minutes) at an overload of 125% of full load amps, a 29-second trip at a 500% overload, and a 20-second trip at a 600% overload. Thus, a motor that is stalled and drawing locked rotor amperage will be taken off-line in 20 to 29 seconds. However, a motor that draws a continuous locked rotor current can be expected to burn out before 20 seconds.

Class 10 will give a nominal 230-second trip (3.83 minutes) at 125% overload, 15 seconds at 500% overload, and 10 seconds at 600% overload.

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.



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. A separate overload device that is responsive to motor current. This device shall be rated at no more than the percentages shown in Table E-1.

Example 1

15 hp, 208V, 3 phase, induction motor, 40oC rise, design B, FLA 48 amps. Overload Protection = 48 amps times 125% = 60 amps

Example 2

25 hp, 208V, 3 phase, induction motor, 1.15 s.f., design C, FLA 72A. Overload Protection = 72 amps times 125% = 90 amps

Example 3

40 hp, 208V, 3 phase, wound rotor motor, FLA 118 amps. Overload Protection = 118 amps times 115%=136 amps

Table E-1: Full Load Current Tolerances

Nameplate Full Load Current Rating % Allowed Above Full Load Current Rating

Service Factor of 1.15 125%

Motors with a marked temperature rise of 40oC or less 125%

All other motors 115%

The motor overloads must be calculated using the nameplate current and not from Tables 430-148 or 430-150 of the National Electrical Code.

In Example 1, the motor has a 40oC rise, the O.L. unit is sized at 125% of the full load motor current.

In Example 2, the motor has a s.f. (service factor) of 1.15. The O.L. unit is sized at 125% of the full load motor current.

In Example 3, where neither of the two conditions exists, it is sized at 115%.



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.

Insulation Class

The National Electrical Manufacturers Association (NEMA) has established insulation classes to meet motor temperature requirements found in different operating environments. The four insulation classes are A, B, F, and H. Class F is commonly used. Class A is seldom used. Before a motor is started, its windings are at the temperature of the surrounding air. This is known as ambient temperature. NEMA has standardized on an ambient temperature of 104oF, or 40oC for all motor classes.

Temperature rises in the motor as soon as it is started. The combination of ambient temperature and allowed temperature rise equals the maximum winding temperature in a motor. A motor with Class F insulation, for example, has a maximum temperature rise of 221oF (105oC). The maximum winding temperature is 293oF (145oC) [140oF (40oC) ambient plus 221oF (105oC) rise]. A margin is allowed for a point at the center of the motor’s windings where the temperature is higher. This is referred to as the motor’s hot spot.

The operating temperature of a motor is important to efficient operation and long life. Operating a motor above the limits of the insulation class reduces the motor life expectancy. A 50oF (10oC) increase in the operating temperature can decrease the life expectancy of a motor by as much as 50%.

Locked Rotor Amps

Also known as inrush current, locked rotor amps is the amount of current the motor can be expected to draw under starting conditions when full voltage is applied. This is the current taken from the supply line at rated voltage and frequency with the rotor at rest.

Motor Load

A motor provides the conversion of electrical energy to mechanical energy that enables a machine to do work. The energy that a machine requires from a motor is

Table E-2: Motor Operating Temperature Class A Class B Class F Class H

Rise 176oF (80oC) 176oF (80oC) 320oF (160oC) 176oF (80oC)Hot Spot 41oF (5oC) 50oF (10oC) 50oF (10oC) 59oF (15oC)



known as the 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. If a load is attached to a motor through a 3:1 gear ratio, the load is 1/9 of the load the motor would see if the load were attached directly to the motor.

A round object attached to the motor shaft has a load related to the square of the radius of the object. If a 16" saw blade is a load of weight multiplied by the radius squared, the load is 82 x weight = 64 x weight. A 20" saw blade is a load of 102 x weight = 100 x weight. The 20" saw blade is 56% more load than the 16" saw blade due to the dimensions.

A motor load is directly related to the weight of an object. A 16" blade weighs 9.28 pounds. A 20" blade weighs 14.61 pounds, or 5.33 pounds more. The 20" blade is 56% more load than the 16" blade due to weight. Remember, weight is the volume of an object times its density, so weight is also related to the dimensions.

In the example of the saw blades, the combined effect of the longer radius, and longer weight means the 20" saw blade is approximately 125% more load on a motor than a 16" saw blade, which partially explains why motors on quads 1 and 4 are more likely to burn out or trip an overload.



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.

NEMA A

The NEMA A motor is similar in many ways to the NEMA B motor. It typically has a higher value of locked rotor torque and its slip can be higher.

NEMA C

The NEMA C motors are well suited to starting high-inertia loads. This is because they have high locked rotor torque capability. Their slip is around 5%, and their starting current requirement is average.

NEMA D

The NEMA D motor is found in heavy duty, high-inertia applications. It has high values of slip (up to 8%), and very high locked rotor torque capability.

Service Factor (s.f.)

A motor designed to operate at its nameplate horsepower rating has a service factor of 1.0. Some applications may require a motor to exceed the rated horsepower. In these cases a motor with a service factor of 1.15 can be specified. The service factor is a multiplier that may be applied to the rated power. A 1.15 service factor motor can be operated 15% higher than the motor’s nameplate horsepower.

Trip Class

Overload relays are rated by a trip class, which defines the length of time it will take for the relay to trip in an overload condition. The most common trip classes are Class 10, 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.Trip Class

Figure E-4: Trip Times for Trip Classes

001083 Drawing Set70

Drawings are inserted in numerical order at the back of the manual.

Some drawings are provided for a particular system length that may differ from yours. The quantity of certain components and the length of certain tubing and hoses may differ due to the number of tables in your system.

Table F-1: Attached Drawings, Listed by Category

Drawing Description Drawing NumberTable AssemblyTable Assembly, top level dwg, 62 ft, flipper, pop-up 63526-501Table Assembly, 62 ft, flipper, pop-up 63529-501Table Assembly, top level dwg, 42 ft, flipper, pop-up 63535-501Table Assembly, 42 ft, flipper, pop-up 63540-501Table Assembly, 42 ft, flipper, end-eject 63548-501Table Assembly, top level dwg, 42 ft, flipper, end-eject 63550-501Pneumatic ComponentsFlipper assembly 63562-501Clamp cylinder assembly 63599-501Pop-up assembly 64563-501Valve plate assembly 64564-501End-eject roller assembly 64573-501Filter/lubricator plate assembly 64585-501Overhead Plate RackOverhead plate rack, 60 ft 63527-501Overhead plate rack, 40 ft, end-eject 64800-501Pneumatic Kits/LayoutsPneumatic kit, 42 ft, flipper, pop-up 63592-501Pneumatic kit, 62 ft, flipper, pop-up 63593-501Pneumatic kit, 42 ft, flipper, end-eject 63595-501Pneumatic layout for 62 ft, flipper, pop-up 64848-560Control Mechanisms (“xxx” indicates the length of the system)Pneumatic controls on pedestal, flipper 64838-xxxPneumatic controls on overhead rack, for flipper, side-eject 64844-xxxPneumatic controls on overhead rack, for flipper, end-eject 64845-xxx

Drawing SetAppendix F


001083 Drawing Set71

Table F-2: Attached Drawings, Listed in Numerical Order

Drawing Description Drawing NumberTable Assembly, top level dwg, 62 ft, flipper, pop-up 63526-501Overhead plate rack, 60 ft 63527-501Table Assembly, 62 ft, flipper, pop-up 63529-501Table Assembly, top level dwg, 42 ft, flipper, pop-up 63535-501Table Assembly, 42 ft, flipper, pop-up 63540-501Table Assembly, 42 ft, flipper, end-eject 63548-501Table Assembly, top level dwg, 42 ft, flipper, end-eject 63550-501Flipper assembly 63562-501Pneumatic kit, 42 ft, flipper, pop-up 63592-501Pneumatic kit, 62 ft, flipper, pop-up 63593-501Pneumatic kit, 42 ft, flipper, end-eject 63595-501Clamp cylinder assembly 63599-501Pop-up assembly 64563-501Valve plate assembly 64564-501End-eject roller assembly 64573-501Filter/lubricator plate assembly 64585-501Overhead plate rack, 40 ft, end-eject 64800-501Pneumatic controls on pedestal, flipper 64838Pneumatic controls on overhead rack, for flipper, side-eject 64844Pneumatic controls on overhead rack, for flipper, end-eject 64845Pneumatic layout for 62 ft, flipper, pop-up 64848-560

001083 Glossary72

actuate to activate, put into action

amperage the strength of an electric current, expressed in amperes

anchor plate a steel plate that holds the tables in place; it is anchored to the concrete floor and the tables are welded to it

auto-eject a pneumatic system that raises the truss off the tables and automatically places the truss on the stand-alone conveyors with the use of a transfer roller

bumper a safety device on each corner of the gantry head (for a total of 4); when the bumper is depressed, the gantry head motion stops

bus bar an electrical device that allows multiple gantry heads to be used simultaneously

connector plate the nail-plate that is embedded into the ends of the tie

cushion an attribute of a hydraulic cylinder that allows adjustment of the pressure in each cylinder

end-eject a pneumatic system that raises the truss off the tables and allows the truss to be manually pushed or pulled off the end of the tables; this system requires that the gantry head rolls back over the truss or a device must be installed to raise the gantry head when it is parked

gantry head the entire traveling weldment that houses the Roller to embed the connector plates

hour-meter a gauge on the gantry head on a 1-enclosure system that tells the amount of time the motor is actually turning and the gantry head is moving; 2-enclosure systems do not have an hour-meter

jigging any of several devices used to hold the truss in place on the tables

layout a scaled diagram of the location of components and the space that they occupy

Glossary

001083 Glossary73

leveling screws large cap head screws that thread into the table legs and allow the table height to be adjusted and leveled

light bar the perimeter access guarding device that uses multiple light beams to detect when something is in the way of the gantry head and stops the machine to prevent injury or damage; the RoofTracker uses a set of 3-beam light bars on both sides of the gantry head

limit switch an electro-mechanical device that consists of an actuator mechanically linked to a set of contacts; when an object comes into contact with the actuator, the device operates the contacts to make or break an electrical connection

lockout/tagout a means of isolating a piece of equipment from its energy source so maintenance can safely occur; guidelines provided in OSHA 29 CFR 1910.147

lubricator a device that allows controlled amounts of lubricants into the pneumatic system

plate see connector plate

PLC Programmable Logic Controller; a solid-state control device that can be programmed to control process or machine operations. It consists of five basic components: processor, memory, input/output module, the power supply, and the programming device.

port a connection point for a peripheral device

proximity switch a switch that uses an electromagnetic field to detect when an object is near, there is no physical contact between the object and the switch; inductive proximity switches detect only metal objects, capacitive proximity switches can sense both metallic and non-metallic objects

puck a type of jigging that is small and round

Glossary

001083 Glossary74

qualified person a person or persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training, or experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work—ANSI B30.2-1983; one who has skills and knowledge related to the construction and operation of the electrical equipment and installations and has received safety training on the hazards involved—NEC2002 Handbook

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 source and regulates the air pressure allowed into the system

Roller the large roller inside the gantry head that initially embeds the plates into the truss

side-eject a pneumatic system that raises the truss off the tables and allows the truss to be manually pushed or pulled off the side of the table and onto the stand-alone conveyors

end stop a type of jigging that provides a straight surface for the end of the truss to rest against during setup and pressing

torque a turning or twisting force

transfer roller a motorized roller sitting perpendicular to the tables on an auto-eject system; it automatically transfers the truss from the Ejectors to the stand-alone conveyors

transmitter bar the light bar that transmits the signal to the receiver bar; every light bar set consists of a receiver bar and a transmitter bar

VFD Variable Frequency Device; controls the speed of the cycle

Glossary

001083 Glossary75

voltage Equal to the difference of electric potential between two point on a conducting wire carrying a constant current of one ampere when the power between the points is one watt

Glossary

001083 Index76

Aaddendum vadjusting air pressure 38air

see also compressed airavailable systems 6

Bbefore you begin 8

Ccaution logo vichecklist

periodic 50weekly 49

clamp pads 41codes and standards 66components 5compressed air

adjusting pressure 38air pressure how it works 56components 20

connecting 22, 23connections 20location 21

control valvessee control valves

cylinders 40drain 39drawings 70filling oil reservoir 36filter/regulator 38FRL 34lubricator 36maintenance 34operation 30overview

for general pneumatic systems 57for this system 20

replacement parts 47requirements 12specifications 12valve bank 35

control valvesmaintaining 39turning 32understanding

customer’s responsibilities 9customer-supplied parts 14cylinders 40

Ddanger logos videfinitions 72delivery 16dimensions 10drawings

description 70, 71drawing numbers 70, 71

Eend stops

placement 29see also jigging

enhancements 6environmental logo vienvironmental requirements 11equipment layout 17evaluation of documentation 51exchanges and returned goods iv

Ffeedback iv, 51floor requirements 11fluid power

see also compressed air

Index

001083 Index77

system components 57foundation requirements 11

Ggeneral information 1general specifications 7glossary

complete list 72overloads 67

Hhazard indicator vi

Iidentification of system 5installation

connecting pneumatics 22, 23delivery 16equipment layout 17jigging 25lifting 18pneumatic system 20responsibilities 16unloading 16unpacking 17

introduction 2

Jjigging

defined 72maintaining 42operating 29supplied 25

Llifting tubes 18location requirements 11lubricator 36

Mmain components 5maintenance

checklists 48, 49, 50introduction 33jigging 42lubricator 36overloads 61parts list 45pneumatics 34

adjusting pressure 38cylinders 40filter/regulator 38

preventive 48replacing wear pads 41

manualevaluation of documentation 51purpose 2understanding formatting 2

mechanical replacement parts 46mitek

items supplied by 8responsibilities of 8

NNEMA design ratings 69notice logo vinotice of change v

Ooperation

Index

001083 Index78

jigging 29laying out the truss 28normal 27pneumatics 30setting up for 28

overloadsclassifications 65codes and standards 66definition 62glossary 67motor inrush curve 63NEMA design ratings 69relays 63starting current 62understanding 61

Ppage change vparts list 45patents ivperiodic checklist 50pneumatics

air pressure 56components and connections 20control valves

see control valvesdrawings 70lubricator 36maintenance 34overview 20see also compressed air

pre-planning 8prior to installation 8

RRailrider Pro System

available systems 6general specifications 7getting to know your system 4layout 17main components 5

purpose 3receiving 13recommendations on documentation im-provement ivremoving the lifting tubes 26replacement parts 45

mechanical 46parts list 45pneumatic 47

requirementsenvironmental 11location 11pneumatics 12space 10

responsibilitiesduring installation 16of customer 9of mitek 8training provided 15

returns iv

Ssafety

safety indicators visafety rules vii

setupgeneral 8jigging 29laying out the truss 28

shipping information 13size of equipment 10space requirements 10, 11spare parts 45specifications 7

pneumatics 12weight 13

startupgeneral 26removing the lifting tubes 26

system dimensions 10system identification 5

Index

001083 Index79

Ttrademark ivtraining provided 15troubleshooting 43truss setup

jigging 25laying out the truss 28

Uunloading 16unpacking 16, 17upgrades 6

Vvalve bank 35

Wwarning logo viwear pads 41weekly checklist 49weight 13

Index

Ra

ilRid

er ® P

ro R

oller Press

Ra

ilRid

er ® P

ro R

oller Press

Ra

ilRid

er ® P

ro R

oller Press

001083 001083 001083

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