Mitek RoofTracker II Reference manual

MiTek®
Machinery Division
Service Bulletin
MiTek Machinery Division
301 Fountain Lakes Industrial Drive
St. Charles, MO 63301
Phone: [phone]
www.mii.com
Part # and Rev. SB229 rev. A
Revision Date 19 December 2017
Revised By
Approved By V.Carroll
Print Date 19 December 2017
Orig Date Created 20 December 2016
Created By G.Gaia
Effectivity Customers with
ACS800
Machinery Affected: RoofTracker II™ press
Document: SB229 rev. A
Title: Installing an ACS880 Variable-Frequency Drive
Distribution: Customers Upon Order
Copyright © 2017 MiTek®. All rights reserved.

Service Bulletin SB229
SB229 rev. A 2 of 16
Original Instructions
Purpose and Scope
The ACS800 variable-frequency drive (VFD) in the RoofTracker II press is obsolete. This
Service Bulletin explains how to replace it with an ACS880 VFD.
The parts included in all kits are shown in Table 1. Your specific VFD is shown in one of
the following tables. Please ensure all parts are present before starting this procedure.
Before beginning the procedure, gather the supplies listed here:
If you have a VFD running 415V or 460V power, gather the supplies listed here as well:
Table 1: Parts in all SB229KIT
Qty. Part Description Part #
1 Service Bulletin SB229
1 Encoder interface module 509305
1 Digital IO extension module 509296
4 #10-32X3/4'' screws 341106
Table 2: Parts in SB229KIT-A
Qty. Part Description Part #
1 ACS880 VFD 208V (programmed) 92294-501
Table 3: Parts in SB229KIT-B
Qty. Part Description Part #
1 ACS880 VFD 230V (programmed) 92294-502
Table 4: Parts in SB229KIT-C
Qty. Part Description Part #
1 ACS880 VFD 415V (programmed) 92295-501
Table 5: Parts in SB229KIT-D
Qty. Part Description Part #
1 ACS880 VFD 460V (programmed) 92295-502
• Phillips screwdriver set • Ruler (preferably metal)
• Slotted screwdriver set • Thin permanent marker
• Torx screwdriver set • Multimeter
• Drill • #10-32 tap
• #21 drill bit • Vacuum
If you have any
questions, call
MiTek Machinery
Division Customer
Service at
800-523-3380.

Service Bulletin SB229
SB229 rev. A 3 of 16
Original Instructions
Procedure
Electrical Lockout/Tagout Procedures
When Working on a Machine Inside the Machine’s Main Electrical Enclosure
or in the Electrical Transmission Line to the Machine
Before opening the main electrical enclosure, or attempting to repair or replace an
electrical transmission line to the machine, lockout/tagout the machine properly. Follow
your company’s approved lockout/tagout procedures which should include, but are not
limited to, the steps here.
1. Engage an E-stop on the machine.
2. Turn the machine’s disconnect switch to the Off position as shown in Figure 1.
This is usually required to open the main electrical enclosure’s door.
Figure 1: Disconnect Switch on Main Electrical Enclosure
!WARNING
ELECTROCUTION HAZARD!
Verify that all power to the machine has been turned
off and follow approved lockout/tagout safety
procedures before performing any maintenance.
All electrical work must performed by a qualified
electrician.
If it is absolutely necessary to troubleshoot an
energized machine, follow NFPA 70E for proper
procedures and personal protective equipment.

Service Bulletin SB229
SB229 rev. A 4 of 16
Original Instructions
3. Shut the power to the machine off at the
machine’s power source, which is
usually an electrical service entry panel
on the facility wall. One example of a
locked-out power source panel is shown
in Figure 2.
4. Attach a lock and tag that meets OSHA
requirements for lockout/tagout to the
electrical service entry panel.
5. Open the door to the enclosure in which
you need access, and using a multimeter,
verify that the power is off.
Figure 2: Lockout/tagout on
the Power Source Panel

Service Bulletin SB229
SB229 rev. A 5 of 16
Original Instructions
Removing an ACS800 VFD
1. Locate the ACS800 VFD in the main electrical enclosure. See Figure 3.
Figure 3: Location of the ACS800 VFD
2. Expose the wiring on the VFD by using the following steps.
a) Insert a slotted screwdriver into the hole near the bottom of the VFD
cover as shown in Figure 4.
Figure 4: Inserting Screwdriver into VFD Cover
b) Press down on the screwdriver to unhook the latch that holds the cover in
place.
c) Pull the cover forward and slightly upward to remove it.
!WARNING
Wait five minutes after turning the disconnect switch
to the Off position to start work on the VFD. Starting
work without waiting five minutes may cause electric
shock.

Service Bulletin SB229
SB229 rev. A 6 of 16
Original Instructions
d) Push up on the latch on the bottom right of the keypad. Pull the keypad
forward by the tab on top. The keypad swings to the left. See Figure 5.
Figure 5: Moving Keypad
3. Remove the wiring from the front of the VFD by using the following steps.
a) Unscrew the four screws holding the encoder module (labeled the Pulse
Encoder Interface) and the extension module (labeled the Digital I/O
Extension) in place using a Phillips screwdriver. See Figure 6.
Figure 6: Removing Modules

Service Bulletin SB229
SB229 rev. A 7 of 16
Original Instructions
b) Loosen the screws on the green terminals on the encoder module with a
slotted screwdriver. Remove the wires from those terminals. Do not
untwist any of the twisted wires. See Figure 7.
c) Loosen the screws on the green terminals of the extension module with a
slotted screwdriver. Remove the wires from these terminals. See Figure 7.
Figure 7: Removing Wires from Modules
d) Pull the gray terminal blocks on the front of the VFD forward to remove
them. Leave the wires in the terminal blocks to make rewiring easier. See
Figure 8.
Use a flathead screwdriver to pry gently on the right sides of the
terminal blocks if necessary.
Figure 8: Removing Terminal Blocks from VFD
e) Cut the zip ties that bundle the gray cable with the blue wires, red wires,
and white and blue wire.

Service Bulletin SB229
SB229 rev. A 8 of 16
Original Instructions
4. Pull the gray cable through the hole on the left-hand side of the wire shield. Then
pull the red wires, blue wires, and white and blue wire through as well. See
Figure 9.
The gray terminal blocks fit through the hole.
Figure 9: Removing Cable and Wires through the Wire Shield
5. Remove the 3-phase wires and ground wire by using the following steps.
a) Locate the green 3-phase input and output terminals on the bottom of the
VFD. See Figure 10.
Figure 10: Location of 3-Phase Input and Output Terminals
b) Remove the black 3-phase wires from the input and output terminals on
the bottom of the VFD using a slotted screwdriver.
c) Remove the green ground wire underneath the 3-phase output terminals
using a Torx screwdriver.

Service Bulletin SB229
SB229 rev. A 9 of 16
Original Instructions
d) Pull the 3-phase wires and the ground wire through the hole on the right-
hand side of the wire shield.
6. Check the wire labels on all of the wires to make sure they are clearly visible. Use
a thin permanent marker to trace any faded letters on the wire labels.
Removing the Old VFD
1. Remove the four screws bolting the wire shield to the VFD. Remove the wire
shield. See Figure 11 for the location of the screws.
Removing the wire shield gives you easy access to the mounting screws.
Figure 11: Wire Shield Screw Locations
2. Loosen the two mounting screws on the bottom of the VFD. Do not remove these
screws yet. Remove the two mounting screws from the top of the VFD. See
Figure 12.
Figure 12: Mounting Screw Locations
3. Tilt the VFD slightly forward. Lift it up and remove it.

Service Bulletin SB229
SB229 rev. A 10 of 16
Original Instructions
Installing the ACS880 VFD
1. Prepare the main electrical enclosure for the ACS880 VFD by using the following
steps.
a) Place a metal ruler on the two mounting screws from the bottom of the old
VFD. Rest the bottom of the VFD on the ruler as shown in Figure 13.
Figure 13: Placing VFD on a Ruler
b) Use a thin permanent marker to mark the locations where the new
mounting screws will hold the new VFD in place. Remove the VFD from
the enclosure.
c) Remove the old mounting screws. Discard the four old mounting screws.
Keep the washers.
d) Drill in the four places indicated by your marks on the rear wall of the
enclosure using a #21 bit. Tap the holes using the #10-32 tap.
If you have an ACS880 VFD using 415V or
460V power, your VFD is physically smaller
than the old one. You need to drill.
Continue to step 1 below this notice.
If you have an ACS880 VFD using 208V or
230 V power, your VFD is the same size as
the old one. Remove the old mounting
screws. Mount the new VFD using the new
mounting screws and old washers. Then
skip to step 1 on page 12.
NOTICE
NOTICE
NOTICE
Have another
person hold the
VFD in place
while you mark
the spots for the
new mounting
screws.

Service Bulletin SB229
SB229 rev. A 11 of 16
Original Instructions
2. Vacuum the inside of the enclosure to remove any metal debris created by the
drilling and tapping.
3. Install the ACS880 VFD in the main electrical enclosure by using the following
steps.
a) Insert two new mounting screws with the old washers in the bottom holes.
Start the screws but do not tighten them.
b) Place the VFD in the enclosure. It should rest on the two new mounting
screws.
c) Insert and tighten two new mounting screws with the old washers through
the holes on the top of the VFD mount using a slotted screwdriver. Then
tighten the bottom two mounting screws. See Figure 14.
Figure 14: Tightening Mounting Screws
NOTICE
Never use compressed air inside the electrical
enclosures! It may force contaminates into the
electrical connections.
Use a vacuum to remove dust from electrical
enclosures. Canned air is acceptable after vacuuming.

Service Bulletin SB229
SB229 rev. A 12 of 16
Original Instructions
Wiring the ACS880 VFD
1. Wire the 3-phase wires and ground wire by using the following steps.
For each wire on the VFD, make sure that the terminal screw is not tightened.
Insert the wire into the terminal. Use a slotted screwdriver to tighten the
screw on the terminal. Tug the wire gently after tightening to make sure the
wire is secure in the terminal. (The ground wire uses a different type of
terminal. It also uses a Torx screwdriver.)
a) Place the black 3-phase wires into the three green input terminals on the
left-hand side of the bottom of the VFD. See Figure 15.
b) Place the black 3-phase wires into the three green output terminals on the
right-hand side of the bottom of the VFD. See Figure 15.
c) Connect the ground wire to the ground wire terminal using a Torx
screwdriver. See Figure 15.
The ground wire may connect to either ground terminal on the VFD.
The right-hand ground terminal to the right of the 3-phase output
terminals is easiest to reach.
Figure 15: Wired 3-Phase Inputs, Outputs, and Ground
TerminalL1L2L3
Wire 1L1 1L2 1L3
Input
Terminal T1/U T2/V T3/W
Wire 2L1 2L2 2L3
Output

Service Bulletin SB229
SB229 rev. A 13 of 16
Original Instructions
2. Wire the modules by using the following steps.
At this point, some wires are still in the gray terminal blocks from the old
VFD. Remove them as necessary to place them into their new terminals.
a) Locate the encoder module (labeled HTL Encoder Interface) by pulling
the tab on the bottom of the keypad forward to flip the keypad up.
b) Locate the blue X82 terminal block on the encoder module. Run wires
from the gray cable as follows. See Figure 16.
Figure 16: Encoder Module Wires
c) Locate the black X81 terminal block on the encoder module. It is below
the blue X82 terminal block. Run wires from the gray cable as follows.
See Figure 16.
d) Flip the keypad down.
Terminal1234567
Wire Blue Black White Black Metal
Twisted wires Twisted wires
Terminal1234567
Wire
Jumper Jumper Red Black
Twisted wires

Service Bulletin SB229
SB229 rev. A 14 of 16
Original Instructions
e) Locate the orange X65 terminal block and orange X66 terminal block on
the front of the extension module (labeled Digital IO Extension). Run
wires as follows. See Figure 17.
Figure 17: Extension Module
f) Locate the blue X61 terminal block on the front of the extension module.
Run wires as follows.
Terminal123 123
Wire 12 15 13 15
Terminal12121212
Wire 55 42

Service Bulletin SB229
SB229 rev. A 15 of 16
Original Instructions
3. Wire the terminal blocks on the front of the VFD by using the following steps.
a) Locate the terminal blocks labels outlined in red in Figure 18. Each
terminal block has a label under it. Knowing the locations of these
terminal blocks allows you to place wires correctly.
The yellow XSTO terminal block has two jumpers. Do not remove the
jumpers or the terminal block.
Figure 18: Locations of Terminal Blocks
b) Locate the orange XRO1 terminal block. Run wires as follows.
c) Locate the orange XRO2 terminal block. Run wires as follows.
d) Locate the orange XRO3 terminal block. Run wires as follows.
Terminal 11 12 13
Wire 9 1
XRO1
Terminal212223
Wire 15 11
XRO2
Terminal313233
Wire 10 1
XRO3
Shown without modules wired

Service Bulletin SB229
SB229 rev. A 16 of 16
Original Instructions
e) Locate the blue XD24 terminal block. Remove the jumper from the
terminal block, if a jumper is present. Run wires as follows.
f) Locate the blue XDI terminal block. Run wires as follows.
Figure 19: Wired VFD
4. Gather the wires toward the bottom of the VFD. This keeps them from interfering
with the cover.
5. Place the front cover on the VFD. Tighten the two screws that hold the cover
using a Torx screwdriver.
Preparing the Press
1. Close the doors on the main electrical enclosure.
2. Turn the black and red disconnect switch on the right-hand door of the electrical
enclosure to the On position.
3. Remove the lock and tag, and restore power at the electrical service entry panel.
4. Resume operation of the press.
Terminal12345
Wire SO6 42
XD24
Terminal123456
Wire 48 52 56 57 53 54
XDI