STEINEL HG ROOF Setup guide

HG ROOF
Maintenance
and Repair

HG ROOF
Maintenance and Repair
2
Table of Contents
Spare parts
Tools Needed
Troubleshooting
Opening the Robot
PCB
Power Supply
Motor
Wheels
Guide Block
3
4
5
9
14
21
23
26
28
Switch
Potentiometer
Start/Stop Switch
LED
Power Cable
Fan
Heat Tool
Heating Element
Reassemble HG ROOF
32
34
37
39
40
43
45
46
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Maintenance and Repair
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Spare Parts

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

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Maintenance and Repair
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Troubleshooting –Main Power Switch
When the main power is turned on, the green control light should turn on and you should hear the fan.
It is a “no volt release switch.” If there is power to the switch, it will click when pressed. If there is no
power, the switch will not click.
Rear view –main power switch Side view –main power switch
Main power switch

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Maintenance and Repair
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Troubleshooting –Main Power Switch
The housing is grounded and when tested from the plug to the case there should be less than 3 Ohm
when used with a cable that is 5m in length.
If above 3 Ohm then either:
1. there is a break on the cord: replace the cable
2. the ground connection on the board (3rd from the left) is loose.

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Maintenance and Repair
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Troubleshooting –Start / Stop switch
When the toggle switch is in the up position and the speed is above 0, the welder should move forward.
If the switch is in the down position, the tool must be placed in the run position and the welder will start
moving forward. If it does not, then the reed switch could be bad.

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Maintenance and Repair
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Troubleshooting –Reed switch. X6.
You can check continuity between red and black.
When there is no magnet, it is open. When there
is a magnet, there is continuity. You must first
remove the wires from the terminal block for a
correct reading.

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Maintenance and Repair
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Opening the Robot
1. Use the 5 mm Allen and remove the two screws at the top of the handlebar.
2. Use the 8 mm socket to remove the guide arm.
3. Replace the nut so it does not get lost and so that the bearing and axle do not fall out when the housing
is removed.
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Maintenance and Repair
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Opening the Robot
4. Use the Torx to remove the back wheels.
5. Use the 5 mm hex to remove the heat tool.
6. Use the 4 mm Allen to remove the wheel. If you only loosen the screw the wheel will stay on and will
spin. To remove the wheel, loosen the screw further until the wheel comes off the axle. The screw
presses on a ball bearing and the ball presses in a groove on the axle.
456

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Maintenance and Repair
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Opening the Robot
7. Use Torx T20 and remove 5 housing screws. The screws on the bottom have a lock washer and aid in
grounding the device. The screws on the sides do not have a lock washer.
8. Use 5 mm Allen to remove the axle guide.
9. Remove the side housing and set on the top.
7 8 9

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Maintenance and Repair
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Opening the Robot
10. Check the power connections on the switch. Tighten the connection contacts if necessary.
11. Check the power connections on the power supply unit.
10 11

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Maintenance and Repair
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Opening the Robot
12. Check the grounding wire and plug connection for ground.
13. The fan runs on 24v. Blue and Red wires.
14. The heat tool runs on 240v. Use #2 Phillips to tighten loose connections as needed.
12 13 14

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Maintenance and Repair
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Removing the PCB
1. Loosen the fan and power terminals from the power supply using a #2 Phillips.
2. Remove the power cable from the terminal block and remove the side with the fan and heat tool.
3. Remove the PCB by using the Torx and remove 3 screws on the bottom of the robot (6 mm length
screws with no lock washer).
1 2 3

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Maintenance and Repair
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Removing the PCB
4. Remove the PCB
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Maintenance and Repair
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Terminal block for the PCB
X3 is the Speed Control Potentiometer
3 Blue 24v
2 White 10 kOhm adjustable resistor
1 Blue/white 0v
X4 is the motor –all inputs are for the stepper motor
and receive pulses at different times
4 Red and blue
3 Black and yellow
2 Brown and white
1 Green and violet
X1 is the start stop switch
2 Blue 24v
1 Blue/white 0v
X6 is the reed switch –red and black cannot be
switches
2 Red positive
1 Black negative
X2 is the 24v power supply input
2 Blue 24v
1 Blue/white 0v

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Maintenance and Repair
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X3 Testing the speed control potentiometer
1. Remove the wires from the block.
2. Check between blue and blue with white stripe. It should be 10 kOhm.
3. Check between white and blue/white and turn the potentiometer. You should get a variation between 0
and 10 kOhm.
1 2 3

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Maintenance and Repair
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X1 Testing the start / stop switch
1. Remove the wires from the terminal.
2. Switch the switch and check for continuity change.
1 2

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Maintenance and Repair
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X2 Check Power Supply
1. Retighten the power input and 24v supply on the power supply.
2. Unplug the power supply input on the PCB and connect the voltage tester.
Plug in the unit and check voltage between blue and blue/white. You should have 24v DC. If there is
not 24v, the power supply unit needs to be replaced.
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Maintenance and Repair
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Replacing the PCB
1. Remove the wires and label or remove one wire at a time and immediately install in the new PCB
because some of the wire colors are the same.
2. Reinstall the new PCB.
1 2