tài liệu sửa chữa máy hàn nhựa leister Astro e 20130619

19 6.2 Replacement of drive unit and electronic circuit board DZF 01 .... re-4 Check mechanics  Check undercarriage for cracks and deformations  Check roller chain and sprocket wheels

© 2013 Leister Technologies AG, CH-6056 Kaegiswil

These repair instructions may not be distributed or reproduced in part or in whole in any form without prior written consent from Leister Technologies AG, CH-6056 Kaegiswil

Leister Technologies AG, CH-6056 Kaegiswil/Switzerland Tel +41 41 662 74 74 Fax +41 41 662 74 16

Table of contents

1 Scope of applicability 3

2 Safety precautions 3

3 Remarks 3

4 Check mechanics 4

4.1 Movable parts 4

4.2 Replacement of drive roller chains 6

4.3 Plain roller centering 9

4.4 Hot-wedge adjustment 9

5 Electronics 11

5.1 Wiring 11

5.2 Wiring details 12

5.3 Power supply cord 14

5.4 Main switch 14

5.5 Triac 15

5.6 Relay 15

5.7 Electronic circuit board TRN 02 16

5.8 Electronic circuit board ZPM 05 17

5.9 Connect electronic circuit board CSE temporarly 18

5.10 DIP switch on electronic circuit board CSE 06 18

6 Drive unit 19

6.1 Check drive unit 19

6.2 Replacement of drive unit and electronic circuit board DZF 01 20

7 Heater unit 22

7.1 Check of hot-wedge 22

7.2 Temperature check of hot-wedge 23

7.3 Check of thermocouple 23

7.4 Check of heating cartridge 24

7.5 Replacement of heating cartridges and therocouple 24

7.6 Hot-wedge supervision 28

8 Check force sensor and USB port (optional) 29

8.1 Force sensor 29

8.2 USB port 29

9 Setup menu 30

9.1 Menu CSE 03 31

9.2 Menu CSE 06 32

10 Settings 34

11 Possible causes of trouble 35

12 Wiring diagram 36

13 Test procedure for ASTRO (protection class I) 37

14 Equipment required for Leister repair service 39

15 Appendix screw locking 40

1 Scope of applicability

These repair instructions are reserved exclusively for Leister service centres Only enced and qualified personnel trained by Leister Technologies AG, CH-6056 Kaegiswil, are allowed to do repair work on Leister tools Additional national requirements relative to per-sonnel carrying out repair work are to be observed by each service centre

A well-equipped working place (see "Equipment required for Leister repair service") is tial for doing qualified work For safety reasons use only identical original Leister replacement parts for each type of tool when servicing

 If it is impossible to repair a tool, it should be returned immediately to the manufacturer,

Leister Technologies AG, CH-6056 Kaegiswil, Switzerland, carriage paid to Kaegiswil

Leister will repair the tool within 24 hours after its arrival

 When ordering spare parts use the order numbers of the spare parts list When ing use only identical original Leister replacement parts!

servic-Warning! If you open the tool or remove its parts, except the ones they are

accessi-ble without using a tool, some life parts could appear Its contact can

cause danger to life! Insure tool is disconnected from the line/mains

be-fore any work is commenced!

Repaired tools must pass the Leister test procedure and any additional

local requirements Check with your local Statutory Authority for testing quirements

re-4 Check mechanics

 Check undercarriage for cracks and deformations

 Check roller chain and sprocket wheels and replace them if necessary

 Clean all polluted parts

 Make sure that there are no other particles than the essential grease inside the toothed wheel work

 Check all moving parts for smooth running and replace them if necessary

 Lubricate all moving parts with unpolluted grease, chain with chain oil

 Ensure which screws are to be locked prior to the tool assembly or its components (see chapter 15)

 Carry out the assembling according to the exploded diagrams and the spare parts lists

The numbering of the parts in chapter 4 refers to the exploded diagrams!

4.1 Movable parts

Lubricate these parts with grease (e.g Microlube GBUY 131), chain with chain oil:

Remove gear cover (64), clean and lubricate cog wheels (310, 19, 26)

Remove chain covers (31, 210), cate sprocket wheels and oil chains

lubri-Remove cover of pressure roller (223) and lubricate sprocket wheels

Lubricate guide slide (112)

Lubricate pivots of clamping lever (50) and adjustment screw (59)

Remove undercarriag cover (132) and lubricate guide axle of hot-wedge

4.2 Replacement of drive roller chains

 Push cable protective tube beside and remove gear cover (illustration 1)

 Remove cog wheel (illustration 2)

 Remove chain protection (illustration 3)

 Turn lower pressure roller as long as good accessibility to the chains master link is

 Oil new roller chain by using chain oil

 Insert roller chain from the top (illustration 7) and feed it in counter-clockwise (illustration 8)

 Interconnect roller chain and assemble chain protection

 Remove chain protection plates (illustration 9)

 Turn upper pressure roller as long as good accessibility to the chains master link is

 A deflection pulley serves as chain tensioner (illustration 11)

 Remove deflection pulley by loosening the set screw (illustration 12)

 Oil new roller chain by using chain oil

 Insert roller chain from the top (illustration 13) and feed it in untill the chains master link may be inserted (illustration 10)

 Press deflection pulley to the top to tense the roller chain (illustration 14)

 Tighten set screw, then loose it for approx ½ revolution and make sure the deflection pulley rotates together with the roller chain

 Lock set screw by using Loctite 242

 Assemble chain protection plates

 Re-insert cog wheel (illustrations 1 and 2) and assemble gear cover

11

12

4.3 Plain roller centering

 Center plain roller by screwing in the set

screws (73) from both sides

 Tighten set screws, then loosen them for ¼

revolution each and lock them by using the

counter nuts (74)

 Check: The plain rollers (66 and 67) must

ro-tate without applying real effort

4.4 Hot-wedge adjustment

 Remove cover sheet from undercarriage (illustration 1)

 Center hot-wedge (illustration 3) by using both cheese head screws (illustration 2)

 Reassemble cover sheet (illustration 1)

3

 Insert two PE membranes of 2.5mm thickness between the pressure rollers and actuate tension lever (illustration 4)

 Keep pressing catch spring (illustration 5.1)

 Position pressure rollers by using adjustment nut (illustration 5.2) untill they smoothly touch the membranes (illustration 5.2)

 Insert two PE membranes of 2.5mm thickness into the machine

 Apply tension by turning the adjustment nut for 10 numbers (illustration 6) or 1250N (version with force sensor)

 Tilt machine to the side to get good accessibility to the guide rollers (illustration 7)

 Start drive unit for a short time to ensure the hot wedge will move close to the drive ers Fix hot-wedge if necessary to prevent it from sliding back

 Loosen hexagon head screws M8 x 25 of guide rollers (illustration 8)

 Turn guide rollers clockwise to the membrane The guide rollers must fit closely to the membranes, but smooth movement must be ensured (illustration 9)

 Tighten hexagon head screws M8 x 25 of guide rollers (illustration 8)

Warning! Disconnect the tool from the line/mains (plug unplugged!) while

doing the component checks described in chapters 6.1 to 6.4!

5.1 Wiring

 Check all wires, leads and cables for mechanical damages

 Check all wires, leads and cables for proper connection (loose contacts), for breaks and short circuits

 Check cable protective tube for cracks or other mechanical damages

 Grey clip (see illustration on the right) must have engaged shortly

Visual inspection

9

8

Main switch

Relay

5 TRN 02-J4  ZPM 05 leads

6 TRN 02-J1-Pin1  Gate Triac

TRN 02-J1-Pin4 & 5  Relay

TRN 02-J1-Pin6 & 7  Terminal

5.3 Power supply cord

Visual inspection, Continuity checker / Buzzer

Replace the power supply cord if it shows a short

cir-cuit, interruption or mechanical damage!

 Do not shorten the power supply cord! If the

cus-tomer did so or if a third-party cord is used, the

power supply cord has to be replaced

5.4 Main switch

1 Set main switch to OFF position

2 Check continuity between L1 and T1  No continuity

3 Check continuity between L2 and T2  No continuity

4 Set main switch to ON position

5 Check continuity between L1 and T1  Must have continuity

6 Check continuity between L2 and T2  Must have continuity

5.5 Triac

If the tool heats (possibly not pulsing) when switching on the main switch before the heating

is turned on, switch the tool off Disconnect the gate connection to the triac (20AWG, red) on the electronic circuit board TRN 02 and switch the tool on again If the performance is still the same, the triac is defective and has to be replaced

5.6 Relay

If the tool does not heat, the relay might be defective To verify this, the relay must be passed Unplug both white leads to the relay and short-circuit them If the tool heats now, the relay must be replaced

by-Caution! The following test procedure sometimes requires the tool

to be connected to the line/mains Insure the tool is disconnected from the line/mains before any work is commenced!

Caution! The following test procedure sometimes requires the tool

to be connected to the line/mains Insure the tool is disconnected from the line/mains before any work is commenced!

short-circuiting

5.7 Electronic circuit board TRN 02

 Check electronic circuit board for scorch marks and expanded/swelled parts

 Check fuse link (T630mA / 250V)

 Between housing and electronic circuit board an insulation paper must be installed

Visual inspection

 Unplug force sensor (if available)

 Switch the tool on and measure the voltage between Pin 1 and Pin 3 of the force

sen-sor terminal by using a voltmeter

 The measured voltage must read approx 4.85VDC

 If no voltage is detected or if its value exceeds the given range essentially, the

Caution: Prior to the replacement of the electronic circuit board TRN 02 check or possibly

replace the electronic circuit board ZPM 05 as well (see following chapter)!

Caution! The following test procedure sometimes requires the tool

to be connected to the line/mains Insure the tool is disconnected from the line/mains before any work is commenced!

1

2

3

5.8 Electronic circuit board ZPM 05

 Check electronic circuit board for scorch marks and expanded/swelled parts

 Between housing and electronic circuit board an insulation paper must be installed (see

 Unplug connector with black, blue and yellow

flex wires

 Measure resistance between black and blue

flex wires by using an ohmmeter

 Resistance value approx 3.2k Ω

 Unplug motor connector, connect diode checker as stated in the table and compare

This check does not serve as a complete test of the electronic circuit board If this test is not successful, check the drive motor (see chapter 6.1)

Pin 1 2 3

5.9 Connect electronic circuit board CSE temporarly

Connect a new (tested) electronic circuit board CSE temporarly, if display or USB recording

do not work

Disconnect ribbon (1) and USB cable (2) and connect new electronic circuit board CSE (3)

5.10 DIP switch on electronic circuit board CSE 06

Check DIP switch settings on electronic circuit board CSE 06:

2

3

1

ON: 2, 4, 7 OFF: 1, 3, 5, 6, 8

6 Drive unit

6.1 Check drive unit

 Check connections of drive motor (illustration 1)

 Disconnect drive motor (illustration 1)

 Connect drive motor to a direct current voltage of 180VDC (illustration 2); if no direct current power supply is available, use a bridge rectifier (i.e B250C1500G) and apply approx 130VAC

 Check current consumption: Nominal value is 80 200mADC (illustration 3)

Ammeter

Following items indicate the drive motor is defective and must be replaced:

 Excessive noise  Bearing defect

 Speed varies at constant direct current voltage (180VDC)

 Carbon brush abraison

 Motor does not turn any more

If the current consumption exceeds 200mA, the motor works with overload!

Possible causes: Chains, gearing or bearing defect

Connect/apply 180VDC

Bridge rectifier Current

6.2 Replacement of drive unit and electronic circuit board DZF 01

 Disconnect socket connectors of drive unit and speed sensor on electornic circuit board

ZPM 05 (illustration 1)

 Remove socket connectors (illustration 2)

 Remove grey clip (illustration 3)

 Extract cable protection tube

 Unwind flex wires

 Push cable protection tube aside and loosen fillister head screw M4 x 10 (illustration 4)

 Extract cog wheel carefully by using a screw driver (illustration 5)

 Prior to reassembling the cog wheel must be cleaned and lubricated

 Loosen countersunk screws M4 x 16 (illustration 6)

 Loosen cheese head screw M6 x 12 in the electronic box (illustration 7)

 Extract drive unit to the left (illustration 8)

 Disassemble electronic circuit board DZF 01 (illustration 9)

 Replace drive unit und reassemble

 Lock all screws shown in illustrations 4, 6 und 9 with Loctite 242 (illustration 10)

8

10

9

7

7 Heater unit

7.1 Check of hot-wedge

Hot-wedge with cheese head screw

Check proper fitting and distance of tow lug cheese head screw Visual inspection

Hot-wedge with tow lug

The hot-wedge of the USB model is equipped with a tow lug (no cheese head screw) fore an appropriate recessed area in the undercarriage is required, Check tow lug and re-

6 – 7 mm

7.2 Temperature check of hot-wedge

Connect tool to rated voltage and set temperature to 420°C

Check temperature of hot-wedge by using a temperature meter, i.e Fluke 52, as shown in the illustration Position temperature probe approx in the middle of the hot-wedge Use ther-

7.3 Check of thermocouple

 Remove thermocouple socket connector

 Check continuity between yellow-green flex wire and jacket of the thermocouple by ing a continuity checker / buzzer; otherwise replace thermocouple

us- Measure thermocouple resistance between the signal lines (green and red) Make sure, thermocouple is cooled down to ambient temperature! Nominal value: approx 3Ω (no short circuit or break)

 Check isolation between both signal lines (green and red) and the shielding Nominal

Thermocouple connector

7.4 Check of heating cartridge

 Do a visal inspection of the hot-wedge

 Disassemble connections of the heating

car-tridges from the terminal

 Measure resistance of the heating cartridges by

using an ohmmeter

 Measure current consumption at rated voltage by

using an ammeter

 Nominal values see table

Visual inspection, Ohmmeter, Ammeter

7.5 Replacement of heating cartridges and therocouple

 Unplug / remove following cables:

Heating cartridge Resistance [Ω] Current consumption [A]