tài liệu sửa chữa máy hàn nhựa leister (Comet USB e 20100628)

6.1 Opening housing cover Remove cheese head screws M3 x 10 4x of the housing cover and lift cover carefully Remove protective earth connection Models with USB port only: Disconnect 5 p

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

LEISTER Process Technologies, CH-6056 Kaegiswil/Switzerland, Tel +41 41 662 74 74 Fax +41 41 662 74 16

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Table of contents

1 Scope of applicability 3

2 Safety precautions 3

3 Remarks 3

4 Check mechanics 4

5 Assembly and adjustment 5

5.1 Assembly of tension lever (version without force sensor) 6

5.2 Assembly of tension lever (version with force sensor) 7

5.3 Adjustment of hot-wedge and guide rollers 8

5.4 Assembly of guide aids (version for subroofchannel) 9

6 Electronics 11

6.1 Opening housing cover 11

6.2 Power supply cord 11

6.3 Wiring 12

6.4 Main switch 13

6.5 Triac 14

7 Drive unit 14

7.1 Function check 14

7.2 Electronic circuit board STV 02 15

7.3 Power supply 16

7.4 Electronic circuit board ZPM 02 16

7.5 Short circuit test of bridge rectifier on ZPM 02 board 17

7.6 Disassembly of the housing lower part 17

7.7 Check MOSFET on ZPM 02 board 18

7.8 Check carbon brushes 19

7.9 Check drive motor 20

7.10 Replacement of the drive unit 21

8 Check heater unit 23

8.1 Check thermocouple 23

8.2 Check hot-wedge 24

8.3 Function check of heating 24

8.4 Hot-wedge supervision 25

9 Check force sensor and USB port (optional) 26

9.1 Force sensor 26

9.2 USB port 26

10 Setup menu 27

10.1 Setup menu CSE 03 27

10.2 Setup menu CSE 06 without USB port 28

10.3 Setup menu CSE 06 with USB port 29

11 Settings 30

12 Possible causes of trouble 32

13 Wiring diagram 33

14 Test procedure for COMET (protection class I) 34

15 Equipment required for LEISTER repair service 36

16 Appendix screw locking 37

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1 Scope of applicability

These repair instructions are reserved exclusively for LEISTER service centres Only enced and qualified personnel trained by LEISTER Process Technologies, CH-6056 Kaegis-wil, are allowed to do repair work on LEISTER tools Additional national requirements relative

experi-to personnel carrying out repair work are experi-to be observed by each service centre

2 Safety precautions

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

es-3 Remarks

• If it is impossible to repair a tool, it should be returned immediately to the turer, LEISTER Process Technologies, CH-6056 Kaegiswil, Switzerland, carriage paid

manufac-to Kaegiswil LEISTER will repair the manufac-tool within 24 hours after its arrival

• When ordering spare parts use the order numbers of the spare parts list When

servic-ing use only identical original LEISTER replacement parts!

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

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re-4 Check mechanics

• Check smooth movement of eye bolts and set nut: Parts have to be easily turned out any physical effort, otherwise they are to be replaced

with-(Overload: maximum pressure = 1000N = 225lbs)

• Check undercarriage for cracks and deformations

• Check roller chains and sprocket wheels and replace them if necessary

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

• Clean all polluted parts

• Lubricate all moving parts with unpolluted grease, chains with chain oil

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

Lubricate guide bar with teflon spray (e.g Fin Lube Tf)

Duplex roller chain and sprocket wheels in the tower

Roller chain and sprocket wheels in the tension arm Lubricate axle of downholder rollers with high-temperature grease, e.g Molykote P-74

Roller chain and sprocket wheels in the undercarriage

Pivot point of tension arm

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5 Assembly and adjustment

The assembling has to be carried out according to the exploded diagrams and the spare parts lists

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

• Assemble chains and apply chain oil Ensure that the closed end of the chain’s master link is installed in rotation direction

• Center the roller with set screws Then, loosen one set screw for ¼ rotation and fix both set screws by using the lock nuts

• When installing the swivel head, screw-in the set screw at least flush and equalize so that the swivel head is parallel to the tension arm

• To fix the tension arm, screw-in the set screw completely, loosen for ½ rotation and tighten it with lock nuts

• Ensure which screws are to be locked by using Loctite 242 prior to the tool sembly or its components Therefore the appendix (chapter 16) contains exploded diagrams highlighting all screws to be locked

as-• When using the machine under hard conditions and over a long time, the chains should be replaced as a precaution

• If torn chains or broken teeth of the sprocket wheels are detected, check the shafts for concentric running and replace them if necessary

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5.1 Assembly of tension lever (version without force sensor)

Tighten the tension lever attachment screw in such a way, that smooth actuating is possible, but the tension lever remains stable in all posi-tions

Screw the set nut between position 5 and 6 on the eye bolt threaded on the left and turn one rotation to position 6; check whether it is fixed Then turn three rotations and three numbers further

Attach the eye bolt threaded on the right and turn it to the top

Adjust tension lever top limiting screw to a length of 15mm; fix by lock nut

Adjust lower limiting screw so that the tension lever stops proximately after locking

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5.2 Assembly of tension lever (version with force sensor)

Tighten the tension lever attachment screw in such a way, that smooth actuating is possible, but the tension lever remains stable in all posi-tions

Attach force sensor to the eye bolt threaded on the right and turn in to the end stop

Adjust tension lever top limiting screw to a length

of 15mm; fix by lock nut

Adjust lower limiting screw so that the tension lever stops proximately after locking

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5.3 Adjustment of hot-wedge and guide rollers

Hot-wedges with 2 cartridges

Adjust eccentric of guide roller to bottom left of the undercarriage Distance to the floor is equal

to the tape thickness plus 1mm

Hot-wedges with 3 or 4 cartridges

Center the guide roller, farther from the drive roller, with the undercarriage, horizontally in di-rection of the pressure roller

Insert two pieces of the tape to be welded Set pressure force to zero If the material is un-known, the adjustment is made with PE 2.5mm Tension with 1000N

Having a hot-wedge with 3 or 4 cartridges the guide roller, located closer to the drive rollers, must be moved clockwise to the tape and has to

be fixed in such a way, that both guide rollers have the same smooth running

2 cartridges

3 and 4 cartridges

1/3 2/3

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5.4 Assembly of guide aids (version for subroofchannel)

Setup menu settings (see chapter 10)

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" Note

• Observe markings on drive roller end pins pos 61 for correct directional stability!

Marking in welding directionMarking against welding direction

Top viewWelding direction

Detail on the right

Detail on the left

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6 Electronics

Warning! Disconnect the tool from the line/mains (plug unplugged) while doing the component checks described in this chapter!

6.1 Opening housing cover

Remove cheese head screws M3 x 10 (4x)

of the housing cover and lift cover carefully Remove protective earth connection

Models with USB port only:

Disconnect 5 poles cable of the USB port Disconnect 14 poles ribbon cable of the electronic circuit board CSE 06

Housing cover may be removed now

6.2 Power supply cord

Replace the power supply cord if it shows a short circuit, interruption or mechanical damage

Continuity checker / Buzzer, visual inspection

• Do not shorten the power supply cord! If the customer did so or if a third-party cord

is used, the power supply cord has to be replaced

• Check carefully the protective earth conductor for continuity

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6.3 Wiring

Opening of the housing cover see chapter 6.1

• Check all wires, leads and cables for mechanical damages

• Check all wires, leads and cables for proper connection (loose contacts), for breaks and

1 Force sensor (optional)

2 Drive unit

3 Dummy plug

4 Thermocouple

Red Green Shielding

1 yellow-green Heating cartridges

2 grey Heating cartridges

20AWG from STV 02 20AWG from power supply

3 white * 20AWG from STV 02

20AWG from power supply

* yellow for 120V-tools

4 black Heating cartridges

5 brown 1mm2 from triac

6 black 1mm2 from Triac

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• Check cable protection tube for cracks, gaps and mechanical damages

Visual inspection

6.4 Main switch

Position OFF Switch must have no continuity

Position ON Switch must have continuity

Grey clip must have engaged shortly

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6.5 Triac

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!

If the tool heats (possibly not pulsing) when switching on the

main switch before the heating is turned on, switch the tool off

Unplug the gate connection to the triac from the electronic circuit

board STV 02 and switch the tool on again If the performance is

still the same, the triac is defective and has to be replaced

7 Drive unit

7.1 Function check

1 Switch the tool off and disconnect it from the line/mains

(plug unplugged)

2 Connect an ammeter between the center terminal of

the main switch and the black flex wire 20AWG of the

electronic circuit board STV 02

3 Connect the tool to line/mains and switch it on

4 Set the motor speed to maximum

5 The current consumption must be 100 300mA

Ammeter

• An excessive noise of the motor indicates a bearing defect

Î Replace drive unit (see chapter 7.10)

• If the current consumption exceeds 300mA, the motor works with overload!

Possible causes:

- Defective chains, gearing or bearing

- Invalid settings of I-Gain or I-Offset

- Defective electronic circuit board CSE

Black flex wire

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7.2 Electronic circuit board STV 02

Check electronic circuit boards for visual error indications:

• Scorch marks, exploded parts

• Expanded/swelled parts (e.g blue choke)

• Between the housing and the electronic circuit board STV 02 an insulation paper must

be installed as well as distance bushings ø 3.1/6 x 2.5 (2x) Visual inspection

If the drive motor does not start, the electronic circuit STV 02 must be checked applying

• Disconnect power supply of the electronic circuit ZPM 02 (white 2 poles connector)

• Line/mains voltage must appear at the white connector of the electronic circuit board

STV 02

If no line/mains voltage is detected, first check the electronic circuit board ZPM 02

(see chapter 7.4) and afterwards replace the electronic circuit board STV 02

Power supply

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7.3 Power supply

If the display remains dark after switching on the main switch, check the electronic circuit

board TRN 05 applying appropriate line/mains voltage (according to nameplate): Voltmeter

• Remove white dummy plug of the power supply’s spare line

• Connect power supply test board

• A voltage of 5VDC (±0.2V) must be measured (test duration 15 minutes)

7.4 Electronic circuit board ZPM 02

Check the electronic circuit board ZPM 06 (e.g in case of overvoltage indication, if a tool was possibly connected to 400V):

230V-Dummy plug

Power supply test board

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7.5 Short circuit test of bridge rectifier on ZPM 02 board

Connect a continuity checker/buzzer to both contacts of the white plug (see photo) If ity is detected, the electronic circuit board ZPM 02 is defective Before doing the replacement

continu-of the electronic circuit check the drive motor (see chapter 7.9) Continuity checker / Buzzer

To continue testing of the electronic circuit board ZPM 02 the lower part of the housing must

be removed

7.6 Disassembly of the housing lower part

Loosen screw fitting of the cable tion tube

protec-Disconnect all connections of the wedge

hot-Disconnect plug of the force sensor, if available

Loosen hexagon head screws M6 x 16 (2x)

Loosen hexagon socket head cap screws M4 x 12 (2x) of the drive unit Disconnect 6 poles ribbon cable be-tween drive unit and STV 02 board Unplug white plug of STV 02 board Carefully extract the housing lower part off the drive unit

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7.7 Check MOSFET on ZPM 02 board

Disassembly of the housing lower parts see chapter 7.6

Desolder red-white flex wire to the lower carbon brush holder of the motor Connect a meter as a diode checker between the desoldered flex wire and the upper carbon brush holder (white flex wire) Connect test terminals according to the table stated below and verify

Upper carbon brush holder Red-white flex wire Results

(This check does not serve as a complete test of the electronic circuit board)

If this test is not successful, check the drive motor first (see chapter 7.9) and then replace the electronic ciruit board ZPM 02

• The connectors of the ribbon cable must be sealed by

using silicone rubber

• After replacement of the electronic circuit board enter the

values I-Offset and I-Gain (according to the tag fixed to

the ribbon cable) by using the setup menu

Setup menu see chapter 10

upper carbon brush holder red-white flex wire

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7.8 Check carbon brushes

Disassembly of the housing lower parts see chapter 7.6

Carefully bend back the ears of both carbon brush supports Caution, springs are under tension!

Check length of both carbon brushes

Replace the carbon brushes if their length measure 4mm or even less Check both carbon brushes! If the carbon brushes are not to be replaced make sure to re-insert them the same way (abraison)

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