tài liệu sửa chữa máy hàn nhựa leister ( EXAMO dv07122009 ENG)

6.2 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 contact

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REPAIR INSTRUCTIONS

Tensiometer EXAMO

Production code from 0017

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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1 Scope of applicability 3

2 Safety precautions 3

3 Remarks 3

4 Check mechanics 4

5 Assembly and adjustment 5

5.1 Drive distance adjustment 5

5.2 Safety clutch 6

5.3 Force sensor 7

6 Electronics 8

6.1 Opening housing cover 8

6.2 Wiring 9

6.3 Line/mains filter 10

6.4 Main switch 10

7 Drive unit 11

7.1 Function check 11

7.2 Electronic circuit board STV 03 12

7.3 Power supply TRN 01 13

7.4 Electronic circuit board ZPM 02 14

7.5 Disassembly of the housing lower part 16

7.6 Check carbon brushes 17

7.7 Check drive motor 18

7.8 Disassembly of the drive unit 19

7.9 Replacement of the motor 20

7.10 Replacement of the force sensor 21

7.11 Replacement of the inductive proximity switch 22

7.12 Assembly of the drive unit 23

7.13 Replacement of the mandrel 25

8 Force measurement, display and recording 26

8.1 Force sensor 26

8.2 Electronic circuit board CSE 26

8.3 USB recording (optional) 27

9 Setup menu 28

9.1 Electronic circuit board CSE 03 28

9.2 Electronic circuit board CSE 06 29

10 Settings 30

11 Possible causes of trouble 31

12 Wiring diagram 32

13 Test procedure for EXAMO (protection class I) 33

14 Equipment required for LEISTER repair service 35

15 Verification and calibration kit 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 manufacturer,

LEISTER Process Technologies, 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

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re-4 Check mechanics

• Check smooth movement of slide and tension levers, respectively clamping jaws

• Check mandrel for concentricity

• Check clamping jaws for abraison, replace them if necessary

• Check safety clutch, slide must release manually

• Clean all polluted parts

• Lubricate all moving parts with unpolluted grease

Lubricate these parts with grease (e.g GBUY 131):

Mandrel and guide bars

Tension levers (all movable wear points) and threads of tension shafts

Sintered bearing (shaft extension) Loosen countersunk screws M3 x 12 (4x), open cover

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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 there are no other particles than the essential grease inside the mandrel

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

5.1 Drive distance adjustment

• Check distance at 50mm length of run

• Adjust zero position by using set screw if deviant

• Check distance at 50mm and 130mm length of run each

• Lock set screw by counternut

• The deviation may also be adjusted in the setup menu (chapter 9) using menu item

"Offset length"

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5.2 Safety clutch

For safety reasons the movable slide is equipped with a safety srew (safety clutch) It acts due to too high counterforce, and the slide will be decoupled from the drive mandrel This prevents finger or hand pinch while the slide reverses

Safety screw

Check of safety screw:

The slide must get decoupled without ing essential force, but not of its own during regular slide reverse!

apply-The torque is specified by construction and may not be altered

CAUTION:

If defective DO NOT replace the fety screw by a standard screw – for safety reasons use original LEISTER safety screw only!!!

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sa-5.3 Force sensor

The set screw M10 x 16 actuates the force sensor Do not tighten this set screw too strong, because then the force sensor may indicate a force with no load On the other hand do not tighten the set screw too weak, because of the clearance Support must remain slightly mo-vable (testing by hand)!

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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

Loosen hexagon nuts M6/0.8d (4x) and cheese head screws M6 x 12 (4x) on the bottom part of the metal case

Lift tensiometer out of the metal case

Remove cheese head screws M3 x

8 (4x) of the housing cover and carefully lift the cover

Unplug ribbon cable of the electronic circuit board STV 03 and protective earth connection to the upper part of the electronic box

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6.2 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 – 230V, 200V, 120V (ø 20AWG): Grey from STV 03

Grey from power supply

2 – 230V (ø 20AWG):

White from STV 03 White from power supply

2 – 200V (ø 20AWG):

Violet from STV 03 Violet from Power supply

2 – 120V (ø 20AWG):

Yellow from STV 03 Yellow from power supply Inductive proximity switch

Brown Black Blue Force sensor

Red Yellow White with shielding

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6.3 Line/mains filter

Check continuity of the line/mains filter from input terminal to opposite output terminal (check

6.4 Main switch

Check continuity of the main switch

by using a continuity checker / buzzer

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7 Drive unit

7.1 Function check

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!

Switch the tool off and disconnect it from the line/mains (plug unplugged)

Connect an ammeter between the ter terminal of the main switch and the flex wire 20AWG of the electronic circuit board STV 03 (color depends on rated voltage)

cen-230V: White 200V: Violet 120V: Yellow

Connect the tool to rated voltage and turn it on

Initialize and press button fast mode to the right

The current consumption must be 100 300mA

• An excessive noise of the motor indicates a bearing defect

Ä Replace motor (see chapter 7.9)

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

Ä Possible causes: Defective gearing, blocked bearing, mandrel highly bent

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7.2 Electronic circuit board STV 03

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 03 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 03 must be checked applying

• Disconnect power supply of the electronic circuit board ZPM 02 (unplug white 6-poles

plug)

• Line/mains voltage must appear at the two terminals on the right Caution: Avoid short

circuit of the voltmeter probe tips!

• 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 03

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7.3 Power supply TRN 01

If the display remains dark after switching on the main switch, check the power supply

• 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)

Dummy plug

Power supply test board

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7.4 Electronic circuit board ZPM 02

Check the electronic circuit board ZPM 02 (e.g in case of overvoltage indication, if a tool was possibly connected to 400V):

230V-7.4.1 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 board check the drive motor (see chapter 7.7)

Continuity checker / Buzzer

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7.4.2 Check MOSFET on ZPM 02 board

Connect a multimeter as a diode checker between the green and the grey flex wires of the white 6-poles plug Connect probe tips according to the table stated below and verify the re-

Green flex wire Grey flex wire Results

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

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

be removed (see chapter 7.5)

Check drive motor (see chapter 7.7) and, if the motor is ok, replace the electronic circuit 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 on the ribbon cable) by using the setup menu

Setup menu see chapter 9

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7.5 Disassembly of the housing lower part

With the exception of the power supply loosen and unplug all connectors to the electronic circuit board STV 03

Loosen hexagon head screws M6 x 16 (2x) and hexagon socket head cap screws M4 x 12 (2x) of the drive unit

Carefully extract the housing lower part off the drive unit

Hint:

Secure the upper hexagon head screw M6 x 16 with a nut M6 after removal of the housing lower part

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7.6 Check carbon brushes

Disassembly of the housing lower parts see chapter 7.5

Carefully bend back the ears of both carbon brush supports; do not harm the varistor

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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7.7 Check drive motor

Caution! The following measurement 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!

Visual check of commutator:

• Worn out lamella

• Bluish discoloration

Measure the resistance between the carbon brush holders by using an ohmmeter (see photo) Turn the commutator slowly by hand and check all lamella The resistance must be 50 100Ω per segment Otherwise replace the motor (see chapter 7.8)

Ohmmeter

Connect a bridge rectifier to both carbon brush supports (see picture on the left) Apply age by using a transformer and an ammeter Check for correct polarity Slowly increase the voltage from 0V and check the current consumption If the current consumption exceeds 100mA at a voltage of less than 10V, either the gear or the motor are defective Î remove

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7.8 Disassembly of the drive unit

Slide must be positioned at least 10cm off the central support!

Loosen cheese head screws M4 x 40 (4x) next to the force sonsor cover and remove cover

The central support may be moved now

Loosen hexagon socket head cap screws M4 x 12 (2x) and remove green attachment flange

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Carefully remove motor Keep an eye on the two cables – do not pull too strongly!

7.9 Replacement of the motor

Disassembly of the drive unit see chapter 7.8

Remove the cable tie and both green socket connectors, extract the cables off the guid-ance and replace the motor

Assembly a replacement motor in reverse order: Insert cables through the guidance, fix

a cable tie and connect the socket tors accurately (see chapter 6.2)

connec-Assembling according to chapter 7.12

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7.10 Replacement of the force sensor

Remove cable tie and green plug of the force sensor cable Extract cable off the guidance of the motor

The force sensor is freely supported and may be removed without any effort

Keep an eye on the two lobes of the force sensor during replacement They have to be

in line with the appropriate stud holes of the central support Otherwise the force sensor does not fit properly, and this could cause measurement errors

Assembly according to chapter 7.12

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7.11 Replacement of the inductive proximity switch

Remove cable tie and green plug of the ductive proximity switch Extract cable off the guidance of the motor

in-Loosen cheese head screws M3 x 8 (2x) and replace inductive proximity switch

Assemble replacement proximity switch and tighten the screws slightly, so that it still could be moved

For correct adjustment of the position a ler gauge 0.5mm is required

fee-Push the pin from the rear into the housing and adjust the distance to the inductive proximity switch by using the feeler gauge Assembly according to chapter 7.12 Feeler gauge

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