tài liệu sửa chữa máy hàn nhựa leister ( LHS 15 to 6120130412 ENG )

 Heater tube Difference in length between S- and L-types  Mica tube Difference in length between S- and L-types  Heating element Differences in length, voltage and power consumption 

REPAIR INSTRUCTIONS

Serial number from 101120

CLASSIC / PREMIUM / SYSTEM

© 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

1 Scope of applicability 3

2 Safety precautions 3

3 Remarks 3

4 Conversion instructions 4

5 Repair instructions 5

5.1 Check internal wiring 5

5.2 Check components 5

5.3 Check heating element 6

5.4 Check leakage current circuitry 7

5.5 Check temperature sensor (LHS 61S/L) 8

5.6 Replacement of temperature sensor (LHS 61S/L) 8

5.7 Check thermocouple (SYSTEM models) 10

5.8 Replacement of thermocouple (SYSTEM models) 11

5.9 Replacement of electronic circuit board 13

5.10 Check display electronics (SYSTEM models) 16

5.11 Replacement of cover with display electronics (SYSTEM models) 16

5.12 Check power controllers (triacs) 17

5.13 Replacement of power controllers (triacs) 17

6 Final assembly 18

6.1 Final assembly LHS 15 18

6.2 Final assembly LHS 21S/L 19

6.3 Final assembly LHS 41S/L 19

6.4 Final assembly LHS 61S/L 20

7 Test procedure 21

8 Test instructions 23

8.1 LHS Field Tester description 23

8.2 LHS Field Tester start of operation 24

8.3 Check leakage current protection circuitry 24

8.4 Check communication interface (SYSTEM models) 29

8.5 Check potentiometer mode (SYSTEM models) 32

8.6 Check closed loop interface mode (SYSTEM models) 33

9 DIP switch and operating mode (SYSTEM models) 35

10 Error messages 36

11 Table heating elements: Resistances / Load resistors 37

11.1 Heating elements LHS 15 37

11.2 Heating elements LHS 21S/L 37

11.3 Heating elements LHS 41S/L 37

11.4 Heating elements LHS 61S/L 37

12 Wiring diagrams 38

12.1 LHS 15 and LHS 21S/L (CLASSIC / PREMIUM / SYSTEM) 38

12.2 LHS 41S/L (CLASSIC / PREMIUM / SYSTEM) 39

12.3 LHS 61S/L three-phase (CLASSIC / PREMIUM / SYSTEM) 40

12.4 LHS 61S/L one-phase (CLASSIC / PREMIUM / SYSTEM) 41

13 Equipment required for Leister repair service 43

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 ESD-protected working place according to chapter 13 (page 43) "Equipment required for Leister repair service") is essential for doing qualified work For safety reasons use only identical original Leister replacement parts for each type of tools 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 servicing use only identical original Leister replacement parts!

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

without using a tool, some life parts could appear Its contact can cause

dan-ger to life! Insure tool is disconnected from the line/mains on every pole

be-fore any work is commenced!

Repaired tools must pass the Leister test procedure – see chapter 7 (page 21) – and any additional local requirements Check with your local Statutory Authority for testing requirements

4 Conversion instructions

Make sure the correct spare parts will be assembled according to the heater type!

 Heater tube Difference in length between S- and L-types

 Mica tube Difference in length between S- and L-types

 Heating element Differences in length, voltage and power consumption

 Thermocouple For SYSTEM models only

 Nameplate Differences in type designation, voltage and power consumption

 Load resistor According to table chapter 11 (page 37)

Never assemble a short mica tube of the S-type in a L-type heater, because the insulation distances would not be kept anymore and danger to life would occur for the users!

If a conversion of a heater is carried out (e.g other power consumption), the heater has to pass the test procedure chapter 7 (page 21) – according to the new type – suc- cessfully! The nameplate must agree with type designation, voltage, current and pow-

er consumption

Note: The following repair instructions are understood so, that the repair work is carried out

in a service center, which means that the tool is removed from an existing equipment

5.1 Check internal wiring

Heater and possible additional control units are to be disconnected from the line/mains on every pole! Remove housing cover, heater tube and mica tube and pull out the heating ele-ment from its socket Check visually, mechanically and electrically all of the soldering joints and the wiring in the housing Visual inspection/Continuity checker/Buzzer

5.2 Check components

All components have to be checked visually Replace defective parts and clean up the other

41L

41S

41L

5.3 Check heating element

Measure the resistance of the heating element coils between pins N, L1, L2 and L3 by using

an ohmmeter Replace the heating element if the measured resistance deviates more than +/- 10% of the value stated in the tables from chapter 11 (page 37) Ohmmeter

Make a visual inspection of the heating element Replace the heating element if it is either mechanically damaged or if any heating channels are clogged Visual inspection

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page21) )!

N/L2 L1

LHS 41S/L

N L1

5.4 Check leakage current circuitry

5.4.1 Heating element

Check leakage current pin for continuity (must have continuity) Continuity checker/Buzzer

5.4.2 Electronic leakage current protection circuitry

The electronic leakage current circuitry must be tested according to chapter 8.3 (page 24)

N L1

Leakage current pin

5.5 Check temperature sensor (LHS 61S/L)

Pull the red and the blue flex wire of the temperature sensor out of the terminal strip by using

a slotted screw driver and connect it to a multimeter (position “diode check”) Ensure correct

5.6 Replacement of temperature sensor (LHS 61S/L)

Carry out the disassembling as follows:

 Remove cover attachment screws

 Remove heater tube attachment screws

 Access to terminal strip is possible now

 Pull the red and the blue flex wire out of the terminal strip by using a slotted screw driver

 Pull the temperature sensor including the flex wires carefully out of the socket by ing tweezers

+ - Diode voltage approx 0.5-0.6V

- + No diode voltage

Measuring diode voltage of temperature sensor

For assembling go reverse order (temperature sensor is supplied including flexible wires) Insert temperature sensor carefully in the socket and ensure correct placement according to the color code Twist the flexible wires!

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

5.7 Check thermocouple (SYSTEM models)

Pull the white and the green flex wire of the thermocouple out of the terminal strip by using a slotted screw driver and connect thermocouple to an ohmmeter (white flex wire  negative pole; green flex wire  positive pole) Cool thermocouple down to room temperature

Nominal value: approx 5Ω (no short circuit and no break may occur) Ohmmeter

Check sufficient insulation between both signal lines (green and white) and thermocouple

5.8 Replacement of thermocouple (SYSTEM models)

Carry out the disassembling as follows:

 Remove heater tube attachment screws

 Remove heater tube, mica tube and heating element

 Remove cover attachment screws

 Access to terminal strip is possible now

 Pull white and green flex wires out of the terminal strip by using a slotted srew driver

 Thermocouple including flex wires may be removed from its support now

For assembling go reverse order Insert thermocouple carefully to its support

Connect flex wires to terminal strip Keep an eye on correct color scheme LHS 21

Thermocouple tip must protrude from heating element for min 15mm

If the thermocouple of heater type LHS 61S/L must be replaced the electronic circuit board has to be removed as well Otherwise it would not be possible to extract the thermocouple (see illustrations below)

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

min 15mm

5.9 Replacement of electronic circuit board

After replacement of the electronic circuit board an appropriate load resistor must be bled to the terminal strip of the electronic circuit board The specific load resistor value de-pends on the heating element and is given in the table of chapter 11 (page 37)

assem-Important: The load resistors are available as a set under article no 143.222 and are to be

ordered separately The air heater does not heat if no load resistor is assembled!

After replacement of the electronic circuit board the air heater must be labelled with the propriate nameplate All nameplates are available as spare parts and could be ordered ac-cording to the Leister spare parts lists

ap-5.9.1 Electronic circuit board LHS 15, 21S/L and 41S/L

The electronic circuit is integrated in the housing by using silicone potting compound and has

to be replaced completely with the housing (delivery as spare part without cable glands) Proceed as follows after replacement:

 Do NOT connect LHS air heater to rated voltage

 Select and assemble load resistor according to table of chapter 11 (page 37)

 For SYSTEM models only: Connect thermocouple to terminal strip according to

chapter 5.8 (page 11)

 Assemble heating element, mica tube and heater tube

 Label housing of the air heater with the appropriate spare part nameplate (type, voltage and power ratings must correspond with the tool)

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

LHS 21S/L LHS 15

Load resistor

LHS 41S/L

Load resistor Load resistor

Load resistor bent for terminal strip

Shorten load

resistor

13mm

5.9.2 Electronic circuit board LHS 61S/L

 Remove flex wires of temperature sensor (blue and red) from terminal strip

 Remove flex wires to heating element (black, red and white) from terminal strip

 Remove flex wires to triac gates (red and black) from terminal strip (models PREMIUM and SYSTEM)

 Remove flex wires of thermocouple (green and white) from terminal strip (models SYSTEM)

 Remove attachment screws of the electronic circuit board

 Displace the electronic circuit board sidewise

 Unplug contact pins to heating element

 Replace electronic circuit board, assemble and connect in reverse order

 Important: Ensure the insulating paper is inserted between electronic circuit board and housing

Remove all flex wires from their terminal strips

black red brown White Insulating paper

Cable of thermocouple

Flex wires to temperature sensor

Flex wires to heating element

Flex wires to triac gates

Caution: If the flex wires to the triac gates (red / black) are mixed up, the electronic circuit will be destroyed!

After replacemant oft he electronic circuit board proceed as follows:

 Do NOT connect LHS to rated voltage

 Select load resistor according to table in chapter 11 (page 37) and insert it

 For models SYSTEM only: Connect thermocouple according to chapter 5.8 (page 11)

to terminal strip

 Plug in heating element, assemble mica tube and heater tube

 Affix appropriate spare part nameplate to housing (type, voltage and power tion must correspond with the tool ratings)

consump-After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

LHS 61S/L Load resistor red

black

5.10 Check display electronics (SYSTEM models)

There are several roots for a defective display (display, electronic circuit board HCU …, ternal wiring) Doing the following checks the defect may be localised:

in-1 Check, whether connector of ribbon cable fits properly to display cover

Remark: Unplug connector of ribbon cable carefully and evenly when disassembling

2 If the tool works with a replacement display, replace the display Replace housing cover with built-in display according to chapter 5.11 (page 16)

Warning: Doing this check the tool is connected to line/mains voltage!

3 If the tool works with a replacement electronic circuit board HCU …, the electronic circuit board HCU … may be defective Replace electronic circuit board according to chapter 5.9

(page 13).

Warning: Doing this check the tool is connected to line/mains voltage!

5.11 Replacement of cover with display electronics (SYSTEM models)

The display electronics is integrated in the housing cover using silicone potting compound and has to be replaced completely with the housing cover

 Unplug 16 poles socket connector (red) from display electronics in housing cover

 Plug socket connector of ribbon cable to replacement display electronics; pay attention

to pilot pin

Plug socket connector to replacement electronics Unplug socket connector with

ribbon cable

Pilot pin

5.12 Check power controllers (triacs)

5.12.1 LHS 15, 21S/L and 41S/L PREMIUM / SYSTEM

No check possible, because triac is assembled in the electronic circuit board

+ : Red probe tip (terminal plus pole)

- : Black probe tip (terminal minus pole)

5.13 Replacement of power controllers (triacs)

5.13.1 LHS 15, 21S/L and 41S/L PREMIUM / SYSTEM

The power controller (triac) is assembled in the electronic circuit board The electronic circuit board must be replaced according to chapter 5.9 (page 13)

5.13.2 LHS 61S/L PREMIUM / SYSTEM

 Remove the electronic circuit board, unplug flexible wires

 Remove attachment screws of power controller (triac)

 Cover bottom side of power controller (triac) with thermal conducting paste

 Replace power controller (triac) and connect flexible wires

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

6 Final assembly

Note:

The handling with thread forming screws bears the challenge not to „miscut“ the thread fore fastening turn the screws slightly counter-clockwise (ccw) untill they fit in the thread, and then tighten clockwise (cw)

Be-No 1 Thread forming screws

for metals

No 2 Thread forming screws

for plastics

6.1 Final assembly LHS 15

The illustration shows model SYSTEM as an example

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

1

LHS 15

2

6.2 Final assembly LHS 21S/L

The illustration shows model SYSTEM as an example

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

6.3 Final assembly LHS 41S/L

The illustration shows model SYSTEM as an example

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

LHS 21

LHS 41

6.4 Final assembly LHS 61S/L

The illustration shows model SYSTEM as an example

LHS 61

After doing repair work each heater has to pass a final check

(see test procedure chapter 7 (page 21) )!

7 Test procedure

Protective earth conductor test (type LHS 61 only)

 Measure the resistance between the attachment screw of the heater tube and the ing/grounding terminal by using the protective earth conductor tester (< 0.1Ω; if the heater is tested with a power supply cord, the resistance between the attachment screw

earth-of the heater tube and the earthing/grounding conductor may be < 0.2Ω)

Insulation test

 Check correct functioning of the high voltage tester

Shorten tips  signal-lamp and horn

 LHS 15, 21 and 41: Apply a test voltage of 3000V (release current < 30mA) for 1 ond between the line/mains terminal and accessible metal parts; there must be no flashover or breakdown

sec- LHS 61: Apply a test voltage of 1000V (release current < 30mA) for 1 second between the line/mains terminal and accessible metal parts; there must be no flashover or breakdown

Test of leackage current circuitry

 Procedure see chapter 8.3 (page 24)