tài liệu sửa chữa máy hàn nhựa leister ( TRIAC BT dv12102009 ENG )

4.3 Power supply cord • Replace the power supply cord if it shows a short circuit, interruption or mechanical da-mage • Check strain relief and terminals Continuity checker / buzzer, vis

REPAIR INSTRUCTIONS

Hot-air tool TRIAC BT

Serial number from 0908260458

© 2009 LEISTER Process Technologies, 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 Process Technologies, CH-6056 Kaegiswil

LEISTER Process Technologies, 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 Electronics 4

4.1 Opening tool 4

4.2 Handle 4

4.3 Power supply cord 5

4.4 Line/mains switch 5

4.5 Wiring 5

4.6 Electronic circuit board HCU 26 6

4.7 Replace electronic circuit board HCU 26 6

5 Motor 9

5.1 Function check 9

5.2 Check carbon brushes 9

5.3 Check commutator 10

5.4 Replace motor 10

5.5 Replace turbines 11

5.6 Cleaning 12

6 Heating element 13

7 Possible causes of trouble 14

8 Wiring diagram 15

9 Test procedure for TRIAC BT (protection class II) 16

10 Equipment required for LEISTER repair service 18

1 Scope of applicability

These repair instructions are reserved exclusively for LEISTER service centres Only experi-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

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

2 Safety precautions

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

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

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 re-quirements

4 Electronics

4.1 Opening tool

Disconnect tool from the line/mains!

Loosen PT fillister head screws KA35x20 (4x)

Remove handle

4.2 Handle

Replace the handle if it is either strongly weared (abraison, mechanical damage) or if the rub-ber is refractory or extremely soaked (adhesive)

4.3 Power supply cord

• Replace the power supply cord if it shows a short circuit, interruption or mechanical da-mage

• Check strain relief and terminals Continuity checker / buzzer, visual inspection

" Notes

• Do not shorten (cut and use again) power supply cords

• If the customer did so or if third party cords are assembled, they are to be replaced

4.4 Line/mains switch

Check line/mains switch: - Position "O": Switch must have no continuity

- Position "I": Switch must have continuity

Continuity checker / buzzer

4.5 Wiring

• Check all flex wires for interruptions, short circuits and mechanical damages

• Check correct wiring (compare with the photo) Visual inspection

4.6 Electronic circuit board HCU 26

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!

• Check electronic circuit boards for visual error indications (scortch marks, exploded or

• Perform function check (see test procedure)

4.7 Replace electronic circuit board HCU 26

Opening of the tool see chapter 4.1

Put turbine housing upper part aside

Make sure the flex wire guide is correctly positioned when assembling

Loosen PT fillister head screws KL30x10 (3x) and remove cover plate

ESD

Remove electronic circuit board

Push flex wires off the brackets

Extract flex wires of the motor from spring terminals by using a screwdriver

Extract power supply cord from the strain relief clamps and remove it by actuating the spring contacts

Remove spring contacts by using a screw-driver and extract them from the guide

Extract electronic circuit board from the terminal

Break the replacement electronic circuit board apart by using flat pliers and dispose connecting pieces

Insert O-ring in potentiometer knob and snap it on the potentiometer

Assemble electronic circuit board in reverse order

Recommended torque for KA35x20 and KL30x10:

Torque: 1.20 Nm Revolution speed: 6501/min

5 Motor

5.1 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!

Connect tool to rated voltage and turn it on Motor must run steadily and its power consump-tion may not exceed 100W Turn the tool off and disconnect it from the line!

Wattmeter

" Notes

• An excessive noise indicates a bearing defect

Î Replace motor (see chapter 5.4)

• A power consumption >100W indicates a commutator defect

Î Replace motor (see chapter 5.4)

• Unsteady noise (irregular movements, loose contact)

Î Check carbon brushes (see chapter 5.2)

5.2 Check 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)

Opening of the tool see chapter 4.1

Carefully bend back the ears of both carbon brush supports

Caution, springs are under tension!

Check length of both carbon brushes

5.3 Check commutator

• Worn out lamella

• Bluish discoloration

• Deep grooves (U-shaped)

Replace the motor if a defect is detected (see chapter 5.4)

5.4 Replace motor

Opening of the tool see chapter 4.1

Push flex wires off the brackets

Extract flex wires of the motor from spring terminals by using a screwdriver and re-move terminal

Connect replacement motor to spring termi-nals and slide the flex wires in the brackets; then connect terminal to the motor

5.5 Replace turbines

The turbines are to be replaced if they are damaged or essentially deformed

Opening of the tool see chapter 4.1

Loosen hexagon nut by using a socket wrench (no 8)

Remove upper turbine by using two screwdrivers

Remove deflector

Make sure the deflector is correctly posi-tioned when assembling

Move the lower turbine to the top; as soon as

it is enough far from the bottom, it may be removed the same way as the upper turbine

Assemble replacement turbines in reverse order

Recommended torque for the hexagon nut: Torque: 0.6 Nm

Revolution speed: 6501/min

After replacement of the turbines a function check of the motor must be performed

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!

Connect flex wires of the motor to rated voltage and check if the turbines do not touch any housing parts If the blower shows real vibrations, disconnect it from rated voltage, loosen nut, turn the upper turbine slightly, tighten nut and check function once again

5.6 Cleaning

Clean the tool!

If the air filters of the handle are defective or missing, they are to be replaced If the air filters are clogged, they are to be cleaned

6 Heating element

Loosen PT fillister head screws KA35x20 (4x) and remove heater tube and mica tube

Heating element and gasket may be re-moved now

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

• Check the heating element by using an ohmmeter Ohmmeter

Voltage [V] Power [W] Resistance [Ω]

7 Possible causes of trouble

Error Possible cause Method of resolution

Unexpected AC power failure Potentiometer illuminates,

motor runs, tool does not

heat

Line/mains switch on position

"I" (ON) when tool connected

to line/mains

Switch the tool off for at least

1 second; then turn it on again

Heating element defective Replace heating element

(chapter 6) Triac defective

Temperature limit switch de-fective

Photo sensor defective

Tool does not heat, motor

runs

LED defective

Replace electronic circuit board (chapter 4.7)

Carbon brushes too short Replace carbon brushes

(chapter 5.2) Commutator defective

Bearing defect

Replace motor (chapter 5.4) Motor does not run

Flex wires of motor incor-rectly connected to spring terminals

Check whether flex wires are properly connected

Potentiometer defective Tool heats at potentiometer

position "0" Triac defective

Replace electronic circuit board (chapter 4.7) Interruption of power supply

cord

Replace power supply cord (chapter 4.3)

Tool does not heat and motor

does not run

Line/mains switch defective Replace line/mains switch

(chapter 4.4) Heating element with

in-curect rated voltage

Replace heating element (chapter 6)

Defective nozzle: Photo sen-sor receives extraneous light Repalce nozzle

Maximum air temperature

can not be reached

Mica tube missing Assemble mica tube Maximum air temperature

exceeded Photo sensor polluted Clean photo sensor

Excessive noise Bearing defect Replace motor (chapter 5.4)

Power consumption of motor

>100W

Commutator defective:

• Worn out lamella

• Bluish discoloration

• Deep grooves (U-shaped)

Replace motor (chapter 5.4)

Unsteady noise (irregular

movement, loose contact)

Carbon brushes too short or blocked

Replace carbon brushes (chapter 5.2)

8 Wiring diagram

9 Test procedure for TRIAC BT (protection class II)

Insulation test

• Function check of the high voltage tester:

Shorten tips Î Signal lamp illuminates and horn sounds

• Set line/mains switch of the tool to position "I" (ON)

• Apply a high voltage of 3000V (release current 100mA) for 1 second between line/mains plug and protection tube of the heating element; no flashover or breakdown must occur

Function test

• Set line/mains switch of the tool to position "I" (ON), turn potentiometer to the right end stop (cw) up to position "9"

• Connect tool to rated voltage (check error recovery) Î Motor runs, potentiometer knob illuminates red, tool must not heat!

• Check power consumption of the motor by using a wattmeter (50 65W)

• Check smooth running of motor (bearings, commutator) and fan (vibrations, particles)

• Turn potentiometer to the left end stop (ccw) up to position "0"

• Set line/mains switch of the tool for at least 1 second to position "O" (OFF) and then to position "I" (ON) Î Motor runs, potentiometer knob is not illuminated, tool does not heat

• Check heating:

Set potentiometer to position "1" Î Tool starts heating

Set potentiometer to position "8" Î Tool heats almost fully

Set potentiometer to position "9" Î Tool heats fully for a short time (rated power)

Ensure power consumption increases steadily between potentiometer positions "1" and

"8" (ammeter, wattmeter)

• Block air outlet, respectively reduce it essentially

Î Electronic circuit must cut the power consumption down (protection of the heating element); with free air outlet the power consumption must increase

• Switch the tool off: Set potentiometer to position "0", let the tool cool down, set line/mains switch to position "O" (OFF) and disconnect the tool from rated voltage

Checking completeness

• Check printed details on the nameplate: Type, voltage, current, power consumption (must correspond with the above measurements)

• Check serial number (yymmddxxxx)

yy year of production

mm month of production

dd day of production

• Warnings must be printed on the handle

• Check power supply cord mechanically and electrically (correct plug type for country, conductor cross-section as per rated current)

• Check nozzle orientation (see photos, keep an eye on the company label!)

• Both air filters must be fitted

• All screws must be tightened

• Check for cleanliness and possible damage

• Shake the tool: Heating element may not hit the heater tube

Additional test for repaired tools

The maximum temperature (potentiometer on position "9") may not exceed the maximum values stated in the table below for all nozzle models

Rated voltage [V] Nozzle Temperature [°C]

Round nozzle ø 5mm 620 700

230

Wide slot nozzle 40mm 550 640 Round nozzle ø 5mm 620 700

120

Wide slot nozzle 40mm 550 640 Correct thermocouple arrangements (thermocouple must not touch the nozzle!):

If the maximum temperature according to the table is exceeded, clean the photo sonsor Should the temperature be below the minimum value, check if the correct heating element (voltage/power) and the mica tube are assembled In addition make sure the photo sensor does not receive extraneous light (e.g due to a hole in the nozzle or in the turbine hous-ing)

1 2mm

5mm

10 Equipment required for LEISTER repair service

Mobile Equipment

• 1 protective earth conductor tester (e.g Elabo)

• 1 high voltage tester up to 4000V (e.g Elabo, Korntal)

• 1 temperature meter with temperature measurement probe (e.g Fluke, Testo)

• 1 multimeter with following measurement options: (e.g Fluke)

- Continuity (test buzzer)

• 1 rotational speed meter

• 1 water column

• 1 soldering iron

• 1 complete set of tools (screw drivers etc.)

Installed equipment

• ESD-protected working environment

• Transformer, possibly separated into variable and isolating transformer

Data: 3 x 0 500V

• 3 built-in voltmeters (500V)

• 3 built-in ammeters (30A) or wattmeters