tài liệu sửa chữa máy hàn nhựa leister ( UNIROOF e dv28052009 ENG )

Disassemble guide bar support: - Lock swivel roller by using multigrip pliers protect pliers with scraped plastic material, a rag or similar to avoid damage of the swivel roller - Loose

© 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 Mechanics check 4

5 Assembly and adjustment 5

5.1 Nozzle 5

5.2 Transportation lock for hot-air blower (Ghibli) 5

5.3 Automatic drive start-up 6

6 Electronics 6

6.1 Cover 6

6.2 Power supply cord 7

6.3 Wiring 8

6.4 Main switch 9

6.5 Automatic drive start-up 9

6.6 Triac 9

7 Drive unit 10

7.1 Function check 10

7.2 Electronic circuit TRN 05 11

7.3 Electronic circuit ZPM 06 12

7.4 Carbon brushes 15

7.5 Drive motor check 16

7.6 Drive motor replacement 17

7.7 Housing assembly 19

8 Hot-air blower (Ghibli) 19

8.1 Disassembly 19

8.2 Wiring 21

8.3 Heating element 21

8.4 Thermocouple 22

8.5 Blower motor 24

8.6 Assembly 24

9 Setup menu 25

10 Possible causes of errors 26

11 Wiring diagram 27

12 Test procedure for UNIROOF E (protection class I) 28

13 Equipment required for LEISTER repair service 30

14 Appendix screw locking 31

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 ESD-protected working place (see "Equipment required for LEISTER repair service") is essentiel for doing qualified work For safety reasons use only identical original LEISTER replacement parts for each type of tool when servicing

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

cau-se danger to life! Insure tool is disconnected (unplugged) from the

line/mains on every pole before any work is commenced!

Repaired tools must pass the LEISTER test procedure (see "Test

proce-dure") and any additional local requirements Check with your local tory Authority for testing requirements

Statu-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 giswil LEISTER will repair the tool within 24 hours after its arrival

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

servi-cing use only identical original LEISTER replacement parts!

4 Mechanics check

• Check undercarriage for cracks and deformations Visual inspection

• Check silicon rubber rings for possible damages

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

• Clean all polluted parts

• Lubricate all moving parts with unpolluted grease

The following parts are to be lubricated with grease (e.g Microlube GBUY 131):

Round toothed rack

Between tool holder and guide roller

Ball bearing of swivel roller

5 Assembly and adjustment

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

Before assembling the tool or its components check which screws are to be locked by using Loctite 242 Therefore the appendix contains an exploded diagram highlighting all screws to be locked

5.1 Nozzle

Check basic nozzle adjustment according to the illustration stated below Visual inspection

5.2 Transportation lock for hot-air blower (Ghibli)

The ball pressure screw must hold the Ghibli securely in the rest position

The distance between ball pressure screw and tool holder has to be approx 0.4 mm

5.3 Automatic drive start-up

Set bolt of the automatic drive start-up must

be moveable against little resistance Check whether the set bolt is bent

Set bolt of drive switch must protude 22mm (see lower picture on the left)

Set bolt must not be lubricated because it glides on teflon

Disassemble guide bar support:

- Lock swivel roller by using multigrip pliers (protect pliers with scraped plastic material, a rag or similar to

avoid damage of the swivel roller)

- Loosen cheese head screw M6x25

Loosen screws M4x10 to the cover (2x) Open cover

6.2 Power supply cord

Replace the power supply cord, if it shows a short circuit, a break 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

6.3 Wiring

• Check all connections (wires, leads and cables) for mechanical damage

• Check whether all wires, leads and cables are connected correctly (loose contact) and

do not show any interruptions or short circuits

Continuity checker/Buzzer, visual inspection

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

Visual inspection

Grey clip must have engaged shortly

6.4 Main switch

Check main switch - position 0: Switch must have no continuity

- position 1: Switch must have continuity Continuity checker/Buzzer

6.5 Automatic drive start-up

Check electric contact

- Drive switch not actuated: Switch must have no continuity

- Drive switch actuated: Switch must have continuity Continuity checker/Buzzer

The middle contact may not be connected!

6.6 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 (red flex wire) and switch the tool on again If the performance is still the same, the triac is defective

7 Drive unit

7.1 Function check

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!

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

2 Connect an ammeter between the orange plug and the black flex wire of the drive motor (see picture on the left)

3 Connect tool to line/mains and switch it on

4 Set motor speed to maximum (5m/min)

5 The current consumption must be 100 300mA Ammeter

• An excessive noise of the motor indicates a bearing defect

Î Replace motor (see chapter 7.6)

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

Possible causes: Pressure roller touches the housing or defective gearing

7.2 Electronic circuit TRN 05

Check electronic circuit boards for visual error indications:

• Scorch marks, exploded parts

• Expanded/swelled parts (e.g transformer)

• An insulation paper must be installed between housing and electronic circuit TRN 05

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!

If the display remains dark after switching on the main switch, check the electronic circuit TRN 05 applying appropriate line/mains voltage (according to nameplate): Voltmeter

• The voltage measured at the white 2-poles terminals must be 5VDC (+/- 0.2V); use the free terminal for measuring (see picture on the left)

• With the drive unit switched off, the orange 2-poles plug (see picture on the right) shows the line/mains voltage (e.g 230V AC voltage)

If the fuse link is defective test the electronic circuit ZPM 06 first (see chapter 7.3), before replacing the fuse link

7.3 Electronic circuit ZPM 06

Check the electronic circuit ZPM 06 (e.g in case of overvoltage indication, if a 230V-tool was possibly connected to 400V):

Open housing, see chapter 6.1

Disassemble round belt

Loosen raised cheese head screw M4x10 and remove pressure roller carefully from the axle

Loosen screws M8x16 of the support (2x)

Loosen screw M4x10 of the heat sink (triac)

Loosen screws M4x10 (4x):

- 1 behind electronic circuit TRN 05

- 1 next to the heat sink

- 2 between the rollers

Unplug cable and ribbon cable of the ronic circuit ZPM 06

elect-Remove cable ties Unwind housing carefully

Connect continuity checker/buzzer to both contacts of the orange plug (see picture) If nuity is detected the electronic circuit ZPM 06 is defective Check the drive motor prior to re-place the electronic circuit (see chapter 7.5) Continuity checker/Buzzer

conti-Desolder red flex wire leading to the upper carbon brush support of the motor Connect tinuity checker/buzzer between desoldered flex wire and the lower carbon brush support (white flex wire) Connect and verify the results according to the table stated below

con-Soldering iron, Continuity checker/Buzzer

Lower carbon brush support

Red flex wire

Lower carbon brush support Red flex wire Results

(This is not a complete testing of the electronic circuit)

Should this test not be successful, check drive motor (see chapter 7.5) and finally replace the electronic circuit ZPM 06

7.4 Carbon brushes

Separation of drive unit see chapter 7.3

Loosen hexagon head screws M5x12 from the undercarriage (2x)

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)

7.5 Drive motor check

Visual check of commutator:

• Worn out lamella

• Bluish discoloration

• Deep grooves (U-shaped)

Visual inspection

Desolder red flex wire (see chapter 7.3) and measure the resistance on the carbon brushes

by using an ohmmeter (see picture) Turn the commutator slowly by hand and check all mella The resistance must be 50 100Ω per segment Otherwise replace the motor (see

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!

With desoldered red flex wire (see chapter 7.3) connect a bridge rectifier to both carbon brush supports (see picture on the left) Allpy voltage by using a transformer and an amme-ter 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 motor (see chapter 7.6) and repeat the meas-

7.6 Drive motor replacement

Separation of drive unit see chapter 7.4

Disassemble electronic circuit ZPM 06:

- Desolder flex wires (red and white)

- First loosen raised cheese head screw M3x6 of the MOSFET

- Then loosen other screws M3x12 (2x)

Loosen hexagon head screws M4x14 (2x)

Open cover of gear box:

- Loosen cheese head screws M3x8 (4x)

- Pay attention not to lose too much grease

Loosen hexagon head screw M4x14 Extract motor carefully from the gear box

Remove split pin on suitable base (e.g

wooden plate) by using punch (ø max

1.9mm) and hammer Pay attention the worm rests properly on the base to prevent any damage of the mo-tor ball bearings

Disassemble worm, silicone gasket, sealing

of gear box and round cord from the motor

Replace motor

Assembly:

• Assemble in reverse order

• Check by beating whether the gearing is filled with grease up to the center level

of the axle; refill if necessary

• Tighten cheese head screws M3x8 (4x)

of the gear box cover with 1.2Nm only (use torque screwdriver)!

• Heat sink for triac must be covered with thermal conducting paste

8 Hot-air blower (Ghibli)

8.1 Disassembly

Disconnect all connections of the hot-air tool, remove cable ties

white black/blue

black

green white black

Remove grey clip from hose screw fitting:

• Unlock clip by pushing a screwdriver to one side flap and lift clip with an addi-tional screwdriver size 2

• Proceed the same way from the site side and remove the clip

oppo-Remove cables including cable protection tube from the Uniroof E housing

Loosen countersunk screws M5x12 (4x) and remove Ghibli

Loosen cheese head screws M3x8 (4x) of the overlap welding nozzle

Remove mica tube and heater tube The gasket can not be removed, because it is joined with the Ghibli housing!

Extract rubber plugs (3x) Loosen raised cheese head screws M3.5x20 (5x)

Open housing

8.2 Wiring

• Check all wires and leads for interruptions, short circuits and mechanical damage

• Check correct wiring (compare with picture)

• The flexible wires of the thermocouple (green and white) may not be provided with

ferrules Continuity checker/Buzzer, visual inspection

8.3 Heating element

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

• Measure the resistance of the heating element by using an ohmmeter

Ohmmeter, visual inspection

Resistance must be 25Ω (+/- 10%); otherwise replace heating element

• Measure thermocouple resistance between both signal leads (green and white) Therefore the thermocouple must be cooled down to ambient temperature! Nominal value: approx 7Ω (no short circuit or interruption)

• Check insulation between both signal leads (green and white) and shielding lead

8.4.2 Thermocouple replacement

Remove cable ties and extract thermocouple cable

Push distance bushing back by using pliers

Extract thermocouple carefully from its cket by using pliers

so-Remove distance bushing and mount it to the replacement thermocouple

Assembly of replacement thermocouple:

• Pay attention to correct cable routing

• Assembly of Ghibli see chapter 8.6

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!

After thermocouple replacement the temperature offset must be re-adjusted:

• Switch Uniroof E on and set temperature to 600°C (1112°F)

• Wait until set temperature is reached

• Move thermocouple in parallel to the nozzle and find hottest spot; make sure couple does not touch the nozzle (see picture on the right)

thermo-• Re-adjust the temperature offset if the display does not agree with the actual value (see

chapter 9) The maximum offset may not exceed 40°C (heating element could be

de-stroyed!) If this should be the case, check thermocouple, heating element and tronic circuit once again and replace them if necessary Temperature meter