tài liệu sửa chữa máy hàn nhựa leister ( VARIMAT v2 dv12042010 ENG )

• Make sure the unplugged conductors do not cause short-circuits insulate, fix Switch the tool off and disconnect the power supply to one triac brown flex wire directly at the line/main

© 2010 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 Check mechanics 4

5 Assembly and adjustment 5

5.1 Assembly of guide roller 5

5.2 Assembly of adjusting pendulum 5

5.3 Adjustment of drive sensor 5

5.4 Adjustment of nozzle 6

6 Check electronics 7

6.1 Power supply cord 7

6.2 Main switch 7

6.3 Wiring 7

6.4 Drive motor 8

6.5 Triac 9

6.6 Electronic circuit boards 10

7 Electron for Varimat V2 12

7.1 Blower motor 12

7.2 Heater unit 12

7.3 Thermocouple 13

8 Setup menu 14

8.1 Setup menu overview 14

8.2 Service menu 15

8.3 Percent menu 16

9 Error messages 16

10 Possible causes of errors 17

11 Wiring diagram 19

12 Test procedure for Varimat V2 (protection class I) 20

13 Equipment required for LEISTER repair service 22

14 Appendix screw locking 23

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

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

re-4 Check mechanics

• Check undercarriage for cracks and deformations

• Check roller chain, sprocket wheels, toothed belt and round belt 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, chain with chain oil

5 Assembly and adjustment

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

Ensure which screws are to be locked by using Loctite 242 prior to the tool assembly or its components Therefore the appendix (chapter 14) contains exploded diagrams highlighting all screws to be locked

5.1 Assembly of guide roller

• Lock knob of the guide roller on the right hand side of

the crank

• The distance between the left edge of the

undercar-riage and the guide roller must be 94mm

5.2 Assembly of adjusting pendulum

• Lock screw with screw lock high-strength

• Fix adjusting pendulum by using the screw in such a

way that it remains movable sidewards

• Adjust pendulum by using the set screw until tool runs

straight on

5.3 Adjustment of drive sensor

Adjust drive sensor as follows:

• Turn main switch to "0" OFF position

• Arrange cable as a loop

• Tool holder must be locked at the left end of the guide

shaft

• Position drive sensor to 0.1mm off the end stop

(pho-to: spacer) The proximity switch acts from

approxi-mately 0.2 – 0.5mm

• Lock sensor by using the set screw (tighten carefully)

5.4 Adjustment of nozzle

• Distance between center of swivel-joint roller and nozzle tip 42mm

• Adjust standard nozzle slightly sloped, approx 1mm (illustration 2)

• Adjust grip nozzle plain (illustration 2; Y = 0mm)

• Distance between nozzle edge and swivel-joint roller approx 2mm (illustration 3)

6 Check electronics

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

6.1 Power supply cord

Open housing cover and check power supply cord Replace the power supply cord if it shows

a short circuit, interruption or mechanical damage

Continuity checker / Buzzer, visual inspection

" Notes

• 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

6.2 Main switch

Check main switch: - Position 0: No continuity between L1 – T1 and L2 – T2

- Position 1: Continuity between L1 – T1 and L2 – T2

Continuity checker / Buzzer

6.3 Wiring

• Check all wires, leads and cables for mechanical damages

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

Terminal connections of transformer

6.4 Drive motor

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!

Prop the Varimat V2 up in such a way (on a support) that the drive roller does not touch the ground any more Then turn the tool on and let the motor run on maximum speed (12m/min): Press button Speed and press rotary knob e-Drive within 3 seconds as well Î motor runs Adjust speed by using e-Drive

Check motor for possible bearing or commutator defects An excessive noise indicates a bearing defect, immoderate brush arcing indicates a commutator defect

Measure current consumption of the motor: It may not exceed 350mA after approx 5 minutes

• Worn out lamella

• Bluish discoloration

• Deep grooves (U-shaped)

With desoldered red-white flex wire measure the resistance between the carbon brush ers 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 drive unit

hold-Ohmmeter

With desoldered red-white flex wire connect a bridge rectifier (see photo on the left) to both carbon brush supports Apply voltage by using a transformer and an ammeter Check for cor-rect 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 mo-tor are defective Î replace drive unit Bridge rectifier, Ammeter

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 and unplug the Gate conductors to the triacs (orange and

red-white flex wires) Switch the tool on again If the performance is still the same, one or both triacs are defective

" Notes

• The Gate conductors could be energized in case of fault!

• Make sure the unplugged conductors do not cause short-circuits (insulate, fix)

Switch the tool off and disconnect the power supply to one triac (brown flex wire) directly

at the line/mains terminal (unplug, insulate, fix) Switch the tool on again If the

performan-ce is still the same, the triac with the existing power supply connection is defective and must

be replaced If the tool does not heat any more, the triac with the disconnected power supply connection is defective and must be replaced

red-white

red

white

brown orange

brown

6.6 Electronic circuit boards

6.6.1 Electronic circuit board TRN 06

Prior to replacement of the electronic circuit board TRN 06

(power) unplug all socket connectors and remove the

attachment screws (4x) Make sure the replacement

electronic circuit board rests properly on the distance

bushings and the copper ring surrounding the holes (see

photo) is not covered with silicone potting compound Then

tighten the screws (4x) and connect the socket connectors

correctly

After replacement of the electronic circuit board TRN 06 enter the values for V-Gain and Temp.Air by using the setup menu

6.6.2 Electronic circuit board CSE 07

Loosen screws (4x) of the electronic circuit board CSE 07 (CPU) Make sure the washers do not drop into the tool housing Unplug both ribbon cables and remove the electronic circuit board

After replacement of the electronic circuit board CSE 07 enter the values for V-Gain, Temp.Air., Temp.Amb., Ser.Number, Disp Unit and Mains volt by using the setup menu

6.6.3 Electronic circuit board ZPM 06

Disconnect power supply of the electronic circuit board

ZPM 06 (firing): Unplug socket connector on the electronic

circuit board TRN 06 and check it for continuity

Î no continuity must be detected

Check the electronic circuit board ZPM 06 in case of

overvoltage indication

(e.g if a 230V-tool was possibly connected to 400V)

Desolder red flex wire to the lower carbon brush holder of the motor Connect a multi-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 the

Upper carbon brush holder Red 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 6.4) and then replace the electronic circuit board ZPM 06

• The flex wires for power supply are to be twisted

• The connectors of the ribbon cable must be sealed by using silicone rubber

• Make sure the ribbon cable does nout touch the load resistor (becomes hot!)

• 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

7 Electron for Varimat V2

7.1 Blower motor

Check all connections (wires, flex wires) for breaks (due to vibrations) Replace the blower

motor if its bearing is defective

7.2 Heater unit

• Check heating element for continuity (must have continuity) Continuity checker / Buzzer

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

heat-ing element if the measured resistance value deviates more than +/- 10% from the value

39A1 200 2000 + 2000 2 x approx 19 / 1 x approx 38

39A1 230 2200 + 2200 2 x approx 23 / 1 x approx 46

39A1 400 2750 + 2750 2 x approx 55 / 1 x approx.110

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

7.3 Thermocouple

Measure thermocouple resistance between the signal lines (green and white flex wires) Thermocouple must be cooled down to room temperature!

Reference value: approx 5Ω (no short circuit

or break)

Check the insulation between both signal lines (green and white flex wires) and the shielding

Reference value: >1MΩ

Check continuity between the shielding ductor and the jacket of the thermocouple by using the ohmmeter; otherwise replace the thermocouple

After replacement of the thermocouple the temperature must be measured Insert temperature probe 1cm in the nozzle and search for the hottest spot If the dis-play value does not agree with the measured value, the temperature offset must

be re-adjusted by using the setup menu (do not exceed a maximum of +40°C)

8 Setup menu

8.1 Setup menu overview

PUSH e-Drive

keep pressing keep pressing

Main switch OFF

Percent Mode Yes

TURN POWER OFF

Percent menu

chapter 8.3

2 4 6 8

8.2 Service menu

Adjustments per and e-Drive V-Gain

Voltage too low: Decrease value

Voltage too high: Increase value

V-Offset Voltage too low: Decrease value

Voltage too high: Increase value

Temp Air Offset Temperature too low: Increase value

Temperature too high : Decrease value Temp Amb Offset

Temperature too low: Increase value

Temperature too high : Decrease value Ser Number

Disp Unit

Display of °C/m or °F/ft

Mains volt

Power supply (line / mains voltage)

Reset Drive/Blower Time

Reset of counters for drive (service sage after 400h) and blower motor (ser-

mes-vice message after 2000h) View Error

Index „Length“ indicates every 10th meter of the drive unit

kilo-8.3 Percent menu

Using the percent mode the controller set value of the closed loop will be displayed (in %) for heater, drive and line/mains voltage

Thus the user may estimate the controller tion

modula-9 Error messages

Error Type of error

Err01 Overtemperature of the air or defective thermocouple

Err02 Heating element defective (break in one or both coils)

Err03 Err01 and Err02

Err04 Triac defective (one or both triacs are defective)

Err05 Err01 and Err04

Err06 Err02 and Err04

Err07 Err01 and Err02 and Err04

Err08 Blower motor defective

Err09 Err01 and Err08

Err0A Err02 and Err08

Err0B Err01 and Err02 and Err08

Err0C Err04 and Err08

Err0D Err01 and Err04 and Err08

Err0E Err02 and Err04 and Err08

Err0F Err01 and Err02 and Err04 and Err08

Err10 Overtemperature of the electronics

(generates an error item, but does not result in a stop)

Err11 - Err1F Error from Err01 to Err0F and Err10 (Err1A = Err0A and Err10)

Err40 Undervoltage (line/mains voltage -25%)

Err41 - Err4F Error from Err01 to Err0F and Err40 (Err4A = Err0A and Err40)

10 Possible causes of errors

• Check all electronic circuit boards for visual error indications (exploded parts, black spots)

• Check whether all ribbon cables, wires and flex wires are connected correctly

No announcement on the display

• Correct input voltage at the transformer assumed (output voltage approx 9VAC +/- 1V), the green 3-poles connector for the drive switch must show a direct current voltage of +5VDC (+/- 0.2V) between pins 1 and 3

• Connect replacement electronic circuit board CSE 07 temporarly

Drive motor does not start or pauses suddenly

• Check supply voltage of 230V at the transformer

• Check fuse link (2AT) on the electronic circuit board TRN 06

• Check temperature limit switch 120°C

• Check carbon brushes and commutator

• Check ribbon cable for breaks

• Seal ribbon cable with silicone (carbon dust etc may cause short circuits)

• Connect replacement electronic circuit board CSE 07 temporarly

• Replace electronic circuit board ZPM 06

Drive motor speed unsteady

• Flex wires to electronic circuit board ZPM 06 are not twisted

Drive motor does not start automatically when swivelling in the Electron

• Adjust drive sensor

• Replace drive sensor

Tool does not heat (no error message in the display)

• Check heating element connections at line/mains terminal

• Check order of thermocouple connections and its tightening

• Check triacs

• Connect replacement electronic circuit board CSE 07 temporarly