tài liệu sửa chữa máy hàn nhựa leister (PID (EN)

Check of power supply cord, switch, wiring and motor 4.1 Power supply cord Disconnect tool from line/mains!. Continuity checker/Buzzer or Ohmmeter 5.1 Heating element Disconnect tool

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R EPAIR I NSTRUCTIONS FOR T RIAC PID

1 Scope of applicability

These repair instructions are reserved exclusively for LEISTER service centres Only experienced and qualified personnel trained by LEISTER Process Technologies,

CH-6060 Sarnen, are allowed to do repair work on LEISTER tools Additional national re-quirements relative to personnel carrying out repair work are to be observed by each service centre

2 Safety precautions

A well-equipped working place (see appendix: „Equipment for LEISTER repair service“)

is essential for doing qualified work When servicing use only identical original LEISTER replacement parts for each type of tool

3 Remarks

- Each repaired tool has to pass the test procedure! ==> Test procedure

- If there exist any additional national testing requirements exceeding the LEISTER test procedure, the repaired tool has also to pass those requirements

- If it is impossible to repair a tool, it should be returned immediately to the

manufactur-er, LEISTER Process Technologies, CH-6060 Sarnen, Switzerland, carriage paid

up-to Sarnen The LEISTER company will repair the up-tool within 24 hours after its arrival

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

ser-vicing use only identical original LEISTER replacement parts!

are accessible without using a tool, some life parts could ap-pear Its contact can cause danger to life! Insure tool is dis-connected from the line before any work is commenced!

Repaired tools must pass the LEISTER test procedure (see page 8) and any additional local requirements Check with your local Statutory Authority for testing requirements

4 Check of power supply cord, switch, wiring and motor

4.1 Power supply cord

Disconnect tool from line/mains! Remove the enclosure and the power supply cord The power supply cord has to be replaced, if there is a short circuit, a break or any mechanical damage detected Continuity checker/Buzzer, visual inspection

Do not shorten the power supply cord! If the customer did so, the power supply cord has to be replaced

4.2 Switch

Check power switch: - Position 0: No continuity

- Position 1: Continuity Continuity checker/Buzzer

4.3 Internal wiring

Check all of the connections (leads, wires) and make sure, that there are no breaks (due to vibrations) Visual inspection

4.4 Motor

Check motor brushes: Remove motor brushes, measure its length and replace them,

if their length is 4 mm or even less Check both brushes! If the carbon brushes are not to be replaced make sure to re-insert them the same way as removed (abraison)

Visual inspection

Clean up the tool For cleaning up the handle’s display-window use only water, spirit

or seam-cleaner If the air filter at the end of the enclosure is missing or if it is defec-tive, replace it If the air filter is clogged, clean it up and give a message to the cus-tomer as follows:

Clean up the air filter at the end of the enclosure with a small brush when polluted!

Mount power supply cord and handle again Connect the tool to line/mains and switch it on Motor must turn now; if not, it has to be replaced Make sure, that the tool is disconnected from line/mains in this case!

The motor has also to be replaced if there is a defect of the bearing or of the commutator A defect of the bearing causes an excessive noise The commutator is defective, if the power consumption of the motor exceeds

5 Function control of heating

Check if tool heats correctly:

- Adjustment of Set value by potentiometer:

Set value Heating output Actual value Tolerance Time

000 032 Tool may not heat 060 140

300 570 Tool heats 300 570 +/- 5° after about 2 minutes

600 1110 Tool heats 600 1110 +/- 5° after about 2 minutes

- Adjust Actual value with trimmpotentiometer at the electronic circuit board PID-02-R

(turn clockwise  Actual value increases)

- Check the temperature with a probe (ø < 1mm) while the tool is fitted with a tubular

nozzle ø 5mm Replace the thermocouple if the temperature deviates more than

- Make sure that the periodical pulsing of the current increases steadily after the

Check continuity of thermocouple (must have continuity), if the temperature

display shows permanently flashing „SEr“

Continuity checker/Buzzer or Ohmmeter

5.1 Heating element

Disconnect tool from line/mains! Remove heater tube and mica tube and pull the

heating element carefully (do not bend the thermocouple!) out from its socket Check

continuity of the heating element (must have continuity) Continuity checker/Buzzer

Make a visual inspection of the heating element Replace the heating

ele-ment, if it is either mechanically damaged or if any heating channels are

Clean up the photo resistor, if it is dirty (powder of the brushes) Rag

Restore heating element, mica tube and heater tube to the tool, connect the tool to

line/mains and check for proper heating (see Function control of heating)

5.2 Thermocouple

Disconnect the thermocouple by screws and measure the resistance of the thermo-couple between the two leads (value about 5) Ohmmeter

Check thermocouple for short circuit between leads and jacket (insulating resistance

at 600°C/1110°F: at least 12 M) Continuity checker/Buzzer and Ohmmeter

Connect thermocouple with correct polarity

Clean the thermocouple carefully with an emery paper if strongly oxydated

5.3 Temperature limit switch (KLIXON) and photo resistor

Disconnect tool from line/mains! Dismount rubber stand and connecting head and remove turbines and distributor Replace defective parts and clean up the other parts Check continuity of the temperature limit switch (must have continuity)

Function control of photo resistor: Desolder one of the two wires of the photo resis-tor, complete the tool, connect it to line/mains and check its proper heating (see Function control of heating)

If the tool heats properly now, disconnect it from line/mains and replace the photo resistor The back of the photo resistor and its leads must be covered with silicone caoutchouc

If the tool does not heat (properly), disconnect it from line/mains and resolder the removed wire

+ pole (green) PID-02-R

Terminal block for thermocouple

Connector

to PID-03-V

Trimmer Actual value Connector

to display

5.4 Check of potentiometer and triac and

replacement of the electronic circuit boards

5.4.1 Potentiometer

Desolder connections to potentiometer and measure its resistance:

Pin Resistance Pin 1 - Pin 3: 20 k

1 2 3 Resistance Pin 1 - Pin 2: 0 - 20 k *

Resistance Pin 2 - Pin 3: 0 - 20 k *

* Check the entire range of the potentiometer Ohmmeter

Replace the potentiometer if the measured values deviate more than +/- 10% from the values stated above Cover the soldering tags with insulating varnish 2451, black

5.4.2 Triac

Desolder connections to the triac Check continuity of triac as follows and replace

it, if this check does not agree with the table stated below:

MT1 MT2 Gate Results

+ - open circuit

- + open circuit

+ : Red probe tip (terminal plus pole)

- : Black probe tip (terminal minus pole)

If the triac has to be replaced, cover its bottom side (heat sink) with thermal con-ducting paste Each of the soldering connections must be equiped with a shrink sleeve and afterwards covered with insulating varnish 2451, black

If the tool still does not heat properly, the electronic circuit (printed wiring board) must be replaced

5.4.3 Replacement of the electronic boards

Warning! The following measurement has to be carried out on the tool

which is under line/mains voltage Therefore when touching elec-trical components and connections this can cause danger to life! The tool has to be built on a insulated base and saved so that it cannot slip away mistakenly during doing measurement

If the temperature display module

does not show any values,

dis-connect its plug Measure the

voltage on VDC-range between

pin 3 and 4 on the electronic

cir-cuit board PID-02-R (see drawing

beside) The voltage has to be 5V

+/-0.2V If this voltage is not

de-tected, the power electronic circuit

board (PID-03-V) has to be

re-placed If the voltage is within the

balance, replace the temperature

display module

If the temperature display module permanently shows 60-70°C, the error has to be located either on the control unit PID-02-R or on the power unit PID-03-V - correct functioning of the triac required To find out, which board is defective, connect the connector to the power unit and the thermocouple to another control unit (without replacing the original one) Do a function control now If the tool heats properly and the display shows the correct values now, replace the control unit PID-02-R, otherwise the power unit PID-03-V

Before replacing the electronic circuit board PID-03-V find out its type, voltage and color of the leads The wiring has to be made in accordance with the Wiring Diagram (page 10) Notice the following hints for re-placement of the electronic circuit board:

- Equip each of the soldering tags of the Triac with a shrink sleeve and after that cover them with insulating varnish 2451, black

- Cover the soldering tags of the potentiometer with insulating varnisch

2451, black as well

Trimmer Actual value

Connector

to PID-03-V

Temperature Display module

PID-02-R Top view

4 3

Test procedure for TRIAC PID Prot class II

1 Insulation test

- Check correct functioning of the high voltage tester

(shorten tips  signal-lamp and horn)

- Set power switch of the LEISTER tool to „1“ position

- Apply test voltage of 4000V for 1 second between plug and accessible metal parts (heater tube) No breakdown should occur

2 Functioning test

- Set power switch to „0“, potentiometer to „0“ and connect LEISTER tool to rated volt-age (line/mains or transformer)

- Set power switch to „1“ ==> motor turns, check power consumption of the motor

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

- Check heating: Equip the tool with a tubular nozzle ø 5mm, adjust the set value by potentiometer and verify the temperature values with a probe (diameter of probe < 1mm)

Set value Heating output Actual value Tolerance Time

000 032 Tool may not heat 060 140

300 570 Tool heats 300 570 +/- 5° after about 2 minutes

600 1110 Tool heats 600 1110 +/- 5° after about 2 minutes

Make sure that the periodical pulsing of the current increases steadily after the

- Check rated power consumption of the tool at full heat output

3 Check all components clear

- Filter must be fitted

- Check details printed or die-stamped on handle: type, voltage, current, power (must correspond with the above measurements!)

- Warnings must be printed on the handle

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

- Rubber stand must be fitted; all screws must be tightened

- Company label (LEISTER) must be fixed on the handle

- Tool should be checked for cleanliness and possible damage

7 Color chart for electronic circuit boards PID-03-V

8 Markings and connections of motors «T» 47/25

Photo resistance

Photo resistance

PID-03-V

9 Wiring diagram

100-230V and 120V UL

TRIAC_PID_03_V

P534 GND GATE VCC

INPUT AC

SET VREF GND VREF

NO CONNECT

TRIAC_PID_02_R

GND GATE VCC

P534

ACTUAL SET VREF GND VREF

NO CONNECT

100-230VAC

100-230VAC

Yellow

Blue

Blue

Green White

Blue

Red

Red

White

Turquoise,(Grey UL) Black

Black

Switch

Potentiometer 20k

10uH

R_Photo 2200pFY

10uH

MOTOR T 47/25

Thermocouple +

-2 1

Temperature limit switch

t

Heating element according to volatage / power

TRIAC 25A

42V

TRIAC_PID_03_V

P534 GND GATE VCC

INPUT AC

SET VREF GND VREF

NO CONNECT

TRIAC_PID_02_R

GND GATE VCC

P534

ACTUAL SET VREF GND VREF

NO CONNECT

42VAC

Blue

Green

Blue

Red

Red

White

Black

Black

Turquoise

42V/950W White

Blue

White

Switch

Potentiometer 20k

R_Photo

MOTOR T 47/25

Thermocouple +

-2 1

Temperature limit switch

t

1

2

TRIAC 40A

2200pFY

10 Exploded diagram for

11 Spare parts list

1 100.258 1 Air filter

2 100.032 1 Company label 75 x 22

3 106.185 1 Handle (with display), Warnings printed

4 100.260 1 Nameplate Triac PID, 230V/1600W with SEV approval mark

4 100.631 1 Nameplate Triac PID, 200V/1400W

4 100.632 1 Nameplate Triac PID, 120V/1600W with UL approval mark

4 100.634 1 Nameplate Triac PID, 100V/1400W

4 100.635 1 Nameplate Triac PID, 42V/1000W

4 100.633 1 Nameplate Triac PID, 120V/1600W

5 100.261 6 Raised countersunk screw M4 x 8

6 106.186 1 Rocker switch complete

6 108.319 1 Rocker switch complete, 250V/20A, with snap-fit tabs (UL)

7 100.263 1 Potentiometer knob red

8 100.046 1 Potentiometer 20kOhm

9 100.264 1 Connecting piece complete

10 100.266 2 Raised cheese head screw combination M4 x 8

11 100.267 2 PT-screw KL30 x 10

12 100.268 1 Strain relief for cord 2 x 1mm2

12 100.637 1 Strain relief for cord 2 x 1.5mm2 / 2 x 14AWG (UL)

13 100.269 2 Thread forming raised cheese head screw M4 x 10

14 100.270 1 Thread forming raised cheese head screw M3 x 6

15 109.927 1 Triac 25A/800V

16 100.272 3 Shrink sleeve 1/8" x 12mm, black

17 100.273 1 Electronic circuit board PID-03-V, 100-230V

17 100.638 1 Electronic circuit board PID-03-V, 120V (UL)

17 100.639 1 Electronic circuit board PID-03-V, 42V

18 100.274 1 Electronic circuit board PID-02-R

19 100.275 1 Temperature display module complete °C

19 100.640 1 Temperature display module complete °F

20 100.276 1 Motor T47/25 complete, 230V

20 100.641 1 Motor T47/25 complete, 200V

20 100.642 1 Motor T47/25 complete, 120V

20 100.643 1 Motor T47/25 complete, 100V

20 100.644 1 Motor T47/25 complete, 42V

22 100.278 1 Cord guide

23 100.279 2 Brushholder

24 100.645 2 Carbon brush (200/230V)

24 100.646 2 Carbon brush (42/100/120V)

26 100.628 1 Turbine housing (with display) complete

26 100.647 1 Turbine housing (with display) complete, 42V

28 100.284 3 Thread forming raised cheese head screw M4 x 14

29 100.305 2 Turbine

30 100.629 1 Stripper complete

31 100.287 1 Hexagon nut M5

32 100.288 1 Thermocouple

33 106.184 1 Photo resistance bended

34 106.183 1 Temperature limit switch 135°C

35 100.291 1 Connecting head complete

36 100.295 1 Rubber stand