QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI REPAIR INSTRUCTIONS Wedge Welder Astro Production code from 0215 Software version from 1.0 © 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 www.leister.com Tel +41 41 662 74 74 Fax +41 41 662 74 16 leister@leister.com QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Table of contents 10 11 12 13 14 15 Scope of applicability Safety precautions Remarks Check mechanics 4.1 Movable parts 4.2 Replacement of drive roller chains 4.3 Plain roller centering 4.4 Hot-wedge adjustment Electronics 11 5.1 Wiring 11 5.2 Wiring details 12 5.3 Power supply cord 14 5.4 Main switch 14 5.5 Triac 15 5.6 Relay 15 5.7 Electronic circuit board TRN 02 16 5.8 Electronic circuit board ZPM 05 17 5.9 Connect electronic circuit board CSE temporarly 18 5.10 DIP switch on electronic circuit board CSE 06 18 Drive unit 19 6.1 Check drive unit 19 6.2 Replacement of drive unit and electronic circuit board DZF 01 20 Heater unit 22 7.1 Check of hot-wedge 22 7.2 Temperature check of hot-wedge 23 7.3 Check of thermocouple 23 7.4 Check of heating cartridge 24 7.5 Replacement of heating cartridges and therocouple 24 7.6 Hot-wedge supervision 28 Check force sensor and USB port (optional) 29 8.1 Force sensor 29 8.2 USB port 29 Setup menu 30 9.1 Menu CSE 03 31 9.2 Menu CSE 06 32 Settings 34 Possible causes of trouble 35 Wiring diagram 36 Test procedure for ASTRO (protection class I) 37 Equipment required for Leister repair service 39 Appendix screw locking 40 QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Scope of applicability These repair instructions are reserved exclusively for Leister service centres Only experienced and qualified personnel trained by Leister Technologies AG, CH-6056 Kaegiswil, are allowed to repair work on Leister tools Additional national requirements relative to personnel carrying out repair work are to be observed by each service centre Safety precautions A well-equipped working place (see "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 tool when servicing 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 danger to life! Insure tool is disconnected from the line/mains before 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 requirements Remarks 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! QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Check mechanics Check undercarriage for cracks and deformations Check roller chain and sprocket wheels and replace them if necessary Clean all polluted parts Make sure that there are no other particles than the essential grease inside the toothed wheel work Check all moving parts for smooth running and replace them if necessary Lubricate all moving parts with unpolluted grease, chain with chain oil Ensure which screws are to be locked prior to the tool assembly or its components (see chapter 15) Carry out the assembling according to the exploded diagrams and the spare parts lists Note The numbering of the parts in chapter refers to the exploded diagrams! 4.1 Movable parts Lubricate these parts with grease (e.g Microlube GBUY 131), chain with chain oil: Remove gear cover (64), clean and lubricate cog wheels (310, 19, 26) Remove chain covers (31, 210), lubricate sprocket wheels and oil chains QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Remove cover of pressure roller (223) and lubricate sprocket wheels Lubricate guide slide (112) Lubricate pivots of clamping lever (50) and adjustment screw (59) Remove undercarriag cover (132) and lubricate guide axle of hot-wedge QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 4.2 Replacement of drive roller chains Push cable protective tube beside and remove gear cover (illustration 1) Remove cog wheel (illustration 2) Remove chain protection (illustration 3) Turn lower pressure roller as long as good accessibility to the chains master link is given (illustration 4) Open roller chain (illustration 5) and lift it upwards (illustration 6) QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Oil new roller chain by using chain oil Insert roller chain from the top (illustration 7) and feed it in counter-clockwise (illustration 8) Interconnect roller chain and assemble chain protection Remove chain protection plates (illustration 9) Turn upper pressure roller as long as good accessibility to the chains master link is given (illustration 10) Open roller chain and remove it 10 QM Leister Technologies AG Repair instructions Astro Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI A deflection pulley serves as chain tensioner (illustration 11) Remove deflection pulley by loosening the set screw (illustration 12) Oil new roller chain by using chain oil Insert roller chain from the top (illustration 13) and feed it in untill the chains master link may be inserted (illustration 10) Press deflection pulley to the top to tense the roller chain (illustration 14) Tighten set screw, then loose it for approx ½ revolution and make sure the deflection pulley rotates together with the roller chain Lock set screw by using Loctite 242 11 12 13 14 Assemble chain protection plates Re-insert cog wheel (illustrations and 2) and assemble gear cover QM Repair instructions Astro Leister Technologies AG Revision: C Page / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 4.3 Plain roller centering Center plain roller by screwing in the set screws (73) from both sides Tighten set screws, then loosen them for ¼ revolution each and lock them by using the counter nuts (74) Check: The plain rollers (66 and 67) must rotate without applying real effort 4.4 Hot-wedge adjustment Remove cover sheet from undercarriage (illustration 1) Center hot-wedge (illustration 3) by using both cheese head screws (illustration 2) Reassemble cover sheet (illustration 1) QM Leister Technologies AG Repair instructions Astro Revision: C Page 10 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Insert two PE membranes of 2.5mm thickness between the pressure rollers and actuate tension lever (illustration 4) Keep pressing catch spring (illustration 5.1) Position pressure rollers by using adjustment nut (illustration 5.2) untill they smoothly touch the membranes (illustration 5.2) 5.2 5.1 Insert two PE membranes of 2.5mm thickness into the machine Apply tension by turning the adjustment nut for 10 numbers (illustration 6) or 1250N (version with force sensor) Tilt machine to the side to get good accessibility to the guide rollers (illustration 7) Start drive unit for a short time to ensure the hot wedge will move close to the drive rollers Fix hot-wedge if necessary to prevent it from sliding back QM Repair instructions Astro Leister Technologies AG Revision: C Page 30 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Setup menu There are three different kinds of setup menus: Version 1: CSE 03 Standard Version 2: CSE 06 Standard Version 3: CSE 06 USB version with force sensor Serial number The old serial number is seven-digit, the new one ten-digit: Software release upto 2.0B / 3.1C USB Digits Year xx Software-Release from 2.0C / 3.1D USB Digits 10 Year xx Month xx Week xx Number xxx Day xx Number xxxx I-Gain, I-Offset, V-Gain, V-Offset The values for Gain- and Offset adjustment are given in adhesive labels affixed on the electronic circuit boards QM Repair instructions Astro Leister Technologies AG Revision: C Page 31 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 9.1 Menu CSE 03 Adjust settings At the same time press + H M and switch the tool on Enter code: H M H H + - save not save Select tool type: Astro / Sure Grip M H Serial number: xxxxxxx M H Gear: 91:1 / 162:1 M H I-Gain: 101:100 M H I-Offset: -9 M H Max current: 800mA M H Max speed: 5.00m/min M H Min speed: 0.80m/min M H Max temperature: 420°C M H Temp offset: +0°C M H V-Gain: 78:100 M H V-Offset: -1 M H Display Unit? - C/m F/ft + Store Parameter? - no yes setup done + - + adjust QM Repair instructions Astro Leister Technologies AG Revision: C Page 32 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 9.2 Menu CSE 06 (upto Software release 2.0B / 3.1C USB) At the same time press Modifications in the setup menu will be safed automatically M – + Adjust settings H and switch the tool on Enter code: HMHH+Select tool type: Astro / Sure Grip H Serial number xx xx xxx H confirm – + Gear 91:1 / 162:1 H I-Gain 101 H I-Offset -9 H Max current 800mA H Max speed 5.0 m/min H adjust Min speed 0.8 m/min H Max temperature 420°C H Temp offset 0°C H V-Gain 78 H V-Offset -1 H USB-Stick? no yes F-Offset – USB version + H F-Gain 95 H Display Unit? – M C/m F/ft setup done + – + adjust QM Repair instructions Astro Leister Technologies AG Revision: C Page 33 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI (from Software release 2.0C / 3.1D USB) At the same time press M – + Adjust settings H and switch the tool on Enter code: HMHH+Select tool type: Astro / Sure Grip H Entering old digit serial number: Enter week in month column mitand first M digitbestätigen Set day of serial number to Serial number xx xx xx xxxx H Gear 91:1 / 162:1 H M year 00 I-Gain 101 H M M M month day 00 00 no 0000 I-Offset -9 H Max current 800mA H Max speed 5.0 m/min H – adjust + Min speed 0.8 m/min H Max temperature 420°C H Temp offset 0°C H V-Gain 78 H V-Offset -1 H USB-Stick? no yes F-Offset – + H F-Gain 95 H Display Unit? – C/m F/ft setup done + – + adjust QM Leister Technologies AG Repair instructions Astro Revision: C Page 34 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 10 Settings Enter the setup menu Set main switch to "0" (OFF) position and connect tool to rated voltage Press all of the four buttons at the same time and set the main switch to "1" (ON) position, then enter code: H M H H + By pressing button M the setting will be saved By pressing button H the cursor jumps to the next menu item (without saving) Select tool type Astro Enter serial number Select gearing 91:1 (standard version) 162:1 (nap version) Enter I-Gain and I-Offset according to label on electronic circuit board ZPM 05 Max current 800mA Max speed 5m/min Min speed 0.8m/min Max temperature 420°C Offset temperature 0°C Enter V-Gain and V-Offset according to label on transformer of TRN 02 board Select temperature indicator °C or °F Save and exit setup menu Date and time adjustment (version with USB recording only) Press buttons - and + at the same time Select menu item "Date/Text" by using button + Select menu item "Set Date" by using button + Adjust time and date Use buttons - and + for adjustment and confirm with button H Caution: If the given number exactly agrees with the intended setting, always verify by using buttons - and + if definitely the correct number is stored! Example: The number 165 may also be displayed as 16 If the value 16 is stored, it will change to 15, respectively 17, by one-time pressing of buttons - or + If the value keeps at 16, press button - as long as the designated value appears Exit menu by using button M Check force load cell (version with USB recording only) If the force load cell shows a force on the display with released tension lever, the force may be reset by using item F-Offset in the setup menu The actual measured force will be displayed in the upper line on the right Release tension lever and adjust F-Offset by using buttons - and + until the display shows "0" If the force load cell needs to be calibrated, the tool must be sent to LEISTER Process Technologies, CH-6056 Kaegiswil, Switzerland QM Leister Technologies AG Repair instructions Astro Revision: C Page 35 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 11 Possible causes of trouble No indication on the display Check wiring Check electronic circuit board TRN 02 Connect electronic circuit board CSE temporarly chapter 5.1 chapter 5.7 chapter 5.9 Error indication on the display See hot-wedge supervision (display indication) chapter 7.6 Drive motor does not run Check wiring Check electronic circuit board ZPM 05 Check drive unit Replace electronic circuit board DZF 01 chapter 5.1 chapter 5.8 chapter 6.1 chapter 6.2 Tool does not heat Check wiring Check heating cartridges Check triac Check relay Check electronic circuit board TRN 02 Connect electronic circuit board CSE temporarly chapter 5.1 chapter 7.4 chapter 5.5 chapter 5.6 chapter 5.7 chapter 5.9 Tool heats all the time Check triac Check electronic circuit board TRN 02 Connect electronic circuit board CSE temporarly chapter 5.5 chapter 5.7 chapter 5.9 Bad welding quality Check hot-wedge adjustment Check heating cartridges Check line/mains voltage chapter 4.4 chapter 7.4 For options force sensor and USB port only No force value on display No data recording Check DIP switch settings chapter 8.1 chapter 8.2 chapter 5.10 rot / red AWG20 blau / blue AWG21 grau / grey AWG22 - Thermoelement shield ZPM 05 J4 / Pin J4 / Pin J4 / Pin Litze / f lex Litze / f lex Litze / f lex + Hall-Element / hall generator Vcc OUT Klemme / blade terminal J2 Kabel 6-polig / cable 6-poles J3 / Pin J3 / Pin Triac Q8025L1 TRN 02 J1 / Pin J1 / Pin J1 / Pin J1 / Pin J1 / Pin J1 / Pin J1 / Pin J1 / Pin Kraf tsensor / f orce sensor (optional) USB-Stecker / USB plug CSE 03 / USB-Version: CSE 06 Kabel 5-polig / cable 5-poles Kabel 5-polig / cable 5-poles schwarz / black 1mm2 rot / red 1mm2 Relais / relay rot / red AWG20 braun / brown braun / brown AWG20 blau / blue AWG20 blau / blue AWG20 schwarz / black AWG20 gelb-gruen / green-y ellow Erde / earthing J9 Kabel 14-polig / cable 14-poles J3 Kabel 14-polig / cable 14-poles GND weiss / white 0.25mm2 J8 / Pin MT2 F gelb / yellow 0.25mm2 J8 / Pin MT1 G C_X1_150nF/440V + rot / red 0.25mm2 J8 / Pin gelb-gruen / yellow-green J5 / Pin gruen / green J5 / Pin rot / red J5 / Pin blau / blue 0.5mm2 J4 / Pin schwarz / black 0.5mm2 J4 / Pin gelb / yellow 0.5mm2 J4 / Pin Hauptschalter / main switch GND Filter Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Leister Technologies AG Antriebsmotor / driv e motor Heizung / heating L N M 36 / 44 Revision: C Page Repair instructions Astro QM 12 Wiring diagram J6 Kabel 6-polig / cable 6-poles QM Leister Technologies AG Repair instructions Astro Revision: C Page 37 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 13 Test procedure for ASTRO (protection class I) Protective earth conductor test Measure resistance between the earth/ground pin of the plug and the undercarriage as well as between the earth/ground pin of the plug and a screw of the electronic box by using the protective earth conductor tester (< 0.2Ω) Insulation test Function check of high voltage tester (Shorten tips Signal lamp illuminates and horn sounds) Connect tool to a short circuit receptacle Set main switch of the tool to "1" (ON) position Apply a high voltage of 1000V (release current < 30mA) for second between the short circuit receptacle and a screw of the electronic box; no flashover or breakdown must occur Function test Set main switch to "0" (OFF) position and connect tool to rated voltage Press buttons H and M at the same time, set main switch to "1" (ON) position and enter code: H M H H + Start drive Increase speed from minimum to maximum and make sure the speed increases steadily Let the drive motor run with maximum speed Check smooth running of the motor Set main switch to "0" (OFF) position and then to "1" (ON) position again Check heating: Heating switched off Tool must not heat Heating switched on Tool must heat on maximum power Heat the tool up to maximum temperature 420°C Check current consumption (according to nameplate) Check temperature on the display 415°C – 425°C Measure surface temperature of hot-wedge and adjust temperature offset, if necessary Let the tool cool down Check setup menu and write parameters in tool certificate Checking completeness Check ratings of the nameplate Check power supply cord (type of plug) Two labels "ASTRO" and one company label LEISTER and must be bonded Check for cleanliness and possible damages Enclose tool set and accessories Packaging label QM Leister Technologies AG Repair instructions Astro Revision: C Page 38 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI Function test of USB recording Stop drive by using button M Activate tension lever and adjust force in such a way that at least 400N will be reached Release tension lever Start drive by using button M Insert USB stick The display indicates the message "wait for USB" for approx seconds Afterwards the lower display line shows on the right: *001 The tool is now ready for recording of the welding parameters Activate tension lever; the lower display line on the right changes to ->001, the parameters are recorded now Release tension lever after approx minute and stop drive by using button M Wait until the display shows the message "wait for USB" Once the lower display line on the right shows USB, the USB stick may be removed Check setup menu and write parameters in tool certificate Set main switch to "0" (OFF) position and let the tool cool down Insert USB stick to a PC and check the file Actual date-no.csv (e.g 0520-001.csv) The Excel program should start automatically (example) COMPANY File-number according to date Actual date and clock time Unit according to tool type QM Leister Technologies AG Repair instructions Astro Revision: C Page 39 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI 14 Equipment required for Leister repair service Mobile Equipment protective earth conductor tester high voltage tester up to 4000V temperature meter with temperature measurement probe multimeter with following measurement options: - Current - Voltage - Resistance - Continuity (test buzzer) rotational speed meter water column soldering iron complete set of tools (screw drivers etc.) (e.g Elabo) (e.g Elabo, Korntal) (e.g Fluke, Testo) (e.g Fluke) Installed equipment ESD-protected working environment Transformer, possibly separated into variable and isolating transformer Data: x 500V x 30A built-in voltmeters (500V) built-in ammeters (30A) or wattmeters QM Leister Technologies AG Repair instructions Astro Revision: C 15 Appendix screw locking Page 40 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI QM Leister Technologies AG Repair instructions Astro Revision: C Page 41 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI QM Leister Technologies AG Repair instructions Astro Revision: C Page 42 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI QM Leister Technologies AG Repair instructions Astro Revision: C Page 43 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI QM Leister Technologies AG Repair instructions Astro Revision: C Page 44 / 44 Created 15.07.10 PRI Released 04.08.10 PRI Modified 19.06.13 PRI ... 14 Equipment required for Leister repair service Mobile Equipment protective earth conductor tester high voltage tester up to 4000V temperature meter with temperature measurement... out repair work are to be observed by each service centre Safety precautions A well-equipped working place (see "Equipment required for Leister repair service") is essential for doing qualified... socket connector Check continuity between yellow-green flex wire and jacket of the thermocouple by using a continuity checker / buzzer; otherwise replace thermocouple Measure thermocouple resistance