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Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified REPAIR INSTRUCTIONS Hot Air Blower HOTWIND PREMIUM / SYSTEM Production code from 1128 © 2012 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 Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Table of contents: Scope of applicability Safety precautions Remarks Heating element 4.1 Check heating element 4.2 Replacement of heating element 4.3 Check and replacement of load resistor 5 Electrics and electronics 5.1 Open tool 5.2 Power supply cord 5.3 Internal wiring 5.4 Main switch with function button 5.5 Thermocouple 5.6 Remove motor 5.7 Check motor 10 5.8 Electronic circuit board heater and blower unit 11 5.9 Electronic circuit board interface (SYSTEM models only) 11 Possible causes of trouble 12 Test procedure 13 Test instructions 14 8.1 LHS Field Tester description 14 8.2 Check leakage current protection circuitry 15 8.3 Check interfaces 16 Wiring diagrams 19 9.1 Wiring diagram 120/230V 19 9.2 Wiring diagram 400V 20 10 Equipment required for Leister repair service 21 Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 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 tools 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! Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Heating element 4.1 Check heating element Warning! Hot air blower must be disconnected from the line/mains on every pole! Loosen PT fillister head screws KA35 x 16 (4x), remove heater tube with mica tube and gasket Extract heating element vertically up from its socket (ensure thermocouple of SYSTEM models will not be damaged!) 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 Visual inspection Measure resistance of the heating element coil by using an ohmmeter; replace the heating element if the measured resistance deviates more than +/- 10% of the value stated in the table Ohmmeter Check leakage current pin for continuity (must have continuity, resistance < 1Ω) Ohmmeter Article no 143.035 143.033 143.034 143.530 140.822 Length S S L S S Voltage [V] 120 230 230 230 400 Power [W] 2200 2200 3100 3600 5300 Resistance [Ω] 23 17 14 29 Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 4.2 Replacement of heating element Usually the replacement heating element is of the same size (length) and the same ratings (voltage/power) as the original heating element L S 151 127 161 133 If the replacement heating element power rating is different (size and voltage rating must correspond!), nameplate and load resistor are to be replaced as well (see table) S L 4.3 Check and replacement of load resistor Extract load resistor from its socket, measure its resistance and replace it if necessary Ohmmeter Article no 143.035 143.033 143.034 143.530 140.822 Length S S L S S Voltage [V] 120 230 230 230 400 Power [W] 2200 2200 3100 3600 5300 Load resistor [kΩ] 1.3 1.3 2.0 2.0 7.5 Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Electrics and electronics 5.1 Open tool Warning! Hot air blower must be disconnected from the line/mains on every pole! Remove heating element (chapter 4.1) Loosen PT fillister head screws KA35 x 16 (5x); carefully remove cover Check plastic housing for possible cracks and replace housing parts if mechanically damaged 5.2 Power supply cord Replace power supply cord if there is a short circuit, a break or any mechanical damage detected Check strain relief and line/mains terminal Note Do not shorten the power supply cord! If the customer did so, the power supply cord has to be replaced 5.3 Internal wiring Check all flex wires for breaks, short circuits and mechanical damage Check correct wiring (double-check with wiring diagram) Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 5.4 Main switch with function button Remove heating element (chapter 4.1) Open tool (chapter 5.1) Remove blower wheel (chapter 5.6) Check main switch with function button by using a multimeter (as continuity checker) 1: Brown 2: Black 3: Yellow Mid-position Pin 1-2: No continuity Pin 2-3: No continuity On Pin 1-2: Continuity Pin 2-3: No continuity Service Pin 1-2: No continuity Pin 2-3: Continuity (while function button pressed) Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 5.5 Thermocouple 1: White 2: Green Press white buttons (open spring terminals) by using a slotted screw driver (size 2) and carefully extract thermocouple flex wires Loosen thermocouple from its support Check sufficient insulation between both signal lines (green and white) and thermocouple jacket Nominal value: > 1MΩ Connect thermocouple at room temperature to thermometer (green +; white -) Thermometer must indicate ambient temperature Heat thermocouple tip by using a hot air tool Temperature must increase Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 5.6 Remove motor Open tool (chapter 5.1) Stall blower wheel and remove hexagon nut SW8 from motor shaft by using a wrench Stall motor shaft by using slotted screw driver (size 2), turn blower wheel counterclockwise (ccw) and extract it Remove PT fillister head screws KA35x16 (3x) 1: Brown 2: Black 3: Yellow 23 Extract receptacles from main switch with function button (3x) and line/mains terminal (2x) Remove PT fillister head screws KA35x16 (3x) Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A 120/230V QM INN_FO_29 Page 10 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 400V Remove motor interconnect plug and extract flex wires from their retaining brackets 5.7 Check motor Measure resistance between neutral point (SP, flex wires outlet) and the phase connections U, V and W by using an ohmmeter; resistance nominal values for each phase must correspond with the ranges given in the table SP W U V Voltage [V] Resistance [Ω] 120 26 32 230 67 82 400 154 189 Ensure the motor shaft turns smoothly and does not touch the stator After motor replacement make sure the blower wheel does not touch the housing Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 11 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 5.8 Electronic circuit board heater and blower unit 1: Black 2: Brown 3: White Remove blower wheel and motor (chapter 5.6) Desolder flex wires to heating element (3x) Remove electronic circuit board (HCU 38, respectively HCU 39) and check it for possible defects (scorch marks, deformations) 5.9 Electronic circuit board interface (SYSTEM models only) If interface and/or display not operate correctly replace electronic circuit board (IDU 04) In addition check correct functioning of the leakage current protection circuitry (chapter 8.2) Loosen PT fillister head screws KL35 x 16 (2x) Then press carefully snap-fit mechanism an extract socket connector Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 12 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Possible causes of trouble Error ERR 01 ERR 02 ERR 03 ERR 04 - 06 ERR 07 ERR 08 Tool does not heat, motor runs Motor does not run Tool does not heat and motor does not run Max air temperature can not be reached Max air temperature exceeded Excessive noise Interface does not work No display indication Possible cause Internal tool temperature too high (>70°C) Tool protection diode defective Heating elment temperature exceeded Wrong load resistor assembled Thermocouple defective Measurement circuit defective Electronic circuit board defective Wrong load resistor Leakage current protection circuitry defective Motor defective Heating element defective Triac defective Temperature limit switch defective Photo sensor defective LED defective Wrong load resistor Thermocouple defective Bearing defect Motor interconnect plug not properly assembled Break of power supply cord Main switch with function button defective Heating element with wrong voltage ratings Mica tube is missing Method of resolution Check air circulation Replace electronic circuit board Check load resistor Replace thermocouple Replace electronic circuit board Replace electronic circuit board Check load resistor Replace electronic circuit board Replace motor Replace heating element 5.8 4.3 5.8 5.6 4.2 Check load resistor Replace thermocouple Repalce motor 4.3 5.5 5.6 Check motor interconnect plug Repalce power supply cord Replace main switch with function button Replace heating element 5.2 5.4 4.2 Assemble mica tube Replace motor Check socket connector and ribbon cable Replace interface Check socket connector and ribbon cable Replace interface Interface defective 5.5 5.8 5.8 Bearing defect Break of internal wiring 4.3 Replace electronic circuit board Clean photo sensor Interface defective 5.8 Let the tool cool down Photosensor polluted Break of internal wiring Chapter 5.6 5.9 5.9 Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 13 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Test procedure Insulation test Function check of high voltage tester: Shorten tips Signal lamp illuminates and horn sounds Apply high voltage of 2500V (release current < 30mA) for second between line/mains plug and heater tube; no flashover or breakdown must occur Function test Set red and blue potentiometers to position 0, main switch with function button to midposition Connect tool to rated voltage Set HOTWIND SYSTEM to potentiometer mode open loop (see chapter 8.3): Set value Heater ( Pot), Set value Air ( Pot), Control ( OPE) Record customer adjustments for further reference and re-adjust tool accordingly after passing the test procedure! Switch the tool on (main switch with function button to position I) Blower runs on minimum speed Turn blue potentiometer from position to position 10 Motor speed increases Turn red potentiometer from position to position 10 Heating power increases Check maximum power consumption (must correspond with nameplate) Turn blue potentiometer from position 10 to position Check max output temperature (approx 650°C, respectively 800°C) Block air inlet or outlet Electronic circuit must cut the power down (check heating element protection); remove blockage and heating power must re-increase Set main switch with function button to mid-position Motor speed must increase, power consumption < 150W Blower turns off automatically after 90 seconds no display indication HOTWIND SYSTEM models: Check interfaces (chapter 8.3) Customer specifications are to be observed if applicable Checking completeness Check correct assembling of heater tube: Protection grid horizontally aligned All screws and cable gland must be tightened Check for cleanliness and possible damage Potentiometers red and blue must be set to position Main switch with function button must be set to mid-position Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 14 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Test instructions 8.1 LHS Field Tester description LED Nr Power: Tool switched on Nr Current level: Current level (brightness) Nr Voltage level: Voltage level (brightness) Nr Relais: Logic state of relay contact Power switch ON/OFF Selection of Test out signal Voltage control - Voltage 10V Current control - Current 20mA Selection Pot+ output signal OFF – No voltage at Pot+ Pin 7, RJ-45 ON – 5VDC at Pot+ Pin 7, RJ-45 Potentiometer Adjustment of current or voltage level Of the Test out signal Port for 8-poles test jack connector Port for RJ45 connector Pin assignment RJ-45 Current GND NC NC NC 24VDC out GND Pot + (5VDC out) Pot var (0 10VDC/ 20mA out) RJ-45 8 Pin assignment 8-poles port and color code 24VDC out (red) GND (black) Resistor 100k (yellow) Resistor 100k (yellow) Relais LED (blue) Relais LED (blue) GND (white) Current out (brown) Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 15 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 8.2 Check leakage current protection circuitry Disconnect hot air blower on every pole from the line/mains! Remove heating element (chapter 4.1) Open tool (chapter 5.1) Remove blower wheel (chapter 5.6) Connect blue flex wires to 2-poles relay contact plug Equip red, black and brown flex wire with one crocodile clip each Red Brown Black Plug relay contact plug with blue flex wires into appropriate receptacle Set main switch to Blue position I Turn tool upside down Connect red flex wire to soldering lug on the left Connect black flex wire to soldering lug on the right Connect brown flex wire to the center heating element receptacle LHS Field Tester: Set switch Test out to position Current 0-20mA Set switch Pot+ 5VDC to position OFF Set potentiometer to position 0mA, 0% Set Power switch to ON position LED + LED must illuminate Turn potentiometer slowly clockwise (cw) and keep an eye on the „relay-LED“ no LED must turn off before reaching the maximum potentiometer position Check the load resistor if the relay does not switch off If the load resistor is correctly connected the electronic circuit board must be replaced (chapter 5.8) Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page 16 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 8.3 Check interfaces Set HOTWIND SYSTEM to interface mode closed loop: Set value Heater ( COn), Set value Air ( COn), Control ( CLO) Mode Display Standby Unit Uni CEL/FAr HEA Pot/COn Air Pot/COn LOO CLO/OPE Set value Heater Set value Air Control Press function button for a long time (> sec.) Activate configuration Celsius/Fahrenheit Potentiometer/Interface Potentiometer/Interface Closed loop/Open loop Press function button for a short time (< sec.) go to set value Heater go to set value Air go to Control go to Unit Representative illustration of interface plug assembling The specific pin assignment is given in the following tables 10 Connect LHS Field Tester to hot air blower by using interface cable Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page 17 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 8.3.1 Current control heater Assemble interface cable to interface plug according to table below Designation 24VDC 4-20mA 4-20mA + 0-10V GND RJ 45 Cable LHS Field Tester blue black brown orange Interface plug Connect hot air blower to LHS Field Tester by using interface cable Switch LHS Field Tester on; switch hot air blower on LHS Field Tester: Set switch Test out to position Current 20mA Set switch Pot+ 5VDC to position OFF Set potentiometer to position 4mA, 0% Set Power switch to ON position Display temperature set value: OFF Turn potentiometer step-by-step to position 20mA Display temperature set value must increase to 650°C or 1200°F, temperature actual value must increase slowly (if temperature decreases the thermocouple connections are inverted) Switch hot air blower off by using main switch with function button 8.3.2 Voltage control heater Assemble interface cable to interface plug according to table below Designation 24VDC 4-20mA 4-20mA + 0-10V GND RJ 45 Cable LHS Field Tester blue black brown orange Interface plug no connection Connect hot air blower to LHS Field Tester by using interface cable Switch LHS Field Tester on; switch hot air blower on LHS Field Tester: Set switch Test out to position Voltage 10V Set switch Pot+ 5VDC to position OFF Set potentiometer to position 0V, 0% Set Power switch to ON position Display temperature set value: OFF Turn potentiometer step-by-step to position 10V Display temperature set value must increase to 650°C or 1200°F, temperature actual value must increase slowly (if temperature decreases the thermocouple connections are inverted) Switch hot air blower off by using main switch with function button Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page 18 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 8.3.3 Current control air quantity Assemble interface cable to interface plug according to table below Designation 24VDC 4-20mA 4-20mA + 0-10V GND RJ 45 Cable LHS Field Tester blue black brown orange Interface plug 10 Connect hot air blower to LHS Field Tester by using interface cable Switch LHS Field Tester on; switch hot air blower on LHS Field Tester: Set switch Test out to position Current 20mA Set switch Pot+ 5VDC to position OFF Set potentiometer to position 4mA, 0% Set Power switch to ON position Display temperature set value: OFF Turn potentiometer step-by-step to position 20mA Display set value Air must increase to 100, blower motor speed and air quantity must increase in evidence Turn potentiometer step-by-step to position 4mA Display set value Air must decrease to Lo, blower motor speed and air quantity must decrease in evidence Switch hot air blower off by using main switch with function button 8.3.4 Voltage control air quantity Assemble interface cable to interface plug according to table below Designation 24VDC 4-20mA 4-20mA + 0-10V GND RJ 45 Cable LHS Field Tester blue black brown orange Interface plug no connection 10 Connect hot air blower to LHS Field Tester by using interface cable Switch LHS Field Tester on; switch hot air blower on LHS Field Tester: Set switch Test out to position Voltage 10V Set switch Pot+ 5VDC to position OFF Set potentiometer to position 0V, 0% Set Power switch to ON position Display temperature set value: OFF Turn potentiometer step-by-step to position 10V Display set value Air must increase to 100, blower motor speed and air quantity must increase in evidence Turn potentiometer step-by-step to position 0V Display set value Air must decrease to Lo, blower motor speed and air quantity must decrease in evidence Switch hot air blower off by using main switch with function button Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page 19 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified Wiring diagrams 9.1 Wiring diagram 120/230V + - Load resistor Bürdewiderstand 0.5mm2 (yellow / gelb) 0.5mm2 (black / schwarz) 0.5mm2 (brown / braun) 0.25mm2 (blue / blau) 0.25mm2 (green / grün) 0.25mm2 (red / rot) 2.5mm2 blue / blau Power Supply Cord Netzkabel N (blue / blau) Clamp Klemme L (brown / braun) 2.5mm2 white / weiss 2.5mm2 brown / braun 2.5mm2 black / schwarz Heating element Heizelement Thermocouple Thermoelement 2.5mm2 brown / braun green / grün white / weiss HCU 38 0.25mm2 (black / schwarz) Main Switch Hauptschalter Ribbon cable / Flachbandkabel 26 x 28AWG Repair instructions HOTWIND Premium / System Leister Technologies AG Revision: A QM INN_FO_29 Page 20 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 9.2 Wiring diagram 400V 0.5mm2 (brown / braun) 0.5mm2 (black / schwarz) 0.5mm2 (yellow / gelb) 0.25mm2 (blue / blau) Load resistor Bürdewiderstand 0.25mm2 (black / schwarz) 0.25mm2 (red / rot) 2.5mm2 blue / blau 2.5mm2 brown / braun Power Supply Cord Netzkabel L2 (blue / blau) Clamp Klemme L1 (brown / braun) 2.5mm2 white / weiss 2.5mm2 brown / braun 2.5mm2 black / schwarz Heating element Heizelement HCU 39 white / weiss Thermocouple Thermoelement green / grün +- 0.25mm2 (green / grün) Main Switch Hauptschalter Ribbon cable / Flachbandkabel 26 x 28AWG Leister Technologies AG Repair instructions HOTWIND Premium / System Revision: A QM INN_FO_29 Page 21 / 21 Created 25.06.12 PRI Released 27.06.12 PRI Modified 10 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.) LHS Field Tester (Leister article no 128.650) Interface connectors package (Leister article no 143.129) (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 ... circuitry defective Motor defective Heating element defective Triac defective Temperature limit switch defective Photo sensor defective LED defective Wrong load resistor Thermocouple defective Bearing... PRI Modified 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... elment temperature exceeded Wrong load resistor assembled Thermocouple defective Measurement circuit defective Electronic circuit board defective Wrong load resistor Leakage current protection circuitry
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