PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified REPAIR INSTRUCTIONS Tensiometer EXAMO Production code from 0017 © 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, www.leister.com Tel +41 41 662 74 74 Fax +41 41 662 74 16 leister@leister.com PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Table of contents 10 11 12 13 14 15 16 Scope of applicability Safety precautions Remarks Check mechanics Assembly and adjustment 5.1 Drive distance adjustment 5.2 Safety clutch 5.3 Force sensor Electronics 6.1 Opening housing cover 6.2 Wiring 6.3 Line/mains filter 10 6.4 Main switch 10 Drive unit 11 7.1 Function check 11 7.2 Electronic circuit board STV 03 12 7.3 Power supply TRN 01 13 7.4 Electronic circuit board ZPM 02 14 7.5 Disassembly of the housing lower part 16 7.6 Check carbon brushes 17 7.7 Check drive motor 18 7.8 Disassembly of the drive unit 19 7.9 Replacement of the motor 20 7.10 Replacement of the force sensor 21 7.11 Replacement of the inductive proximity switch 22 7.12 Assembly of the drive unit 23 7.13 Replacement of the mandrel 25 Force measurement, display and recording 26 8.1 Force sensor 26 8.2 Electronic circuit board CSE 26 8.3 USB recording (optional) 27 Setup menu 28 9.1 Electronic circuit board CSE 03 28 9.2 Electronic circuit board CSE 06 29 Settings 30 Possible causes of trouble 31 Wiring diagram 32 Test procedure for EXAMO (protection class I) 33 Equipment required for LEISTER repair service 35 Verification and calibration kit 36 Appendix screw locking 37 PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Scope of applicability These repair instructions are reserved exclusively for LEISTER service centres Only experienced and qualified personnel trained by LEISTER Process Technologies, 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 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 servicing use only identical original LEISTER replacement parts! PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Check mechanics • • • • • • Check smooth movement of slide and tension levers, respectively clamping jaws Check mandrel for concentricity Check clamping jaws for abraison, replace them if necessary Check safety clutch, slide must release manually Clean all polluted parts Lubricate all moving parts with unpolluted grease Lubricate these parts with grease (e.g GBUY 131): Mandrel and guide bars Tension levers (all movable wear points) and threads of tension shafts Sintered bearing (shaft extension) Loosen countersunk screws M3 x 12 (4x), open cover PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Assembly and adjustment The assembling has to be carried out according to the exploded diagrams and the spare parts lists " Notes • Make sure there are no other particles than the essential grease inside the mandrel • Ensure which screws are to be locked by using Loctite 242 prior to the tool assembly or its components Therefore the appendix (chapter 16) contains exploded diagrams highlighting all screws to be locked 5.1 Drive distance adjustment • • • • Check distance at 50mm length of run Adjust zero position by using set screw if deviant Check distance at 50mm and 130mm length of run each Lock set screw by counternut " Note • The deviation may also be adjusted in the setup menu (chapter 9) using menu item "Offset length" PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified 5.2 Safety clutch For safety reasons the movable slide is equipped with a safety srew (safety clutch) It acts due to too high counterforce, and the slide will be decoupled from the drive mandrel This prevents finger or hand pinch while the slide reverses Safety screw Check of safety screw: The slide must get decoupled without applying essential force, but not of its own during regular slide reverse! The torque is specified by construction and may not be altered CAUTION: If defective DO NOT replace the safety screw by a standard screw – for safety reasons use original LEISTER safety screw only!!! PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified 5.3 Force sensor The set screw M10 x 16 actuates the force sensor Do not tighten this set screw too strong, because then the force sensor may indicate a force with no load On the other hand not tighten the set screw too weak, because of the clearance Support must remain slightly movable (testing by hand)! PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Electronics Warning! Disconnect the tool from the line/mains (plug unplugged) while doing the component checks described in this chapter! 6.1 Opening housing cover Loosen hexagon nuts M6/0.8d (4x) and cheese head screws M6 x 12 (4x) on the bottom part of the metal case Lift tensiometer out of the metal case Remove cheese head screws M3 x (4x) of the housing cover and carefully lift the cover Unplug ribbon cable of the electronic circuit board STV 03 and protective earth connection to the upper part of the electronic box PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified 6.2 Wiring Opening of the housing cover see chapter 6.1 • Check all wires, leads and cables for mechanical damages • Check all wires, leads and cables for proper connection (loose contacts), for breaks and short circuits Continuity checker / Buzzer, visual inspection – 230V, 200V, 120V (ø 20AWG): Grey from STV 03 Grey from power supply – 230V (ø 20AWG): White from STV 03 White from power supply – 200V (ø 20AWG): Violet from STV 03 Violet from Power supply – 120V (ø 20AWG): Yellow from STV 03 Yellow from power supply Inductive proximity switch Brown Black Blue Force sensor Red Yellow White with shielding PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page 10 / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified 6.3 Line/mains filter Opening of the housing cover see chapter 6.1 Check continuity of the line/mains filter from input terminal to opposite output terminal (check all of the three terminals) Continuity checker / Buzzer 6.4 Main switch Opening of the housing cover see chapter 6.1 Check continuity of the main switch by using a continuity checker / buzzer Position OFF: Switch must have no continuity Position ON: Switch must have continuity PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page 26 / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Force measurement, display and recording 8.1 Force sensor The following items are to be checked if the force sensor displays no force, permanently too high force or constantly the same value: • Check plug and cable of the force sensor (chapter 6.2) Visual inspection • Check DIP switch configuration on the electronic circuit board CSE (1, and ON) Force sensor replacement see chapter 7.10 If the replacement does not solve the problem, replace the electronic circuit board CSE • After replacement of the force sensor a calibration is essential (chapter 15) • After replacement of the electronic circuit board CSE the new calibration parameters are to be entered (chapter 10) 8.2 Electronic circuit board CSE Approximately in the middle of 2009 the electronic circuit board CSE 03 has been replaced by the electronic circuit board CSE 06 which requires another ribbon cable So, if there is no replacement electronic circuit board CSE 03 deliverable, order the electronic circuit board CSE 06 together with the appropriate ribbon cable (pos 116 and 131 of the spare parts list)! CSE 06 CSE 03 Front view Rear view Ribbon cable PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page 27 / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified 8.3 USB recording (optional) If the USB recording according to chapter 13 does not work, the following items are to be checked: • Option "USB-Stick" in the setup menu must be enabled (chapter 9.2) • Check cable from the USB port and its 5-poles plug Continuity checker / Buzzer • Check connection to the electronic circuit board CSE 06 Visual inspection Arrangements if no error was detected: • Test with another USB stick • Replace the electronic circuit board CSE 06 " Notes • If a new USB stick is used, this must be formatted in format FAT 32 with memory size 512 bytes • Important: Always test new USB sticks on the device! Sometimes not all USB sticks work with the device This can depend on USB design or on preinstalled software which wants to start up automatically, for example PROCESS TECHNOLOGIES Repair instructions EXAMO Revision: A QM INN_FO_29 Page 28 / 40 Created 03.12.09 PRI Released 07.12.09 PRI Modified Setup menu 9.1 Electronic circuit board CSE 03 At the same time press Adjust settings SET Caution: "Green" at this position will delete all parameters! Green and switch the tool on „WRONG KEY COMB TURN POWER OFF“ Setup mode press any button Change setting + or - button View parameters set button Save parameters green button Save: Green Green Green Green Green Green Green Green Green Green Green I-Gain 100 I-Offset Max current 230V= 500mA / 100/120V= 1200mA Max Speed 300mm/min Min Speed 10mm/min Max length 300mm / 600mm Offset length +0 Force Sensor “-“ → No, “+“ → Yes P-Gain P-Max +4000 Display Unit “-“ → N/mm, “+” → lb/in Store Parameter? “ - “ → N o , “ + ” → ye s Press