PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified REPAIR INSTRUCTIONS Hot-air tool TRIAC BT Serial number from 0908260458 © 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, Tel +41 41 662 74 74 Fax +41 41 662 74 16 www.leister.com leister@leister.com PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Table of contents Scope of applicability Safety precautions Remarks Electronics 4.1 Opening tool 4.2 Handle 4.3 Power supply cord 4.4 Line/mains switch 4.5 Wiring 4.6 Electronic circuit board HCU 26 4.7 Replace electronic circuit board HCU 26 Motor 5.1 Function check 5.2 Check carbon brushes 5.3 Check commutator 10 5.4 Replace motor 10 5.5 Replace turbines 11 5.6 Cleaning 12 Heating element 13 Possible causes of trouble 14 Wiring diagram 15 Test procedure for TRIAC BT (protection class II) 16 10 Equipment required for LEISTER repair service 18 PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 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 TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Electronics 4.1 Opening tool Disconnect tool from the line/mains! Loosen PT fillister head screws KA35x20 (4x) Remove handle 4.2 Handle Replace the handle if it is either strongly weared (abraison, mechanical damage) or if the rubber is refractory or extremely soaked (adhesive) PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified 4.3 Power supply cord • Replace the power supply cord if it shows a short circuit, interruption or mechanical damage • Check strain relief and terminals Continuity checker / buzzer, visual inspection " Notes • Do not shorten (cut and use again) power supply cords • If the customer did so or if third party cords are assembled, they are to be replaced 4.4 Line/mains switch Check line/mains switch: - Position "O": Switch must have no continuity - Position "I": Switch must have continuity Continuity checker / buzzer 4.5 Wiring • Check all flex wires for interruptions, short circuits and mechanical damages • Check correct wiring (compare with the photo) Visual inspection PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified 4.6 Electronic circuit board HCU 26 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! • Check electronic circuit boards for visual error indications (scortch marks, exploded or expanded/swelled parts) Visual inspection • Perform function check (see test procedure) 4.7 Replace electronic circuit board HCU 26 ESD Opening of the tool see chapter 4.1 Put turbine housing upper part aside Make sure the flex wire guide is correctly positioned when assembling Loosen PT fillister head screws KL30x10 (3x) and remove cover plate PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Remove electronic circuit board Push flex wires off the brackets Extract flex wires of the motor from spring terminals by using a screwdriver Extract power supply cord from the strain relief clamps and remove it by actuating the spring contacts PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Remove spring contacts by using a screwdriver and extract them from the guide Extract electronic circuit board from the terminal Break the replacement electronic circuit board apart by using flat pliers and dispose connecting pieces Insert O-ring in potentiometer knob and snap it on the potentiometer Assemble electronic circuit board in reverse order Recommended torque for KA35x20 and KL30x10: Torque: 1.20 Nm Revolution speed: 6501/min PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Motor 5.1 Function check 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! Connect tool to rated voltage and turn it on Motor must run steadily and its power consumption may not exceed 100W Turn the tool off and disconnect it from the line! Wattmeter " Notes • An excessive noise indicates a bearing defect Ỵ Replace motor (see chapter 5.4) • A power consumption >100W indicates a commutator defect ẻ Replace motor (see chapter 5.4) ã Unsteady noise (irregular movements, loose contact) Ỵ Check carbon brushes (see chapter 5.2) 5.2 Check carbon brushes Replace the carbon brushes if their length measure 4mm or even less Check both carbon brushes! If the carbon brushes are not to be replaced make sure to re-insert them the same way (abraison) Opening of the tool see chapter 4.1 Carefully bend back the ears of both carbon brush supports Caution, springs are under tension! Check length of both carbon brushes PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 10 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified 5.3 Check commutator Visual chek of commutator: • Worn out lamella • Bluish discoloration • Deep grooves (U-shaped) Replace the motor if a defect is detected (see chapter 5.4) Visual inspection 5.4 Replace motor Opening of the tool see chapter 4.1 Push flex wires off the brackets Extract flex wires of the motor from spring terminals by using a screwdriver and remove terminal Connect replacement motor to spring terminals and slide the flex wires in the brackets; then connect terminal to the motor PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 11 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified 5.5 Replace turbines The turbines are to be replaced if they are damaged or essentially deformed Opening of the tool see chapter 4.1 Loosen hexagon nut by using a socket wrench (no 8) Remove upper turbine by using two screwdrivers Remove deflector Make sure the deflector is correctly positioned when assembling PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 12 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Move the lower turbine to the top; as soon as it is enough far from the bottom, it may be removed the same way as the upper turbine Assemble replacement turbines in reverse order Recommended torque for the hexagon nut: Torque: 0.6 Nm Revolution speed: 6501/min After replacement of the turbines a function check of the motor must be performed 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! Connect flex wires of the motor to rated voltage and check if the turbines not touch any housing parts If the blower shows real vibrations, disconnect it from rated voltage, loosen nut, turn the upper turbine slightly, tighten nut and check function once again 5.6 Cleaning Clean the tool! If the air filters of the handle are defective or missing, they are to be replaced If the air filters are clogged, they are to be cleaned PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 13 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Heating element Loosen PT fillister head screws KA35x20 (4x) and remove heater tube and mica tube Heating element and gasket may be removed now • 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 • Check the heating element by using an ohmmeter Ohmmeter Voltage [V] 120 230 Power [W] 1500 1550 Resistance [Ω] approx 10 approx 35 PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 14 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Possible causes of trouble Error Possible cause Method of resolution Unexpected AC power failure Switch the tool off for at least Line/mains switch on position second; then turn it on "I" (ON) when tool connected again to line/mains Replace heating element Heating element defective (chapter 6) Triac defective Tool does not heat, motor Temperature limit switch deruns Replace electronic circuit fective board (chapter 4.7) Photo sensor defective LED defective Replace carbon brushes Carbon brushes too short (chapter 5.2) Commutator defective Replace motor Motor does not run (chapter 5.4) Bearing defect Flex wires of motor incorCheck whether flex wires are rectly connected to spring properly connected terminals Tool heats at potentiometer Potentiometer defective Replace electronic circuit position "0" board (chapter 4.7) Triac defective Interruption of power supply Replace power supply cord (chapter 4.3) Tool does not heat and motor cord does not run Replace line/mains switch Line/mains switch defective (chapter 4.4) Heating element with inReplace heating element curect rated voltage (chapter 6) Maximum air temperature Defective nozzle: Photo sencan not be reached Repalce nozzle sor receives extraneous light Mica tube missing Assemble mica tube Maximum air temperature Photo sensor polluted Clean photo sensor exceeded Excessive noise Bearing defect Replace motor (chapter 5.4) Commutator defective: Power consumption of motor • Worn out lamella Replace motor (chapter 5.4) >100W • Bluish discoloration • Deep grooves (U-shaped) Unsteady noise (irregular Carbon brushes too short or Replace carbon brushes movement, loose contact) blocked (chapter 5.2) Potentiometer illuminates, motor runs, tool does not heat PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 15 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Wiring diagram PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 16 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified Test procedure for TRIAC BT (protection class II) Insulation test • Function check of the high voltage tester: Shorten tips Ỵ Signal lamp illuminates and horn sounds • Set line/mains switch of the tool to position "I" (ON) • Apply a high voltage of 3000V (release current 100mA) for second between line/mains plug and protection tube of the heating element; no flashover or breakdown must occur Function test • Set line/mains switch of the tool to position "I" (ON), turn potentiometer to the right end stop (cw) up to position "9" • Connect tool to rated voltage (check error recovery) Ỵ Motor runs, potentiometer knob illuminates red, tool must not heat! • Check power consumption of the motor by using a wattmeter (50 65W) • Check smooth running of motor (bearings, commutator) and fan (vibrations, particles) • Turn potentiometer to the left end stop (ccw) up to position "0" • Set line/mains switch of the tool for at least second to position "O" (OFF) and then to position "I" (ON) Ỵ Motor runs, potentiometer knob is not illuminated, tool does not heat • Check heating: Set potentiometer to position "1" Ỵ Tool starts heating Set potentiometer to position "8" Ỵ Tool heats almost fully Set potentiometer to position "9" Ỵ Tool heats fully for a short time (rated power) Ensure power consumption increases steadily between potentiometer positions "1" and "8" (ammeter, wattmeter) • Block air outlet, respectively reduce it essentially Ỵ Electronic circuit must cut the power consumption down (protection of the heating element); with free air outlet the power consumption must increase • Switch the tool off: Set potentiometer to position "0", let the tool cool down, set line/mains switch to position "O" (OFF) and disconnect the tool from rated voltage Checking completeness • Check printed details on the nameplate: Type, voltage, current, power consumption (must correspond with the above measurements) • Check serial number (yymmddxxxx) yy year of production mm month of production dd day of production xxxx consecutive number PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 17 / 18 Created 09.12.09 PRI Released 10.12.09 PRI Modified • Warnings must be printed on the handle • Check power supply cord mechanically and electrically (correct plug type for country, conductor cross-section as per rated current) • Check nozzle orientation (see photos, keep an eye on the company label!) • • • • Both air filters must be fitted All screws must be tightened Check for cleanliness and possible damage Shake the tool: Heating element may not hit the heater tube Additional test for repaired tools The maximum temperature (potentiometer on position "9") may not exceed the maximum values stated in the table below for all nozzle models Rated voltage [V] Nozzle Temperature [°C] Round nozzle ø 5mm 620 700 230 Wide slot nozzle 40mm 550 640 Round nozzle ø 5mm 620 700 120 Wide slot nozzle 40mm 550 640 Correct thermocouple arrangements (thermocouple must not touch the nozzle!): 2mm 5mm If the maximum temperature according to the table is exceeded, clean the photo sonsor Should the temperature be below the minimum value, check if the correct heating element (voltage/power) and the mica tube are assembled In addition make sure the photo sensor does not receive extraneous light (e.g due to a hole in the nozzle or in the turbine housing) PROCESS TECHNOLOGIES Repair instructions TRIAC BT Revision: A QM INN_FO_29 Page 18 / 18 Created 09.12.09 PRI Released 10.12.09 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.) (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 ... 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... motor by using a wattmeter (5 0 65W) • Check smooth running of motor (bearings, commutator) and fan (vibrations, particles) • Turn potentiometer to the left end stop (ccw) up to position "0" • Set... motor (chapter 5. 4) Commutator defective: Power consumption of motor • Worn out lamella Replace motor (chapter 5. 4) >100W • Bluish discoloration • Deep grooves (U-shaped) Unsteady noise (irregular