QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified REPAIR INSTRUCTIONS Hot-air automatic welder UNIROOF E Production code from 0847 Software version from 1.0A © 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 QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Table of contents 10 11 12 13 14 Scope of applicability Safety precautions Remarks Mechanics check Assembly and adjustment 5.1 Nozzle 5.2 Transportation lock for hot-air blower (Ghibli) 5.3 Automatic drive start-up Electronics 6.1 Cover 6.2 Power supply cord 6.3 Wiring 6.4 Main switch 6.5 Automatic drive start-up 6.6 Triac Drive unit 10 7.1 Function check 10 7.2 Electronic circuit TRN 05 11 7.3 Electronic circuit ZPM 06 12 7.4 Carbon brushes 15 7.5 Drive motor check 16 7.6 Drive motor replacement 17 7.7 Housing assembly 19 Hot-air blower (Ghibli) 19 8.1 Disassembly 19 8.2 Wiring 21 8.3 Heating element 21 8.4 Thermocouple 22 8.5 Blower motor 24 8.6 Assembly 24 Setup menu 25 Possible causes of errors 26 Wiring diagram 27 Test procedure for UNIROOF E (protection class I) 28 Equipment required for LEISTER repair service 30 Appendix screw locking 31 QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 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 ESD-protected working place (see "Equipment required for LEISTER repair service") is essentiel 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 (unplugged) from the line/mains on every pole before any work is commenced! Repaired tools must pass the LEISTER test procedure (see "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! QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Mechanics check • • • • • Check undercarriage for cracks and deformations Visual inspection Check silicon rubber rings for possible damages Check all moving parts for smooth running and replace them if necessary Clean all polluted parts Lubricate all moving parts with unpolluted grease The following parts are to be lubricated with grease (e.g Microlube GBUY 131): Round toothed rack Between tool holder and guide roller Ball bearing of swivel roller QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Assembly and adjustment The assembly has to be carried out according to exploded diagrams and spare parts lists " Note Before assembling the tool or its components check which screws are to be locked by using Loctite 242 Therefore the appendix contains an exploded diagram highlighting all screws to be locked 5.1 Nozzle Check basic nozzle adjustment according to the illustration stated below Visual inspection 5.2 Transportation lock for hot-air blower (Ghibli) The ball pressure screw must hold the Ghibli securely in the rest position The distance between ball pressure screw and tool holder has to be approx 0.4 mm QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 5.3 Automatic drive start-up Set bolt of the automatic drive start-up must be moveable against little resistance Check whether the set bolt is bent Set bolt of drive switch must protude 22mm (see lower picture on the left) Set bolt must not be lubricated because it glides on teflon Electronics Warning! Disconnect the tool from the line/mains (plug unplugged) while doing the component checks described in this chapter! 6.1 Cover Disassemble handle: Loosen countersunk screws M6x16 (2x) QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Disassemble guide bar support: - Lock swivel roller by using multigrip pliers (protect pliers with scraped plastic material, a rag or similar to avoid damage of the swivel roller) - Loosen cheese head screw M6x25 Loosen screws M4x10 to the cover (2x) Open cover 6.2 Power supply cord Replace the power supply cord, if it shows a short circuit, a break or mechanical damage Continuity checker/Buzzer, Visual inspection " • • Notes Do not shorten the power supply cord! If the customer did so or if a third-party cord is used, the power supply cord has to be replaced Check carefully the protective earth conductor for continuity QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 6.3 Wiring • Check all connections (wires, leads and cables) for mechanical damage • Check whether all wires, leads and cables are connected correctly (loose contact) and not show any interruptions or short circuits Continuity checker/Buzzer, visual inspection • Check cable protection tube for cracks, gaps and mechanical damages Visual inspection Grey clip must have engaged shortly QM Repair instructions UNIROOF E PROCESS TECHNOLOGIES Revision: A Page / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 6.4 Main switch Check main switch - position 0: Switch must have no continuity - position 1: Switch must have continuity Continuity checker/Buzzer 6.5 Automatic drive start-up Check electric contact - Drive switch not actuated: - Drive switch actuated: Switch must have no continuity Switch must have continuity Continuity checker/Buzzer The middle contact may not be connected! 6.6 Triac 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! If the tool heats (possibly not pulsing) when switching on the main switch before the heating is turned on, switch the tool off, unplug the gate connection to the triac (red flex wire) and switch the tool on again If the performance is still the same, the triac is defective QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 10 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Drive unit 7.1 Function check Caution! The following measurement 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! Switch the tool off and disconnect (unplug) it from the line/mains Connect an ammeter between the orange plug and the black flex wire of the drive motor (see picture on the left) Connect tool to line/mains and switch it on Set motor speed to maximum (5m/min) The current consumption must be 100 300mA Ammeter " • • Notes An excessive noise of the motor indicates a bearing defect Ỵ Replace motor (see chapter 7.6) If the current consumption exceeds 300mA, the motor works with overload Possible causes: Pressure roller touches the housing or defective gearing QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 18 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Remove split pin on suitable base (e.g wooden plate) by using punch (ø max 1.9mm) and hammer Pay attention the worm rests properly on the base to prevent any damage of the motor ball bearings Disassemble worm, silicone gasket, sealing of gear box and round cord from the motor Replace motor Assembly: • Assemble in reverse order • Check by beating whether the gearing is filled with grease up to the center level of the axle; refill if necessary • Tighten cheese head screws M3x8 (4x) of the gear box cover with 1.2Nm only (use torque screwdriver)! QM Repair instructions UNIROOF E PROCESS TECHNOLOGIES Revision: A Page 19 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 7.7 Housing assembly Assembly: • Check in the appendix which screws are to be mechanically secured • Adjust the housing in such a way that the distance to the drive roller is steady all around • Heat sink for triac must be covered with thermal conducting paste Hot-air blower (Ghibli) 8.1 Disassembly Disconnect all connections of the hot-air tool, remove cable ties black white black/blue green white black QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 20 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Remove grey clip from hose screw fitting: • Unlock clip by pushing a screwdriver to one side flap and lift clip with an additional screwdriver size • Proceed the same way from the opposite side and remove the clip Remove cables including cable protection tube from the Uniroof E housing Loosen countersunk screws M5x12 (4x) and remove Ghibli Loosen cheese head screws M3x8 (4x) of the overlap welding nozzle Remove mica tube and heater tube The gasket can not be removed, because it is joined with the Ghibli housing! Extract rubber plugs (3x) Loosen raised cheese head screws M3.5x20 (5x) Open housing QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 21 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 8.2 Wiring • • • Check all wires and leads for interruptions, short circuits and mechanical damage Check correct wiring (compare with picture) The flexible wires of the thermocouple (green and white) may not be provided with ferrules Continuity checker/Buzzer, visual inspection 8.3 Heating element • • Do a visible inspection of the heating element Replace the heating element if it is either mechanically damaged or if any heating channels are clogged Measure the resistance of the heating element by using an ohmmeter Ohmmeter, visual inspection Resistance must be 25Ω (+/- 10%); otherwise replace heating element QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 22 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 8.4 Thermocouple Open hot-air blower (Ghibli) according to chapter 8.1 8.4.1 Thermocouple check • Extract thermocouple connections from screwed connector and remove overlap welding nozzle including heating element (see chapter 8.1) • Check with continuity checker/buzzer whether continuity exists between shielding lead and jacket of the thermocouple Otherwise replace thermocouple (see chapter 8.4.2) • Measure thermocouple resistance between both signal leads (green and white) Therefore the thermocouple must be cooled down to ambient temperature! Nominal value: approx 7Ω (no short circuit or interruption) • Check insulation between both signal leads (green and white) and shielding lead Nominal value: > 5MΩ Ohmmeter 8.4.2 Thermocouple replacement Remove cable ties and extract thermocouple cable QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 23 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Push distance bushing back by using pliers Extract thermocouple carefully from its socket by using pliers Remove distance bushing and mount it to the replacement thermocouple Assembly of replacement thermocouple: • Pay attention to correct cable routing • Assembly of Ghibli see chapter 8.6 Caution! The following measurement 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! After thermocouple replacement the temperature offset must be re-adjusted: • Switch Uniroof E on and set temperature to 600°C (1112°F) • Wait until set temperature is reached • Move thermocouple in parallel to the nozzle and find hottest spot; make sure thermocouple does not touch the nozzle (see picture on the right) • Re-adjust the temperature offset if the display does not agree with the actual value (see chapter 9) The maximum offset may not exceed 40°C (heating element could be destroyed!) If this should be the case, check thermocouple, heating element and electronic circuit once again and replace them if necessary Temperature meter QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 24 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 8.5 Blower motor Open hot-air blower (Ghibli) according to chapter 8.1 8.5.1 Function check Caution! The following measurement 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! Switch Uniroof E off Connect ammeter between terminal and black flex wire of the blower (see picture) Switch the tool on The current consumption must be 200 300mA Ammeter " • • • Notes An excessive noise of the motor indicates a bearing defect Ỵ Replace motor (see chapter 7.6) If the current consumption exceeds 300mA, the motor works with overload (e.g motor not correctly positioned, turbine touches housing) Check carbon brushes if strange sound (stuttering) is detected 8.5.2 Carbon brushes Extract motor from its rest Remove carbon brushes according to chapter 7.4, measure its length and replace them, if their length is 4mm or even less Check both carbon brushes! If the carbon brushes are not to be replaced make sure to insert them the same way (abraison) Re-assemble motor correctly to its rest Sliding caliper 8.6 Assembly • • • • Reverse order of chapter 8.1 Correct wiring see chapter 8.2 Put air filter correctly in its support Prior to close the housing make sure the motor will be pushed to the bottom to prevent the turbine touches the housing! • Do not pinch the warning label „Hot surface“ QM Repair instructions UNIROOF E PROCESS TECHNOLOGIES Page Revision: A 25 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified Setup menu Modifications in the Setup menu are automatically stored At the same time press M - + H and switch the tool on „WRONG KEY COMB TURN POWER OFF“ Code eingeben (HMHH+-) H press Serial Number H press M year 00 M M week serial number 00 000 Max Speed 5.00m/min - + select with Min Speed 1.00m/min - + select with Max temperature 600°C - + select with Temp Offset +0°C - + select with Display Unit `-`>C/m, `+`>F/ft - + select with H press H press H press H press 1.00 5.00 20 600 QM Repair instructions UNIROOF E PROCESS TECHNOLOGIES Page Revision: A 26 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 10 Possible causes of errors • No announcement on the display Check wiring Check electronic circuit TRN 05 Connect replacement electronic circuit CSE 06 temporarly Check thermocouple (short circuit) chapter 6.3 chapter 7.2 chapter 8.4 • Drive motor does not run or pauses suddenly Check wiring (ribbon cable: interruption / short circuit) Check electronic circuit TRN 05 Check carbon brushes and drive motor Test electronic circuit ZPM 06 chapter 6.3 chapter 7.2 chapter 7.4 & 7.5 chapter 7.3 • Drive motor does not start automatically when swivelling in the Ghibli Check automatic drive start-up Check DIP-switch positions OFF OFF ON OFF chapter 6.5 OFF OFF OFF OFF • Tool does not heat Check wiring Check hot-air blower (Ghibli) Check electronic circuit TRN 05 Connect replacement electronic circuit CSE 06 temporarly chapter 6.3 chapter 8.1 - 8.4 chapter 7.2 • Tool heats all the time Check triac Check electronic circuit TRN 05 Connect replacement electronic circuit CSE 06 temporarly chapter 6.6 chapter 7.2 • Blower motor does not run Check wiring Check blower motor of hot-air blower (Ghibli) Check electronic circuit TRN 05 chapter 6.3 chapter 8.5 chapter 7.2 1A braun / brown 1.5mm2 Schalter / Switch S1 Phase / Line 2A 3A Klemme / Terminal J1 Null-Leiter / Neutral Erdung / Earthing (+) Signal (-) + Grün / green - Weiss / withe TRN05A Anf ahrsensor / Proximity switch Signal (+) Anf ahrsensor / Proximity Switch ZPM06 Schrim / shield TRN05 ZPM06 VCC VCC Erdung / Earthing GND GND nc Drehzahl / speed Drehzahl / speed Phase / Line braun / brown 20AWG Gate_v Gate_v Null / Neutral blau / blue 20AWG Strom_v Strom_v nc nc nc Gate Motor + - M= - + shield T1 CSE06 Anf ahren / driv eaway nc Limit_t LCD-Modul 150nF/275V C1 weiss / white 16AWG braun / brown 16AWG Revision: A blau / blue 1.5mm2 Anf ahren / driv eaway nc Limit_t nc Vref nc Temp Vref ZC Gate_t1 Strom_v / current_v Gate_v Temp ZC Gate_t1 Strom_v / current_v 1A 2A 3A Klemme / Terminal J2 Q1 MT1 TRIAC MT2 Page braun / brown 1.5mm2 rot / red 20AWG VSS Drehzahl / speed GND VSS CSE06 VCC Gate_v schwarz / black 20AWG blau / blue 1.5mm2 VCC Drehzahl / speed 10uH schwarz / black 20AWG L2 10uH Gebläsemotor / Blower Motor M2 L1 weiss / white 1.5mm2 GND HE1 Heizelement / Heating element Thermoelement / Thermocouple M1 -PWM 230VAC 230VAC +PWM 230VAC 230VAC PROCESS TECHNOLOGIES Repair instructions UNIROOF E QM 27 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 11 Wiring diagram QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 28 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 12 Test procedure for UNIROOF E (protection class I) Protective earth conductor test • Measure resistance between the the earth/ground pin of the plug and the nozzle as well as between the the earth/ground pin of the plug and the undercarriage by using the protective earth conductor tester (< 0.2Ω) Insulation test • Function check of high voltage tester: Shorten tips Ỵ Signal lamp illuminates and horn sounds • Connect tool to a short circuit receptacle • Set main switch of the tool to position "1" (ON) • Apply a high voltage von 1000V (release current 100mA) for second between the short circuit receptacle and the undercarriage; no flashover or breakdown must occur Settings • Set main switch to position "0" (OFF) and connect tool to rated voltage (line/mains or transformer) • Enter the Setup menu: Press all of the four keys together and set the main switch to position "1" (ON) at the same time Enter key combination H M H H + – Enter serial number Max speed 5m Min speed 1m Max temperature 600°C Temp Offset 0°C (to be modified after thermocouple replacement only) Select unit °C or °F • Set main switch to position "0" (OFF) Function test • Change to %-mode: Press keys + and – together and set the main switch to position "1" (ON) at the same time • Press key M to deactivate the automatic restart protection • Press key M once again to start the motor • Run the drive motor with max speed (5m/min) Ỵ Check percential power consumption of the drive, max 65% • Heat the tool up to maximum temperature 600°C Ỵ Check current consumption (according to nameplate) • Check display announcement 595 605°C QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A Page 29 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified • After 15 minutes search for the hottest spot and measure the temperature • Actual value of temperature meter 590 610C ã Adjust temperature offset, if necessary (ẻ Setup menu) Example: Temperature display = 600°C; temperature meter = 610°C Î Offset: - 10°C • Restart tool and heat it up; check temperature after another 15 minutes • Check function of the drive switch • Let the tool cool down • Check Setup menu Checking completeness • • • • Check ratings of the nameplate: Type, voltage, current, power consumption Check production code / serial number Check power supply cord mechanically and electrically (type of plug) The following labels must be bonded: Company label LEISTER large on the side panel and small on the cover of the electronic box Warning label „Hot surface“ and small company label LEISTER on the Ghibli housing • Check for cleanliness and possible damages QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E Page Revision: A 30 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified 13 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 PROCESS TECHNOLOGIES Repair instructions UNIROOF E Revision: A = lock with LOCTITE 242 = tighten with 1.2Nm only 14 Appendix screw locking Page 31 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified QM PROCESS TECHNOLOGIES Repair instructions UNIROOF E = lock with LOCTITE 242 Revision: A Page 32 / 32 Created 26.05.09 PRI Released 28.05.09 PRI Modified ... Otherwise replace thermocouple (see chapter 8.4. 2) • Measure thermocouple resistance between both signal leads (green and white) Therefore the thermocouple must be cooled down to ambient temperature!... personnel carrying out repair work are to be observed by each service centre Safety precautions A well-equipped ESD-protected working place (see "Equipment required for LEISTER repair service ") is essentiel... 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,