QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified REPAIR INSTRUCTIONS Automatic hot-air welding machine Varimat V2 Production code from 0937025 Software version from 1.0 © 2010 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 Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Table of contents 10 11 12 13 14 Scope of applicability Safety precautions Remarks Check mechanics Assembly and adjustment 5.1 Assembly of guide roller 5.2 Assembly of adjusting pendulum 5.3 Adjustment of drive sensor 5.4 Adjustment of nozzle Check electronics 6.1 Power supply cord 6.2 Main switch 6.3 Wiring 6.4 Drive motor 6.5 Triac 6.6 Electronic circuit boards 10 Electron for Varimat V2 12 7.1 Blower motor 12 7.2 Heater unit 12 7.3 Thermocouple 13 Setup menu 14 8.1 Setup menu overview 14 8.2 Service menu 15 8.3 Percent menu 16 Error messages 16 Possible causes of errors 17 Wiring diagram 19 Test procedure for Varimat V2 (protection class I) 20 Equipment required for LEISTER repair service 22 Appendix screw locking 23 QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 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! QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Check mechanics • Check undercarriage for cracks and deformations • Check roller chain, sprocket wheels, toothed belt and round belt and replace them if necessary • Check all moving parts for smooth running and replace them if necessary • Clean all polluted parts • Lubricate all moving parts with unpolluted grease, chain with chain oil " Note When using the tool under hard conditions and over a long time, the chain and the toothed belt should be replaced as a precaution Lubricate these parts with grease (e.g Microlube GBUY 131), chain with chain oil: Guide shaft Downholder rollers Axle Roller chain and sprocket wheels Closed end of the chain’s master link must be installed in rotation direction QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Assembly and adjustment The assembling has to be carried out according to the exploded diagrams and the spare parts lists Ensure which screws are to be locked by using Loctite 242 prior to the tool assembly or its components Therefore the appendix (chapter 14) contains exploded diagrams highlighting all screws to be locked 5.1 Assembly of guide roller • Lock knob of the guide roller on the right hand side of the crank • The distance between the left edge of the undercarriage and the guide roller must be 94mm 5.2 Assembly of adjusting pendulum • Lock screw with screw lock high-strength • Fix adjusting pendulum by using the screw in such a way that it remains movable sidewards • Adjust pendulum by using the set screw until tool runs straight on 5.3 Adjustment of drive sensor Adjust drive sensor as follows: • Turn main switch to "0" OFF position • Arrange cable as a loop • Tool holder must be locked at the left end of the guide shaft • Position drive sensor to 0.1mm off the end stop (photo: spacer) The proximity switch acts from approximately 0.2 – 0.5mm • Lock sensor by using the set screw (tighten carefully) QM Repair instructions Varimat V2 PROCESS TECHNOLOGIES Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 5.4 Adjustment of nozzle • • • • Distance between center of swivel-joint roller and nozzle tip 42mm Adjust standard nozzle slightly sloped, approx 1mm (illustration 2) Adjust grip nozzle plain (illustration 2; Y = 0mm) Distance between nozzle edge and swivel-joint roller approx 2mm (illustration 3) Illustration Illustration Nozzle 2mm Illustration Y X X Y Standard 40mm 42mm (+/- 2mm) 1mm Grip 40mm 42mm (+/- 2mm) 0mm QM Repair instructions Varimat V2 PROCESS TECHNOLOGIES Page Revision: A / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Check electronics Warning! Disconnect the tool from the line/mains (plug unplugged) while doing the component checks described in this chapter! 6.1 Power supply cord Open housing cover and check power supply cord Replace the power supply cord if it shows a short circuit, interruption 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 6.2 Main switch Check main switch: - Position 0: No continuity between L1 – T1 and L2 – T2 - Position 1: Continuity between L1 – T1 and L2 – T2 Continuity checker / Buzzer 6.3 Wiring • 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 Visual inspection Terminal connections of transformer to TRN 06 to TRN 06 Line / mains Line / mains 400V version to TRN 06 Line / mains to TRN 06 Line / mains 230 version to TRN 06 to TRN 06 Line / mains Line / mains 200V version QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 6.4 Drive motor 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! Prop the Varimat V2 up in such a way (on a support) that the drive roller does not touch the ground any more Then turn the tool on and let the motor run on maximum speed (12m/min): Press button Speed and press rotary knob e-Drive within seconds as well Ỵ motor runs Adjust speed by using e-Drive Check motor for possible bearing or commutator defects An excessive noise indicates a bearing defect, immoderate brush arcing indicates a commutator defect Measure current consumption of the motor: It may not exceed 350mA after approx minutes of operating time Visual inspection, Ammeter Visual check of commutator: • • • Visual inspection Worn out lamella Bluish discoloration Deep grooves (U-shaped) With desoldered red-white flex wire measure the resistance between the carbon brush holders by using an ohmmeter (see photo) Turn the commutator slowly by hand and check all lamella The resistance must be 50 100Ω per segment Otherwise replace the drive unit Ohmmeter QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified With desoldered red-white flex wire connect a bridge rectifier (see photo on the left) to both carbon brush supports Apply voltage by using a transformer and an ammeter Check for correct polarity Slowly increase the voltage from 0V and check the current consumption If the current consumption exceeds 100mA at a voltage of less than 10V, either the gear or the motor are defective Ỵ replace drive unit Bridge rectifier, Ammeter 6.5 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 and unplug the Gate conductors to the triacs (orange and red-white flex wires) Switch the tool on again If the performance is still the same, one or both triacs are defective orange red-white white brown brown " • • red Notes The Gate conductors could be energized in case of fault! Make sure the unplugged conductors not cause short-circuits (insulate, fix) Switch the tool off and disconnect the power supply to one triac (brown flex wire) directly at the line/mains terminal (unplug, insulate, fix) Switch the tool on again If the performance is still the same, the triac with the existing power supply connection is defective and must be replaced If the tool does not heat any more, the triac with the disconnected power supply connection is defective and must be replaced QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 10 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 6.6 Electronic circuit boards 6.6.1 Electronic circuit board TRN 06 Prior to replacement of the electronic circuit board TRN 06 (power) unplug all socket connectors and remove the attachment screws (4x) Make sure the replacement electronic circuit board rests properly on the distance bushings and the copper ring surrounding the holes (see photo) is not covered with silicone potting compound Then tighten the screws (4x) and connect the socket connectors correctly After replacement of the electronic circuit board TRN 06 enter the values for V-Gain and Temp.Air by using the setup menu 6.6.2 Electronic circuit board CSE 07 Loosen screws (4x) of the electronic circuit board CSE 07 (CPU) Make sure the washers not drop into the tool housing Unplug both ribbon cables and remove the electronic circuit board After replacement of the electronic circuit board CSE 07 enter the values for V-Gain, Temp.Air., Temp.Amb., Ser.Number, Disp Unit and Mains volt by using the setup menu QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 11 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 6.6.3 Electronic circuit board ZPM 06 Disconnect power supply of the electronic circuit board ZPM 06 (firing): Unplug socket connector on the electronic circuit board TRN 06 and check it for continuity Ỵ no continuity must be detected Check the electronic circuit board ZPM 06 in case of overvoltage indication (e.g if a 230V-tool was possibly connected to 400V) Desolder red flex wire to the lower carbon brush holder of the motor Connect a multi-meter as a diode checker between the desoldered flex wire and the upper carbon brush holder (white flex wire) Connect test terminals according to the table stated below and verify the results Soldering iron, diode checker Upper carbon brush holder Red flex wire Results + - + Diode voltage approx 0.5V No diode voltage (This check does not serve as a complete test of the electronic circuit board) If this test is not successful, check the drive motor first (see chapter 6.4) and then replace the electronic circuit board ZPM 06 " • • • • • • Notes Make sure the distance bushings ø 3.1/6 x 2.5 (2x) are inserted when assembling the electronic circuit board ZPM 06 Temperature limit switch and MOSFET are to be covered with thermal conducting paste when assembling The flex wires for power supply are to be twisted The connectors of the ribbon cable must be sealed by using silicone rubber Make sure the ribbon cable does nout touch the load resistor (becomes hot!) After replacement of the electronic circuit board enter the values I-Offset and I-Gain (according to the tag fixed to the ribbon cable) by using the setup menu QM Repair instructions Varimat V2 PROCESS TECHNOLOGIES Revision: A Page 12 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Electron for Varimat V2 7.1 Blower motor Check all connections (wires, flex wires) for breaks (due to vibrations) Replace the blower motor if its bearing is defective 7.2 Heater unit • Check heating element for continuity (must have continuity) Continuity checker / Buzzer • Measure the resistance of the heating element by using an ohmmeter Replace the heating element if the measured resistance value deviates more than +/- 10% from the value stated in the table: Ohmmeter Type Voltage [V] Power [W] Resistance [Ohm] 39A1 39A1 39A1 200 230 400 2000 + 2000 2200 + 2200 2750 + 2750 x approx 19 / x approx 38 x approx 23 / x approx 46 x approx 55 / x approx.110 " Note 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 QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 13 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 7.3 Thermocouple Measure thermocouple resistance between the signal lines (green and white flex wires) Thermocouple must be cooled down to room temperature! Reference value: approx 5Ω (no short circuit or break) Check the insulation between both signal lines (green and white flex wires) and the shielding Reference value: >1MΩ Check continuity between the shielding conductor and the jacket of the thermocouple by using the ohmmeter; otherwise replace the thermocouple " Note After replacement of the thermocouple the temperature must be measured Insert temperature probe 1cm in the nozzle and search for the hottest spot If the display value does not agree with the measured value, the temperature offset must be re-adjusted by using the setup menu (do not exceed a maximum of +40°C) QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Page Revision: A 14 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Setup menu 8.1 Setup menu overview Main switch OFF Free Adj Varimat V2 2.5 m 350 °C 85 Keep pressing buttons while switching ON Start % Profil Varimat V2 Operating manual + keep pressing »temporary« Percent Mode Varimat V2 Yes No Percent menu chapter 8.3 + keep pressing » temporary« Varimat V2 WRONG KEY COMBINATION TURN POWER OFF + 0000 PUSH e-Drive keep pressing » temporary« Service menu chapter 8.2 QM Repair instructions Varimat V2 PROCESS TECHNOLOGIES Revision: A Page 15 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 8.2 Service menu Adjustments per and e-Drive V-Gain Voltage too low: Decrease value Voltage too high: Increase value V-Offset Voltage too low: Decrease value Voltage too high: Increase value Temp Air Offset Temperature too low: Increase value Temperature too high: Decrease value Temp Amb Offset 2468 Temperature too low: Increase value Temperature too high: Decrease value Ser Number Disp Unit Display of °C/m or °F/ft Mains volt Power supply (line / mains voltage) Reset Drive/Blower Time Reset of counters for drive (service message after 400h) and blower motor (service message after 2000h) View Error Index „Length“ indicates every 10th kilometer of the drive unit QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 16 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 8.3 Percent menu Using the percent mode the controller set value of the closed loop will be displayed (in %) for heater, drive and line/mains voltage Thus the user may estimate the controller modulation Error messages Error Err01 Err02 Err03 Type of error Overtemperature of the air or defective thermocouple Heating element defective (break in one or both coils) Err01 and Err02 Err04 Err05 Err06 Err07 Triac defective (one or both triacs are defective) Err01 and Err04 Err02 and Err04 Err01 and Err02 and Err04 Err08 Err09 Err0A Err0B Err0C Err0D Err0E Err0F Blower motor defective Err01 and Err08 Err02 and Err08 Err01 and Err02 and Err08 Err04 and Err08 Err01 and Err04 and Err08 Err02 and Err04 and Err08 Err01 and Err02 and Err04 and Err08 Overtemperature of the electronics Err10 (generates an error item, but does not result in a stop) Err11 - Err1F Error from Err01 to Err0F and Err10 (Err1A = Err0A and Err10) Err40 Undervoltage (line/mains voltage -25%) Err41 - Err4F Error from Err01 to Err0F and Err40 (Err4A = Err0A and Err40) QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 17 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 10 Possible causes of errors • Check all electronic circuit boards for visual error indications (exploded parts, black spots) • Check whether all ribbon cables, wires and flex wires are connected correctly No announcement on the display • Correct input voltage at the transformer assumed (output voltage approx 9VAC +/- 1V), the green 3-poles connector for the drive switch must show a direct current voltage of +5VDC (+/- 0.2V) between pins and • Connect replacement electronic circuit board CSE 07 temporarly Drive motor does not start or pauses suddenly • Check supply voltage of 230V at the transformer • Check fuse link (2AT) on the electronic circuit board TRN 06 • Check temperature limit switch 120°C • Check carbon brushes and commutator • Check ribbon cable for breaks • Seal ribbon cable with silicone (carbon dust etc may cause short circuits) • Connect replacement electronic circuit board CSE 07 temporarly • Replace electronic circuit board ZPM 06 Drive motor speed unsteady • Flex wires to electronic circuit board ZPM 06 are not twisted Drive motor does not start automatically when swivelling in the Electron • Adjust drive sensor • Replace drive sensor Tool does not heat (no error message in the display) • Check heating element connections at line/mains terminal • Check order of thermocouple connections and its tightening • Check triacs • Connect replacement electronic circuit board CSE 07 temporarly QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 18 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Blower does not run • Check supply voltage of 230V at the transformer • Check fuse link (2AT) on the electronic circuit board TRN 06 • Check blower motor for blockage • Connect replacement electronic circuit board CSE 07 temporarly Trouble with buttons • Attachment screws fastened • Cellular rubber part assembled Welding temperature may not be reached • Line/mains voltage too low • Air quantity too high (* appears next to air quantity display) Caution: Achievement of the welding temperature is ensured in the automatic mode only (see diagram)! QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A 11 Wiring diagram Page 19 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 20 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified 12 Test procedure for Varimat V2 (protection class I) Protective earth conductor test • Measure resistance between the earth/ground pin of the plug and the nozzle, respectively the undercarriage, by using the protective earth conductor tester (< 0.2Ω) Insulation test • Function check of high voltage tester (Shorten tips ẻ Signal lamp illuminates and horn sounds) ã Connect tool to a short circuit receptacle • Set main switch of the tool to "1" (ON) position • Apply a high voltage of 1000 V (release current 100mA) for second between the short circuit receptacle and the nozzle, respectively the undercarriage; no flashover or breakdown must occur Function test • Prop the tool up in such a way that the drive roller does not touch the ground • Set main switch to position "0" (OFF) and connect tool to rated voltage • Enter the setup menu: Press all of the three buttons and e-Drive at the same time and set main switch to position "1" (ON); enter code; check values of V-Gain, Temp.Amb., Ser.Number, Disp Unit and Mains volt., respectively readjust if necessary; quit setup menu and turn the tool off • Start tool in the percent mode: Press buttons and at the same time and set main switch to position "1" (ON); select percent mode with "Yes" • Heat the tool up to maximum temperature 620°C; air quantity will be cut down to 50%, if a higher value was selected • Start drive motor and let it run on maximum speed • Check current consumption (according to nameplate) • Check display temperature (615 625°C) • After 15 minutes of operating time insert a temperature probe 1cm in the nozzle and search for the hottest spot • Adjust temperature offset by using the setup menu (Temp.Air.), if necessary; Example: Temperature display = 620°C; temperature on temperature meter = 630°C Î temperature offset: – 10°C • Restart the tool (in the percent mode) and heat it up Check temperature after another 15 minutes of operating time • Let the tool run for 30 minutes under these conditions and check correct functioning • Let the tool cool down • Check function of drive sensor • On maximum speed the modulation must represent 60 70% • Check starting behaviour at minimum speed (single overshooting) • Switch the tool off • Check smooth movement of mechanical control parts QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Page 21 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified Checking completeness • Check ratings of the nameplate • Check power supply cord (cross-sectional area, type of plug) • company labels (LEISTER) must be bonded on the top and on the side of the housing • Cord clip and snap-hook must be assembled • welding sheets must be inserted in the appropriate support • Steel brush must rest in the attachment of the guide bar • Check for cleanliness and possible damages QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Page Revision: A 22 / 24 Created 21.01.10 PRI Released 26.01.10 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.) power supply test board (distributed on training) (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 Varimat V2 Revision: A 14 Appendix screw locking Page 23 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified QM PROCESS TECHNOLOGIES Repair instructions Varimat V2 Revision: A Torque max 100 N/cm Page 24 / 24 Created 21.01.10 PRI Released 26.01.10 PRI Modified ... Continuity (test buzzer) rotational speed meter water column soldering iron complete set of tools (screw drivers etc .) power supply test board (distributed on training) (e.g Elabo) (e.g Elabo, Korntal)... Power supply (line / mains voltage) Reset Drive/Blower Time Reset of counters for drive (service message after 400h) and blower motor (service message after 2000h) View Error Index „Length“ indicates... for Varimat V2 (protection class I) 20 Equipment required for LEISTER repair service 22 Appendix screw locking 23 QM PROCESS TECHNOLOGIES Repair instructions Varimat V2