PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified REPAIR INSTRUCTIONS Software version from 1.0 Production code from 0736 HAND WELDING EXTRUDER WELDPLAST S2 © 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 WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Table of contents Scope of applicability Safety precautions 3 Remarks Power supply cord, drive switch and line/mains switch 4.1 Power supply cord 4.2 Drive switch 4.3 Line/mains switch Display and electronic circuit PCU 03 5.1 Display 5.2 Electronic circuit PCU 03 5.3 Potentiometer Extrusion unit 6.1 Thermocouple and helix heater 6.2 Disassembling of the extrusion unit 10 Extruder feed motor 14 7.1 Thermocouple of feeder unit 14 7.2 Check of rotor and stator 14 7.3 Check of carbon brushes 14 7.4 Disassembly of feed motor 15 Hot-air blower 16 8.1 Thermocouple 16 8.2 Heating 16 8.3 Disassembly of hot-air blower 17 8.4 Blower motor 17 Service menu 18 9.1 Service code 18 9.2 Type 18 9.3 Parameter 19 9.4 Offset 19 9.5 Motor/Rotor 19 9.6 Counter 19 9.7 View Error 20 10 Wiring diagram 21 11 Test procedure for WELDPLAST S2 (protection class I) 22 12 Equipment required for LEISTER repair service 24 12.1 Mobile equipment 24 12.2 Installed equipment 24 13 Recommended spare parts for LEISTER repair service 24 PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 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 • Every repaired tool must pass the test procedure (see “Test procedure”)! • If there exist any additional national testing requirements exceeding the LEISTER test procedure, the repaired tool has also to pass those requirements • 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! Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Power supply cord, drive switch and line/mains switch Important! The welding rod is to be completely ejected and the welding shoe removed in its warm state prior to opening the tool! 4.1 Power supply cord With the line/mains plug pulled out remove the housing shell, disassemble the power supply cord and check it for continuity by using an ohmmeter Replace the power supply cord if it shows a short circuit, interruption or mechanical damage Continuity checker / Buzzer, visual inspection 7x Disassemble housing shell Strip rubber ring 1x Loosen screw to blower unit Loosen screws to gearing 2x PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Keep holding the display and remove upper housing shell External surge protection unit (production code from 0736) Internal surge protection unit (prodction code from 0813) 4.2 Drive switch Disassemble flexible wire from the switch by pushing with a screw driver no PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified All flexible wires connected to the switch are to be removed To check the switching contact connect an ohmmeter to the terminals "2q" (plug-in contact) und "2" (screw contact): • Switch not actuated: • Switch actuated: 10 Resistance > 1MΩ (OL) Resistance < 1Ω 2q 11 4.3 Line/mains switch Remove both plug-in contacts (blue) of the line/mains switch To check the line/mains switch connect an ohmmeter to the two terminals • Switch position "0" (OFF): Resistance > 1MΩ (OL) • Switch position: "1" (ON): Resistance < 1Ω 12 13 Disconnect both cable shoes Press the two latches together to disassemble the line/mains switch PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Display and electronic circuit PCU 03 5.1 Display Remove all screws of the housing shell (see clause 4.1) Carefully extract the display up from the guide slot Disconnect the ribbon cable carefully, vertical to the printed circuit board Caution: Make sure the ribbon cable will not be squeezed between the housing shells when re-assembling 14 Extract display module 15 Disconnect plug straightly There are several possible roots for a defective display (display, electronic circuit PCU 03, wiring) The defect may by located doing the following checks: Check if the plug of the ribbon cable fits properly with the outer plug socket Remark: Remove plug of the ribbon cable carefully and evenly while disassembling If the tool works with a replacement display the original display has to be replaced First connect the display and afterwards turn the line/mains switch on Warning: The tool must be connected to line/mains voltage for this check! If the tool works with a replacement electronics the original electronic circuit board PCU is possibly defective First connect the replacement electronic circuit and afterwards turn the line/mains switch on Warning: The tool must be connected to line/mains voltage for this check! Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 5.2 Electronic circuit PCU 03 Prior to disassembling the electronic circuit PCU 03 all flexible wires and plugs are to be removed 17 16 Lift the electronic circuit slightly from its support before removing the flexible wires 5.3 Potentiometer All flexible wires of the potentiometer are to be disconnected c a b 18 a – red b – blue c – black Connect ohmmeter between contacts b and c Turn potentiometer to the right end stop (cw) The resistance now reads 220kΩ +/- 5% Connect ohmmeter between contacts a and c The resistance reads approx 1Ω Turn potentiometer to the left end stop (ccw) The resistance reads 220kΩ +/- 5% PROCESS TECHNOLOGIES QM Repair instructions WELDPLAST S2 Page Revision: A / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Extrusion unit 6.1 Thermocouple and helix heater 20 19 Thermocouple: At room temperature the resistance between green and white lead is approx 12Ω The resistance between the green, respectively the white lead and the shielding (bare) must be > 1MΩ (OL) 21 Helix heater: The resistance of the helix heater (230V/630W) must be approx 85Ω Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page 10 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 6.2 Disassembling of the extrusion unit The welding rod is to be completely ejected and the welding shoe removed in its warm state prior to opening the tool! Should this not be possible (e.g because the tool or the heating is defective), the cylinder must be heated from the outside until the plastic is sufficiently plasticized Then first disassemble the welding shoe and afterwards the cylindric tube Caution: Danger of burns! 22 2x Loosen welding shoe attachment 23 Detach welding shoe Let the tool cool down! 24 1x 25 Loosen attachment screw of the tubular clamp, enlarge clamp by hand and detach it 26 Detach hot-air guidance forwards Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A 27 QM Page 11 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 28 1x Loosen blower unit Remove blower unit 2x 29 Disassemble housing 30 3x Loosen cylinder screw connection 31 Extract extrusion part carefully forwards from the gearing; Caution! Do not damage the cables Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A 32 Remove the black flange, extend the handle 33 Extend feeder sleeve Carefully extend thermocouple 34 Fix thermocouple during extraction of the heater tube! QM Page 12 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A 35 QM Page 13 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 36 If the cylinder tube is stuck to the screw, heat the cylinder (plasticize plastic) 37 Extract screw; Danger of burns! Clean cylinder and screw in warm condition Clean screw, cylinder tube and feeder sleeve and a visual inspection When disassembling the extrusion nozzle notice the connection is realized with a left-hand thread The feeder sleeve is protected against rotation with a pin in the front Ensure correct assembling! When re-assembling the extrusion unit make sure the cables and flexible wires will not be damaged PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 14 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Extruder feed motor 7.1 Thermocouple of feeder unit At room temperature the resistance of the thermocouple is approx 50 75Ω for 230V-tools Both flexible wires are to be disconnected for carrying out the measurement Ohmmeter 38 Check of thermocouple 7.2 Check of rotor and stator 39 40 Check of rotor Check of stator Rotor: The resistance of the rotor winding, measured across the carbon brushes, is approx 6Ω for 230V-tools (turn the fan wheel by hand and check the resistance value on all sections of the commutator) If the measured resistance value is 0Ω or more than 20Ω the rotor has to be replaced Ohmmeter Stator: The resistance value of the stator winding is approx 13Ω for 230V-tools Both flexible wires of the stator winding (black) must be removed for carrying out the measurement Ohmmeter 7.3 Check of carbon brushes Measure the length of the carbon brushes and replace them, if their length is less than 15mm (original length 22mm, limit stop at approx 8.5mm) To replace the carbon brushes loosen the attachment screws for approx ½ turn One of the brushes is equipped with a limit stop 41 Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page 15 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 7.4 Disassembly of feed motor 42 Remove distance bushes 44 Loosen screws • • 43 Unscrew air conduction; Caution thin-walled! 4x 45 Gearing may be opened now Gearing: If vibrations or unusual noise emission are detected, open gearing and check: - gear wheels for abrasion (if necessary replace complete gearing unit) - quantity and condition of grease (replace grease when indicated) Caution: Use original grease only (see spare parts list)! Clean the tool completely when doing repair work and remove carbon dust (hazard of short circuits)! Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page 16 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Hot-air blower 8.1 Thermocouple At room temperature the resistance value between green and white flexible wire is approx 12Ω Between the green, respectively the white flexible wire and the shielding (bare) the resistance value must be > 1MΩ (OL) 46 47 8.2 Heating The resistance of the heating element may be checked by using an ohmmeter If the measured value deviates more than +/- 10% of the value stated in the table, the heating element has to be replaced Ohmmeter Type 32 Voltage [V] 230 Power [W] 1100 + 1100 Resistance [Ω] x white-white approx 90 x black-black approx 45 48 Note: Do a visual check of the heating element If the heating element is either mechanically damaged or clogged, it has to be replaced Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page 17 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 8.3 Disassembly of hot-air blower 50 49 Loosen screws, extract protection tube Unplug heating element 51 (a) (b) (c) The thermocouple must be twisted such that the bayonet connector (a) is correctly positioned Carefully bend the thermocouple leads into the correct position without kinking it (b) It is important that the leads not touch the turbine (c) 8.4 Blower motor The blower motor (Mistral) is maintenance-free and must be completely replaced if defective PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 18 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Service menu For operation details of the tool refer to the LEISTER operating manual WELDPLAST S2 MENU BACK ENTER Program select Actual value PLAST Set value PLAST Display PLAST Actual value AIR Set value AIR Display AIR Operating state SPEED PLAST SPEED bar graph Motor speed DOWN SELECT UP The significant aspects for servicing are dealt in the menu Working time 9.1 Service code Tap MENU button, select menu Working time by using UP/DOWN buttons and confirm with SELECT Enter service code (choose appropriate number using buttons UP/DOWN, change to next digit with SELECT, conform input with ENTER) Thus the menu Service appears, containing the following sub-menus from Software version 1.3: Brief description Type: Parameter: Offset: Motor/Rotor: Counter: View Error: Tool types Standard, PVC and TPO For internal use only (tool development) Display correction for AIR and PLAST Check and reset Motor/Rotor counter Check and reset Service counter List of error messages 9.2 Type In this menu the type of tool will be defined Possibilities: Standard, PVC or TPO PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 19 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 9.3 Parameter The parameter menu is intended for internal use only (further development of the tool) 9.4 Offset The service centre can implement a display correction (temperature offset) for the PLAST and the AIR temperature each from -15 to +15°C This allows an offset to be entered for the customer’s all-purpose material, such that the display agrees with the output temperatures Procedure: - Temperature display (e.g 210°C), temperature of the plastic material (e.g 205°C) Add the PLAST temperature offset to this (e.g -5°C) Repeat this procedure untill the temperatures agree The same procedure also applies for AIR 9.5 Motor/Rotor This menu allows the check of the feed motor running time as well as the reset of the counter Motor/Rotor After replacement of the complete gearing unit including rotor (see next clause) a reset of this counter must be carried out 9.6 Counter With a new tool the service message „Check drive brushes“ appears first time after 250 hours of operation of the feeder unit Then the carbon brushes are to be be replaced After another 150 hours of operation the same message appears again If the commutator abrasion is not to strong the carbon brushes may be replaced once again From any further replacement of the carbon brushes the service message appears already after another 100 hours of operation If the commutator is strongly worn the entire feeder unit must be revised It is recommended to replace the complete motor with or without gearing Reset the counter Motor/Rotor at this time (see previous clause) The service centre must reset the service counter after each service where the carbon brushes were replaced, because this counter records the operating hours of the PLAST feeder motor between the service intervals Make a note of the counter value before resetting it Repair instructions WELDPLAST S2 PROCESS TECHNOLOGIES Revision: A QM Page 20 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 9.7 View Error The times of the last occurring error messages can be determined in the menu View Error An entry 0000:00 means that the error has never occurred If 0000:10 is registered for E02, the error 02 last occurred with this tool after an operating time of 10 minutes The customer can therefore be addressed in regard to this error For checking purposes the times of errors occurring must be recorded during servicing as well Error E01 Type of error E02 Overtemperature Feeder motor, PLAST and AIR heater PLAST turn off, if PLAST temperature > 300°C E04 Overtemperature Motor Overtemperature heating element Feeder motor turns off, if winding temperature > 120°C Feeder motor, PLAST and AIR heater turn off Overtemperature electronic circuit Short circuit of PLAST thermocouple Feeder motor, PLAST and AIR heater turn off Feeder motor, PLAST and AIR heater turn off E08 E10 E40 Note: Behaviour Overtemperature Feeder motor, PLAST and AIR heater AIR turn off, if AIR temperature > 365°C Method of resolution ã Check AIR thermocouple (ẻ chapter 8.1) • Replacement of the electronic circuit board PCU 03 (Ỵ chapter 5.2) ã Check PLAST thermocouple (ẻ chapter 6.1) ã Replacement of the electronic circuit board PCU 03 (Ỵ chapter 5.2) ã Check thermocouple of feeder motor (ẻ chapter 7.1) • Check function of blower motor (Ỵ chapter 8.4) • Check heating element (ẻ chapter 8.3) ã Check thermocouples AIR and PLAST (see E01 and E02) • Replacement of the electronic circuit board PCU 03 (ẻ chapter 5.2) ã Check PLAST thermocouple (ẻ chapter 6.1) ã Check helix heater (ẻ chapter 6.1) • Replacement of the electronic circuit board PCU 03 (Ỵ chapter 5.2) With the exception of errors E08 and E40 the tool can automatically return to normal operation, if the error conditions not exist any more Regarding errors E08 and E40 a reset is compulsory (switch the tool off, wait a couple of seconds and switch it on again) PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 21 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 10 Wiring diagram The wiring diagram shows the wiring with internal surge protection (from 0813) The wiring with external surge protection (from 0736) was identical (PCB component layout was slightly changed) Illustration on page shows the connection of the external surge protection PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 22 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified 11 Test procedure for WELDPLAST S2 (protection class I) Protective earth conductor test • Measure the resistance between the earthing/grounding connector pin on the appliance plug and the protection tube by using the protective earth conductor tester (< 0.2Ω) Insulation test • Check correct functioning of the high voltage tester: Shorten tips Ỵ signal lamp and horn • Set the line/mains switch and the feed switch to "1" (ON), respectively press and lock it • Connect the tool to a short circuit receptacle • Apply a test voltage of 1000V (release current 100mA) for second between the short circuit receptacle and protection tube; there must be no flashover or breakdown Function test Tool is in power-off condition (plug disconnected from the line/mains)! • Loosen handle and check if position is adjustable and lockable • Check smooth movement of the potentiometer and the feed switch • Functional check of the feed switch locking mechanism • Set the line/mains switch to position "0" (OFF), turn the feed potentiometer to the left end stop (counter-clockwise, position "0") and connect the tool to rated voltage • Line/mains switch to position "1" (ON) Ỵ Check the display software version ẻ Fan motor runs ã Check the running noise of the fan motor (bearings) and the turbine (vibration, particles) • Activate feed switch for several times Ỵ Feed motor does not run (this test must be carried out within the first minutes after activating the line/mains switch) Plastifying the tool Independent of the type of tool always use welding rod Simona PE-HWST, ø4.0mm, transparent, for plastifying the tool • Setting parameters Menu PE-HD Air 260°C Plast 230°C Speed 100% • Check the heating power consumption after turning on (approx 2900W, 13A) • Heat the tool up for approx minutes ẻ Display message: Ready * ã Activate feed switch for several times Ỵ Feed motor runs / stops • Lock the feed switch Ỵ Feed motor runs continuously PROCESS TECHNOLOGIES Repair instructions WELDPLAST S2 Revision: A QM Page 23 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified • Slowly turn the feed potentiometer from minimum to maximum (clockwise) Ỵ Check the running noise of feed motor (bearing) and extrusion screw (vibrations, particles) • Turn the feed potentiometer to minimum (counter-clockwise, left end stop) • Insert plastic welding rod Ỵ Feed motor runs continuously and the overcurrent shutdown does not activate • Increase the feed in three steps to the maximum (by using potentiometer) • Observe whether bubbles are formed in the extruded material; one bubble is allowed per 300mm extruded material • Check the welding rod in-feed on both sides (consecutively, not simultaneously!) • Use approx 5m of welding rod per plastification procedure • Cut off welding rod and completely eject • Release the feed switch lock Î Feed motor stops • Press the enter key "E" Î Display message: OFF • Let the extruder cool down • Set the line/mains switch of the tool to position "0" (OFF) • Temperature check (every time after repairs!) Type of tool Standard PVC TPO Menu PE-HD PVC TPO Material Simona PE-HWST GEHR PVC GSE PELD TunelLiner Diameter [mm] 4.0 Air [°C] 260 300 230 Tolerance [%] +/- 10 Measuring point Hottest spot, approx 5mm in the nozzle Plast [°C] 230 200 190 Tolerance [%] +/- 10 Measuring point Insert into extruded material Speed [%] 100 Checking completeness • Check labelling on the nameplate: type, voltage, current, power (must correspond with the above measurements!) • Check production code / serial number • Check power supply cord for electrical and mechanical damage (plug type dependent on country, conductor cross-section dependent on current rating) • The following labels must be affixed: o "WELDPLAST S2" label on the left housing shell (in direction of output) o Warnin label "Heisse Oberfläche" on the cylinder flange o Company labels "LEISTER" on the left and on the right housing shell • All screws must be tightened (visual inspection) • Check for cleanliness and any damage or scratches PROCESS TECHNOLOGIES 12 Repair instructions WELDPLAST S2 Revision: A QM Page 24 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Equipment required for LEISTER repair service 12.1 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) 12.2 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 13 Recommended spare parts for LEISTER repair service No Article no Designation 126.806 LCD module complete 128.906 El circuit PCU 03 ... 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... WELDPLAST S2 Revision: A QM Page 18 / 24 Created 26.02.09 PRI Released 06.03.09 PRI Modified Service menu For operation details of the tool refer to the LEISTER operating manual WELDPLAST S2 MENU... 10 Wiring diagram 21 11 Test procedure for WELDPLAST S2 (protection class I) 22 12 Equipment required for LEISTER repair service 24 12.1 Mobile equipment