tài liệu sửa chữa máy hàn nhựa leister (PID (EN)

- Repair instructions LEISTER TRIAC PID 0142 Seite REPAIR INSTRUCTIONS FOR TRIAC PID Table of contents Page Scope of applicability 2 Safety precautions Remarks Check of power supply cord, switch, wiring and motor 4.1 4.2 4.3 4.4 3 3 Power supply cord Switch Wiring Motor Function control of heating 5.1 5.2 5.3 5.4 Heating element Thermocouple Temperature limit switch (Klixon) and photo resistor Check of potentiometer and triac and replacement of the electronic circuit boards 5 5.4.1 Potentiometer 5.4.2 Triac 5.4.3 Replacement of the electronic circuit boards 6 Test procedure Color chart for electronic circuit boards PID-03-V Markings and connections of motors «T» 47/25 9 Wiring diagram 10 10 Exploded diagram 11 11 Spare parts list 12 12 Appendix: "Equipment for LEISTER repair service" 14 Repair instructions LEISTER TRIAC PID Seite Scope of applicability These repair instructions are reserved exclusively for LEISTER service centres Only experienced and qualified personnel trained by LEISTER Process Technologies, CH6060 Sarnen, 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 appendix: „Equipment for LEISTER repair service“) is essential for doing qualified work When servicing use only identical original LEISTER replacement parts for each type of tool 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 before any work is commenced! Repaired tools must pass the LEISTER test procedure (see page 8) and any additional local requirements Check with your local Statutory Authority for testing requirements Remarks - Each repaired tool has to pass the test procedure! ==> 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-6060 Sarnen, Switzerland, carriage paid upto Sarnen The LEISTER company 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 LEISTER TRIAC PID Seite Check of power supply cord, switch, wiring and motor 4.1 Power supply cord Disconnect tool from line/mains! Remove the enclosure and the power supply cord The power supply cord has to be replaced, if there is a short circuit, a break or any mechanical damage detected Continuity checker/Buzzer, visual inspection  Note Do not shorten the power supply cord! If the customer did so, the power supply cord has to be replaced 4.2 Switch Check power switch: - Position 0: No continuity - Position 1: Continuity Continuity checker/Buzzer 4.3 Internal wiring Check all of the connections (leads, wires) and make sure, that there are no breaks (due to vibrations) Visual inspection 4.4 Motor Check motor brushes: Remove motor brushes, measure its length and replace them, if their length is mm or even less Check both brushes! If the carbon brushes are not to be replaced make sure to re-insert them the same way as removed (abraison) Visual inspection Clean up the tool For cleaning up the handle’s display-window use only water, spirit or seam-cleaner If the air filter at the end of the enclosure is missing or if it is defective, replace it If the air filter is clogged, clean it up and give a message to the customer as follows: Clean up the air filter at the end of the enclosure with a small brush when polluted! Mount power supply cord and handle again Connect the tool to line/mains and switch it on Motor must turn now; if not, it has to be replaced Make sure, that the tool is disconnected from line/mains in this case!  Note The motor has also to be replaced if there is a defect of the bearing or of the commutator A defect of the bearing causes an excessive noise The commutator is defective, if the power consumption of the motor exceeds 100W Wattmeter Repair instructions LEISTER TRIAC PID Seite Function control of heating Check if tool heats correctly: - Adjustment of Set value by potentiometer: Set value °C °F 000 300 600 Heating output Actual value Tolerance Time °C °F 032 Tool may not heat 570 Tool heats 1110 Tool heats 060 300 600 140 570 1110 +/- 5° +/- 5° after about minutes after about minutes - Adjust Actual value with trimmpotentiometer at the electronic circuit board PID-02-R (turn clockwise  Actual value increases) - Check the temperature with a probe (ø < 1mm) while the tool is fitted with a tubular nozzle ø 5mm Replace the thermocouple if the temperature deviates more than 20°C/36°F - Make sure that the periodical pulsing of the current increases steadily after the transient state Ampèremeter or Wattmeter  Note Check continuity of thermocouple (must have continuity), if the temperature display shows permanently flashing „SEr“ Continuity checker/Buzzer or Ohmmeter 5.1 Heating element Disconnect tool from line/mains! Remove heater tube and mica tube and pull the heating element carefully (do not bend the thermocouple!) out from its socket Check continuity of the heating element (must have continuity) Continuity checker/Buzzer  Note Make 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 Clean up the photo resistor, if it is dirty (powder of the brushes) Rag Restore heating element, mica tube and heater tube to the tool, connect the tool to line/mains and check for proper heating (see Function control of heating) Repair instructions LEISTER TRIAC PID Seite 5.2 Thermocouple Disconnect the thermocouple by screws and measure the resistance of the thermocouple between the two leads (value about 5) Ohmmeter Check thermocouple for short circuit between leads and jacket (insulating resistance at 600°C/1110°F: at least 12 M) Continuity checker/Buzzer and Ohmmeter Connect thermocouple with correct polarity Terminal block for thermocouple Connector to display Trimmer Actual value + pole (green) PID-02-R Connector to PID-03-V Clean the thermocouple carefully with an emery paper if strongly oxydated 5.3 Temperature limit switch (KLIXON) and photo resistor Disconnect tool from line/mains! Dismount rubber stand and connecting head and remove turbines and distributor Replace defective parts and clean up the other parts Check continuity of the temperature limit switch (must have continuity) Continuity checker/Buzzer Function control of photo resistor: Desolder one of the two wires of the photo resistor, complete the tool, connect it to line/mains and check its proper heating (see Function control of heating) If the tool heats properly now, disconnect it from line/mains and replace the photo resistor The back of the photo resistor and its leads must be covered with silicone caoutchouc If the tool does not heat (properly), disconnect it from line/mains and resolder the removed wire Repair instructions LEISTER TRIAC PID Seite 5.4 Check of potentiometer and triac and replacement of the electronic circuit boards 5.4.1 Potentiometer Desolder connections to potentiometer and measure its resistance: Pin Resistance Pin - Pin 3: 20 k Resistance Pin - Pin 2: - 20 k * Resistance Pin - Pin 3: - 20 k * * Check the entire range of the potentiometer Ohmmeter Replace the potentiometer if the measured values deviate more than +/- 10% from the values stated above Cover the soldering tags with insulating varnish 2451, black 5.4.2 Triac Desolder connections to the triac Check continuity of triac as follows and replace it, if this check does not agree with the table stated below: Continuity checker/Buzzer MT1 + + - MT2 Gate Results + + - + + open circuit open circuit closed circuit closed circuit open circuit open circuit + : Red probe tip (terminal plus pole) - : Black probe tip (terminal minus pole) If the triac has to be replaced, cover its bottom side (heat sink) with thermal conducting paste Each of the soldering connections must be equiped with a shrink sleeve and afterwards covered with insulating varnish 2451, black If the tool still does not heat properly, the electronic circuit (printed wiring board) must be replaced Repair instructions LEISTER TRIAC PID Seite 5.4.3 Replacement of the electronic boards Warning! The following measurement has to be carried out on the tool which is under line/mains voltage Therefore when touching electrical components and connections this can cause danger to life! The tool has to be built on a insulated base and saved so that it cannot slip away mistakenly during doing measurement If the temperature display module does not show any values, disconnect its plug Measure the voltage on VDC-range between pin and on the electronic circuit board PID-02-R (see drawing beside) The voltage has to be 5V +/-0.2V If this voltage is not detected, the power electronic circuit board (PID-03-V) has to be replaced If the voltage is within the balance, replace the temperature display module Temperature Display module Top view Trimmer Actual value 43 PID-02-R Connector to PID-03-V If the temperature display module permanently shows 60-70°C, the error has to be located either on the control unit PID-02-R or on the power unit PID-03-V - correct functioning of the triac required To find out, which board is defective, connect the connector to the power unit and the thermocouple to another control unit (without replacing the original one) Do a function control now If the tool heats properly and the display shows the correct values now, replace the control unit PID-02-R, otherwise the power unit PID-03-V  Note Before replacing the electronic circuit board PID-03-V find out its type, voltage and color of the leads The wiring has to be made in accordance with the Wiring Diagram (page 10) Notice the following hints for replacement of the electronic circuit board: - Equip each of the soldering tags of the Triac with a shrink sleeve and after that cover them with insulating varnish 2451, black - Cover the soldering tags of the potentiometer with insulating varnisch 2451, black as well Repair instructions LEISTER TRIAC PID Seite Test procedure for TRIAC PID Prot class II Insulation test - Check correct functioning of the high voltage tester (shorten tips  signal-lamp and horn) - Set power switch of the LEISTER tool to „1“ position - Apply test voltage of 4000V for second between plug and accessible metal parts (heater tube) No breakdown should occur Functioning test - Set power switch to „0“, potentiometer to „0“ and connect LEISTER tool to rated voltage (line/mains or transformer) - Set power switch to „1“ ==> motor turns, check power consumption of the motor Wattmeter - Check smooth running of motor (bearings, commutator) and fan (vibrations, particles) - Check heating: Equip the tool with a tubular nozzle ø 5mm, adjust the set value by potentiometer and verify the temperature values with a probe (diameter of probe < 1mm) Set value °C °F 000 300 600 Heating output Actual value Tolerance Time °C °F 032 Tool may not heat 570 Tool heats 1110 Tool heats 060 300 600 140 570 1110 +/- 5° +/- 5° after about minutes after about minutes Make sure that the periodical pulsing of the current increases steadily after the transient state Amperemeter or Wattmeter - Check rated power consumption of the tool at full heat output Check all components clear - Filter must be fitted - Check details printed or die-stamped on handle: type, voltage, current, power (must correspond with the above measurements!) - Warnings must be printed on the handle - Check power supply cord mechanically and electrically (correct plug type for country, cord diameter as per rated current) - Rubber stand must be fitted; all screws must be tightened - Company label (LEISTER) must be fixed on the handle - Tool should be checked for cleanliness and possible damage Repair instructions LEISTER TRIAC PID Seite Color chart for electronic circuit boards PID-03-V Type Triac PID Triac PID (UL) Triac PID Voltage Leads to photo resistance Gate 100-230V 100-230V 42V Turquoise (Green) Grey Turquoise (Green) short short long Photo resistance Photo resistance PID-03-V Markings and connections of motors «T» 47/25 Markings External connetions «T» 230V «T» 200V «T» 120V «T» 100V «T» 42V Black/Black Black/Black Brown/Brown Yellow/Yellow Blue/Blue Repair instructions LEISTER TRIAC PID Seite 10 Wiring diagram 100-230V and 120V UL Potentiometer 20k Blue TRIAC_PID_03_V Switch Black Red TRIAC_PID_02_R Yellow 100-230VAC INPUT AC P534 GND GATE VCC Blue 100-230VAC INPUT AC P534 GND GATE VCC ACTUAL SET VREF GND VREF NO CONNECT ACTUAL SET VREF GND VREF NO CONNECT Black Red Blue Turquoise,(Grey UL) TRIAC 25A White 2200pFY R_Photo 10uH t Temperature limit switch 10uH MOTOR T 47/25 Heating element according to volatage / power White Green Thermocouple + 42V Potentiometer 20k Blue TRIAC_PID_03_V Switch Yellow 42VAC Black Red INPUT AC Blue 42VAC Black TRIAC_PID_02_R P534 GND GATE VCC INPUT AC P534 GND GATE VCC ACTUAL SET VREF GND VREF NO CONNECT ACTUAL SET VREF GND VREF NO CONNECT Blue Red White Turquoise TRIAC 40A t Temperature limit switch White 2200pFY 42V/950W R_Photo MOTOR T 47/25 -1 Thermocouple + White Green Repair instructions LEISTER TRIAC PID Seite 11 10 Exploded diagram for Repair instructions LEISTER TRIAC PID Seite 12 11 Spare parts list Leg no Order no Qty 4 4 4 6 10 11 12 12 13 14 15 16 17 17 17 18 19 19 20 20 20 20 20 22 23 24 24 26 26 28 29 30 31 32 33 34 35 36 100.258 100.032 106.185 100.260 100.631 100.632 100.634 100.635 100.633 100.261 106.186 108.319 100.263 100.046 100.264 100.266 100.267 100.268 100.637 100.269 100.270 109.927 100.272 100.273 100.638 100.639 100.274 100.275 100.640 100.276 100.641 100.642 100.643 100.644 100.278 100.279 100.645 100.646 100.628 100.647 100.284 100.305 100.629 100.287 100.288 106.184 106.183 100.291 100.295 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 Article Air filter Company label 75 x 22 Handle (with display), Warnings printed Nameplate Triac PID, 230V/1600W with SEV approval mark Nameplate Triac PID, 200V/1400W Nameplate Triac PID, 120V/1600W with UL approval mark Nameplate Triac PID, 100V/1400W Nameplate Triac PID, 42V/1000W Nameplate Triac PID, 120V/1600W Raised countersunk screw M4 x Rocker switch complete Rocker switch complete, 250V/20A, with snap-fit tabs (UL) Potentiometer knob red Potentiometer 20kOhm Connecting piece complete Raised cheese head screw combination M4 x PT-screw KL30 x 10 Strain relief for cord x 1mm2 Strain relief for cord x 1.5mm2 / x 14AWG (UL) Thread forming raised cheese head screw M4 x 10 Thread forming raised cheese head screw M3 x Triac 25A/800V Shrink sleeve 1/8" x 12mm, black Electronic circuit board PID-03-V, 100-230V Electronic circuit board PID-03-V, 120V (UL) Electronic circuit board PID-03-V, 42V Electronic circuit board PID-02-R Temperature display module complete °C Temperature display module complete °F Motor T47/25 complete, 230V Motor T47/25 complete, 200V Motor T47/25 complete, 120V Motor T47/25 complete, 100V Motor T47/25 complete, 42V Cord guide Brushholder Carbon brush (200/230V) Carbon brush (42/100/120V) Turbine housing (with display) complete Turbine housing (with display) complete, 42V Thread forming raised cheese head screw M4 x 14 Turbine Stripper complete Hexagon nut M5 Thermocouple Photo resistance bended Temperature limit switch 135°C Connecting head complete Rubber stand Repair instructions LEISTER TRIAC PID Seite 13 Leg no Order no Qty 37 37 37 37 37 38 39 40 41 45 47 47 47 48 48 48 48 48 48 48 48 48 48 49 50 51 51 53 66 51 60 61 62 63 64 65 100.296 100.649 100.650 100.651 100.652 100.297 103.224 100.299 100.300 100.304 100.306 100.444 100.653 100.618 100.020 100.697 100.655 100.656 100.657 100.658 100.659 100.660 100.095 101.264 100.622 100.625 100.664 100.151 100.623 100.665 100.666 100.667 100.668 100.670 111.196 100.672 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Article Heating element type 33D, 230V/1550W Heating element type 33D, 200V/1350W Heating element type 33D, 120V/1600W Heating element type 33D, 100V/1350W Heating element type 33D, 42V/900W Mica tube Gasket ø 30/50 x 4mm Raised cheese head screw M4 x 10 Heater tube for push-fit nozzles Heater tube for screw-on nozzles Cord guard ø x 75 (200/230V) Cord guard ø 9.6 x 7.5 (100/120V) Cord guard ø 11.2 x 90 (42V) Power supply cord x 1mm2 x 3m with Schuko-plug Power supply cord x 1mm2 x 3m with CH-plug Power supply cord x 1mm2 x 3m, without plug Power supply cord x 1mm2 x 3m, with Australian-plug Power supply cord x 14AWG x 3m, with US-plug Power supply cord x 2.5mm2 without plug Power supply cord x 1.5mm2 x 3m, with 100V-Japanese plug Power supply cord x 1mm2 x 3m, with 200V Japanese plug Power supply cord x 1.5mm2 x 3m, with UK plug 16A yellow Power supply cord x 1.5mm2 x 3m, without plug Insulating tube ø x 0.4 x 90mm, white Insulating tube ø 4.5 x 0.4 x 80mm, white Temperature resistant wire 1mm2 x 240mm, black Temperature resistant wire AWG16 x 240mm, black Cord fastener 85 x 22 Insulating tube ø 4.5 x 0.4 x 20mm, white Temperature resistant wire 2.5mm2 x 290mm, black Heat sink PT-screw KA40 x 14 Triac 40A Temperature resistant wire 2.5mm2 x 290mm, blue Temperature resistant wire 2.5mm2 x 30mm, white Insulating tube ø x 0.5 x 80mm Repair instructions LEISTER TRIAC PID Seite 14 Appendix: „Equipment for LEISTER repair service“ Mobile Equipment: - High voltage tester up to 4000 V (i.e Elabo, Korntal) - Temperature measuring instrument with temperature probe (i.e Fluke, Testo) - Multimeter to measure: - Current - Voltage - Resistance - Continuity (Buzzer) (i.e Fluke) - Speed measuring instrument - Watergauge column - Soldering iron - Complete tool kit (screw-driver etc.) Built-in equipment: - Transformer, may be splitted in regulating and insulating transformer Specifications: x 500 V x 30 A - Built-in Voltmeter (500 V) - Built-in Ampèremeter (30 A) or Wattmeter Repair instructions LEISTER TRIAC PID Seite 15 ... Appendix: "Equipment for LEISTER repair service" 14 Repair instructions LEISTER TRIAC PID Seite Scope of applicability These repair instructions are reserved exclusively for LEISTER service centres... centres Only experienced and qualified personnel trained by LEISTER Process Technologies, CH6060 Sarnen, are allowed to repair work on LEISTER tools Additional national requirements relative to... working place (see appendix: „Equipment for LEISTER repair service“) is essential for doing qualified work When servicing use only identical original LEISTER replacement parts for each type of