repair instructions - querotools · 2019-12-02 · these repair instructions may not be distributed...

Leister Technologies AG

Repair instructions

UNIROOF E Revision: B

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Created 26.05.09 PRI

Released 28.05.09 PRI

Modified 23.03.13 PRI

REPAIR INSTRUCTIONS

Hot Air Welder UNIROOF E

Production code from 0847 Software version from 1.0A

© 2013 Leister Technologies AG, 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 Technologies AG, CH-6056 Kaegiswil. Leisters Technologies AG, CH-6056 Kaegiswil/Switzerland Tel. +41 41 662 74 74 Fax +41 41 662 74 16 www.leister.com [email protected]

http://www.leister.com/

mailto:[email protected]


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Table of contents

1 Scope of applicability ...................................................................................................... 3

2 Safety precautions .......................................................................................................... 3

3 Remarks ........................................................................................................................... 3

4 Mechanics check ............................................................................................................. 4

5 Assembly and adjustment .............................................................................................. 5

5.1 Nozzle ....................................................................................................................... 5 5.2 Transportation lock for hot-air blower (Ghibli) ........................................................... 5 5.3 Automatic drive start-up ............................................................................................ 6

6 Electronics ....................................................................................................................... 6

6.1 Cover ........................................................................................................................ 6 6.2 Power supply cord..................................................................................................... 7

6.3 Wiring ........................................................................................................................ 8 6.4 Main switch ............................................................................................................... 9

6.5 Automatic drive start-up ............................................................................................ 9

6.6 Triac .......................................................................................................................... 9

7 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

8 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

9 Setup menu .................................................................................................................... 25

10 Possible causes of errors ............................................................................................. 27

11 Wiring diagram .............................................................................................................. 28

12 Test procedure for UNIROOF E (protection class I) ................................................... 29

13 Equipment required for Leister repair service ............................................................ 31

14 Appendix screw locking ............................................................................................... 32


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1 Scope of applicability

These repair instructions are reserved exclusively for Leister service centres. Only experi-enced and qualified personnel trained by Leister Technologies AG, CH-6056 Kaegiswil, are allowed to do repair work on Leister tools. Additional national requirements relative to per-sonnel carrying out repair work are to be observed by each service centre.

2 Safety precautions

A well-equipped ESD-protected 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.

3 Remarks

If it is impossible to repair a tool, it should be returned immediately to the manufacturer, Leister Technologies AG, 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 servi-cing use only identical original Leister replacement parts!

Warning! If you open the tool or remove its parts, except the ones they are accessi-ble 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 proce-

dure") and any additional local requirements. Check with your local Statu-tory Authority for testing requirements.


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4 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


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5 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 di-agram 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


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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

Nozzle 30mm: Set bolt of drive switch must protrude 22mm (see lower picture on the left)

Nozzle 40mm: Set bolt of drive switch must protrude 25mm

Set bolt must not be lubricated because it glides on teflon

6 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)


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Disassemble guide bar support: - Lock swivel roller by using multigrip

pliers (protect pliers with scraped plas-tic 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.


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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 do 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


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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: Switch must have no continuity - Drive switch actuated: Switch must have continuity Continuity checker/Buzzer

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.

The middle contact may not be connected!


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7 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!

1. Switch the tool off and disconnect (unplug) it from the line/mains 2. Connect an ammeter between the orange plug and the black flex wire of the drive

motor (see picture on the left) 3. Connect tool to line/mains and switch it on 4. Set motor speed to maximum (5m/min) 5. The current consumption must be 100..300mA Ammeter

Notes

An excessive noise of the motor indicates a bearing defect 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


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7.2 Electronic circuit TRN 05

Check electronic circuit boards for visual error indications:

Scorch marks, exploded parts

Expanded/swelled parts (e.g. transformer)

An insulation paper must be installed between housing and electronic circuit TRN 05

Fuse link defective? Visual inspection


If the display remains dark after switching on the main switch, check the electronic circuit TRN 05 applying appropriate line/mains voltage (according to nameplate): Voltmeter

The voltage measured at the white 2-poles terminals must be 5VDC (+/- 0.2V); use the free terminal for measuring (see picture on the left).

With the drive unit switched off, the orange 2-poles plug (see picture on the right) shows the line/mains voltage (e.g. 230V AC voltage).

Note

If the fuse link is defective test the electronic circuit ZPM 06 first (see chapter 7.3), before replacing the fuse link.


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7.3 Electronic circuit ZPM 06

Check the electronic circuit ZPM 06 (e.g. in case of overvoltage indication, if a 230V-tool was possibly connected to 400V): Open housing, see chapter 6.1

Disassemble round belt

Loosen raised cheese head screw M4x10 and remove pressure roller carefully from the axle

Loosen screws M8x16 of the support (2x)

Loosen screw M4x10 of the heat sink (triac)


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Loosen screws M4x10 (4x): - 1 behind electronic circuit TRN 05 - 1 next to the heat sink - 2 between the rollers

Unplug cable and ribbon cable of the elec-tronic circuit ZPM 06 Remove cable ties Unwind housing carefully


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Connect continuity checker/buzzer to both contacts of the orange plug (see picture). If conti-nuity is detected the electronic circuit ZPM 06 is defective. Check the drive motor prior to re-place the electronic circuit (see chapter 7.5). Continuity checker/Buzzer

Desolder red flex wire leading to the upper carbon brush support of the motor. Connect con-tinuity checker/buzzer between desoldered flex wire and the lower carbon brush support (white flex wire). Connect and verify the results according to the table stated below. Soldering iron, Continuity checker/Buzzer

Lower carbon brush support Red flex wire Results

+ - Diode voltage approx. 0.5V

- + No diode voltage

(This is not a complete testing of the electronic circuit) Should this test not be successful, check drive motor (see chapter 7.5) and finally replace the electronic circuit ZPM 06.

Notes

Make sure the distance bushings (ø 3.1/6 x 5) are inserted when assembling the electronic circuit ZPM 06

Temperature limit switch and MOSFET are to be covered with thermal conducting paste when assembling

The connectors of the ribbon cable must be sealed by using silicone rubber

Lower carbon brush support

Red flex wire


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7.4 Carbon brushes

Separation of drive unit see chapter 7.3

Loosen hexagon head screws M5x12 from the undercarriage (2x)

Carefully bend back the ears of both carbon brush supports. Caution, springs are under tension!

Check length of both 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).


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7.5 Drive motor check

Visual check of commutator:

Worn out lamella

Bluish discoloration

Deep grooves (U-shaped) Visual inspection Desolder red flex wire (see chapter 7.3) and measure the resistance on the carbon brushes by using an ohmmeter (see picture). Turn the commutator slowly by hand and check all la-mella. The resistance must be 50..100Ω per segment. Otherwise replace the motor (see chapter 7.6) Ohmmeter


With desoldered red flex wire (see chapter 7.3) connect a bridge rectifier to both carbon brush supports (see picture on the left). Allpy voltage by using a transformer and an amme-ter. 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 remove motor (see chapter 7.6) and repeat the meas-urement without gear. Bridge rectifier, ammeter


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7.6 Drive motor replacement

Separation of drive unit see chapter 7.4

Disassemble electronic circuit ZPM 06: - Desolder flex wires (red and white) - First loosen raised cheese head

screw M3x6 of the MOSFET - Then loosen other screws M3x12 (2x)

Loosen hexagon head screws M4x14 (2x)

Open cover of gear box: - Loosen cheese head screws M3x8

(4x) - Pay attention not to lose too much

grease

Loosen hexagon head screw M4x14 Extract motor carefully from the gear box


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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 mo-tor 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)!


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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

8 Hot-air blower (Ghibli)

8.1 Disassembly

Disconnect all connections of the hot-air tool, remove cable ties

green white black

black

black/blue

white


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Remove grey clip from hose screw fitting:

Unlock clip by pushing a screwdriver to one side flap and lift clip with an addi-tional screwdriver size 2

Proceed the same way from the oppo-site 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


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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. Replace heating element if measured resistance deviates more than ± 10% from the value given in the table. Ohmmeter, visual inspection

Article no. Voltage [V] Power [W] Resistance [Ω]

103.604 230 2100 approx. 25

103.605 230 2750 approx. 19


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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


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Push distance bushing back by using pliers

Extract thermocouple carefully from its sock-et 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.


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 thermo-couple 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 de-stroyed!). If this should be the case, check thermocouple, heating element and electron-ic circuit once again and replace them if necessary. Temperature meter


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8.5 Blower motor

Open hot-air blower (Ghibli) according to chapter 8.1

8.5.1 Function check


1. Switch Uniroof E off 2. Connect ammeter between terminal and

black flex wire of the blower (see pic-ture)

3. Switch the tool on 4. The current consumption must be

200..300mA Ammeter

Notes

An excessive noise of the motor indicates a bearing defect Replace motor (see chapter 7.6)

If the current consumption exceeds 300mA, the motor works with overload (e.g. mo-tor 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 (abrai-son). 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“


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9 Setup menu

(upto software release 1.0A) Modifications in the Setup menu are automatically stored

At the same time press

and switch the tool on

„WRONG KEY COMB

TURN POWER OFF“

Enter code (HMHH+-)

Serial Number

Max. Speed

5.00m/min

Temp. Offset

+0°C

Display Unit

`-`>C/m, `+`>F/ft

1.00 20

5.00 600

M - + H

H press

H press

Min. Speed

1.00m/min

Max. temperature

600°C

H press

H press

H press

H press

- + select with

- + select with

- + select with

- + select with

- + select with

year week serial number 00 00 000

M M M


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(from software release 1.0B)

At the same time press

and switch the tool on

„WRONG KEY COMB

TURN POWER OFF“

Enter code (HMHH+-)

Serial Number

Max. Speed

5.00m/min

Temp. Offset

+0°C

Display Unit

`-`>C/m, `+`>F/ft

1.00 20

5.00 600

M - + H

H press

H press

Min. Speed

1.00m/min

Max. temperature

600°C

H press

H press

H press

H press

- + select with

- + select with

- + select with

- + select with

- + select with

year month day no. 00 00 00 0000

M M M M

Entering old 7 digit serial number: Enter week in month column Set day and first digit of serial number to 0


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10 Possible causes of errors

No announcement on the display

1. Check wiring chapter 6.3 2. Check electronic circuit TRN 05 chapter 7.2 3. Connect replacement electronic circuit CSE 06 temporarly 4. Check thermocouple (short circuit) chapter 8.4

Drive motor does not run or pauses suddenly

1. Check wiring (ribbon cable: interruption / short circuit) chapter 6.3 2. Check electronic circuit TRN 05 chapter 7.2 3. Check carbon brushes and drive motor chapter 7.4 & 7.5 4. Test electronic circuit ZPM 06 chapter 7.3

Drive motor does not start automatically when swivelling in the Ghibli

1. Check automatic drive start-up chapter 6.5 2. Check DIP-switch positions

1 2 3 4 5 6 7 8

OFF OFF ON OFF OFF OFF OFF OFF

Tool does not heat

1. Check wiring chapter 6.3 2. Check hot-air blower (Ghibli) chapter 8.1 - 8.4 3. Check electronic circuit TRN 05 chapter 7.2 4. Connect replacement electronic circuit CSE 06 temporarly

Tool heats all the time

1. Check triac chapter 6.6 2. Check electronic circuit TRN 05 chapter 7.2 3. Connect replacement electronic circuit CSE 06 temporarly

Blower motor does not run

1. Check wiring chapter 6.3 2. Check blower motor of hot-air blower (Ghibli) chapter 8.5 3. Check electronic circuit TRN 05 chapter 7.2


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11 Wiring diagram

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M

M

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 pro-tective earth conductor tester (< 0.2Ω)

Insulation test

Function check of high voltage tester: Shorten tips 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 1 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 po-sition "1" (ON) at the same time

Enter key combination 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 to deactivate the automatic restart protection

Press key once again to start the motor

Run the drive motor with max. speed (5m/min) Check percential power consumption of the drive, max. 65%

Heat the tool up to maximum temperature 600°C Check current consumption (according to nameplate)

Check display announcement 595..605°C

–

H M H H + –

+


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After 15 minutes search for the hottest spot and measure the temperature

Actual value of temperature meter 590..610°C

Adjust temperature offset, if necessary ( Setup menu) Example: Temperature display = 600°C; temperature meter = 610°C 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 hous-

ing

Check for cleanliness and possible damages


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13 Equipment required for Leister repair service

Mobile Equipment

1 protective earth conductor tester (e.g. Elabo)

1 high voltage tester up to 4000V (e.g. Elabo, Korntal)

1 temperature meter with temperature measurement probe (e.g. Fluke, Testo)

1 multimeter with following measurement options: (e.g. Fluke) - Current - Voltage - Resistance - Continuity (test buzzer)

1 rotational speed meter

1 water column

1 soldering iron

1 complete set of tools (screw drivers etc.)

Installed equipment

ESD-protected working environment

Transformer, possibly separated into variable and isolating transformer Data: 3 x 0..500V 3 x 30A

3 built-in voltmeters (500V)

3 built-in ammeters (30A) or wattmeters


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14 Appendix screw locking

= lock w

ith

LO

CT

ITE

24

2

= t

orq

ue

1.2

Nm

on

ly


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= lock w

ith

LO

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ITE

24

2

= t

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1.2

Nm

on

ly


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= lo

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LO

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24

2

repair instructions - querotools · 2019-12-02 · these repair instructions may not be distributed...

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