Leister TRIAC AT Setup guide

Leister Technologies AG
Repair Instructions
TRIAC AT
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REPAIR INSTRUCTIONS
Hot Air Tool
TRIAC AT
Serial number from 1106067414
Software version from 1.00
© 2012 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.
Leister Technologies AG, CH-6056 Kaegiswil / Switzerland, Tel. [phone] Fax [phone]
www.leister.com lei[email protected]

Leister Technologies AG
Repair Instructions
TRIAC AT
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Table of contents
1Scope of applicability......................................................................................................3
2Safety precautions ..........................................................................................................3
3Remarks ...........................................................................................................................3
4Errors and possible causes............................................................................................4
5Service menu...................................................................................................................6
5.1 Service code.............................................................................................................7
5.2 Temperature unit.......................................................................................................7
5.3 Reset of "Service recommended" announcement.....................................................8
5.4 Operating hours counter .........................................................................................11
5.5 Number of operation activations .............................................................................11
5.6 Error code memory .................................................................................................11
5.7 Quit menu ...............................................................................................................12
6Electronics.....................................................................................................................13
6.1 Opening tool............................................................................................................13
6.2 Tool assembling......................................................................................................14
7Electric components.....................................................................................................15
7.1 Power supply cord...................................................................................................15
7.2 Internal wiring..........................................................................................................17
7.3 Thermocouple.........................................................................................................18
7.4 Electronic circuit boards..........................................................................................19
8Motor ..............................................................................................................................24
8.1 Function check........................................................................................................24
8.2 Commutator check..................................................................................................24
8.3 Check carbon brushes............................................................................................24
8.4 Replace motor.........................................................................................................26
8.5 Replace impellers....................................................................................................27
9Cleaning .........................................................................................................................28
10 Heating element.............................................................................................................29
11 Wiring diagram ..............................................................................................................31
12 Test procedure for TRIAC AT (protection class II) .....................................................32
13 Equipment required for Leister repair service............................................................34
14 Error messages and repair methods ..........................................................................35

Leister Technologies AG
Repair Instructions
TRIAC AT
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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 working place (see "Equipment required for Leister repair service") is essen-
tial 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 servic-
ing 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 from the line/mains be-
fore 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 re-
quirements.

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4 Errors and possible causes
Error
Possible cause
Method of resolution
No function
Tool does not heat and mo-
tors does not run
Wiring error
If the flex wires for power
supply (blue and brown) are
inverted at the print adapter
front terminal, the electronic
circuit was destroyed
Break of power supply cord
Replace power supply cord
(chapter 7.1)
Electronic circuit defective
Check internal wiring and
replace print adapter rear
(chapter 7.4.4)
Tool does not heat
Heating element not correct-
ly plugged into the socket
Check heating element and
its installation (chapter 10)
Heating element defective
Replace heating element
(chapter 10)
No heating element current
detected/measured
Replace print adapter front
(chapter 7.4.3)
Tool does not heat, motor
runs
Triac defective
Replace print adapter front
(chapter 7.4.3)
Temperature limit switch
defective
Photo transistor defective
Motor does not run
Motor flex wires not properly
connected to terminal
Connect flex wires properly
Carbon brushes too short
Replace carbon brushes
(chapter 8.3)
Check motor (chapter 8.1)
Replace motor (chapter 8.4),
respectively print adapter
rear (chapter 7.4.4)
Air temperature not achieved
Heating element with incor-
rect voltage rating
Replace heating element
(chapter 10)
Mica tube is missing
Assemble mica tube
Air temperature exceeds
range
Thermocouple defective
Replace thermocouple
Incorrect temperature mea-
surement
Replace print adapter front
(chapter 7.4.3)
Incorrect voltage
measurement
Coorect line/mains voltage,
but incorrect measurement
Replace print adapter front
(chapter 7.4.3)

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Error
Possible cause
Method of resolution
Temperature controller de-
fective
Thermocouple not connect-
ed (loose contact)
Connect thermocouple
Thermocouple defective
Replace thermocouple
Incorrect temperature mea-
surement
Replace print adapter front
(chapter 7.4.3)
Excessive noise
Bearing defect
Replace motor (chapter 8.4)
Power consumption of blow-
er motor > 100W
Commutator defective: Worn
out lamella
Replace motor (chapter 8.4)
Power consumption of blow-
er motor > 100W
Unsteady noise (jolting,
loose contact)
Commutator defective: Blu-
ish discoloration
Replace motor (chapter 8.4)
Replace carbon brushes
(chapter 8.3)
Commutator defective: Deep
groove (U-shaped)
Significant carbon brush ab-
rasion
"Service recommended" an-
nouncement
Timer "Service recom-
mended" elapsed
Check carbon brushes
(chapter 8.3.)
Temperature limit switch
acts often / over and over
Triac AT air flow is too little
Clean air filters (according to
operating manual)
Check nozzle for obstruction
(clean or replace)
Temperature limit switch in
blower housing defective
Replace print adapter front
(chapter 7.4.3)
Motor does not run, respec-
tively turns too slowly
Replace motor (chapter 8.4)
Triac AT announces an error
message
Troubleshooting according
to chapter 14

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5 Service menu
Caution: Service menu requires the tool to be connected to line/mains!
The service menu enables a selection of the temperature unit, reset of the announcement
"Service recommended" and shows the error memory. Select the specific menu items by
turning e-Drive control button clock- (cw) or counterclockwise (ccw). Display and setting op-
tions will be described in the following chapters.
Start
Temperature unit
Reset «Service
rcommended»
Hours of operation
Number of switch-
on cycles
Error memory 0
Error memory 1
Error memory 9
Enter service code
Select the specific menu
items clockwise (cw) by
turning e-Drive control
button clockwise
Select the specific menu
item counterclockwise (ccw)
by turning e-Drive control
button counterclockwise
No heating output as long as the Triac AT is in service menu mode
Numbers of more than 4 digits are displayed as ticker
Quit service menu by disconnecting tool from rated voltage only

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5.1 Service code
Requiring a service code prevents the user to enter the service menu accidentally.
&
Press e-Drive control button and connect tool
to line/mains at the same time
&
For 2 seconds "Setup" appears. Within this
time first turn e-Drive control button one step
to the right, then one step to the left (without
pressing e-Drive control button at the same
time)
First menu item pops up
5.2 Temperature unit
Triac AT enables to display the set and actual temperatures in °C or °F units. Select °C or °F
unit in the service menu.
or
Menu item "Temperature unit" shows the
selected temperature unit
Press e-Drive control button shortly to alter
the temperature unit
=
Turning e-Drive control button counterclock-
wise selects °F temperature unit

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=
Turning e-Drive control button clockwise se-
lects °C temperature unit
Save the temperature unit selection and quit
the menu item by pressing e-Drive control
button for a long time (at least 1 second)
Not save the temperature unit selection and
quit the menu item by pressing e-Drive con-
trol button shortly
or
Then menu item "Temperature unit" shows
the selected temperature unit
5.3 Reset of "Service recommended" announcement
After expiration of a preset time limit the display shows the an-
nouncement "Carbon brushes nearing end of life". The icon "Motor"
flashes, but the Triac AT hot air tool may be used further on with no
restrictions.
As long as this time is not expired the menu item "Reset service recommended" shows the
number of hours until expiration.
If the warning notice "Reset service recommended" is still enabled, the number of hours will
be displayed with a negative prefix. This number of hours corresponds with the time the
warning notice was launched.
The operating time may be reset in the service menu. Doing so, the preset time limit of 1800h
will be relaunched.

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5.3.1 From software version 1.02
Menu item "Reset service recommended"
indicates the number of hours until warning
notice "Service recommended" will appear
Reset warning notice "Service recommend-
ed" by pressing e-Drive control button shortly
Unit "h" for hours is flashing
=
Select clearance for reset by turning e-Drive
control button clockwise; this is indicated
with a flashing "R"
=
Note: By turning e-Drive control button coun-
terclockwise the clearance for release will be
cancelled
Reset warning notice "Service recommend-
ed" and quit the menu item by pressing e-
Drive control button for a long time (at least 1
second) while clearance
Not save the input and quit the menu item by
pressing e-Drive control button shortly
Menu item "Reset service recommended"
reappears

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5.3.2 Software version 1.01 and earlier
Menu item "Reset service recommended"
indicates the number of hours until warning
notice "Service recommended" will appear
Reset warning notice "Service recommend-
ed" by pressing e-Drive control button short-
ly
"R" is displayed constantly
Select clearance for reset by turning e-Drive
control button clockwise
Software bug: Turning e-Drive control button
clockwise more than one step, clearance for
reset is alternately enabled and disabled;
because clearance is not shown, the reset
procedure possibly must be performed for
several times
By turning e-Drive control button counter-
clockwise the clearance for release will be
cancelled
Reset warning notice "Service recommend-
ed" and quit the menu item by pressing e-
Drive control button for a long time (at least
1 second) while clearance
Not save the input and quit the menu item
by pressing e-Drive control button shortly
Menu item "Reset service recommended"
reappears

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5.4 Operating hours counter
The operating hours counter indicates the blower operating time in hours.
Note: Tools with software versions up to 1.01 indicate the time the electronic circuit was en-
ergized. So, the warning notice "Service recommended" will be launched too early for tools
connected to line/mains voltage, but not switched on.
Menu item "Operating hours counter" indi-
cates the operating hours
5.5 Number of operation activations
Triac AT increases the number of operation activations with each connection of the tool to
line/mains voltage. Line/mains interrupts are recorded as well.
Menu item "Number of operation activa-
tions" indicates the number of operation ac-
tivations
5.6 Error code memory
The error code memory enables a previous history access for analysis purposes. Detailed
descriptions of the error codes are given in chapter 14.
The error code memory records the latest 10 errors in register positions 0 to 9. If the same
error iterates, the number of iterations (repetitions) will be recorded as well. A maximum of
255 iterations may be recorded. If this number exceeds the counter reading remains on 255.
As soon as a new error occurs, the previous error will not increase any more.

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Menu item "Error code memory" indicates
recorded error code (Error message and
troubleshooting see chapter 14)
Note: The error code is of three digits; low-
ercase digit indicates position in the error
memory
Display alters by pressing e-Drive control
button shortly
Display shows first occurrence of an error;
unit "h" for hours and position number in the
error memory are displayed alternating
Display alters by pressing e-Drive control
button shortly
The number of iterations (repetitions) of this
specific error code is displayed; "R" for repe-
tition and position number in the error
memory are displayed alternating
Note: Number of 0 means, error occurred
once but with no repetition
Display alters by pressing e-Drive control
button shortly
Menu item "Error code memory" re-indicates
recorded error code
5.7 Quit menu
There is no e-Drive control button manipula-
tion to quit the service menu; disconnect tool
from the line/mains

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6 Electronics
Caution: The following test procedure sometimes requires the tool to be connect-
ed to the line/mains. Insure the tool is disconnected from the line/mains before
any work is commenced!
6.1 Opening tool
Disconnet tool from the line/mains!
Loosen PT pan head cap screws KA35x20
(4x)
Extract handle
Put housing front aside
Extract print adapter front from blower
housing top
Attention: Do not damage thermocouple!

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6.1.1 Handle
Replace handle if it is fairly worn out (abrasion, mechanical damage) or if the rubber is refrac-
tory or extremely soaked (sticky). It is recommended to affix a spare part nameplate to the
replacement handle.
6.2 Tool assembling
Insert flex wires in correct order in retaining
bracket: Brown, blue, orange, green, grey,
violet, red (bottom-up in the photo)
Insert print adapter front in blower housing
top
Make sure groove and cam fit properly
Put handle over the tool
Tighten PT pan head cap screws KA35x20
(4x) to cross

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7 Electric components
7.1 Power supply cord
- Check power supply cord for mechanical damages (jacket insulation, sharp kink, plug)
- Check strain relief and terminal
- Check for short circuit and breaks by using a continuity checker/buzzer
- Replace cord guard as well when indicated Continuity checker/buzzer, visual inspection
Replace power supply cord if it shows mechanical damage, short circuit or break
Extract power supply cord from strain relief
clamps
Disconnect power supply cord from termi-
nals: Press slotted screw driver size 1 in
terminal, extract flex wires
Extract power supply cord from cord guard
and handle

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Insert replacement power supply cord from
outside into the handle
Insert power supply cord into cord guard
Press slotted screw driver size 1 in terminal;
connect flex wires to terminal
Keep an eye on correct color code!
Press power supply cord between strain
relief clamps
Note
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.

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7.2 Internal wiring
Check all flex wires for breaks, short circuits and mechanical damages
Check correct wiring. Terminal and flex wires are of the same color (compare with illustra-
tion)
Visual inspection
Note
Incorrect flex wires connection causes destruction of the electronic circuit boards!

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7.3 Thermocouple
Open tool according to chapter 6.1
Check thermocouple for mechanical damages
Check correct connection of thermocouple (ob-
serve color code; short circuits caused by untwist-
ed ends of flex wires)
Measure ambient temperature
Disconnect thermocouple flex wires from terminal
(press terminal lever with screw driver; extract flex
wires)
Connect thermocouple to thermometer (calibration:
Type K)
Ambient temperature (± 5°C/10°F)
Heat thermocouple by using a hot air tool
Temperature must increase
Short-circuit both thermocouple flex wires (green
and white)
Measure resistance between short-circuited flex
wires and thermocouple jacket
Resistance > 1MΩ
Replace thermocouple when indicated
Extract thermocouple from its support
Connect thermocouple to replacement electronic
circuit board: Press terminal levers with a screw
driver, connect thermocouple flex wires and insert
thermocouple in support untill it snaps in
Reassemble tool in reverse order, terminate assem-
bling according to chapter 6.2

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7.4 Electronic circuit boards
Caution! The following measurement 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!
7.4.1 Visual inspection
Check electronic circuit boards for visual error indications:
Scortch marks, destroyed components
Expanded/swelled parts
7.4.2 Function check
According to test procedure chapter 12
7.4.3 Replacement of the electronic circuit board in blower housing top
Open tool according to chapter 6.1
Power supply (blue and brown flex wire):
Press slotted screw driver in terminal, ex-
tract flex wires
Signal lines: Press terminal lever with a
screw driver; extract flex wires
Replace thermocouple according to chapter
7.3 and reassemble it to replacement elec-
tronic circuit board

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Power supply (blue and brown flex wire):
Press slotted screw driver in terminal, con-
nect flex wires
Signal lines: Connect flex wires without op-
erating terminal levers; make sure terminal
color corresponds with flex wire color
Reassemble tool in reverse order, terminate
assembling according to chapter 6.2
7.4.4 Replacement of the electronic circuit board in the handle
Open tool according to chapter 6.1
Extract flex wires off the support
Remove motor flex wires from terminals:
Press terminal lever by using a screw driv-
er, extract flex wires