Leister GHIBLI AW Setup guide

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
Page
1 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
Modified
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REPAIR INSTRUCTIONS
Hot Air Tool
GHIBLI AW
Serial number from 1411191700 (dc1448)
Software version from 3.02
© 2018 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
Ghibli AW
Revision: B
QM
INN_FO_29
Page
2 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
Modified
02.07.18 PRI
Table of contents
1Scope of applicability......................................................................................................4
2Safety precautions ..........................................................................................................4
3Remarks ...........................................................................................................................4
4Components naming.......................................................................................................5
5Errors and possible causes............................................................................................6
5.1 No function................................................................................................................6
5.2 Operation not properly possible ................................................................................6
5.3 Tool does not heat (correctly), motor runs ................................................................7
5.4 Motor does not run (correctly), tool heats..................................................................8
5.5 Indication of warnings ...............................................................................................8
5.6 Indication of error numbers Exxxh ............................................................................8
6Service menu...................................................................................................................9
6.1 Select service menu (enter service code)...............................................................10
6.2 Quit service menu...................................................................................................10
6.3 Temperature unit.....................................................................................................11
6.4 Nominal voltage ......................................................................................................12
6.5 Carbon brushes operating time (reset "Service recommended") ............................13
6.6 Tool operating hours...............................................................................................14
6.7 Number of operation activations .............................................................................14
6.8 Number of temperature limit switch activations.......................................................14
6.9 Maximum temperature adjustment..........................................................................15
6.10 Error code memory .................................................................................................16
7BossMode menu............................................................................................................17
7.1 Select BossMode menu (enter BossMode code)....................................................17
8Tool opening / assembling ...........................................................................................19
8.1 Tool opening ...........................................................................................................19
8.2 Tool assembling......................................................................................................20
9Electric components.....................................................................................................22
9.1 Power supply cord...................................................................................................22
9.2 Internal wiring..........................................................................................................24
9.3 Heating element......................................................................................................25
9.4 Thermocouple.........................................................................................................26
10 Electronic circuit boards ..............................................................................................28
10.1 Function check........................................................................................................28
10.2 Visual inspection.....................................................................................................28
10.3 Replacement of electronic circuit board HCU .........................................................28
10.4 Replacement of electronic circuit board PTU..........................................................30
10.5 Replacement of electronic circuit board HMI...........................................................32

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
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Created
13.04.15 PRI
Released
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11 Blower unit (motor) .......................................................................................................36
11.1 Commutator ............................................................................................................36
11.2 Function check........................................................................................................36
11.3 Carbon brushes ......................................................................................................37
11.4 Motor.......................................................................................................................38
11.5 Impellers .................................................................................................................39
12 Mechanical parts ...........................................................................................................41
12.1 Housing parts: Housing shells, air filter and blower housing top.............................41
12.2 Operating parts: e-Drive control button...................................................................41
12.3 Metal parts: Heater tube, screws.............................................................................41
13 Cleaning .........................................................................................................................41
14 Test procedure for GHIBLI AW (protection class II)...................................................42
14.1 Insulation test..........................................................................................................42
14.2 Function test ...........................................................................................................42
14.3 Maximum temperature adjustment (optional)..........................................................44
14.4 Checking completeness..........................................................................................44
15 Wiring diagram ..............................................................................................................45
16 Equipment required for Leister repair service............................................................45
16.1 Mobile equipment....................................................................................................45
16.2 Installed equipment.................................................................................................45
17 Error messages and repair methods ...........................................................................46

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
Page
4 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
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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 chapter 16 " Equipment required for Leis-
ter 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 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 (see chapter 14
"Test procedure") and any additional local requirements! Check with your
local Statutory Authority for testing requirements.

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
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INN_FO_29
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4 Components naming
Legend
1. Electronic circuit board PTU
2. Electronic circuit board HMI
3. Electronic circuit board HCU (Print adapter front)
4. Attachment ring
5. Motor with blower unit (impellers, deflector)
6. Power supply cord with cord guard
7. Strain relief clamps
8. Thermocouple
9. Temperature limit switch
10. Blower housing top
11. Heating element
12. Gasket
13. Mica tube
14. Heater tube
8
9
1
2
3
4
5
6
7
11
12
13
14
10

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
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5 Errors and possible causes
5.1 No function
Error
Possible causes
Repair methods
No function
No display, tool does
not heat and motor does
not run
1. No power supply
Check line/mains voltage
2. Break of power supply
cord
Replace power supply cord (chap-
ter 9.1)
3. Wiring error
Check internal wiring and contact-
ing (chapter 9.2)
If the flex wires for power supply
(blue and brown) are inverted at
the print adapter front terminal, the
electronic circuitry was destroyed.
Then, replace electronic circuit
board PTU (chapter 10.4) and/or
electronic circuit board HMI (chap-
ter 10.5) and/or electronic circuit
board HCU (chapter 10.3)
4. Electronic circuit defec-
tive
Replace electronic circuit board
PTU (chapter 10.4) and/or elec-
tronic circuit board HMI (chapter
10.5) and/or electronic circuit
board HCU (chapter 10.3)
5.2 Operation not properly possible
Error
Possible causes
Repair methods
Manipulation impossible
(switch the tool on)
1. Control knob e-Drive
blocked, push-button de-
fective
Replace electronic circuit board
HMI (chapter 10.5)
No feedback on manipu-
lations (temperature or
air flow altering)
1. BossMode is activated
Indication: Key symbol
flashes permanently or if
altering a value
Check BossMode adjustment
(chapter 7); this behaviour might
be desired
2. Control knob e-Drive
blocked, encoder defective
Replace electronic circuit board
HMI (chapter 10.5)

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
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Created
13.04.15 PRI
Released
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5.3 Tool does not heat (correctly), motor runs
Error
Possible causes
Repair methods
Tool does not heat
Warning "Heating ele-
ment defective" is dis-
played
1. Heating element not
correctly plugged into the
socket
Check heating element and its in-
stallation (chapter 9.3)
2. Heating element defec-
tive
Replace heating element
(chapter 9.3)
Temperature limit switch
is activated or defective
Warning "Overheating"
is displayed
1. Overheating: Ghibli AW
air flow is too low
Clean air filters (according to oper-
ating manual)
Check nozzle for clogging (clean or
replace)
2. Overheating: Motor
does not run or runs too
slowly
Check motor and perform mainte-
nance (chapter 11)
3. Temperature limit switch
defective
Replace electronic circuit board
HCU (chapter 10.3)
Air temperature not
achieved
1. Undervoltage
Check line/mains voltage
2. Heating power is possi-
bly not sufficient to achieve
temperature at high air
flow without using a nozzle
No solution possible
Check function by using a round
nozzle ø 5/8mm (chapter 14.2)
3. Thermocouple defective
Replace thermocouple
(chapter 9.4)
4. Heating element with
incorrect voltage rating
Replace heating element
(chapter 9.3)
5. Mica tube is missing
Assemble mica tube
Air temperature exceeds
range
1. Thermocouple defective
Check/replace thermocouple
(chapter 9.4)
2. Incorrect temperature
measurement
Replace electronic circuit board
HCU (chapter 10.3)

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
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8 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
Modified
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5.4 Motor does not run (correctly), tool heats
Error
Possible causes
Repair methods
Motor does not run
1. Connection to motor in-
terrupted (flex wires, plug)
Establish correct connection
2. Carbon brushes worn
out or blocked
Replace carbon brushes
(chapter 11.3)
3. Motor or its control de-
fective
Check motor and perform mainte-
nance (chapter 11)
Replace electronic circuit board
PTU (chapter 10.4) and/or elec-
tronic circuit board HMI (chapter
10.5), if motor is not defective
Motor runs with exces-
sive or unsteady noise
(jolting, loose contact)
1. Bearing defect, commu-
tator defective, carbon
brushes worn out or
blocked
Check motor and perform mainte-
nance (chapter 11)
5.5 Indication of warnings
Warning
Possible causes
Repair methods
"Service recommended"
announcement
1. Timer "Service recom-
mended" elapsed
Check carbon brushes
(chapter 11.3)
"Voltage error"
announcement
(Display shows actual voltage by
pushing e-Drive two times short-
ly)
1. Line/mains voltage too
low or too high (warning dis-
played at -20%, resp. +15%
from nominal voltage)
Check line/mains voltage
2. Wrong configuration of
nominal voltage
Check nominal voltage
(service menu, chapter 6.4)
3. Line/mains voltage ok,
but incorrectly measured
Replace electronic circuit board
HCU (chapter 10.3)
5.6 Indication of error numbers Exxxh
Error number
Possible causes
Repair methods
1. Ghibli AW displays an
error message
Error correction according to error
list (chapter 17)

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
Page
9 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
Modified
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6 Service menu
Caution: Service menu requires the tool to be connected to line/mains voltage!
Service menu enables altering of temperature unit, nominal voltage and maximum tempera-
ture adjustment as well as reset of the announcement "Service recommended". In addition
the service menu offers a readout of operating hours, number of switching on cycles and er-
ror memory.
After entering service code the specific menu items can be selected by turning e-Drive con-
trol button clock- (cw) or counterclockwise (ccw). Display and setting options will be de-
scribed in the following chapters.
Select the specific menu items
clockwise by turning e-Drive
control button clockwise
Select the specific menu items
counterclockwise by turning
e-Drive control button
counterclockwise
V3.xx
Start
Temperature unit
Reset «Service
recommended»
Hours of operation
Number of switch-on
cycles
Number temperature
limit switch-off cycles
Error memory 0
Error memory 1
Error memory 4
Enter service code
Rated voltage Temperature
adjustment
No heating output as long as Ghibli AW is in the service mode menu
Numbers of more than 4 digits are displayed as scrolling text
Quit service menu by disconnecting tool from the line/mains voltage only (unplug the tool)

Leister Technologies AG
Repair instructions
Ghibli AW
Revision: B
QM
INN_FO_29
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10 / 48
Created
13.04.15 PRI
Released
20.04.15 PRI
Modified
02.07.18 PRI
6.1 Select service menu (enter service code)
Requiring a service code prevents the user to enter the service menu accidentally.
and
Push e-Drive control button and connect tool
to line/mains at the same time
and
For 3 seconds "Setup" appears. Within this
time release e-Drive control button and turn
it 360° in both directions
After correct manipulations first menu item
pops up
6.2 Quit service menu
There is no e-Drive control button manipula-
tion to quit the service menu; disconnect tool
from the line/mains (unplug the tool)