Leister GHIBLI AW Setup guide

Leister Technologies AG
Repair instructions
Ghibli AW
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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]

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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

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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

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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.

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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

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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)

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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)

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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)

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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)

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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)

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6.3 Temperature unit
Ghibli AW enables to display temperatures in °C or °F units. Select °C or °F unit in the ser-
vice menu.
or
Menu item "Temperature unit" indicates the
currently selected temperature unit
Push e-Drive control button shortly to alter
the temperature unit
Select desired temperature unit by turning
e-Drive control button
clockwise unit °C
counterclockwise unit °F
or
Quit menu item:
Save temperature unit selection by push-
ing e-Drive control button for a long time
Not save temperature unit selection by
pushing e-Drive control button shortly
or
Then menu item "Temperature unit" indi-
cates the currently selected temperature
unit again

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6.4 Nominal voltage
Ghibli AW enables nominal voltage selection. The service menu offers nominal voltages of
100V, 120V and 230V. Nominal voltage input defines the limits for under- and overvoltage
announcements from line/mains voltage.
or or
Menu item "Nominal voltage" indicates the
currently selected nominal voltage
Push e-Drive control button shortly to alter
the nominal voltage
or or
Displayed nominal voltage flashes
Select requested nominal voltage according
to rated voltage on the nameplate by turning
e-Drive control button
clockwise increase voltage
counterclockwise decrease voltage
or
Quit menu item:
Save nominal voltage selection by push-
ing e-Drive control button for a long time
Not save nominal voltage selection by
pushing e-Drive control button shortly
or or
Then menu item "Nominal voltage" indicates
the currently selected nominal voltage again

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6.5 Carbon brushes operating time (reset "Service recommended")
The carbon brushes operating time counts back from a recommended op-
erating time to zero. After expiration of this recommended operating time
the display shows the announcement "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.
Menu item "Reset service recommended" offers a readout of the remaining operating time
until warning notice (positive prefix). If the recommended carbon brushes operating time is
expired, a warning notice is displayed. From then the number of hours is shown with a nega-
tive prefix.
If either carbon brushes or motor are to be replaced, the operating hours must be re-
set to the recommended operating time using this menu item.
Menu item "Reset service recommended"
indicates the number of hours until warning
notice "Service recommended" will appear; if
the number is shown with a negative prefix,
service is recommended since then
Reset carbon brushes operating time, re-
spectively warning notice "Service recom-
mended", by pushing e-Drive control button
shortly
Unit "h" for hours is flashing
=
=
Select clearance for reset
Select clearance for reset by turning e-
Drive control button clockwise; this is in-
dicated with a flashing "R"
By turning e-Drive control button counter-
clockwise the clearance for release will
be cancelled

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+
Quit menu item with reset:
Pushing e-Drive control button for a long
time while clearance for reset ("R") is acti-
vated generates a reset of the carbon
brushes operating time and the warning no-
tice "Service recommended"; new preset
carbon brushes operating time is displayed
=
Quit menu item without reset:
Not save the input by pushing e-Drive con-
trol button shortly; previous carbon brushes
operating time is displayed
6.6 Tool operating hours
The operating hours counter indicates the tool (blower unit) operating time in hours.
Menu item "Operating hours counter" indi-
cates the operating hours
6.7 Number of operation activations
Ghibli AW increases the number of operation activations with each connection of the tool to
the line/mains (and pushing e-Drive control button for a long time blower motor runs).
Menu item "Number of operation activa-
tions" indicates the number of operation ac-
tivations
6.8 Number of temperature limit switch activations
Ghibli AW increases the number of temperature limit switch activations if it acts.
Menu item "Number of temperature limit
switch activations" indicates the number of
temperature limit switch activating cycles

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6.9 Maximum temperature adjustment
Ghibli AW offers the possibility to adjust the maximum temperature. This is an optional pro-
cedure and not compulsory during service work.
Adjustment procedure is described in chapter 14.3.
Menu item "Temperature adjust" (Adjust)
offers the possibility to adjust the maximum
temperature optionally
Push e-Drive control button shortly to dis-
play, respectively adjust the value for maxi-
mum temperature
or
Adjustment of maximum temperature
Measured temperature is too low:
Turning e-Drive control button clockwise
temperature increases (to max. +10°C /
+18°F)
Measured temperature is too high:
Turning e-Drive control button counter-
clockwise temperature decreases (to
max. -20°C / -36°F)
or
Quit menu item:
Save input by pushing e-Drive control
button for a long time
Not save input by pushing e-Drive control
button shortly

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6.10Error code memory
The error code memory enables a previous history access for analysis purposes. Detailed
descriptions of the error codes are given in chapter 17 "Error codes and repair methods".
The error code memory records the latest 5 errors in register positions 0 to 4. 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.
Menu item "Error code memory" indicates
recorded error code (see chapter 17)
Note: The error code is three-digit; lower-
case digit indicates position in the error
memory (5 menu items, numbered 0-4)
To display timestamp push e-Drive control
button shortly
Display shows last occurrence of an error;
unit "h" for hours and position number in the
error memory are displayed alternating
Push e-Drive control button shortly to dis-
play the number of error iterations
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 1 means, error occurred
once (etc.)
Push e-Drive control button shortly to return
to menu item "Error code memory"
Menu item "Error code memory" indicates
recorded error code again

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7 BossMode menu
Caution: BossMode menu requires the tool to be connected to line/mains voltage!
BossMode menu is intended to limit user adjustments (temperature and/or air flow).
Disable possible limitations during repair and service work to operate and check the
tool correctly (set to mode 0). Ship the tool back to customer in mode 0 as well.
Detailed description of BossMode menu is given in the appropriate application note. This is
just a brief instruction how to enter the menu and to alter the mode:
Mode 0: free operation no limitations
Mode 1: limited operation definition of operating range
Mode 2: fixed operation definition of operating point
7.1 Select BossMode menu (enter BossMode code)
Requiring a BossMode code prevents the user to alter the limitations accidentally. BossMode
limitations may be altered after entering code.
and
Push e-Drive control button and connect
tool to line/mains at the same time
For 3 seconds "Setup" appears. Within this
time release e-Drive control button and then
push it shortly for 4 times
, ,
After correct manipulations display indi-
cates selected BossMode ("M" and mode
number, not flashing)
or
Modes 0-2 may be selected by turning e-
Drive control button; not active modes are
indicated flashing
During repair and service work make
sure mode 0 is selected (no limitations)
Ship the tool back to customer in mode 0
4x

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Save selected mode by pushing e-Drive
control button for a long time (flashing dis-
play changes to static display).
If e-Drive control button is mistakenly
pushed shortly, the configuration of the ap-
propriate mode could be entered. Do not
turn e-Drive control button then (because
this would alter the selection); push e-Drive
control button for a long time.
There is no e-Drive control button manipu-
lation to quit the BossMode menu; discon-
nect tool from the line/mains (unplug the
tool)

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8 Tool opening / assembling
Caution! Disconnect tool from the line/mains before any work is commenced!
Following tools will be needed for repair work:
Screw driver Torx Size T15 (housing screws)
Screw driver slotted Size 0 (opening terminals)
Socket wrench Size 8 (blower unit nut)
Needle-nosed pliers (motor connections)
8.1 Tool opening
Disconnect tool from the line/mains!
Loosen PT pan head cap screws KA35x20
(4x), remove heater tube and mica tube
Heating element may be removed now; gas-
ket will be extracted with heating element
from blower housing top
Caution: Do not damage thermocouple!
Loosen PT pan head cap screws KA35x20
(4x) and remove blower housing top
Loosen PT pan head cap screws KA35x20
(6x) at top housing shell
Remove top housing shell

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8.2 Tool assembling
Check mechanical parts for abrasion before
assembling (chapter 12)
Fix 4 black flex wires (interconnection of
electronic circuit board PTU and electronic
circuit board HMI) in their supports
Fix power supply (blue and brown flex wire)
to attachment ring
Fix 2 black flex wires to motor in their sup-
ports
During assembling make sure, the attach-
ment ring is correctly positioned in the guid-
ing rails of the housing shells
Assemble all components and motor to the
bottom housing shell
Cover with top housing shell and tighten PT
pan head cap screws KA35x20 (6x)
Assemble blower housing top to print adapt-
er front
Make sure groove and cam fit properly
Tighten PT pan head cap screws KA35x20
(4x) to cross