Leister TWINNY T7 Setup guide

Repair instruction
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REPAIR INSTRUCTION
Hot Air Welder
TWINNY T7/T5
Production code from dc: 2201070001
T7 Software version from 1.04
T5 Software version from 1.08
© 2019 Leister Technologies AG, CH-6056 Kaegiswil
This repair instruction 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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TWINNY T7 / TWINNY T5
Revision B
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Table of contents
1Scope of applicability...................................................................................................... 4
2Safety precautions .......................................................................................................... 4
3Remarks ........................................................................................................................... 4
4Mechanics ........................................................................................................................ 5
4.1 Mechanical check...................................................................................................... 5
4.2 Additives ................................................................................................................... 5
4.3 Drive unit................................................................................................................... 6
4.4 Roller chains ............................................................................................................. 7
4.5 Pendulum head......................................................................................................... 9
4.6 Wiper ring lower drive shaft..................................................................................... 10
4.7 Changing the electronics housing ........................................................................... 10
4.8 Tension arm ............................................................................................................ 11
4.9 Clamping lever ........................................................................................................ 12
4.10 Force module .......................................................................................................... 13
4.11 Contacting system................................................................................................... 17
4.12 Adjustment of welding nozzle.................................................................................. 18
5Electronics ..................................................................................................................... 19
5.1 Open / close electronic cover.................................................................................. 19
5.2 Wiring...................................................................................................................... 20
5.3 power supply cord................................................................................................... 21
5.4 Main switch ............................................................................................................. 21
5.5 Electronic circuits .................................................................................................... 22
5.6 Disassembly of the terminal block........................................................................... 28
5.7 Triac........................................................................................................................ 29
5.8 Drive........................................................................................................................ 30
5.9 Heating element...................................................................................................... 32
5.10 Force sensor (TWINNY T7) .................................................................................... 33
5.11 Fan.......................................................................................................................... 34
5.12 Disassembly hot air blower ..................................................................................... 35
5.13 Check hot air blower Twinny T7.............................................................................. 36
5.14 Check hot air blower Twinny T5.............................................................................. 37
5.15 Check and replace thermocouple ........................................................................... 38
6Service-Menu T7 ............................................................................................................ 40
6.1 Activate service Menu............................................................................................. 41
6.2 Machine Setup ........................................................................................................ 41
6.3 Calibration............................................................................................................... 43
6.4 Error History............................................................................................................ 46
6.5 Force Monitor.......................................................................................................... 49
7Service Menu T5 ............................................................................................................ 50
7.1 Activate service menu ............................................................................................. 50
7.2 Service menu .......................................................................................................... 51
8Error massages TWINNY T5 ......................................................................................... 52
9Wiring diagram TWINNY T7 .......................................................................................... 53

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10 Wiring diagram TWINNY T5 .......................................................................................... 54
11 Test ................................................................................................................................. 55
11.1 Test procedure for TWINNY T7 (Protection class I)................................................ 55
11.2 Test procedure for TWINNY T5 (protection class I) ................................................ 59
12 Equipment required for Leister repair service............................................................ 62

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1 Scope of applicability
These repair instructions are reserved exclusively for Leister service centres. Only experienced
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 personnel carry-
ing 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 ser-
vice") is essential for doing qualified work. For safety reasons use only identical original LEIS-
TER 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 accessible
without using a tool, Live electrical components could be exposed. Contact
with these parts can cause danger to life! Ensure tool is disconnected (un-
plugged) from the line/mains every time before you commence any work!
Repaired tools must pass the Leister test procedure (see "Test proce-
dure") and any additional local requirements. Check with your local Statu-
tory Au-thority for testing requirements.

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4 Mechanics
4.1 Mechanical check
During each repair the tool has to be cleaned completely and be checked for damage.
•Check undercarriage for cracks and deformations
•Check sprocket wheels and replace them if necessary
•Replace roller chain if its joints are stiff or stretched.
•Make sure that there are no other particles than the essential grease inside the toothed
wheel workings.
•Clean all dirty parts
•Check all moving parts for smooth running and replace them if necessary
•Travel roller must run smoothly
•Lubricate all moving parts according to the spare parts drawing.
•Ensure which screws are to be locked prior to the tool assembly or its components (see
parts drawing)
4.2 Additives
Following the additives recommended for repair work on TWINNY T7/T5:
Additives (Symbol)
Manufacturer Name
Screw lock (@)
LOCTITE 242
LOCTITE 243
Thermal conducting paste (#)
WACKER® Silicone Paste P12
High temperature grease (§)
MOLYKOTE P74 Super Anti-Seize
Solid lubricant paste (+)
MOLYKOTE G-rapid plus
Mehrzweckfett (&)
KLÜBER Microlube GBU-Y 131
Teflon spray gease base ($)
INTERFLON Fin Grease (aerosol)
Teflon spray oil base (°)
INTERFLON Lube TF (aerosol)
Note
The required additives are also marked with colors and symbols in the spare parts
drawings as an aid.

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4.3 Drive unit
1. Remove belt cover (Fig. 1)
2. Loose drive unit, 3 screws (Fig. 2 & Fig. 3)
3. Place the drive unit underneath the electronic case (Fig. 4) Watch out: Make sure
there is no tension on the motor wiring.
Fig. 1
Fig. 2
Fig. 3
Fig. 4

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4.4 Roller chains
Notes
•The rounding of the chain lock must be mounted in the running direction of the
chain.
•Leister recommends that when replacing the chain, the drive shafts and
sprockets should also be replaced, as these may also be heavily worn.
4.4.1 Roller chain tension arm
1. Dismount drive unit (Chap. 4.3)
2. Dismount chain protection on tension arm (Fig. 10)
3. Dismount safety cover on pendulum head (Fig. 11)
4. Loose set screw to the drive roller axle (Fig. 12)
5. Remove the drive roller axle and take the drive roller off the chain. Tilt the drive roller up-
wards, so it is easier to get it out of the chain. (Fig. 13)
6. Loose set screw to the guide sprocket axle. (Fig. 14)
7. Push axle and sprocket aside to free the chain. Attention:There is a shim ring between
pendulum head and the sprocket. (Fig. 15)
8. Pull off the sprocket with the roller chain (Fig. 16)
9. Remove roller chain from tension arm (Fig. 17)
To mount a new roller chain, follow step 1-9 in reverse order.
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17

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4.4.2 Roller chain lowerpart
1. Disassemble chain protective plate of the gear box (Fig. 20)
2. Remove retaining ring (Fig. 21) and remove spur wheel and parallel key (Fig. 22)
3. Disassemble chain protection of lowerpart (Fig. 23)
4. Remove retaining ring (Fig. 24) and push the axle a bit through the sprocket (Fig. 25)
5. Remove parallel key (Fig. 26) and push the axle in to the frame (Fig. 27)
6. Remove sprocket and roller chain (Fig. 28)
7. Lay in the new sprocket and roller chain and push the axle through the sprocket (Fig. 29)
8. Mount parallel key and retaining ring (Fig. 30) and push the axle fully into the frame (Fig.
31)
9. Mount the gear wheel with parallel key and retaining ring (Fig. 32)
10. Mount chain protective plate of the gear box (Fig. 33) and chain protection of lowerpart
(Fig. 34). Note: Push the chain protection of lowerpart a little from above, so it is easier to
fit the chain tension device.
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34

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4.5 Pendulum head
1. Dismount safety cover on pendulum head (Fig. 40)
2. Loose set screw to the drive roller axle (Fig. 41)
3. Remove the drive roller axle and take the drive roller off the chain. Tilt the drive roller up-
wards, so it is easier to get it out of the chain (Fig. 42)
4. Loosen set screw to the guide sprocket axle (Fig. 43)
5. Remove sprocket and axle from pendulum head (Fig. 44) Attention:There is a shim ring
between pendulum head and the sprocket.
6. Remove set screws and pressure spring (Fig. 45 & Fig. 46)
7. Dismount the hex socket cap screw and the washer (Fig. 47)
8. Remove pendulum head from its axle (Fig. 48)
9. Make sure, there is a shim washer between tension arm and pendulum head. (Fig. 49)
To mount the pendulum head, follow step 1-9 in reverse order.
Note
Check the pendulum head with every repair and correct it if necessary. To do this,
adjust the two set screws with the compression springs (Fig. 45) so that the pen-
dulum head is horizontal when unloaded. The two set screws must be recessed by
max. 1 mm from the surface of the pendulum head and must not protrude.
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 45
Fig. 46
Fig. 47
Fig. 48
Fig. 49

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4.6 Wiper ring lower drive shaft
Cheick the wiper ring during every service. If it is damaged or brittle, it must be replaced.
1. Remove the roller cover (Fig. 60)
2. Remove the lower drive roller (Fig. 61) and its parallel key
3. Remove retaining ring (Fig. 62)
4. Dismount the old wiper ring. Use a sharp tool (Fig. 63)
5. Mount the new wiper ring
6. Mount parallel key, drive roller and roller cover in reverse order. Adjust the roller cover
to the wiper ring. (Fig. 64)
Fig. 60
Fig. 61
Fig. 62
Fig. 63
Fig. 64
4.7 Changing the electronics housing
1. Disassemble terminal block (Chap. 5.6)
2. TWINNY T7: Disassemble PCU 10 electronic circuit (Chap. 5.5.2)
3. Loosen cap screw and remove toothed belt cover (Fig. 65)
4. Remove locking screw (Fig. 66)
5. Loosen and remove connecting screw to lowerpart (Fig. 67)
6. Remove all parts from the old electronics housing and replace electronics housing.
For the assembly, carry out steps 1 -6 in reverse order.
Fig. 65
Fig. 66
Fig. 67

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4.8 Tension arm
1. Dismount drive unit (Chap. 4.3)
2. Dismount chain protection on tension arm (Fig. 70)
3. Dismount guard plate on pendulum head (Fig. 71)
4. Remove guide roller (Fig. 72 & Fig. 73)
5. Remove lock screw on tension arm (Fig. 74)
6. Push parallel pin out of tension arm (Fig. 75)
7. Remove sprocket (Fig. 65)
8. Disassemble chain protective plate of the gear box (Fig. 77)
9. Remove retaining ring (Fig. 78) and gear wheel with parallel key (Fig. 79)
10.Remove axle to tension arm (Fig. 80 & Fig. 81)
To mount the tension arm, follow step 1-10 in reverse order.
Fig. 70
Fig. 71
Fig. 72
Fig. 73
Fig. 74
Fig. 75
Fig. 76
Fig. 77
Fig. 78
Fig. 79
Fig. 80
Fig. 81

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4.9 Clamping lever
1. Place the clamping lever in a middle position. It should lay on the clamping lever lock
but not latch (Fig. 90).
2. Remove retaining ring and washer from the clamping lever (Fig. 91)
3. Dismount nut and washer (Fig. 92)
4. Dismount the fitting screw and the disc springs (3STK) (Fig. 93 & Fig. 94) Attention:
There is a shim between the clamping lever and the clamping lever lock
5. Tilt the clamping lever off and pull it off the force module (Fig. 95)
To mount the clamping lever, follow step 1-5 in reverse order.
Tighten the fitting screw so you can move the clamping lever easily, but not too loose, so the
clamping lever stays in every position. If so, use the nut to secure the fitting screw.
Fig. 90
Fig. 91
Fig. 92
Fig. 93
Fig. 94
Fig. 95

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4.10 Force module
The force modules of Twinny T7 & Twinny T5 prevent from adjusting accidently a too high
welding force. The aim is to prevent the welding machine from being damaged.
That is why you have to adjust the force module of Twinny T5 if you replace it. The force
module of Twinny T7 needs to be calibrated after a replacement (Chap. 6.3 und Chap. 11.1).
4.10.1 Force module Twinny T7
1. Open the electronic cover (Chap. 5.1)
2. Pull off plug leads by using a screwdriver. Use the screwdriver to push the orange
locks on the plug (Fig. 100).
3. Remove retaining ring and washer from the clamping lever (Fig. 101)
4. Remove lock screw on tension arm (Fig. 102)
5. Dismount chain protection on tension arm (Fig. 103)
6. Push parallel pin out of tension arm (Fig. 104)
7. Pull the force module off the clamping lever (Fig. 105)
8. Unlock the hose connector (Fig. 106) and dismount the force module completely (Fig.
107)
To mount die force module, follow step 1-12 in reverse order
Fig. 100
Fig. 101
Fig. 102
Fig. 103
Fig. 104
Fig. 105
Fig. 106
Fig. 107

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9. Remove adjustment ring lock (Fig. 108)
10.Remove retaining ring and adjustment ring (Fig. 109 & Fig. 110)
11.Dismount set screw (2x) (Fig. 111)
12.Remove the force sensor (Fig. 112). Attention:Pull the wire carefully off the hose.
Fig. 108
Fig. 109
Fig. 110
Fig. 111
Fig. 112
To check the force sensor for damage, see chap. 5.10.
Note
After replacement, the offset and gain values of the force sensor has to be recali-
brated in the menu "Calibration" according chap. 6.3 and chap. 11.1.

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4.10.2 Force module Twinny T5
4.10.2.1 Disassembly force module
1. Remove retaining ring and washer from clamping lever (Fig. 120)
2. Dismount lock screw on tension arm (Fig. 121)
3. Dismount chain protection on tension arm (Fig. 122)
4. Push parallel pin out of tension arm (Fig. 123)
5. Pull the force module off the clamping lever (Fig. 124)
Fig. 120
Fig. 121
Fig. 122
Fig. 123
Fig. 124

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4.10.2.2 Assembly force module
1. Screw force module to maximum length. Hold it by lower spring assembly and turn the
hexagonal nut counter clockwise till block (Fig. 130)
2. Loosen set screw to eyebolt (Fig. 131).
3. Turn the eye bolt till the force module reaches a length of 91mm (Fig. 132 & Fig. 133).
4. Secure the eye bolt by tightening the set screw (Fig. 134). The eye bolt can only be
secured every 180°. The set screw must secure the eyebolt on one of the plain sur-
faces (Fig. 135)
5. Fit the force module on to the clamping lever and mount the washer and retaining ring
(Fig. 136)
6. Push the parallel pin in to the tension arm and force module (Fig. 137).
7. Mount lock screw on tension arm (Fig. 138).
8. Mount chain guard clamping arm (Fig. 139)
9. Close the clamping lever, unlock the locking ring on the force module and turn the ad-
justing ring clockwise to the minimum pressure (Fig. 140).
10.Loose set screw to eye bolt (Fig. 141).
Fig. 130
Fig. 131
Fig. 132
Fig. 133
Fig. 134
Fig. 135
Fig. 136
Fig. 137
Fig. 138
Fig. 139
Fig. 140
Fig. 141

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11.Turn the lowerpart of the force module counter clockwise until the pressure rollers are
slightly in contact or have a maximum distance of 0.5mm (Fig. 142).
12.Turn the lowerpart of the force module back to the next securing surface.
13.Tighten the set screw (Fig. 143)
Note
There are only two possible positions to tighten the set screw (Fig. 144 & Fig. 145)
Fig. 142
Fig. 143
Fig. 144
Fig. 145
4.11 Contacting system
Check the roller and axle of the contacting system during every service for wear. The roller
wears out quicker than the axles.
The axles of the upper and lower contacting system must be lubricated with high temperature
grease at every service according to the spare parts drawings. To do this, the contact rollers
must be temporarily dismantled (Fig. 146 & Fig. 147).
Note
The ease of movement of the upper and lower contact rollers is decisive for a qual-
itatively good welding result and must therefore be checked during every service.
Fig. 146
Fig. 147

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4.12 Adjustment of welding nozzle
The assembly has to be carried out according to exploded diagrams and spare parts list.
1. Loosen pan head cap screw M4x10 (4x) to welding nozzle (Fig. 150).
2. Put the hot air blower in to welding position. Make sure the bolt on the swivel-in mechan-
ics engages (Fig. 151)
3. Turn the welding nozzle till it is parallel to the frame (Fig. 152).
4. Tighten pan head cap screw M4x10 (4x) to welding nozzle (Fig. 153).
5. Loosen set screws (2x) for 4 turns (Fig. 154).
6. Move the bar so the welding nozzle is centrical to the drive roller (Fig. 155 & Fig. 156)
7. Tighten the lower set screw (Fig. 157) till the welding nozzle lifts slightly (Fig. 158). It might
be you have to push a little with your other hand to lift the nozzle. (Fig. 159)
8. Tighten the upper set screw (Fig. 160)
9. The space between the welding nozzle and the lower contacting system should now reach
0.1mm to 1.5mm. This applies to every welding nozzle an is shown in Fig. 161 with a red
line.
Fig. 150
Fig. 151
Fig. 152
Fig. 153
Fig. 154
Fig. 155
Fig. 156
Fig. 157
Fig. 158
Fig. 159
Fig. 160
Fig. 161

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5 Electronics
Warning! Disconnect the tool from line/mains (plug unplugged) while doing the com-
ponent checks described in this chapter!
To check several components, it is necessary to measure the resistance with an ohmmeter. For
resistance values less than 10 Ωnote that the measurement wires and the test tips have a re-
sistance too. Short circuit the test tips and write down the resistance value. The values might be
1-2 Ω. Depending on the measurement the result might not be correct. For that reason, subtract
the noted resistance value from the measured result.
5.1 Open / close electronic cover
Caution! Before opening the cover, make sure the device has cooled down to ambi-
ent temperature. Otherwise there is a risk of burns also from inside the electronic
housing (triacs)!
5.1.1 TWINNY T7
1. Dismount the handle (Fig. 170)
2. Loosen the 4 screws marked red (Fig. 171)
3. Pull the electronic cover a little upwards (Fig. 172)
4. Unplug the cable to the HMI (Fig. 173)
5. Now you can remove the electronic cover.
Fig. 170
Fig. 171
Fig. 172
Fig. 173

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5.1.2 TWINNY T5
1. Dismount the handle (Fig. 174)
2. Loosen the 4 screws marked red (Fig. 175)
3. Pull the electronic cover a little upwards and tilt it over as shown (Fig. 176)
4. Loosen all connections to the electronic cover. Attention: The 4 plugs marked red in Fig.
177 have a lock.
5. Now you can remove the electronic cover.
Fig. 174
Fig. 175
Fig. 176
Fig. 177
5.2 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 (Fig. 9 und Fig. 10).
•Check cable protection tube for cracks, gaps and mechanical damages.
•
Make sure the grey clip has engaged properly