Leister TWINNY T7 Repair Instructions
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Leister TWINNY T7 Repair Instructions

Hot air welder
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REPAIR INSTRUCTION
© 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
www.leister.com
Repair instruction
TWINNY T7 / TWINNY T5
Revision B
Hot Air Welder
TWINNY T7/T5
Production code from dc: 2201070001
T7 Software version from 1.04
T5 Software version from 1.08
Doc. Nr.
Revision
Stand
Created
Released
Modified
Tel. +41 41 662 74 74 Fax +41 41 662 74 16
INN_FO_29
1.1 PRI
25.02.2013
16.05.19 FLS
11.05.22 TSC
10.05.22 LG
leister@leister.com
Seite 1/62

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Summary of Contents for Leister TWINNY T7

  • Page 1 © 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. +41 41 662 74 74 Fax +41 41 662 74 16 www.leister.com...

  • Page 2: Table Of Contents

    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 Service-Menu T7 ......................
  • Page 3 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...

  • Page 4: 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.

  • Page 5: Mechanics

    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) Additives Following the additives recommended for repair work on TWINNY T7/T5: Additives (Symbol) Manufacturer Name Screw lock (@) LOCTITE 242...

  • Page 6: Drive Unit

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Drive unit 1. Remove belt cover (Fig. 1) 2. Loose drive unit, 3 screws (Fig. 2 & Fig. 3) 3.

  • Page 7: Roller Chains

    • 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.
  • Page 8 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Roller chain lowerpart 4.4.2 1. Disassemble chain protective plate of the gear box (Fig. 20) 2.

  • Page 9: Pendulum Head

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Pendulum head 1. Dismount safety cover on pendulum head (Fig. 40) 2. Loose set screw to the drive roller axle (Fig. 41) 3.

  • Page 10: Wiper Ring Lower Drive Shaft

    Fig. 64 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.

  • Page 11: Tension Arm

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Tension arm 1. Dismount drive unit (Chap. 4.3) 2. Dismount chain protection on tension arm (Fig. 70) 3.

  • Page 12: Clamping Lever

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Clamping lever 1. Place the clamping lever in a middle position. It should lay on the clamping lever lock but not latch (Fig.

  • Page 13: Force Module

    10.05.22 LG 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.
  • Page 14 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 9. Remove adjustment ring lock (Fig. 108) 10. Remove retaining ring and adjustment ring (Fig. 109 & Fig. 110) 11.
  • Page 15 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Force module Twinny T5 4.10.2 4.10.2.1 Disassembly force module 1. Remove retaining ring and washer from clamping lever (Fig. 120) 2.
  • Page 16 INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 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.

  • Page 17: Contacting System

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 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).

  • Page 18: Adjustment Of Welding Nozzle

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 4.12 Adjustment of welding nozzle The assembly has to be carried out according to exploded diagrams and spare parts list.

  • Page 19: Electronics

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 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.

  • Page 20: Wiring

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG TWINNY T5 5.1.2 1. Dismount the handle (Fig. 174) 2. Loosen the 4 screws marked red (Fig. 175) 3.

  • Page 21: Power Supply Cord

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG power supply cord Check power supply connections. Replace wires in case of wire break, short circuit or me- chanical damages.

  • Page 22: Electronic Circuits

    Twinny T7 Communication module V01, large HMI11 Twinny T5 El. circuit HCU 47A HCU47 Twinny T7 & Twinny T5 230V El. circuit HCU 48 HCU48 Twinny T5 120V Communication module HMI 03 (TWINNY T7) 5.5.1 Caution! The following measurement procedure sometimes requires the tool to be connected to the line/mains.
  • Page 23 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Caution: For this check the tool is connected to mains! 1. First connect the replacement communication module then switch on the main switch. In case of proper function, the communication module has to be replaced.
  • Page 24 11.05.22 TSC Revision B Modified 10.05.22 LG Electronic circuit PCU 10 (TWINNY T7) 5.5.2 Note By replacing the electronics PCU 10 all calibration data (force sensor, voltage display, etc.) of menu „Calibration“, as well as all setup information of menu „Machine Setup“...
  • Page 25 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 5.5.2.2 Insert electronics PCU 10 1. Push plugs and wires aside and insert circuit board (Fig. 193).
  • Page 26 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Communication module HMI 11 (TWINNY T5) 5.5.3 Note By replacing the electronics HMI 11 all calibration data (Temperature air, Temperature ambient) and setup information (type of machine, range of voltage) will be deleted.
  • Page 27 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Plug-in adapter HCU 47 & HCU 48 5.5.4 Note The plug-in adapters HCU 47 (230V) and HCU 48 (120V) for the heating element have no electronic components.

  • Page 28: Disassembly Of The Terminal Block

    Disassembly of the terminal block 1. Open the electronics housing (Chap 5.1) 2. TWINNY T7: Unplug all connection cables to the circuit and push them aside. Caution: The plug connections circled in red have a locking mechanism (Fig. 203). 3. Disconnect the power cable and strands to the housing. The connection cables can be pulled out of the terminal block by pressing the orange release device with a pin (Fig.

  • Page 29: Triac

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Triac Caution! The following measurement procedure sometimes requires the tool to be connected to the line/mains. Ensure the tool is disconnected from the line/mains be-...

  • Page 30: Drive

    PCU10 (Fig. 216 & Fig. 217). If the micro-fuse is ok, check all plugs. If a loose contact can be ex- cluded the drive has to be replaced. Fig. 216 Fig. 217 Micro-fuse for drive PCU10 (TWINNY T7) Micro-fuse for drive HMI11 (TWINNY T5) Seite 30/62...
  • Page 31 4. Dismount the motor from the drive flange (Fig. 222) 5. Open electronic cover (chap 5.1) 6. TWINNY T7: Remove PCU 10 (chap. 5.5.2.1) TWINNY T5: Unplug drive plugs (Power, encoder and PTC) on PCU10 (chap. 10) 7. Loosen hex socket cap screws. Fig. 223.

  • Page 32: Heating Element

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Heating element Caution! The device must be cooled down to ambient temperature. Otherwise there is a risk of burns.

  • Page 33: Force Sensor (Twinny T7)

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 5.10 Force sensor (TWINNY T7) The force sensor can be checked with an ohmmeter. The sensor is ok if the measured resistance between green and black wire is 400-600kΩ.

  • Page 34: Fan

    2. Remove Roller on the front (Fig. 231) 3. Dismount drive unit (chap. 4.3) 4. Open electronic cover (chap. 5.1) 5. Remove PCU 10 (chap. 5.5.2 ). Only for Twinny T7 6. Remove fan guard (Fig. 232). 7. Remove fan (Fig. 233) To mount the fan, follow step 1-7 in reverse order.

  • Page 35: Disassembly Hot Air Blower

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 5.12 Disassembly hot air blower Caution! The device must be cooled down to ambient temperature. Otherwise there is a risk of burns.

  • Page 36: Check Hot Air Blower Twinny T7

    5.13 Check hot air blower Twinny T7 The blower unit of the Twinny T7 is maintenance free and can only be replaced as a complete unit. It is not necessary to replace the data cable and the power supply of the blower motor if there is no mechanical damage (wire break, defective insolation).

  • Page 37: Check Hot Air Blower Twinny T5

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 5.14 Check hot air blower Twinny T5 To dismount the hot air blower, see chap. 5.12 1.

  • Page 38: Check And Replace Thermocouple

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 5.15 Check and replace thermocouple 1. Open electronic cover (chap. 5.1) 2. Remove thermocouple plug from module PCU 10 or HMI 11. Push down the orange lock- ing mechanism.
  • Page 39 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 1. First lead the compensating cable through the HCU 47 or HCU 48 module (Fig. 288). 2. The black heat shrink tube has to be placed in the cable feedthrough. (Fig. 289).

  • Page 40: Service-Menu T7

    Machine Setup ➔ Res. Hours Drive Machine Setup ➔ Res. Error History Force sensor Calibration ➔ Force Sensor ➔ Offset Calibration ➔ Force Sensor ➔ Gain Thermocouple Calibration ➔ Temp. Air Offset Detailed notes for using: ➔ Leister Operating instructions TWINNY Seite 40/62...

  • Page 41: Activate Service Menu

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Activate service Menu To activate the service menu, proceed as follows: 1. Switch off the tool 2.
  • Page 42 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Menu Function Machine Name No changes necessary. Mains Voltage Mains voltage version (230V): No changes necessary.

  • Page 43: Calibration

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Menu Function Res. Hours Drive Choose this function if the drive motor was replaced.
  • Page 44 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Menu Function Measure the mains voltage with a Multimeter. If the measured value on the machine (Measured Value) does not correspond to the actual value, adjust with “e-drive”...
  • Page 45 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Menu Function Changes the curve of the drive current sensor. Do not change the value (setting is 0) Offset: This item is to adjust the force sensor in no-load condition.

  • Page 46: Error History

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Error History The menu item „Show Error History“ provides the following functions: Error Group:...
  • Page 47 INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Error messages 6.4.1 Before each component check or replacement, make sure all plugs are properly plugged in cor- rectly and the wiring is correct.
  • Page 48 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Error Gruppe 0020: Heating element Error No. description solution Heating element error or tem- •...

  • Page 49: Force Monitor

    Important: There is exactly only one combination possible. The displayed error is always unique. Force Monitor If the welding force is set to high, Twinny T7 will record this. If drive and hot air are switched on and the welding force exceeds 1050N the Twinny will record this.

  • Page 50: Service Menu T5

    Thermocouple Temp. Air Offset Blower motor Res. Hours Blower Detailed notes for using: ➔ Leister Operating instructions TWINNY Activate service menu To activate the service menu, proceed as follows: 1. Switch off the tool 2. Push the buttons "Drive ON/OFF", "Heating ON/OFF" and "Confirm" an switch on the tool by the mains switch at the same time.

  • Page 51: Service Menu

    INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Service menu Before leaving the service menu confirm with . Otherwise the changes will not be saved.

  • Page 52: Error Massages Twinny T5

    Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Error massages TWINNY T5 Before each component check or replacement, make sure all plugs are properly plugged in cor- rectly and the wiring is correct.

  • Page 53: Wiring Diagram Twinny T7

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Wiring diagram TWINNY T7 Seite 53/62...

  • Page 54: Wiring Diagram Twinny T5

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Wiring diagram TWINNY T5 Seite 54/62...

  • Page 55: Test

    Revision B Modified 10.05.22 LG Test 11.1 Test procedure for TWINNY T7 (Protection class I) Protective earth conductor test 11.1.1 • Use the protective conductor tester to measure the resistance between the protective contact pin of the device test plug and the chassis (R < 0.2Ω).
  • Page 56 INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG • Select menu item and enter the following: Mains Volt. Offset: Set Offset Value using the True RMS multimeter.
  • Page 57 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Function test LQS 11.1.4 • Choose symbol and conform with button • Switch Advanced Mode on.
  • Page 58 (must conform with measurements) • The following labels adhesives must be applied: Company logo "LEISTER" on the electronics cover Label "LQS / WiFi / GPS" on the electronics cover Label "max. 1000N" on the pendulum head Warning label „Warning against retraction“...

  • Page 59: Test Procedure For Twinny T5 (Protection Class I)

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG 11.2 Test procedure for TWINNY T5 (protection class I) Protective earth conductor test 11.2.1 •...
  • Page 60 Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG • Push button to switch off the drive. • Switch on heating with the button (Press and hold for 3 seconds).
  • Page 61 (must conform with measurements) • The following labels adhesives must be applied: Company logo "LEISTER" on the electronics cover Warning label „Warning against retraction“ on the pendulum head Warning label „Warning of hand injuries“ on the pendulum head Warning label „Warning of hand injuries“...

  • Page 62: Equipment Required For Leister Repair Service

    Doc. Nr. INN_FO_29 Repair instruction Revision 1.1 PRI Stand 25.02.2013 Created 16.05.19 FLS TWINNY T7 / TWINNY T5 Released 11.05.22 TSC Revision B Modified 10.05.22 LG Equipment required for Leister repair service Mobile equipment • 1 protective earth conductor tester (z.B.

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