GB OPERATING INSTRUCTIONS - Stanmech Technologies Inc.
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1. OPERATING INSTRUCTIONS LEISTER Comet Automatic Wedge Welding Machine pa Please read operating instructions carefully before use 123 and keep for further reference APPLICATION The LEISTER Comet is an automatic wedge welding machine for overlap welding and manufacturing of films and geomembrane liners in tunnels as well as in earthwork and civil engineering Length of Wedge Type of Material Material Thickness Note i PE HD PP 1 5 2 0 mm 60 80 mil For welding materials of 70 mm 2 8 inch PE LD 2 0 3 0 mm 80 120 mil PVC a special wedge PE HD PP 0 5 1 5 mm 20 60 mil Pe iai F must be used 50mm 2 inch PE LD 1 0 2 0 mm 40 80 mil 20mm 08inch BEHO PVC 0 5 1 0 mm 20 40 mil e Overlap max 125mm 5 inch e Type of seam Welding seams are produced in accordance with DVS 2225 part and BAM Other dimensions are possible on request DVS German Welding Association BAM Federal Institute for Materials Research and Testing Berlin CE LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 7474 Fax 41 41 6627416 www leister com sales leister com WARNING A PERS Danger Unplug the tool before opening it as live com ponents and connections are exposed Incorrect use of the hot wedge tool can present a fire and explosion hazard especialy near combustible materials and explosive gases Do not touch the element hou2. 10 Tighten the a oe locking screw 11 by 157 700 hand 134 600 a ace Warning 67 300 If the maximum welding 45 200 pressure of 1000 N is 23 100 exceeded mechanical 1234561234 Screen damage may occur WELDING PARAMETERS LEISTER Comet Welding temperature _ Set the welding temperature with the H El keys The temperature is dependent on the material and the ambient temperature The in put SET value will be shown on the display Switch on the heating by pressing the JH and keys simultaneously Heating up time approx 5 mins Heating cursor will blink on a JH a U the display j J SET value setting Fi ooo 40 JH amp ON OFF i ecb 4 CU Welding Speed According on the film or geomembrane liner and the influence of the wea ther set the welding speed with the El keys The in put SET value will be shown to the display E C co Drive gt i SET value adjustment ON OFF cct cu g m g e0 ugg Cu UU WELDING LEISTER Comet Welding Preparation Laying Width of overlap 80 mm to 125 mm Geomembrane liners must be clean between the overlap as well as above and below Mains supply at least 4kW generator supplied with an RCCB Cable to mains a minimum cable cross section in accordance with the table to 50m 3x1 5 mm 3x14 AWG Operating conditions to 100m 3x2 5 ar 3x12 AWG to 50m 3x1 5mm 3x1
3. DESCRIPTION OF TOOL Cord to mains Housing for drive motor and electronics Main switch Keyboard Display Drive power transmission Hot wedge Handle for hot wedge support Lever for welding pressure Adjustment screw for welding pressure 11 Locking screw 12 Lever locking mechanism 13 Guide handle COmMmNO OK N WELDING PARAMETERS 15 16 17 18 19 20 21 22 23 24 25 26 27 Welding Pressure Engage and position the automatic welding machine onto the material to be welded Pull the lever for welding pressure 9 without engaging the hot wedge By rotating the adjustment screw for welding pressure 10 the drive pressure rollers 20 21 should lightly touch the material to be wel ded Unlock the lever for the locking mechanism 12 and release the tension of the lever 9 at the LEISTER Comet Travelling wheel Deflector Tube to hot wedge Pinch roller Front guide roller Rear guide roller Lower drive pressure roller Upper drive pressure roller Chain Lower part of chassis Adjustment screw swivel head Lower part of chain guard Cap screw for front guide roller Adjustment screw hot wedge LEISTER Comet max welding pressure 1000 N b same time an N Welding pressure _ Illustration A Ea Following illustration A rotate the adjustment 220 1000 screw
4. 100 100 100 100 or lt or L or lt or lt Drive reason for fault e mains under voltage e overlap of the geomembrane liner too wide e dirt on the drive rollers 20 21 e max welding pressure 1000 N has been exceeded e high welding speed with large sudden overload ie anchoring trench T joints If malfunction is still present contact service centre WELDING LEISTER Comet Welding procedure e Check Drive Pressure rollers 20 21 as well as the hot wedge 7 must be clean before engaging into the geomembrane liner or film Cable length cable guide e Guide and position the automatic welding machine into the over lapped geomembrane liner or film e Adjust welding parameters see page 5 6 e The welding temperature must be achieved e Switch on drive motor with Mj key on keyboard 4 e Engage the hot wedge 7 e Pull the lever 9 Beginning of welding process eCheck the welded seam wash seam thickness reduction As required adjust the welding speed with keys on keyboard 4 eThe automatic welding machine is guided along the overlap with the guide handle 13 so that the frontal width of the overlap is kept within the 20 mm 0 8 inch zone see illustration B Illustration B gt A OE geri OS j EEK Max frontal width of overlap gt 20 mm 0 8 inch End of welding process e 1 cm before the end of the welded seam release the tension le
5. 4 AWG e Attach guide handle 13 2 e Pull out handle 8 and pull io Sen eae back the hot wedge support by the handle 8 until it locks again e Connect tool to the mains e Start the tool with Main or Control Level 6 WELDING LEISTER Comet Version Standard Memory card 1 3 1 3 5 Main Level r Q gt nan Ann m lt A OCA main switch 3 ON uae UU BGS ed 850 ecu 8 400 iS0 438 365 2 4 2 4 6 1 3 5 Control Level Eh ge gt 220 400 80 380 850 46 60 4q 60 7365 main switch 3 ON 2 4 2 476 Check the welding process and identify faults by means of the display of power consumption lt Overload Indication Heating Drive active Display no Drive heating 1 Welding speed 2 Welding speed ACTUAL value SET value Power consumption 3 Temperature ACTUAL value 4 Temperature SET value Power consumption 6 Memory card 5 Welding pressure ACTUAL value Residual capacity Memory card Autostart No 7 Residual capacity Led green Led red Pos 7 Not inserted No Yes none 0 Off Off Inserted No Yes Protocol on No Yes flashing Display 4 Heating reason for fault after heating up time 100 e mains under voltage 100 e heating cartridges faulty Display 2 100
6. of upper drive pressure roller LEISTER Comet For various applications for example tunnel construction or civil engineering at or below ground level various overlap welded seams can be manufac tured with the LEISTER Comet These differ in the width of the welded seam and the width of the test channel Also welded seams without a test channel can be manufactured In order to implement these different overlapped seams the appropriate drive pressure rollers must be fixed These drive pres sure rollers can be produced in aluminium or stainless steel according to the customer s requirements 1 Countersunk screw M3x6 6 Spacer ring 2 Guard plate for swivelling head 7 Drive pressure roller 3 Set screw M4x8 8 Woodruff key 4 Straight pin 6x80 9 Drive shaft upper complete 5 Locking ring shaft 15 Dismantling of the drive pressure rollers sequence 1 9 Assembly of the drive pressure rollers reverse order 9 1 Changeover of lower drive pressure roller LEISTER Comet 1 Countersunk screw M3x6 9 Spacer bush 2 Cylinder screw M8x40 10 Guide roller 3 Spacer bush 11 Guard plate drive pressure roller 4 Nilos ring 8 20x1 8 12 Countersunk screw M4x12 5 Shim 8 14x0 1 13 Locking washer 6 Rear travelling wheel complete 14 Drive pressure roller 7 Shim 8 14x0 1 15 Spacer 15 22x0 3 8 Nilos ring 8 20x1 8 16 Woodruff key 5x6 5 Dismantling of the drive pressure rollers sequence 1 16 Assembl
7. sing and hot wedge when hot as they can cause burns Allow the tool to cool down Do not point the hot air flow in the direction of people or animals Connect the tool to a socket outlet with protective earth conductor Any interruption of the protective earth conductor within or outside the tool is dange rous Use only extensions cables with a protective earth conductor CAUTION A materials DA GG APPROVAL MARKS TECHNICAL DATA Length of wedge Voltage V Power consumption W Frequency Hz Temperature C F Welding pressure N Ibs pound Drive m min feet Size LxBxH mm Weight kg The voltage rating stated on the tool should correspond to the mains voltage For personal protection we strongly recommend the tool be connected to an RCCB Residual Current Circuit Breaker before using it on construction sites The tool must be operated under supervision Radiant heat from the hot wedge can ignite flammable Protect the tool from damp and wet Protection class I 70 mm 50 mm 20 mm 120 230 120 230 120 230 x 1500 1200 700 50 60 max 420 790 stepless max 1000 225 stepless 0 8 3 2 2 6 10 5 stepless 285 x 230 x 230 7 0 15 5 Ibs mains voltage cannot be switched over DESCRIPTION OF FUNCTIONS LEISTER Comet e Heating system The hot air temperature is steplessly adjustable and electro nically controlled According to the material thickness the hot wedge position can be s
8. teplessly adjusted as required Cross sectional diagram of hot wedge system Pinch roller Upper geomembrane liner Upper drive pressure roller PF uy LLLL Adjustment screw Bowes wae Lower dirve M NNSS S pressure roller Lower geomembrane liner Rear guide roller Front guide roller e Welding Pressure steplessly adjustable The welding pressure is transmitted via a toggle lever to the pressure rollers The swivel head guarantees the equalisation of the pressure to both welded sections C and D as well as on a welded seam without test channel This allows T joints to be welded easily During the welding process the pressu re adjusts itself linearly to the change in material thickness of the geomem brane liner Cross sectional diagram of an overlap weld Seam thickness reduction A B A Thickness of the upper and lower membrane B Thickness of the welded seam C Welded section 1 Po p D Welded section 2 ZZ BV FIR E Test channel Ss i SSA e Drive Double drive system is steplessly adjustable and electronically con trolled The automatic control system with tachogenerator is designed in such a way that the adjusted welding speed remains constant independently of the load The power transmission to the drive pressure rollers works through a three stage planetary gear 3 LEISTER Comet Description of tool Q S fe c o rs Back view
9. ver 9 and pull the hot wedge 7 out of the overlap and lift up e Switch off the drive motor with M key on the keyboard 4 Switch off the heating by pressing the JHI and FI keys on the keyboard 4 simultaneously 8 ADJUSTING THE HOT WEDGE LEISTER Comet The hot wedge can be adjusted according to the material thickness as required e Engage the automatic wedge welding machine onto the geomembrane liner or film to be welded e Engage the hot wedge 7 e Set the tension lever 9 to the specified welding pressure e Remove the lower part of the gear housing 25 e Loosen the cap screw 26 e Loosen the hexagon cap screw of the rear guide roller 19 e Adjust the rear guide roller 19 to the correct height The distance between the hot wedge 7 and the rear guide roller 19 should be the thickness of the material e Tighten the hexagon cap screw of the rear guide roller 19 e Loosen the adjustment screw for the hot wedge 27 The hot wedge 7 will automatically align itself with the geomembrane liner e Tighten the adjustment screw for the hot wedge 27 e Adjust the front guide roller 18 to the correct height The distance between the inserted material and the front guide roller 18 should be ca lt 1 mm e Tighten the hexagon cap screw 26 While doing so the front guide roller 18 must be held with a hexagon cap screw e Assemble chain guard lower part 25 e Test weld Changeover
10. y of the drive pressure rollers reverse 16 1 TRAINING e LEISTER Process Technologies and their authorised Service Centres offer free welding courses and training ACCESSORIES e Only LEISTER accessories should be used MAINTENANCE e Clean the hot wedge 7 with a wire brush e Clean the drive and pressure roller 20 21 with a wire brush e Treat the chain 22 with a suitable spray as required e Check mains cable 1 and plug for electrical and mechanical damage SERVICE AND REPAIR e The tool should be checked after a maximum of approx 1000 hours running time by an authorised Service Centre eRepairs have to be carried out by authorised LEISTER Service Centres only They guarantee a specialized and reliable repair service within 24 hours using original LEISTER spare parts GUARANTEE AND LIABILITY e Guarantee and liability are in accordance with the guarantee certificate as well as with the currently valid general business and sales conditions e LEISTER Process Technologies rejects any guarantee claims for tools which are not in their original condition The tools must never be altered or changed Technical data and specifications are subject to change without prior notice Your authorized Service Centre is LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 7474 Fax 41 41 6627416 wwwieister com sales leister com
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