LEISTER Astro Automatic Wedge Welding Machine GB OPERATING
Contents
1. 123456123456 Peres max welding pressure 1000 N LEISTER Astro Back wheel Foil guide Cable conduit for hot wedge Pinch roller Front guide roller Rear guide roller Lower drive pressure roller Upper drive pressure roller Adjustment screw for swivel head Chain guard of lower part Chain guard of tension arm Chain guard of gear case LEISTER Astro Welding pressure Engage and position the auto matic welding machine onto the material to be welded Insert the two geomembranes liners or films about 5mm at the back of the machine Pull the lever 9 The hot wedge is automatically pushed forward Push and hold down the locking spring 11 Turn the adjustment screw for welding pressure 10 until the drive pressure rollers 20 21 slightly touch the material to be welded Let go the locking spring 11 and release the tension of the lever 9 Keep pushing the locking spring of the adjustment screw 11 Adjust the welding pressure by turning the corresponding adjustment screw 10 accord ing to illustration A and let go the locking spring 11 at the requested welding pressure Warning If the maximum welding pressure of 1500N is exceeded mechani cal damage may occur WELDING PARAMETERS LEISTER Astro Welding temperature Set the welding temperature with the JH I keys The temperature is dependent on the material and the ambient te2. OPERATING INSTRUCTIONS LEISTER Astro Automatic Wedge Welding Machine AN Please read operating instructions carefully before use Ly and keep it for further reference APPLICATION The LEISTER Astro is an automatic wedge welding machine for overlap welding of geomembrane liners in earthwork and civil engineering e Thermoplastic geomembrane liners e Type of seam High density polyethylene PE HD Welding seams are pro Low density polyethylene PE LD duced in accordance with Chlorinated polyethylene PE C DVS 2225 part Polypropylene PP Other dimensions are pos sible on request DVS German Welding Society for welding LEISTER SALES amp SERVICE CENTER CHINA 20H Building No 1 515 Yishan Road Shanghai PRC Tel 86 021 34141786 Fax 86 021 64360767 http www plasticwelding cn E mail leister plasticwelding cn N WARNING 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 especially near combustible materials and explosive gases Do not touch the element housing and 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 danger ous Use only extensions cables with a protecti
3. cap screw of the front guide roller 18 Cross section diagram of hot wedge system CHANGEOVER OF UPPER DRIVE PRESSURE ROLLER LEISTER Astro The LEISTER Astro is suitable to manufacture overlap welded seams in different fields of applications They differ in the width of the welded seam as well as the width of the test channel Also welded seams without test channel can be manufactured In order to implement these different overlap seams the appro priate drive pressure rollers have to be installed 1 Countersunk screw M3x 7 Shaft 8x118 5 2 Protection sheet swivel head 8 Shaft retaining ring 3 Socket head screw M4x8 9 Distance disk 20x32x0 5 4 Washer 4 2x25 10 Drive pressure roller 5 Slide roller 11 Wooaruff key 5x6 5 6 Set screw M5x12 12 Upper drive shaft complete Dismantling of the drive pressure rollers sequence 1 12 Assembly of the drive pressure rollers reverse order 12 1 CHANGEOVER OF LOWER DRIVE PRESSURE ROLLER LEISTER Astro 1 Countersunk screw M5x16 2 Clamp disk 3 Drive Pressure roller 4 Distance disk 20x32x0 5 Dismantling of the drive pressure rollers sequence 1 4 Assembly of the drive pressure rollers reverse 4 1 e TRAINING LEISTER Process Technologies and their authorised Service Centres offer free welding courses and training ACCESSORIES e Only LEISTER accessories should be used MAINTENANCE e Check mains cable 1 and plug for electrical and mechanical
4. damage e Clean hot wedge 8 with a copper brush e Clean drive and pressure rollers 20 21 with a wire brush e Treat chain 22 with a suitable spray as required chain guard 23 24 e Check whether rollers 13 14 17 18 19 are running smoothly SERVICE AND REPAIR e The tool should be checked by an authorized Service Center if the following message appears on the display 5 maintenance servicing e Repairs 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 SALES amp SERVICE CENTER CHINA 20H Building No 1 515 Yishan Road Shanghai PRC Tel 86 02134141786 Fax 86 021 64360767 http www plasticwelding cn E mail leister plasticwelding cn
5. am thickness reduction As required adjust the welding speed with El keys on keyboard 6 eThe automatic welding machine is guided along the overlap with the carrying handle guide handle 12 so that the frontal width of the overlap is kept within the 22mm zone see illustration B Illustration B 21 EEL Max frontal width of SSNS overlap Dim of pressure rollerSOmm J 9 22mm a Dim of pressure roller 45mm gt 24 5mm End of welding process e Release the tension lever 9 1 cm before the end of the welded seam e Switch off the drive motor with M key on the keyboard 6 Switch off the heating by pressing the DH and keys on the keyboard 6 simultaneously 8 ADJUSTING THE HOT WEDGE LEISTER Astro Adjusting of the guide rollers for the requested material thickness e Engage the automatic wedge welding machine on the geomembrane liner or film to be welded e Stretch the lever 9 e Loosen the hexagon cap screw of the rear guide roller 19 e The distance between the hot wedge 8 and the rear guide roller 19 should be the thickness of the material and the sharp tongue of the wedge should lie centrically to the pressure rollers 20 21 e Tighten the hexagon cap screw of the rear guide roller 19 e Loosen the hexagon cap screw of the front guide roller 18 e The distance between hot wedge 8 and front guide roller 18 should be about 1 mm e Tighten the hexagon
6. ly variable steplessly adjustable The welding pressure is transmitted via a toggle lever to the pressure rollers The swivel head guarantees the equalization 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 pressure adjusts itself linearly to the change in material thickness of the geomembrane liners Cross sectional diagram of an overlap weld Seam thickness reduction A B Thickness of the upper and lower membrane Thickness of the welded seam Welded section 1 Welded section 2 Test channel moOow e Drive gt The welding speed is adjustable and electronically controlled in steps of 0 1 m min feet Digital display of SET and ACTUAL values The power transmission works through a three stage planetary gear DESCRIPTION OF MACHINE LEISTER Astro Frontal view DESCRIPTION OF MACHINE 1 Mains cable 14 2 Cable clip 15 3 Housing of electronics 16 4 Main switch 17 5 Display 18 6 Keyboard 19 7 Motor Drive 20 8 Hot wedge 21 9 Lever 22 10 Adjustment screw for welding pressure 23 11 Locking spring of adjustment screw 24 12 Carrying handle Guide handle 25 13 Front wheel WELDING PARAMETER Folio 5 mm N Welding pressure Illustration A 1500 1375 1250 1125 1000 875 750 625 500 375 250 125
7. mperature The in put SET value will be shown on the display Switch on the heating by pressing the TH and keys simultaneously Heating up time approx 5 mins cursor will blink on nealing S JH The display IF SET value setting 220 400 Welding Speed According on the film or geomembrane liner and the influence of the weather set the welding speed with the El keys The in put SET value will be shown on the display Drive gt SET value setting i 220 20 230V ON OFF 220 400 WELDING LEISTER Astro Welding preparation Laying Width of overlap is about 80mm to 130mm Geomembrane liners must be clean between the overlap as well as above and below Mains supply At least 3kW generator supplied with an RCCB Cable fo mains A minimum cable cross section in accordance with the table 200 230 V to 50m 3x1 0 mm2 to 100m 3x2 5 mm2 120 V to 50m 3x1 5 mm2 to 100m 3x2 5 mm2 WELDING LEISTER Astro Operating conditions e Connect the hot wedge welding machine to the mains e Start the machine with Main or Control Level 1 3 5 Main Level y gt 000 DO e30V Main Switch 4 ON eeu 400 1 Speed ACTUAL value 2 Speed SET value 2 4 3 Temperature ACTUAL value 4 Temperature SET value 5 Voltage display ACTUAL value 1 3 5 n n
8. n anm Control Level amp amp P gt ccoo 400 ezv E 45 60 Main Switch 4 ON 1 Speed ACTUAL value o 4 2 Speed SET value 3 Temperature ACTUAL value 4 Temperature SET value 6 5 Voltage display ACTUAL value Heating Drive active 220 400 230V n lt Overload indication 46 gr Check the welding process and identify faults by means of the display of power consumption Display 4 Heating reason for fault after heating up time 100 e mains under voltage Display 2 Drive reason for fault 100 96 e mains under voltage 10096 or lt e overlap of the geomembrane liner too wide 10096 or lt e dirt on the drive rollers 20 21 10096 or lt e max welding pressure 1500 N has been exceeded 10096 or lt e high welding speed with large sudden overload ie anchoring trench T joints If malfunction does not disappear contact service center 7 WELDING LEISTER Astro Welding procedure e Check Drive Pressure rollers 20 21 as well as the hot wedge 8 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 M key on keyboard 6 e Pull the lever 9 Beginning of welding process e Check the welded seam wash se
9. ve earth conductor o pe N CAUTION 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 materials Protect the tool from damp and wet HO OG APPROVAL MARKS TECHNICAL DATA Protection class I CCA certified Voltage Ne 120 200 230 4 mains voltage is Frequency Hz 50 60 not reversible Power consumption Ww 1800 Temperature C F max 420 788 Welding pressure N Ibs max 1500 337 Drive m min feet 0 8 5 0 2 6 16 5 Overlap width mm Inch max 150 5 9 Thickness of material mm mil 1 5 3 0 60 120 Noise emission level Lpa dB 70 Size LxWxH mm 475 x 355 x 315 with carrying handle guide handle 12 Weight kg lbs 23 50 2 FUNCTIONAL DESCRIPTION LEISTER Astro e Heating system gt The hot air temperature is steplessly adjustable and eletron ically controlled It is a floating hot wedge Cross section diagram of hot wedge system Pinch roller upper geomem brane liner Upper drive pressure roller Welding direction EStdt Fastening screw eet for hot wedge Lower drive pressure roller Lower geo membrane liner Rear guide roller Front guide roller e Welding pressure gt infinite
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