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GB OPERATING INSTRUCTIONS

1. Back view Q gt fe c 9 rs DESCRIPTION OF TOOL Cord to mains 2 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 OO ANARAAKRY WELDING PARAMETERS Engage and lever for weldi ded Unlock th LEISTER Comet 14 Travelling wheel 15 Deflector 16 Tube to hot wedge 17 Pinch roller 18 Front guide roller 19 Rear guide roller 20 Lower drive pressure roller 21 Upper drive pressure roller 22 Chain 23 Lower part of chassis 24 Adjustment screw swivel head 25 Lower part of chain guard 26 Cap screw for front guide roller 27 Adjustment screw hot wedge LEISTER Comet Welding Pressure position the automatic welding machine onto the material to be welded Pull the ng 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 e lever for the locking mechanism 12 and release the tension of the lever 9 at the ae N Welding pressure 220 1000 202 900 179 800 157 700 134 600 112 500 90 400 67 300 45 200 123456
2. OPERATING INSTRUCTIONS LEISTER Comet Automatic Wedge Welding Machine pa Please read operating instructions carefully before use ES 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 A PE HD PP 1 5 2 0 mm 60 80 mil For welding materials of 70 mm 2 8 inch pE LD 20 30 mm 80 120 mil PVC a special wedge l PE HD PP 0 5 1 5 mm 20 60 mil must be used 50 mm 2 inch PE LD 1 0 2 0 mm 40 80 mil 20mm 0 8inch BEND PVOP 0 5 1 0 mm 20 40 mil e Overlap max 125mm 5inch 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 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 WARNING A ee 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
3. dda dl 27 End of welding process e 1 cm before the end of the welded seam release the tension lever 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 JH and 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 mu
4. Nilos ring 8 20x1 8 16 Woodruff key 5x6 5 Dismantling of the drive pressure rollers sequence 1 16 Assembly 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 SALES amp SERVICE CENTER CHINA 20H Building No 1 515 Yishan Road Shanghai PR
5. gases Do not touch the element housing 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 DOLE APPROVAL MARKS 6 TECHNICAL DATA Length of wedge Voltage V Power consumption W Frequency Hz Temperature gep 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 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 gt The hot air temperature is steplessly adjustable and electro nically controlled According to the material thickn
6. 1234 max welding pressure 1000 N same time Illustration A Following illustration A rotate the adjustment screw 10 Tighten the locking screw 11 by hand Warning If the maximum welding pressure of 1000 N is exceeded mechanical Screen damage may occur WELDING PARAMETERS Welding temperature LEISTER Comet Set the welding temperature with the H j 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 x JH cursor will blink on the display SET value setting Welding Speed gt H amp ON OFF 4 4 n U nN u co co According on the film or geomembrane liner and the influence of the wea ther set the welding speed with the E keys The in put SET value will be shown to the display Drive j IE SET value adjustment WELDING Welding Preparation Laying Mains supply Cable to mains gt IMI ON OFF ecu cu ecu 00 LEISTER Comet Width of overlap 80 mm to 125 mm Geomembrane liners must be clean between the overlap as well as above and below at least 4kW generator supplied with an RCCB a minimum cable cross section in accordance with the table to 50
7. C Tel 86 021 34141786 Fax 86 021 64360767 http www plasticwelding cn E mail leister plasticwelding cn
8. ault after heating up time 100 e mains under voltage 100 e heating cartridges faulty Display 2 Drive reason for fault 100 e mains under voltage 100 or lt e overlap of the geomembrane liner too wide 100 or lt e dirt on the drive rollers 20 21 100 or lt e max welding pressure 1000 N has been exceeded 100 or lt 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 M 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 El 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 N WO EELS j KEKE Max frontal width of overlap J gt 0 mm lt 0 8 inch Illustration B
9. ess the hot wedge position can be steplessly adjusted as required Cross sectional diagram of hot wedge system Pinch roller Upper geomembrane liner Upper drive pressure roller Welding direction Adjustment screw hot wedge 3 Lower dirve pressure roller Lower geomembrane liner Front guide roller Rear guide roller e Welding Pressure gt 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 Thickness of the upper and lower membrane Thickness of the welded seam Welded section 1 Pasa Pal Welded section 2 mae TA Sw Test channel OO FD VN 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
10. m Operating conditions to 100m e Attach guide handle 13 to 50m e Pull out handle 8 and pull to 100m 3x1 5 mm2 3x14 AWG 3x2 5 mm2 3x12 AWG 3x1 5 mm2 3x14 AWG 3x2 5 mm2 3x12 AWG 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 B lt 20 gg T Taa N nn main switch 3 ON 000 400 BUS eD B50 eco 400 190 400 365 2 4 2 4 1 3 1 3 Control Level En a n n lt an I amp amp ges z 2e20 lt o0 180 380 850 4B 60 47 60 7365 main switch 3 ON 2 4 2 4 76 Display no Level Check the welding process 7 i Drive heating Main Control and identify faults by means of the display of power 1 Welding speed ACTUAL value consumption 2 Welding speed SET value Power consumption 3 Temperature ACTUAL value 4 Temperature SET value Power consumption lt Overload Indication H eating Drive active 5 Welding pressure ACTUAL value 6 Memory card Residual capacity Memory card Autostart Residual capacity Led green Led red Pos 7 Not inserted No Yes 0 Off No 7 Inserted 365 Off Protocol on 364 flashing Display 4 Heating reason for f
11. st be held with a hexagon cap screw e Assemble chain guard lower part 25 e Test weld Changeover 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

GB OPERATING INSTRUCTIONS

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