LEISTER TWINMAT GB OPERATING INSTRUCTIONS
Contents
1. OPERATING INSTRUCTIONS LEISTER TWINMAT E Automatic wedge welding machine A Please read operating instructions carefully before use and keep for further reference APPLICATION The LEISTER TWINMAT is an automatic wedge welding machine for overlap welding of geomembrane liners for earthwork and civil engineering e Thermoplastic lining membranes e Type of seam Polyvinyl chloride plasticised PVC P Welding seams are Polyethylene high density PE HD produced in accordance Polyethylene low density PE LD with DVS 2225 part 1 and Chlorinated polyethylene PE C BAM Polypropylene PP Other dimensions are Ethylene copolymer bitumen ECB possible on request Ethylene vinyl acetate E VA DVS German Welding Association BAM Federal Institute for Materials Research and Testing Berlin LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 7474 Fax 41 41 6627416 wwweister com sales leister com A gt ep NG Danger to life when opening the tool as live compo nents and connections ar exposed Unplug the tool before opening it Incorrect use of hot air blowers can cause fire and explosion hazard especially near combustible materials and explosive gases Do not touch the element housing and nozzle when they are hot as they can cause burns Let the tool cool down Do not point hot air flow in the direction of people or animals AN CAUTION 230 400 D TECHNICAL DATA Voltage V C2. Tolerance mode TWINMAT Software Rev LEISTER Switzerland Datum Zeit Betriebs Std Start 23 11 94 9 24 Toleranziberschreitung bei 8 10 m 449C 2 61 m min 1300N 3 1 Messbereich mm 4 1 Stop 23 11 94 9 30 Schweisstemperatur min 448 C max 453 C Schweissgeschwindigkeit ohne Speed Control min 1 59 m min max 2 61 m min Fiigekraft min 1275 N max 1305 N SECO OOOO OOOO KICK Figeweg min 0 05 mm max 0 38 mm EEE EEEE EEE OOOO OOOO IOK 19 C 2 05 mm 9 10 m SOOO OOOO KCK AIK Umgebungstemperatur Materialdicke Nahtlange DESCRIPTION OF TOOL LEISTER TWINMAT If the welding data needs to be stored on a memory M card Is card before starting the welding process the operator should set the memory card level to ON See special operating instructions for Memory Card The following data is stored welding speed welding temperature pressure seam thickness reduction ambient temperature length of welding seam Alarm If there is a deviation from the seam thickness reduction Isf audible tolerance an audible signal is activated This signal can be set to ON OFF on the alarm menu The welding operator has a choice of different langua s Language ges e German e English e French e Italian e Spanish Depending on the choice the terms are shown in the selected language on the display This should not be changed during
3. Technical data and specifications are subject to change without prior notice Your authorized service centre is Klappenbach GmbH LEISTER Vertrieb amp Service Rohrstr 16 D 58093 Hagen Tel 49 0 2331 95940 Fax 49 0 2331 959444 info klappenbach de_http www klappenbach de
4. done either with or without the speed control system If the lower seam thickness reduction tolerance is exceeded the welding speed slows down automatically if the upper seam thickness reduc tion tolerance is exceeded the welding speed is increased WELDING PREPARATION e Check laying out of material Width of overlap min 100 mm and max 180 mm Geomembrane liners must be clean between the overlap as well as above and below eCheck Mains supply 8kWandaminimum cord cross section up to 50m 2x1 5 mm from 50m 2x2 5 mm e Attach carrying handle 12 up to 50m 2x2 5 mm and guide rod 11 from 50m 2x4 0 mm eConnect the automatic hot air wedge welding machine to the mains supply e Carry out adjustments in the systems with keys Is and e As required correct with keys j and e Heating up Switch on main switch 3 Switch on hot air blower 5 _ Adjust temperature via the keyboard 15 ty and Switch on heating JH ON Motor IM OFF Heating up time approx 5 min e Perform a test welding according to the welding instructions of the material manu facturer and the national standards or guidelines Check the test welding Adapt the welding temperature welding parameters as required WELDING LEISTER TWINMAT e Check Drive pressure rollers 28 29 as well as the hot air wedge 20 must be clean before beginning operation Required welding temperature must be achieved Cable length cable
5. guide Paper roll for printer e Guide and position the automatic welding machine into the over lapped geomembrane liners e Pull the lever 10 without engaging the hot air wedge e Adjust the welding pressure with the hand wheel 9 e Feed the welding parameter into the program level with the P and fill keys Make corrections as necessary Keys and El e Release the lever 10 e Switch on drive motor M gt ON e Engage the hot air wedge 20 e Pull the lever 10 slowly Check the hot air wedge guide 22 and guide rod arm 23 see detail A page 6 e Switch on on for recording When welding we speed control the welding speed must be corrected using the Vj and j I keys if the seam thickness reduction deviates from the ate e At the end of the welding operation approx 10 cm a removal of the hot air wedge the recording should be stopped Key jo e Release the lever 10 move the hot air wedge 20 OF Re the overlap and swivel up e Switch off the drive motor using key Mj OFF WELDING TIPS e Should waves occur in the laid out geomembrane material the upper or lower drive pressure roller can be switched over alternatively This allows wrinkle free welding so that the overlap width remains constant and the welding process should not have to be interrupted Rippling in the upper geomembrane liner engage upper drive roller 29 only Rippling in the lower geomembrane liner engage lower drive roller 28 only
6. apacity W Frequency Hz Temperature C Air flow l min Drive m min Welding pressure N Operating temp C Size mm Weight kg Marking of conformity Approval mark Certification scheme Protection class II 2 The voltage rating stated on the tool must correspond to the line mains voltage EN 61000 3 11 Zmox 0 059 Q j 0 037 Q If necessary consultate supply authority For personal protection on building sites we strongly recommend the tool be connected to a GFCI Ground Fault Circuit Interrupter or a RCCB Residual Current Circuit Breaker The tool must be operated with supervision Warmth can reach combustible materials which are out of sight Protect tool from damp and wet 230 or 400 Mains voltage cannot be switched over 4600 or 5800 50 60 20 620 steplessly controlled max 500 manual air slide 0 5 5 0 steplessly controlled tachogenerator max 2500 steplessly adjustable 5 to 45 600 x 690 x 450 32 0 CE CCA DESCRIPTION OF TOOL Cord to mains Cord holder Main switch Hot air blower On off switch hot air blower Locking lever for hot air blower On off hand wheel for upper or lower drive pressure roller Locking mechanism for control handle Hand wheel for stepless adjustment of the welding pressure Locking lever for welding pressure 11 12 14 18 19 20 21 LEISTER TWINMAT Handle Carrying handle 13 Printer pr
7. e With T joints or when welding upwards both drive rollers must be engaged e For welding T joints a reduction in welding speed of approx 20 is recom mended BA TWINMAT 06 2001 07 2007 GB TRAINING The LEISTER Company and its authorized service centres offer welding Courses free of charge world wide The customer can be trained on site if necessary MAINTENANCE e The ventilator grill 18 and air intake opening 19 of the tool should be cleaned with a brush when dirty e Clean hot air wedge 20 with a wire brush SERVICE AND REPAIR e The automatic welding machine should be checked after about 1000 hours running time by your service centre see page 9 Print Out e Repairs should only be carried out by authorised LEISTER Service Centres They guarantee a correct and reliable repair service within 24 hours using original spare parts in accordance with the circuit diagrams and spare parts lists WARRANTY e For this tool we generally provide a warranty of one 1 year from the date of purchase verified by invoice or delivery document Damage that has occurred will be corrected by replacement or repair Heating elements are excluded from this warranty e Additional claims shall be excluded subject to statutory regulations e Damage caused by normal wear overloading or improper handling is excluded from the guarantee e Guarantee claims will be rejected for tools that have been altered or changed by the purchaser
8. ead zero See page 7 Display 6 As the knurl pressure rollers press into the geomembrane material according to the welding pressure the electro nic processor already inter prets this as seam thickness reduction and it should there fore be neutralised accord ingly PI Speed Control System The automatic adjustment of the welding speed can be set before starting the welding process by using the ON OFF switch P Recording Mode The print out mode must be selected before starting the welding process Graphic mode Continuous recording and print out of the seam thick ness reduction over the whole length of the welded seam Tolerance mode y Recording of the seam thickness reduction is only printed out if the seam thickness reduction toleran ce has been exceeded PRINT OUT Graphic mode TWINMAT Software Rev LEISTER Switzerland Datum Zeit Betriebs Std Start 22 11 94 4 0 Messbereich mm 15 39 5 0 450C 2 05 452 C 200 11261 N 4 0 Messbereich mm 5 0 Stop 22 11 94 15 40 Schweisstemperatur min 447 C max 459 C Schweissgeschwindigkeit ohne Speed Control 2 00 m min 2 10 m min min max Figekraft 1240 N 1292 N SEO CO OOOO OOOO K Fiigeweg min 0 04 mm max 0 45 mm SECO OOO KK 10 C 2 50 mm 2 40 m min max Umgebungstemperatur Materialdicke Nahtlange
9. ecording of data Recording of welding seam geometry END Value increase Value decrease End of entry Change of menu Skip to beginning function m min m min C pe N mm DESCRIPTION OF TOOL LEISTER TWINMAT System level L SART Basic display V ACTUAL t ACTUAL Welding pressure V SET t SET Seam thickness reduction Thick Y Memory cora i i HI El Heurne ET l y EH E tenguase H l y gt gt H H Speed Control E H It lt 5 0 O Q Q 5 Q i DPs m Welding speed 3 lt lt lt HH temperature H Basic display y E ii J eee H DESCRIPTION OF TOOL Fl Thickness of material LEISTER TWINMAT Before welding the operator must enter the thickness of the geomembrane material The electronic processor requires this value to calculate the relevant seam thickness reduction Depending on the material thickness the range of seam thickness reduction is automatically adjusted on the print out The mate rial thickness settings should not be changed during the welding process PI Seam thickness reduction offset To get an accurate reading before welding the operator must adjust the seam thickness reduction display The value on the display should r
10. metry gt The proof of quality in a welding seam peel test tensile test depends upon the thickness reduction in the area of the seam With a seam thickness reduction ranging between 0 4 0 8 mm the welding seam geometry is within the permissable range DVS 2225 part Il BAM This permissable range reflects the optimum interaction of welding parameter temperature welding pressure and speed under changing ambient condi tions during the welding process Cross sectional diagram of an overlap weld Seam thickness reduction A B A Thickness of upper and lower geomembrane liner B Thickness of welding seam C Width of test channel 15 2mm D Width of weld 15mm DESCRIPTION OF FUNCTIONS LEISTER TWINMAT e Monitoring the welding seam gt Contactless recording of the seam thickness reduction data which is displayed digitally for the welding operator during the welding operation Additionally the seam thickness reduction is graphi cally recorded onto a paper print out continuously during the welding ope ration Speed control system The influence of weather such as sun shade wind and moisture which cause a temperature change in the lining membrane during the welding process can lead to weld faults The TWINMAT speed control system interprets the data from the continuous measurement of the welding seam geometry Through automatic adjustment of the welding speed such weld faults are avoided The welding operation can be
11. otection cover 15 16 17 Printer Keyboard Display Housing for drive motor and electronics Ventilator grill Air intake opening Hot air wedge Front roller DESCRIPTION OF TOOL LEISTER TWINMAT Detail A Detail B Positioning of the hot air wedge Heating system cross sectional diagram 28 29 20 24 30 31 32 Material plasticising Contact heating Pre heating and with hot air cleaning of the membranes 22 Hot air wedge guide 28 Lower drive pressure roller 23 Guide rod arm 29 Upper drive pressure roller 24 Pinch rollers 30 Support rollers 25 Swivel head 31 Lower geomembrane liner 26 Sensor beam 32 Upper geomembrane liner 27 Back roller DESCRIPTION OF TOOL Display 1 3 5 Welding programm check Thickness of material Seam thickness reduction offset Speed control Recording mode Welding speed Welding temperature Welding speed Welding temperature Adjustment of system Memory card Alarm audible Language Date Time Diagnosis LEISTER TWINMAT Welding speed ACTUAL value Welding speed NOMINAL value Temperature ACTUAL value N Ro Temperature NOMINAL value Welding pressure ACTUAL value o 6 Seam thickness reduction ACTUAL value M Drive motor on off EN Heating on off START R
12. the welding process The welding operator can make changes to time and Is Date Time gate on the Date Time menu Summer winter time different time zones f Adjustments are made at the factory on the Diagnosis s menu The welding operator has no access to this menu Printer 1 2 N Slacken the paper feed with the N tension lever 1 NY Feed in paper 2 Pay attention to the direction of es the arrow Lees Tighten the paper feed with the tension lever 1 8 DESCRIPTIONS OF FUNCTIONS LEISTER TWINMAT Heating system gt The hot air temperature is electronically steplessly adjusta ble and electronically controlled for heating up the hot air wedge Digital display of SET and ACTUAL value The flexible hot air wedge has three heat zones Pre heating contact heating material plasticising with hot air Welding pressure gt steplessly adjustable digital ACTUAL value display The welding pressure is transmitted via the toggle lever to the pressure rollers During the welding process the pressure is matched linearly to the change in thickness of the membrane e g T joint Drive gt electronically steplessly adjustable and electronically controlled Digi tal display of SET and ACTUAL value The power transmission works through a three stage planetary gear Should rippling occur in the laid out geomem brane liners the upper or lower drive pressure roller can be switched over alternatively Welding seam geo
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