Leister TWINMAT User manual

LEISTER TWINMAT

Automatic wedge welding machine

Please read operating instructions carefully before use

and keep for further reference.

OPERATING INSTRUCTIONS

The LEISTER TWINMAT is an automatic wedge welding machine for overlap

welding of geomembrane liners for earthwork and civil engineering.

•Thermoplastic lining membranes •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

APPLICATION

TWINMAT with printer

LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland

Tel. +41- 41 662 74 74 Fax +41- 41 662 74 16

www.leister.com [email protected]

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.

The tool must be operated with supervision. Warmth

can reach combustible materials, which are out of sight.

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 voltage rating stated on the tool must correspond to

the line/mains voltage.

EN 61000-3-11; Zmax = 0.059 Ω + j 0.037 Ω. If necessary,

consultate supply authority.

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.

Protect tool from damp and wet.

230

400

WARNING

CAUTION

Voltage V~

Capacity 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

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

CCA

TECHNICAL DATA

DESCRIPTION OF TOOL LEISTER TWINMAT

Detail B

Detail A

13 14 12

1. Cord to mains

2. Cord holder

3. Main switch

4. Hot air blower

5. On/off switch hot air blower

6. Locking lever for hot air blower

7. On/off hand wheel for upper

or lower drive/pressure roller

8. Locking mechanism for control handle

9. Hand wheel for stepless

adjustment of the welding pressure

10. Locking lever for welding pressure

11. Handle

12. Carrying handle

13. Printer

14. Printer protection cover

15. Keyboard

16. Display

17. Housing for drive motor

and electronics

18. Ventilator grill

19. Air intake opening

20. Hot air wedge

21. Front roller

DESCRIPTION OF TOOL LEISTER TWINMAT

Detail B

Drive/pressure roller system

Heating system cross sectional diagram

Detail A

Positioning of the hot air wedge

25 26 28 29 2723 22 20 24

28 29 20 24 30 31 32

22. Hot air wedge guide

23. Guide/rod arm

24. Pinch rollers

25. Swivel head

26. Sensor beam

27. Back roller

28. Lower drive/pressure roller

29. Upper drive/pressure roller

30. Support rollers

31. Lower geomembrane liner

32. Upper geomembrane liner

Material plasticising

with hot air

Contact heating Pre-heating and

cleaning of the

membranes

Esc

–

Display

Keyboard

DESCRIPTION OF TOOL LEISTER TWINMAT

135

1. Welding speed m/min.

ACTUAL value

2. Welding speed m/min.

NOMINAL value

3. Temperature ACTUAL value °C

4. Temperature NOMINAL value °C

5. Welding pressure ACTUAL N

value

6. Seam thickness reduction mm

ACTUAL value

Drive motor on/off

Heating on/off

Skip to beginning function

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

OFF

START

Recording of data/

Recording of welding

seam geometry

END

Value increase

Value decrease

End of entry

Change of menu

DESCRIPTION OF TOOL LEISTER TWINMAT

System level

START

V – ACTUAL t – ACTUAL Welding pressure

V – SET t – SET Seam thickness reduction

Thickness

of material

Seam thickness

reduction offset

Speed-

Control

Recording

mode

Welding speed

Welding

temperature

+–

↵↵

–

+–

Memory-Card

Alarm

(audible)

Language

Date

Time

Diagnosis

Code

+–

ESC ESC

↵↵

Basic display

↵↵

To get an accurate reading,

before welding, the operator

must adjust the seam thickness

reduction display. The value

on the display should read

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.

The automatic adjustment of

the welding speed can be set

before starting the welding

process by using the ON/OFF

switch.

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

Recording of the seam

thickness reduction is only

printed out if the seam

thickness reduction toleran-

ce has been exceeded.

Recording Mode

Speed Control System

Seam thickness reduction - offset

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.

Thickness of material

DESCRIPTION OF TOOL LEISTER TWINMAT

TWINMAT

Software-Rev:

LEISTER, Switzerland

Datum:

Zeit:

Betriebs-Std.

Start 22.11.94 15.39

4.0 Messbereich [mm] 5.0

Stop 22.11.94 15.40

Schweisstemperatur

min 447 °C

max 459 °C

Schweissgeschwindigkeit

ohne Speed-Control

min 2.00 m/min

max 2.10 m/min

Fügekraft

min 1240 N

max 1292 N

Fügeweg

min 0.04 mm

max 0.45 mm

Umgebungstemperatur 10 °C

Materialdicke 2.50 mm

Nahtlänge 2.40 m

450 C 2. 05 1250 N

452 C2. 00 N

1 m

2 m

1261

Toleranzüberschreitung bei 8.10 m

Start 23.11.94 9.24

449 C 2.61 m/min 1300 N

3.1 Messbereich [mm] 4.1

Stop 23.11.94 9.30

Schweisstemperatur

min 448 °C

max 453 °C

min 1.59 m/min

max 2.61 m/min

Schweissgeschwindigkeit

ohne Speed-Control

Fügekraft

min 1275 N

max 1305 N

Fügeweg

min 0.05 mm

max 0.38 mm

Umgebungstemperatur 19 °C

Materialdicke 2.05 mm

TWINMAT

Software-Rev:

LEISTER, Switzerland

Datum:

Zeit:

Betriebs-Std.

Nahtlänge 9.10 m

Graphic mode Tolerance mode

PRINT OUT

DESCRIPTION OF TOOL LEISTER TWINMAT

Memory card

Printer

Alarm

(audible)

Language

Date/ Time

Diagnosis

If the welding data needs to be stored on a memory

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

If there is a deviation from the seam thickness reduction

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-

ges. • German

• English

• French

• Italian

• Spanish

Depending on the choice, the terms are shown in the

selected language on the display. This should not be

changed during the welding process.

The welding operator can make changes to time and

date on the Date/Time menu.

(Summer/winter time, different time zones).

Adjustments are made at the factory on the Diagnosis

menu. The welding operator has no access to this menu.

Slacken the paper feed with the

tension lever (1).

Feed in paper (2).

Pay attention to the direction of

the arrow.

Tighten the paper feed with the

tension lever (1).

DESCRIPTIONS OF FUNCTIONS LEISTER TWINMAT

•Heating system 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 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 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.

DCD

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 +/- 2 mm

D : Width of weld ≥15 mm

•Welding seam geometry 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 II, 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.

•Monitoring the welding seam 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 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.

DESCRIPTION OF FUNCTIONS LEISTER TWINMAT

WELDING PREPARATION

• 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.

• Check: Mains supply ≥8 kW and a minimum cord cross section

• Attach carrying handle (12)

and guide rod (11).

• Connect the automatic hot air wedge welding machine to the mains

supply.

• Carry out adjustments in the systems with keys and

• As required, correct with keys and .

• Heating up: Switch on main switch (3).

Switch on hot air blower (5).

Adjust temperature via the keyboard (15) and

Switch on heating ON, Motor  OFF

Heating up time approx. 5 min.

• 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.

–

↵↵

400 V~ up to 50 m 2x1,5 mm2

from 50 m 2x2,5mm2

230 V~ up to 50 m 2x2,5mm2

from 50 m 2x4,0mm2

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