BAK proton User manual

BAK Thermoplastic Welding Technology AG
OPERATING MANUAL

BAK Thermoplastic Welding Technology AG 2
SAFETY
Danger to life when opening the device as live components and connec-
tions are exposed. Unplug the device before opening it.
Danger of fire and explosion if the device is used incorrectly. Demon-
strate the necessary caution when using the welding machine near com-
bustible materials. Never use the device in inflammable areas.
Danger of burns
Do not touch the hot air device when it is still hot. Let the device cool
down.
Connect the device to a socket with protective earth conductor. Any
interruption of the protective earth conductor within or outside the device
is dangerous! Only use extension cables with protective earth conductor
and a minimum diameter of 2.5 mm².
The voltage rating stated on the nameplate must correspond to the mains
voltage.
Consult your local electricity supply board if necessary.
For personal protection, the device must be connected to a residual cur-
rent circuit breaker before using it on construction sites.
Do not leave the device unobserved. Hot air radiation of the hot air de-
vice may ignite combustible materials. Heat may reach inflammable ma-
terials that are not visible or obvious.
Protect the device from damp and wet!

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WARRANTY AND LIABILTY
Warranty and liability apply from the date of purchase (documented by the in-
voice/delivery note) according to the currently valid general terms of business of
BAK. BAK refuses to honour any warranty for devices which are not in their
original condition. BAK devices may never be reconfigured and/or modified.
BAK reserves the right to deny any responsibility if this is ignored. No liability
can be assumed by BAK for incorrect installation and/or use as well as natural
wear and tear of components (e.g. heating elements).
Note:
This operating manual must be available to the installation and operating person-
nel at all times. Read these operating instructions carefully before installing and
using the device.
Copyright:
This document must not be disclosed to third parties without the explicit written
approval of BAK. Any forms of reproduction or copying and electronic storage
are prohibited.
ITENDED USE
The ProtOn is a combined hot air- and wedge welding machine for overlap weld-
ing and prefabrication of membranes for tunnel- and civil engineering applica-
tions.
Overlap max. 125mm
Type of seam Welding seams are produced in accordance with DVS
2225 and BAM. Other dimensions of seams are
possible on request.
DESCRIPTION OF FUNCTIONS
Heating system:
The hot air temperature is stepless adjustable and electronically controlled. Heat
transmission by combination of all advantages of contact- and hot air welding.
The flexible combined wedge nozzle has 3 heating areas.

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Welding pressure:
The welding pressure is stepless adjustable and transmitted via a toggle lever to
the pressure rollers.
The equalisation of the pressure to both welded sections as well as on a welded
seam without test channel is guaranteed by the swivel head. This allows T-joints
to be welded without problems. During the welding process the pressure adjusts
itself linearly to the change in material thickness of the geomembrane liner.
Drive:
The double drive system is stepless adjustabke and electronically controlled.
Therefore, the speed always stays constant.
WELDING PARAMETERS
Attention: Always do a test welding before real welding to find out the parame-
ters.
Welding temperature
Set the welding temperature with the up- and down buttons of the temperature
controller. The air flow is stepless adjustable with the potentiometer (depending
on material). Switch on the heat and let heat up for approx. 5 minutes.
Temperature unit Actual temperature
Set tempera-
ture
Down-button Up-button

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Welding speed
Set the welding speed by the potentiometer on the front panel. The motor can be
switched on and off by the switch near the potentiometer.
Welding pressure
Engage and position the welding machine onto the material to be welded.
Pull the toggle lever without engaging the nozzle. By rotating the adjustment
screw the drive/pressure rollers will lightly touch the material to be welded, in
this way you will define the point zero N of pressure. Open the toggle lever. Set
the desired pressure by rotating the adjustment screw, to every single step of rota-
tion you will set 80N of pressure on seam.
If the maximum welding pressure (1000 N) is exceeded, mechanical
damages may occur.
WELDING
Welding preparation
Laying of material:
oWidth of overlap from 60 to 125 mm
oMake sure that the surfaces of geomembrane liners, above and be-
low, are cleaned, as well as between the overlap.
Mains supply at least 3kW (generator) supplied with an RCCB.
(Residual Current Circuit Breaker)
Operating conditions
Do not run the machine if power cord or plug is damaged- Damaged power
cords must be changed by professional staff.
Connect the tool to the mains
Start the tool with the main switch/level
5.0
0
2.5
4.5
0.5
m/min.

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Welding procedure
Adjust the welding parameters (see page no. 4)
Wait until the hot air tool has reached the adjusted temperature.
Guide and position the welding machine onto the overlapped geomembrane
liner or film.
Switch on the drive motor with the rocker switch.
Engage the nozzle onto the overlapped geomembrane liner or film.
Push down the toggle lever.
Check the welded seam (wash/seam thickness reduction). Eventually adjust
the welding speed with the potentiometer.
Guide the welding machine along the overlap.
1cm before the end of the welded seam, release the pressure lever.
Engage the nozzle
Switch off device motor.
ASSEMBLY
ATTENTION
ALWAYS unplug the device before working on it!
Changing the heating element (only when the device has cooled down)
Swivel out and lock the hot air system
Loosen four screws at the flange of the nozzle
Pull off the nozzle
Pull off the mica tube (careful, fragile)
Remove the gasket
Pull off the defective heating element
Insert the new heating element - observe marking, voltage and power rating
Slide on the mica tube
Slide on the gasket and position the boreholes
Slide on the nozzle and fix with 4 screws
Readjust the nozzle
MAINTENANCE
Clean the nozzle with a wire brush at the end of welding.
Clean the drive/pressure rollers with a wire brush.
As required, treat the chain with a suitable spray.
After use, always check that the mains cable and plug are not damaged.

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WARNING
If the power supply cable gets damaged, it has to be replaced by the manu-
facturer, its customer service or by a qualified person in order to avoid dan-
ger.
The machine must not be used by personnel (including children) with lim-
ited physical, sensory or mental capabilities or lack of experience and/or
knowledge, except when supervised by a person who is responsible for their
safety or when advised how to use the device by that person.
Children must be supervised in order to ensure that they do not play with
the machine.
Because of the enormous fire danger, the operating personnel must be spe-
cially briefed and regularly instructed.
Fire can occur if the machine is not used carefully.
Do not leave the machine unobserved while it is in operation.
Demonstrate the necessary caution when operating the device near inflam-
mable materials. Do not operate on the same surface for longer periods of
time.
A fire extinguisher must always be within reach in the work area.
The machine must not be used in explosive atmospheres.
Heat may reach inflammable materials that are not readily visible.
There is a very significant risk of fire when the machine stops because of
any disturbance and the hot air device is still running (max. temperature of
the air flow 550 °C). Therefore, special attention should be placed on the
subsurface and the material to be processed.
The welding machine must not be used on inflammable surfaces (e. g.
wooden roofs and floors made of wood)
The machine bears the protection mark IP20 and must therefore be protect-
ed from damp and rain.
When using the machine on roofs and tables, it could fall down due to its
automatic drive system. In order to avoid a fall, necessary precautions must
be taken.

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SAFETY SYMBOLS AND STANDARDS
Existing risks are pointed out with the following warning symbols:
Risk of crushing
Risk of burns
The operator is responsible for the compliance with safety related standards.
Before the machine is commissioned, the operating personnel must be instructed
with respect to these standards.
OPERATIONAL SAFETY
The welding machine is manufactured in accordance with the recognised rules of
technology.
The latest safety standards have been observed to eliminate work related risks to
the life and health of the operating personnel when the machine is used in ac-
cordance with its intended use.
DANGER ZONE
The main danger zone of the welding machine is the nozzle which can heat up to
temperatures of 550 °C. It is recommended to wear heat protective gloves.
There is a risk of crushing when swivelling the nozzle.

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ASSISTANCE AND SUPPORT
The BAK group and its authorised service centres offer free support and assis-
tance in the area of applications technology.
Our specialists will be pleased to help you.
Customer service and orders:
BAK Thermoplastic Welding Technology AG
Industriestrasse 6
CH-6064 Kerns/Switzerland
Telefon: [phone]
Telefax: [phone] 22 51
E-Mail: [e-mail]
ACCESSORIES
Get the best results by using BAK-accessories and spare parts. Please refer to our
brochures for additional information.
SERVICE AND REPAIR
Repairs have to be carried out exclusively by BAK authorised service centres.
SHIPPING
For repairs, please return the machine appropriately packed for transport to your
next BAK service centre.
Shipping to CUSTOMER ACCOUNT
Technical modifications reserved. In case of doubt, consultation with BAK is re-
quired. Images and drawings may deviate from the original. Changes reserved.

BAK Thermoplastic Welding Technology AG 10
TRANSPORT –HANDLING –STORAGE
Transport:
The welding machine is packed appropriately and must be protected from mois-
ture. We recommend the usage of the suitable tool box.
Handling:
The shipment must be checked if complete and for transport damage. In the event
of transport damage, the defect must be confirmed in writing at the time of the
delivery by the carrier. The seller must be promptly informed in writing!
Storage:
In the case of temporary storage, the welding machine should be kept packed and
must be protected from moisture. In the case of damage resulting from improper
storage, no warranty claim will be honoured.
DISPOSAL
Power tools, accessories and packaging should be sorted for envi-
ronmental friendly recycling.
Do not dispose power tools together with household waste!
Only EU countries: According to the European Directive
2002/96/EC on waste electrical and electronic equipment and its
incorporation into national law, power tools that are no longer op-
erational must be separately collected and sent to be environmental
friendly recycled.
TECHNICAL DATA
Technical Data
ProtOn
Voltage
V
230
Frequency
Hz
50/60
Power consumption
W
2200
Max. power input
A
10
Temperature
°C
20 –550
Drive
m/min
0 –5.0
Max. air flow (20 °C)
l/min
ca. 300
Dimensions
mm (L x W
x H)
370x340x330
Weight with 5 m cable
kg
9
Conformity symbol
Protection type I
Other voltages on request.

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CE/ProtOn
D EG –Konformitätserklärung
F Déclaration CE de conformité
I Dichiarazione CE di conformità
GB EC Declaration of conformity
E Declaratión CE de conformidad
D EG –Konformitätserklärung
BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Schweiz
bestätigt, dass das nachfolgend bezeichnete Gerät in der von uns in Verkehr gebrachten Ausführung die Anforderungen der folgenden EG-
Richtlinie(n) erfüllt.
Bezeichnung des Gerätes: Heizkeil-Schweissautomat
Typ: ProtOn
Richtlinien: 2006/42/EC
2004/108/EC
2006/95/EG
2011/65/EU
Harmonisierte Normen: EN55014-1:2006+A1:2009+A2:2011, EN55014-2:1997+A1:2001+A2:2008,
EN61300-3-2:2006, EN61300-3-3:2008
Kägiswil, 20.01.2016 Bruno Zurmühle, CEO
F Déclaration CE de conformité
BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Suisse
déclare qu’á la sortie de ses usines l’appareil désigné ci-dessous était conforme aux dispositions de(s) la directive(s) CEE suivante(s).
Discription de l’appareil: Automatic wedge welding machine
Modéle: ProtOn
Directive(s) CEE: 2006/42/EC
2004/108/EC
2006/95/EG
2011/65/EU
Normes harmonisées: EN55014-1:2006+A1:2009+A2:2011, EN55014-2:1997+A1:2001+A2:2008,
EN61300-3-2:2006, EN61300-3-3:2008
Kägiswil, 20.01.2016 Bruno Zurmühle, CEO
I Dichiarazione CE di conformità
BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Svizzera
dichiara che l’apparecchio qui di seguito descritto nei modelli commercializzati risulta conforme alle direttive di armonizzazione comunitarie imparatite
dalla CEE.
Descrizione del’apparecchio: Automatic wedge welding machine
Modello: ProtOn
Direttive CEE: 2006/42/EC
2004/108/EC
2006/95/EG
2011/65/EU
Norme armonizzate: EN55014-1:2006+A1:2009+A2:2011, EN55014-2:1997+A1:2001+A2:2008,
EN61300-3-2:2006, EN61300-3-3:2008
Kägiswil, 20.01.2016 Bruno Zurmühle, CEO
GB Declaration of conformity
BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Switzerland
declares that the tool described below, released by us fulfils the provisions of the following EC directive(s).
Description of tool: Automatic wedge welding machine
Type: ProtOn
EC directives: 2006/42/EC
2004/108/EC
2006/95/EG
2011/65/EU
Harmonized standards: EN55014-1:2006+A1:2009+A2:2011, EN55014-2:1997+A1:2001+A2:2008,
EN61300-3-2:2006, EN61300-3-3:2008
Kägiswil, 20.01.2016 Bruno Zurmühle, CEO
E Declaración CE de conformidad
BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Suiza
certifica que el aparato que a confinuación se describe cumple con la ejecución que hemos puesto en circulatión, con las exigencias de las direc-
trices armonizadas de la CE.
Denominación del aparato: Automatic wedge welding machine
Modelo: ProtOn
Directrice(s) de la CE: 2006/42/EC
2004/108/EC
2006/95/EG
2011/65/EU
Normas armonizadas: EN55014-1:2006+A1:2009+A2:2011, EN55014-2:1997+A1:2001+A2:2008,
EN61300-3-2:2006, EN61300-3-3:2008
Kägiswil, 20.01.2016 Bruno Zurmühle, CEO

BAK Thermoplastic Welding Technology AG 12