BAK ROOFON User manual

OPERATING MANUAL

BAK Thermoplastic Welding Technology AG 2
SCOPE OF DELIVERY
Content of package:
1 Automatic welding machine type RoofOn Multi
1 Guide handle
1 Starting plate
1 Operating manual
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.
Maintain the maximal allowed impedance Zmax = 0.301 Ω + j 0.188 Ω.
Consult your local electricity supplier 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
device may ignite combustible materials. Heat may reach inflammable
materials that are not visible or obvious.
The tool must not be used by children or people with limited physically,
sensory or mental ability. Children must be supervised to prevent that
they play with the tool.
Protect the device from damp and wet!

BAK Thermoplastic Welding Technology AG 3
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
from BAK. BAK refuses to honour any warranty for devices which are not in
their original condition. BAK devices may never be reconfigured and/or modi-
fied.
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.
INTENDED USE
This device is an automatic welding machine for overlap welding of roofing
membrane.
DESCRIPTION OF FUNCTIONS
Heating system:
The hot air temperature is stepless adjustable and electronically controlled. Ac-
cording to the thickness of the material, the position of the nozzle can be adjusted
stepless.
Welding pressure:
The welding pressure can be changed by adding or reducing weight.
Drive:
The drive is stepless adjustable and electronically controlled. The control system
is designed in a way that the set speed remains constant, independent of the load.
Application:
The tool can be used for Attica, eaves flashing, close to the edge and for normal
overlap welding.

BAK Thermoplastic Welding Technology AG 4
Safety:
The tool has a automatic restart safety system, which means that the tool will be
automatically turned off in case of a power failure. It has to be switched on man-
ually again.
WARNING
If the power supply cable gets damaged, it has to be replaced by the manufactur-
er, its customer service or by a qualified person in order to avoid danger.
The device must not be used by personnel (including children) with limited phys-
ical, sensory or mental capabilities or lack of experience and/or knowledge, ex-
cept when supervised by a person who is responsible for their safety or when ad-
vised how to use the device by that person.
Children must be supervised in order to ensure that they do not play with the de-
vice.
Because of the enormous fire danger, the operating personnel must be specially
briefed and regularly instructed.
Fire can occur if the device is not used carefully.
Do not leave the device unobserved while it is in operation.
Demonstrate the necessary caution when operating the device near inflammable
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 device must not be used in explosive atmospheres.
Heat may reach inflammable materials that are not visible.
There is a very significant risk of fire when the machine stops because of any dis-
turbance and the hot air device is still running (max. temperature of the air flow
650 °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)
The device bears the protection mark IP20 and must therefore be protected from
damp and rain.
When using the device 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.
The welding machine can be operated up to a maximum incline or slope of 30°.
Warning: Danger of poisoning! While processing thermoplastics or similar mate-
rial, gases occur which can be aggressive or poisonous. Avoid inhaling fumes
even if they seem to be harmless. Make sure the workplace is well ventilated or
wear respiratory protection.

BAK Thermoplastic Welding Technology AG 5
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
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
life and health of the operating personnel when the machine is used in accordance
with its intended use.
DANGER ZONE
The main danger zone of the welding machine is the nozzle which can heat up to
temperatures of 650 °C. It is recommended to wear heat protective gloves.
There is a risk of crushing when swivelling the nozzle.
Danger of burns in the working area

BAK Thermoplastic Welding Technology AG 6
38-42mm
OVERLAP WELDING MACHINE BASIC ADJUSTMENT
Basic adjustment:
Perform adjustments only in cold condition (danger of burns!).
Nozzle adjustment:
Loosen the screws on the device frame in order to change the configuration of the
nozzle.
Loosen the screws with allen key SW4.
Adjust distance from nozzle to
pressure roller.
Loosen the screws (B) and move the
nozzle for the nozzle tip (C) to touch
the underground and area (D) is
approx. in 1mm distance from the
underground.
Tighten all screws (A/B) afterwards!
Guide roller adjustment:
Standard
Close to the edge
Attica
Adjustment
Loosen screw (A) to adjust roller (B). Afterwards tighten again.
Move roller (C) with pressure or tension in the right direction until it snaps into the next locking (D).
2mm
A
B
D
C
A
B
C
D
D

BAK Thermoplastic Welding Technology AG 7
WELDING PARAMETERS
Caution: Before any welding operation, a test weld should be performed to de-
termine the welding parameters.
Welding temperature:
The welding temperature is adjusted with a potentiometer or control unit.
Do not start welding before the set temperature has been reached.
Welding speed:
The welding speed is adjusted using a potentiometer or control unit.
The drive starts automatically when the welding tool is swivelled in.
The welding speed is adjusted with the potentiometer or control unit depending
on the plastic film, geomembrane liner or weather conditions.
Welding pressure:
The welding pressure is directly applied onto the pressure roller by the weight of
the machine.
WELDING
Operating conditions:
Maintain the maximum allowed network impedance (Zmax = 0.301 Ω + j
0.188 Ω) and consult your local electricity supply board if necessary.
Check the configuration of the nozzle.
The mains connection must conform to ICE 60364 as well as to national
standards.
Connect the device to the grid. The voltage rating must correspond to the
specifications on the nameplate.
When using extension cords, a minimum diameter of the cable must be ob-
served. Cable length up to 25 m, diameter 2.5 mm² (for automatic welding
machines with 120 V, we recommend a diameter of 4.0 mm²).
Welding procedure:
Adjust the welding parameters.
The welding temperature has to be reached.
Position the welding machine on the overlapping geomembrane liners or
plastic films.
Align the guide roller to the overlap.
Lower the hot air system and slide the nozzle between the overlapping ge-
omembrane liners or plastic films. The device will start automatically.
Guide the welding machine along the overlap. Always observe the position
of the guide roller.
After welding, slide out the nozzle and raise it.
Turn off the heating with the respective switch to cool down the nozzle.
Switch off the device with the main switch and disconnect from mains sup-
ply.

BAK Thermoplastic Welding Technology AG 8
ASSISTANCE AND SUPPORT
The BAK group and its authorised service centres offer free support and assis-
tance in your application.
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
Available accessories:
Additional weight (5232071.1)
Contour welding establishment (5232550)
Transport case (5232551)
The automatic welding machines can either be supplied with the accessories di-
rectly assembled or the assembly can be easily carried out by the operator him-
self.
Optimum results will be achieved when BAK accessories and spare parts are
used. Please refer to our brochures for additional information.
SERVICE AND REPAIR
The welding machine should be checked by an authorised service centre approx.
every 1000 operating hours.
Repairs have to be carried out exclusively by BAK authorised service centres.
SHIPPING
For repairs, please return the device 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 9
ASSEMBLY
ATTENTION
ALWAYS unplug the device before working on it.
1.0. Changing the heating element (only when the device has cooled down)
1.1. Swivel out and lock the hot air system
1.2. Loosen four screws at the flange of the nozzle
1.3. Pull off the nozzle
1.4. Pull off the mica tube (careful, fragile)
1.5. Remove the gasket
1.6. Pull off the defective heating element
1.7. Insert the new heating element - observe marking, voltage and
power rating
1.8. Slide on the mica tube
1.9. Slide on the gasket and position the boreholes
1.10. Slide on the nozzle and fix with 4 screws
1.11. Readjust the nozzle as described under basic adjustments on page
4 - 6.
MAINTENANCE
Clean the welding nozzle with a wire brush (5201330).
Check power cable and plug for electrical and mechanical damage.
Should the mains cable of the tool be damaged, it must be immediately
exchanged by the supplier, his customer service or another qualified per-
son to prevent danger.
The sliding axes as well as all movable parts have to be cleaned regular-
ly and be greased with acid-free oil from time to time.
TRANSPORT –HANDLING –STORAGE
Transport:
The welding machine is packed appropriately and must be protected from mois-
ture. We recommend the use of the suitable tool box. For the transport of the ma-
chine the additional weight (10) should be removed for safety reasons.
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.

BAK Thermoplastic Welding Technology AG 10
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
2012/19/EU 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
RoofOn Multi
Voltage
V
120
230
Frequency
Hz
50 / 60
Power consumption
W
Max. power input
A
22,5
15,0
Temperature
°C
20 –600
Drive
m/min
0.0-6.0
Max. air flow (20 °C)
l/min
500
Noise level (EN ISO
11203)
dB(A)
64
Dimensions
mm (L x W
x H)
500x330x950
Weight with 5 m cable
kg
approx. 21.0
Protection class
IP20
Conformity symbol
Protection type I

BAK Thermoplastic Welding Technology AG 11
DEVICE DESCRIPTION
1= Main switch ON/OFF
2= Drive manual/automatic
3= Air flow adjustment
4= Welding speed adjustment
5= Heating ON/OFF
6= Increase welding temperature
7= Reduce welding temperature
8= Hot air system
9= Locking lever
10 = Guide roller
11 = Carrying handle
12 = Weight
13 = Pressure roller
14 = Roller, movable
15 = Power cable
ASSEMBLY INSTRUCCION FOR GUIDE BAR
Assembly:
Put on upper part of guide bar (A) to lower part of guide bar (B) and place hole (C) above threats (D). Screw in clam-
ping lever (E) and titghten.
Dismantling:
Loosen clamping lever (E) and unscrew. Remove upper part of guide bar.
2
1
4
3
5
6
7
8
9
11
12
13
14
15
10
A
B
C
D
E

BAK Thermoplastic Welding Technology AG 12
ASSEMBLY INSTRUCTION ADDITIONAL WEIGHT
Content:
Art.-no. 5232071.1
Additional weight
Screw
Assembly instruction
Basis weight (A) comes with two guide borings (B) and one threat M6 (C) at the front and the sides. Addi-
tional weight (D) with one screw (E) and two guide pins (F).
1.1. Switch off the device, unplug it and let it cool down if necessary.
1.2. Put the guide pins (F) from the additional weight (D) into the guide borings (B) of the basis
weight. Screw in the screw € into threat (C) and tighten.
LEFT*
BACK*
RIGHT*
* Sight in driving direction of the welding machine!
1.3. Dismantling additional weight:
Loosen screw (E) and remove additional weight.
ASSEMBLY INSTRUCTION CONTOUR WELDING SETTINGS
Inhalt:
Art.-no. 5232550
2 contour guide rollers
1 allen key
1 assembly instruction
Assembly:
Loosen both caps (A) with allen key SW6 and
remove guide rollers (B). Pull on holders (C) of
the contour guide rollers (D) on the shaft and
tighten screws (E).
A
B
C
D
E
F
E
E
A
A
B
E
Dismantling:
Loosen screws (E) and remove contour guide
rollers (D). Pull on both contour guide rollers
(B) again and tighten caps (A) with allen key
SW6.
B
A
C
D

BAK Thermoplastic Welding Technology AG 13
DRAWING/SPARE PARTS LIST
Art.-no.
Description
Qty.
5230043
Overlap welding nozzle 40mm
1
5101274
Mica tube
1
5107616
Heating element
1
5101270
Gasket 70x48x4
1
5280165
Cheese head screw M4x12
4
523010.1
Guide bar upper part incl. clamping lever
1
5232089
Clamping lever
1
5102236
Silicon rubber ring ø 62/82x22mm
1
5100985
Silicon rubber ring ø 62/82x51mm
1
5114229
Pressure belt
1
5280221
Power supply cord
1
5280221
5114229
5100985
5232094
5280165
5107616
5101274
5232010.1
5232089
5101270
5102236