Leister WELDMAX User manual

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LEISTER WELDMAX
Mini-Hand Extruder
Please read operating instructions carefully before
use and keep for further reference.
GB
OPERATING INSTRUCTIONS
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]
®
• Welding of thermoplastic materials made from:
PE-HD PP-H, PP-B, PP-R PPS.
• Do not weld (PE-EL) electronically conductive material.
(Reason: electric shock.)
• Welding seams in containers, appliances and pipe construction are carried
out in accordance with DVS 2207 part 4.
• Welding of geomembrane liners for disposal sites and rubbish tips are carried
out in accordance with DVS 2225 part 4.
Application

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TECHNICAL DATA
DANGER!
Danger when opening up the tool, as live components and
connections are exposed. Therefore, before opening it,
unplug the tool to ensure disconnection from the mains.
Electronically conductive material (eg PE-EL) must not be
welded.
Incorrect use of the hand extruder (eg overheating of the
material) can present a fire and explosion hazard, espe-
cially near combustible materials and explosive gases.
The tool must be operated with supervision. Heat can
reach combustible materials, which are out of sight.
For personal protection on building sites we strongly recom-
mend the tool be connected to a RCCB (Residual Current
Circuit Breaker) .
The voltage rating stated on the tool must correspond to
the mains voltage.
Do not touch the element housing, air nozzle and
discharging plastizised material when they are hot as
they can cause burns. Let the tool cool down. Do not
point the hot air flow and the discharging plastizised
material in the direction of people or animals.
Protect tool from damp and wet.
FI
120
230
WARNING
CAUTION
Voltage V~ 120 200 230
Power consumption W 1800 2200 2200
Frequency Hz 50/60
Air Temperature °C max. 400
Air flow l/min 300
Plast. Temperature °C max. 270
Welding output kg/h 0.7
Welding rod mm ø 4 ± 0.2 (in accordance with DVS 2211)
Size L ××W ××H mm 443 ××94 ××255, handle ø 57
Weight kg 3.8 (without cable to mains)
Electrical Safety: double insulated
APPROVAL MARK
This tool is CCA certified (CENELEC Certification Agreement).
Line/mains
voltage cannot
be switched over

Operating condition
• As required, fit the relevant welding shoe (1) according to instructions for change
of welding shoe.
• Connect the tool to the mains.
• Switch on the tool at main switch (13).
The Software version will appear on the digital display ACTUAL value air temper-
ature (20).
• Adjust the desired values for air and extrudate temperature.
– Potentiometer air temperature (22), digital display SET value air temperature (21).
–Potentiometer extrudate temperature (19), digital display SET value extrudate
temperature (18).
– Set the rod feed to position 2.
•Warning
– Choose appropriate temperature to avoid over-heating of the welding rod.
– Over-heating of the extrudate inside the tool can cause a fire!
• The rod feed will not start (tool protection) until the set temperature of the whole
extrudate material has been reached.
• Until the rod feed is released, the digital display will flash showing the SET value
air temperature (21), SET value extrudate temperature (18), ACTUAL value air
temperature (20) and ACTUAL value extrudate temperature (17).
• After reaching the SET temperature, digital display ACTUAL value extrudate
temperature (17) and after flashing has stopped, the welding procedure can be
started.
– The pre-heating time needs to be extended depending on the materials and
environmental conditions after the rod feed has been released.
– Note: The material in the welding shoe (1) must be plastizised.
• Remove the protruding extrudate in the welding shoe (1) with a pair of pliers by
pulling slightly.
Welding procedure
• By pressing the rod feed switch (14) the rod feed for the welding rod is switched on
(self-locking).
– Renewed pressing of the rod feed switch (14), will switch off the rod feed.
• Start up the tool using the rod feed switch (14), and let a little plastizised material
feed through.
• Adjust the desired rod feed speed by the potentiometer welding rod feed
speed (23) (depending on the seam geometry).
• Switch off the extrudate feed by using the rod feed switch (14).
• Point the pre-heating nozzle (5) at the welding area.
• Pre-heat the welding area by using a swinging motion.
• Position the tool onto the prepared welding seam and activate the rod feed
switch (14).
• Do a test weld.
• Adjust the setting as required.
• CAUTION:
If the digital display SET value air temperature (21) is set higher than the digital
display SET value extrudate temperature (18) and the tool has been running for
some time without the rod feed, the digital display ACTUAL value extrudate
temperature (17) will have risen even though no adjustment on the SET value air
temperature (21) has been made. This operating condition should be avoided as
the extrudate will decompose thermally. By activating the rod feed via the rod
feed switch (14) and by adding the welding rod, the extrudate temperature will
adjust to its SET value again.
•Let the tool cool down after use.
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OPERATING LEISTER WELDMAX Hand Extruder

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Change of welding shoe
CAUTION! Danger of getting burned.
• Do not change the welding shoe when the tool us cold.
• Switch off the hot tool and disconnect from the mains.
• Remove the welding shoe holder (3) from the heater tube (8). by loosening the set
screws for welding shoe holder (4) (use gloves).
• Clean the nozzle for extrudate (7) of welding deposits at every change of welding
shoe (see maintenance).
• Attach an appropriate welding shoe holder (3).
• The welding shoe holder (3) can be attached in four 90° offset positions.
• The welding shoe (1) can be taken off the welding shoe holder (3) by loosening the
set screws for the welding shoe (2) (eg. for reworking).
• Re-connect the tool to the mains supply and operate.
Change of welding rod
• Switch on the tool by the rod feed switch (14).
• Guide the new welding rod into the welding rod feed (15).
• Let the tool run until a pure strand appears from the nozzle for extrudate (7).
OPERATING LEISTER WELDMAX Hand Extruder
Description of tool
1. Welding shoe
2. Set screw for welding shoe
3. Welding shoe holder
4. Set screw for welding shoe holder
5. Pre-heating nozzle
6. Set screw for pre-heating nozzle
7. Nozzle for extrudate
8. Heater tube
9. Handle
10. Air filter
11. Housing
12. Cable to mains
13. Main switch
14. Rod feed switch
15. Welding rod feed
16. Discharge aperture
17. Digital display ACTUAL value
extrudate temperature
18. Digital display SET value
extrudate temperature
19. Potentiometer
extrudate temperature
20. Digital display ACTUAL value
air temperature
21. Digital display SET value
air temperature
22. Potentiometer air temperature
23. Potentiometer welding rod
feed speed

OPERATING LEISTER WELDMAX Hand Extruder
2
5
8
10
min.
1
2
4
3
8
13
11
9
12
14
5
7
15
17 19
18 21
20 22 23
16
6
13
10
Control panel with
digital display
5
Welding positions
V-/ X-weld Filet weld

FAULTS LEISTER WELDMAX Handextruder
Operating faults and preventative measures
• Welding rod obstruction
– Should the welding rod outside the tool get obstructed, the rod feed will skid to
prevent tool damage.
– Safeguard the welding rod feed, check welding rod tolerance.
– Start up the tool using the rod feed switch (14).
– Push-feed the welding rod only by hand into the welding rod feed (15).
– Welding rod residue will escape via the discharge aperture (16).
– CAUTION do not use any tools or other objects to remove welding rod residue.
• In case the welding rod cannot be fed through, the welding rod can be removed
backwards out of the tool.
– Switch off the rod feed by the rod feed switch (14).
– Set the potentiometer air temperature (22) and potentiometer extrudate tem-
perature (19) to the set value OFF position.
– After approx. 2 seconds activate the rod feed switch (14), the machine will start
in reverse (fixed speed).
– The welding rod can be removed by pulling on the protruding welding rod.
– Switch off the rod feed by pressing the rod feed switch (14).
– Set the potentiometer air temperature (22) and potentiometer extrudate tem-
perature (19) to adjust SET value.
– Feed new welding rod and press rod feed switch (14).
Caution: cut off the used welding rod.
– Feed in the new rod by using a low rod feed speed.
– As soon as the plastizised material starts to protrude from the welding shoe (1),
the tool will be operational again.
•Fault indication on the digital display
– Should a fault occur during the operation of the tool , this will be indicated on the
display.
– Send the tool to the nearest Service Centre, indicating the fault code.
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ERR will appear on the Digital display ACTUAL value extrudate temperature (17)
and Digital display ACTUAL value air temperature (20)
The following messages will appear on the Digital display SET value air
temperature (21)
LO No fault in the automatic air control.
L1 Interruption of the temperature probe or air temperature too high
L2 Faulty air heater or the air temperature probe has a short circuit
L3 Element overheated, photoresistor has responded
L6 Electronics over-heated.
The following messages will appear on the digital display SET value
extrudate temperature (18)
PO No fault in the automatic extrudate unit
P1 Interruption of temperature probe or extrudate heater over-heated
P2 Faulty extrudate heater or the temperature probe of the
extrudate heater has a short circuit

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BA WELDMAX/ 06.2001/GB
• Only LEISTER accessories should be used
• The tool’s air filter (10) should be cleaned with a soft brush or be replaced.
• The nozzle for extrudate (7) should be cleaned of welding deposits before every
change of welding shoe.
• Check the mains cable and plug for breaks and mechanical damage.
• At minimal length of the carbon brushes the motor switches off automatically.
The tool should be checked by your Service Centre. The carbon brushes in the
motor will last approx. 1000 hours running time.
• The carbon brushes of the winding motor should be checked after approx. 1000
running time by your Service Centre.
• Repairs should only be carried out by authorized LEISTER Service Centres. They
guarantee a specialised and reliable Repair Service within 24 hours using original
spare parts in accordance with the circuit diagram and spare parts list.
• Guarantee and liability are in accordance with the guarantee certificate as well
as with the currently valid general business and sales conditions.
• 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:
GUARANTEE AND LIABILITY
SERVICE AND REPAIRS
MAINTENANCE
ACCESSORIES
®
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]

Service Record LEISTER WELDMAX
This document should be kept up to date during repair or servicing by the
authorized LEISTER Service Centre. This document should be in the possession of
the owner of the equipment.
Technical data
Order No.
Serial No.
Rated voltage V
Rated capacity W
Sale date
Service
1. Date Service centre Signature
2. Date Service centre Signature
3. Date Service centre Signature
4. Date Service centre Signature
5. Date Service centre Signature
6. Date Service centre Signature
Repair
1. Date Service centre Signature
2. Date Service centre Signature
3. Date Service centre Signature

®
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. + 41 41 662 74 74 Fax [phone] www.leister.com [email protected]
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