Leister WELDPLAST S6 User manual

WELDPLAST
S6
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[e-mail]
®
GB

2
Leister WELDPLAST S6
Hand extruder
Hand extruder for welding thermoplastics from PE and PP filler rod with a diameter of 4 and
5mm (other materials on enquiry) in the construction of containers, apparatus, pipelines
and storage sites.
Electroconductive material (e.g. PE-EL) may not be welded.
Application
Please read operating instructions carefully before
use and keep for further reference.
Operating instructions
(Translation of the original operating instructions)
GB
Danger to life! Danger to life when opening up the tool, as live com-
ponents and connections are exposed. Before opening the tool,
unplug from the mains supply. Electrically conducting material (e.g.
PE-EL) must not be welded.
Fire and explosion hazard with incorrect use of the hand extruder
(e.g. overheating of the material), especially near combustible
materials and explosive gases.
The tool must be operated under supervision.
Heat can ignite flammable materials which are not in view.
The machine may only be used by qualified specialists or under
their supervision. Children are not authorized to use this machine.
For personal protection on building sites we strongly recommend
the tool to be connected to a RCCB (Residual Current Circuit
Breaker).
The voltage rating stated on the name plate of the tool must
correspond to the mains voltage.
In case of a power outage, the main switch and the drive must be
switched off (loosen lock).
Danger of getting burned! Do not touch exposed metal parts
and escaping plastizised material. Do not point the hot air flow
and escaping plastizised material in the direction of people or
animals.
Protect tool from dampness and wet.
FI
120
230
Warning
Caution
Connect the tool to a mains socket with protective earth.
Every interruption of the protective earth inside or outside of the
tool is dangerous!
Only use extension cables with protective earth conductor.
Cross-section of conductor min
. 3 ×4mm
2
1
Use ear protection.

3
Leister Process Technologies, Galileo-Strasse 10, CH-6056 Kaegiswi/Switzerland confirms
that this
product, in the version as brought into circulation through us, fulfils the requirements
of the following EC directives. Directives: 2004/108, 2006/95
Harmonized Standards: EN 55014-1, EN 55014-2, EN 61000-6-2, EN 61000-3-11,
EN 61000-3-12, EN 50366, EN 62233, EN 60335-2-45
Kaegiswil, 15.05.2009
Bruno von Wyl Christiane Leister
Technical Director Owner
Power tools, accessories and packaging should be sorted for environmental-friendly
recycling. Only for EC countries: Do not dispose of power tools into household
waste! 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 suitable for use must be separately collected and sent for recovery
in an environmental-friendly manner.
Disposal
Conformity
Technical data
Voltage V~ 230
Power consumption W 4600
Frequency Hz 50/60
Air flow (20°C) l/min 420
Air temperature °C max. 350
Plastifizer temperature °C max. 260
Emission level LpA (dB) 88
Sound power level LWA (dB) 96
Welding output Ø 4 kg/h PE 3.9 – 4.8 PP 3.4 – 4.0 (Average values at 50 Hz)
Welding output Ø 5 kg/h PE 4.9 – 6.0 PP 4.6 – 5.5 (Average values at 50 Hz)
Welding rod mm Ø 4 / Ø 5
Size L × B × H mm 821 × 116 × 240 (without welding shoe)
Weight kg 14 (without cable to mains)
Marking of conformity 2
Approval mark 3
Certification scheme CCA
Protection class I 1

4
1 Main switch
2 On/off switch drive
3 Potentiometer
4 Drive locking device
5 Display
6 Handle
7 Jacket heating
8 Welding shoe
Operating Leister WELDPLAST S6 hand extruder
1
3
4
17 Welding program
18 Actual value plast
19 Set value plast
20 Actual value air
21 Set value air
22 Bar display for drive
23 Welding output display
24 Menu key
25 Back key
26 Enter key
27 Down key
28 Select key
29 Up key
30 Status display for drive
31 Cursor
9 Pre-heating nozzle
10 Tube clamp
11 Protective tube
12 Welding rod opening
13 Tool handle
14 Mains cable
15 Guiding grip
16 Hot air blower
Description of tool
24
27 28 29
30
31
17
18
19
20
21
22
23
25 26
32 Operating unit
2
5
15
13
910
11
12
6
16
7
8
14
32

5
Operating Leister WELDPLAST S6 hand extruder
Working environment / safety
The hand extruder must not be used in inflammable environments or where
explosion hazards exist. Ensure stable positioning during operation. The
connection cable and the welding rod must remain unimpeded and must not
hinder the user or others during operation.
Rest the hand extruder on a fireproof surface! Hot metal parts and the hot-air jet
must have sufficient clearance from the surface and walls.
Handle Adjustment
1. Loosen the clamping by turning the handle (6) in
counterclockwise direction.
2. Adjust handle (6) to the requested working position.
3. Tighten handle clamping again by turning handle (6) in
clockwise direction.
Workplace
When not welding, the drive should
be switched off with the drive on/off
switch (2).
Place the hand extruder on a stable,
fire resistant base, as shown in the
illustration.
6

6
Operating Leister WELDPLAST S6 hand extruder
Power supply
If an extension cable is used, it should have a cross section of at least 3 × 4mm2and
must be permitted for the place where it is being used (e.g. outside) and labelled
accordingly.
When using a power set for power supply, the nominal power rating for the power
set is: 2 × the nominal power rating of the hand extruder.
After switching on with the main switch (1), press any key on the operating unit (32).
The device then heats up to the last ideal temperature set. When the ideal temperature
is reached, a counter on the status display counts back from 310 seconds to zero. After
this start-up process is complete, the device is ready to weld (status Ready*). The hand
extruder takes around 8 minutes to reach its temperature range. If the power is only
turned off for a short time, the start-up process does not need to be repeated.
motor disabled
WARM-UP LOCK TIME: 310 SEC.
Heat FREE M READY *
Display
Status display
for drive (30)
Heating until target
value is reached
motor release ready to weld
Starting procedure
Temperature monitoring prevents the hand extruder starting up in a cold state.
1
FI
120
230

7
Operating Leister WELDPLAST S6 hand extruder
Preparation for welding
Start window
After turning on the hand extruder with the
main switch (1), the device name and the
current software version are shown in the
display (5). The start window is shown until
any key is pressed on the operating unit (32).
Operating window
The operating window shows the parame-
ters currently set.
24
30
31
27
17
18
19
20
21
22
23
29
25 26
28
Operating window functions
Menu selection
Set contrast
Heating on/off
Change cursor position
Selected parameter [+]
Selected parameter [–]
Key functions
• Operating window
• Menu selection
Menu selection functions
Menu selection / return to operating window
B ack to multifunctional display (Changed entry is not stored!)
Select and return to operating window
Select
Cursor up / selected parameter +
Cursor down / selected parameter –
Tap lightly on the keys to operate them.
Software and menu guide
The Weldplast manual welding extruder is fitted with convenient software, which makes wor-
king with the extruder easy for the user.

8
Adjusting the Output Capacity
Due to the seam form, the output capacity and the pre-heating period can be matched to
each other.
• Pre-adjustment at the display
– By pressing the select key (28), set the cursor to the «SPEED» position.
– Specify the maximum output value (60 to 100) via the up key (29) or down key (27)
(indication via the bar display for drive (22).
• Fine-adjustment during the welding procedure
– By turning the potentiometer (3), the output capacity of the maximal set output value
(e.g. 85) can be reduced to the minimum.
The output capacity depends on the thickness of the welding wire. If the welding output is too
high with the output display «60» and the potentiometer is set to «minimum», the next smallest
welding rod thickness must be selected.
Operating Leister WELDPLAST S6 hand extruder
Setting parameters in the operating window
The cursor (31) shows which parameters can be set. After switching on, the cursor is on
the «SPEED» position.
In the operating window, the following parameters can be selected with the Select key (28)
and changed in their values with the Up key (29) and Down key (27).
3
22
Beispiel
Set value Set value Set value

9
Setting the PLAST and AIR temperatures
• Set the cursor to the «PLAST» or «AIR» position by pressing the Select key (28).
• Set the temperature value with the Up (29) or Down (27) keys.
Monitoring the welding parameters
The actual and ideal values of the AIR and PLAST temperatures
are constantly monitored. If an actual value deviates from the
relevant ideal value (value is outside the range of tolerance), this
will be indicated by a change in status on the status display of
the drive (30). If necessary, the drive motor will be temporari-
ly disabled. When the actual and ideal values of the AIR and
PLAST temperatures are within the range of tolerance again, the
message «Press any key» will appear on the status display of
the drive (30). Any key on the operating unit (32) must be pres-
sed to release the drive motor again (preventing the device from
being started up accidentally). The possible status display and
the ranges of tolerance are shown in the following graphic and
table.
Operating Leister WELDPLAST S6 hand extruder
No. Status display Status properties
1Ready* Ready to weld
2M enabled Deviation of the welding parameters > 10°C
3Heat
Deviation of the welding parameters > -30°C, drive motor disabled
4310s Warm-up lock time of 310 sec., drive motor disabled
5Too hot
Deviation of the welding parameters > +30°C, drive motor disabled
6Press any key Ready to weld, but drive motor is only released after pressing any key on the
operating unit (32).
30
Reference value
Actual value
Displayed state
Time
Motor enabled
Motor enab.
Motor enabled

10
Starting the welding process
• Fit the appropriate welding shoe (8) as required.
• Set the potentiometer (3) to max.
• Once the operating temperature is reached («READY*» status), welding can begin.
• Actuate the drive on/off switch (2).
• Insert a 3 or 4 mm welding rod into the welding-rod intake (12).
• The welding rod is automatically drawn in through the welding-rod intake (12). The
welding rod feed must take place without resistance.
• Interrupt drive by releasing the drive on/off switch (2).
• Direct the pre-heating nozzle (9) towards the welding zone.
• Pre-heat the welding zone with a fanning motion.
• Apply the device to the prepared welding location and actuate the drive on/off switch (2)
again.
• Perform test welding by following the welding instructions from the material
manufacturers and national standards or directives.
• Inspect test welding.
• Adjust the temperature setting and welding output as required.
• For long welding jobs, the drive on/off switch (2) can be locked-on with the drive
locking device (4).
Switching off the tool
• Disengage the drive locking device (4) and release the drive on/off switch (2).
Remove the welding material in the welding shoe so that the welding shoe will not
be damaged when starting the next welding run.
• Switch off the heating systems with the Enter key (26).
• Allow the device to cool down for approx 5 minutes.
• Switch off the main switch (1).
Operating Leister WELDPLAST S6 hand extruder
CAUTION!
Never insert welding rods into both welding-rod intakes at the same time.
Always operate the device with welding rod.

11
Operating Leister WELDPLAST S6 hand extruder
Activate key lock
1. Menu
2. Key lock
3. Activate
If the key lock has been activated,
key lock appears in the display.
The lock can be reset as follows:
Deactivate key lock
1. Back
2. Reset
3. Select
Confirmation with the Select key must
immediately follow the reset!
Further settings
Contrast setting
Given unfavourable lighting conditions and fluctuations in the ambient temperature, the contrast
on the display can be set in the operating window with the back key (25).
Heating on/off
In the case of long interruptions (standby), the heating for PLAST and AIR can be deactivated
with the Enter key (26) in the operating window.
Key lock
activated

12
Operating Leister WELDPLAST S6 hand extruder
Menüführung
Menu
Menu
Scroll
Select
Functions
Scroll
Select and
return
Return to
operating
window
Scroll

13
Operating Leister WELDPLAST S6 hand extruder
Menu
Select program
Scroll
Enter
Welding parameters – Programming
The hand extruder is suitable for the following types of thermoplastic:
• PP/PE-HD/PE-LD
Programs 1-3 are provided with preset values which can be adjusted during the welding process.
The adjustments are not saved.
The free settings 1 - 4 are factory set and can be freely programmed. The parameters remain
saved after the tool is switched off.
Setting the welding output
• Place the cursor on the «SPEED» position by pressing the Select key (28).
• Set the welding output value (60 to 100) with the Up key (29) or Down key (27).
Setting the PLAST and AIR temperature
• Place the cursor on the «PLAST» or «AIR» position by pressing the Select key (28).
• Set temperature value with the Up key (29) or Down key (27).
The welding program (17) currently set is shown in the operating display.
Free
setting
1-4
Welding program Ideal PLAST [°C] Ideal AIR [°C]
Free set 1 – 4 230 260
Prg1 PE-LD 220 260
Prg2 PE-HD 230 260
Prg3 PP 240 260
Set value Set value Set value

14
Operating Leister WELDPLAST S6 hand extruder
•Dismounting
Turn off the device while warm and disconnect from the power supply.
– Remove the welding shoe (8) with the welding shoe holder (34) by unfastening the clamp
screws (35) from the extruder nozzle (36).
– Every time the welding shoe is changed, clean the extruder nozzle (36) of welding residue
and make sure that it is screwed in tightly.
– Remove welding shoe from the welding shoe holder (34) by unfastening the fastening
screws (33).
•Assembly
– Fasten a welding shoe (8), appropriate to the welding seam, onto the welding shoe
holder (34) with fastening screws (33).
– The welding shoe (8) and welding shoe holder (34) must be tightened properly with
the fastening screws (35).
Work with temperature resistant gloves only.
Danger of getting burned!
Replacing the welding shoe
• The welding shoe must only be replaced when the tool has attained its operating temperature.
8 Welding shoe
35 Clamp screws
33 Fastening screws
34 Welding shoe holder
36 Extruder nozzle
35
8
833
36
35 34
35

15
Error messages
An error occurring is shown in the status display (30) (e.g Motor is overheated).
Display
When an error occurs, the heating units for AIR and PLAST, as well as the drive motor, are
switched off immediately!
Should this not take place, the tool must be disconnected from the mains supply
immediately!
Further procedure with status display (30)
• Note down the error code
• Disengage the drive locking device (4) and release the drive on/off switch (2).
• Switch off the main switch (1).
Start using the tool again under supervision and ensure that the extruder is not
overheated from the outside.
• Eject the remaining plastic from the screw if possible.
• Should the error reoccur, the tool should be sent to the Service Centre to be checked,
specifying the error code.
ErrXX
ErrXX
Err04
Drive overheating protection
If the drive is overheated by external influences or because the PLAST temperature
is too low, the internal temperature protection of the drive switches off (see ).
Accidental start-up protection for the drive
The drive motor is protected against accidental start-up after errors, e.g. overheating .
The message «Press any key» appears in the status display of the drive (30) while the drive
motor is disabled. After the error has been corrected, press any key on the operating unit (32).
The message «Press any key» disappears from the status display.
Welding may continue.
Err04
Err04
Troubleshooting Leister WELDPLAST S6 hand extruder
The following errors are recognised by the tool:
Display Type of fault
Err01 Overheating of the air or defective temperature probe
Err02 Overheating of the plastic welding material or defective temperature probe
Err04 Overheating of the motor winding, motor is overheated
Err08 Overheating of the heating element, AIR or failure of the blower motor
Err10 Overheating of the electronics
Err40 Short circuit of the PLAST temperature probe
Several errors can occur at once e.g. and Display: !
Further combinations are displayed with the letters A, B, C, D, E and F.
e.g. and Display !
Err0AErr02Err08
Err06Err04Err02

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ACCESSORIES Leister WELDPLAST S6 hand extruder
Only Leister accessories may be used.
Transportable welding rod dereel holder
• The holder is designed for two welding rod reels with ø 300 mm
• To ensure optimal rod dispensing, the welding rod should be passed through the eyelets (41)
provided.
41
Welding-shoe assortment WELDPLAST S6 standard
Leister Process Technologies offers welding shoes for all the common seam geometries in
various sizes:
Blank V weld Fillet weld Overlap weld

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Check the power supply cord (14) and plug for electrical and mechanical damage.
Clean the extruder nozzle (32) each time the welding shoe is replaced and remove
any welding deposits.
• Repairs should only be carried out by authorized Leister Service Centres. They gua-
rantee a specialised and reliable Repair Service within 24 hours using original spare
parts in accordance with the circuit diagram and spare parts list.
• If the service message appears with the Service Code 1 after
swtiching on WELDPLAST S6, the state of the carbon brushes
should be checked by an authorised Leister Service Centre and
the carbon brushes replaced, if necessary.
• The display can be removed with the Select key (28).
• The hand extruder can be used again for a short time.
• If the carbon brushes are not replaced within a short time, the drive
will run until the mechanical brush reaches its limit stop. No more
error messages appear on the display, the drive no longer runs.
• 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.
• Additional claims shall be excluded, subject to statutory regulations.
• Damage caused by normal wear, overloading or improper handling is excluded from the
guarantee.
• Guarantee claims will be rejected for tools that have been altered or changed by the
purchaser.
Technical data and specifications are subject to change without prior notice
Warranty
Maintenance
Service and repair

20
®
Your authorised Service Centre is:
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel.[phone]
Fax[phone]
www.leister.com
[e-mail]
ENG / BA WELDPLAST S6 /12.2008/08.09
© Copyright by Leister