Leister ALLIED VARIMAT V2 User manual

VARIMAT V2
Leister Technologies AG
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[email protected]

18
How do I start the automatic hot-air welding machine VARIMAT V2?
1. Connect power supply cord to the line/mains
2. Main switch (3) ON
ON
3. Press Drive button Turn e-Drive
4. Press Heating button Turn e-Drive
5. Press e-Drive Heating up time approx. 3 – 5 minutes
6. Carry out a test weld according to the welding instruction of the material manufacturer
and national standards or guidelines. Approve test weld.
7. Welding
How do I switch off the automatic hot-air welding machine VARIMAT V2?
1. Press e-Drive (Fig. 1).
2. Press «Cool down OK» e-Drive and allow to cool approx. 4 minu-
tes
(Fig. 2) . Blower switches off automatically.
3. After welding nozzle (9) has cooled down, main switch (3) OFF
OFF
Congratulations on purchasing an automatic hot-air welding machine VARIMAT V2!
You have chosen a top-class automatic hot-air welding machine made of high-quality materials.
This device has been developed and produced according to the latest welding technologies.
Every VARIMAT V2 passes stringent quality checks before leaving the factory in Switzerland.
Table of contents
Quick info Page 18
Application, warning, caution Page 19
Conformity, disposal, technical data Page 20
Description of device, controls Page 21
Transport Page 22
Joining force, operating preparation, drive sensor adjustment Page 23
Device positioning, welding procedure Page 24
Button combinations Page 25
Work mode (chapter 1) 1.1 Setpoint display Page 25
1.2 Work display Page 26
1.3 Setting the drive speed
1.4 Setting the welding temperature Page 27
1.5 Setting the air volume
1.6 Length measurement, blower and drive counter Page 28
1.7 Selecting profiles
1.8 Cooling down Page 29
1.9 Standby
1.10 Error messages Page 30
Profil setup (chapter 2) 2.1 Creating profiles Page 30
2.2 Standby setup Page 31
FAQ Page 31
Types of Leister VARIMAT V2, accessories, training, maintenance, service and repair, warranty Page 32
Quick info
(Fig. 1) (Fig. 2)
GB
USA

19
Leister VARIMAT V2
Automatic hot-air welding machine
Application
• Overlap welding of roofing membranes made of PVC, TPO, ECB, EPDM, CSPE for basic weld seams.
Can also be used in areas close to edges and on uneven surfaces.
• Overlap welding of sheets and coated fabrics
Please read operating instructions carefully before use
and keep for future reference.
Incorrect use of the hot air tool can present a fire and explosion hazard
especially near combustable materials and explosive gases.
Do not touch hot welding nozzle and welding plate as they can cause burns.
Allow the tool to cool down. Do not point the hot-air flow in direction of people
or animals.
Danger to life when opening the device as live components and connections are
exposed. Unplug the line/mains plug from the plug socket before opening the device.
Warning
Connect tool to a receptacle with protective earth terminal. Any interruption of
the protective earth conductor inside or outside the tool is dangerous!
Use only extension cables/cords with protective earth conductor!
For personal protection, we strongly recommend the tool be connected to an
RCCB (Residual Current Circuit Breaker) before using it on construction sites.
FI
Protect the device from damp and wet.
The tool must be operated under supervision.
Heat can ignite flammable materials which are not in view.
The device machine may only be used by qualified specialists or under their super-
vision. Children are not authorized to use this device.
Rated voltage stated on the device must correspond to line/mains voltage.
N 61000-3-11; Zmax = 0.115 Ω+ j 0.072 Ω. If necessary, consultate supply
authority.
Extract hot-air blower in case of power breakdown.
230
400
Caution
Device must not be lifted at additional weight / end weight.
Operating Instructions (Translation of the original operating instructions)
GB USA

20
Technical data
Voltage V~ 200, 230 EU, 400 V~ 200, 230 US, 400 
Power consumption W 4200, 3680, 5700 W4200, 4600, 5700
Frequency Hz 50/60 Hz 50/60
Temperature °C 100 – 620 stepless °F 212 – 1148 stepless
Speed m/min. 0.7 – 12 stepless ft/min 2.3 – 39.4 stepless
Welding pressure N approx. 190 (2 weights) N approx. 190 (2 weights)
Air flow % 50 – 100 % 50 – 100
Emission level LpA (dB) 70 LpA (dB) 70
Weight kg 35 lbs 77
without power supply cord
Dimensions L× W× H mm 650 × 430 × 330 inch 25 × 17 × 13
Mark of conformity 2
Protection class I 1
Technical data and specifications are subject to change without prior notice
Mains voltage cannot be switched over
Electrical equipment, accessories, and packaging should be recycled in an environmentally friendly
way. When you are disposing of our products, please observe the national and local regulations. For
EU countries: Do not dispose of electrical equipment with household refuse.
Disposal

21
Description of device
1Power supply cord
2Housing
3Main switch
4Controls
5Display
6Drive sensor
7Locking screw
8Hot air blower
9Welding nozzle
10 Tool holder
11 Locking lever
12 Pendulum roller
13 Adjustment screw for tracking
14 Track-alignment roller
15 Guide roller
16 Adjustable transport roller
17 Transport roller
18 Guide roller
19 Shift spring for transport roller
20 Gate
21 Scale for tool adjustment
22 Additional weight
23 End weight
24 Carrying handle
12 30 13
32 7 6
1
2
3
16
5
4
10
11 17
9
8
12
14
18
19
20
21
2223
24
25
26
28
31
33
25 Cheese head screw
26 Lower guide bar
27 Upper guide bar
28 Clamping lever,
upper guide bar
29 Holder for power supply cord
30 Round belt
31 Clamping screw,
lower guide bar
32 Drive sensor covering
33 Wire brush
34 Welding plate
35 Hold-down devices for round belts
Controls (4)
For switching the automatig hot-air welding machine VARIMAT V2 on/off
Drive
Setting the drive speed
Heating
Setting the welding temperature
Blower
Setting the air volume
e-Drive
The e-Drive serves as a navigator.
It has two functions
Turn left or right, in order to
set several menus or values
Press to confirm or to activate
34
30 35 1215
Main switch (3)
29
27

22
Moving VARIMAT V2 out of carrying case:
Open carrying case at top
Open carrying case at sides
Open clamping screw, lower guide bar (31) and move lower guide bar (26) into required position;
tighten clamping screw, lower guide bar (31)
Open clamping lever, upper guide bar (28)
Adjust upper guide bar (27) to required height; tighten clamping lever, upper guide bar (28)
Carefully move the automatic hot-air welding machine VARIMATV2 out of the carrying case
Moving VARIMAT V2 in carrying case:
Carefully move the automatic hot-air welding machine VARIMAT V2 from the side in the carrying case
Open clamping lever, upper guide bar (28) and move in upper guide bar (27);
tighten clamping lever, upper guide bar (28)
Open clamping screw, lower guide bar (31) and move guide bar (27) into transport position;
tighten clamping screw, lower guide bar (31)
Close carrying case at sides
Close carrying case at top
Transport:
For transporting the storage case by hand use carrying handles.
1
2
3
4
5
5
4
3
Transport
Use the storage case included in the scope of delivery as transport protection for
the automatic hot-air welding machine VARIMAT V2. The storage case is provided
with a handle and transport rollers.
VARIMAT V2 may not be lifted with additional weight (22) and end weight (23).
Carrying handles on the storage case as well as Carrying handle (24) and
guide bar (27) on the hot-air welding machine may not be used as transport
help by crane.
For lifting up the hot-air welding machine by hand use carrying handle (24)
and guide bar (27).
For transport preparation let welding nozzle (9) of the VARIMAT V2 cool down
2
1
6
27
24
22
23
1 2
3 4 5 6

23
If the drive motor does not start automatically after moving in the
welding nozzle (9), the drive sensor (6) adjustment is possibly incorrect
Action
• Set drive sensor (6) as follows:
– Turn off main switch (3)
OFF
– Remove drive sensor covering (32)
– Lower hot-air blower (8) and move as far as the left limit stop
– Locking lever (11) must latch in
– Loosen locking screw (7) for drive sensor
– Slide drive sensor (6) on tool holder (10); IMPORTANT: Sensing distance 0.2 – 0.5 mm
– Tighten locking screw (7) for drive sensor
– Mount drive sensor covering (32)
– Move out hot-air blower (8) as far as limit stop and swivel up
– Check function
If the drive motor still does not start automatically, the service centre must be contacted.
Operating preparation
Joining force
• Before putting into operation, check power supply cord (1) and connector as well as
extension cable for electrical and mechanical damages.
• Move lower guide bar (26) into the required position using clamping screw,
lower guide bar (31) and upper guide bar (27) using clamping lever, upper
guide bar (28)
• Clip strain relief of power supply cord (1) in holder (29)
• Check the basic setting of the welding nozzle (9) (ex works illustration B and C)
• Transport setting
– Swivel the guide roller (18) upwards
– Release the transport roller (16) by raising the guide bar (27)
– Push the transport roller (16) by applying a little pressure to the shift spring (19)
to the left until it stops (illustration D)
– Position the hot-air blower (8) by pulling the locking lever (11) and swivel it up
until it locks
Connect tool to rated voltage.
Rated voltage stated on the device must correspond to line/mains voltage.
Extract hot-air blower in case of power breakdown.
Illustration A
• The welding pressure is transmitted to the pendulum roller (12).
• As necessary, the additional weights (22) and the end weight (23)
can be put on (see illustration A).
Drive sensor adjustment
32 7 11 106
38
120N
155N 190N
120N
155N
190N
120N 155N
190N
22
12
23
22
120
230
Illustration B
1 mm
Illustration B
9
Illustration D
18 16 19
12

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Perform a test welding according to the welding instructions of the material manufacturer and the
national standards or guidelines. Approve the test welding.
•Set welding parameters drive, heating and blower (chapter 1, Work mode)
•Welding temperature must be reached (heating up time approx. 3-5 min)
• Pull locking lever (11), lower hot-air blower (8) and move in welding nozzle (9) between the overlapping
sheets as far as the limit stop; drive motor starts automatically
No automatic start, see Drive sensor adjustment section
• Machine can be started manually with the controls (4) Drive and e-Drive
• The automatic hot-air welding machine is guided along the overlap at the guide bar (27). Guide the automatic
hot-air welding machines without pressure onto the guide bar (27) during welding. Pressure on the guide
bar (27) can lead to welding errors. Observe position of the guide roller (18)
• After the welding pull locking lever (11), move out hot-air blower (8) as far as the limit stop and swivel up
to the latching point
• After finishing the welding work, use e-Drive (press 2 x) to switch off heating
In this way, the welding nozzle (9) is cooled down and the blower automatically switches off after
approx. 4 minutes (section 1.8, Cooling down)
• Turn off main switch (3)
OFF
120
230 Disconnect power supply cord (1) form the line/mains.
• Clean welding nozzle (8) with wire brush (33)
Device positioning
•Lift automatic hot-air welding machine applying pressure onto guide bar (27) and move to weld position
•Take welding plate (34) from holder and position according to Illustration E
WARNING: The welding plate (34) may only be removed from the holder and positioned if the welding
nozzle (9) has cooled down.
•Release the transport roller (16) by lifting it with the guide bar (27)
•Push the transport roller (16) to the left until it stops by applying light pressure to the shift spring (19)
•Swivel the guide roller (18) down
•The guide roller (18) should be set parallel to the edge of the pendulum roller (12) (see illustration F)
•Do a test run
•To correct the tracking, adjust the adjustment screw for tracking (13) (see illustration G and H, and the function
notes on the automatic hot-air welding machine)
Illustration F
12 18
Welding procedure
12
Illustration G
13
Illustration H
12 13
Illustration E
34
34

25
Button combinations
Main switch ON
Heating and Blower buttons pressed
at the same time and the main switch ON
Work mode
Chapter 1
Profile setup
Chapter 2
1. Work mode
1.1 Setpoint display (after switching on the device)
Main switch (3) ON
• After switching on the device, the values last set appear on the display (5) (Fig. 3).
• Heating, plower and drive are switched off in this menu.
• The user can use the controls (4) here to perform all settings which are described in
the following chapters.
• If, however, the heating element temperature is higher than 80°C when switching
on, the display will immediately change to the Cool down mode (section 1.8, Cooling
down) in which the blower is always operated at full power, thus cooling down the
welding nozzle (9). It is possible to change back to Work mode from this mode at
any time.
• If the heating element temperature reaches 60°C during cooling down, the blower will
continue to operate for 2 minutes and then switches off automatically. The display (5)
changes back to the Setpoint display (Fig. 3).
• Turning the e-Drive to Profile allows various welding profiles to be selected
(Fig. 4; section 1.7, Selecting profiles).
(Fig. 3)
(Fig. 4)
ON
ON
ON

26
1. Work mode
1.2 Work display
• Pressing the e-Drive starts the heating and blower, and the
Setpoint display changes to the Work display.
• When the welding nozzle (9) is heating up, this is indicated on
the display (5) with progress bar and arrow (up) together with
the actual value of the welding temperature (flashing).
• If the mains voltage is outside (+/- 15%) the specified nominal
voltage (200 V, 230 V, 400 V), this is displayed flashing with the
symbol and the measured undervoltage/overvoltage.
If the air volume is less than 100 %, the percentage indication
changes with the symbol.
The welding result can be affected, depending on the undervoltage/
overvoltage.
• If no button is pressed after a definite time (welding nozzle (9)
NOT in welding position), the Standby menu is displayed (section
1.9, Standby).
• If the welding nozzle is not swivelled in, the menus Cool Down (section 1.8, Cooling down) or Profiles
(section 1.7, Selecting profiles) can be selected by turning the e-Drive .
• If the welding nozzle (9) is swivelled in, the two menu items disappear on the display (5)
and can no longer be selected.
• If the welding nozzle (9) is cooling down, this is indicated with filled out progress bar and arrow
(down) as well as flashing actual value of the welding temperature on the display (5).

27
1. Work mode
1.3 Setting the drive speed
• The drive speed can be adapted with the Drive button . This can be set by tur-
ning the e-Drive in 0.1 m/min. increments from 0.7 m/min. to 12.0 m/min. This
setting can be carried out with the drive switched on or off.
• If the welding nozzle (9) is not in the welding position, the symbol
will appear at the lower left edge of the displays (5).
• The drive can be switched on by pressing the e-Drive , the following symbol
Stop appearing. The drive speed can be adjusted directly by turning the e-Drive .
• Pressing the e-Drive again executes the Stop command, which switches off the drive. The Set-
point display or Cool down appears on the display.
• If no entry is made by the controls (4) within 3 seconds, the new drive speed will be accepted.
The Setpoint display or Cool down appears on the display (5).
• If the Drive button is pressed for 3 seconds, the display will change to another menu (section 1.6,
Length measurement, blower and drive counter).
• You can change to the relevant menu by pressing the Heating or Blower button.
1.4 Setting the welding temperature
• The welding temperature can be changed with the Heating button . The
welding temperature can be set in 10°C increments from 100°C to 620°C by
turning the e-Drive . The setting is accepted after 3 seconds, as long as no
button is pressed within these 3 seconds.
• If this menu is called up from the Setpoint display, heating and blower can be star-
ted by pressing the e-Drive . Once the heating is switched on, the cool down
can be selected (section 1.8, Cooling down).
• If the Heating button is pressed within 3 seconds, the display (5) will chan-
ge and the mains voltage will appear below the drive. This call-up is only possib-
le from the Work display (section 1.2).
• The air volume is automatically reduced at a set welding temperature of 500°C and hig-
her. However, the user can manually adjust the air volume using the Blower button
(see section 1.5).
If a star appears after the air volume display , achievement of the wel-
ding temperature is no longer ensured.
• You can change to the relevant menu by pressing the Drive or Blower button.

28
1. Work mode
1.5 Setting the air volume
• The air volume can be changed with the Blower button . The air volume can
be set in 5% increments from 50% to 100% by turning the e-Drive . The setting
is accepted after 3 seconds, as long as no button is pressed within these 3
seconds. If the air volume is set to 100%, no information will appear on the dis-
play (5).
• The air volume is automatically reduced at a set welding temperature of 500°C and
higher. The air volume can be increased manually by turning the e-Drive . If a
star appears after the air volume display , achievement of the welding temperature is no longer
ensured.
• If this menu is called up from the Setpoint display, heating and blower can be started by pressing
the e-Drive .
• The cool down menu can be selected by pressing the e-Drive (section 1.8, Cooling down).
• You can change to the relevant menu using the Drive button or Heating button .
1.6 Length measurement, blower and drive counter
• This menu (Fig. 4) appears if the Drive button is pressed for at least 3 seconds.
• The menu displays all operating times and the distance which the device has travelled
since being switched on. The total distance (here: 1034 m) cannot be changed and
shows the entire path taken since starting up.
• The daily distance (here: 012 m) is not reset automatically, but instead must be
annulled by the user via «Reset» by pressing the e-Drive .
• The Time values concern the operating time for the individual components of the
device. The time is assigned to the blower «Blow» (here: 043:58) and the drive «Drive»
(here: 020:10). The «Total» time refers to the operating time. It counts the hours and minutes (here: 143:12)
during which the main switch (3) is switched on.
• If the Back arrow is selected by pressing the e-Drive , you will be taken back to the menu
from which the Drive button has been pressed.
(Fig. 6)

29
1.7 Selecting profiles
• If the display at the bottom right of the display (5) is activated, profiles can
be loaded by pressing the e-Drive . The display «Select Profile» then appears.
A profile can be selected by turning the e-Drive . The profiles Free Adj. 1, 2
and 3 can be defined by the user him/herself (chapter 2, Profile setup). All other profi-
les have permanently assigned values and cannot be defined by the user.
• Turning the e-Drive activates left or right arrows on the dis-
plays (5) at the bottom. Right arrow by pressing the
e-Drive to the next page.
Left arrow by pressing the
e-Drive to the previous page.
• If the Back arrow is activated by turning the e-Drive
, you will be taken back to the menu by pressing the e-Drive ,
from which the Profile menu has been selected.
Perform a test welding according to the welding instructions of the material manufacturer and the
national standards or guidelines. Approve the test welding.
1. Work mode
1.8 Cooling down
• If the symbol is selected by pressing the e-Drive , the menu «Cool down
OK?» will appear. Pressing the e-Drive actives the symbol OK at the bottom right of
the display (5), thereby initiating the cooling down process.
• During the cooling down process, the air volume is increased to
100% and the instantaneous welding temperature displayed.
If the welding temperature of 60 °C is fallen below, the blower will continue to operate
for 2 minutes and will automatically switch off after this time
expires. The display changes to the Setpoint display.
• After pressing the e-Drive the display (5) shows the last set
values for blower and heating.
• If the Cool down is active, the drive can be switched on/off
manually via the Drive button .
The Heating button and Blower button do not have any
function.

30
2.1 Creating Profiles
• In the Profile Setup, 3 individual profiles can be created, in
which all three parameters can be freely set and then saved by
pressing the e-Drive .
• The various menu items can be selected using the controls (4).
Pressing the e-Drive will take you back to the Profile Setup
selection.
Perform a test welding according to the welding instructions
of the material manufacturer and the national standards or guidelines. Approve the test welding.
2. Profile setup (see button combination)
1.9 Standby
• If the welding nozzle (9) is not in the welding position and no button is pressed
during a definite time, the Cool down mode will automatically start after the stand-
by time has passed.
The cooling down process is initiated.
• If the e-Drive is pressed before the countdown (180 seconds) has finished in
Standby mode, the display will change back to the initial state.
• For setting the standby time, (section 2.2, Standby setup)
1. Work mode
1.10 Error message
• If a malfunction occurs in the automatic hot-
air welding machine VARIMAT V2, a messa-
ge will appear on the display (5), which is
also provided with an error code. This code
stands for a more exact definition of the error
which can be seen in the lower list.
• In case of error 02 and error 40, separate
symbols are displayed
• An acoustic warning signal will sound in the event of serious error messages
• If the setpoint/actual welding temperature divergence is > 20 °C, an acoustic warning signal will sound
• In case of all other errors, the spanner is displayed for the service prompt
Error Type of error
Err01 Interruption or short-circuit of the temperature probe
Err02 Heating element defective (interruption in one/both winding(s)
Err04 Triac defective (one or both triacs are defective)
Err08 Blower motor defective
Err40 Undervoltage 25% (mains voltage 75%)

31
2.2 Standby setup
• The standby time can be set in this setup.
– Turning the e-Drive allows the time to be set from 5 to 120 minutes. 40 minutes
are set at the factory.
• Pressing the e-Drive will take you back to the Profile setup selection.
• Machine switches off automatically
– The machine is automatically switched off after a set time with Standby mode (factory setting 40 minutes).
• Quality of the welding process is insufficient.
– Check drive speed, welding temperature and air volume
– Clean welding nozzle (9) with wire brush (33)
– Welding nozzle (9) is incorrectly set (see Operating preparation, page 23)
• The set welding temperature is not reached
– The air volume is set too high
– Insufficient voltage
• Startup mechanism not working
– Adjust drive sensor (see page 23)
• Device does not move straight
– Device positioning (see page 24)
• A star appears in the air volume display
– Blower is no longer on the specified curve, but instead in manual mode (see blower curve)
• Why is the air volume automatically adjusted when setting the welding temperature above 500°C ? (see blower curve)
– Achievement of the welding temperature is not ensured at too high air volume
FAQ Error – Cause – Remedy
2. Profile setup (see button combination)
Blower curve VARIMAT V2
Air volume V [%]
Welding temperature T [°C]
Specified curve
>3680W
Specified curve
EU-Plug
Automatic
mode
Manual
mode

32
Types of Leister VARIMAT V2
Article no. 137.821 VARIMAT V2, CEE plug 400 V~ / 5700 W
Article no. 138.982 VARIMAT V2, without plug 230 V~ / 4600 W
Article no. 138.108 VARIMAT V2, Schuko plug 230 V~ / 4600 W
Article no. 139.734 VARIMAT V2, Japan plug 200V~ / 4200 W
Accessories
Only Leister accessories should be used
Article no. 139.048 Carrying case (included in scope of delivery)
Article no. 138.817 Wire brush (included in scope of delivery)
Article no. 132.429 Welding plate (included in scope of delivery)
Article no. 107.067 Additional weight
Article no. 113.995 Grip nozzle 30 mm
Article no. 113.600 Grip nozzle 40 mm
Article no. 110.714 Maintenance set
Training
• Leister Technologies AG and its authorised Service Centres offer free welding courses and training.
Informationen below www.leister.com.
Maintenance
• The air inlet on the hot-air blower (8) must be cleaned with a brush if soiled
• Clean welding nozzle (9) with wire brush (33)
• Check power supply cord (1) and plug for electrical and mechanical damages
Service and repair
• If the drive counter reaches 400 h or the blower counter reaches 2000 h, the message
«Maintenance servicing» will appear on the display the next time the main switch (3) is
switched on. This message is displayed for 10 seconds and cannot be skipped by the
controls (4).
• Repairs should only be carried out by authorised Leister Service Centres. They guarantee
a correct and reliable repair service within 24 hours, using original spare parts in
accordance with the circuit diagrams and spare parts lists.
Warranty
• For this tool, the guarantee or warranty rights granted by the relevant distributor/seller shall apply. In case of gua-
rantee or warranty claims any manufacturing or workmanship defects will either be repaired or replaced by the
distributor at its discretion. Warranty or guarantee rights have to be verified by an invoice or a delivery document.
Heating elements shall be excluded from warranty or guarantee.
• Additional guarantee or warranty claims shall be excluded, subject to mandatory provisions of law.
• Warranty or guarantee shall not apply to defects caused by normal wear and tear, overload or improper handling.
• Warranty or guarantee claims will be rejected for tools that have been altered or changed by the purchaser.

Your authorised Service Centre is:
Leister Technologies AG
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[email protected]
© Copyright by Leister
BA VARIMAT V2 / 08.2009 / 07.2020 Art. 137.889 (part 1)
Allied Power Tools
12/ 76 Rushdale St, Knoxfield VIC 3180 Australia
T: + 61 3 9764 2911
E: [email protected]
W: www.alliedpowertools.com.au