Leister TWINMAT User manual

LEISTER Twinmat
Automatic wedge welding machine
Please read operating instructions carefully before use
and keep for further reference.
GB
OPERATING INSTRUCTIONS
The LEISTER Twinmat is an automatic wedge welding machine for overlap
welding of geomembrane liners for earthwork and civil engineering.
•Thermoplastic lining membranes •Type of seam
Polyvinyl chloride plasticised PVC-P Welding seams are
Polyethylene high density PE-HD produced in accordance
Polyethylene low density PE-LD with DVS 2225 part 1 and
Chlorinated polyethylene PE-C BAM.
Polypropylene PP Other dimensions are
Ethylene copolymer bitumen ECB possible on request.
Ethylene vinyl acetate E/VA
DVS: German Welding Association
BAM: Federal Institute for Materials Research and Testing, Berlin
APPLICATION
TWINMAT with printer
®
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]

2
WELDING Pages 11 – 12
• welding preparation
• welding procedure
• welding tips
TRAINING Pages12
MAINTENANCE Pages12
SERVICE AND REPAIR Pages12
NOTICE Pages12
Authorized Service
Centre Pages12
Contents:
APPLICATION Pages1
WARNING Pages2
CAUTION Pages2
TECHNICAL DATA Pages3
FUNCTIONS Pages 3 – 4
DESCRIPTION OF TOOL Pages 5 – 10
• mechanics
• key board
• software system level
• printer
Danger to life when opening the tool, as live compo-
nents and connections ar exposed. Unplug the tool
before opening it.
Incorrect use of hot air blowers can cause fire and
explosion hazard, especially near combustible materials
and explosive gases.
The tool must be operated with supervision. Warmth
can reach combustible materials, which are out of sight.
For personal protection on building sites we strongly
recommend the tool be connected to a GFCI (Ground
Fault Circuit Interrupter) or a RCCB (Residual Current
Circuit Breaker) .
The voltage rating stated on the tool must correspond to
the line/mains voltage.
Do not touch the element housing and nozzle when
they are hot as they can cause burns. Let the tool cool
down. Do not point hot air flow in the direction of
people or animals.
Protect tool from damp and wet.
FI
230
400
WARNING
CAUTION

Electrical safety: double insulated
Voltage V~
Capacity W
Frequency Hz
Temperature °C
Air flow l/min.
Drive m/min.
Welding pressure N
Operating temp. °C
Size mm
Weight kg
230 or 400 ★
4600 or 5800
50 / 60
20 – 620 steplessly controlled
max. 500 manual air slide
0,5 – 5,0 steplessly controlled (tachogenerator)
max. 2500 steplessly adjustable
- 5 to 45
600 x 690 x 450
32,0
4M1Order No.
TECHNICAL DATA LEISTER Twinmat (4M1)
3
DESCRIPTIONS OF FUNCTIONS LEISTER Twinmat (4M1)
•Heating system ➝The hot air temperature is electronically steplessly adjusta-
ble and electronically controlled for heating up the hot air wedge. Digital
display of SET and ACTUAL value. The flexible hot air wedge has three heat
zones:
Pre-heating, contact heating, material plasticising with hot air.
•Welding pressure ➝steplessly adjustable, digital ACTUAL value display. The
welding pressure is transmitted via the toggle lever to the pressure rollers.
During the welding process the pressure is matched linearly to the change
in thickness of the membrane (e.g. T-joint).
•Drive ➝electronically steplessly adjustable and electronically controlled. Digi-
tal display of SET and ACTUAL value. The power transmission works through a
three stage planetary gear. Should rippling occur in the laid-out geomem-
brane liners, the upper or lower drive/pressure roller can be switched over
alternatively.
★Mains voltage cannot be switched over

•Monitoring the welding seam ➝Contactless recording of the seam thickness
reduction data, which is displayed digitally for the welding operator during
the welding operation. Additionally, the seam thickness reduction is graphi-
cally recorded onto a paper print out continuously during the welding ope-
ration.
• Speed control system
The influence of weather such as sun, shade, wind and moisture, which cause
a temperature change in the lining membrane during the welding process,
can lead to weld faults. The TWINMAT speed control system interprets the data
from the continuous measurement of the welding seam geometry. Through
automatic adjustment of the welding speed, such weld faults are avoided.
The welding operation can be done either with or without the speed control
system. If the lower seam thickness reduction tolerance is exceeded, the
welding speed slows down automatically; if the upper seam thickness reduc-
tion tolerance is exceeded, the welding speed is increased.
DESCRIPTION OF FUNCTIONS LEISTER Twinmat (4M1)
4
D C D
BA
Cross-sectional diagram of an overlap weld
Seam thickness reduction = A – B
A : Thickness of upper and lower
geomembrane liner
B: Thickness of welding seam
C : Width of test channel 15 +/- 2 mm
D : Width of weld ≥15 mm
•Welding seam geometry ➝The proof of quality in a welding seam (peel test,
tensile test) depends upon the thickness reduction in the area of the seam.
With a seam thickness reduction ranging between 0.2 – 0.8 mm, the welding
seam geometry is within the permissable range (DVS 2225 part II, BAM). This
permissable range reflects the optimum interaction of welding parameter
temperature, welding pressure and speed under changing ambient condi-
tions during the welding process.

5
DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
Detail B
Detail A
5
19
68
7
10
9
21
4
20
3
2
1
11
13 14 12
15
16
17
18
1. Cord to mains
2. Cord holder
3. Main switch
4. Hot air blower
5. On/off switch hot air blower
6. Locking lever for hot air blower
7. On/off hand wheel for upper
or lower drive/pressure roller
8. Locking mechanism for control handle
9. Hand wheel for stepless
adjustment of the welding pressure
10. Locking lever for welding pressure
11. Handle
12. Carrying handle
13. Printer
14. Printer protection cover
15. Keyboard
16. Display
17. Housing for drive motor
and electronics
18. Ventilator grill
19. Air intake opening
20. Hot air wedge
21. Front roller

DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
Detail B
Drive/pressure roller system
Heating system cross sectional diagram
Detail A
Positioning of the hot air wedge
6
12
3
25 26 28 29 2723 22 20 24
28 29 20 24 30 31 32
22. Hot air wedge guide
23. Guide/rod arm
24. Pinch rollers
25. Swivel head
26. Sensor beam
27. Back roller
28. Lower drive/pressure roller
29. Upper drive/pressure roller
30. Support rollers
31. Lower geomembrane liner
32. Upper geomembrane liner
Material plasticising
with hot air
Contact heating Pre-heating and
cleaning of the
membranes

S
S
M
M
P
P
v
v
t
t
Esc
Esc
–
–
+
+
Display
Keyboard
DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
7
2
135
4 6
1. Welding speed m/min.
ACTUAL value
2. Welding speed m/min.
NOMINAL value
3. Temperature ACTUAL value °C
4. Temperature NOMINAL value °C
5. Welding pressure ACTUAL N
value
6. Seam thickness reduction mm
ACTUAL value
Drive motor on/off
Heating on/off
Skip to beginning function
Welding programm check
- Thickness of material
- Seam thickness reduction offset
- Speed control
- Recording mode
- Welding speed
- Welding temperature
Welding speed
Welding temperature
Adjustment of system
- Memory card
- Alarm (audible)
- Language
- Date
- Time
- Diagnosis
ON
OFF
ON
OFF
START
Recording of data/
Recording of welding
seam geometry
END
H
H
Value increase
Value decrease
End of entry
Change of menu

DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
System level
8
START
V – ACTUAL t – ACTUAL Welding pressure
V – SET t – SET Seam thickness reduction
Thickness
of material
Seam thickness
reduction offset
Speed-
Control
Recording
mode
Welding speed
Welding
temperature
P
+–
+
ß
–
+–
+–
+–
+–
Memory-Card
Alarm
(audible)
Language
Date
Time
Diagnosis
Code
S
+–
+–
+–
+–
+–
ESC ESC
ß
ß
ß
ß
ß
ß
ß
ß
ß
ß
Basic display
Basic display
ß

To get an accurate reading,
before welding, the operator
must adjust the seam thickness
reduction display. The value
on the display should read
zero. See page 7 Display (6).
As the knurl pressure rollers
press into the geomembrane
material according to the
welding pressure, the electro-
nic processor already inter-
prets this as seam thickness
reduction and it should there-
fore be neutralised accord-
ingly.
The automatic adjustment of
the welding speed can be set
before starting the welding
process by using the ON/OFF
switch.
The print-out mode must be
selected before starting the
welding process.
–Graphic mode
Continuous recording and
print-out of the seam thick-
ness reduction over the whole
length of the welded seam
– Tolerance mode
Recording of the seam
thickness reduction is only
printed out if the seam
thickness reduction toleran-
ce has been exceeded.
Recording Mode
Speed Control System
Seam thickness reduction - offset
Before welding, the operator must enter the thickness of the geomembrane
material. The electronic processor requires this value to calculate the relevant
seam thickness reduction. Depending on the material thickness, the range of
seam thickness reduction is automatically adjusted on the print-out. The mate-
rial thickness settings should not be changed during the welding process.
Thickness of material
DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
9
P
P
P
TWINMAT
Software-Rev:
LEISTER, Switzerland
Datum:
Zeit:
Betriebs-Std.
Start 22.11.94 15.39
4.0 Messbereich [mm] 5.0
4.0 Messbereich [mm] 5.0
Stop 22.11.94 15.40
Schweisstemperatur
min 447 °C
max 459 °C
Schweissgeschwindigkeit
ohne Speed-Control
min 2.00 m/min
max 2.10 m/min
Fügekraft
min 1240 N
max 1292 N
Fügeweg
min 0.04 mm
max 0.45 mm
Umgebungstemperatur 10 °C
Materialdicke 2.50 mm
Nahtlänge 2.40 m
450 C 2. 05 1250 N
452 C2. 00 N
1 m
2 m
1261
Toleranzüberschreitung bei 8.10 m
Start 23.11.94 9.24
449 C 2.61 m/min 1300 N
3.1 Messbereich [mm] 4.1
Stop 23.11.94 9.30
Schweisstemperatur
min 448 °C
max 453 °C
min 1.59 m/min
max 2.61 m/min
Schweissgeschwindigkeit
ohne Speed-Control
Fügekraft
min 1275 N
max 1305 N
Fügeweg
min 0.05 mm
max 0.38 mm
Umgebungstemperatur 19 °C
Materialdicke 2.05 mm
TWINMAT
Software-Rev:
LEISTER, Switzerland
Datum:
Zeit:
Betriebs-Std.
Nahtlänge 9.10 m
P
Graphic mode Tolerance mode
PRINT OUT

DESCRIPTION OF TOOL LEISTER Twinmat (4M1)
10
Memory card
Printer
Alarm
(audible)
Language
Date/ Time
Diagnosis
S
If the welding data needs to be stored on a memory
card, before starting the welding process, the operator
should set the memory card level to ON. (See special
operating instructions for Memory Card).
The following data is stored:
– welding speed
– welding temperature
– pressure
– seam thickness reduction
– ambient temperature
– length of welding seam
If there is a deviation from the seam thickness reduction
tolerance, an audible signal is activated. This signal can be
set to ON/OFF on the alarm menu.
The welding operator has a choice of different langua-
ges. • German
• English
•French
• Italian
• Spanish
Depending on the choice, the terms are shown in the
selected language on the display. This should not be
changed during the welding process.
The welding operator can make changes to time and
date on the Date/Time menu.
(Summer/winter time, different time zones).
Adjustments are made at the factory on the Diagnosis
menu. The welding operator has no access to this menu.
S
S
S
S
12
Slacken the paper feed with the
tension lever (1).
Feed in paper (2).
Pay attention to the direction of
the arrow.
Tighten the paper feed with the
tension lever (1).

Welding preparation
•Check laying out of material: Width of overlap min. 100 mm and max.180 mm.
Geomembrane liners must be clean between the
overlap as well as above and below.
•Check: Mains supply ≥8 kW and a minimum cord cross section
• Attach carrying handle (12)
and guide rod (11).
•Connect the automatic hot air wedge welding machine to the mains
supply.
•Carry out adjustments in the systems with keys and
• As required, correct with keys and .
• Heating up: Switch on main switch (3).
Switch on hot air blower (5).
Adjust temperature via the keyboard (15) and
Switch on heating ➝ON, Motor ➝ OFF
Heating up time approx. 5 min.
Welding procedure
•Check: – Drive/pressure rollers (28) (29) as well as the hot air wedge (20)
– must be clean before beginning operation.
– Required welding temperature must be achieved.
– Cable length/cable guide.
– Paper roll for printer.
•Guide and position the automatic welding machine into the over-lapped
geomembrane liners.
• Pull the lever (10) (without engaging the hot air wedge).
• Adjust the welding pressure with the hand wheel (9).
• Feed the welding parameter into the program level with the
and keys.
Make corrections as necessary. Keys and
• Release the lever (10).
•Switch on drive motor ➝ON.
• Engage the hot air wedge (20).
•Pull the lever (10) slowly. Check the hot air wedge guide (22) and guide rod
arm (23) (see detail A page 6).
• Switch for recording.
When welding without speed control, the welding speed must be corrected
using the and keys if the seam thickness reduction deviates from
the tolerance.
•At the end of the welding operation, approx. 10 cm before removal of the
hot air wedge, the recording should be stopped. Key
•Release the lever (10), move the hot air wedge (20) out of the overlap and
swivel up.
•Switch off the drive motor using key ➝OFF.
WELDING LEISTER Twinmat
11
+
+
–
–
P
V
S
H
ß
ß
M
ON
OFF
M
t
400 V~ up to 50 m 2x1,5 mm2
from 50 m 2x2,5 mm2
230 V~ up to 50 m 2x2,5 mm2
from 50 m 2x4,0 mm2
+
+
–
–
M

BA Twinmat/ 06.2001/GB
Welding tips
•Should waves occur in the laid-out geomembrane material, the upper or lower
drive/pressure roller can be switched over alternatively. This allows wrinkle-free
welding, so that the overlap width remains constant and the welding process
should not have to be interrupted.
Rippling in the upper geomembrane liner: engage upper drive roller (29) only.
Rippling in the lower geomembrane liner: engage lower drive roller (28) only.
• With T-joints or when welding upwards, both drive rollers must be engaged.
•For welding T-joints, a reduction in welding speed of approx. 20% is recom-
mended.
The LEISTER Company and its authorized service centres offer welding courses
free of charge world wide. The customer can be trained on site if necessary.
•The ventilator grill (18) and air intake opening (19) of the tool should be
cleaned with a brush when dirty.
•Clean hot air wedge (20) with a wire brush.
•The automatic welding machine should be checked after about 1000 hours
running time by your service centre (see page 9 Print-Out).
•Repairs should only be carried out by authorized LEISTER service centres
using original spare parts. They guarantee a specialized and reliable repair
service within 24 hours.
•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 REPAIR
MAINTENANCE
TRAINING
®
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]