Leister Twinny T User manual

LEISTER Twinny T
Combination wedge automatic
hot air welding machine
Please read operating instructions carefully before use and
keep for further reference.
GB
OPERATING INSTRUCTIONS ®
• Overlap max. 125 mm / 5 inch
• Type of seam Welding seams are produced in accordance with
DVS 2225 part I and BAM. Other dimensions are possible
on request
DVS: German Welding Association
BAM: Federal Institute for Materials Research and Testing, Berlin.
The LEISTER Twinny T is a combination wedge automatic hot air welding machine
for overlap welding and manufacturing of films and geomembrane liners in
tunnels as well as in earthwork and civil engineering. The heat transmission
occurs through optimum combination of contact and hot air.
APPLICATION
Type Heating System
Civil engineering
Tunnel
construction
combination
wedge long
Type of Material Material Thickness
PE-HD, PE-C, PFA, PD, PP
PVC-P, PE-LD, ECB, EVA
0,8 – 2,0 mm
/ 32 – 80 mil
1,0 – 3,0 mm / 40 – 120 mil
tube nozzle
short
PE-HD, PE-C, PFA, PD, PP
PVC-P, PE-LD, ECB, EVA
0,3 – 1,0 mm
/ 12 – 40 mil
0,3 – 2,0 mm / 12 – 80 mil
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]

2
Danger! Unplug the tool before opening it as live com-
ponents and connections are exposed.
Incorrect use of the hot air tool can present a fire and
explosion hazard especially near combustible materials
and explosive gases.
The tool must be operated under supervision. The heat
can reach combustible materials which are out of sight.
For personal protection, we strongly recommend the
tool be connected to an RCCB (Residual Current Circuit
Breaker) before using it on construction sites.
The voltage rating stated on the tool should correspond
to the mains voltage.
Do not touch the element housing and hot wedge
when hot as they can cause burns. Allow the tool to
cool down. Do not point the hot air flow in the direction
of people or animals.
Protect the tool from damp and wet.
FI
120
230
WARNING
CAUTION
TECHNICAL DATA
APPROVAL MARKS
Voltage V~
Power consumption W
Frequency Hz
Temperature °C /°F
Welding pressure N/lbs (pound)
Drive m/min. /feet
Emission level L
pA
(dB)
Size LxBxH mm
Weight kg
Connect the tool to a socket outlet with a protective
earth conductor. Any interruption of the protective
earth conductor inside or outside the tool is dange-
rous! Use only extension cables with a protective earth
conductor!
100, 120, 200, 230 #
1600, 1900, 2200, 2300
50 / 60
max. 560 stepless
max. 1000 stepless
0,8 – 3,2 stepless
71
340 ×360 ×245
7,9 (Civil engineering below ground) / 6,9 (tunnel construction)
#mains
voltage
cannot be
switched
over
Protection class Ι

Cross sectional diagram of an overlap weld
Seam thickness reduction = A – B
A : Thickness of the upper and lower membrane
B:Thickness of the welded seam
C : Welded section 1
D: Welded section 2
E : Test channel
B
CD
A
B
E
•Welding Pressure →steplessly adjustable. The welding pressure is transmitted
via a toggle lever to the pressure rollers. The swivel head guarantees the
equalisation of the pressure to both welded sections (C and D) as well as on a
welded seam without test channel.
This allows T-joints to be welded easily. During the welding process the welding
pressure adjusts itself linearly to the change in material thickness of the
geomembrane liner.
•Drive →Double drive system, is steplessly adjustable and electronically con-
trolled. The automatic control system with tachogenerator is designed in such
a way, that the adjusted welding speed remains constant independently of
the load. The power transmission to the drive/pressure rollers works through a
three stage planetary gear.
•Heating system →The hot air temperature is steplessly adjustable and electro-
nically controlled. The heat transmission occurs with optimum combination of
all the advantages of contact hot air. The flexible combination wedge con-
tains three heating zones:
DESCRIPTION OF FUNCTIONS LEISTER Twinny T
Material plasticising
with hot air
Contact heating Pre-heating, drying
cleaning of the material
3
Combiwedge
Drive/pressure roller
Welding direction
Hot air outlet
Pinch roller
Upper geomembrane liner
Lower geomembrane liner
Guide roller
Heating system cross sectional diagram

M
Description of tool LEISTER Twinny T
1
2
4
Frontal view
Back view
1
31
2 5
4
10
16
6
9
7
3
8
28
12
13
24
29
27
23
22
21
20
19
18
11
17
30 25
26
15 14

5
Description of tool LEISTER Twinny T
WELDING PARAMETERS LEISTER Twinny T
1. Cable to mains
2. Housing for drive motor and electronics
3. Main switch
4. Keyboard
5. Display
6. Hot air blower
7. Blower switch/heating ON/OFF
8. Two-step switch for air volume
9. Locking lever
10. Drive/power transmission
11. Lever for welding pressure
12. Lever for locking mechanism
13. Adjustment screw for welding pressure
14. Locking screw
15. Adjustment screw for restraining device
16. Guide handle
17. Travelling wheel
18. Combination wedge
19. Pinch roller
20. Guide roller
21. Rear travelling wheel
22. Lower drive/pressure roller
23. Upper drive/pressure roller
24. Chain
25. Restraining bar
26. Air filter
27. Lower part of the chassis
28. Guide shaft set screw
29. Adjusting screw for swivel head
30. Guide bar
31. Cable holder
1
2
12 1415 13
– Welding Pressure
Engage and position the automatic welding machine
onto the material to be welded. Pull the lever (11)
without engaging the combination wedge.
By turning the adjusting screw (13), the drive/pressure
rollers (22/23) should lightly touch the material to be
welded. Release the locking mechanism (12) of the
lever and at the same time release the tension of the
lever (11).
Following illustration A,
rotate the adjustment
screw (13). Tighten the
locking screw (14) by
hand. As required adjust
the pressure of the pinch
roller (19) with the adjust-
ment screw for the restrai-
ning device (15).
Warning:
If the maximum welding
pressure of 1000 N is
exceeded mechanicall
damage may occur.
4
5
Illustration A
Welding pressure
Screen
max. welding pressure 1000 N
[N]
1000
900
800
700
600
500
400
300
200
100
220
202
179
157
134
112
90
67
45
23
1234561234
lb
(pound)

Heating cursor will blink on
the display
H
Welding temperature
Set the welding temperature with the , keys. The temperature is
dependent on the material and the ambient temperature. The in-put SET value
will be shown on the display. Switch the heating on by pressing the and
keys simultaneously. Heating up time approx. 5 minutes.
+–
+
–
H
+H
Drive
ON/OFF
SET value adjustment
–+
M
ON/OFF
SET value setting
–+
+
&
H
WELDING LEISTER Twinny T
6
Welding Preparation
– Laying Width of overlap 80 mm to 125 mm
Geomembrane liners must be clean between
the overlap as well as above and below.
–
Mains supply at least 4kW (generator)
supplied with an RCCB
–
Cable to mains a minimum cable cross section in accordance
with the table.
WELDING PARAMETERS LEISTER Twinny T
Welding Speed
Depending on the film or geomembrane liner and the influence of the wea-
ther, set the welding speed with the keys. The in-put SET value will be
shown on the display.
230 V~ to 50 m 3x1,5 mm2 / 3 x14 AWG
to 100 m 3x2,5mm2 / 3 x12 AWG
120 V~ to 50 m 3x1,5mm2 / 3 x14 AWG
to 100 m 3x2,5mm2 / 3 x12 AWG
Operating conditions
•Attach guide bar (30) or guide handle (16).
• Move the hot air blower (6) out and lift up until it locks.
• Connect tool to the mains.
• Start the tool with Main– or Control–Level.

WELDING LEISTER Twinny T
7
Display (2) Drive reason for fault
100 % • mains under-voltage
100 % or <• overlap of the geomembrane liner too wide
100 % or <• dirt on the drive rollers (22/23)
100 % or <• max. welding pressure (1000 N) has been exceeded.
100 % or <• high welding speed with a large sudden overload (ie
anchoring trench, T-joints....)
Display (4) Heating reason for fault after heating up time
100 % • mains under-voltage
100 % • heating element faulty
?
Main – Level
Version: Memory card
main switch (3) ON
Control – Level
+
–
& &
13
2 4
1 3
2 4
1 3 5
2 4 6
135
2 4 7 6
Memory card
Not inserted
Inserted
Autostart
No / Yes
No ?
I
→
365*
364*
On
On
Yes
No /Yes
Protocol on
No.7
(none) 0 Off Off
Off
flashing
Residual capacity
(Pos.7)
Led green Led red
<Overload Indication
*Heating / Drive active
Welding process control and
fault finding by displaying the
power consumption.
main switch (3) ON
Standard
If malfunction is still present, contact the Service Centre.
Display no. Level
Drive/heating Main Control
1. Welding speed ACTUAL value
2. Welding speed SET value Power consumption
3. Temperature ACTUAL value
4. Temperature SET value Power consumption
5. Welding pressure ACTUAL value
6. Memory card Residual capacity

8
WELDING LEISTER Twinny T
Illustration B
23
25
27
Max. frontal
width of overlap.
20 mm
0,8 inch
Welding procedure
• Check: – Drive rollers/pressure rollers (22/23) as well as the combination
wedge (18) must be clean before engaging with the geomem-
brane liner or foil.
– Mains cable length/cable guide
– Cable length/cable guide
• Guide and position the automatic welding machine into the over-lapped
geomembrane liner or film.
• Adjust welding parameters, see page 5/6.
•The welding temperature must be achieved.
• Perform a test welding according to the welding instructions of the material
manufacturer and the national stand-ards or guidelines.
• Check the test welding.
•Switch on drive motor with key on keyboard (4).
•Engage combination wedge (18).
• Pull the lever (11).
•Check the welded seam (wash/seam thickness reduction). as required,
adjust the welding speed with keys on keyboard (4).
•The automatic welding machine is guided along the overlap with the guide
bar (30) or at the guide handle (16), so that the frontal width of the overlap
is kept within the 20 mm / 0,8 inch zone (see illustration B).
Beginning of welding process
•Release tensioning lever (11). Withdraw combination wedge (18) from the
overlap and swing upwards.
•Switch off the drive motor with key on the keyboard (4).
Switch off heater with keys and on keyboard (4) (by pressing them
simultaneously).
End of welding process
M
M
+–
H+

Combination wedge short
Combination wedge long
with test
channel
with test
channel
without
test channel
without
test channel
• Application/guidelines
Depending on the material, possibly deviating
PE-HD, PE-C, PFA, PP material thickness of 0,8 – 2,0 mm / 32 – 80 mil
PVC-P, PE-LD, ECB, EVA material thickness of 1,0 – 3,0 mm / 40 – 120 mil
• Contains three heating zones: pre-heating, contact heating,
material plasticising
Through the combination of contact heat and hot air, the long
combination wedge permits very good quality of the welding
seam and high welding speed.
• Application/guidelines
Depending on the material, possibly deviating
PE-HD, PE-C, PFA, PP material thickness of 0,3 – 1,0 mm / 12 – 40 mil
PVC-P, PE-LD, ECB, EVA material thickness of 0,5 – 2,0 mm / 20 – 80 mil
•Makes welding of films from 0,3 mm / 12 mil thickness possible
• In order to prevent thin materials melting onto the contact area,
the material to be welded is carried by a hot air cushion. Thus
this has only brief contact with the combination wedge.
Work process
• Loosen four screws on the combination wedge (18).
• Install the new heating system.
• Lightly tighten screws.
• Drive combination wedge (18) between the drive/pressure rollers.
• Check: align combination wedge (18) in the pressure rollers (22/23).
• Tighten screws.
• Test–weld/check: The test channel must be in the centre of the welding seam.
• As required, adjustments can be made to the running–in depth of the heating
system with the guide shaft set screw (28), in order to run the test channel
off–centre.
• Maximum possible width of welding seam without test channel 50 mm / 2 inch
• Welding seam width, with test channel in accordance with DVS 2225 part I and
BAM
• Other dimensions possible on request.
Changeover of the heating system LEISTER Twinny T
Depending upon the materials to be welded, the heating system with a long
or short combination wedge should be employed.
9

Different overlap joints can be produced with the LEISTER Twinny T for various
applications, e.g. in tunnel construction or civil engineering. These differ in width
of the welded seam and in width of the test channel. Welding seams without
test channel can also be produced. In order to achieve these different welding
seams, the appropriate drive/pressure rollers have to be installed. These
drive/pressure rollers are manufactured either in aluminium or stainless steel
depending on customers’ requests.
Dismantling of the drive pressure rollers, in sequence Nos. 1 – 9
Assembly of the drive/pressure rollers, in reverse order Nos. 9 – 1
1. Countersunk screw M3x6
2. Guard plate for swivel head
3. Setscrew M4x8
4. Cylinder pin 6x80
5. Guard ring (shaft Ø 15)
6. Spacer
7. Drive/pressure roller
8. Woodruff key
9. Upper drive shaft complete
1 2 9 8
7
6
5
3 3 4
Changeover of upper drive/pressure roller LEISTER Twinny T
10

Changeover of lower drive/pressure roller LEISTER Twinny T
Dismantling of the drive/pressure rollers, in sequence Nos. 1 – 16
Assembly of the drive/pressure rollers, in reverse order Nos. 16 – 1
11
1. Countersunk screw M3x6
2. Cylinder screw M8x50
3. Nilos ring Ø 8/20x1,8
4. Shim Ø 8/14x0,1
5. Rear travelling wheel complete
6. Shim Ø 8/14x0,1
7. Nilos ring Ø 8/20x1,8
8. Spacer brush
9. Guard plate drive/pressure roller
10. Hexagon nut M8
11. Washer M8
12. Countersunk screw M4x12
13. Locking washer
14. Drive/pressure roller
15. Spacer Ø 15/22x0,3
16. Woodruff key 5x6,5
10
1
11
16 15 14
13
12
9
8
2
3
4
5
6
7

• LEISTER Process Technologies and their authorised Service Centres offer free
welding courses and training.
•Only LEISTER accessories should be used.
• The tool’s air filter (26) should be cleaned with a fine brush
when dirty.
• Clean combination wedge (18) with a wire brush.
• The drive and pressure roller (22/23) should be cleaned
with a wire brush.
• Treat the chain (24) with a suitable spray as required.
• Check mains cable (1) and plug for electrical and mechanical damage.
•
The tool should be checked after a maximum of approx. 1000 hours running
time by an authorised Service Centre
•Repairs have to be carried out by authorised LEISTER Service Centres only. They
guarantee a specialized and reliable repair service within 24 hours using original
LEISTER spare parts.
• 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.
Your authorized Service Centre is:
WARRANTY
SERVICE AND REPAIR
MAINTENANCE
ACCESSORIES
TRAINING
BA Twinny T/10.97/09.2007/GB
®
26
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]