Leister Uniplan Wedge User manual

1
LEISTER Uniplan Wedge
Hot wedge Automatic Welding Tool
Read the operating instructions carefully before use and
keep for future reference.
GB
OPERATING INSTRUCTIONS
LEISTER Uniplan Wedge
Hot Wedge Automatic Welding Tool
•Overlap and tape welding of coated fabric covers, foils and geomembrane
liners made from PVC-P, PE, ECB, CSPE, EPDM, PVDF etc, PE coated tape fabric
for lorries, tents, agricultural covers, building trade, biotopes, swimming pools,
marquees, boat covers, inflatable boats, advertising billboards etc.
Welding seam width 20 or 30 mm
APPLICATION
®
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]

Voltage V~
Frequency Hz
Power consumption W
Temperature °C
Noise level LpA(dB)
Drive speed m/min.
Dimensions mm
Weight kg
TECHNICAL DATA
230 ★120 ★100 ★
50 / 60 50 / 60 50 / 60
900 900 900
max. 420 max. 420 max. 420
70 70 70
1.0 – 7.5 1.0 – 7.5 1.0 – 7.0
420×270×210 420×270×210 420×270×210
11.5 11.5 11.5
★Connection voltage not switchable
CCA certified
Protection Class Ι
Approval Marks
2
Danger! Unplug the tool before opening it, as live compo-
nents and connections are exposed.
Incorrect use of hot air tools can present a fire and explo-
sion hazard, particularly in the proximity of flammable
materials and explosive gases.
The tool must be operated under supervision.
Heat can ignite flammable materials which are not in view.
For personal protection, we strongly recommend the tool
to be connected to an RCCB (Residual Current Circuit
Breaker) before using it on construction sites.
The rated voltage stated on the tool must correspond with
the mains voltage.
Danger of getting burned! Do not touch the end of the
heater tube and nozzle when they are hot. Let the tool
cool down. Do not point the hot air flow in the direction of
people or animals.
Protect the tool from damp and wet.
FI
230
120
WARNING
CAUTION
Connect tool to a receptacle with protective earth terminal.
Any disconnection of the protective conductor in or outsi-
de the tool is dangerous!
Only use extension lead with protective conductor.
Laser radiation! Do not look into the beam, Laser Class 2.

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TOOL DESCRIPTION LEISTER Uniplan Wedge
1
6
7
10
Main components
1. Housing
2. Carrying handle
3. Extra weight
4. Base plate
5. Mains cable
6. Hot wedge
7. Connection hose
8. Drive/pressure roller
9. Pinch roller
10. Drive roller
11. Steering roller
12. Lifting device
13. Display
14. Thread for fixing 22 mm tape
dereeling device
15. Holding arm
Operating components
16. Main switch
17. Keyboard
18. Lifting device lever
19. Swivel lever
20. Fixing screw
21. Adjusting screw
22. Track adjustment screw
Steering equipment
23. Guide roller lever
24. Guide roller knob
25. Guide roller
26. Guide cover
12
18
11
14
26 25 23 24
22
15
9
20
21 8
5
19
3
4
13
17
16 2
Figure 1

Hot wedge
Direction of weld
Upper membrane
Pinch roller
Lower membrane
Cross-section of hot wedge system
Drive/pressure roller
•Drive speed → continuously adjustable and electronically controlled. The
control circuit is configured such that the desired welding speed remains
constant during any voltage fluctuations. The drive/pressure roller (8) is
configured as a pendulum roller.
•Welding pressure → the welding pressure is brought to bear on the material
by means of the machine’s weight and the extra weight (3) via the
drive/pressure roller (8).
•Heating system → the hot wedge temperature is continuously adjustable and
electronically controlled. Depending on the material, the hot wedge position
can be sent to any required horizontal position.
FUNCTION DESCRIPTION LEISTER Uniplan Wedge
4
Figure 2
Heater Cursor flashes
on display
H
Welding temperature
Adjust the welding temperature using the keys, , . The temperature
setting depends on the material and ambient temperature. The SET value is
shown on the display.
Press keys and simultaneously to switch heater on.
Heating up time is appr. 5 minutes.
+
–
H
+
H
ON/OFF
SET - value adjustment
–+
+
&
H
WELDING PARAMETERS LEISTER Uniplan Wedge

Drive
ON/OFF
SET - value adjustment
–+
M
WELDING– PARAMETERS LEISTER Uniplan Wedge
Welding speed
Adjust welding speed using keys, , , depending on the material to be
welded and the ambient temperature.
The SET value is shown on display (13).
+–
Hot wedge welding position
•Depending on the material thickness, pre-adjust the position of the hot wedge
(6) in relation to the drive/pressure roller (8) in accordance with Fig 2, Page 4.
•Procedure
– Loosen fixing screw (20)
– Using adjusting screw (21), adjust the position of the hot wedge in relation to
the drive/pressure roller. (One complete turn = 1.25 mm)
– Push holding arm (15) up to the stop in the direction of the hot wedge.
– Tighten fixing screw (20).
-Tracking correction of the drive/pressure roller
•Tracking control should be carried out using the track
adjustment screw (22), see functional directions on the
lifting device (12).
•Carry out test run.
21
20
15
5
12
22

Display 2 Drive
100 % • Reduced mains voltage
100 % • High welding speed with heavy torque loading
Display 4 Heating after warm up time
100 % • Reduced mains voltage
100 % • Heating cartridge fault (Contact Service Centre)
Control level Display/cause
WELDING LEISTER Uniplan Wedge
6
Main level (SET & ACTUAL value)
Main switch (3) ON
Control level (ACTUAL value and power requirement)
+
–
& &
1 3
4
Heating active
Control of the welding process by means of the power requirement display
(main level or control level)
Display Drive/Heating
Number Main level Control level
1Speed ACTUAL value ACTUAL value
2Speed SET value % power
3Temperature ACTUAL value ACTUAL value
4 Temperature SET value % power
Main switch (3) ON
*
Heating/drive active
*
2
13
24

Fig. A
Führungsrolle deaktiv
19
68
Fig. B
24 25 23
Fig. C
12
18
Fig. D
9
Fig. E
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WELDING LEISTER Uniplan Wedge
Weld preparation
•Spread the weld material on a clean and level surface.
•The material to be welded must be dry and clean between the overlaps.
•The overlap width should be set as follows:
– Heating wedge 20 mm = overlap width 23 mm
– Heating wedge 30 mm = overlap width 31 mm
•The material must be stretched out tightly and fixed.
Preparing for use
•Hook extra weight (3) onto base plate (4).
•Swing hot wedge (6) upwards using swivel lever (19) and engage, (Fig. A).
•Set guide roller (25) to position "Inaktiv" (inactive) by means of guide roller
knob (24) and guide roller lever (23), (Fig. B).
•Operate lifting device (12) by means of lifting device lever (18) so that
drive/pressure roller (8) and drive roller (10) are at no-load, (Fig. C).
•Raise pinch roller (9), (Fig. D).
•Drive/pressure roller (8) should be positioned parallel to the edge of guide
roller (25). See Page 5 for drive/pressure roller (8) track correction.
•Connect tool to mains. Mains voltage must correspond with tool voltage.
•Switch tool on using main switch (16).
•The upper and lower surfaces of the hot wedge (6)
must be cleaned after each weld run, using a fine
brass wire brush (Fig. E)
6

OPERATION LEISTER Uniplan Wedge
8
Tool positioning
•Place automatic welder onto the overlap of material to be welded.
•Guide cover (26) or laser guide (optional extra) should be lined up with over-
lap edge of the material to be welded (Fig. E).
•Drive/pressure roller (8) should protrude over overlap edge of the material to
be welded by about 2 mm (Fig. E).
•If welding takes place with guide roller (25) in position, then set guide roller
lever (23) to "aktiv" (active) and engage (Fig. F).
•Operate lifting device (12) by means of lifting device lever (18) so that the
automatic welder is ready to move (Fig. G).
Fig. E
8
26
25
Fig. F
23 24
Fig. G
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18

Welding process
•Set welding parameters, see Pages 4 and 5.
• Allow welding temperature to be reached, Display 3, see Page 6.
•Position hot wedge (6) using swivel lever (19) between the materials to be wel-
ded (Fig. H).
The welding process will start automatically via automatic drive.
•Carry out test weld in accordance with the material manufacturer's welding
instructions and national guidelines or regulations.
•Check welding process. If necessary, correct welding parameters, see Pages
4 and 5.
•After weld run, swing hot wedge (6) out and up to the stop using swivel lever
(19), raise up and engage (Fig. A).
The welding process will stop automatically.
•Operate the lifting device (12) by means of lifting device lever (18) so that
drive/pressure roller (8) and drive roller (10) are at no-load (Fig. C).
• The upper and lower surfaces of the hot wedge (6) must be cleaned after
each weld run, using a fine brass wire brush (Fig. E).
•Switch off tool at main switch (16).
•Disconnect tool from mains.
Fig. H
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WELDING LEISTER Uniplan Wedge
Fig. A
19
6
9
Fig. E
Fig. C
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18

DROUBLE SHOOTING LEISTER Uniplan Wedge
Problem Possible cause Solution
Poor weld strength Wedge temperature too low. Adjust temperature to requi-
red welding temperature
and/or reduce speed.
Hot wedge (6) too far from Move wedge closer to
drive/pressure roller (8).drive/pressure roller (8) using
adjusting screw (21).
Faults at regular intervals Drive/pressure roller (8) Allow tool to travel several
along welded seam out of true having been left meters using motor switch;
in standing position. always lift tool onto lifting
device (12) after weld runs.
Lower membrane ripples Membrane tension too low. Increase membrane (material)
tension.
Hot wedge (6) too close to Remove hot wedge (6) some-
drive/pressure roller (8). what further from drive/
pressure roller (8) using
adjusting screw (21).
Pinch roller (9) may be stiff. Contact authorised Service
Centre.
Edge of weld outside the Incorrect overlap widht Hot wedge / overlap width
seam on the under side of selected. 20mm / 23mm
the upper 30mm / 31mm
The machine tends to the left Connection lead is not Connection lead must run
or right of direction of travel running directly behind tool.
freely behind tool avoiding
The cable may be rubbing rubbing points.
against table edge.
The adjustment between Check adjustment between
guide cover (26) and guide guide cover (26) and guide
roller (25) has shifted. roller (25) using ruler, re-align
guide cover (26) if necessery.
Adjusting screws on See Page 5 for drive/pressure
drive/pressure roller (8) are roller (8) track correction or
out of adjustment. contact authorised Service
Centre.
10
Power control: heater/drive
Control of the welding process and fault recognition by means of power
requirement display (see Page 6).

Accessories
• Fine brass wire brush Article No. 116.798
Optional extras
•Laser guide Article No. 116.506
•22 mm tape dereeling device Article No. 116.231
•Large base weight, 3.5 kg Article No. 116.800
•Replacement hot wedge, 20 mm Article No. 116.161
•Replacement hot wedge, 30 mm Article No. 116.162
Only LEISTER accessories may be used
ACCESSORIES LEISTER Uniplan Wedge
11

• LEISTER Process Technologies and its authorised Service Centres offer welding
and induction courses.
• Check mains cable (5) and plug for any electrical
or mechanical damage.
• Clean hot wedge (6) with fine brass wire brush.
• Check guide roller (25) for stiffness.
• Lubricate slide on holding arm (15) (see Fig.).
• The tool must be checked at an authorised Service Centre if "maintenance;
servicing" appears on Display (13)
• Repairs should only be carried out by authorised LEISTER Service Centres.
These assure, within 24 hours, a correct and reliable repair service using
original replacements in accordance with the circuit diagrams and spare
parts lists.
• Guarantee and liability are in accordance with the Guarantee Certificate as
well as the prevailing general Business and Delivery conditions.
• LEISTER Process Technologies rejects any guarantee for tools which are not
in their original condition. Under no circumstances should LEISTER tools be
converted or modified.
Technical data and specifications are subject to change without prior notice.
Your authorised Service Centre is:
GUARANTEE AND LIABILITY
SERVICE AND REPAIR
MAINTENANCE
TRAINING
BA UNIPLAN Wedge /12.03
LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland
Tel. [phone] Fax [phone] www.leister.com [email protected]
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Shifting gate
15
®