Leister VARIMAT V2 User manual

VARIMAT V2
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[e-mail]
®
USA
GB

2
Congratulations on purchasing a VARIMAT V2 kit!
You have chosen a top-class hot-air tool kit made of high-quality materials. Every VARIMAT V2T kit undergoes strin-
gent quality checks before leaving the factory in Switzerland.
Table of Contents
Quick Info Page 2
Application, Maintenance, Caution Page 3
Conformity, Disposal, Technical Data Page 4
Device Description, Controls Page 5
Joining Force, Operational Availability, Sensor Setting Page 6
Sensor Setting Page 8
Work Mode (Chapter 3) 3.1 Setpoint Value Display
3.2 Work Display Page 9
3.3 Setting the Drive Speed
3.4 Setting the Welding Temperature Page 10
3.5 Setting the Air Volume
3,6 Length Measurement Page 11
3.7 Selecting Profiles
3.8 Cooling Down Page 12
3.9 Standby
3.10 Error Messages Page 13
Profile Setup (Chapter 4) 4.1 Creating Profiles
4.2 Standby Setup Page 14
Percent Mode (Chapter 5) 5.1 Creating Profiles Page 14
Accessories, Training, Maintenance, Service and Repair, Warranty Page 15
Quick Info
How do I start the hot-air welding machine VARIMAT V2 ?
1. Establish power supply cord to the electrical mains
2. Main switch (3) ON
3. Press Drive key Turn e-Drive
4. Press Heating key 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. Check test weld.
7. Welding
How do I switch off the hot-air welding machine VARIMAT V2 ?
1. Press e-Drive
2. Press «Cool down OK» e-Drive and allow to cool approx. 5 minutes
3. After welding nozzle (9) has cooled down, main switch (3) OFF

3
Leister VARIMAT V2
Hot-Air welding machine
• Overlap welding of roof sheeting made from 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
Application
Operating Instructions (Translation of the original operating instructions)
GB
Please read operating instructions carefully before use
and keep for future reference.
Danger to life if you open the equipment, since this reveals current-conducting
components and connections.
Remove the mains plug from the plug socket before opening the equipment.
Incorrect use of the hot air tool can present a fire and explosion hazard
especially near combustable materials and explosive gases.
Do not touch the element housing and nozzle when hot as they can cause burns.
Allow the tool to cool down. Do not point the hot air flow at people or animals.
Warning
Connect tool to a receptacle with protective earth terminal. Any interruption of
the protective conductor inside or outside the tool is dangerous!
Use only extension cables/cords with protective conductor!
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, we strongly recommend the tool be connected to an
RCCB (Residual Current Circuit Breaker) before using it on construction sites.
The mains voltage, that is quoted on the equipment must agree with the mains
voltage.
Move out hot-air blower upon mains failure.
Protect the tool from damp and wet.
FI
230
400
Caution
The equipment must not be lifted using the additional weight.
USA

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Leister Process Technologies, Galileo-Strasse 10, CH-6056 Kaegiswil/Switzerland confirms that this product,
in the version as brought into circulation through us, fulfils the requirements of the following EC directives.
Directives
: 98/37, 89/336, 73/23
Harmonised standards: EN 292-1, EN 292-2, EN 60204-1, EN 55014-1, EN 55014-2,
EN 61000-3-2, EN 61000-3-3, EN 50366, EN 60335-2-45
Kaegiswil, 28.08.2009
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/ 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, 400 V~ 230, 400 
Power consumption W 4600, 5700 W4600, 5700
Frequency Hz 50 / 60 Hz 50 / 60
Temperature °C 20 – 620 stepless °F 212 – 1148 stepless
Drive m/min. 0,7 – 12 stepless ft/min 2.3 – 39.4 stepless
Welding pressure N ca.190 (2 weights) Nca.190 (2 weights)
Air flow % 50 – 100 %50 – 100
Emission level LpA (dB) 68 LpA (dB) 68
Weight kg 35 lbs 77
without power supply cord
Dimensions L×W×Hmm 650 × 430 × 330 inch 25 × 17 × 13
Mark of conformity 2
Approval mark 3
Certification scheme CCA
Protection class I 1
Technical data and specifications are subject to change without prior notice.
 Mains voltage cannot be switched over

5
Description of tools
1. Power supply cord
2. Housing
3. Main switch
4. Controls
5. Display
6. Sensor
7. Locking screw
8. Hot air blower
9. Welding nozzle
10. Tool holder
11. Locking lever
12. Pendulum action 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
15
11
17
29
9
8
12
14
18
19
20
21
22
23
24
25
26
27 28
31
33
25. Fillister head screw
26. Lower guide bar
27. Upper guide bar
28. Clamping lever guide bar
heigh adujstable
29. Holder for power supply cord
30. Round belt
31. Clamping lever guide bar
32. Sensor covering
33. Wire brush
34. Welding plate
Controls (4)
Main switch (3)
For switching the 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 diverse menus or values
Press to confirm or to activate
34

Automatic starter reason for fault
• Drive motor does not start automatically after the nozzle has been positioned
–Sensor (6) set incorrectl
Allow the welding nozzle (8) to cool.
Action adjust Sensor
•Sensor (6) adjustment:
–
Switch off main switch (3)
– Remove sensor covering (32)
– Lower the hot air blower (8) and guide it to the left until it locks
– Locking lever (11) must click in
– Loosen locking screw for sensor (7)
– Push sensor (6) to tool holder (10). IMPORTANT ! Distance between tool holder and sensor > 0,2 – 0,5mm max.
– Tighten locking screw for sensor (7)
– Fix sensor covering (32)
– Move the hot air blower (8) out until it locks and swivel up
– Make a functional test
•If malfunction is still present, contact your Service Center.
6
Operating condition
Welding pressure
• Before putting into operation, check power supply cord (1) and connector as well as
extensive cable for electrical and mechanical damage.
• Move guide bar (26/27) to required position using the clamping lever (28/31).
• Hang strain relief of
power supply cord (1) in holder (29).
• Check the basic setting of the welding nozzle (9).
(ex works illustration A 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 B).
– Position the hot air blower (8) by pulling the
locking lever (11) and swivel it up until it locks.
• Connect VARIMAT V2 to the electrical mains. The mains voltage must correspond to the device voltage.
Illustration B
Illustration A
Illustration C
1 – 2 mm
40 – 50 mm
18 16
12
9
2
22
19
120N 155N 190N
Illustration H 22
12
• The welding pressure is transmitted to the pendulum action roller (12).
• As necessary, the additional weights (22) and the end weight (23) can
be put on (see illustration H).
2.5 mm
Sensor Setting
32 7 11 106
3 3

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Perform a test welding according to the welding instructions of the material manufacturer and the
national standards or guidelines. Check the test welding.
• Set welding parameters (drive, heating and blower), see Chapter 3 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 between the overlapping sheets as far as the
limit stop. Drive motor starts automatically.
No automatic start, see Sensor (6) Setting.
Machine can be started manually with the controls (4) Drive and e-Drive .
• The welding machine is guided along the overlap at the guide bar (27). No pressure on guide bar (27), this
could lead to welding problems. 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, switch off heating with e-Drive (press 2 x).
This allows the welding nozzle (8) to cool down.
• After the welding nozzle (8) has cooled down, the blower switches off automatically after approx. 4 minutes.
• Turn off main switch (3) .
• Clean welding nozzle (8) with wire brush (33).
Tool positioning
• Lift hot-air welding machine with pressure onto guide bar (27) and move to weld position.
Take welding plate (34) from holder and position according to Illustration H.
WARNING: The welding plate (34) may only be removed from the holder and positioned if the wel-
ding 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 action roller (12) (see illustration E).
• Do a test run
• To correct the tracking , adjust the adjustment screw for tracking (13) (see illustration F and G, and the function
notes on the automatic welding machine).
Illustration E
12 12
18
Illustration F Illustration G
13
Welding Workflow
12 13
Illustration H
34
34

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Startup Combination
Main switch ON
Keys Drive and Heating buttons pressed down
at the same time and the main switch ON
Work mode
Chapter 3
Profile setup
Chapter 4
Keys Heating and Blower buttons pressed
down at the same time and the main switch ON
Percent mode
Chapter 5

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3. Work Mode
3.1 Setpoint Value Display (after switching on the device)
Main switch (3) ON
• After switching on the device, the Overview (Fig. 1) appears on the display (5).
• If <80°C appears on the display (5), the welding nozzle (9) will have cooled down.
• The heating 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.
• However, if the heating element temperature is greater than 80°C when switching on,
the display will immediately change to Cool Down mode (Chapter 3.8 Cooling Down) in
which the blower is always operated at full power and hence the welding nozzle (8) is
cooled down.
• It is possible to change back to Work mode from this mode at any time, however.
• If the heating element temperature reaches 60°C, the blower will continue to operate
for about 2 min. and then switch off automatically again. The display (5) changes back
to the setpoint value display (Fig. 1).
• Pressing the e-Drive starts the heating and blower (if they are still switched off) and
the display changes to a mode described in Chapter 3.2 Work Display (Fig. 2).
• In addition, turning the e-Drive to Profile allows the carious welding profiles to be
selected (Chapter 3.7 Selecting Profiles, Fig. 3).
(Fig. 1)
( Fig. 2)
(Abb. 3)
3.2 Work Display
• The heating and blower are active in Work mode.
• The drive starts after the wedge has been moved into the welding
position or if the drive is manually switched on via the Drive menu
(Chapter 3.3 Setting the Drive Speed).
• If no button is pressed for a definite period of time (welding
nozzle (9) NOT in welding position), the Standby menu
(Chapter 3.9 Standby) will be called up.
• If the mains voltage is outside (-13% / +15%) the specified nominal
voltage (230V or 400V), this is displayed with the symbol
and the measured undervoltage /overvoltage.
• The VARIMAT V2 continues the work.
• Depending on the undervoltage/overvoltage, the welding result can
be affected.
If the blower power is less than 100%, the set blower power
changes with the symbol.
• If the welding nozzle (9) is heating up, this is displayed on the display with the progress bar, arrow (up) and
actual value of the temperature (flashing).
• If the welding down (9) is cooling down, this is shown on the display with full progress bar, arrow (down)
and flashing actual value of the temperature.
• If the welding nozzle is not swivelled in, the menu Cool Down (Chapter 3.8 Cooling Down) and Profiles
(Chapter 3.7 Selecting Profiles) can be selected via the e-Drive controls (4). If the welding nozzle (9) is
swivelled in, the two menu items disappear and can therefore no longer be selected.

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3. Work Mode
3.3 Setting the Drive Speed
•
The Drive key can be used to adjust the welding speed or the drive speed. This can be
set by turning the e-Drive in 0.1m/min. increments from 0.7m/min. – 12.0m/min. This
setting can be carried out with the drive switched on or switched 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 and the symbol will
appear. The speed can be set by turning the e-Drive .
• Pressing the e-Drive again executes the Stop command, which switches off the drive. The Setpoint
Value 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 Value display or Cool Down appears on the display (5).
• If the Drive key is pressed for 3 seconds, the display will change to another menu (see Chapter 3.6
Length Measurement, Service / Blower and Drive Counter). You can change to the relevant menu from
this menu by pressing the Heating key or Blower key .
Stop
3.4 Setting the Welding Temperature
• The heating temperature can be changed with the Heating key . The temperature
can be set in 10°C increments from 100°C – 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.
• The Cool Down menu (Chapter 3.8 Cooling Down) can also be selected here.
• Pressing the Heating key for 3 seconds changes the display (5) to Work mode. The
mains voltage appears below the drive speed. This call is only possible from the Work
display Chapter 3.2. A call from the Setpoint Value display or from the Cool Down
display is not possible.
• In case of a set temperature of 500°C and higher, the blower power is automatically
adjusted, if necessary. The adjustment only occurs if the set blower power is higher than
the suggested value. This adjustment is necessary in order to be able to reach higher
temperatures (> 500°C). However, the user can adjust the blower power to any value via
the Blower key (see Chapter 3.5, Setting the Blower Power).
You can change to the relevant menu from this menu by pressing the Drive key or
Blower key .

11
3. Work Mode
3.5 Setting the Air Volume
• Work mode allows the power of the blower to be changed using the Blower key .
The blower power can be set in 5% increments from 50% – 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 blower power is set to 100%, no display will appear on the
displays (5).
• If the blower power is automatically reduced when setting the air temperature, the
blower power can be increased manually by turning the e-Drive . If the set blower
power is higher than the suggested value, a star will appear next to the
number. In this case, 100%* will also be shown on the display (5).
• The Cool Down menu can be selected by pressing the e-Drive (Chapter 3.8, Cooling Down).
• You can change to the relevant menu using the Drive key or Heating key .
3.6 Length Measurement, Service / Blower and Drive Counter
• This menu (Fig. 4) appears if the Drive key 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. If the value rises above 9999 m, the value
is increased by 1 in the Service menu under «View Error» at «Length» and the total
distance begins again at 0000 m.
• 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. For this, the time
«Blow» (here: 0034:58) is assigned to the blower and drive «Drive» (here: 0020:10). This begins to count as
soon as the relevant component is switched on. The «Total« times refers to the operating time of the device
and counts as soon as the device is switched on via the main switch.
The values are displayed in hours and minutes.
• If the Back arrow is selected by pressing the e-Drive , you will be taken back to the menu
from which the Drive key has been pressed.
(Abb. 4)

12
3.7 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 (see Chapter 4 Profile Setup). All other profiles
have permanently assigned values and cannot be defined by the user.
• Turning the e-Drive activates left or right arrows on the displays (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. Check the test welding.
3. Work Mode
3.8 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 process.
•
The instantaneous temperature is displayed during the cooling process. If the temperature
falls below 60 °C, the blower will continue for a further 2 minutes and automatically shut off
after this time has passed.
• 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 «Cool» menu has been selected.
•
If the Cool Down is active, the drive can be switched on/off
manually via the Drive key .
The Heating key and Blower key do not have any function.

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3.9 Standby
• If the welding nozzle (9) is not in the welding position and no key entry is made
during a certain time, the standby process will start automatically after the standby
time has passed (5 – 120 min., see Chapter 4.2 Standby Setup) A time of 40 minutes
is set ex works. A symbol and a counter (counts down from 180 seconds) appears on
the display (5). During this time, the heating is switched on.
• If the time has expired without the controls (4) having been pressed, the display (5)
will automatically change to Cool Down mode (Chapter 3.8, Cooling Down).
• If the e-Drive is pressed before the countdown has finished, the display will change back to the initial
state.
3. Work Mode
3.10 Error Messages
•
If a malfunction occurs in the hot-air welding
machine VARIMAT V2, a message 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.
• 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 (mains voltage -25%)

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4.1 Creating Profiles
• In the Profile Setup, 3 individual profiles can be created in which
all three parameters can be freely set and then saved.
• 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. Check the test welding.
4. Profile Setup (see Startup Combination)
4.2 Standby Setup
• The standby time can be set in this setup.
Turning the e-Drive allows the time to be set from 5 – 120 minutes.
Pressing the e-Drive will take you back to the Profile Setup selection.
5.1 Creating Profiles
• If the Percent mode is selected (see Startup Combination), the
Percent mode becomes active after confirming by pressing
the e-Drive .
• Pressing the e-Drive again will start the heating and blower.
The reference value of the control circuit (in %) for the heating
and drive in Work mode becomes visible.
• The mains voltage is also indicated for the user. In this way, the
user can estimate what kind of load the controller (heating / drive) is subject to.
5. Percent Mode (see Startup Combination)

15
• Only Leister accessories should be used.
• Wire brush article no. 138.817
• Welding plate article no. 132.429
•
Leister Process Technologies and its authorised Service Centres offer free welding courses and training.
• The air inlet on the hot-air blower (8) must be cleaned with a brush if soiled.
• Clean welding nozzle (9) with wire brush.
• Check power supply cord (1) and plug for electrical and mechanical damage.
• If the drive counter reaches 400 h or the blower counter reaches 2000 h, the message «Maintenance servi-
cing» 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 accor-
dance with the circuit diagrams and spare parts lists.
• 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.
Warranty
Accessories
Training
Service and Repair
Maintenance

®
Your authorised Service Centre is:
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[e-mail]
© Copyright by Leister
ENG / BA VARIMAT V2 / 08.2009 Art. 139.550