Leister WELDPLAST S2 User manual

WELDPLAST
S2
S2-PVC
S2-TPO
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel. [phone]
Fax [phone]
www.leister.com
[e-mail]
®
GB
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2
Leister WELDPLAST S2 / S2-PVC / S2-TPO
Hand extruder
Extrusion welding of the following materials:
WELDPLAST S2 PP / PE-HD / PE-LD
WELDPLAST S2-PVC PP / PE-HD / PE-LD / PVC-U
WELDPLAST S2-TPO PP / PE-HD / PE-LD / TPO
Other materials on enquiry
The welding seam shape of the hand extruder does correspond to norm DVS 2207–4.
DVS: Deutscher Verband für Schweisstechnik
Application
Please read operating instructions carefully before
use and keep for further reference.
Operating instructions
GB
Danger to life!
Danger to life when opening up the tool, as live components and
connections are exposed. Before opening the tool, unplug from the
mains supply. Electrically conducting material (e.g. PE-EL) must not
be welded.
Fire and explosion hazard with incorrect use of the hand extruder
(e.g. overheating of the material), especially near combustible
materials and explosive gases.
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 on building sites we strongly recommend
the tool to be connected to a RCCB (Residual Current Circuit
Breaker).
The voltage rating stated on the name plate of the tool must
correspond to the mains voltage.
In case of a power outage, the main switch and the drive must be
switched off (loosen lock).
Danger of getting burned! Do not touch exposed metal parts
and escaping plastizised material. Do not point the hot air flow
and escaping plastizised material in the direction of people or
animals.
Protect tool from dampness and wet.
FI
120
230
Warning
Caution
Connect the tool to a mains socket with protective earth.
Every interruption of the protective earth inside or outside of the
tool is dangerous!
Only use extension cables with protective earth!
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3
Technical data
Voltage V~ 230
power consumption W 3000
Frequency Hz 50/60
Air flow (20°C) l/min ca. 270
Air temperature °C max. 350
Plastifizer temperature °C max. 260
Welding output (Ø 3 mm) kg/h PE 0.6 –1.3 PP 0.5 –1.2 *PVC-U 0.9 – 1.7 (Average values at 50 Hz)
Welding output (Ø 4 mm) kg/h PE 1.0 – 2.3 PP 0.9 – 2.0 *PVC-U 1.5 – 2.7 (Average values at 50 Hz)
Welding rod mm Ø 3 / Ø 4
Size L ×B ×Hmm450 ×98 ×260 (without welding shoe)
Weight kg 5.8 (without cable to mains)
Marking of conformity 2
Approval mark 3
Certification scheme CCA
Protection class I 1
* WELDPLAST S2-PVC
Leister Process Technologies, Galileo-Strasse 10, CH-6056 Kaegiswi/Switzerland confirms
that this
product, in the version as brought into circulation through us, fulfils the requirements
of the following EC directives. Directives: 2004/108, 2006/95.
Harmonized Standards: EN 55014-1, EN 55014-2, EN 61000-3-2, EN 61000-3-3, EN 61000-6-2,
EN 50366, EN 60335-2-45
Kaegiswil, 06.02.2009
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

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Description of tool
1 Main switch
2 On/off switch drive
3 Potentiometer
4 Drive locking device
5 Display
6 Handle
7 Jacket heating
8 Welding shoe
17 Welding program
18 Actual value plast
19 Set value plast
20 Actual value air
21 Set value air
22 Bar display for drive
23 Welding output display
24 Menu key
25 Back key
26 Stand-by/Enter key
27 Down key
28 Select key
29 Up key
30 Status display for drive
31 Cursor
9 Pre-heating nozzle
10 Tube clamp
11 Protective tube
12 Welding rod opening
13 Tool handle
14 Mains cable
15 Heating element
16 Hot air blower (brush-free)
44 External hot air duct
24
27 28 29
30
31
17
18
19
20
21
22
23
25 26
Multifunctional display
With integrated air ductWith external air duct
1
12
16
8
10
3
2
4
13
57
14
11 9 6
15
9
44

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Operating
Working environment / safety
When interrupting the welding, the drive is to be
switched off with the drive on/off switch (2).
With the handle properly adjusted and firmly tightened,
place down the manual extruder on a stable and
fire-proof surface as shown in the figure.
The hand extruder must not be used in inflammable environments or where
explosion hazards exist. Ensure stable positioning during operation. The
connection cable and the welding rod must remain unimpeded and must not
hinder the user or others during operation.
Rest the hand extruder on a fireproof surface! Hot metal parts and the hot-air jet
must have sufficient clearance from the surface and walls.
Handle Adjustment
1. Loosen the clamping by turning the handle (6) in
counterclockwise direction.
2. Adjust handle (6) to the requested working position.
3. Tighten handle clamping again by turning handle (6)
in clockwise direction.
Workplace
For starting operation of and placing down the hand
extruder, Leister offers a universal device stand.
1
2
3

6
Operating
Power supply
When using an extension cable, take care to ensure the minimal cable cross-section:
Extension cables must be approved for the working environment (e.g. outdoors) and labelled
accordingly.
If a generator is used to supply electricity, the rated power of the generator must be 2x the
rated power of the hand extruder.
Length
[m]
Minimum cross-section (at ~230V) [mm2]
Up to 19 2.5
20 – 50 4.0
After switching on the main switch (1), the device directly heats up to the last adjusted set
values. When the set values are reached, a counter in the status indication counts back from
220 seconds to zero. Once this starting procedure has elapsed, the device is ready for welding
(status: Ready*). The operating temperature of the manual extruder is reached after approx.
5 minutes.
After a short-term mains break, the starting procedure is not repeated.
motor disabled
WARM-UP LOCK TIME: 220 SEK.
Heat FREE M READY *
Display
Status display
for drive (30)
Heating until target
value is reached
motor release ready to weld
Starting procedure
Temperature monitoring prevents the hand extruder starting up in a cold state.

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Operating window functions
Menu selection
Set contrast
Heating on/off
Change cursor position
Selected parameter [+]
Selected parameter [–]
Operating
• Operating window
• Menu selection Menu selection functions
Menu selection / return to operating window
B ack to multifunctional display (Changed entry is not stored!)
Select and return to operating window
Select
Cursor up / selected parameter +
Cursor down / selected parameter –
Software and menu navigation
The Weldplast S2 manual extruder comes with comfortable and convenient operator software,
allowing for easy operation.
Key functions
The keys respond with gentle keystrokes.
Preparation for welding
Start window
After switching on the extruder, the name
of the tool and the current software version
are displayed for 3 sec.
Operating window
The operating window shows the parame-
ters currently set.
24
27 28 29
30
31
17
18
19
20
21
22
23
25 26

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Adjusting the Output Capacity
Due to the seam form, the output capacity and the pre-heating period can be matched to
each other.
• Pre-adjustment at the display
– By pressing the select key (28), set the cursor to the «SPEED» position.
– Specify the maximum output value (30 to 100) via the up key (29) or down key (27)
(indication via the bar display for drive (22).
• Fine-adjustment during the welding procedure
– By turning the potentiometer (3), the output capacity of the maximal set output value
(e.g. 85) can be reduced to the minimum.
The output capacity depends on the thickness of the welding wire. If the welding output is too
high with the output display “30” and the potentiometer is set to “minimum”, the next smallest
welding rod thickness must be selected.
Operating
Setting parameters in the operating window
The cursor (31) shows which parameters can be set. After switching on, the cursor is on
the «SPEED» position.
In the operating window, the following parameters can be selected with the Select key (28)
and changed in their values with the Up key (29) and Down key (27).
3
22
Example
Set value Set value Set value

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Setting the PLAST and AIR temperatures
• Set the cursor to the «PLAST» or «AIR» position by pressing the Select key (28).
• Set the temperature value with the Up (29) or Down (27) keys.
Monitoring the welding parameters
The set and actual values of the AIR and PLAST tempe-
ratures are continuously monitored. If the actual value
deviates from the respective set value (value outside the
tolerance band), this is indicated on the status display
(30) with a status change. If necessary, the drive motor is
temporarily disabled until the welding parameters are
once again within the prescribed tolerance band. The
possible status displays and the tolerance bands may be
seen in the following graph and table.
Operating
No. Status display Status properties
1Ready* Ready to weld
2M enabled Deviation of the welding parameters > 10°C
3Heat
Deviation of the welding parameters > -30°C, drive motor disabled
4220s Warm-up lock time of 220 sec., drive motor disabled
5Too hot
Deviation of the welding parameters > +30°C, drive motor disabled
30
Temperature display
Reference value
Actual value
Displayed state
Time
Motor enabled
Motor enab.
Motor enabled

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Starting the welding process
• Fit the appropriate welding shoe (8) as required.
• Set the potentiometer (3) to max.
• Once the operating temperature is reached («READY*» status), welding can begin.
• Actuate the drive on/off switch (2).
• Insert a 3 or 4 mm welding rod into the welding-rod intake (12).
• The welding rod is automatically drawn in through the welding-rod intake (12). The welding
rod feed must take place without resistance.
• Interrupt drive by releasing the drive on/off switch (2).
• Direct the pre-heating nozzle (9) towards the welding zone.
• Pre-heat the welding zone with a fanning motion.
• Apply the device to the prepared welding location and actuate the drive on/off switch (2)
again.
• Perform test welding by following the welding instructions from the material manufacturers
and national standards or directives.
• Inspect test welding.
• Adjust the temperature setting and welding output as required.
• For long welding jobs, the drive on/off switch (2) can be locked-on with the drive locking
device (4).
WELDPLAST S2 PVC
• PVC-U may only be processed in the PVC-U menu.
• WARNING: Use only PVC-U, not PVC-C.
• To prevent corrosion, if the machine is not going to be used for a longer period of time
(more than 2 days) it is recommended to fill it with HD-PE.
Switching off the tool
• Disengage the drive locking device (4) and release the drive on/off switch (2). Remove
the welding material in the welding shoe so that the welding shoe will not be damaged
when starting the next welding run.
• Switch off the heating systems with the Stand-by/Enter button (26).
• Allow the device to cool down for approx 5 minutes.
• Switch off the main switch (1).
Operating
CAUTION!
Never insert welding rods into both welding-rod intakes at the same time.
Always operate the device with welding rod.

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Activate key lock
1. Menu
2. Key lock
3. Activate
If the key lock has been activated,
key lock appears in the display.
The lock can be reset as follows:
Deactivate key lock
1. Back
2. Reset
3. Select
Confirmation with the Select key must
immediately follow the reset!
Operating
Further settings
Contrast setting
Given unfavourable lighting conditions and fluctuations in the ambient temperature, the contrast
on the display can be set in the operating window with the back key (25).
Heating on/off
In the case of long interruptions (standby), the heating for PLAST and AIR can be deactivated
with the Stand-by/Enter key (26) in the operating window.
Key lock
activated

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Operating
Menu
Menu
Scroll
Select
Functions
Scroll
Select and
return
Return to
operating
window
Scroll
Menu navigation
Program: the display of the materials may vary according
to the machine and software versions.

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Operating
Menu
Select program
Scroll
Enter
Welding parameters – Programming
For the hand extruders WELDPLAST S2 the following thermoplastics are suitable:
• WELDPLAST S2 = PP/ PE-HD/ PE-LD,
• WELDPLAST S2-PVC = PVC-U/ PP/ PE-HD/ PE-LD
• WELDPLAST S2-TPO = TPO/ PP/ PE-HD/ PE-LD
Programs 1 – 3 include the relevant preset values, which can be adjusted during the course of
the welding process.
The adjustments are not saved!
The free settings 1 - 4 are factory set and can be freely programmed. The parameters remain
saved after the tool is switched off.
Setting the welding output
• Place the cursor on the «SPEED» position by pressing the Select key (28).
• Set the welding output value (30 to 100) with the Up key (29) or Down key (27).
Setting the PLAST and AIR temperature
• Place the cursor on the «PLAST» or «AIR» position by pressing the Select key (28).
• Set temperature value with the Up key (29) or Down key (27).
The welding program (17) currently set is shown in the operating display.
The display of the materials may vary according to the machine and software versions.
Free
setting
1-4
Welding program Soll PLAST [°C] Soll AIR [°C]
Free settings. 1 – 4 230 260
Prg1 PE-LD 220 260
Prg2 PE-HD 230 260
Prg3 PP 240 260
Prg0 PVC-U 200 300
Set value Set value Set value
Program: the display of the materials may vary according
to the machine and software versions.

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Operating
•Dismounting
– Switch off the unit at operating temperature and disconnect from the power supply.
– Remove the welding shoe (8) with welding-shoe holder (34) by loosening the clamping
screws (35) from the extruder nozzle (32).
– Each time when changing the welding shoe, clean the extruder nozzle (32) from welding-
material remainders and ensure that the extruder nozzle (32) is screwed tight.
– Remove the welding shoe (8) by loosening the fastening screws (33) from the welding-
shoe holder (34).
•Assembly
– Mount a welding shoe (8) (which is adapted to the welding seam) to the welding-
shoe holder (34) with the fastening screws (33).
– The welding shoe (8) and the welding-shoe holder (34) must be firmly tightened with the
clamping screws (35).
Work with temperature resistant gloves only.
Danger of getting burned!
Replacing the welding shoe
• The welding shoe must only be replaced when the tool has attained its operating temperature.
8 Welding shoe
32 Extruder nozzle
33 Welding shoe clamping bolts
34 Welding shoe holder
35 Clamping screw
35
8
Welding direction
By loosening the clamping screws (35), the welding shoe (8) can be variably adjusted (by
turning) to the desired welding direction. Afterwards, the clamping screws (35) must be
firmly retightened
833
32
35
34
35
888

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Replacing the hot-air tube
To disassemble the hot-air tube (44), firstly remove the
welding shoe (8). After loosening the countersunk locating
screw (45) on the tube clamp (10) and the clamping
screw (47) on the hot-air tube connector, the complete
unit can be removed.
Assembly in the reverse sequence.
Work with temperature resistant gloves only.
Danger of getting burned!
Replacing the pre-heating nozzles
Dissassembly: For the pre-heating nozzle, pre-heating
nozzle (9), unscrew clamp screw (43)
and pull pre-heating nozzle (9) off the
hot air duct (44).
Assembly: Push pre-heating nozzle (9) onto the
hot air duct (44).Make sure that it is
aligned parallel to the nozzle shoe.
Tighten clamp screw (43).
Operating
Pre-heating nozzles for extruders with external air duct
There are three different pre-heating nozzles (9) available according to the required welding
seam width. The nozzle cross-sections comply with DVS guidelines.
Nozzle 1
Seam widht
up to 15 mm
Nozzle 2
Seam widht
16 to 20 mm
Nozzle 3
Seam widht
21 to 40 mm
9
44
43
8
44
4510
47

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ERROR
An error occurring is shown in the status display (30) (e.g Motor is overheated).
Display
When an error occurs, the heating units for AIR and PLAST, as well as the drive motor, are
switched off immediately!
Should this not take place, the tool must be disconnected from the mains supply immediately!
Further procedure with status display (30)
• Note down the error code
• Disengage the drive locking device (4) and release the drive on/off switch (2).
• Switch off the main switch (1).
• Start using the tool again under supervision and ensure that the extruder is not overheated
from the outside.
• Eject the remaining plastic from the screw if possible.
• Should the error reoccur, the tool should be sent to the Service Centre to be checked,
specifying the error code.
ErrXX
ErrXX
Err04
Drive overheating protection
If the drive is overheated by external influences or because the PLAST temperature
is too low, the internal temperature protection of the drive switches off (see ).
False start protection
The drive motor is secured against automatic starting after errors/malfunctions, e.g., overheating
. The indication «Switch off drive» appears on the display (5), while the drive motor remains
in blocked condition. After correcting the malfunction and switching off the drive (loosen
drive
locking device (4))
and release the drive on/off switch (2)), the indication «Switch off drive» in the
display (5) goes out. Working can now be continued.
Err04
Err04
Operating
The following errors are recognised by the tool:
Display Type of fault
Err01 Overheating of the air or defective temperature probe
Err02 Overheating of the plastic welding material or defective temperature probe
Err04 Overheating of the motor winding, motor is overheated
Err08 Overheating of the heating element, AIR or failure of the blower motor
Err10 Overheating of the electronics
Err40 Short circuit of the PLAST temperature probe
Several errors can occur at once e.g. and Display: !
Further combinations are displayed with the letters A, B, C, D, E and F.
e.g. and Display !!
Err0AErr02Err08
Err06Err04Err02

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Accessories
Only Leister accessories may be used.
Transportable welding rod dereel holder
• The holder is designed for two welding rod reels with
ø 300 mm
• To ensure optimal rod dispensing, the welding rod
should be passed through the eyelets (41) provided.
41
Leister Process Technologies offers welding shoes for all the common seam geometries in
various sizes:
Blank V weld Fillet weld Overlap weld
Unit stand
Corner, short Corner, long
WELDPLAST S2 with integrated air duct
Blank V weld Fillet weld Overlap weld
Welding-shoe assortment
WELDPLAST S2 / WELDPLAST S2-PVC with external air duct

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• Check the power supply cord (14) and plug for electrical and mechanical damage.
• Clean the extruder nozzle (32) each time the welding shoe is replaced and remove any
welding deposits.
• Repairs should only be carried out by authorized Leister Service Centres. They gua-
rantee a specialised and reliable Repair Service within 24 hours using original spare
parts in accordance with the circuit diagram and spare parts list.
• If the service message appears with the Service Code 1 after
swtiching on WELDPLAST S2, the state of the carbon brushes
should be checked by an authorised Leister Service Centre and
the carbon brushes replaced, if necessary.
• The display can be removed with the Select key (28).
• The hand extruder can be used again for a short time.
• If the carbon brushes are not replaced within a short time, the drive
will run until the mechanical brush reaches its limit stop. No more
error messages appear on the display, the drive no longer runs.
• 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.
• In the case of PVC related corrosion, the extrusion screw and cylinder tube are excluded from
the guarantee.
• 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
Warranty
Service and repair
Maintenance

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®
Your authorised Service Centre is:
Leister Process Technologies
Galileo-Strasse 10
CH-6056 Kaegiswil/Switzerland
Tel.[phone]
Fax[phone]
www.leister.com
[e-mail]
BA WELDPLAST S2 / 07.2007 / 04.2008 BA WELDPLAST S2-PVC / S2-TPO / 01.2009
© Copyright by Leister