SFS isoweld 3000 User manual

isoweld®
3000 &
isoweld® Backpack
Operating Instructions
Installation Instructions
Version 2.0
North America - English

2
Table of contents
Operating Instructions
isoweld ®induction welding tool 3
Symbols used 4
Rating plate 5
Safety instructions 5
Special safety instructions 8
Danger areas 10
System components isoweld ®3000, isoweld ®3000 Backpack 11
Overview isoweld ®3000, isoweld ®Backpack, Standard items supplied 13
Description of function 15
Transport 15
Power requirements 16
Start-up isoweld ®3000, isoweld ®Backpack 17
Calibration 21
Additional setting options 22
Test welding 22
Operation: welding 23
Checking the welding 25
Optional operation isoweld ®3000, isoweld ®Backpack:
working with the hand inductor 25
Technical data 26
Error messages 27
Disposal 28
Maintenance, service and warranty 28
Declaration of conformity 32
System components 35
Deciding on installation strategy 36
Preparing the roof for fastening 36
Measuring and marking fastening points 36
Fixing the stress plates 37
Rolling out the waterproof membrane 38
Marking the fastening points 38
Preparing the induction tool 39
Welding the membrane at the fastening points 40
Installation Instructions

3
Identification
Type: isoweld
®3000, isoweld ® Backpack
Manufacturer: SFS
Division Construction
Rosenbergsaustrasse 10
CH-9435 Heerbrugg
Switzerland
www.sfsintec.biz
Rating: see type plate
The induction welding tool of the isoweld
®series has been designed in
Switzerland. The isoweld
®3000 is assembled in Switzerland and the isoweld ®
Backpack is assembled in the US.
Responsible for documentation:
Daniel Gasser,
Reserach and Technology
Preface
Purpose of the document
This document is written for skilled building operatives working in the field of
flat roofs. It is intended to instruct skilled operatives in how to work safely and
efficiently with the units (see the section on "Safety instructions").
Structure of the documentation
The documentation describes all the phases in the life of the tool from transport,
installation, operation, maintenance and servicing up to disposal.
This manual was drawn up taking into account the provisions of the EU
Machinery Directive 2006/42/EC, Annex I, Clause 1.7.4 "Instructions".
The original operating instructions were prepared in German and modified in
English.
Keep this document safe
These operating instructions are part of the product and must be kept with the
unit at all times. They must be available to the operator at all times.
isoweld
®induction welding tool

4
Indicates a hazardous situation. Death or severe permanent injury could result if
the situation is not avoided.
Indicates a potentially hazardous situation. Death or severe permanent injury
could result if the situation is not avoided.
Indicates a potentially hazardous situation. Slight or minor permanent injury could
result if the situation is not avoided.
DANGER!
WARNING!
CAUTION!
Symbols used
This symbol highlights hazard instructions that must be observed when
dealing with electrical equipment.

This symbol signals hazards that must be taken account of when
working on roofs.
This symbol signals hazards associated with crane transport.
This symbol signals risks for people who have a cardiac pacemaker.
This symbol makes clear the requirement to wear personal protective
equipment. Personal protective equipment always includes: safety
glasses, safety gloves, safety shoes, closely fitting working clothes
as well as a belt and safety rope. In every case the internal accident
prevention requirements must be observed.
The operating instructions must be read and understood before setting
up or using the tool. The instructions must be observed. Ask the
responsible department if the operating instructions are missing or if you
do not understand sections of the operating instructions.
This symbol signals hazards associated with magnetic fields.
FI
This symbol alerts operators to use the mandatory protective ground
conductor.
This symbol alerts operators to use the mandatory RCD switch.
This symbol alerts operators to use the mandatory protection against
moisture.
This symbol alerts operators to use the required network voltage.
This symbol highlights instructions that point out a fire hazard.
Instructions regarding additional important information.

5
Safety instructions
Rating plate
1 Machine type
2 Year of manufacture, serial number
3 Technical data
4 CE, FCC marking,Protection rating
Meaning of general safety instructions
The general safety instructions in this section provide information on possible
residual hazards that are always present or that could occur unexpectedly,
despite the correct usage of the unit.
The safety instructions must be observed by all persons who work on or with
the tool to prevent physical injury, damage or harm to the environment. These
persons are therefore obliged to read, understand and observe the provisions of
this section.
1
2
3
4
isoweld®

6
Safety instructions
Meaning of specific safety instructions
For certain situations the applicable safety instructions are given at the relevant
place in the operating instructions. These instructions must be observed in order
to prevent physical injury, damage or harm to the environment.
Statutory requirements
In addition to the safety instructions in this operating manual, the statutory
accident prevention and environmental protection regulations applicable in the
country of use must be observed. Likewise the generally accepted rules for
safety and working in a technically correct manner must be observed.
Consequences of failure to observe the safety instructions
Failure to observe the safety instructions can lead to accidents with resultant
physical injury, damage or harm to the environment.
The manufacturer accepts no liability for injury or damage resulting from failure
to observe the safety instructions.
Intended use
The induction welding tool has been designed exclusively for the installation of
roofing membranes recommended by SFS on roofs.
Only fasteners, stress plates and sleeves approved for the tool and provided by
SFS may be used. The tool must be used within the limits defined in the
"Technical data" section.
Foreseeable misuse
• Starting to use the tool without instruction.
• Rendering the safety features inoperative and removing the warning labels.
• Working on roofs with a slope of more than 10°.
• Working backwards on roofs.
• Unsafeguarded or reckless working on roofs.
• Modifying the tool without the permission of the manufacturer.
• Using accessories or spare parts from another manufacturer without the
permission of SFS.
• Using or wearing isoweld®Backpack on an unstable support, steep incline or
ladder.
• In the case of misuse there is a risk of death or injury, damage to the tool
and damage to the material processed.
• It is not permitted to open the isoweld® induction generator under any
circumstances. Non-observance involves the risk of death or injury,
damage to the tool and damage to the processed material.
DANGER!
NOTICE
Welding with plates without an SFS
stamp may result in roof assembly failure.
USE ONLY SFS MARKED PLATES

7
• It is not permitted to use the isoweld®Backpack as a safety harness or wear
the isoweld®Backpack over a safety harness, under any circumstances.
Non-observance involves the risk of dealth or injury, damage to the tool and
damage to the processed material.
Safety instructions
• Keep your workplace tidy. An untidy workplace increases the risk
of accident.
• Keep children at a safe distance. Do not allow third parties to touch
the machine or the cable.
• It is imperative to comply with the safety regulations in the
respective country.
• Always wear the correct personal protective equipment when
working. Personal protective equipment includes: safety goggles,
safety gloves, safety shoes, closely fitting working clothes.
• When working on a roof it is possible for the tool or the operator to
accumulate a static charge. For this reason, we recommend that
anti-static clothing and anti-static shoes be worn and/or the use of
anti-static sprays.
• The induction welding tool and the magnets may have an effect on
the function of cardiac pacemakers and implanted defibrillators. It
is possible that cardiac pacemakers switch to test mode and cause
discomfort. It is possible that defibrillators cease to function. If you
are fitted with any such instruments, you must keep a minimum
distance of 20 inches (50 cm) from the inductor (also hand
inductor) and the magnets. You must warn persons fitted with such
instruments against coming too close to the magnets and inductors.
• Do not hold any objects containing metal in the direct proximity of
the inductor (e.g. watches, jewelry, keys, mobile phones, hearing
equipment, implants etc.).
• The isoweld®stress plates become very hot due to the induction
process. There is a risk of burns when touching the stress plates
immediately following the welding process.
• Take account of environmental influences. Do not expose the
induction welding tool to rain. Do not use the induction welding
tool in damp or wet conditions. Ensure that you have good lighting.
Do not use the induction welding tool in the proximity of flammable
liquids or gases.
• Connect the tool to a socket with protective ground conductor. Any
breakage/disconnection of the protective conductor inside or
outside of the tool is potentially dangerous! Only use extension
cables with an earth conductor!
• The mains voltage must be as stated on the generator type plate.
• When the tool is used on building sites, the RCD switch is a
mandatory requirement for personal protection.
• Place the electric cable (supply cable) in a suitable location. Ensure
that it does not constitute a trip hazard and does not wear through.
Regularly check the electric cable, inductor cable and temperature
cable for damage.
• In the open, only use extension cables approved and marked for
this purpose.
General safety instructions – Part 1
FI

8
• Always switch the tool off and remove the mains connector during breaks or
maintenance work. Do not leave the tool unattended.
• When carrying out maintenance and service work, the power connection to
the tool must be disconnected.
• Regularly check the tool for damage, and that it is functioning properly. Use
the tool only if it is functioning properly.
• Repairs may only be carried out by a specialist.
• Only use system components from SFS or approved by SFS. Do not use any
accessories or spare parts from other manufacturers without approval by SFS.
•
The functionality of this system is guaranteed when original fastener, stress
plate, spare parts from SFS are used, and the unit is operated in accordance
with the operating instructions.
• Do not use or wear isoweld®Backpack on an unstable support, steep incline
or ladder.
• Always inspect isoweld ®Backpack straps and connection points before use.
• Using an isoweld®Backpack tool with damaged straps or connection points
may result in a strap or connection breaking while in use and the machine
may fall causing personal injury.
Special safety instructions
• When working on roofs with a
slope of between 0 and 10° a
guard rail must be fixed at the
edge of the roof.
• When the roof slope is more than
10° special safety devices must be
employed.
• When the working height is more
than 10 ft. (3 m) above ground,
appropriate fall prevention
measures must be employed
(see below).
• Fall prevention measures for work lasting less than 2 working days. In the case
of work that takes longer, proceed as described above (see below).
>5 m
>3 m
max. 47 cm
100 cm
max. 47 cm
100 cm
>5 m
Safety instructions
General safety instructions – Part 2
• Never start the welding process while the supply cable is under
the tool. Ensure that the cable is far enough away from the
inductor during the work process.
WARNING!

9
• Risk of falling through: beware of areas
in the roof that are not structurally safe,
e.g. rooflights, tarpaulins etc. These
areas must be appropriately marked and/
or secured with gangways.
• When working on roofs the entire risk
area on the ground must be cordoned
off and signed. It is important to ensure
that third parties are not endangered by
falling objects.
• Do not use or wear isoweld®Backpack on an unstable support, steep incline
or ladder.
• It is not permitted to use the isoweld®Backpack as a safety harness or wear
the isoweld®Backpack over a safety harness, under any circumstances.
Non-observance involves the risk of dealth or injury, damage to the tool and
damage to the processed material.
Special safety instructions
WARNING!

10
1 Fall hazard at roof edge
2 Fall hazard at step in roof
3 Break-through hazard, e.g.
glass windows
4 Trip hazard from cable
Always work in a forward
direction, never backwards.
Danger areas
1
DANGER!
3
4
1
1
2
3
3
4
4
1
1
1
2
2

11
System components isoweld®3000
Induction welding tool
isoweld®3000
Magnet
FI Magnet
Calibration template
isoweld®
Included in delivery:
Fixing components:
Additional accessories:
Hand inductor
FI-H
Optional:
Fastener:
DF-#15xL"
PUR-#12xL"
FI-P-6.8 isoweld® plate
for metallic systems
Stress plate:
TPR-L-6,3xL(mm)
FI-Pad

12
System components isoweld®Backpack
Magnet
FI Magnet
Fixing components:
Additional accessories:
Fastener:
DF-#15xL"
PUR-#12xL"
FI-P-6.8 isoweld®plate
for metallic systems
FI-Pad
Stress plate:
Calibration template
isoweld®
Induction welding tool
isoweld®Backpack
Included in delivery:
TPR-L-6,3xL(mm)

13
Overview isoweld®3000
4
1
2
1 Inductor
2 Weld button
3 Cable holder
4 Handle
5 Clamping lever for height adjustment
6 Clamping lever for plug connection
7 Display
8 Generator
9 On/Off switch
10 Calibration template
11 Connector 1
2
11
Hand inductor FI-H (optional)
5
7
9
8
6
3
Calibration template
10
11
Standard items supplied isoweld®3000
Induction welding tool, complete
1 Induction welding tool isoweld®3000
1 Calibration template
1 Set of instruction material
5 Protective foils for inductor
1 Transport box

14
1 Hand-held inductor
2 Flexible handle adaptor allows inductor to be placed on a slanted surface (+/- 5º)
3 Same as magnet pole
4 Turn lock clamp
5 Adjustable Handle
6 Wireless activation switch and handle
7 For thumb action
8 Index finger activation
9 Weld
10 x2
11 OK
12 Cord management
13 Integral waist strap
14 Closed cell foam padded straps
15 Carry handle
16 Standard generator (same as stand-up tool)
17 4 T20 Screws to remove generator
18 Rubberized feet for impact resistance
19 OK
20 Wired activation switch
21 x2
22 Weld
23 Calibration
Template
Overview isoweld®Backpack
9
10
11
87
6
15 14
16
17
18
21
19 20
22
2
3
4
5
12
13
1
Standard items supplied isoweld® Backpack
23
Induction welding tool, complete
1 Induction welding tool
isoweld®Backpack
1 Calibration template
1 Set of instruction material
5 Protective foils for inductor
1 Transport box
1 Hand-held inductor with
cord straps
1 Wired activation switch
1 Adjustable handle
1 Flexible handle adaptor

15
Description of function
Transport
The isoweld
®induction welding tool has been designed for efficient welding of
waterproof membranes with metal stress plates. It is possible to use PVC and
TPO waterproof membranes. The tool has been designed as an upright unit and
therefore allows ergonomic work without excessive fatigue. As soon as the
induction welding tool has been placed over a metal stress plate, the welding
process is triggered by pressing the start button. The welding process ensures
that the waterproof membrane is connected to the stress plate. It is important
that this connection is subsequently weighed down with a magnet.
DANGER!
38 Kg
©
Falling load
Note: NEVER lift or hang the isoweld®3000 transport box at the
handles.
38 Kg
NOTICE
Welding with plates without an SFS
stamp may result in roof assembly failure.
USE ONLY SFS MARKED PLATES

16
General
• The points below describe the power requirements for the use of the
isoweld ®induction machine. These notes are recommendations.
Each job site and its power situation is individual and therefore no
performance guarantee can be given.
• In addition to the recommendations stated in this document, the local
safety and electrical regulations applicable in the country of use must be
observed.
• Consultation of a qualified electrician is advisable.
Electrical safety
• Connect the machine to a socket with a protective ground conductor
Any breakage/disconnection of the protective conductor inside or
outside the tool is potentially dangerous! Use only extension
cables with an ground conductor!
• When the tool is used on building sites, the use of an RCD switch is a
mandatory requirement for personal protection.
Power supply
• Stable power is essential for problem-free operation of the induction
machine.
• A minimum of
- 20 amps per electrical circuit required for countries with 110 volts /
120 volts nominal voltage
- 10 amps per electrical circuit required for countries with 230 volts
nominal voltage
• Maximum one induction machine per circuit, with a recommendation
not to use other devices on the same circuit as the isoweld®3000,
isoweld ® Backpack.
• Off-load voltage shall not exceed:
- 160 volts for countries with 110 volts / 120 volts nominal voltage
- 240 volts for countries with 230 volts nominal voltage
• On-load voltage at the point of utilization at the machine terminals, with
the machine running, must be higher than:
- 110 volts for countries with 110 volts / 120 volts nominal voltage
- 200 volts for countries with 230 volts nominal voltage
• It is preferable for the induction machine to have its own dedicated
power supply so as to avoid power surges from other equipment, e.g.
drill machines.
Generator
• Use a minimum 5000 watt generator
• Requirements volts and amps see above
• With ground fault circuit interrupter (GFCI)
• Grounding / earthing required
Transformer
• Necessary for use in countries with a nominal voltage of 110 volts if the
voltage at the point of utilization, with the machine running, falls below
110 volts.
• The functionality of the system is only ensured if the transformer
provided by SFS is used.
Power requirements Part 1

17
Start-up isoweld®3000
After opening the container, the body of the unit
can be carefully lifted out. Then the handle of the
tool (see overview) is removed from the transport
box and carefully inserted into the tool.
1. Use fixing screw to secure the
push-fit connection.
2. Adjust the handle to an ergonomic
working height. For this purpose,
release the clamping lever at the
upright and adjust the height.
Re-tighten the clamping lever.
3. Connect the tool to a suitable
power source.
- the cable should not be too long
- suitable conductor cross section
- unroll extension cable
Ensure that the connection is
correctly made.
4. Operate mains switch to turn unit
on.
5. The display shows the input
screen.
The induction welding tool is delivered ready for operation ex-works.



4.
5.
1.
2.
The country-specific regulations must be observed.
3.

Power requirements Part 2
Power cables
• The usable cable thickness and length depend on the power situation on
the job site.
• General rule: The shorter and thicker the cable, the better.
• Recommendations cable thickness:
- for countries with 230 volts nominal voltage: 3 x 1.5 mm2
- for countries with 110 volts / 120 volts nominal voltage: 12 gauge
cable (3 x 2.5 mm2)
• Use only cables appropriate for this application. Check the
cables regularly for damage.
• Outdoors, use only extension cables approved and marked for
this purpose.

18
The induction welding tool is delivered ready for operation ex-works.
After opening the container, remove the poles and hand-held inductor, then the
backpack unit can be carefully lifted out. The inductor unit, pole and cords can be
carefully assembled and attached to the tool.
Start-up isoweld® Backpack
1. For use in stand-up mode, connect the handle
adaptor to the hand inductor.
2. Screw the adjustable handle into the top of
the handle adaptor.
3. Press the wireless activation switch/handle
grip on to top of adjustable handle.
4. Adjust the pole with the turning lock clamp to
an ergonomic working height.
5. Open the cover to the hand-held port and
connect the hand-held inductor.
5a. If desired, connect wired activation
switch.
6. Connect the tool to a suitable power source.
- the cable should not be too long
- suitable conductor cross section
- unroll extension cable (diagram page 19)
Ensure that the connection is correctly
made.
©
1
3
55a
4
2

19
7. Operate main switch to turn unit on.
8. The display shows the input screen.
9. Perform start-up calibration and test weld
procedures. (see pages 20 & 21)
These procedures must be performed prior
to putting the backpack on.
The country-specific regulations must be
observed.
First, inspect the shoulder straps to
ensure they are not damaged and that they
are firmly connected to the tool body with no
damage or wear at the connection points.
10. After inspection, place your arms through the
shoulder straps to support the backpack on
your back.
Using a tool with damaged straps or
connection points may result in a strap or
connection breaking while in use and the
machine may fall causing personal injury.
If there is any damage noted to the straps or
connections, follow the instructions noted in
the maintenance, service and warranty
section of this manual.
11. Adjust the straps
11a. Adjust the shoulder straps to a good
working fit by adjusting the strap
length at the clip
11b. Attach the chest strap and adjust to
length
11c. Attach the waist strap and adjust its
length so that the machine is
supported by your hips.
12. Use the cord management straps to organize
the power cord and inductor cord for safe,
efficient working.
11a
11b
11c
WARNING!
8
6
7

20
Start-up
Before working with the induction welding tool, the project parameters must
be entered into the display. The parameters required are the waterproof
membrane material and thickness. The following options are available:
For changing the settings, proceed as follows:
The position display is on the choice of the waterproof membrane material
(4first line).
1. Press the button OK . ≥ appears and flashes.
2. Press the Lbutton or press the Mbutton until the required waterproof
membrane material is displayed.
3. Confirm the selection by pressing the OK button. 4appears.
4. Press the Mbutton to go to the waterproof membrane thickness selection.
5. Press the OK button. ≥ appears and flashes.
6. Press the Lor Mbutton to determine the waterproof membrane thickness.
7. Confirm the selection by pressing the OK button.
The parameters have now been set and stored.
Note: the settings (parameters) used last will be loaded. It is possible to
either adopt these settings or make new selections of the following settings.
Display examples
Waterproof
membrane
material
Waterproof membrane thickness (mm/mil)
PVC
TPO
0.9-1.1/35-44 1.2-1.4/45-59 1.5-1.7/60-69 1.8-2.0/70-79 2.1-2.3/80-90