Leister Astro Operating Instructions Manual

Please read operating instructions carefully before use and keep it for further reference. GB OPERATING INSTRUCTIONS ® LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland Tel. +41 41 662 74 74 Fax +41 41 662 74 16 www.leister.com [email protected] The LEISTER Astro is an automatic wedge-welding machine for overlap welding of geomembrane liners in earthwork and civil engineering. • Thermoplastic geomembrane liners High-density polyethylene PE-HD Low density polyethylene PE-LD Chlorinated polyethylene PE-C Polypropylene PP DVS: German Welding Society for welding APPLICATION • Type of seam Welding seams are pro- duced in accordance with DVS 2225 part I Other dimensions are pos- sible on request. LEISTER SALES & SERVICE CENTER CHINA , 20H Building No.1 515 Yishan Road ,Shanghai, PRC Tel. +86 021 34141786 Fax. +86 021 64360767 http://www.plasticwelding.cn E-mail: [email protected]

50 / 60 1800 max. 420/788 max. 1500/337 0,8– 5,0/2.6 - 16.5 max. 150/5.9 1,5 – 3,0/60 - 120 70 475 × 355 × 315 with carrying handle / guide handle (12) 23/50 Voltage V~ Frequency Hz Power consumption W Temperature °C/°F Welding pressure N/Ibs Drive m/min./feet Overlap width mm/Inch Thickness of material mm/mil Noise emission level LpA (dB) Size L×W×H mm Weight kg/lbs Protection class Ι # mains voltage is not reversible Danger! Unplug the tool before opening it as live com- ponents and connections are exposed. Incorrect use of the hot wedge tool can present a fire and explosion hazard especially near combustible materials and explosive gases. Do not touch the element housing and 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. WARNING The tool must be operated under supervision. Radiant heat from the hot wedge can ignite flammable materials. 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. Protect the tool from damp and wet. FI 120 230 CAUTION Connect the tool to a socket outlet with protective earth conductor. Any interruption of the protective earth conductor within or outside the tool is danger- ous! Use only extensions cables with a protective earth conductor! APPROVAL MARKS CCA certified

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 C D A B E Wedge Welding direction upper geomem- brane liner Pinch roller Lower geo- membrane liner Cross-section diagram of hot wedge system Rear guide roller Lower drive / pressure roller Upper drive / pressure roller Front guide roller Fastening screw for hot wedge Cross sectional diagram of an overlap weld • Welding pressure → infinitely variable (steplessly adjustable). The welding pressure is transmitted via a toggle lever to the pressure rollers. The swivel head guarantees the equalization 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 pressure adjusts itself linearly to the change in material thickness of the geomembrane liners. • Drive → The welding speed is adjustable and electronically controlled in steps of 0.1 m/min / feet. Digital display of SET and ACTUAL values. The power transmission works through a three stage planetary gear. • Heating system → The hot air temperature is steplessly adjustable and eletron- ically controlled. It is a floating hot wedge. FUNCTIONAL DESCRIPTION LEISTER Astro 3

LEISTER Astro 4 Frontal view Side view 15 7 4 3 2 23 24 1 22 5 6 10 9 17 17 11 21 14 12 20 18 8 19 13 25 16

matic welding machine onto the material to be welded. Insert the two geomembranes liners or films about 5mm at the back of the machine. Pull the lever (9). The hot wedge is automatically pushed forward. Push and hold down the locking spring (11). Turn the adjustment screw for welding pressure (10) until the drive/pressure rollers (20/21) slightly touch the material to be welded. Let go the locking spring (11) and release the tension of the lever (9). Keep pushing the locking spring of the adjustment screw (11). Adjust the welding pressure by turning the corresponding adjustment screw (10) accord- ing to illustration A and let go the locking spring (11) at the requested welding pressure. Warning: If the maximum welding pressure of 1500N is exceeded mechani- cal damage may occur. 5 DESCRIPTION OF MACHINE LEISTER Astro 1. Mains cable 2. Cable clip 3. Housing of electronics 4. Main switch 5. Display 6. Keyboard 7. Motor/ Drive 8. Hot wedge 9. Lever 10. Adjustment screw for welding pressure 11. Locking spring of adjustment screw 12. Carrying handle / Guide handle 13. Front wheel 14. Back wheel 15. Foil guide 16. Cable conduit for hot wedge 17. Pinch roller 18. Front guide roller 19. Rear guide roller 20. Lower drive/pressure roller 21. Upper drive/pressure roller 22. Adjustment screw for swivel head 23. Chain guard of lower part 24. Chain guard of tension arm 25. Chain guard of gear case WELDING PARAMETER LEISTER Astro Illustration A Welding pressure Screen 10 11 max. welding pressure 1000 N [N] 375 500 625 750 875 1000 1125 1250 1375 1500 250 125 1 2 3 4 5 6 1 2 3 4 5 6 ca. 5 mm Wedge Folie

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 on the heating by pressing the and keys simultaneously. Heating up time approx. 5 mins. + – H + H Drive ON/OFF SET value setting – + M ON/OFF SET value setting – + + & H WELDING LEISTER Astro Welding preparation – Laying Width of overlap is about 80mm to 130mm Geomembrane liners must be clean between the overlap as well as above and below. – Mains supply At least 3kW (generator) supplied with an RCCB – Cable to mains A minimum cable cross section in accordance with the table. 200 – 230 V~ to 50 m 3x1,0 mm2 to 100 m 3x2,5 mm2 120 V~ to 50 m 3x1,5 mm2 to 100 m 3x2,5 mm2 WELDING PARAMETERS LEISTER Astro Welding Speed According on the film or geomembrane liner and the influence of the weather, set the welding speed with the keys. The in-put SET value will be shown on the display. + –

100 % • mains under-voltage 100 % or < • overlap of the geomembrane liner too wide 100 % or < • dirt on the drive rollers (20/21) 100 % or < • max. welding pressure (1500 N) has been exceeded 100 % or < • high welding speed with large sudden overload (ie anchoring trench, T-joints....) Display (4) Heating reason for fault after heating up time 100 % • mains under-voltage WELDING LEISTER Astro 7 Operating conditions •Connect the hot wedge-welding machine to the mains •Start the machine with Main- or Control Level If malfunction does not disappear, contact service center Main – Level + – & & < Overload indication Check the welding process and identify faults by means of the display of power consumption. 1. Speed ACTUAL value 2. Speed SET value 3. Temperature ACTUAL value 4. Temperature SET value 5. Voltage display ACTUAL value 1. Speed ACTUAL value 2. Speed SET value 3. Temperature ACTUAL value 4. Temperature SET value 5. Voltage display ACTUAL value Main Switch (4) ON Main Switch (4) ON Control – Level Heating / Drive active * 1 3 5 6 1 3 5 2 4 2 4

overlap. 22mm 24.5mm Dim. of pressure roller 50mm Dim. of pressure roller 45mm Welding procedure •Check: – Drive/ Pressure rollers (20/21) as well as the hot wedge (8) must be clean before engaging into the geomembrane liner or film. – 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. •Switch on drive motor with key on keyboard (6). •Pull the lever (9). •Check the welded seam (wash/seam thickness reduction). As required, adjust the welding speed with keys on keyboard (6). •The automatic welding machine is guided along the overlap with the carrying handle/guide handle (12), so that the frontal width of the overlap is kept within the 22mm zone (see illustration B). Beginning of welding process •Release the tension lever (9) 1 cm before the end of the welded seam. •Switch off the drive motor with key on the keyboard (6). Switch off the heating by pressing the and keys on the keyboard (6) simultaneously. End of welding process 8 WELDING LEISTER Astro M + – M H +

• Engage the automatic wedge-welding machine on the geomembrane liner or film to be welded. • Stretch the lever (9) • Loosen the hexagon cap screw of the rear guide roller (19). • The distance between the hot wedge (8) and the rear guide roller (19) should be the thickness of the material and the sharp tongue of the wedge should lie centrically to the pressure rollers (20/21). • Tighten the hexagon cap screw of the rear guide roller (19). • Loosen the hexagon cap screw of the front guide roller (18). • The distance between hot wedge (8) and front guide roller (18) should be about 1 mm. • Tighten the hexagon cap screw of the front guide roller (18). ADJUSTING THE HOT WEDGE LEISTER Astro 9 18 Cross-section diagram of hot wedge system 19 21 8 20

fields of applications. They differ in the width of the welded seam as well as the width of the test channel. Also welded seams without test channel can be manufactured. In order to implement these different overlap seams, the appro- priate drive/pressure rollers have to be installed. Dismantling of the drive/pressure rollers, sequence 1 – 12 Assembly of the drive/pressure rollers, reverse order 12 – 1 1. Countersunk screw M3×6 2. Protection sheet swivel head 3. Socket head screw M4×8 4. Washer 4.2×25 5. Slide roller 6. Set screw M5×12 7. Shaft 8×118.5 8. Shaft retaining ring 9. Distance disk 20×32×0.5 10. Drive/pressure roller 11. Woodruff key 5×6.5 12. Upper drive shaft complete 1 3 7 6 6 4 5 12 11 10 9 8 2 CHANGEOVER OF UPPER DRIVE/PRESSURE ROLLER LEISTER Astro

Assembly of the drive/pressure rollers, reverse 4 – 1 1. Countersunk screw M5×16 2. Clamp disk 3. Drive/Pressure roller 4. Distance disk 20×32×0.5 4 CHANGEOVER OF LOWER DRIVE/PRESSURE ROLLER LEISTER Astro 11 4 3 2 1

welding courses and training. • Only LEISTER accessories should be used. • Check mains cable (1) and plug for electrical and mechanical damage. • Clean hot wedge (8) with a copper brush. • Clean drive and pressure rollers (20/21) with a wire brush. • Treat chain (22) with a suitable spray as required (chain guard 23/24). • Check whether rollers (13/14/17/18/19) are running smoothly. • The tool should be checked by an authorized Service Center if the following message appears on the display (5): «maintenance; servicing». • 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. • Guarantee and liability are in accordance with the guarantee certificate as well as with the currently valid general business and sales conditions. • LEISTER Process Technologies rejects any guarantee claims for tools which are not in their original condition. The tools must never be altered or changed. Technical data and specifications are subject to change without prior notice. Your authorized Service Centre is: GUARANTEE AND LIABILITY SERVICE AND REPAIR MAINTENANCE ACCESSORIES TRAINING ® LEISTER Process Technologies, Riedstrasse, CH-6060 Sarnen/Switzerland Tel. +41 41 662 74 74 Fax +41 41 662 74 16 www.leister.com [email protected] LEISTER SALES & SERVICE CENTER CHINA , 20H Building No.1 515 Yishan Road ,Shanghai, PRC Tel. +86 021 34141786 Fax. +86 021 64360767 http://www.plasticwelding.cn E-mail: [email protected]