Automatic wedge welding machine type COMON with recording system

Transcription

1 OPERATING INSTRUCTION Automatic wedge welding machine type COMON with recording system Please read the operating instructions carefully before use and keep for further reference! APPLICATION The COMON is an automatic hot wedge welding machine for overlap welding and for manufacturing of films and geomembrane liners in tunnels as well as in earthwork and civil engineering. Overlap max. 140mm Type of seam Welding seams are produced in accordance with DVS 2225 part I. Other dimensions of seams are possible on request. Type of wedge In standard version the COMON is supplied with a copper wedge for welding of PE and PP, on request it is possible to get it with an universal ceramic wedge for all different kinds of material. BAK Thermoplastic Welding Technology AG 1

2 SECURITY WARNING Danger! Unplug the tool before opening it as live components and connections are exposed. Danger of fire and explosion in case of incorrect use of the hot wedge welder, especially near combustible materials and/or explosive gases. Danger of burns! Do not touch the hot wedge when hot, allow the tool to cool down. Connect the tool to a socket outlet with protective earth conductor. Any interruption of the protective earth conductor within or outside the tool is dangerous!!! Use only extension cables with a protective earth conductor! CAUTION The voltage rating stated on the tool should correspond to the mains voltage. For personal protection, we strongly recommend to connect the tool to a RCCB (Residual Current Circuit Breaker) before using it on construction sites. The tool must be operated under supervision. Radiant heat from the hot wedge can ignite flammable materials. Protect the tool from damp and wet. TECHNICAL DATA Tool with protection of class I Voltage V~ 230 Power consumption W 1700 Frequency Hz 50/60 Temperature C Welding pressure N max Drive m/min Size LxWxH mm 460 x 300 x 330 Weight kg 14 BAK Thermoplastic Welding Technology AG 2

3 DESCRIPTION OF FUNCTIONS Heating system The wedge temperature is stepless adjustable and electronically controlled. According to the material thickness the hot wedge position can be adjusted stepless as required. Cross-sectional diagram of the hot wedge system Upper drive / pressure roller Pinch roller Upper geomembrane liner Welding direction Lower drive/ pressure roller Hot wedge Adjustment screw hot wedge Lower geomembrane liner Rear guide roller Front guide roller Welding pressure stepless adjustable. The welding pressure is transmitted via a toggle lever to the pressure rollers. The equalisation of the pressure to both welded sections (L1 and L2) as well as on a welded seam without test channel is guaranteed by the swivel head. This allows T-joints to be welded without problems. During the welding process the pressure adjusts itself linearly to the change in material thickness of the geomembrane liner. Cross-sectional diagram of an overlap weld L1 S2 S2 L2 S1 LC Reduction of seam thickness = S1 S2 S1 : thickness of the upper and lower membrane S2 : thickness of welded seam L1 : welded section 1 L2 : welded section 2 LC : test channel BAK Thermoplastic Welding Technology AG 3

4 Drive: double (upper and lower), stepless adjustable and electronically controlled. The control system is designed in such a way, that the adjusted speed remains constant independently of the load. WELDING PRESSURE Welding pressure: engage and position the welding tool onto the material to be welded. Pull the toggle lever without engaging the hot wedge. By rotating the adjustment screw the drive/pressure rollers will lightly touch the material to be welded, in this way you will define the POINT ZERO (0) N of pressure. Unhook the toggle lever for the locking mechanism and open the toggle lever. Set the pressure by rotating the adjustment screw, to every single step of rotation you will set more pressure. After a couple of steps, close the toggle lever and check the pressure in the display. If necessary open the toggle lever again and rotate the adjusting screw. Close the toggle lever and check the pressure on the display again Warning: If the maximum welding pressure (1400 N) is exceeded, mechanical damages may occur. Recommended pressure adjustments: HDPE 1.5mm thickness pressure approx. 800N HDPE 2 mm thickness pressure approx. 950N HDPE 2.5mm thickness pressure approx. 1200N Test welding is necessary to find out the perfect welding pressure! BAK Thermoplastic Welding Technology AG 4

5 OPERATING 1 Motor button (green) 5 Up ward button 2 Motor LED (green) 6 Heating button (red) 3 Status LED (yellow) (plus button 5 = Heating on/off) 4 Heating LED (red) 7 Down ward button Button 6 and 7 start recording system OPERATING LEVEL Change value with button 5 and 7. Forward to next level with red button. This message shows only if the recommended service time is reached. Confirm with the red button. Standard display to adjust the parameters. Speed adjustment Motor Start/Stop with green button. Green LED shows you the condition. BAK Thermoplastic Welding Technology AG 5

6 Standard display to adjust the parameters. Temperature adjustment Press red button, beside the set-temperature appears a X. Now adjust the temperature. To switch on the heating press the red and up ward button together, when the red LED is flashing up the temperature is reached. Switch off the heat with pressing this two buttons together. BAK Thermoplastic Welding Technology AG 6

7 WELDING Welding preparation -Laying of material -Mains supply Width of overlap from 80 to 140 mm Make sure that the surfaces of geomembrane liners, above and below, are cleaned, as well as between the overlap. at least 3kW (generator) supplied with an RCCB (Residual Current Circuit Breaker) Operating conditions Connect the tool to the mains Start the tool with the main switch/level Welding procedure Adjust the welding parameters (see page no. 4 to 6) Wait until the wedge has reached the adjusted temperature. Guide and position the welding machine into the over-lapped geomembrane liner or film. Switch on the drive motor. Engage the hot wedge into the over-lapped geomembrane liner or film. Push down the toggle lever to obtain the blockade. Start the recording system. Drive / adjust the direction of welding machine by the guide handle so that the minimum overlap is reached. End of welding Before the end of the welded seam, stop the recording system, release the pressure lever, pull back the hot wedge and switch off the motor and heat. BAK Thermoplastic Welding Technology AG 7

8 ADJUSTING THE HOT WEDGE The hot wedge can be adjusted depending to the material thickness. By cold wedge, engage the welding machine onto the geomembrane to be welded. Engage the wedge onto the geomembrane. Lower the pressure lever after having adjusted the needed pressure. Remove the lower part of the chain housing. Loosen the hexagon cap screw which is inside the chain housing. Loosen the hexagon cap screw of the rear roller guide. Adjust the rear roller guide to the correct height. The distance between the rear roller guide and the wedge should be the same as thickness of material to be welded. Tighten the hexagon cap screw of rear roller guide. Loosen the adjustment screw of wedge. The wedge equalizes automatically to the thickness of material to be welded. Tighten the adjustment screw of the hot wedge. Adjust the front guide roller to the correct height. The distance between the inserted material and the front guide roller should be approx. 1mm. Tighten the hexagon cap screw in the chain housing keeping blocked the correspondent screw of guide roller. Assemble chain guard lower part. Unhook the pressure lever and move the wedge back. Check that all the screws are well tight and proceed with a welding test. MAINTENANCE Clean the hot wedge with a wire brush at the end of working day. Clean the drive/pressure rollers with a wire brush. As required treat the chain with a suitable spray. After use, always check that the mains cable and plug are not damaged. SERVICE AND REPAIR The welding machine should be checked by an authorised service centre approx. every 1000 hours of running time. Inspections and repairs have to be executed exclusively by BAK authorised service centres. GUARANTEE AND LIABILITY For BAK guarantee and liability see the general and sales conditions on the back of invoice paper. BAK Thermoplastic Welding Technology rejects any guarantee claims for tools which are not in original condition. Technical data are subject to change without prior notice. BAK Thermoplastic Welding Technology AG 8

9 PRESSURE ADJUSTMENT AND DATA RECORD Change values with Forward to next level with RED Display of the measure units Confirm with Or wait for 3 sec. RED speed-pressure-temperature available recording space Enter seam number If you don t give a seam number, it is impossible to start a record! If you don t need a number confirm with RED Push RED twice, it shows you an X beside the set pressure. Pre choice the pressure Date and time can be changed in the adjustment menu Press together for 5sec. BAK Thermoplastic Welding Technology AG 9

10 CE/COMON D F I GB E EG Konformitätserklärung Déclaration CE de conformité Dichiarazione CE di conformità EC Declaration of conformity Declaratión CE de conformidad D EG Konformitätserklärung BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Schweiz Bestätigt, dass das nachfolgend bezeichnete Gerät in der von uns in Verkehr gebrachten Ausführung die Anforderungen der folgenden EG-Richtlinie(n) erfüllt. Bezeichnung des Gerätes : Heizkeil-Schweissautomat Typ : Comon EG Richtlinie : Maschinenrichtlinie 98/37/EC Elektromagnetische Verträglichkeit 89/336/EEC Niederspannungsrichtlinie 73/23/EEC Harmonisierte Normen : EN , EN ,EN Kägiswil, Bruno Zurmühle, Geschäftsführer F Déclaration CE de conformité BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Suisse déclare qu á la sortie de ses usines l appareil désigné ci-dessous était conforme aux dispositions de(s) la directive(s) CEE suivante(s). Discription de l appareil : Automatic wedge welding machine Modéle : Comon Directive(s) CEE : 8/37/EC, 89/336/EEC, 73/23/EEC Normes harmonisées : EN , EN ,EN Kägiswil, Bruno Zurmühle, Geschäftsführer I Dichiarazione CE di conformità BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Svizzera dichiara che l apparecchio qui di seguito descritto nei modelli commercializzati risulta conforme alle direttive di armonizzazione comunitarie imparatite dalla CEE. Descrizione del apparecchio : Automatic wedge welding machine Modello : Comon Direttive CEE : 98/37/EC, 89/336/EEC, 73/23/EEC Norme armonizzate : EN , EN ,EN Kägiswil, Bruno Zurmühle, Geschäftsführer GB Declaration of conformity BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Switzerland declares that the tool described below, released by us. Fulfils the provisions of the followings EC directive(s). Description of tool : Automatic wedge welding machine Type : Comon EC directives : 98/37/EC, 89/336/EEC, 73/23/EEC Harmonized standards : EN , EN ,EN Kägiswil, Bruno Zurmühle, Geschäftsführer E Declaración CE de conformidad BAK Thermoplastic Welding Technology, CH-6056 Kägiswil/Suiza certifica que el aparato que a confinuación se describe cumple con la ejecución que hemos puesto en circulatión, con las exigencias de las directrices armonizadas de la CE. Denominación del aparato : Automatic wedge welding machine Modelo : Comon Directrice(s) de la CE : 98/37/EC, 89/336/EEC, 73/23/EEC Normas armonizadas : EN , EN ,EN Kägiswil, Bruno Zurmühle, Geschäftsführer BAK Thermoplastic Welding Technology AG 10

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