LEISTER Cosmo Automatic wedge welding machine GB
Contents
1. OPERATING INSTRUCTIONS LEISTER Cosmo Automatic wedge welding machine LL Please read operating instructions carefully before use and keep for further reference APPLICATION The LEISTER Cosmo is an automatic wedge welding machine for overlap welding of geomembrane liners for earthwork and civil engineering e Thermoplastic lining membranes e Type of seam Polyethylene high density PE HD welding seams are produced Polyethylene low density PE LD in accordance with DVS 2225 Chlorinated polyethylene PE C part and BAM Polypropylene PP Other dimensions are possible on request DVS German Welding Association BAM Federal Institute for Materials Research and Testing Berlin CE LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 662 7474 Fax 41 41 6627416 www leister com sales leister com 1 AN WARNING e eD DAGO Danger Unplug the tool before opening it as live components and connections are exposed Incorrect use of the hot air tool can present a fire and explosion hazard especially near combustible materials and explosive gases Do not touch the hot air wedge when hot as it can cause burns Allow the tool to cool down Connect tool to a receptacle with protective earth terminal Any interruption of the protective conductor inside or outside the tool is dangerous Line mains extension cables must always have a pro tective ground conductor CAUTION The voltage ratin2. and lower geomembrane liner B Thickness of welding seam C Width of test channel 15 2 mm D Width of weld gt 15mm Monitoring the welding seam gt Contactless recording of the seam thickness reduction data which is displayed digitally for the welding operator during the welding operation Additionally the seam thickness reduction is gra phically recorded onto a paper print out continuously during the welding operation Speed control system The influence of weather such as sun shade wind and moisture which cause a temperature change in the lining membrane during the welding process can lead to weld faults The Cosmo speed control system interprets the data from the continuous measurement of the welding seam geometry Through automatic adjustment of the welding speed such weld faults are avoided The welding operation can be done either with or without the speed control system If the lower seam thickness reduction tolerance is exceeded the welding speed slows down automatically if the upper seam thickness reduction tolerance is exceeded the welding speed is increased DESCRIPTION OF TOOL Cable to mains Cable holder Housing for drive motor Ventilator grill Carrying handle Handle Main switch Display Keyboard Protection cover printer Printer Hot wedge 13 Adjustment nut for hot wedge 14 Guide roller front 15 Guide roller rear 16 Tension lever for welding pressure N O0MNOAMRW
3. LEISTER accessories should be used TRAINING The LEISTER Company and its authorized Service Centres offer welding courses free of charge world wide The customer can be trained on site if necessary MAINTENANCE e The ventilator grill 4 should be cleaned with a brush when dirty e Clean hot wedge 12 with a wire brush SERVICE AND REPAIR e 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 e Guarantee and liability are in accordance with the guarantee certificate as well as with the currently valid general business and sales conditions e 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 authorised Service Centre is LEISTER Process Technologies Riedstrasse CH 6060 Sarnen Switzerland Tel 41 41 6627474 Fax 41 41 6627416 wwwieister com sales leister com 12
4. NH 19 20 21 Lower drive pressure roller 23 24 25 26 27 28 29 LEISTER Cosmo Hand wheel for stepless adjustment of the welding pressure ON OFF switch lever for upper or lower drive pressure roller Locking device for switch lever 18 Front roller Rear roller Upper drive pressure roller Swivel head Sensor bar Hexagonal cap screw for guide roller front Hexagonal cap screw for guide roller rear Hot wedge locking lever Hot wedge guide handle DESCRIPTION OF TOOL Display 1 ecu 90 ecu 490 N U N U D 5 Welding programme check Thickness of material Seam thickness reduction offset Speed control Recording mode Welding speed Welding temperature Welding speed Welding temperature Adjustment of system Memory card Alarm audible Language Data Time Diagnosis LEISTER Cosmo 1 Welded speed ACTUAL value 2 Welding speed NOMINAL value 3 Temperature ACTUAL value 4 Temperature NOMINAL value 5 Welding pressure ACTUAL value 6 Seam thickness reduction ACTUAL value Drive motor on off Heating on off M H m min m min ge START ON Recording of data Recording of welding seam geometry pa Esc Skip to first function yo ON j Valu
5. 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 pres sure is matched linearly to the change in thickness of the geomembrane liner Guide roller rear Guide roller front Cross sectional diagram of an overlap weld Seam thickness reduction A B A Thickness of upper and lower geomembrane liner Thickness of welding seam c D Welded section 1 gt Welded section 2 Test channel O00Q e Drive electronically steplessly adjustable and electronically controlled Digital display of SET and ACTUAL value The power transmission works through a three stage planetary gear Should rippling occur in the laid out geomem brane liners the upper or lower drive pressure roller can be switched over alternately 3 DESCRIPTION OF FUNCTIONS LEISTER Cosmo e Welding seam geometry gt The proof of quality in a welding seam peel test tensile test depends upon the thickness reduction in the area of the seam With a seam thickness reduction ranging between 0 2 0 8 mm the welding seam geometry is within the permissable range DVS 2225 part Il BAM This permissable range reflects the optimum interaction of the welding parame ters for temperature welding pressure and speed during the welding process Cross sectional diagram of an overlap weld Seam thickness reduction A B A Thickness of upper
6. cess by 8 10 m 449C 2 61 m min 1300 N 3 1 Measuring range mm 4 1 9 24 29 05 98 Welding temperature 448 C 453 C Stop 9 30 min max Welding speed without speed control min 1 59 m min max 2 61 m min Pressure min 1275 N max 1305N SOOO OOOO E EES E KKK Seam thickness reduction min 0 05 mm max 0 38 mm SOOO OOOO OOOO E E E E E S Ambient temperature 19 C 2 05 mm Length of welded seam 9 10 m Thickness of material ORK KKK KKK t t e e KKK DESCRIPTION OF TOOL LEISTER Cosmo sl Memory Card lf the welding data needs to be stored on a memory card before starting the welding process the operator should set the memory card level to ON See special operating instructions for Memory Card The following data is stored welding speed welding temperature pressure seam thickness reduction ambient temperature length of welding seam Alarm If there is a deviation from the seam thickness reduction sl audible tolerance an audible signal is activated This signal can be set to ON OFF on the alarm menu The welding operator has a choice of different languages s Language e German e English e French e Italian e Spanish Depending on the choice the terms are shown in the selected language on the display This should not be changed during the welding process The welding operator can make changes to time and sl Date Time date
7. e increase KON Value decrease End of entry Change of menu DESCRIPTION OF TOOL LEISTER Cosmo System level STRT Basic display V ACTUAL t ACTUAL Welding pressure V SET t SET Seam thickness reduction i Thickness of material Memory Card 7 y y l J H Ei Ei H y l lel E nes co lL a J Lf mr E in EH n J Welding y temperature H FI code Basis display lt i I at DESCRIPTION OF TOOL P Thickness of material LEISTER Cosmo Before welding the operator must enter the thickness of the geomembrane material The electronic processor requires this value to calculate the relevant seam thickness reduction Depending on the material thickness the range of seam thickness reduction is automatically adjusted on the print out The material thickness settings should not be changed during the welding process PI Seam thickness reduction offset To get an accurate reading before welding the operator must adjust the seam thickness reduction display The value on the display should read zero See page 6 Display 6 As the knurl pressure rollers press into the geomebrane material according to the welding pressure the electronic processor already interprets this as seam thickness reduc
8. g stated on the tool should correspond to the mains voltage For personal protection we strongly recommed the tool be connected to an RCCB Residual Current Circuit Breaker before using it on construction sites The tool must be operated under supervision The radiating heat can ignite combustible materials Protect the tool from damp and wet The tool is CCA certified CENELEC Certification Agreement Technical Data Voltage Power consumption Capacy Temperature Welding pressure Drive Overlap width Material thickness Size Weight 2 V 230 Hz 50 60 Ww 2000 XS max 450 stepless N max 2500 stepless m min 0 5 5 0 stepless mm 180 mm 1 5 3 0 mm 600 x 380 x 450 kg 320 DESCRIPTION OF FUNCTIONS LEISTER Cosmo e Heating System The hot wedge temperature is steplessly adjustable and electronically controlled As required the hot wedge can be steplessly adjusted to match the material thickness Heating system cross sectional diagram drive Pinch rollers Upper geomembrane liner pper drive pressure roller or egg aD Welding aa Z Adjustment direction gt KK Hot wedge HH j nut for hot Ss E 0 d wedge NNS S P Lower geomembrane liner Lower drive pressure roller e Welding pressure steplessly adjustable The welding pressure is transmitted via the toggle lever to the pressure rollers The swivel head guarantees an even seam thickness reduction on
9. on the Date Time menu Summer winter time different time zones f Adjustments are made at the factory on the Diagnosis Isi Diagnosis menu The welding operator has no access to this menu Printer Slacken the paper feed with the tension lever 1 Feed in paper 2 Pay attention to the direction of the arrow Tighten the paper feed with the tension lever 1 9 HOT WEDGE ADJUSTMENT LEISTER Cosmo The Hot wedge can be adjusted according to the material thickness as required e Guide the automatic wedge welding machine into the geomembrane liner or film to be welded e Hold the hot wedge guide handle 29 pull the hot wedge locking lever 28 and position the hot wedge 12 with the hot wedge guide handle 29 to engage release the hot wedge locking lever 28 e Tighten the tension lever 16 to the specified welding pressure e Loosen the hexagonal cap screw 26 e Adjust the guide roller front 14 to the correct height The distance of the hot wedge 12 from the guide roller front 14 should match the material thickness e Tighten the hexagonal cap screw 26 and secure the guide roller front 14 with a spanner e Loosen the hexagonal cap screw 27 e Adjust the guide roller rear 15 to the correct height The distance of the hot wedge 12 from the guide roller rear 15 should match the material thickness e Tighten the hexagonal cap screw 27 and secure the guide roller rear 15 with a
10. spanner e Do a test weld WELDING LEISTER Cosmo 4MC1 Welding preparation e Attach the carrying handle 5 and handle 6 e Check laying out of material Width of overlap min 100 mm and max 180 mm The geomembrane liners must be clean bet ween the overlap as well as above and below e Check Mains supply gt 5 kW anda minimum cable cross section 230 V upto50m 2x2 5mm from 50m 2x4 0mm e Connect the hot wedge welding machine to the mains supply e Carry out adjustments in the system with keyes 5 and e As required correct with keys and I e Heating up Switch on main switch 7 Adjust temperature via the keybord 9 H land I Switch on heating JH gt ON Motor Mj OFF Heating up time approx 5 min WELDING LEISTER Cosmo Beginning of welding process e Check Drive pressure rollers 22 23 as well as the hot wedge 12 must be clean before positioning Required welding temperature must be achieved Cable length cable guide Paper roll for printer e Guide and position the automatice wedge welding machine into the over lapped geomembrane liners e Pull the tension lever 16 without engaging the hot wedge e Set welding pressure Gently press the pressure roller with hand wheel 17 onto the material to be welded laid overlap _ _ e Feed the welding parameter into the programme level with the and keys Make corrections as necessary Keys and e Release the tension le
11. tion and it should therefore be neutralised accordingly P Speed Control System The automatic adjustment of the welding speed can be set before starting the welding process by using the ON OFF switch See page 4 JP The print out mode must be s elected before starting the welding process Graphic mode Continuous recording and print out of the seam thickness reduction over the whole length of the welded seam Tolerance mode Recording of the seam thickness reduction is only printed out if the seam thickness reduction tolerance has been exceeded Recording Mode _ gt Print Out Graphic mode COSMO Software Rev LEISTER Switzerland Date Time Hours of operating Start 29 05 98 15 39 4 0 Measuring range mm 5 0 450 C 2 6 1250 4521 C 2 10 4 0 Measuring range mm 5 0 Stop 29 05 98 15 40 Welding temperature min 447 C max 459 C Welding speed without speed control min 2 00 m min max 2 10 m min Pressure min 1240 N max 1292 N peteteceter set ee EEEE EEEE EE Seam thickness reduction min 0 04 mm max 0 45 mm ROOK Ambient temperature 10 C 2 50 mm Length of welded seam 2 40 m Thickness of material OOOO OOOK Tolerance mode COSMO Software Rev LEISTER Switzerland Date Time Hours of operating Start 29 05 98 MC File 00 07 28 002 Tolerance ex
12. ver 16 e Switch on the drive motor M gt ON e Engage the hot wedge 12 e Pull the tension lever 16 slowly e Start recording with If the welding is done without speed control the welding speed should be corrected with keys Vi and I should the seam thickness reduction deviate from the tolerance End of welding procedure e At end of the welding procedure approx 10 cm before end of weld before the hot wedge is moved out the recording should be stopped Key e 1 cm before the end of the welding seam release the tension lever 16 pull the locking lever 28 move the hot wedge 12 by the guide handle 29 out of the overlap and swivel up until it stops e Switch off drive motor using key M OFF e Clean hot wedge 12 with a wire brush Welding tips e Should ripples occur in the laid out geomembrane material the upper or lower drive pressure roller can be switched over alternately This allows wrinkle free welding so that the overlap width remains constant and the welding process should not have to be interrupted Rippling in the upper geomembrane liner engage upper drive roller 23 only e Rippling in the lower geomembrane liner engage lower drive roller 22 only e With T joints or when welding upwards both drive rollers must be engaged e For welding T joints a reduction in welding speed of approx 20 is recommen ded 11 BA Cosmo with printer 10 99 ACCESSORIES e Only
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