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Leister SEAMTEK 900 AT, Operating Instructions Manual

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Leister SEAMTEK 900 AT Operating Instructions Manual Download Page 11

11

6. Overview of Machine Elements

6.1 Front View

 1. 

Adjusting screws for nozzle position (Chapter 7.1)

 2. 

Touch panel (Chapter 7.2)

 3. 

Emergency stop button (Chapter 7.3)

 4. 

USB connection (Chapter 7.4)

 5. 

Main switch (Chapter 7.5)

 6. 

Feet (Chapter 7.6)

 7. 

Pedal unit (Chapter 7.7)

 8. 

Welding arm (pedestal) (Chapter 7.8)

 9. 

Transport rollers (Chapter 7.9)

 10. 

Upper pressure roller (upper wheel module, UWM)

 11. 

Guide holder (Chapter 7.10)

 12. 

Welding nozzle (Chapter 7.1)

 13. 

Adjustable hot air module

1

2

3

4

5

6

7

8

10

12

13

11

9

Summary of Contents for SEAMTEK 900 AT

Page 1: ...Leister Technologies AG Galileo Strasse 10 CH 6056 Kaegiswil Switzerland Tel 41 41 662 74 74 Fax 41 41 662 74 16 www leister com sales leister com SEAMTEK 900 AT GB ...

Page 2: ...ioning the Machine 9 4 8 1 Power Supply 9 4 9 Connecting the Compressed Air Supply 10 5 Your SEAMTEK 900 AT 10 5 1 Type Plate and Identification 10 5 2 Scope of Delivery standard model in transport box 10 6 Overview of Machine Elements 11 6 1 Front View 11 6 2 Back View 12 6 3 Outlets 12 6 4 Optional Accessories 12 6 4 1 Sidearm 12 6 4 2 Quickarm 13 6 4 3 Tape Delivery System 13 7 Operation and Ope...

Page 3: ... 31 8 10 Add Ons Screen 32 8 11 Information 32 9 Welding Sequence and Tips 33 9 1 Welding Sequence 33 9 2 Tips for a Better Weld Result 33 10 Seamtek 900 AT Warning and Error Messages 34 10 1 Error Levels 34 10 2 Error List 34 11 Frequently Asked Questions 37 12 Maintenance 38 12 1 Machine Fault 45 13 Accessories 45 14 Add ons 45 14 1 Monitoring 45 14 1 1 Monitoring the Welding Parameters 46 14 1 ...

Page 4: ...s that are available for using your SEAMTEK 900 AT This documentation also comprises a list outlining troubleshooting tips as well as warranty information and a table of contents This manual is intended to ensure that the SEAMTEX 900 AT is installed and operated in a proper manner Please read through all of the sections in this manual carefully before using your SEAMTEK 900 AT This version invalid...

Page 5: ...not reach between moving parts e g transport rollers in order to avoid any risk of objects being pulled in Danger At least two people are needed to safely remove the machine from the wooden crate Make sure that the machine does not topple over Caution The nominal voltage specified on the device must match the local supply voltage If the supply voltage fails the main switch and the drive must be swi...

Page 6: ...8 as an external blow off unit Local laws and regulations must be observed for this purpose Volume flow 20 C 234 m h 68 F 138 cfm Hose connection 90 mm 3 54 2 2 2 Extraction Normal operation In this mode the machine welds material The machine can be used in manual automatic and semi au tomatic operation Setup operation Everything must be set up first in order to prepare the machine for normal operat...

Page 7: ...y attention to the symbols for the center of gravity 4 2 Unloading the Machine from the Transport Crate Danger At least two people are needed to safely remove the machine from the wooden crate Make sure that the machine does not topple over Turn the feet 6 upward until the stop to ensure maximum floor clearance 4 Transport and Commissioning To safely unload the machine from the transport crate we r...

Page 8: ...tek 900 AT in readily inflammable surroundings and maintain a sufficient dis tance from combustible materials or explosive gases at all times The hot air welding machine must only be used in well ventilated rooms 4 5 Work Environment The Seamtek 900AT has rollers on its frame which allow the machine to be moved easily to a different location Please make sure that the required space for the machine ...

Page 9: ...dity of 95 and a maximum tempe rature of 45 C Individual components of the machine may no longer function properly if it is still used above these limits The operator should work in front of the machine on a height adjustable chair This allows the operating personnel to correctly view the welding point and therefore prevents postural problems The machine must always be used with gloves to protect ...

Page 10: ...ly 19 5 1 Type Plate and Identification 5 Your SEAMTEK 900 AT The type designation and serial number are specified on the type plate on your device Transfer this information to your operating instructions in the event of any inquiries to our representatives or authorized Leister service center please always refer to this information Article no Serial no 5 2 Scope of Delivery standard model in trans...

Page 11: ...ton Chapter 7 3 4 USB connection Chapter 7 4 5 Main switch Chapter 7 5 6 Feet Chapter 7 6 7 Pedal unit Chapter 7 7 8 Welding arm pedestal Chapter 7 8 9 Transport rollers Chapter 7 9 10 Upper pressure roller upper wheel module UWM 11 Guide holder Chapter 7 10 12 Welding nozzle Chapter 7 1 13 Adjustable hot air module 1 2 3 4 5 6 7 8 10 12 13 11 9 ...

Page 12: ...Leister accessories The electrical connection is supplied with mains voltage Leister is not liable for any non approved use 14 Ethernet output for accessory A 15 Electrical connection for accessory A 16 Compressed air connection for accessory A 17 Air line to heating element 18 Electrical connection for heating element 19 Compressed air connection for machine supply 20 Electrical connection for ac...

Page 13: ...gluing bonding non weldable materials The machine can be equipped with the tape delivery system in two different ways The tape delivery system is either fitted to the machine directly by Leister or mounted on the machine afterwards by the customer Before making any adjustments screw the nozzle as far as possible from the transport rollers 9 in order to prevent collisions Danger of crushing When the...

Page 14: ...y readjusted Before readjusting the welding nozzle 12 remove the mounted guide where applicable Turn the welding nozzle 12 in the starting position as far as possible away from the machine to ensure that the welding nozzle 12 does not collide with the machine when swiveling into position Slightly tighten the clamping lever for the positioning screws once the welding nozzle 12 has been adjusted Ini...

Page 15: ...e welding nozzle 12 as far as possible away from the machine in direction Y Before changing the welding nozzle 12 allow the machine to completely cool down The Seamtek 900 AT is a hot air welding machine Depending on the respective process some components can become incredibly hot Always operate the machine with due caution Danger The welding nozzle 12 heating element pipe and the heating element ...

Page 16: ... as to edit all welding parameters Before operating the touch panel carefully read through Chapters 7 and 9 Caution Only use your fingers to operate the touch panel Do not use non authorized objects such as pens and tools in order to avoid damaging the touch panel 2 7 1 6 Air Outlet Air from the pump that is not required in the machine is discharged from the machine via a bypass This is why hot air...

Page 17: ...lement and the pump are switched off Caution If the emergency stop switch is activated while the heating element is switched on this can cause considerable damage to the machine Therefore make sure that the machine is switched on again as soon as possible otherwise the heating element can be damaged As soon as the machine is switched on again it automatically activates the cooling process This mea...

Page 18: ...at the separating wall between the two pedals 7 A 7 B 7 7 Feet Turn the feet 6 clockwise seen from above to turn the feet downward and turn the feet anticlockwise to turn the feet upward Ensure that the machine is suitably and securely positioned before it is commissioned 7 9 3 bar Pressure Reducing Valve Compressed air cylinders are used to move the AHAM For this purpose a pressure reducing valve...

Page 19: ...alls downward unchecked it may sustain irreparable damage When folding down the pedal be mindful of a possible crushing risk and do not keep any parts of your body between the contact surface and pedestal To make replacements between the individual arms please set all settings to Manual and Off in advance The transport rollers 9 are now open and the welding nozzle 12 is in the starting position Sw...

Page 20: ... mechanism for the quickarm 28 Now carefully fold the arm downward and fit the lower retaining pin 28 B until it fully engages Pull the lower retaining pin 28 B out to disen gage the locking mechanism of the quickarm 28 Now fold the arm upward into the upper position and insert the upper retaining pin 28 A until it completely engages Swivel the sidearm 27 upward and screw the quick release 27 A in ...

Page 21: ...the quick release 27 A and carefully and slowly swivel the sidearm 27 downward 25 mm wide transport rollers 9 are mounted as standard The powered transport rollers 9 clamp and transport the material The maximum roller speed for original Leister accessory rollers is 30 m min To change the transport rollers 9 completely cool the machine in advance using the cool down mode In the Periphery area set t...

Page 22: ...re now open and can be changed Completely detach the M6 screws 9 A and remove these together with the washer The transport rollers 9 can now be easily removed To mount the transport rollers 9 push the transport roller 9 onto the holder 9 B Make sure that the guide pins of the holder match the friction holes of the transport roller 9 Check the seating of the transport roller 9 to ensure that the en...

Page 23: ...e guide can be moved into the desired position on the clamping elements Once the guide and the welding nozzle 12 have been adjusted check that the welding nozzle 12 does not touch anything when swiveling in and out Different guides are available as accessories Ask your distribution partner about the various options available Caution First adjust the welding nozzle 12 according to Chapter 7 1 1 bef...

Page 24: ... and delete welding formulas Perform test weld to determine parameters Select machine accessory Choose language Information screen current values error display and external data storage load data via USB At the upper edge of the screen tabs for individual screen views can be selected The view you currently see is indicated by the tab selected The tab for the current view is in white ...

Page 25: ...he time between the last nozzle movement and the start of the transport rollers 9 By means of the pre heating time the transport rollers 9 can be started after a delay in order to heat the material at the start of the weld seam for a longer period of time Air volume The air volume is controlled between the air pump and heating element Depend ing on the welding nozzle 12 used the setpoint must be a...

Page 26: ...e between the three pedestal sidearm and quickarm drives the motor must be deactivated in advance in each case Pedestal drive By selecting this tab the pedestal drive can be switched on or off The pedestal drive is switched off The pedestal drive is switched on Sidearm drive By selecting this tab the sidearm drive can be switched on or off The sidearm drive is switched off The sidearm drive is swi...

Page 27: ...f the machine To change the current user shaded in gray select the relevant user in this case User or Guest and enter the password Log in by pressing the Log in button The following standard passwords are defined as passwords Standard passwords Admin 11 User 22 Guest 33 You can change these standard passwords First login in as the user for which you would like to change the password and then select...

Page 28: ...abs can be selected 9 9 Load formula 9 9 Save formula 9 9 Delete formula 9 9 Test Tabs can be selected 9 9 Add ons Tabs can be selected 9 9 Settings 9 9 Language Tabs can be selected 9 9 Language selection 9 9 Info Tabs can be selected 9 9 9 Formula backup 9 9 Formula recovery 9 9 Delete alarms 9 9 Individual users have different authorizations The table below gives an overview of the authorizatio...

Page 29: ...Machine Settings Setting Description Language In the language selection tab choose your standard language Selecting Save saves your choice and your language is automatically preselected when the system is re started The standard language is English EN Auto reverse distance Distance that the material is lead back at the end of the weld With the correct setting you can achieve a seamless and leak pr...

Page 30: ...rmulas select the respective formula and then press the Load button You will then be prompted to confirm your selection with OK Once the selected formula is loaded the view switches to the Home view Pay attention to the formula labels at the top right when entering the welding parameters The label contains the formula number selected and is visible until the welding parameters are changed Note If a...

Page 31: ...er the approximate welding speed in the left hand window area The welding process for the test strip begins with 50 of this approximate welding speed and is linearly reduced to 50 Start the test weld using the foot pedal of the Start Weld pedal unit 7 View 4 Carefully tear the test strip starting from the beginning of the weld and measure the distance from the start of the test strip to the point ...

Page 32: ... instructions separately enclosed with the product The Information view enables users to see the process data for simplified troubleshooting or fault localization In addition in the event of an error errors are displayed in the alarm list with the date time of the first occurrence error number and a brief error description If an error occurs please refer to Chapter 10 Warning and Error Messages Trou...

Page 33: ...h as little tension in the material as possible In practice tension is inevitable but can be significantly reduced by feeding in the material correctly Pay attention to how the material leaves the welding zone too The still warm weld seam should not immediately fall downward upon leaving the welding zone The cooling phase should also be as tension free as possible It is advisable to use a table or ...

Page 34: ...alue Air Flow Set point adjusted lowered Check and correct if necessary Max pump power limit reached 101 1 Warning 101 Air Flow increased Check Value Air Flow Set point adjusted increased Check and correct if necessary Max pump power limit reached 102 1 Warning 102 Reset of Air Volume Controller Too high Setpoint Air Volume can not be reached Setpoint is too high 103 1 Warning 103 Reset of Air Vol...

Page 35: ...LC corrupted 216 2 Error 216 Can not read Recovery Source File Recipe File on Memory Stick corrupted Do backup your Data from PLC to Memory Stick 217 2 Error 217 Can not write Recovery Destination File Recipe File on PLC corrupted 218 2 Error 218 Can not close Recovery Destination File Recipe File on PLC corrupted 219 2 Error 219 Can not close Recovery Source File Recipe File on Memory Stick corru...

Page 36: ...le Missing Memory Stick 262 2 Error 262 Can not close Backup Destination File Missing Memory Stick 263 2 Error 263 Can not close Backup Source File Machine Settings File on PLC corrupted Do recover your Data from your Memory 264 2 Error 264 Can not open Recovery Source File Machine Settings File on Memory Stick corrup ted Do backup your Data from PLC to Memory Stick 265 2 Error 265 Can not open Re...

Page 37: ...h Heat Controller Restart initiated Wedge Temperature can not be reached for long Time Wedge Temp Controller has been reset Stop and restart Heating 274 2 Error 274 Air Temperature Setpoint not reached Lower Airvolume or Temperature Setpoint restart Heater Air Temperature of fast Controller can not be reached Setpoint is too high Air Volume is too high Ambient Temperature or Inlet Air Temperatur o...

Page 38: ...he heater is switched on If the heater is active the display value PWM is displayed in green on the information screen If the heater is switched off the display is shown in red If this value is greater than 20 and no temperature increase can be determined at the welding nozzle replace the heating element 7 Significant wave formation at the weld seam Make sure that the correct arm pedestal quickarm ...

Page 39: ...filter reservoir the pres sure must be removed from the system For detailed information on disassembling and assembling the filter see reference document in annex Time period Monitoring and maintenance work Spare parts Tools As Necessary Clean the welding nozzle 12 with a brass brush designed for this purpose Clean or replace the air filter Air filter Brass brush Daily before Start Up Check the stabil...

Page 40: ...ation on disassembling and assembling the filter see reference document in annex 4 Change heating element 1 Remove the screws 24 A Danger to life because of volt age bearing component Before opening the switch cabinet the device must be disconnected from the power supply at all poles Disconnect the power plug 2 Remove the cover 24 B 3 Detach the hose clip 24 C and pull the hose from the connector 4...

Page 41: ...24 B Detach the white and green cable on the side of the thermocouple 3 Loosen the nut of the lead through 24 G and the nut on the T piece 24 H 4 Remove the thermocouple 154 620 and replace it with a new one 5 Re assemble the elements following the disassembly steps in reverse CAUTION There is a risk of burning when changing the heating element This process must only be performed after the cool do...

Page 42: ...is of nozzle 1A Control the clamping movement of the roller 1B Control the opening movement of the roller 2A Nozzle Z axis Control upward movement 2B Nozzle Z axis Control downward movement 3A Nozzle X axis Control extension movement 3B Nozzle X axis Control retraction move ment 4A Nozzle Y axis Control extension movement 4B Nozzle Y axis Control retraction move ment 1A 1B 2A 2B 3A 3B 4A 4B 7 Disp...

Page 43: ... angle of the welding arm Caution Following the adjustment process tighten the nuts 2 1 Detach the screws 8 C 2 2 Adjust the welding arm using the screws 8 D Caution Following the adjustment process tighten the screws 3 1 Detach the nuts 8 E ...

Page 44: ...ller Caution Following the adjustment process tighten the nuts 4 1 Detach the screws 8 G on both sides 4 2 Manually move the welding arm backward or forward Caution Following the adjustment process tighten the screws 5 1 Detach the safety screw on both sides 8 H ...

Page 45: ...age occurs during the welding process end the weld immediately with the right pedal of the pedal unit 7 In the event of this set NOZZLE IN CLAMP PRESSURE and WELD PRESSURE to Manual The rollers must be open In addition switch off the motor and start the cool down mode Once the system has completely cooled down the stuck welding material can be detached 12 1 Machine Fault This machine add on allows...

Page 46: ...lue exceeds this air volume range this is indicated by a visual alarm During welding an acoustic alarm is emitted in addition to the visual alarm The monitoring of both the air volume and temperature welding parameters is deactivated The monitoring of both the air volume and temperature welding parameters is activated A Within the limits Green lamp signal B Outside the limits Heating cooling or st...

Page 47: ... No guarantee or warranty claims exist for devices which have been converted or changed by the purchaser or for which non original Leister spare parts have been used 17 Warranty A Within the limits Green lamp signal B Outside the limits Heating cooling or standby phase Red lamp signal B Outside the limits During welding an alarm is emitted in addition to the red lamp 14 1 4 Operating Hours Counter...

Page 48: ...6 Bruno von Wyl CTO Andreas Kathriner GM 18 Declaration of Conformity 20 Quick Reference Guide 20 1 Switching on Starting 20 2 Switching Off 1 Swivel the hot air blowers 8 upward stops the drive motor 2 Switch off the heater with the Heater On Off button 3 Wait for the end of the cool down process approx six minutes 4 Switch off the main switch 5 5 Pull out the supply voltage plug 1 Make sure that...

Page 49: ...49 Quelle Bilder SMC 21 Appendix ...

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Page 56: ...rvice Centre is Leister Technologies AG Galileo Strasse 10 CH 6056 Kaegiswil Switzerland Tel 41 41 662 74 74 Fax 41 41 662 74 16 www leister com sales leister com Copyright by Leister BA SEAMTEK 900AT 03 2017 Art 157 271 ...

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