Leister SEAMTEK W-2000 AT Manual Download Page 1

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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

[email protected]

SEAMTEK

W-900 AT

W-2000 AT

Summary of Contents for SEAMTEK W-2000 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 W 900 AT W 2000 AT EN ...

Page 2: ...ing the Machine 9 4 8 1 Power Supply 9 5 Your SEAMTEK W 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 Switch Cabinet 12 6 4 Outlets for Accessories 12 6 5 Optional Accessories 13 6 5 1 Quickarm 13 6 5 2 Tape Delivery System 13 7 Operation and Operating Elements 13 7 1 Hot ...

Page 3: ... Tab 32 9 6 1 Safety Instructions 32 9 6 2 Wedge Adjustment Wizard 32 9 6 3 Changing the Welding Wedge 33 9 6 4 Positioning the Welding Wedge 35 9 7 Accessories Tab 38 9 8 Information Tab 38 10 Welding Sequence and Tips 39 10 1 Welding Sequence 39 10 2 Tips for a Better Weld Result 39 11 SEAMTEK W AT Warning and Error Messages 40 11 1 Error Levels 40 11 2 Error List 40 12 Maintenance 44 12 1 Maint...

Page 4: ...ontents Please read through all of the sections in these operating instructions carefully before using your SEAMTEK W AT for the first time These operating instructions supersede all operating instructions with an earlier date The older versions no longer ap ply When a new version of the operating instructions is issued this version will be superseded and will no longer apply Leister Technologies ...

Page 5: ...lectromechanical parts Take the necessary precautions to prevent hazards posed by mechanical parts Risk of entanglement Avoid reaching between moving parts such as the transport rollers in order to prevent objects or body parts becoming entangled Two people are needed to move the machine Make sure that the machine cannot topple over Caution The nominal voltage specified on the device must match th...

Page 6: ...use beyond the type of use described is deemed non intended use Normal operation In this mode the machine welds material The machine can be used in manual axes on off manually automatic axes controlled automatically and semi automatic operation mixture of manual and automatic Setup operation Everything must be set up first in order to prepare the machine for normal operation This is done in the se...

Page 7: ...hen moving the machine in the transport crate pay 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 To ensure that the machine is unloaded ...

Page 8: ... The working area may exceed the marked area 4 4 Transportation outside of the Company s Premises Danger Never use the SEAMTEK W AT in readily inflammable surroundings and maintain a sufficient distance from combustible materials at all times The SEAMTEK W AT must only be used in well ventilated rooms 4 5 Work Environment 4 6 Workplace and Workplace Environment SEAMTEKW 900AT SEAMTEKW 2000AT A Req...

Page 9: ...trained specialist must connect a plug that guarantees the specifications of the machine and complies with all statutory requirements specified in the respective country The following specifications regarding the current source and the connector plug must be observed Connection Plug The machine must be connected to a residual current circuit breaker Residual current protection devices prevent dang...

Page 10: ...ry 1 x tape delivery system optionally mounted optional accessory Connection cable International 230 V Function USA 240 V Function Wire colors of the machine connection cable brown L1 230 V AC L1 120V AC light blue N L2 120 V AC yellow green PE PE The type designation and serial number are specified on the type plate on your device Please transfer this information to your operating instructions in...

Page 11: ...stal 7 Foot pedal 8 Adjustable feet 9 Switch cabinet 10 Main switch 11 USB connection 12 Emergency stop switch 13 Operating unit 14 Tape delivery system accessory 15 Quickarm accessory 16 Suspension equipment for pedal 17 Air inlet for switch cabinet cooling 18 Power connection for machine 19 Ethernet output for accessory B 1 11 12 13 14 15 10 9 7 8 2 3 6 5 4 ...

Page 12: ... The switch cabinet 9 has two separate chambers an upper and a lower chamber The chambers must never be opened while the machine is connected to the power supply The switch cabinet and in particular the elements inside it can reach very high temperatures The machine must therefore always be allowed to cool down sufficiently before opening the switch cabinet in order to prevent burns 20 Electrical ...

Page 13: ...rimarily used for sealing taping seams and 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 an authorized person Danger The hot wedge 22 wedge holder 3 wedge bracket fixture 2 and surrounding ele ments can become v...

Page 14: ... pens and tools in order to avoid damaging the touch panel 13 Caution In emergency situations press the emergency stop button 12 to disconnect the machine from the current supply The touch panel 13 can be used to see current operating statuses as well as to edit all welding parameters Before operat ing the touch panel carefully read through Chapter 9 for information on this subject Pressing the em...

Page 15: ... emergency stop button is released Select the language and press Start to start up the machine Caution The axes will then move automatically to their initial position The accessories are set to their initial state Use the USB connection 11 to back up your saved recipes or settings externally or to use them on several SEAMTEK W AT machines at the same time Use an empty USB stick and insert it into ...

Page 16: ...l If the pedal is pressed during the welding process the hot wedge swivels out and welding is stopped You can start the welding process by pressing the right hand pedal 7B once hot wedge swivels in and the wheels then start turn ing The basic speed is set in advance via the min speed parameter Once the process has started the welding speed can be adjusted step lessly with pedal 7B The maximum spee...

Page 17: ...hat no body parts become trapped Set the Wedge In and Clamp Force sliders to Manual to prevent the machine from starting inadvertently To change between the individual welding arms please set all settings to Manual and Off in advance The trans port rollers 4 are now open and the welding wedge 22 is in the starting position Switch off the motor and select the welding arm you want to activate Pedest...

Page 18: ...ing mechanism of the quickarm 15 Now fold the arm upward into the upper position and insert the up per retaining pin 28A until it completely engages It is essential to ensure that the quickarm is securely fastened to prevent it from folding down and causing injuries The transport rollers 4 are normally the same width as the hot wedge The width of the hot wedge determines the welding width In speci...

Page 19: ...order to prevent burns Danger Do not reach between moving components e g the transport rollers 4 When working on the open system do not wear articles of clothing such as scarves shawls or neckties and tie up long hair or protect it by wearing headgear The transport rollers 4 are now open and can be changed Completely detach the M6 screws and remove these to gether with the spring ring and washer 4...

Page 20: ...er to release it Before fastening a guide check whether the welding wedge 22 has been adjusted Insert the rod and then clamp the guide holder 5 with the clamping lever The guide can be moved into the desired position on the clamping elements Once the guide and the welding wedge 22 have been adjusted check that the hot wedge does not touch anything when swiveling in and out Different guides are ava...

Page 21: ...ays make sure that you mount the right wedge 22 on the right welding holder This wedge can be used at up to 10 m min This wedge has a small wedge material contact surface This means that the material can be guided effectively and the guiding resistance is lower This wedge is ideal for cases such as curves products with complex shapes and applications where a maximum speed of 10 m min is sufficient...

Page 22: ...slag If the welding performance deteriorates or mechanical damage occurs replace the wedge Chapter 8 5 The wedge holder must be replaced in the event of damage or if the welding width needs to be changed Thanks to the quick change system the holder can be replaced quickly and easily Turn screws 2A and 2B a quar ter turn counterclockwise while holding on to the wedge The wedge holder can then simpl...

Page 23: ...mizes potential errors Always ensure that the heating is switched off before changing the wedge The hot wedge plate is fastened in place with four screws Loosen the screws slightly and remove the hot wedge 22 the hot wedge plate Then check the filler piece 22A for possible damage The filler piece holds the wedge in the right shape during the welding process and protects the wedge from mechanical d...

Page 24: ...h a number of languages to choose from Select your language and press the Start button Note that certain axis initialization movements will be performed when you press Start After startup the Home screen will be displayed In this view all welding parameters can be set and peripheral devices such as the heating and drive can be switched on 9 2 Home Screen Tabs to change the view Chapter 9 2 1 Weldi...

Page 25: ... recipes Adjust or change the wedge 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 indi cated by the tab selected The tab for the current view is in white ...

Page 26: ...r wheel can be operated 100 faster double speed or up to 99 slower If the maximum speed of 30 m min is exceeded by the differential the value is automatically adjusted to the speed The value of the upper differential is maintained Energy The energy is the energy value acting on a defined area The energy value can be set from 0 E A to 200 E A The theoretical hot wedge temperature is calculated auto...

Page 27: ...f The pedestal drive is switched on Quickarm drive By selecting this tab the quickarm drive can be switched on or off The quickarm drive is switched off The quickarm drive is switched on Wedge In Wedge In is in Auto mode and the wedge is automatically swiveled in by pressing the Start Stop Weld pedal unit Wedge In is in Manual mode and the wedge is swiv eled out Wedge In is in Manual mode and the ...

Page 28: ...e defined as passwords Standard passwords Admin 11 User 22 Guest 33 You can change these standard passwords First log in as the user for which you would like to change the password and then select Change Password Now enter the old password You will then need to enter the new password twice When entering the password for a second time make sure that it is identical to the password you entered the f...

Page 29: ...ted Load recipe Save recipe Delete recipe Wedge Tabs can be selected Wedge Change Wedge Adjustment Accessories Tabs can be selected Settings Language Tabs can be selected Language selection Info Tabs can be selected Recipe backup Recipe recovery Meter Values Delete counter values Axis Setup Delete Alarms Setting the date time Individual users have different authorizations The table below gives an ...

Page 30: ...n be made 9 4 Settings Tab Setting Symbols Description Auto Reverse Distance Distance by which the material is reversed at the end of the weld With the correct setting you can achieve a seamless and leak proof weld seam As standard 2 to 3 mm is to be selected Clamp Force Clamp force used to press the wheels against each other in standby mode The clamp force can only be adjusted if the Clamp Force ...

Page 31: ...unted Aham Right Enable Activates the AHAM installed on the right hand side Can only be acti vated if the relevant mechanical components are installed Prewarming factor The calculating factor for the prewarming energy saved in the soft ware This should only be changed when the parameter of the pre warming chapter 9 2 2 borders on the limits of the settings range and satisfactory welding results ca...

Page 32: ...aded parameters in a new recipe location Change recipe Load the recipe to be changed and edit the recipe parameters in the Home view Delete the previously loaded recipe and save your edited welding parameters under the desired recipe location 9 6 Wedge Tab This tab contains the Wedge Change and Wedge Adjustment menu options These menus guide you through the process of changing the wedge and or adj...

Page 33: ...r to carry out the next step Symbol Designation Wedge Change Click on this symbol to change the wedge by following the step by step instructions You can then position the wedge in a subsequent step Wedge Adjustment This menu option provides step by step instructions for positioning the wedge 9 6 3 Changing the Welding Wedge Switching off the Heating ...

Page 34: ...ware will use this information to calculate the required welding energy in relation to the speed In this step you need to switch the heating on again in order to calibrate the hot wedge Then press Calibrate The hot wedge will be calibrated on the basis of the resistance value Selecting the right welding holder and welding wedge width Calibrating the hot wedge ...

Page 35: ...he right welding holder welding width has been selected and whether the contact surfaces are free from contamination see Chapter 8 Resistance check Before adjusting the position of the welding wedge make sure there are no objects e g mounted guides within the movement radius of the wedge holder in order to prevent any collisions when the wedge is swiveled in Switch the slider to Auto and carry out...

Page 36: ...pedal is activated the wedge will swivel to the welding position Use the and buttons to set the wheel pressure so that the wheels are just touching without exerting any pressure on each other Then confirm with OK The wheels are then automatically pressed together by 1 5 mm Preparing the wedge Setting the wheel pressure ...

Page 37: ...o that it is in contact with the wheels along its entire length as shown in the picture Confirm with OK Setting the wedge clearance to the wheels Then adjust the X axis alignment of the wedge so that the entire wedge width is in contact with the wheels Adjusting the X axis Pressing the foot pedal saves the values and moves the hot wedge back to its initial position Saving settings ...

Page 38: ...rrors 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 12 Warning and Error Messages Troubleshooting Q A This tab also allows you to save recipes to an external USB stick 9 7 Accessories Tab 9 8 Information Tab Process data Recipes Error table Software version Date time Setting the date ...

Page 39: ...ng 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 other similar object on which the material can rest after it leaves the welding zone Speed Feeding in material requires experience Personnel new to the process should start with a lower welding speed t...

Page 40: ... Clearance UPWM Axis is more than 10 mm 111 1 Warning 111 Heat turned off due to low min speed Heat turned off due to low min speed 120 1 Warning 120 Touch Calibration failed ADS Return Code Trouble in calibration procedure of Touch Pa nel Restart machine if warning is recurrent 200 2 Error 200 Puller Motor Driver Error Driver error Puller Check for Overload 201 2 Error 201 Upper Motor Driver Erro...

Page 41: ... on PLC SPS corrupted 219 2 Error 219 Can not close Recovery Source File Recipe File on Memory Stick corrupted Do backup your Data from PLC SPS to Memory Stick 220 2 Error 220 Open File in Read Machine Settings In SettingsRead Error Machine Settings Open File All Pass words set to Standard 221 2 Error 221 Read CSV Line in Read Machine Settings InSettingsRead Error Read CSV Line Machine Settings 22...

Page 42: ...Movement not possible UPWM Axis is alrea dy operating 239 2 Error 239 LV Wedge Resistance Tempera ture too high In LvWedge Wedge requires recalibration change wedge 240 2 Error 240 Open File in Read Recipes In RecipesRead Error Recipes Open File 241 2 Error 241 Read CSV Line in Read Recipes In RecipesRead Error Read CSV Line Recipes 242 2 Error 242 Close File in Read Recipes In RecipesRead Error C...

Page 43: ...r Data from your Memory 264 2 Error 264 Can not open Recovery Source File Machine Settings File on Memory Stick cor rupted Do backup your Data from PLC SPS to Memory Stick 265 2 Error 265 Can not open Recovery Destina tion File Machine Settings File on PLC SPS corrup ted 266 2 Error 266 Can not read Recovery Source File Machine Settings File on Memory Stick cor rupted Do backup your Data from PLC ...

Page 44: ...loth Damp cloth 6 months Clean or replace the filter for the switch cabi net Depending on the ambient conditions Filter Art 156 762 Isopropyl alcohol compressed air 12 1 Maintenance Intervals 292 2 Error 292 Supervision EL6080 NOVRAM fbWrite bWcState Invalid Working Counter of EL6080 Shutdown SEAMTEK W AT Machine and restart 293 2 Error 293 Supervision EL6080 NOVRAM Write FB busy for t 200ms Can n...

Page 45: ...end the weld immediately with the left hand pedal 7A of the pedal unit 7 If a hazardous situation arises switch off the machine immediately with the emergency stop button 12 Set the sliders in the Periphery area to Manual so the wheels are opened Carefully remove the material causing the blockage Good wheel positioning is very important to ensure good contact between the wedge weld material and wh...

Page 46: ...e range of accessories available at www leister com Use only original Leister spare parts and accessories otherwise any warranty or guarantee claims will be invalidated You can find more information at www leister com Leister Technologies AG and its authorized service centers offer welding courses and training sessions You can find more information at www leister com 13 Accessories 14 Add ons 15 S...

Page 47: ...CH 6056 Kaegiswil Switzerland hereby declares the machine described below released by us fulfills the provisions of the following EC directive s Designation Welding Machine Type SEAMTEK 900 AT SEAMTEK 2000 AT SEAMTEK W 900 AT SEAMTEK W 2000 AT Option EC directive s 2006 42 EC Machinery Directive 2014 30 EU EMC Directive 2011 65 EU RoHS Directive Harmonised standards EN ISO 12100 2010 EN 55014 1 20...

Page 48: ...e center 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 SEAMTEK W AT en 08 2018 03 2020 Art 163 181 ...

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