Model: Pro-X High Output Extrusion Welder

Size: px

Start display at page:

Download "Model: Pro-X High Output Extrusion Welder"

Darleen McCarthy
6 years ago
Views:

for general unpacking, installation, setup and operation of

1 Model: Pro-X High Output Extrusion Welder Instruction Manual Model Scope of Manual: This manual contains procedures for general unpacking, installation, setup and operation of your DEMTECH Services, Inc. Extrusion Welder. DEMTECH Services, Inc.

2 TABLE OF CONTENTS Introduction General Safety Information (Safety) 3 Intended use 3 Maintenance Advice 3 Unpacking and Power Connection (Start-up) 4 Unpacking 4 Electrical Plug Connection 4 Power Requirements 4 Generator Recommendation 5 Extension Cords 5 Accessories 5 Operating Procedure (Operation) 6 Power-up 6 Setting/Adjusting Operating Temperatures 6 Recommended Temperature Settings 6 Setting Barrel (molten rod) Temperature 7 Setting Pre-heat Air Temperature 7 Feeding Rod 7 Shutdown 8 2

3 SAFETY GENERAL SAFETY INFORMATION The Pro-X is a high voltage piece of equipment. Always disconnect the power source before performing service and maintenance to the unit. Never pull or carry welder by the power cord or electrical connection. Always keep slack in extension cord while in operation to avoid damage to the power connection. Keep hands and other body parts clear of hot air nozzle and elements when hot. Always use Pro-X in a well-ventilated area when welding materials that produce toxic fumes. Do not inhale toxic fumes when present. Do not operate near flammable materials. Do not apply flammable liquids to seam area. Allow unit to cool down for at least 5 minutes before putting it back into shipping/storage case. Protect unit from exposure to direct rainfall or standing water. Never attempt to weld in standing water.. INTENDED USE The Pro-X extrusion welder has been manufactured according to the latest technology and current safety regulations. However, improper use or abuse may lead to hazardous conditions for the user or third party or damage to the unit. Always have this manual handy at the location where the Pro-X is being used so that it can be referred to quickly and easily. The technician assigned to operate this welder must have read through and become familiar with this manual before staring work. Do not make changes or modifications to the Pro-X relative to safety without contacting the manufacturer for advice. 2. MAINTENANCE Maintenance, inspection, and adjustment of the Pro-X may only be carried out by qualified personnel. Before removing or installing spare parts or performing other repair operations to the Pro-X, consult the manufacturer for advice on proper procedures. This will help insure a safe and successful outcome. Always make sure all screw connections are tight before attempting to operate the unit after maintenance or repair. Also make sure all covers, guards, and other safety devices have been reinstalled before use. 3

4 START-UP UNPACKING AND POWER CONNECTION. UNPACKING The Pro-X extrusion welder is delivered to you in a sturdy, reusable shipping/storage case. The custom foam insert protects the unit from damage during shipping and should be left in the case at all times. When the unit is out of the case, make sure the lid is closed to avoid dirt, dust, and rain from getting inside. Once the Pro-X has been removed from the case, it is ready for use except for any necessary set-up adjustments. For set-up procedure, refer to the set-up adjustment section in this manual. 2. ELECTRICAL PLUG CONNECTION The Pro-X is supplied with an appropriate plug-end according to the specified operating voltage of the welder. The supplied plug-end can be replaced by the customer as long as the new one is rated at a minimum of 20 amps. 3. POWER REQUIREMENTS The voltage requirement of your Pro-X extrusion welder is 220V AC. It will operate properly with voltage ranging from 200V AC to 250V AC. NOTE: The above operating voltage range refers to actual voltage at point of welder plug-in. In other words, the voltage under load at the welder end of extension cord. To measure voltage under load, connect the welder to the extension cord and generator that will be used. Start generator and turn both welder power switches to the on position. While both the green and red indicator lights located on the control panel are illuminated showing that the barrel and pre-heater are heating, separate the plug at the end of the welders power cord just enough to expose the prongs. Using a digital volt meter, measure the voltage under load between the hot and neutral prongs. This procedure should only be performed by a qualified electrician. 4

5 4. GENERATOR RECOMMENDATION If using house power from a building circuit, please contact the manufacturer for advice on plug and cord configuration. In-field generators should be rated for at least 3500 watts, however a rating of 5000 watts or more is recommended in order to obtain the best welder performance and temperature control. The higher the wattage rating of the generator, the better the performance of the welder. Keep in mind that the length and wire gauge of the extension cord being used combined with the capacity of the generator will ultimately determine the operating voltage reaching the welder. 5. EXTENSION CORDS Extension cords should be at least 2 gauge and regardless of overall length should have a minimum of plug-end connections. The more plug end connections you have between the power supply and the welder, the more severe the operating voltage drop will be. Maximum recommended extension cord length: 0 gauge, 3 wire 2 gauge, 3 wire 4 gauge, 3 wire 6 gauge, 3 wire 300 Feet 200 Feet 00 Feet Not Recommended 6. ACCESSORIES The Pro-X has been designed for user friendly operation. However, Demtech strives to make your life easier by inventing accessories and attachments to our welders that make operation even friendlier. For example, the SP-00 Spool holder attachment is available to help manage welding rod while welding. Please contact supplier for more information and pricing. 5

6 OPERATION OPERATING PROCEDURE. POWER-UP Connect Pro-X power cord to power source making sure that the voltage is correct for the model of welder you have. Please refer to page 4 and 5 of this manual for details. Both temperature controllers should illuminate and display current temperature of barrel and pre-heat air (usually ambient temperature when starting-up for the first time that day). Switch the pre-heat blower fan rocker switch located on the control panel to the on position (up). The hot air blower unit, situated on top of the welder should turn on and air should begin blowing out of preheat nozzle at the end of the barrel. Switch the pre-heater element rocker switch located on the rear of the green colored pre-heat blower unit to the on or I position. This will allow the pre-heat air to begin heating. SETTING/ADJUSTING OPERATING TEMPERATURES: Note: There are two temperature controllers located on the main control panel. The one on the top controls the hot air pre-heat temperature and the one on the bottom controls the barrel (molten rod) temperature. For recommended temperature settings, please refer to chart below or contact Demtech technical support for advice. RECOMMENDED TEMPERATURE SETTINGS: Temperature setting will vary a great deal due to the wide range of variables that can be experienced in the field. For example, ambient temperature, sheet temperature, sheet thickness, wind conditions, etc. will vary. As it is difficult to create a chart that covers all conditions, we recommend contacting Demtech with information on the above conditions. We will be happy to recommend appropriate settings. 6

7 2. SETTING BARREL (MOLTEN ROD) TEMPERATURE To display current barrel temperature set point, press and hold blue set button located on the bottom temperature controller. To adjust set point, press up or down arrow buttons while holding down set button. 3. SETTING PRE-HEAT AIR TEMPERATURE To display current pre-heat air temperature set point, press and hold blue set button located on the top temperature controller. To adjust set point, press up or down arrow buttons while holding down set button. NOTE: Once temperatures have been adjusted to desired settings, allow 5 minutes for barrel and air temperatures to rise and stabilize to set points before attempting to feed welding rod. The Pro-X is equipped with electronic cold start protection. However, feeding rod before barrel temperature has reached set point can cause damage to drive motor unit. 4. FEEDING WELDING ROD Start drive motor by pulling trigger switch and lock in the on position by depressing lock button and then releasing trigger. Molten extrudate may or may not begin to exit Teflon welding shoe depending on how well the unit was purged after its last use. While drive motor is on insert 4 or 5mm welding rod into the rod feed hole located on barrel near adjustable handle mount. Apply inward pressure until rod begins to feed without assistance. Molten material (extrudate) will begin to extrude from end of Teflon welding shoe. Upon initial start-up, allow extrudate to flow for 5 to 0 seconds, purging any residual material from previous use, then turn drive motor off by pulling and releasing trigger. You may now proceed with welding operations. 7

8 SHUT-DOWN 5. SHUT-DOWN PROCEEDURE When all work is completed but before powering-down welder, it is recommended that the residual welding rod and extrudate be purged from barrel as follows:. Cut welding rod leaving approximately 6-2 inches in welder. 2. Start drive motor and allow remaining rod to enter barrel. Continue to run motor until RPM increases and extrudate no longer exits Teflon shoe. 3. Stop drive motor and allow extrudate hanging from end of welder to cool for several minutes. 4. Once extrudate has cooled, pull from end of welder in a twisting motion. This removes all material remaining in Teflon shoe area and prevents a cold plug from causing problems on next start-up. Turn hot air pre-heat element off by switching rocker located on the back of blower unit to the O position. Allow blower to run for several minutes or until temperature displayed on pre-heat controller is at 200 F or below. At this point you can simply un-plug the Pro-X extrusion welder, allow to cool for 5 minutes, and place in shipping/storage case. FOR ALL ADDITIONAL INFORMATION OR IF YOU HAVE ANY QUESTIONS, PLEASE CONTACT US AT: Demtech Services, Inc 644 Capitol Avenue Diamond Springs, CA, USA 9569 (888) 324-WELD (9353) (530) (530) Fax demodave@demtech.com 8

9 Warranty DEMTECH Services, Inc. warrants all equipment of its manufacture to be free from defects in materials, workmanship, mechanical parts, and labor for a period of one year from the date of shipment to the original buyer and ninty days for electrical. This warranty excludes normal wear items such as gears, bearings and chains. The liability under this warranty is limited to replacement parts and labor on equipment when the equipment is returned prepaid to the factoryor its authorized service center with prior authorization from DEMTECH Services, Inc., and upon examination by DEMTECH Services, Inc., is determined to be defective. At DEMTECH Services, Inc.'s option, a service representative may be dispatched to the equipment location. As an additional protection, DEMTECH Services, Inc. warrants that for a period of 90 days from the date of shipment to the original buyer, pending prior authorization from DEMTECH Services, Inc., there will be no charge for service related shipping of parts and/or equipment or for authorized travel of a service representative to the equipment location. After 90 days, all costs incurred for shipping the equipment or parts thereof or for travel are the responsibility of the buyer. Our warranty for this equipment is rendered void if the unit has been repaired, taken apart or modified, or attempted to be, unless such actions have been taken in accordance with written instructions received from DEMTECH Services, Inc. The warranty is also void if the equipment has been subjected to abuse, accident or other abnormal conditions. IF ANY FAULT DEVELOPS, THE FOLLOWING STEPS SHOULD BE TAKEN:. Notify DEMTECH Services, Inc. by calling Overseas customers should contact the local DEMTECH authorized service center. Please be prepared with the model number, serial number and full details of the difficulty. Upon receipt of this information, service data or shipping instructions will be provided by DEMTECH Services, Inc. Do not return the unit for repair without first contacting the factory or its representative for instructions. 2. After the initial 90 day period, on receipt of shipping instructions, forward the equipment prepaid to the factory or its authorized service center as instructed. If requested, an estimate of the charges will be made before work begins, especially with those cases where the DEMTECH Services, Inc. product is not covered by the warranty. 3. If the original carton and packing are not available, the product should be packed in a container with a strong exterior and surrounded by a protective layer of shock-absorbing material. DEMTECH Services, Inc. advises returning the equipment at full value to the carrier. DEMTECH Services, Inc. reserves the right to make changes in design at any time without incurring any obligation to install the same changes on units previously purchased. This warranty states the essence of the obligations or liabilities on the part of DEMTECH Services, Inc. THE FORMAL, COMPLETE AND EXCLUSIVE STATEMENT OF DEMTECH SERVICES, INC. S WARRANTY IS CONTAINED IN ITS QUOTATIONS, ACKNOWLEDGEMENTS AND INVOICES. DEMTECH Services, Inc. neither assumes, nor authorizes any person to assume for it, any liability in connection with the sale of its equipment other than those set forth herein. Appendix D

The PRO - X High output extrusion gun for production welding of geomembranes and

Pro-X Model 600-000 Demtech s custom drive motor design with precision, matched

Electronic switches and controls are easy to use and are protected from damage and

Includes custom shipping/storage case, sealed for protection against moisture,

(888) 324-WELD (specifications on reverse) 2 ea. Teflon Welding Shoes included.

10 The PRO - X High output extrusion gun for production welding of geomembranes and rigid thermoplastics. Pro-X Model Demtech s custom drive motor design with precision, matched gears for super quiet operation and long life. Guaranteed. Electronic switches and controls are easy to use and are protected from damage and accidental adjustment. Includes custom shipping/storage case, sealed for protection against moisture, with foam insert. Call Demo Dave today for information on a test drive. (888) 324-WELD (specifications on reverse) 2 ea. Teflon Welding Shoes included. Custom models available upon request. Call for details. DEMTECH Services, Inc. P.O. Box 265, Placerville, CA Capitol Ave., Diamond Springs, CA (888) 324-WELD (9353) (530) Fax: (530) demodave@demtech.com

PRO - X High Output Extrusion Welder The PRO-X Model 600-000 High Output Extrusion Welder, manufactured by DEMTECH Services, Inc.

11 PRO - X High Output Extrusion Welder The PRO-X Model High Output Extrusion Welder, manufactured by DEMTECH Services, Inc., is the standard of the industry extrusion welder for production welding of thermoplastic liners, pipe, rigid sheet stock, as well as many other plastic welding applications. Drawing from many years of experience in the plastic welding industry, we ve designed features and functions into its design to satisfy the needs of the most demanding welding technicians. Powerful drive motor with bullet Proof gearbox and custom built armature and windings with extended warranty. Exclusive high precision gears (interchangeable with existing units) for super quiet operation and increased drive motor life. GUARANTEED! Large control box makes it easy to diagnose and repair electronic components. Control box cover hoods controls and switches protecting them from direct sunlight and accidental contact. Separate measurement and control of pre-heat and barrel temperatures with electronic cold start protection. Reliable Grand L pre-heat air unit maintains accurate temperature and high air flow. Ergonomic soft grip mid handle adjusts easily to different positions for right handed or left handed operation. Handle doubles as a stand, making it nearly impossible to tip welder over, preventing pre-heat air from burning a hole in the liner material. Hardened screw and barrel promotes high flow rates with minimal load on the drive motor. Non-Twisting rod feed design makes it easier to manage welding rod. Works with 4 or 5MM rod. Custom 200W barrel heater maintains tight temperature control. Teflon welding shoes are available in Demtech s pre-machined design or blanks. Lightweight.. High output.. Reliable.. Affordable Technical Specifications: Model Number: Weight (welder only) 29 lbs. (3 kilos) Shipping Weight 65 lbs. (29.5 kilos) Dimensions (welder only) 30 X 9 X Welding Rod Size 4 or 5 mm Round Output w/4mm Rod 9 lbs. (4 kilos) per hour Output w/5mm Rod 2 lbs. (5.44 kilos) per hour Material Range PE, PP, PVC Welding Range 2 mil to 2 wall thickness Operating Voltage 230VAC, single phase Power Consumption 4320W, VAC Packaging Sturdy molded case w/foam insert DEMTECH Services, Inc. P.O. Box 265, Placerville, CA Capitol Ave., Diamond Springs, CA (888) 324-WELD (9353) (530) Fax: (530) demodave@demtech.net

13 8 7

15 D29 D23 D6 D5 D24 D2 D3 D22 9 D7 2 D0 D9 D26 D8 D7 D 3 D8 4 D27 D28 2 D6 D D25 D2 D3 D4 D4 D20 D9 D D4 4 D5

16 Parts List Pro X Model /A Reference # Order # Description 600 2EX/A Thermocouple, Air, X2 w/ Plug Tube Assembly, Pre Heat Pre Heat Nozzle Snap Ring, Thrust & Drive Shaft D20 Bearings, Thrust A Screw, Extrusion, Mixing Plug Style Clamp, Barrel Barrel Only Nozzel TS M Mount Block, Teflon Shoe 600 TS 60 Teflon Shoe Only, 40 80mil EX/A Thermocouple Barrel, X2 w/ Plug X/A Heat Band ASSY Lockdown Knob, Standle Standle EX Plug, X2 Pre Heater Bracket, Leister Pre Heat PreHeat/A Pre Heater Assembly, Forsthoff Grand L, w/ Plug PreHeat/ERON/A Pre Heater Assembly, Eron complete w/ Plug Temperature Controler, Pre Heat Program EX Receptical, Pre Heater Relay EX Receptical, Pre Heat, Thermocouple EX Receptical, Heat Blanket, Thermocouple, Female EX Receptical, Heat Blanket Temperature Controller, Heat Band Program Curcuit Breaker, 25A EX Curcuit Breaker, 5A B. Mixing Plug All Thread 5/6 8 x Spring, Strandle Insert, Lockdown Knob Switch, Pre Heater Blower On/Off Clamp, Cable 35 Non Stock Screw, Cable Clamp to Electrical Box, 4x0 SHCS 36 Non Stock Screw, Lid to Electrical Box, 4x6 SHCS D 600 D3EX Key, Drive Shaft D Snap Ring, Thrust & Drive Shaft D3 600 D7 Bearing, Drive Shaft D4 600 D24.EX Screw, Gear Housing D5 600 D24EX Housing, Gear Box D6 600 D30EX/A Drive Shaft w/ Larger Gear D7 600 D Helical Gear w/ Pinion Small ASSY D8 600 D5 Sper Gear w/ Pinion ASSY

17 D9 600 D0EX Bearing Plate D0 600 D26 Vent Disc D Non Stock Screw, Bearing Plate, Vent Disc D2 600 D02EX/A Armature Complete w/ Fan & Bearing D3 600 D23 Seat, Rear Arm Bearing D4 600 D22 Field Coil D5 600 D06 "D" Handle Kit D6 600 D07 Trigger Switch D7 Non Stock Screw, Trigger Switch, Drill Motor D8 Non Stock Screw, Brush, Drill Motor D9 600 D03 Brush, Holder D D04 Brush Insulator D2 600 D05 Carbon Brush, (Sold as Pairs) D22 Non Stock Screw, "D" Handle, Drill Motor D Plug, Standle D D08 Motor Housing D D02/S Seal, Armature D D25 Bearing, Gear Box D27 Non Stock Oil Plug, Gear Box D28 Non Stock Washer, Oil Plug D D30/S Seal, Drill Output Shaft

18 Pre-Heater, Eron Style, DemTech Part No. 600-PREHEAT/Eron/A

19 Spare Parts List ErOn/DemTech Reference # Part # Qty. Description 2 A Air Filter 3 A Handle 4 A Countersunk Screw, 3(30)x80mm 5 A Company Logo 7 A Cord Guard, 9.6x75mm 8 A PT Fillister Head Screw M4x6 9 A Strain Relief 0 A Slotted Pan Head Screw M4x6 A Torsional Protection Washer 2 A Mains Terminal M4 3 A Rocker Switch 4 A Terminal Block 5 A Thread Forming Fillister Head Screw M4x8 6 A Motor 230V SL 7 A Carbon Brush 22 A Rubber Ring 23 A 6025 Steel Hub 24 A Countersunk Screw M4x2 25 A Turbine Housing Lower Part 26 A Turbine 27 A Stripper 28 A Turbine 29 A Hexagon Nut, M5/0, 5D 32 A Countersunk Screw, 3(30)x0mm 33 A Turbine Housing Upper Part 34 A Plug Socket 35 A Double Soldering Tag 36 A PT Fillister Head Screw 30x8 37 L Heating Element Type 32, 230V/2200W 38 A Gasket 70x48x4 39 A Mica Tube 47, 6x95mm 40 A Fillister Head Screw M4x0 4 A Heater Tube 42 A Blind Plug

OPERATING MANUAL. BAK Thermoplastic Welding Technology AG 1

OPERATING MANUAL. BAK Thermoplastic Welding Technology AG 1 OPERATING MANUAL BAK Thermoplastic Welding Technology AG 1 SAFETY Danger to life Unplug the tool before opening it as live components and connections are exposed. Danger of fire and explosion in case of