Technical Data General Material:PP, PE, PVDF Pipe diameter rangeOD = 20mm – 110mm (1/2” to 4” Asahi Pipe) Shipping box (l, w, h) appr. 710 x 410 x 410 mm appr. 28” x 17” x 17” Total weight (without crate) appr. 30 kg / 67 Lbs Breaker required10A Emissions ●Sound level is below 70 dB ●When using the above mentioned materials and welding temperature below 500˚F (260˚C), No toxins are emitted Environment●Keep the work area clean (especially weld area) ● D o not weld in environment below 40˚F (5˚C), If necessary heat and tent area before welding ●Avoid humidity, if necessary erect a tent ●Avoid direct sunlight ●If it is windy, close ends of pipe
Technical Data Heating Element Details Power:600 Watts Voltage:110 V (± 10%) Current:3.5 A (± 10%) Frequency:50 / 60 Hz Element: ●electric temperature control ●Power indicator light, on / off switch ●Connecting cable with plug and earth ground Weightappr. 4.5 Lbs (2kg)
Technical Data Planer Tool Details Weightappr.4.5 Lbs (2 kg) Basic Machine with Table Support Material frame and clamping toolAluminum Max. force135 Lbs. (600N)
Safety Rules All persons using the machine must have the following ◦Basic safety and accident prevention training ◦Trained and understanding the function of the machine ◦Have all the personal protection equipment necessary ◦Have a copy of the working instructions provided with the machine ◦Only skilled workers are allowed to work on the electrical components
Electrical Only skilled workers are allowed to work at electrical appliances! The electrical equipment of the machine must be checked regularly. Loose connections and damaged cables must be replaced immediately. Disconnect the current supply before making any repairs to electrical tool components. All electric tools (heating element, planer, basic machine with clamping tools and control unit) need to be protected from rain and dripping water. (If necessary use welding tent).
Risk of Burns: You can be burned, and/or flammable materials can be ignited! The heating element is heated up to more than 392 °F ! Do not touch the surface of the heating element. Do not leave the heating element unattended. Use enough safety distance to materials which may be ignited. Wear safety gloves. Insert the heating element into the heat protective metal frame box after use. Only transport or hold the heating element at the handle. Other heater surfaces present burn risk.
Trip Hazards Be sure that electrical wires do not impede safe egress around the tool work area. Be sure that the cables lie in such a way that danger is maintained to a minimum.
Description 1Planer 2Heating element 3Protective box 4Tabletop base 5Basic machine
Heating Element 1Red on/off switch 2Temperature control knob 3Green indicating light Note: Green blinking light indicates “go” weld temp
Base Machine Horizontal alignment 2Miter weld adjustment 3Upper guide rod 4Spindle 5Tightening nut 6Vertical alignment 7Force scale 8Hand wheel 9Base frame 10Lower guide rod
Planer (or planing tool) 1Cutting blades 2Guide to move center of planer (for angle & T-pieces) 3Locking pin 4Ratchet
Electric Planer 1Cutting blades 2Guide to move center of planer (for angle & T-pieces) 3Locking pin 4On/Off switch
Proper Welding Environment Protected from direct sunlight Temperature above 40˚F (5˚C) Protected from rain, wind and dust
Welding Process Wear safety gloves as a protection against burns! A stop-watch should be available for recording the actual times for the heating and cooling. A table should be available from which the parameters for the pipe dimensions to be welded may be taken. The heating element surfaces are to be clean and, above all, free from grease. Therefore, they are to be cleaned with lint free cloth and clean spirits (eg. isopropyl alcohol) before every weld joint or if they are dirty. The anti-adhesive coating of the heating element must remain undamaged in the working area.
Welding Process (Heater) Switch on the heating element and adjust the required welding temperature at the adjusting screw. Note: Heater may be preset by factory. The proper temperature is obtained when the green control light is blinking.
Welding Process (Clamping) Screw in the required reduction inserts according to the outside diameter of the pipes to be welded. (Tools/screws in zippered bag) Put the work pieces into the clamping tools, tighten the clamping nuts and align the work pieces with respect to one another. For the fabrication mitered joints, the angle on the basic clamping tools can be set (on each side from –30° up to +30°). In case of long pipe ends, use roller stands for alignment.
Flange Adapter & Fitting Clamp For flanges and other machined fittings a special flange adapter can be used For fittings a narrow fitting clamp must be used. Change clamp under base.
Welding Process (Planing) Pipe ends must be planed square to one another. Open the clamps so planer fits between the work pieces. Place the planer between the pipe ends and lock in place at lower rail before starting the planer. Secure clothing from risk of catching on electric planer tool! Move the pipe ends towards one another using the hand wheel and plane pipe ends with a low force. Planing must be carried out until a circumferential “ribbon” is planed from both pipe sides.
Welding process (heater) Open the clamps slightly using the hand wheel. Note heat-soak time, maximum change-over time and cooling time for the pipe dimension to be welded from the welding tables. Place the heating element, which has been cleaned and brought to nominal temperature, between the pipes. Close clamps to the weld pressure.
Welding Process (Alignment) Close clamps by turning hand wheel on spindle shaft. Check pipe alignment and gap on the joining pipe ends. According to DVS 2207, the misalignment on the pipe outer side must not exceed 0.1 x pipe wall thickness, the admissible gap must not exceed 0.5 mm. The adjustment is made with the horizontal (dovetail) and vertical ramp (high-low) adjustments and locking screws.
Welding Process (Initial Bead) Bring pipe ends together at Initial Weld Force. When the prescribed circumferential bead height has been reached, reduce pressure by moving the hand wheel. (Heat Soak should be at zero to 10% of the initial weld pressure or force.) The heat-soak time starts. (See Weld Charts)
Welding Process (Joining) After completion of the heat-soak time, open the clamps, remove the heating element as quickly as possible, close the clamps and gradually bring up the force to final weld pressure. After joining pipe, place heater into its storage box. The maximum time frame for this process is predetermined by the value for the change-over time taken from the weld charts.
Welding Process When the final weld pressure has been reached, start the cooling time. During the cooling period, re-adjust pressure if necessary. After the cooling time, relieve pressure force, open the clamps and remove the welded parts for inspection and quality control check.
Weld Charts: Weld Charts: Identify proper pipe material, size and wall thickness for precise weld data. Follow weld force data for initial melt force, heat soak force is “near zero” to 10% of initial weld force. Heat soak time commences after melt bead forms on heater plate surface. After heat soak time, employ fast changeover to open/close clamps. Final weld force equals initial melt force. Note cooling time after joining.
Planer Maintenance Never lay planer onto the planer discs. The blades of the planer must be checked for sharpness. Replace as needed (blades are sharp on two sides) Max. thickness of shaving = 0.2mm
Care of Heating Element Take care - Do not scratch surface of heater. Contractor is responsible for heater repair costs.
Storage Keep both guide rods and spindle lubricated. Store the machine dry.