Mini- Plast 4” Butt Fusion Plastic Pipe Welding Tool w/ electric heating element.

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Mini-Plast 4” Butt Fusion Plastic Pipe Welding Tool w/ electric heating element.

description

Mini- Plast 4” Butt Fusion Plastic Pipe Welding Tool w/ electric heating element. Technical Data General. Technical Data Heating Element Details. Technical Data Planer Tool Details. Basic Machine with Table Support. Safety Rules. All persons using the machine must have the following - PowerPoint PPT Presentation

Transcript of Mini- Plast 4” Butt Fusion Plastic Pipe Welding Tool w/ electric heating element.

Page 1: Mini- Plast  4” Butt Fusion Plastic Pipe Welding Tool  w/ electric heating element.

Mini-Plast 4” Butt Fusion Plastic Pipe Welding Tool w/ electric heating element.

Page 2: Mini- Plast  4” Butt Fusion Plastic Pipe Welding Tool  w/ electric heating element.

Technical Data GeneralMaterial: PP, PE, PVDF

Pipe diameter range OD = 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 LbsBreaker required 10AEmissions ●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)●Do 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

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Technical DataHeating Element DetailsPower: 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

Weight appr. 4.5 Lbs (2kg)

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Technical DataPlaner Tool Details

Weight appr.4.5 Lbs (2 kg)

Basic Machine with Table SupportMaterial frame and clamping tool Aluminum

Max. force 135 Lbs. (600N)

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Safety RulesAll 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

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ElectricalOnly 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).

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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.

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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.

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Description1 Planer2 Heating element3 Protective box4 Tabletop base5 Basic machine

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Heating Element

1 Red on/off switch2 Temperature control knob3 Green indicating light

Note: Green blinking light indicates “go” weld temp.

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Base Machine

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1 Horizontal alignment2 Miter weld adjustment3 Upper guide rod4 Spindle5 Tightening nut6 Vertical alignment7 Force scale8 Hand wheel9 Base frame10 Lower guide rod

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Planer (or planing tool)1 Cutting blades2 Guide to move center of planer

(for angle & T-pieces)3 Locking pin4 Ratchet

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Electric Planer 1 Cutting blades2 Guide to move center of planer

(for angle & T-pieces)3 Locking pin4 On/Off switch

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Proper Welding EnvironmentProtected from direct sunlight

Temperature above 40˚F (5˚C)

Protected from rain, wind and dust

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Clamps / Reducing Inserts

Pipe clamp Fitting clamp

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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.

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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.

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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.

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Flange Adapter & Fitting ClampFor flanges and other machined fittings

a special flange adapter can be usedFor fittings a narrow fitting clamp must

be used. Change clamp under base.

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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.

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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.

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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.

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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)

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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.

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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.

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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.

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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

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Care of Heating ElementTake care - Do not scratch surface of heater.

Contractor is responsible for heater repair costs.

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StorageKeep both guide rods and spindle lubricated.Store the machine dry.