SimTech WeldTech Instruction manual

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WeldTech
MiniPlast
OPERATION
MANUAL
Corrosion Resistant Fluid and
Air Handling Systems.
WeldTech - MiniPlast Instruction Manual
Table of Contents
1. DESCRIPTION OF THE PRODUCT...................................................................................................... 3
1.1 Usage and Purpose-oriented Use............................................................................................. 3
1.2 Overview............................................................................................................................... 3
1.3 Safety Measures...................................................................................................................... 4
1.4 Conformity............................................................................................................................. 4
1.5 Designation of the Product...................................................................................................... 4
1.5.1 Technical data . ........................................................................................................ 4
1.6 Equipment and Accessories:.................................................................................................... 5
2. SAFETY RULES..................................................................................................................................... 6
2.1 Explanation of the Symbols and Indications............................................................................. 6
2.2 Obligations of the Owner....................................................................................................... 6
2.3 Obligations of the Worker . .................................................................................................... 6
2.4 Measures of Organization ...................................................................................................... 7
2.5 Instructions for the Staff.......................................................................................................... 7
2.6 Structural Modifications on the Machine................................................................................. 7
2.7 Cleaning the Machine............................................................................................................. 7
2.8 Danger while Handling the Machine....................................................................................... 7
2.9 Dangers caused by Electric Energy.......................................................................................... 8
2.10 Specific Dangers................................................................................................................... 8
2.10.1 Danger of being burnt by Heating Element, Reception Box and Welding Area .......... 8
2.10.2 Danger of Stumbling over Electric Wires.................................................................. 8
2.10.3 Danger of Cutting / Squeezing / Catching Clothes . .................................................. 8
2.11 Warranty and Liability........................................................................................................... 9
3. FUNCTIONAL DESCRIPTION . ..........................................................................................................10
4. OPERATING AND INDICATING ELEMENTS.......................................................................................11
4.1 Elements on the Basic Machine / Table Support......................................................................11
4.2 Elements at Heating Element and Planer.................................................................................12
4.3 Elements at the Electric Planer (optional)................................................................................13
5. STARTING AND OPERATING.............................................................................................................14
5.1 Starting . ...............................................................................................................................14
5.1.1 Exchanging the Reduction Inserts..............................................................................15
5.2 Welding Process....................................................................................................................15
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WeldTech - MiniPlast Instruction Manual
6. WELDING TABLES............................................................................................................................. 18
7. MAINTENANCE AND REPAIR ............................................................................................................20
7.1 General .................................................................................................................................20
7.2 Clamping Elements ...............................................................................................................20
7.3 Planer....................................................................................................................................20
7.4 Storage .................................................................................................................................20
8. TRANSPORT ........................................................................................................................................................ 21
9. WIRING DIAGRAMS ....................................................................................................................... 22
10. SPARE PARTS LIST............................................................................................................................ 23
10.1 Basic Machine with Clamping Devices and Reduction Inserts...............................................23
10.2 Basic Machine ....................................................................................................................26
10.3 Clamping Devices for Fittings...............................................................................................27
10.4 Manual Planer 4504220 ......................................................................................................28
10.5 Electric Planer (optional) .....................................................................................................30
10.6 Heating Element..................................................................................................................32
10.7 Protection Box.................................................................................................................... 34
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WeldTech - MiniPlast Instruction Manual
1. Description of the Product
This chapter gives important basic information about the product and its prescribed use. All technical
details of the machine are put together as a general arrangement.
1.1. Usage and Purpose-oriented Use
The SIMTECH MINIPLAST 2 has been designed for heating element butt welding of pipes and
fittings out of PE, PP and PVDF with a diameter range of Ø = 20 - 110 mm.
The machine is kept small so that it can easily be used in the pipe system.
For moulded narrow bends and fittings, special small basic clamping devices are available.
All use going beyond is not purpose-oriented.
The manufacturer is not responsible for damages caused by misuse. The risk is held only by the
user.
Also part of the purpose-oriented use is
• Respecting all the indications of the working instructions and
• Performing the inspection and maintenance works.
1.2. Overview
4
1
2
5
3
.O
WITHOUTILLUSTR
1.060606
$ENOMINATION
-ANUALPLANER
%LECTRICPLANEROPTIONAL
"ASICMACHINE
4ABLESUPPORT
(EATINGELEMENT
2ECEPTIONBOX
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WeldTech - MiniPlast Instruction Manual
1.3. Safety Measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured. Therefore these working instructions have
to be thoroughly read and the corresponding safety regulations must be necessarily adhered to.
1.4. Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications. The development,
manufacturing and mounting of the machine were made very carefully.
1.5. Designation of the Product
The product is designated by a sign at the basic frame.
It contains the type of the machine, the serial number and the year of construction.
1.5.1 Technical data
1.5.1.1 SIMTECH MINIPLAST 2 General Data
-ATERIAL
0IPEDIAMETERRANGE
3HEETSTEELCARRYINGCASELXWXH
7EIGHTWITHOUTPACKING
&USE
7IRECROSSSECTION
%MISSIONS
!MBIENTCONDITIONSINTHEWELDINGAREA
000%($06$&0%
/UTSIDE ŒMM
XXMM
KG
!
MMÁ
4HESOUNDINTENSITYLEVELISBELOW
D"!
7HENUSINGTHENAMEDPIPEMATERIALS
ANDWHENWELDINGBELOW—#NO
TOXICANTDAMPARISES
+EEPTHEWORKSHOPCLEANNODUSTAT
THEWELDINGAREA
DONOTWELDBELOW—#IFNECESSARY
PREHEAT
AVOIDHUMIDITYIFNECESSARYUSEA
WELDINGTENT
AVOIDSTRONGSUNRAYSINFLUENCE
PROTECTFROMWINDSHUTTHEPIPEENDS
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WeldTech - MiniPlast Instruction Manual
1.5.1.2
Heating Element
0OWER
6OLTAGE
#URRENT
&REQUENCY
/UTSIDE Œ
3URFACE
!TTACHEDELEMENTS
7ATT
6 Õ
! Õ
(Z
MM
NONSTICKCOATED
ELECTRONICTEMPERATURECONTROL
CONTROLLAMP
CONNECTINGCABLEWITHPLUG
APPRKG
7EIGHT
1.5.1.3
Manual Planer
7EIGHT
APPRKG
1.5.1.4Basic Machine and Table Support
-ATERIALFRAMEANDCLAMPINGDEVICES
-AXFORCE
1.5.1.5
!LUMINIUM
.
Electric Planer (optional)
ONREQUEST
0OWER
6OLTAGE
#URRENT
&REQUENCY
7EIGHT
6 Õ
ONREQUEST
(Z
ONREQUEST
3EESPAREPARTSLISTFORORDERNUMBERSANDSINGLEPARTSWHENORDERINGPLEASESTATETHEMACHINE
NUMBER
1.6. Equipment and Accessories:
Following tools and accessories are part of the delivery:
X
X
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(EXAGONALSOCKETSCREWKEYSIZEFORSCREWINGINOUTTHE
REDUCTIONINSERTS
(EXAGONALSOCKETSCREWKEYSIZEFORTIGHTENINGTHEOPTIONAL
CLAMPINGSHELLSFORFITTINGS
3CREWSFORREDUCTIONINSERTSFLATHEADSCREWSFORREDUCTION
INSERTSFLATHEADSCREWSFORMOUNTINGTHEOPTIONALCLAMPING
SHELLSFORFITTINGS
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WeldTech - MiniPlast Instruction Manual
2. Safety Rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of the basic
safety indications and rules.
• These working instructions contain the most important indications to run the machine safely.
• The safety indications are to be followed by all persons working on the machine.
2.1. Explanation of the Symbols and Indications
In the working instructions, the following denominations and signs are used for dangers:
This symbol signifies a possible danger for the life and the health of persons.
• The non-respect of these indications may have heavy consequences for the health.
I
I
This symbol means a possible dangerous situation.
• The non-respect of these indications may cause light injuries or damages on goods.
This symbol gives important indications for the proper use of the machine.
• The non-respect of these indications may conduct to malfunctions and damages on
the machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
• It is a help for using all the functions on your machine in an optimal way and helps
you to make the job easier.
The regulations for the prevention of accidents are valid (UVV).
2.2. Obligations of the Owner
I
The owner is obliged only to let persons work at the machine who
• Know about basic safety and accident prevention rules and are instructed in the handling of the
machine, as well as who
• Have read and understood the safety chapter of this manual and certify this by their signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the Worker
All persons who are to work at the machine are obliged before working:
• to follow the basic safety and accident protection rules.
• to have read and understood the safety chapter and the warnings in this manual and to confirm
by their signature that they have well understood them.
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WeldTech - MiniPlast Instruction Manual
2.4. Measures of Organisation
• All equipment required for personal safety is to be provided by the owner.
• All available safety equipment is to be inspected regularly.
• The working instructions have to be permanently kept at the place of use of the machine. They
are to be at the operator‘s disposal at any time and without much effort.
• In addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
• Every time the machine changes hands or is being rent to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.5. Instructions for the Staff
• Only skilled and trained persons are allowed to work at the machine.
• It must be clearly defined who is responsible for transport, mounting and dismounting,
starting the operation, setting and tooling, operation, maintenance and inspection, repair and
dismounting.
• A person who is being trained may only work at the machine under supervision of an
experienced person.
2.6. Structural Modifications on the Machine
• No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
• Machine parts which are not in a perfect condition are to be replaced immediately.
• Only use original SIMTECH spare and wear parts.
2.7. Cleaning the Machine
The used materials and tissues are to be handled and disposed of properly, especially:
• When cleaning with solvents
• When lubricating with oil and grease.
2.8. Danger while Handling the Machine
The machine SIMTECH MINIPLAST 2 is constructed according to the latest technical standards and
the acknowledged technical safety rules. However, dangers for the operator or other persons standing
nearby may occur. Also material damages are possible.
The machine may only be used
• According to the purpose-oriented usage
• In safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately.
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WeldTech - MiniPlast Instruction Manual
2.9. Dangers caused by Electric Energy
Only skilled persons are allowed to work at electrical appliances.
• The electrical equipment of the machine has to be checked regularly. Loose connections and
damaged cables have to be replaced immediately.
• The heating element has to be protected from rain and dropping water, if need be use a welding
tent.
• According to VDE 0100, the use on construction sites is only allowed with a power distributor
with a FI-safety switch.
2.10. Specific Dangers
2.10.1 Danger of being burnt by Heating Element, Reception Box and Welding Area
You can burn yourself, inflammable materials can be ignited! The heating element is heated up to more
than 200° C !
• Do not leave the heating element unsupervised.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
• Always put the heating element back into the reception box before and after each use.
• Transport the heating element at the handle only, do not touch the surfaces of the heating
element.
2.10.2 Danger of Stumbling over Electric Wires
• Make sure that no person has to step over the wires.
2.10.3 Danger of Cutting / Squeezing / Catching Clothes
• Always put the planer back into the reception box before and after each use.
• Transport the planer at the handle only and do not touch surfaces.
• Do not put hands between clamped pipe ends.
• Make sure that your clothes are not caught by the planer.
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WeldTech - MiniPlast Instruction Manual
2.11. Warranty and Liability
Fundamentally our “General Sales and Delivery Conditions” are valid.
They are at the owner’s disposal latest when signing the contract. Guarantee and liability demands
referring to personal injuries or damages on objects are excluded if they are caused by one or several of
the following reasons:
• Not using the machine according to the prescriptions.
• Inexpert transport, mounting, starting , operating and maintenance of the machine.
• Running the machine with defective or not orderly mounted safety appliances.
• Ignoring the information given in this manual.
• Structural modifications on the machine without permission.
• Unsatisfactory checking of parts of the machine which are worn out.
• Repairs performed in an inexpert way.
• In case of catastrophes and force majeure.
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WeldTech - MiniPlast Instruction Manual
3. Functional Description
Basically the international and national guidelines are to be followed.
The plastic pipes are clamped by means of the clamping devices.
Then the front sides of the pipes are cut plane and parallel by means of the planer and the misalignment
of the pipes is checked.
The heating element is inserted and the pipes are pressed against the heating element under defined
adjusting pressure. This process is called “adjusting”.
After the prescribed bead height being reached, pressure is reduced, the heating time begins. The
function of this time is to heat up the pipe ends.
After expiration of the heating time, the slides are opened, the heating element is removed quickly and
the pipes are driven together again. The time gap from the removal of the heating element to joining the
pipes is called change over time.
The pipes are joined under prescribed welding pressure and then cool down under pressure (cooling
time).
The welded joint can be un-clamped, the welding process is finished.
Heating element heats
the pipes up to welding
temperature
Finished welding with internal
and external bead
10
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WeldTech - MiniPlast Instruction Manual
4. Operating and Indicating Elements
4.1. Elements on the Basic Machine / Table Support
6
7
8
9
10
11
13
14
15
12
.O
$ENOMINATION
4IGHTENINGNUT
5PPERGUIDEBAR
3CALE
(ANDWHEEL
3TARGRIPFORBASICMACHINE
3PINDLE
,OWERGUIDEBAR
3CREWSFORVERTICALOFFSET
(EXAGONSCREWX
3CREWSFORHORIZONTALOFFSET
1.060606
&UNCTION
4IGHTENINGOFTHEPIPES
'UIDANCEFORTHESLIDE
$ISPLAYOFTHEAPPLIEDWELDINGFORCE
MAXKPDISPLAYED
/PENINGCLOSINGTHESLIDES
APPLICATIONOFTHEADJUSTINGFORCE
!TTACHINGTHEBASICMACHINEATTHETABLE
SUPPORT
!DVANCEOFTHESLIDE
'UIDANCEFORTHESLIDE
&IXINGTHEPLANER
2ESTFORTHEHEATINGELEMENT
"YLOOSENINGTHESCREWSTHECLAMPINGDEVICE
CANBEMOVEDUPWARDSORDOWNARDS
3ETTINGTHEANGLE
"YLOOSENINGTHESCREWSTHECLAMPINGDEVICE
CANBEMOVEDTOTHELEFTORTOTHERIGHTSIDE
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WeldTech - MiniPlast Instruction Manual
4.2. Elements at Heating Element and Planer
18
19
16
17
.O $ENOMINATION
+NOBWITHSLOT
#ONTROLLAMPGREEN
&UNCTION
3ETTINGTHETEMPERATUREFORTHEHEATINGELEMENT
4HEREARETHREEDIFFERENTSTATES
s /UTSIGNALIZESTHATTHEHEATINGELEMENTISNOT
HEATEDUPATTHEMOMENTORTHATITCOOLSDOWN
s "LINKINGTHETEMPERATUREOFTHEHEATINGELEMENTIS
MAINTAINEDBYAPULSEPOSITIONRATIO
s /NSIGNALIZESTHATTHEHEATINGELEMENTISHEATEDUP
12
2ATCHET
/NOFFnSWITCH
FORELECTRICPLANEROPTION
3TARGRIPSCREW
ATTHEMOMENTANDHASNOTYETREACHEDTHEDESIRED
TEMPERATURE
4URNINGAROUNDTHEPLANER
4HEPLANERCANBESWITCHEDONOFF
4HEPLANERHASTOBESWITCHEDOFFAFTERUSE
!TTACHINGTHEPLANERATTHEGUIDANCEBARBY
TURNINGTHESCREW
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WeldTech - MiniPlast Instruction Manual
4.3. Elements at the Electric Planer (optional)
21
20
.O
.AME
"UTTONONOFF
,OCKINGKNOB
1.060606
&UNCTION
4HEBUTTONMUSTBEPUSHEDFORPLANING
4HEPLANERHASTOBESWITCHEDOFFAFTEREACHPLANING
PROCESS
+EEPSTHEONOFFBUTTONINPOSITION/.
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WeldTech - MiniPlast Instruction Manual
5. Starting and Operating
The instructions of this chapter are supposed to initiate in the operation of the machine and lead during
the appropriate starting of the machine.
This includes
• The safe operation of the machine
• Using all the possible options of the machine
• Economic operation of the machine
5.1. Starting
The machine may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and
DVGW.
• In situations of danger for persons and the machine, the mains plug has to be unplugged
immediately.
• After completion of the welding work and during breaks the machine has to be switched off.
Further take care that no unauthorized person has access.
• Protect the machine from wetness and humidity.
• According to VDE 0100, the use on construction sites is only allowed with a power distributor
with a FI-security protective switch.
• Connect the heating element and the electric planer (optional) to the mains supply
(230 V / 50 Hz).
I
Lay electric cables carefully (danger of stumbling) !
• Take into account the surrounding conditions:
• The welding may not be performed under direct sun rays influence, use a welding umbrella if
necessary.
• If the surrounding temperature is under 5° C, measures have to be taken:
• Use a welding tent or preheat the pipe ends if necessary.
• In addition, take measures against rain, wind and dust.
I
14
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WeldTech - MiniPlast Instruction Manual
5.1.1 Exchanging the Reduction Inserts
• Unscrew the mounted reduction inserts by means of the provided Allan key.
• Screw the reduction inserts with the corresponding diameter into the clamping devices.
• When welding bends, the angle can be set on the basic clamping devices (on each side
between -15° to +15°).
• If necessary (e.g. for T-pieces) a special basic clamping device can be provided by means of
which very short sections can be clamped.
Large clamping device
Small clamping device
5.2. Welding Process
The respectively valid welding prescriptions (ISO / CEN / DVS ...) are to be basically followed.
• Do wear safety gloves as protection against burning.
• A stop-watch must be available for recording the actual times for heating up and cooling.
• A welding table must be available from which the parameters for the pipe dimensions to be
welded prescribed by the welding prescriptions may be taken.
• The heating element surfaces must be clean and especially non greasy. Therefore they need to
be cleaned shortly before each welding or in case of dirtiness by means of a fibre-free paper and
a cleaning agent (e.g. PE cleaner or pipe cleaning tissues which are available at the SIMTECH
company). The anti-adhesive coating of the heating element must remain undamaged in the
working area.
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WeldTech - MiniPlast Instruction Manual
• Switch on heating element and set the required welding temperature (standard value PE-HD:
210° C) on the adjustment screw on the handle.
• As soon as the control light blinks, the nominal temperature has been reached and is
maintained at a constant level by a pulse-position ratio.
• Screw in reduction inserts according to the outer diameter of the pipes to be welded, if
necessary set the angle.
• Attach the basic frame at the table support, if required fix the table support at the support
surface or insert machine without table support directly into the pipe system.
Machine working directly in the pipe system
• Put the work pieces into the clamping device, fasten clamping nuts tightly and align the work
pieces with respect to one another.
• Insert the manual planer between the ends of the work pieces, lock it by turning the star grip on
the guide bar and plane with low force.
• Insert the electric planer (optional) between the ends of the work pieces, lock it by turning the
star grip at the guide rod. Switch on planer at the on/off button and keep it switched on with the
locking knob. Plane the pipes with low force. For releasing the locking knob, push shortly the
button.
• Planing should be carried out until a revolving cutting has been formed on both sides.
• Open slide again, remove the planer and put it into the reception box. Remove the produced
cuttings without contacting the worked surfaces.
• Close slide again.
• Check pipe mismatch and gap on the joining pipe ends.
According to DVS 2207, the mismatch on the pipe outer side must not exceed 0.1 x pipe wall
thickness, the admissible gap must not exceed 0.5 mm.
The mismatch compensation is carried out by further tightening or releasing the clamping nuts. In
case mismatch compensation was carried out, planing must be repeated afterwards.
• The adjustment force for the pipe dimension to be welded can be gathered from the welding
table. Add the movement force.
• Open slide again somewhat.
• Gather heating time, maximum change over time, cooling time and bead height for the pipe
dimension to be welded from the table.
16
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WeldTech - MiniPlast Instruction Manual
• Move the heating element which has been cleaned and brought to desired temperature
between the pipes with the handle facing downwards (hang into guide bar).
• Close the slide smoothly with the determined adjustment force.
The applied force can be read at the force scale on the hand wheel.
When the prescribed revolving bead height is reached, reduce the force
(Heating force = approx. 10 % of the adjustment force).
• The heating time starts now. Press the stop-watch and compare the actual time with the
nominal time taken from the table.
• After expiration of the heating time, open the slide, remove the heating element as quickly as
possible, put it into the heat protection box and close the slide smoothly. The maximum time
frame for this process is predetermined by the value for the change over time taken from the
table.
• Press the stop-watch when the welding pressure is built up.
If necessary, readjust the force during cooling (the force for cooling is the same as the adjustment
pressure).
• After expiration of the cooling time, release the force, remove the welded parts and open the
slide.
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WeldTech - MiniPlast Instruction Manual
6. Welding Tables
PP Welding Table
Diameter
Weld
Beginning Melt Pressure
Heating
Change Over Time
Weld
Cooling
& Wall Thickness
Temp °C
& Bead Height
Time
(Remove Heater
Pressure
Time Before
(Kg./Force)
(Pressure at
& Gradually
(Kg./Force)
Removing
Near 0 Lbs.
Increase to
Force)
Weld Pressure)
Clamps
Seconds
Pressure
Height
Seconds
Change
Bring To
Over
Pressure
Minutes
½”
PN3.2
-
-
-
-
-
-
-
-
½”
PN6
-
-
-
-
-
-
-
-
½”
PN10
210
1
1/32”
30
3
4
1
3
¾”
PN3.2
-
-
-
-
-
-
-
-
¾”
PN6
-
-
-
-
-
-
-
-
¾”
PN10
210
1
1/32”
35
3
4
1
3
1”
PN3.2
-
-
-
-
-
-
-
-
1”
PN6
-
-
-
-
-
-
-
-
1”
PN10
210
2
1/32”
40
4
4
2
4
1 ¼”
PN3.2
-
-
-
-
-
-
-
-
1 ¼”
PN6
-
-
-
-
-
-
-
-
1 ¼”
PN10
210
3
1/32”
45
4
4
3
5
1 ½”
PN3.2
-
-
-
-
-
-
-
-
1 ½”
PN6
-
-
-
-
-
-
-
-
1 ½”
PN10
215
4
1/32”
50
5
6
4
6
2”
PN3.2
-
2
1/32”
30
3
4
2
3
2”
PN6
210
4
1/32”
45
4
4
4
4
2”
PN10
205
6
1/32”
60
5
6
6
7
2 ½”
PN3.2
-
3
1/32”
35
4
4
3
4
2 ½”
PN6
210
6
1/32”
55
5
6
6
5
2 ½”
PN10
205
9
1/16”
75
5
7
9
8
3”
PN3.2
-
5
1/32”
35
4
4
5
5
3”
PN6
205
8
1/32”
60
5
6
8
8
3”
PN10
200
13
1/16”
90
6
8
13
10
4”
PN3.2
210
7
1/32”
40
4
5
7
5
4”
PN6
205
12
1/32”
70
5
7
12
9
4”
PN10
200
19
1/16”
100
6
10
19
12
SR45 = PN3.2; SR90 = PN6; SR150 = PN10; SR232 = PN16
18
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WeldTech - MiniPlast Instruction Manual
PVDF Welding Table
Diameter
Weld
Beginning Melt Pressure
Heating
Change Over Time
Weld
Cooling
& Wall Thickness
Temp °C
& Bead Height
Time
(Remove Heater
Pressure
Time Before
(Kg./Force)
(Pressure at
& Gradually
(Kg./Force)
Removing
Near 0 Lbs.
Increase to
Force)
Weld Pressure)
Clamps
Seconds
Pressure
Height
Seconds
Change
Bring To
Over
Pressure
Minutes
½”
PN16
230
1.36
1/32”
25
4
5
1.36
3
¾”
PN16
230
2.82
1/32”
25
4
5
2.82
3
1”
PN16
230
3.18
1/32”
30
4
5
3.18
3
1 ¼”
PN16
230
3.64
1/32”
35
4
5
3.64
4
1 ½”
PN16
230
5.45
1/32”
40
4
5
5.45
5
2”
PN16
230
7.27
1/32”
45
4
5
7.27
5
2 ½”
PN16
230
7.27
1/32”
50
4
5
7.27
5
3”
PN16
230
10.00
1/16”
40
4
5
10.00
6
4”
PN16
230
15.45
1/16”
50
4
5
15.45
7
SR45 = PN3.2; SR90 = PN6; SR150 = PN10; SR232 = PN16
1.060606
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
19
WeldTech - MiniPlast Instruction Manual
7. Maintenance and Repair
7.1. General
I
Replace damaged parts immediately, be particularly care full with electrical parts.
Dirt and wetness are very good current conductors.
Prescribed maintenance and inspection works should be performed in time. The
DVS gives the advice of inspection works after 1 year.
For machines with a specially high usage percentage the testing cycle should be
shortened .
The works should be performed at the SIMTECH company or by an authorized
partner.
I
7.2. Clamping Elements
• For a long service life clean and grease regularly the threaded spindles and the joint parts
which are used for clamping the pipes.
7.3. Planer
• Do not lay the planer on its blades !
• Check the blades of the planer for sharpness, turn them if necessary (grinded on both sides,
max. thickness of the shavings: 0,2 mm !).
7.4. Storage
• Cover the guide bars and the spindle with a thin oil film.
• Store dry.
20
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
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1.060606
WeldTech - MiniPlast Instruction Manual
8. Transport
• Protect the machine from heavy chocs.
• Handle the machine carefully.
• Make sure that the case is closed correctly.
The machine is transported in a sheet steel carrying case.
Gibs for the box of the reduction inserts
Placing the single elements in the steel sheet carrying case:
• There is a rectangular shape inside of the box, in which the planer is inserted.
• Put in the table support and the basic machine next to it (see picture).
• Put in the heating element with the cable and temperature control in such a way that it is
situated below the gibs for the reduction inserts.
• Insert both boxes containing the reduction inserts.
1.060606
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
21
WeldTech - MiniPlast Instruction Manual
9. Wiring Diagrams
22
SIMTECH
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1.060606
WeldTech - MiniPlast Instruction Manual
10. Spare Parts List
10.1. Basic Machine with Clamping Devices and Reduction Inserts
1.060606
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
23
WeldTech - MiniPlast Instruction Manual
Basic Machine with Clamping Devices and Reduction Inserts Miniplast 2
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
24
Name
Spring block
Guidance
Counter bracket
Upper guide bar
Lower guide bar
Ball bushing
Ball bushing
Spindle
Trapezoidal nut
Adjusting nut
Bearing plate
Spring washer
Sleeve
Ring with pressure display
Scale
Hand wheel
Hexagon nut M 10 DIN 934
Tooth lock washer J 10,5 DIN 6797
Thrust ball bearing
Pressure spring
Flat-head screw M 8x25 DIN 7991
Flat-head screw M 8x35 DIN 7991
Flat-head screw M 5x25 DIN 7991
Flat-head screw M 5x10 DIN 7991
Headless pin M 5x6 DIN 916
Pipe clamp, upper part
Pipe clamp, lower part
Gib for screwing
Disk with scale
Clamping nut
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
Piece
Order no.
1
1
1
1
1
2
1
1
1
1
1
1
1
1
3
1
1
1
1
1
3
1
3
1
2
2
2
2
2
2
450113
450102
450103
450112
450111
LKH 2540
LKH 1630
450104
450105
450106
450107
450108
450109
450110
450114
BH100
0934J
67979J
L51103
450115
799.28E+
799.38E+
799.28E+
799.13E+
91.68E+
450701
450702
450703
450707
450705
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WeldTech - MiniPlast Instruction Manual
Basic Machine with Clamping Devices and Reduction Inserts Miniplast 2
1.060606
31
32
33
34
35
36
37
38
39
40
41
42
Threaded insert M 8
Coupling
Threaded insert M 4
Eye bolt BM 8x45 DIN 444
Straight pin 6 M 6x28 DIN 6325
Straight pin 8 M 6x26 DIN 6325
Straight pin 4 M 6x20 DIN 6325
Flat-head screw M 6x25 DIN 7991
Cylinder-head screw
Star grip M 6 DIN 6336
Washer 6,3 DIN 125
Reducer inserts OD 20-90
43
44
45
Half shells (optional)
Cylinder-head screw M 4x20 DIN 912
Cylinder-head screw M 4x25 DIN 912
Type plate
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
2
4
8
2
4
2
4
2
2
4
4
1 set
GEW-M8
450704
GEW-M4
0444H045
6325F028
6325H026
6325D020
7991F025
450706
BG032
0125F
2008
8
8
1
0912D020
0912D025
SCHTMINI
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WeldTech - MiniPlast Instruction Manual
10.2. Basic Machine
3
2
6
4
5
1
Pos.
26
Name
Piece
Order no.
1
Basic frame
1
450101
2
Hexagon nut M 8 DIN 934
2
0934H
3
Fixing bolt
2
450116
4
Star grip DIN 6336-KU-M8-K
1
on request
5
Headless pin M 8x40S DIN 6332
1
on request
6
Threaded insert M 8x12
1
GEW-M8
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
10.3. Clamping Devices for Fittings
Pos.
1.060606
Name
Piece
Order no.
46
Left-hand clamping device for fittings
1
45081 10L
47
Right-hand clamping device for fitting
1
45081 10R
48
Draw bar
2
S0115067
49
Hinge
2
S0112
50
Knurled screw
2
S0113
51
Handle
2
S0114-1
52
Rivet
2
S0110
53
Straight pin 4 M 6 DIN 6325
4
6325D012
54
Flat-head screw M 6x12 DIN 7991
4
7991F012
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
27
WeldTech - MiniPlast Instruction Manual
10.4 Manual Planer
28
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
10.4 Manual Planer
Pos.
1.060606
Name
Piece
Order no.
1
Holder for planer
1
450401
2
Planer disk, right-hand
1
450402
3
Planer disk, left-hand
1
450403
4
Blade
2
MES072
5
Flat-head screw M 3x6 DIN 965
6
0965C006
6
Square bar
1
450404
7
Bearing ring
2
450405
8
Driving plate, right-hand
1
450406
9
Driving plate, left-hand
1
450407
10
Flat-head screw M 5x10 DIN 7991
6
7991J010
11
Flat-head screw M 3x6 DIN 965
2
0965C006
12
Mechanical drive
1
450410
13
Ball bearing
1
L0623
14
Grooved taper pin 3x16 DIN 1471
2
1471C016
15
Star grip screw
1
BG3230
16
Hexagon nut M 6 DIN 934
1
0934F
17
Closing disc
1
450408
18
Ball Ø 4
1
L0004
19
Pressure spring
1
450409
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
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29
WeldTech - MiniPlast Instruction Manual
10.5. Electric Planer (optional)
7
6
19
16
11 / 12
1
22
20 / 21
25
23 / 24
26
28 / 29
32
27
30 / 31
2
5
9
14
17
18
4
3
30
8
10
13
15 / 16
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
10.5. Electric Planer (optional)
Pos.
1.060606
Name
Piece
Order no.
1
Planer housing
1
450431
2
Ball bearing 6010 RS
1
on request
3
Bevel gear m=1,5 / z=75
1
450438
4
O-ring 3x108
1
on request
5
Bolt for planer disk
1
450436
6
Flat head screw M 6x20 DIN 7991
2
7991F020
7
Flat head screw M 6x25 DIN 7991
2
7991F025
8
Adapter ring
1
450437
9
Planer disk, right-hand
1
450432
10
Planer disk, left-hand
1
450433
11
Blade
2
MES072
12
Flat head screw M 3x6 DIN 965
6
0965C006
13
Pinion with shaft m=1,5 / z=15
1
450439
14
Ball bearing 16101
2
on request
15
Washer M 10 DIN 125
1
0125J
16
Nut M 10x1, hardened and tempered
1
450442
17
Nut M 36x1,5
1
450441
18
Coupling piece
1
on request
19
Driving motor 230 V
1
on request
20
Washer M 6 DIN 433
1
0433F
21
Cylinder head screw M 6x30 DIN 912
1
0912F030
22
Adapter plate
1
on request
23
Counter-plate
1
on request
24
Hexagon head screw M 5x20 DIN 933
2
933.24E+
25
Holder for planer
1
4504011
26
Star grip screw
1
BG3230
27
Hexagon nut M 6 DIN 934
1
0934F
28
Ball bearing 623 2Z
2
L0623
29
Grooved taper pin 3x16 DIN 1471
2
1471C016
30
Ball Ø 4
1
L0004
31
Compression spring
1
450409
32
Closing disc
1
450408
SIMTECH
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31
WeldTech - MiniPlast Instruction Manual
10.6. Heating Element
10
11
1
12
2
3-5
13
6
14
15
7/8
16 - 18
19
20
9
21
32
SIMTECH
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www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
10.6. Heating Element
1.060606
Pos.
Name
Piece
Order no.
1
Teflon-conical nipple
1
H09091
2
Switch on/off with control lamp (red)
1
H0903
3
Control cnob with slot
1
H09075
4
Scale 180°-280° (d33)
1
H09074
5
Window cap for handle shell (white)
1
H09072
6
Control lamp (green)
1
H2105
7
Cylinder-head screw M 6x50 DIN 912
2
0912F075
8
Spring washer 6 DIN 7980
2
7980F
9
Electronic control without probe GZ4
1
H0918220
10
Isolator piece
11
Temperature probe PT1000
1
H09082
12
Heating element , complete
1
HMINIE
Heating plate new, electric
1
HPMINIE
Heating plate for change, electric
1
HPTMINIE
13
Triac with heat sink
1
H09081
14
Heating element holder
15
Cylinder-head screw M 4x70 DIN 912
3
0912D070
16
Handle shell
1
H0907
17
Strain relief
1
H09076
18
Sheet metal screw C 2,9x13 DIN 7981
2
7981C013
19
Sheet metal screw C 4,8x16 DIN 7981
3
798.19E+
20
Cable bushing
1
EKT08
21
Connection cable with plug
1
EK3220
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
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1450506
1450508
33
WeldTech - MiniPlast Instruction Manual
10.7. Protection Box
Pos.
34
Name
Piece
Order no.
1
oot
2
450517
2
Screw cap
4
200117
3
Insert for planer
1
450511
4
Insert for heating element
1
450512
5
Protective sheet
1
450513
6
Bar for distance 1
4
450514
7
Bar for distance 2
4
450515
8
Sleeve nut M 6
8
HÜ006
9
Threaded bolt
4
450518
10
Hoop
1
450516
11
Washer 10,5 DIN 125
4
0125J
12
Rivet Ø 2,4x8 DIN 7337
10
7337B008
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
NOTES:
1.060606
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
35
WeldTech - MiniPlast Instruction Manual
NOTES:
36
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606
WeldTech - MiniPlast Instruction Manual
NOTES:
1.060606
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
37
WeldTech - MiniPlast Instruction Manual
Simtech Industrial Products, Inc.
47-A Runway Road, Levittown, PA 19057
Phone: 215-547-0444 Fax: 215-547-9129
E-mail: info@SimtechUSA.com
Web site: www.SimtechUSA.com
WARRANTY
Simtech Industrial Products, Inc. products are warranted to be free from defects in materials and workmanship for one (1) year from date of
shipment. No claim shall be permitted under this warranty unless Buyer gives Simtech Industrial Products, Inc. written notice of all respects in
which Buyer claims the product to be defective. Notice must be received within ten (10) days from the date which the Buyer discovers, or should
have discovered the defect. Buyer shall give Simtech Industrial Products, Inc. a reasonable opportunity to inspect the product after notice has been
given. This warranty shall not apply to any products or components, which have been subjected to abnormal use, negligence or accident.
Seller’s sole obligation under this warranty shall be limited solely on the repair or replacement, as elected by Simtech Industrial Products, Inc., of
defective or nonconforming material. To the maximum extent permitted by law, Buyer irrevocably waives all claims for money damages relating
to the condition, use and performance of the goods purchased. In no event shall Simtech Industrial Products, Inc. liability exceed the purchase
price of the product sold by Simtech Industrial Products, Inc.
In no event, whether because of a breach of warranty or representation or any other cause, whether based upon contract, tort, warranty or
otherwise, arising out of the performance or nonperformance by seller of its obligations under this agreement or with respect to the products sold
pursuant here to; shall seller be liable for lost earnings, income or profits or indirect, incidental, liquidated or consequential damages.
The implied warranties of merchantability and fitness for a particular purpose except as set forth in this warranty, express or implied, are hereby
disclaimed and excluded. Nothing shall be construed as an additional warranty unless specifically designated as such in writing and signed by
Simtech Industrial Products, Inc.
Simtech Industrial Products, Inc. reserves the right, in its discretion, at any time and from time to time, to make changes to any specification, data
or information contained herein.
38
SIMTECH
Phone: 877-777-2467 • Fax: 215-547-3410
www.SimtechUSA.com
1.060606