|
GT-100/120V HAND-HELD WEDGE WELDER* OWNER'S MANUAL
For models purchased from 1990 to 2000.
SAVE THESE INSTRUCTIONS
CONTENTS:
*Important Safeguards
* How to Use
* Operation
* Instructions
* Maintenance
* Troubleshooting Guide
* Technical Information
* Warranty Information
PLEASE READ ENTIRE MANUAL BEFORE OPERATING THIS EQUIPMENT
IMPORTANT SAFEGUARDS
· Read all instructions prior to operation.
· Warning: Electric shock could occur if used incorrectly or on wet surfaces
· Do not touch hot surfaces. Always hold product by heat-resistant handle.
· Keep hands, feet, loose clothing away from hot wedge.
· Do not immerse any part of this product in water or other liquid.
· Do not use this product outdoors when it is raining or snowing.
· Do not use this product on wet or damp materials.
· Never use GT-100 in presence of flammable or combustible liquid or fumes.
· Do not cool the wedge with liquid.
· Always operate product in a well-ventilated area or outdoors.
· Unplug product when not in use. Allow to cool completely before storing. Store in clean, dry area.
· Do not operate this product if cord or plug has been damaged in any way. If cord or plug is damaged return this product to manufacturer for repair or adjustment.
· Be sure Temperature Control Knob is set at lowest setting prior to inserting or removing plug from outlet or power source.
· Never leave plugged-in product unattended.
· Use GT-100 only for its intended use as described in this Owner's Manual.
· Always wear protective eye goggles when operating GT-100.
· Always wear appropriate, non-flammable work gloves when operating GT-100.
· Manufacturer recommends wearing respirator when working with materials that generate toxic or hazardous fumes.
· Do not drop product.
· If power source or generator fails while GT-100 is in use, simply turn off GT-100, recharge power source or generator, and re-start GT-100 per instructions.
· Product must only be used with 110/120 VAC power source. Failure to use with 110/120 VAC may result in electric shock and permanent damage to product.
· WARNING: Lowest setting of the Temperature Control Knob does not turn off heat to the wedge. At the lowest temperature setting, the wedge is too hot to touch.
· Do not let the GT-100 sit unused after it has reached set temperature. Temperature spiking may occur when the wedge is hot and not used.
· All repairs must be made by qualified personnel at Novaseal. If repairs are necessary, package GT-100 securely and ship via UPS or Federal Express to Novaweld, 5933 W. Hillsboro Boulevard, Unit 104, Parkland, FL 33067 USA.
HOW TO USE
GT-100 MUST ONLY BE POWERED BY A 110/120 VAC POWER SOURCE. TO AVOID ELECTRICAL CIRCUIT OVERLOAD OR POSSIBLE SHOCK, DO NOT USE WITH OTHER THAN 110/120 VAC POWER SOURCE.
-- Before plugging in GT-100, make sure the Temperature Control Knob is at the lowest setting.
-- When the Temperature Control Knob is set, the indicator lamp located on the control panel will automatically become illuminated indicating that the GT-100 is heating up. When the unit reaches specified temperature, this indicator lamp will dim, flicker, or turn off.
-- Other than the cleaning prescribed herein, no other maintenance or servicing of this product is necessary. All repairs must be performed by the manufacturer or authorized manufacturer's representative.
OPERATION
GT-100 operation is based on the principle that as the temperature of the thermoplastic material to be welded is increased, the coefficient of friction decreases. Therefore the GT-100 is placed between the two sheets of material, and the heated wedge increases the temperature of each material at the contact surface to the correct temperature whereby ease of movement of the wedge between these materials is accomplished with less effort. Welding of geosynthetic and other thermoplastic materials is accomplished by heating up the contact surface and immediately applying downward pressure followed by a cooling period. GT-100 operation uses a translational movement whereby the wedge moves between the materials and a hand roller moves in the same direction directly behind the wedge and above both sheets of material to be welded. For optimal results, allow the welded material to cool prior to testing peel and shear strength of the weld. The cooling period must not be less than ten (10) minutes.
INSTRUCTIONS
1. Prior to use, make sure Temperature Control Knob is at lowest setting.
2. Plug cord into 110/120 VAC electrical outlet.
3. Push red rocker switch to "On" position. Note that Rocker Switch becomes illuminated.
4. Turn Temperature Control Knob clockwise to desired temperature setting. Lowest temperature setting is 400°F, highest temperature setting is 900°F. Most applications require a temperature between 650°F and 750°F, which corresponds to a setting between "3" and "5.5".
After setting temperature, place GT-100 on a level, dry, non-flammable surface and allow approximately 5 to 10 minutes for warm-up. The Red Pilot Lamp is illuminated and remains illuminated until the wedge heats up to set temperature. During continued use, the Red Pilot Lamp will dim or flicker on and off. This represents normal operation.
If the Red Pilot Lamp never turns off, or if heating never occurs, refer to Troubleshooting section of this manual.
5. Welding. To prepare for operation, assure that both materials to be welded are the same or chemically near the same and that the thicknesses of both materials are the same or nearly the same and that both materials are thermoplastic or synthetic in composition. Overlap materials such that the overlap width is at least two inches. Place the wedge of the GT-100 in between the overlapped materials at a position perpendicular to the seam direction. Best application is when the direction of wedge movement is away from you. Behind the wedge and above both sheets of material apply a downward and forward moving force with the hand-held silicon or metal roller.
Welding requires a combination of heat, pressure, time and cooling. Prior to using GT-100 in a production environment, test the specific materials to be welded by:
a. Cutting several test samples, approximately 3 feet in length x 8 inches in width.
b. Start with a lower temperature setting, place the wedge between the materials as previously described, apply a steady pressure with the hand roller and note whether the welding process seems "sticky" and not easy to weld. If this is the case, slightly increase temperature and try again.
c. If the wedge is burning a hole into the material or seems too hot, either increase the speed of wedge/roller movement or decrease the temperature.
d. If the temperature and ease of movement seems correct and a weld doesn't seem to be happening, then try applying more downward pressure on the hand roller. Another technique often used is either angling the wedge up/down or side/side to achieve optimal level of comfort and welding. For additional welding techniques, refer to geotextile or geomembrane hints.
e. Make a note of the appropriate setting and technique established for each material.
Novaweld has experimental welding results for many materials tested. This data is available upon request. Refer to geotextile or geomembrane hints.
6. Cooling. Immediately after material is welded, allow the material to cool to room temperature prior to testing weld integrity. Cooling is required as part of the welding process.
7. At the completion of operations, push the red rocker switch to "Off" position. Note that rocker switch is no longer illuminated. Allow the wedge to cool down to ambient temperature prior to storing the GT-100. To speed-up cooling you may heat sink the wedge by bringing another metal, such as aluminum or steel in contact to one surface of the wedge. Proper cooling may require up to thirty (30) minutes. It is important to note that you may not cool the wedge by either immersing the wedge into a liquid or by thermally shocking the GT-100 unit.
MAINTENANCE
1. Cleaning Process. For the most part, GT-100 is self-cleaning. Removal of residue on the wedge occurs continuously during and between welding operations.
2. Additional cleaning may be accomplished by using a metal brush to remove plastic residue from wedge. Cleaning must only be done when the GT-100 is unplugged and the wedge temperature is the same as the ambient air temperature.
3. If conditions make the self-cleaning feature inappropriate, disconnect GT-100 from electrical source and allow GT-100 to properly cool to ambient room or outdoor temperature. Use commercially available cleaning products such as "Energen" with Novaweld's metal brush and/or a rough cloth such as steel wool to properly clean wedge.
4. For best welding results, GT-100 wedge should be cleaned daily after each use.
TROUBLESHOOTING GUIDE
Problem and Remedy(ies)
Rocker Switch not illuminated
1. Check Rocker Switch is in the "On" position.
2. Check Power and Power Cord integrity.
3. Check Fuse. If fuse is defective, replace with Littelfuse Part Number 2AG 8A-225 or equivalent. Replacement is accomplished by inserted a flat blade screwdriver into the fuse holder slot and turning counter-clockwise approximately half turn. Once fuse is replaced, apply slight pressure and turn clock-wise until properly seated.
4. Contact Novaweld for technical support.
No heat at all
1. Check Rocker Switch is in the "On" position.
2. Check Power and Power Cord integrity.
3. Check Fuse. Refer to Remedy for "Rocker Switch not illuminated" step 3.
4. Check if Red Pilot Lamp is illuminated. If Red Pilot Lamp is not illuminated, turn Rocker Switch to "Off" position and contact Novaweld for technical support.
Partial heat
1. Assure that an adequate heat-up time has been allowed, for a low setting, 15 minutes; for a high setting, 20 to 30 minutes.
2. From a high setting, begin turning Temperature Control Knob to the lowest position, furthest counter-clockwise. Note whether Red Pilot Lamp turns off while turning the Temperature Control Knob to the lowest position. If this occurs, one of the two heating cartridges may have failed.
3. Contact Novaweld for technical support.
Red Pilot Lamp never turns off
1. Refer to Remedy, "Partial heat", steps 1 and 2.
2. Is wedge hot? If yes, thermocouple or controller may have failed, immediately turn Rocker Switch to "Off" position and contact Novaweld for technical support.
Temperature varies at a single setting
1. Controller allows a plus or minus six (6) percent variance of the temperature setting for normal operation. If the variance is greater, contact Novaweld for technical support.
2. Once the wedge has reached the set temperature it is possible that temperature "spikes" will occur if the GT-100 is not used immediately. Do not leave the GT-100 turned on when not in use.
TECHNICAL INFORMATION
Dimensions 18 inches (457 mm) Length x 4 inches (102 mm) Outside Diameter
Cartridge Heaters Watlow Firerod G1R14-G2H12H or equivalent, 3/8-inch (9.525 mm) O.D. x 1 - 7/8 inch (48 mm) Length with stainless steel hose protection.
Controller Novaweld temperature controller custom module
Fuse Littelfuse Tracor 2AG-8A-225, 8 Amp Fast Blow
Power Source 110/120 VAC, 6 Amps
Red Pilot Lamp Illuminated when GT-100 is heating-up to desired temperature setting.
Rocker Switch Up position depressed is "On"
Thermocouple K-type (up to 1995), RTD-type (since 1996)
Weight 4 pounds (1,814 grams)
WARRANTY INFORMATION
Any liability of Novaweld resulting from any defect in workmanship or material in the product covered by this document shall be limited to and fully discharged by replacement or repair of such item at Novaweld's option without charge. The warranty provided is in lieu of all other warranties, express or implied, arising by law or otherwise, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILILTY AND FITNESS FOR A PARTICULAR PURPOSE, and shall not be modified except by an agreement signed by both parties specifically referencing this clause. In no event shall Novaweld be liable for consequential damages which may arise through the use of this equipment by the Customer or others, whether used alone or in combination with other equipment or products, and the Customer assumes and will hold Novaweld harmless in respect of such loss.
Notice of any defect in workmanship or material must be given by the Customer to Novaweld within ninety (90) days after delivery to Customer. In the event the Customer fails to give notice within the specified period, the Novaweld will be relieved of any and all liability hereunder and Customer agrees to accept goods as is. During the warranty period, the warranty shall not apply to damages resulting from accident, unauthorized modification, misuse, abuse, or improper maintenance. To obtain service, write to NOVAWELD LLC, 5933 W. Hillsboro Boulevard, Unit 104, Parkland, FL 33067, advising of the problem and providing proof of purchase and serial number. Customer shall prepay all shipping charges for equipment returned for warranty service, and Novaweld will pay shipping charges for return of equipment to Customer.
Any action for breach of this warranty or other action arising out of this contract must be commenced within one year after delivery. Novaweld and Customer agree that governing law shall be governed by the laws of the State of Colorado and State of Florida.
*U.S. Patent No. 4,894,112
© Novaweld LLC, 7/94, Rev. 10/96
|
