Demtech Pro-X5 600-0105/X5/A User manual

Model: Pro-X5

Part Number: 600-0105/X5/A

High Output Thermoplastic Extrusion Welder

Operator’s Manual

Revision: A

Scope of Manual: This manual contains procedures for safety, general unpacking,

installation, setup and operation of your DEMTECH Services, Inc. Pro-X5

Extrusion Welder.

DEMTECH Services, Inc.

Ship to address: 6414 Capitol Avenue Diamond Springs, CA 95619 U.S.A.

Rev. A: January 2015

ii Pro-X5 Operator’s Manual 600-Manual_Pro-X5 RA.docx

This page is intentionally without content.

Rev. A: January 2015

600-Manual_Pro-X5 RA.docx Pro-X5 Operator’s Manual iii

The text of this publication, or any part thereof, may not be reproduced or transmitted in any form

or by any means, electronic or mechanical, including photocopying, recording, storage in an

information retrieval system, or otherwise, without prior written permission of DEMTECH

Services, Inc.

Any firmware and/or software program contained within the Pro-X5

for operation of the welder

is protected by copyright laws that pertain to computer firmware and/or software. Use of this

firmware and/or software does not authorize de-compiling, disassembling or reverse engineering

to gain access to the program code. DEMTECH Services, Inc. does not authorize any copying,

changing, or other use of this firmware and/or software.

Notice

Patents have been granted and/or patent applications are pending or are in the process of

preparation on all DEMTECH Services, Inc. developments.

The material in this manual is for informational purposes only and is subject to change without

notice.

DEMTECH Services, Inc. assumes no responsibility for any errors that may appear in this manual.

Printed in the USA

Manual Number: 600-Manual/Pro-X5, Rev. A

DEMTECH Services, Inc.

Ship to address: 6414 Capitol Avenue

Diamond Springs, CA 95619 U.S.A.

Telephone: (530) 621-3200

Toll Free: (888) 324-9353

Fax: (530) 621-0150

Web Site: www.demtech.com

Rev. A: January 2015

iv Pro-X5 Operator’s Manual 600-Manual_Pro-X5 RA.docx

Table of Contents

Safety Precautions............................................................................................................vi



General Safety & Maintenance Information.....................................................................1



1.1.



Intended Use ........................................................................................................1



1.2.



Maintenance.........................................................................................................2



General Product Data..........................................................................................................3



Operating Environment ......................................................................................................3



Site Preparation ...................................................................................................................4



Unpacking & Installation Instructions ..............................................................................4



5.1.



Unpacking and Preparation..................................................................................5



5.2.



Electrical Plug Connection ..................................................................................5



5.3.



Generator Recommendations...............................................................................8



Welder Controls...................................................................................................................9



6.1.



Recommended Temperature Settings ..................................................................10



6.2.



Setting Pre-Heat Temperature..............................................................................10



6.3.



Setting Plastic Heat Temperature.........................................................................10



Welder Set-Up and Operation ............................................................................................11



7.1.



Set-Up Preparation...............................................................................................11



7.2.



Start a weld ..........................................................................................................13



7.3.



During a Weld......................................................................................................14



7.4.



Stop a weld...........................................................................................................14



7.5.



Between welds .....................................................................................................14



7.6.



Shut-Down Procedure..........................................................................................15



7.7.



Changing the Teflon Shoe Assembly ..................................................................16



Factory Servicing .................................................................................................................18



Rev. A: January 2015

600-Manual_Pro-X5 RA.docx Pro-X5 Operator’s Manual v



Welder Wiring Diagram......................................................................................................18



10.



Service/Spare Parts ID ........................................................................................................20



10.1.



600-0105/X5/A, Assembly, Pro-X5 Extrusion Welder (Parts ID) ......................21



10.2.



600-0105/X5/A, Assembly, Pro-X5 Extrusion Welder (Parts List) ....................22



10.3.



600-100/X5/A, Assembly, Controller, Pro-X5 (Parts ID) ...................................23



10.4.



600-100/X5/A, Assembly, Controller, Pro-X5 (Parts List) .................................24



10.5.



600-BARREL/X5/A, Assembly, Barrel Complete, Pro-X5 (Parts ID) ...............25



10.6.



600-BARREL/X5/A, Assembly, Barrel Complete, Pro-X5 (Parts List) .............26



10.7.



600-DRILL/X5/A, Assembly, Drill Motor Complete, Pro-X5 (Parts ID)...........27



10.8.



600-DRILL/X5/A, Assembly, Drill Motor Complete, Pro-X5 (Parts List).........28



10.9.



600-D08/X5/A, Assembly, Motor Housing Complete, Pro-X5 (Parts ID)..........29



10.10.



600-D08/X5/A, Assy, Motor Housing Complete, Pro-X5 (Parts List)................30



10.11.



600-D100/X4/A, Assembly, Gear Box Complete, w/o Armature (Parts ID) ......31



10.12.



600-D100/X4/A, Assy, Gear Box Complete, w/o Armature (Parts List) ............32



10.13.



600-D100A/X5/A, Assembly, Gear Box Complete, w/ Armature (Parts ID) .....33



10.14.



600-D100A/X5/A, Assy, Gear Box Complete, w/ Armature (P/L).....................34



11.



Product Warranty................................................................................................................35



Rev. A: January 2015

vi Pro-X5 Operator’s Manual 600-Manual_Pro-X5 RA.docx

Safety Precautions

Safety precautions for operating personnel and equipment:

WARNING 1: Operating personnel should perform only the procedures described and recommended in

this manual. Only qualified service personnel familiar with electrical shock hazards and mechanical

entanglement hazards present inside the equipment should perform disassembly or corrective maintenance

of the equipment.

WARNING 2: To avoid shock hazards, the equipment must be grounded with an adequate earth ground in

accordance with local and national electrical codes.

WARNING 3: The locations of potentially dangerous voltages and other hazards are identified and labeled

on the equipment. Be careful to observe these warnings when installing, operating, maintaining or servicing

the equipment. Observe all warnings in this manual.

WARNING 4: Make sure to turn off the equipment power and remove the ~ (AC) line cord from the power

outlet before attempting to service the equipment. Do not perform service unless you are qualified and

trained to do so.

WARNING 5: This product is intended for operator attended operation only. This product should never

be left unattended at any time while it is plugged in and the power is turned on. Incorrect use of the product

such as overheating of the material can present a fire and explosion hazard, especially near combustible

materials and explosive gases.

WARNING 6: This product is intended for operation in dry environments only. Higher humidity

environments should be kept non-condensing by avoiding large temperature swings.

WARNING 7: Do not touch the main housing, air nozzle and output molten material when they are hot as

they can cause burns. After use allow ample time for the product to tool cool down before handling and

stowing. Do not point the hot air flow and the output molten material in the direction of personnel.

CAUTION 1: Observe the precautions given on the equipment and within this manual to prevent damage

to the equipment.

CAUTION 2: Before connecting the equipment to its electrical source, check that the ~ (AC) voltage,

frequency and current to be supplied to the equipment are correct and match the serial plate affixed to the

welder.

CAUTION 3: Use proper handling and packaging procedures for Electro-Static Discharge (ESD) sensitive

circuit boards. Assume that all circuit boards are sensitive to potential damage from ESD.

CAUTION 4: Unauthorized personnel should not remove from the equipment those panels that are

provided for protection and/or require a tool to remove.

Rev. A: January 2015

600-Manual_Pro-X5 RA.docx Pro-X5 Operator’s Manual Page 1

1. General Safety & Maintenance Information

The DEMTECH Services, Inc. Pro-X5

Thermoplastic Extrusion Welder, hereinafter referred to

as the Pro-X5 or welder, is a high temperature and voltage piece of equipment. Always disconnect

the power source before performing any service and/or maintenance procedures on the welder.

Never pull or carry the welder by the power cord or electrical connection. Always maintain slack

in any extension cords connected to the welder while in operation to avoid damage to the power

connections. Keep hands, fingers and other body parts well clear of the heating element and related

mounting components at all times. Always use the Pro-X5 in a well-ventilated area when welding

materials such as PVC which can produce toxic fumes. Do not inhale toxic fumes when present.

Do not operate near flammable materials of any kind. Do not apply flammable materials, including

liquids, to seam area. Allow welder to cool completely, at least fifteen (15) minutes, before

returning to the shipping/storage case. Protect welder from exposure to rain or standing water.

Never attempt to weld in standing water.

1.1. Intended Use

The Pro-X5 is intended as professional use equipment and is not intended for sale to the general

public. The total input power of the Pro-X5 is specified as greater than 1 kW although in

lightly loaded conditions the actual power may be less than 1 kW.

The Pro-X5 has been manufactured utilizing the latest technology and current safety standards

and regulations. However, improper use or abuse may lead to hazardous conditions for the

user or other personnel or cause damage to the welder.

Always keep this manual with the welder at or near the location where the Pro-X5 is being

used for quick and easy reference.

Rev. A: January 2015

Page 2 Pro-X5 Operator’s Manual 600-Manual_Pro-X5 RA.docx

The technician assigned to operate this welder must have read through and become familiar

with this manual, particularly all safety information, before using the Pro-X5.

No changes and/or modifications should be made to the Pro-X5 especially as it relates to safety.

1.2. Maintenance

Maintenance, inspection and adjustment of the Pro-X5 may only be carried out by qualified

personnel. Before removing or installing spare parts or performing any other repair operations

to the welder consult DEMTECH Services, Inc. or your authorized DEMTECH service center

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 welder after

maintenance and/or repair procedures have been performed. Make sure all covers, guards and

other safety devices have been fully reinstalled before use.

Rev. A: January 2015

600-Manual_Pro-X5 RA.docx Pro-X5 Operator’s Manual Page 3

2. General Product Data

The DEMTECH Services, Inc. Pro-X5

Thermoplastic Extrusion Welder, hereinafter referred to

as the Pro-X5 or welder, dramatically speeds the welding of plastic sheet materials utilizing molten

plastic. This function, combined with its simple construction and easy-to-use controls, makes

performing welding tasks very efficient. With minimal setup, the welder speeds up processing

time; while providing a very rugged and reliable welder. You can be assured the Pro-X5 has been

built using the highest quality materials available which include billet aluminum, stainless steel

and ground and hardened steel. DEMTECH Services, Inc. strives to make our welders easy to use

and built to last. Just like all other DEMTECH Services, Inc. products, even a first time user will

be productive in minutes.

3. Operating Environment

The Pro-X5 is intended to be operated within the following environmental conditions. Operating

the welder in environments which are less than, or greater than nominal can degrade and/or

adversely affect performance.

Temperature .................................+32 to +100°F; 74°F Nominal (+0 to +38°C; 23°C Nom)

Humidity

(non-condensing) ................

0 to 90%; 45% Nominal

Elevation ......................................0 to 7,000 Ft; 2,000 Ft Nominal

......................................................(0 to 2,134 meters; 610 meters Nominal)

Rev. A: January 2015

Page 4 Pro-X5 Operator’s Manual 600-Manual_Pro-X5 RA.docx

4. Site Preparation

Before proceeding with the unpacking and installation instructions in the following section(s),

make sure the work site is prepared and ready to use the Pro-X5. You should have an adequate

power source capable of providing clean Alternating Current (AC) power at 220-240 Volts at the

welder rated current. Refer to the welder serial plate affixed to the front side of the controller

housing for the voltage and current requirements of your welder. The install area should be clean,

dry and free of debris and provide adequate working area to allow efficient and effective use of

the welder.

Follow the detailed unpacking and installation instructions carefully.

5. Unpacking & Installation Instructions

This section contains instructions for the unpacking, placement and installation of the Pro-X5.

Carefully review the following information, sub-sections and each procedure before beginning

unpacking and installation of the welder.

The Pro-X5 comes complete in a sturdy, reusable, portable shipping/storage case. The custom

foam inserts protect the welder from damage during shipping and storage and should always be

left inside the case at all times. When the welder is out of the case, make sure to keep the lid closed

to avoid dirt, dust, debris and/or water from getting inside. The welder must be removed from the

case and placed onto the work site for use. When not in use, the Pro-X5 should always be stored

in the shipping/storage case to protect it from the elements and potential damage.

Note: The welder illustrated in this manual shows ALL available features for the

Pro-X5, therefore, your welder may vary slightly in appearance from that depicted.

Table of contents

Other Demtech Welding System manuals

Demtech

Demtech Pro-X 600-0100/A Pro-X 600-0100/PRT/A User manual

Demtech

Demtech Pro-X 600-0100 User manual

Demtech

Demtech Pro-Wedge VM-20 User manual

Demtech

Demtech Pro-Wedge XL User manual

Demtech

Demtech Pro-Wedge 3XL User manual

Demtech

Demtech Pro-Tacker User manual

Demtech

Demtech Pro-Wedge VM-20 User manual

Demtech

Demtech Pro-Wedge 3XL User manual

Demtech

Demtech Pro-XMP 605-0102/XMP/A User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual