Wedge Welder Instructions

The welder you have received has been preset to run PPL24 or PPL30, included in this box is a sample of a good weld for your comparison.
Prior to starting a field seam, the welder requires testing to insure that no damage or problems arose in transit.
This testing procedure will help familiarize you with the actual welding process.
Please refer to Step 2 prior to beginning the welding process.
The following items are required to run and test the welder:
Generator or power source 110v   20-amp minimum. 5kw or equivalent 
100' extension cord type 12/3 minimum (200' may be used if 10/3 or above wire gauge.)
Under no circumstance should more than 200' of cord be used, the controller in the machine requires a constant load, and drops in line voltage can cause damage (a replacement controller will cost "you" $850.00).

Rags
Grease pencils
Scissors
For testing  2 -  12" wide samples of the liner 15' long

The wedge welder you are using is an inseam or fixed overlap welder, the welded seam is produced by the 2 edges of the liner going thru the machine (1 piece over the wedge and 1 piece under the wedge) at a fixed rate of speed over a hot wedge which melts the sheets and continues on until they are clamped together by the rear pressure/drive wheels.

The liner sections require a fixed overlap of  3" to 4", this may require trimming of the top sheet to ensure that the 4" overlap is continuous along the length of the seam to be welded.

Step1  check that the pressure release for the roller wheels at the back of the machine (figure 3) is disengaged (down). Figure 3 shows the lever in the locked  (up) position. Figure 8 shows it down and unlocked.

Step 2 Plug the machine in, and turn on drive switch 2 (figure 6) this will engage the drive wheels.

Step3 Now that the drive wheels are turning, it is time to load the material into the machine. The machine travels forward with the drive wheels being at the rear of the machine (figure 8). The material is loaded with a top sheet and a bottom sheet, looking from the rear or behind the machine the top sheet is the sheet that will be on the left hand side, the bottom sheet will load on the right.  

The welder was shipped to you with material in the welding position. Practice loading the machine a few times with the heat turned off and the drive wheels running.

Slide the bottom (right) sheet over the lower drive wheel and under the wedge, the front right rubber wheel of the welder will be on top of the liner. Once lined up, ensure that the material is pushed as far to the left within the machine as possible.

Slide the upper (left) sheet thru the machine above the plate and wedge and under the upper drive wheel. Once lined up ensure that the material is pushed as far to the right within the machine as possible.

 Once the material pieces are approx 2" beyond the back of the machine, engage the drive wheels by locking the pressure release handle in the up position (figure 3). This should cause the welder to begin traveling along the material.  Once you reach the end of the seam or material, disengage the drive wheels by moving the pressure release handle down. Caution: allowing the drive wheels to run while locked in place and no material in the machine can cause damage to the wedge assembly.

Step 4  At this time turn on switch 1 (figure 6) which is on the left rear side of the machine, this will start the warm-up process.

The welder needs to run a self-test and heat up to the preset temp. (750 –800 deg) the warm-up process takes about 5 minutes. The indicator should read between 750-800 constantly once the machine is warmed up.

Once the machine is warmed up it is time to try welding, please repeat step 3 to begin. Please note: With the wedge being hot, beginning immediately upon loading the material is critical as the material may start melting prior to engaging of the drive.

Note: Setting for temperature is generally between 750-800 deg.

Speed setting is generally between 50-60

Warmer weather will cause you to slightly adjust the speed upward, colder weather slow the machine down.

Temperature of the machine usually will not require adjustment.

The machine will require slight adjustments as you weld on the seams.

Click Here for printable Instructions

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