Demtech Pro-Wedge 3XL User manual

Pro-Wedge
3XL Operator’s Manual
Model Number: 500-0100/3XL/A
Revision: D

Rev. D, November 2020
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Pro-Wedge 3XL Operator’s Manual ii
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© Copyright 2020 by DEMTECH Services, Inc.
All Rights Reserved
Scope of Manual:
This manual contains procedures for safety, general unpacking,
set-up, and operation of your DEMTECH Services, Inc. Pro-Wedge.
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 software program contained within the Pro-Wedge for operation of the welder is protected
by copyright laws that pertain to computer software. Use of this 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
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 the 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.
Manual Number: 500-OPERATOR’S MANUAL/3XL, Revision: D
DEMTECH Services, Inc.
6414 Capitol Avenue Diamond Springs, CA 95619 U.S.A.
Telephone: [phone]
Toll Free: [phone]
Fax: [phone]
Web Site: www.demtech.com

Rev. D, November 2020
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Pro-Wedge 3XL Operator’s Manual iii
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Table of Contents
1  SAFETY PRECAUTIONS.........................................................................................2 
2  GENERAL SAFETY & MAINTENANCE INFORMATION ...............................3 
2.1  Intended Use................................................................................................3 
2.2  Maintenance ................................................................................................3 
3  GENERAL PRODUCT DATA..................................................................................4 
4  OPERATING ENVIRONMENT ..............................................................................4 
5  SITE PREPARATION...............................................................................................4 
6  UNPACKING, POWER CONNECTION, AND ACCESSORIES ........................5 
6.1  Unpacking ...................................................................................................5 
6.2  Electrical Plug Connection ..........................................................................5 
6.3  Power Requirements....................................................................................6 
6.4  GeneratorRecommendation ........................................................................7 
6.5  Extension Cords ..........................................................................................7 
6.6  Accessories..................................................................................................7 
7  WELDER SET-UP .....................................................................................................8 
7.1  Set-Up Preparation ......................................................................................8 
7.2  Adjustment #1: Wedge Centering ...............................................................9 

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7.3  Adjustment #2: Wedge Engagement Position.............................................14 
7.4  Adjustment #3: Upper and Lower Contour Rollers ....................................17 
7.5  Wedge Timing Definition ...........................................................................19 
7.6  Wedge Re-Timing .......................................................................................19 
7.7  Wedge Removal ..........................................................................................21 
8  FACTORY SERVICING...........................................................................................23 
9  REFERENCE DOCUMENTS...................................................................................23 
9.1  Appendix A .................................................................................................24 
9.2  Appendix B .................................................................................................25 

Rev. E, October 2015
2 Pro-Wedge
TM VM-20 Series Operator’s Manual
1Safety 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.
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.
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 power 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 system.
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
or covers that are provided for protection and/or require a tool to remove.

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Pro-Wedge 3XL Operator’s Manual Page 3
2General Safety & Maintenance Information
The Pro-Wedge is a high voltage piece of equipment. Always disconnect the power source
before performing service and maintenance to the unit. Never pull or carry welder by the
power cord or electrical connection. Always keep slack in extension cord while in
operation to avoid damage to the power connection. Keep hands and other body parts
clear of heating wedge and elements when hot. Always use Pro-Wedge in a well-
ventilated area when welding materials such as PVC that produce toxic fumes. Do not
inhale toxic fumes when present. Do not operate near flammable materials. Do not apply
flammable liquids to seam area. Allow unit to cool down for at least 5 minutes before
putting back into shipping/storage case. Protect unit from exposure to direct rainfall or
standing water. Never attempt to weld in standing water.
2.1 Intended Use
For additional product information please refer to the product data sheet.
The Pro-Wedge 3XL is intended as professional use equipment and not intended for sale
to the general public. The total input power of the Pro-Wedge is specified as greater than
1 kW although in lightly loaded conditions the actual power may be less than 1 kW.
The Pro-Wedge has been manufactured according to the latest technology and current
safety regulations. However, improper use or abuse may lead to hazardous conditions
for the user or third party or damage to the unit.
Always have this manual handy at the location where the Pro-Wedge is being used so that
it can be referred to quickly and easily.
The technician assigned to operate this welder must have read through and become
familiar with this manual before starting work, particularly the section on safety.
Do not make changes or modifications to the Pro-Wedge relative to safety without
contacting the manufacturer for advice.
2.2 Maintenance
Maintenance, inspection and adjustment of the Pro-Wedge may only be carried out by
qualified personnel. Before removing or installing spare parts or performing other repair
operations to the Pro-Wedge, consult the manufacturer 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 unit after maintenance or repair.
Also make sure all covers, guards, and other safety devices have been reinstalled before
use.

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Pro-Wedge 3XL Operator’s Manual Page 4
3General Product Data
The DEMTECH Services, Inc. Pro-Wedge 3XL Geo-Membrane Wedge Welder, hereinafter
referred to as the Pro-Wedge or welder, dramatically speeds the welding of plastic sheet materials
through the use of its wedge heating elements and multiple pressure roller design. These features
combined with state-of-the-art electrical and electronics controls and an easy to use User Interface
(UI) makes performing welding tasks very efficient. The semi-automated operation of the welder
eliminates cumbersome setup and speeds up processing time while providing a very rugged and
reliable welder. The enclosed controller sub-system is easy to maintain. You can be assured the
Pro-Wedge has been built using the highest quality materials available which include Billet
Aluminum 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.
4Operating Environment
The Pro-Wedge is intended to be operated within the following environmental conditions.
Operating the welder in environments which are less than or greater than nominal can adversely
affect performance.
Temperature ..............................+65 to +90°F; 74°F Nominal (+18 to +32°C; 23°C Nominal)
Humidity (non-condensing)......0 to 90%; 45% Nominal
Elevation ...................................0 to 7,000 Ft; 2,000 Ft Nom (0 to 2,134 meters; 610 meters Nom)
5Site Preparation
Before proceeding with the unpacking and installation instructions in the following section(s)
make sure the work site is prepared and ready to install the Pro-Wedge. You should have an
adequate power source capable of provided clean Alternating Current (AC) power at 220-240
Volts at the rated current. Refer to the welder serial plate affixed to the inside side of the Side
Frame near the Upper Nip Arm 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.

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Pro-Wedge 3XL Operator’s Manual Page 5
6Unpacking, Power Connection, and Accessories
6.1 Unpacking
Before opening the shipping/storage case for the first time and unpacking the welder,
inspect the outside of the case thoroughly for any signs of mishandling or damage during
shipping. Report any damage to the shipping carrier immediately and do not proceed with
unpacking. You should consult your administration concerning claims for shipping
damage. Please notify DEMTECH Services, Inc. or your authorized DEMTECH
distributor where the product was purchased in the event of any shipping damage.
Unlatch and open the shipping/storage case lid and inspect inside the case and equipment
thoroughly for any signs of mishandling or damage during shipping. Report any damage
to the shipping carrier immediately and do not proceed with unpacking. You should
consult your administration concerning claims for shipping damage. Please notify
DEMTECH Services, Inc. or your authorized DEMTECH distributor where the product
was purchased in the event of any shipping damage.
The Pro-Wedge hot wedge welder is delivered to you in a sturdy, reusable
shipping/storage case. The custom foam insert protects the unit from damage during
shipping and should be stor ed in the case at all times when not in use. When the unit
is out of the case, make sure the lid is closed to avoid dirt, dust and rain from getting
inside. Once the Pro-Wedge has been removed from the case, it is ready for use except
for any necessary set-up adjustments. For set-up procedure, refer to the set-up adjustment
section in this manual.
Make note of the orientation of the equipment and packing foam inserts inside the shipping
case to facilitate any repackaging requirements in the future. To avoid injury and/or
damage to the welder, be sure to use adequate care when lifting, removing or replacing the
welder into the shipping/storage case. The welder must be removed from the
shipping/storage case and placed in an appropriate location suitable for the welding you
intend to perform.
6.2 Electrical Plug Connection
The Pro-Wedge is supplied with an appropriate U.S. plug-end according to the specified
operating voltage of the welder. The supplied plug-end can be replaced by the customer
as long as the new one is rated at a minimum of 20 amps.

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Pro-Wedge 3XL Operator’s Manual Page 6
6.3 Power Requirements
The voltage requirement of your Pro-Wedge is 220-240 Volts AC only.
Note: The above operating voltage range refers to actual voltage at point of welder plug-in.
In other words, the voltage under load at the welder end of the extension cord. To measure voltage
under load, connect the welder to the extension cord and generator that will be used. Start the
generator and turn both welder power switches to the on position. While the number 1 indicator
light on the temperature controller is illuminated and the wedge is heating, separate the plug at
the end of the welders power cord just enough to expose the prongs. Using a digital voltmeter,
measure the voltage under load between the hot and neutral prongs.
This procedure should only be performed by a qualified electrician.

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Pro-Wedge 3XL Operator’s Manual Page 7
6.4 Generator Recommendation
If using house power from a building circuit, please contact the manufacturer for advice
on plug and cord configuration. In-field generators should be rated for at least 3500
watts; however, a rating of 5000 watts or more is recommended in order to obtain the
best welder performance and temperature control. As a rule, the higher the wattage of the
generator, the better the performance of the welder. Keep in mind that the length and
wire gauge of the extension cord being used, combined with the capacity of the generator,
will ultimately determine the operating voltage reaching the welder.
6.5 Extension Cords
Extension cords should be at least 12 gauge and regardless of overall length should have
a minimum of 3 plug-end connections.
Maximum recommended extension cord length:
10 gauge, 3 wire 12 gauge, 3 wire 14 gauge, 3 wire
500 Feet 250 Feet 100 Feet
6.6 Accessories
The Pro-Wedge has been designed to weld a wide range of materials on most sub grade
types. However, for the best results on each job site, there are many different accessories
available to help make the welding process easier. For example, the independent front
travel rollers can be replaced with a wide tubular roller to help prevent sand and loose
dirt from pushing up onto the bottom sheet of material. For extreme cases of sandy sub
grades, an outrigger system and raised rear travel roller are available. Please contact
supplier for more information and pricing.

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Pro-Wedge 3XL Operator’s Manual Page 8
7Welder Set-up
The initial set-up of the Pro-Wedge is by far the most critical aspect for proper operation of the
welder. Proper set-up not only leads to quality welding results but also minimizes wear and tear
on the welder itself. Adjusting the welder too tight can result in excessive wear on drive-train
parts such as gears, chains, sprockets, etc.
7.1 Set-Up Preparation
The procedures described in the following sections cover the initial set-up required for
various mil thickness materials and tolerances. These adjustments must be made while the
wedge heater is at room temperature. Refer to Figures 1 through 7 on the following pages
while performing these procedures. Referring to Diagram 1, use the actual material you
intend to weld, or if this is not possible use material that is the same mil thickness, cut two
pieces approximately 4 inches wide by 18 inches long and three smaller pieces
approximately 1/2 inch wide by 6 inches long. These five pieces of material will be used
as "gauges" for setting three adjustments on the Pro-Wedge.

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Pro-Wedge 3XL Operator’s Manual Page 9
Diagram 1
7.2 Adjustment #1: Wedge Centering
a. Adjust the upper and lower contour rollers away from the wedge so they will not
interfere with the wedge centering adjustment. Using a 4mm hex wrench remove the
Lower Contour Roller Adjustment Cover (1) (see Figure 1) to expose the Adjustment
Screw. Using a 10mm box end wrench loosen the Locknut (2) (see Figure 1). Using
a 3mm hex wrench turn the Adjustment Screw (3) (see Figure 1) counter-clockwise,
lowering the Lower Contour Roller Assembly (4) (see Figure 1) away from the Wedge.

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Pro-Wedge 3XL Operator’s Manual Page 10
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Figure 1
(4)
3
4
12

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Pro-Wedge 3XL Operator’s Manual Page 11
b. Using a 10mm box end wrench loosen the Locknut (1) (see Figure 2) on the Upper
Contour Roller Adjustment Knob. Turn the Adjustment Knob (2) (see Figure 2)
counter-clockwise, raising the Upper Contour Roller Assembly (3) (see Figure 2)
away from the Wedge.
Figure 2
2
13
4
5

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Pro-Wedge 3XL Operator’s Manual Page 12
c. Place two of the 1/2" X 6" material pieces, each folded in half, between the Nip
Rollers (1) (see Figure 3). This procedure simulates two layers of material between
the Rollers. Be sure these pieces do not extend past the Nip Rollers into the welder.
Rotate the Nip Pressure Cam (2) (see Figure 3) to the corresponding mil thickness
position indicated on the side of the Pressure Cam by rotating the Nip Pressure Cam
Lever (3) (see Figure 3) clockwise.
Figure 3
2
1
3

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Pro-Wedge 3XL Operator’s Manual Page 13
d. Move the Wedge to the Engaged/Welding position by rotating the Wedge Engagement
Handle (1) (see Figure 4) counter-clockwise. Using a 5mm hex wrench adjust the
Wedge with the Wedge Height Adjustment Screw (2) (see Figure 4) as needed, up or
down, to center the Wedge between the Nip Rollers. Turning the Adjustment Screw
clockwise raises the Wedge, counter-clockwise lowers it.
Figure 4
2
1

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Pro-Wedge 3XL Operator’s Manual Page 14
7.3 Adjustment #2: Wedge Engagement Position
Before beginning Adjustment #2 make sure the Wedge Engagement Handle has no free
play. If it does tighten the Pinion Gear Set Screw (1) (see Figure 5). This adjustment
controls how close the Wedge is to the Nip Rollers when it is in the Engaged/Welding
position.
Figure 5
1

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a. While adjusting the Wedge engagement position refer to Diagram 2 and Figure 6. Pull
out the Wedge Engagement Handle Lock-In Plunger (1) (see Figure 6) and rotate the
Handle to a central position between the two Hold-Down Screws (2) (see Figure 6).
Loosen the Hold-Down Screws and rotate the Wedge Engagement Handle counter-
clockwise until the Lock-In Plunger drops into the Lock-In Hole (3) (see Figure 6).
The Lock-In Disc (4) (see Figure 6) should now rotate with the Engagement Handle.
b. Slowly turn the Engagement Handle to position the Wedge so the distance between the
upper tip surface of the Wedge and the Upper Nip Roller is the same distance as
between the two Nip Rollers. This distance will be equal to twice the thickness of the
material to be welded. This same clearance should be maintained between the lower
tip surface of the Wedge and the Lower Nip Roller.
Diagram 2
WEDGE
UPPER
NIP ROLLER
LOWER
NIP ROLLER
UPPER CONTOUR
ROLLER ASSY
LOWER CONTOUR
ROLLER ASSY
DISTANCE #1
DOUBLE THICKNESS OF
MATERIAL TO BE WELDED
DISTANCE #3
(SAME AS DISTANCE #1)
DISTANCE #2
(SAME AS DISTANCE #1)

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Pro-Wedge 3XL Operator’s Manual Page 16
Figure 6
c. Once adjusted the Lock-In Disc must be tightened in place. Firmly hold down the
Lock-In Disc, pull out the Wedge Engagement Handle Lock-In Plunger and rotate the
Handle to a central position between the two Hold-Down Screws. Do not allow the
Lock-In Disc to move during this procedure. Firmly tighten both Hold-Down Screws
then rotate the Wedge Engagement Handle counter-clockwise until the Lock-In
Plunger drops into the Lock-In Hole. Verify that the Wedge engaged position did not
change during this procedure.
3
4
1
5225

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Pro-Wedge 3XL Operator’s Manual Page 17
7.4 Adjustment #3: Upper and Lower Contour Rollers
Before beginning Adjustment #3 make sure the Wedge is locked into the Engaged/Welding
position and the two folded 1/2" X 6" material pieces are still locked between the Nip
Rollers. This Adjustment may seem time consuming at first but with practice and
experience the entire set-up process takes only a few minutes.
a. Insert one of the 4" X 18" material pieces between the Lower Contour Roller Assembly
and the Wedge (see Diagram 3). This piece should extend out of the front of the welder
(opposite end from the Nip Rollers). Adjust the Lower Contour Roller Assembly
upwards by turning the Adjustment Screw (3) (see Figure 1) clockwise until the Wedge
begins to move up slightly.
b. Insert the remaining 4" X 18" material piece between the Upper Contour Roller
Assembly and the Wedge (see Diagram 4). This piece should extend out of the front
of the welder (opposite end from the Nip Rollers). Adjust the Upper Contour Roller
Assembly downwards by turning the Upper Contour Roller Adjustment Knob (2) (see
Figure 2) clockwise until the desired tension is achieved.
c. Check for proper adjustment by grabbing hold of the upper material piece protruding
from the front of the welder and move it forward and backward. The fit should be snug
causing a drag on the material. Check the lower material piece in the same way.
Further adjust the Upper and/or Lower Contour Roller Assemblies as necessary to
achieve the desired snug fit. When finished the drag (friction) on the upper and lower
material pieces should feel the same. During all adjustments make sure the Wedge
remains centered between the Nip Rollers.
d. Once the desired tension is achieved tighten both Upper and Lower Contour Roller
Assembly Locknuts being careful not to over-tighten, replace the Lower Contour Roller
Adjustment Cover remove all material pieces from welder.