Zenit PPW-2000 User manual
InstructIon manual
PlastIc PIPe
weldIng machIne
PPw-2000
3
GENERAL SAFETY PRECAUTIONS
WARNING! When using electric
tools, basic safety precautions should al-
ways be followed to reduce the risk of re,
electric shock and personal injury, includ-
ing the following.
Read all these instructions before operat-
ing this product and save these instruc-
tions.
For safe operations:
1. Keep work area clean. Cluttered areas
and benches invite injuries.
2. Consider work area environment. Do
not expose power tools to rain. Do not
use power tools in damp or wet locations.
Keep work area well lit. Do not use power
tools where there is risk to cause re or
explosion.
3. Guard against electric shock. Avoid
body contact with earthed or grounded
surfaces. (e.g. pipes, radiators, ranges, re-
frigerators).
4. Keep children and inrm persons away.
Do not let visitors touch the tool or exten-
sion cord. All visitors should be kept away
from work area.
5. Store idle tools. When not in use, tools
should be stored in a dry, high or locked
up place, out of reach of children and in-
rm persons.
6. Do not force the tool. It will do the job
better and safer at the rate for which it was
intended.
7. Use the right tool. Do not force small
tools or attachments to do the job of a
heavy duty tool. Do not use tools for pur-
poses not intended.
8. Dress properly. Do not wear loose
clothing or jewelry; they can be caught in
moving parts. Rubber gloves and non-skid
footwear are recommended when working
outdoors. Wear protecting hair covering to
contain long hair.
9. Use eye protection. Also use face or dust
mask if the cutting operation is dusty.
10. Connect dust extraction equipment. If
devices are provided for the connection
of dust extraction and collection facilities
ensure these are connected and properly
used.
11. Do not abuse the cord. Never carry the
tool by the cord or yank it to disconnect it
from the receptacle. Keep the cord away
from heat, oil and sharp edges.
12. Secure work. Use clamps or a vise to
hold the work. It is safer than using your
hand and it frees both hands to operate
tool.
13. Do not overreach. Keep proper footing
and balance at all times.
14. Maintain tools with care. Keep cut-
ting tools sharp and clean for better and
safer performance. Follow instructions
for lubrication and changing accessories.
Inspect tool cords periodically and if
damaged, have it repaired by authorized
service center. Inspect extension cords pe-
riodically and replace, if damaged. Keep
handles dry, clean, and free from oil and
grease.
15. Disconnect tools. When not in use, be-
fore servicing, and when changing acces-
sories such as blades, bits and cutters.
16. Remove adjusting keys and wrench-
es. Form the habit of checking to see that
keys and adjusting wrenches are removed
from the tool before turning it on.
17. Avoid unintentional starting. Do not
carry a plugged in tool with a nger on the
switch. Ensure switch is off when plug-
ging in.
18. Use outdoor extension leads. When
tool is used outdoors, use only extension
cords intended for outdoor use.
4
19. Stay alert. Watch what you are doing.
Use common sense. Do not operate tool
when you are tired.
20. Check damaged parts. Before further
use of the tool, a guard or other part that
is damaged should be carefully checked to
determine that it will operate properly and
perform its intended function. Check for
alignment of moving parts, free running of
moving parts, breakage of parts, mounting
and any other conditions that may affect
its operation. A guard or other part that is
damaged should be properly repaired or
replaced by an authorized service center
unless otherwise indicated in this instruc-
tion manual. Have defective switches re-
placed by an authorized service center. Do
not use the tool if the switch does not turn
it on and off.
21. Warning Use only accessories or at-
tachments recommended in this instruc-
tion manual or in the catalogue of ZENIT
ТМ.
22. Have your tool repaired by a qualied
person. This electric tool is in accordance
with the relevant safety requirements. Re-
pairs should only be carried out by quali-
ed persons using original ZENIT TM
spare parts. Otherwise this may result in
considerable danger to the user.
SAFETY PRECAUTIONS ON USING
PLASTIC PIPE WELDING MA-
CHINE
Plastic pipe welding machine can be used
indoors as well as outdoors when being
protected from atmospheric fallout and at
positive air temperature. Before switching
on make sure the power cord, plug and re-
ceptacle are in order. Make sure the power
tool has no mechanical damage. Pipe
welding machine can be switched on only
when installed on a stand. Put warmed up
machine only on metal surfaces.
Operate only in a well-ventilated area. Do
not operate the tool if any of the following
malfunctions occur:
ATTENTION! The tool must be discon-
nected from the power source:
When changing heating sockets; When
sustained interruption in operation.
Operating temperatures of the heating ele-
ment reach 300°С. Never touch the heat-
ing element after switching the machine
on.
When welding and after operation do not
touch weld joint.
After disconnecting the machine from the
mains let it cool for a while.
Never speed up the cooling process by im-
mersing into liquid.
When putting hot machine after operation
do not allow contact with inammable
material. Put the machine only on special
surfaces (stands, holders or resafe sur-
faces). Change ttings and bushings of the
heating elements only in cooled state.
5
DESCRIPTION
Warm-up time 10 min
1. Handle
2. «On / Off» switch for 1000 W
and +1000 W
3. Indicator
4. Insulating jacket
5. Stand
6. Heating element
7. Power cord
8. Temperature control
TECHNICAL SPECIFICATIONS
Model PPW-2000
Rated voltage 220-240 V
Rated frequency 50-60 Hz
Rated power 2000 W
Heating element tem-
perature
30-300° С
Heating sockets
20 mm/
25 mm/
32 mm/
40 mm
50 mm/
63 mm
APPLICATIONS
Plastic pipe welding machine is an elec-
tric heating device which complies with
the requirements documents GOST IEC
60335-2-45-99, GOST R 51318.14.1-99,
GOST R 513 18.14.2-99, GOST R
51317.3.2.-99 and GOST R 51317.3.3-
99.
STANDARD ACCESSORIES
Welding machine holder 1
Allen wrench 1
Gauge tape 1
Heating sockets 6
Pipe shears 1
Screwdriver 1
Gloves 1 pair
Case 1
Plastic pipe welding machine is intended
for welding pipes made of polymer mate-
rials through muff joint.
Pipe welding machine has built-in tem-
perature control, which allows maintain-
ing set temperature.
WELDING TABLE
(detailed information must be provided by
plastic pipe manufacturer)
2 3
6
Pipe diameter,
mm
Melting depth,
mm Heatingtime, s Melting time, s Cooling time, s
20 14 5 4 3
25 16 7 4 3
32 20 8 4 4
40 21 12 6 4
50 22,5 18 6 5
63 24 24 6 6
1.PRIOR TO OPERATION
1.1. Power source.
Ensure that the power source to be utilized
conforms to the power requirements spec-
ied on the product nameplate.
1.2. «On\Off» switch.
Ensure that the power switch is in the OFF
position. If
the plug is connected to a receptacle while
the power switch is in the ON position, the
power tool will start operating immediate-
ly, inviting serious accident.
1.3. Extension cord.
When the work area is removed from the
power source use an extension cord of suf-
cient thickness and rated capacity. The
extension cord should be kept as short as
practicable.
2. HOW TO USE\
2.1. Connecting to mains
Pipe welding machine must be connected
to the earthed receptacle with a protective
conductor.
2.2. Choice of heating sockets
The choice of heating sockets for heating
element is made based on size of pipes to
be welded.
They are installed on heating element by
allen wrench from standard set.
Depending on requirements and machine
model several heating sockets can be in-
stalled on heating element.
2.3. Operating temperature control
To provide operating temperature stabil-
ity, heating element of the machine is
equipped with stepped temperature con-
trol. Operating temperature is xed to 260
± 10°C.
Follow pipes, ttings manufactures’ in-
structions!
Before operation check temperature on
working surfaces of heating sockets in-
stalled on the heating element.
2.4. Warm-up
Manufacturer sets operating temperature
of pipe welding machines to 260°С. De-
pending on pipe material, necessity to
change this value may occur. Before op-
eration familiarize yourself with informa-
tion from pipes and formed parts manu-
facturer!
It is recommended to control temperature
of heating sockets of the heating element
(heating ttings), for example with the
help of surface thermometer. If necessary,
temperature can be adjusted by turning the
temperature control. When adjusting tem-
perature remember that heating element is
ready for operation only after 10 minutes
after reaching the set temperature.
7
3. WELDING PLASTIC PIPES
3.1. Technology description
When performing sleeve welding with
the help of heating sockets on the heating
element, pipe joint and proled part are
lapped. Pipe end and sleeve of the pro-
led part are heated with the help of heat-
ing spigots and sockets, installed on the
heating element, and then joined. There
are two methods of sleeve welding with
different sizes of the spigot and sockets.
Method A does not include mechanical
tooling of pipes, method B includes me-
chanical tooling – centreless grinding.
Heating spigots and sockets ZENIT are
intended for method A welding only.
Sleeve welding with the help of heating
sockets can be performed on pipes with
diameter up to 63 mm.
When working with pipes of bigger diam-
eter it is recommended to use an appropri-
ate welding machine.
3.2. Prior to welding
Follow recommendations of the pipe man-
ufacturer and proled part manufacturer!
End of the pipe must be cut square and
evenly. These parameters are achieved
by using pipe shears. Besides, end of the
pipe must be beveled for easy joint. Right
before welding pipe end and internal sur-
face of the sleeve of the proled part and
heating spigot and socket, if necessary,
are cleaned with a piece of paper, leav-
ing no paper dust or a napkin leaving no
laments, moistened with gasoline or
commercial alcohol. Make sure plastic
remainders don’t stick to the surface of
the heating socket. When cleaning heat-
ing sockets make sure not to damage spe-
cial teon coating. Do not touch surfaces
treated in this way before welding.
3.3. Welding technology
3.3.1. Heating of pipes and proled
parts
To heat the pipe and proled part quickly
insert them on heating spigots, xed on
the heating element of the machine, to the
end position or to the marking, and keep
for time required (see welding table).
It is recommended to follow instructions
of the pipe manufacturer.
When heating, the heat gets inside the sur-
faces to be welded and Во время разогрева
тепло проникает в подлежащие
спаиванию поверхности соединений,
доводя их до нужной температуры.
3.3.2. Welding and xing
After heating remove the pipe and pro-
led part from the spigots of the heating
element and push them inside one another
without turning. Fix (hold) them for a pe-
riod of time, recommended by the plastic
pipe manufacturer (see welding table).
Time between removing from the heat-
ing element and welding must not exceed
time, recommended by the pipe manufac-
turer (see welding table). Otherwise weld-
ing surfaces will not be heated enough for
quality welding.
3.3.3. Cooling
Load on joints must be applied only after
estimated cooling time (indicated by the
plastic pipe manufacturer), (see welding
table).
4. MAINTENANCE
ATTENTION! Before maintenance and
repair disconnect the tool from the power
source and let it cool! These operations
must be performed by qualied specialists
only.
Before every welding clean the teon coat-
ing of the heating element spigots with a
8
piece of paper, leaving no paper dust or
a napkin leaving no laments, moistened
with gasoline or commercial alcohol.
Make sure plastic remainders don’t stick
to the surface of the heating socket. When
cleaning heating sockets make sure not to
damage special teon coating.
NEVER! Clean the heating spigots with
metal tools, sand paper and abrasive
pastes. After operation switch off the tool,
disconnect the plug from the receptacle
and let the welding machine cool. After
cooling take the machine from the stand
and put into the case.
5.TROUBLESHOOTING
5.1. Welding machine does not heat:
Reason:
• machine is not connected to the
mains
• power cord is damaged
• receptacle is defective
• machine is defective
5.2. Plastic particles cannot be re-
moved from the surface of the spigots of
the heating element
Reason:
• heating element is dirty (see
clause 4)
• teon coating is damaged
6. WARRANTY TERMS
Warranty does not cover damage to the
teon cover of the spigots of the heating
element caused by unqualied operation.
Warranty does not cover defects, caused
by natural wear, unqualied operation or
noncompliance with instruction manual,
overload, перегрузки, unintended use,
personal interference or interference of
unauthorized persons, as well as other
causes beyond the control of the manufac-
turer TM ZENIT.
CAUTION
When using the tool follow these rules:
- do not allow mechanic damage
(strikes, falls etc.);
- protect the tool from external
sources of heat and chemically active sub-
stances, as well as liquid and objects pen-
etration;
- before disconnecting the tool
from the power source turn off the On/Off
switch;
Inobservance of these rules will make
warranty void!
WARNING
Repair, modication and check of ZENIT
power tools should be performed only in
authorized service centers ZENIT. While
use or maintenance of power tools follow
all safety rules and standards.
NOTE
Zenit Power Tools are constantly being
improved and modied to incorporate the
latest technological advancements.
Accordingly, some parts may be changed
without prior notice.
9
Demix LLC
Head ofce:
14, Shevchenko str., 3rd oor
Dnepropetrovsk, Ukraine, 49044
tel./fax: +38 056 375-43-16
http://www.en.zenit-pro.com
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