Tech Tips

Wiring Instructions for WELDPLAST S1 120V

11/12/2021

Plug specifications: 120 Volt; 20+ Amp; 2-pole; 3-wire; grounding; twist-lock Example: Hubbell HBL2311 plug

When installing a plug:

Connect the green wire to the pin with the bent tab
Connect the white wire to one of the pins directly left or right of the bent tab
Connect the black wire to the other pin directly left or right of the bent tab
Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Making an Extension Cord:

Use a 10 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions:

Equipment must be switched off before turning the generator on or off
When using a generator make sure the plug is wired for A/C
Recommended Generator Size: 4,000W

Wiring Instructions for 230V COMET, UNIDRIVE 500, UNIFLOOR 300/500, and UNIPLAN 300/500

11/12/2021

Plug specifications:

250 Volt; 15+ Amp; 2-pole; 3-wire; grounding; twist-lock
Example: Hubbell HBL 4570CCN
This tool is single phase

When installing a plug:

Connect the green wire to the pin with the bent tab
Connect the white wire to one of the pins directly left or right of the bent tab
Connect the black wire to the other pin directly left or right of the bent tab
Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Making an Extension Cord:

Use a 12 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions:

Equipment must be switched off before turning the generator on or off
When using a generator make sure the plug is wired for A/C
Recommended Generator Size:
- COMET: 4,000W
- UNIDRIVE: 5,000W
- UNIFLOOR: 5,000W
- UNIPLAN: 7,000W

Wiring Instructions for 230V ELECTRON ST, FUSION 2/3/3C, and TRIAC AT/ST

11/12/2021

Plug specifications:

250 Volt; 20+ Amp; 2-pole; 2-wire; non-grounding; twist-lock
Example: Hubbell HBL7102C plug
This tool is single phase

When installing a plug:

Connect one wire to either one of the plug pins, and the other wire to the other pin
Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Making an Extension Cord:

Use a 10 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions:

Equipment must be switched off before turning the generator on or off
When using a generator make sure the plug is wired for A/C
Recommended Generator Size:
- ELECTRON ST: 4,000W
- FUSION 2/3/3C: 7,000W
- TRIAC ST: 4,000W

Wiring Instructions for 230V GEOSTAR G5/G7, TWINNY T5/T7, UNIROOF AT/ST, VARIANT T1, and WELDPLAST S1/S2/S4

11/12/2021

Plug specifications:

250 Volt; 20+ Amp; 2-pole; 3-wire; grounding; twist-lock
Example: Hubbell HBL2321 plug
This tool is single phase

When installing a plug:

Connect the green wire to the pin with the bent tab
Connect the white wire to one of the pins directly left or right of the bent tab
Connect the black wire to the other pin directly left or right of the bent tab
If using a 4 prong plug, leave the pin opposite the one with the bent tab disconnected
Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Making an Extension Cord:

Use a 10 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions:

Equipment must be switched off before turning the generator on or off
When using a generator make sure the plug is wired for A/C
Recommended Generator Size:
- GEOSTAR G5/G7: 6,000W
- TWINNY T5/T7: 7,000W
- UNIROOF AT/ST: 7,000W
- VARIANT T1: 7,000W
- WELDPLAST S1: 4,000W
- WELDPLAST S2: 6,000W
- WELDPLAST S4: 7,000W

Wiring Instructions 230V BITUMAT B2, VARIMAT V2, and WELDPLAST S6

11/12/2021

Plug specifications:

250 Volt; 30+ Amp; 2-pole; 3-wire; grounding; twist-lock
Example: Hubbell HBL2621 plug
This tool is single phase

When installing a plug:

Connect the green wire to the pin with the bent tab
Connect the white wire to one of the pins directly left or right of the bent tab
Connect the black wire to the other pin directly left or right of the bent tab
If using a 4 prong plug, leave the pin opposite the one with the bent tab disconnected
Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Making an Extension Cord:

Use a 10 Gauge or thicker cable if you plan to make a 100 ft or longer extension cord

Generator Instructions:

Equipment must be switched off before turning the generator on or off
When using a generator make sure the plug is wired for A/C
Recommended Generator Size:
- BITUMAT B2: 10,000W
- VARIMAT V2: 10,000W

How to Clean the Welding Shoe on an Extrusion Welder

10/19/2020

Cleaning the welding shoe of an extrusion welder is an important step when stopping work for the day or any extended period of time.

Extrude until six inches of extrudate comes out of the shoe.
Cut a piece of rod about 8 inches long. Insert one end of the rod into the end of the shoe. Move it in a small circle along the edge of the hole of the shoe. Wait 5 seconds.
Slowly pull out the rod. The extrudate inside the shoe will come out with it.
While wearing a heat-resistant glove, remove the welding shoe holder.
Look behind the welding shoe holder into the back of the shoe. Gently remove any extrudate from the back of the hole in the shoe. Be careful not to cut into the shoe.
If any rod pulls out of the back of the shoe and remains on the brass nozzle, cut it off of the nozzle.
Brush off any extrudate from the shoe and the nozzle.

General Tips

10/10/2019

When installing a plug on to a power cord:

Screw down the wire contacts on to the bare electrical wire only and do not clamp down on the insulation of the wire. Bad contacts cause sparking which may cause the cord to heat up and may damage equipment.

Ensure your tool is completely cooled down before shutting off:

Repeatedly shutting down the tool without allowing it to cool adequately may cause the element to crack; the cracking of the ceramic element may also cause the mica tube to burn or peel.

Watch for a plugged air intake:

A plugged air intake will cause bad welds. Regularly check that the air intake is clear. Clean it with a soft brush when needed.

If a tool's heater tube gets wet:

Do not turn the heat on right away the next time the tool is started as there is a risk of damage to the element and mica tube. Run the blower or tool without heat for 10 minutes so that the moisture is safely blown off prior to slowly increasing the heat to the desired level.

VARIMAT Tech Tips

10/8/2019

Changing the element on a VARIMAT

See our article for more details.

Correct the nozzle position on a VARIMAT

See our article for more details.

Working with generators

The minimum generator capacity required when using only a VARIMAT is 6000W with at least 5000W of continuous output. However, if a 120V hand tool will be used simultaneously a 10,000W or higher rated generator is recommended. Do not run a generator above 85% of its rated power (not maximum power).
To avoid electrical surges which may blow fuses or damage circuit boards:
- Never turn the generator on or off with the tool connected and switched on.
- Do not use dirty or water-contaminated fuel, or poorly maintained extension cords.

How to Repair the Hold-Down Assembly of a Varimat

10/2/2019

The two hold-down assemblies and the green belt in the picture below keep the top layer of membrane flat on the bottom layer as it is heated by the nozzle, just before the drive tire presses down on it.

Each hold-down assembly contains the following parts:

Item # in Drawing	Part #	Name
62	104.262	Circlip for shaft ø 8, Varimat
85	104.225	Pressure spring, 0.9 x 13.5 x 37.5 Varimat
200	108.125	Holding-down roller, Varimat
201	107.055	Guide Pillar, Varimat
202	107.056	U-profile, Varimat
203	107.077	Roller, hold down Varimat belt
204	104.267	Spring, roll pin 8 x 20 Varimat
205	100.299	Screw, raised cheese head M4 x 10

What to Check if your VARIANT T1 Stops in the Middle of a Weld

10/2/2019

If your Variant T1 stops driving while welding, check that the heater locks correctly into the welding position.

How the Weld Position Locking Mechanism Works

After allowing the tool to cool down completely. Slide the heater all the way to the right/outside of the tool. Note that you can now see a groove in the guide shaft.

In the picture below, a small flat screw driver is being held against a ball bearing set screw.

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​Each hold-down assembly contains the following parts:

How the Weld Position Locking Mechanism Works

Each hold-down assembly contains the following parts: