HF1000 Operator Manual

Transcription

HF1000 Operator Manual
Contents
Safety precautions ................................................................................................................................................. 2
Limited Warranty .................................................................................................................................................... 3
HF1000 Machine Description................................................................................................................................. 4
Pipe alignment .................................................................................................................................................................... 4
Facer ................................................................................................................................................................................... 4
Heater ................................................................................................................................................................................. 4
Heater/Facer Guard ............................................................................................................................................................ 4
Stabilisers............................................................................................................................................................................ 4
Pipe lifter ............................................................................................................................................................................. 4
Fittings holder...................................................................................................................................................................... 5
Reducing liners ................................................................................................................................................................... 5
Power requirement .............................................................................................................................................................. 5
Shipping container .............................................................................................................................................................. 5
Component weights ............................................................................................................................................................ 5
Operator controls ................................................................................................................................................... 5
Before starting machine ...................................................................................................................................................... 5
Electrical.............................................................................................................................................................................. 5
Pressure Gauges ................................................................................................................................................................ 6
Pressure selector ................................................................................................................................................................ 6
Pressure regulators ............................................................................................................................................................. 6
Hydraulic control levers ....................................................................................................................................................... 6
Cylinder balance valve ........................................................................................................................................................ 6
Using the HF1000 .................................................................................................................................................. 7
Preparation.......................................................................................................................................................................... 7
Installing fittings holder ....................................................................................................................................................... 7
Installing reducing liners ..................................................................................................................................................... 7
Drag pressure ..................................................................................................................................................................... 7
Pipe loading and alignment ................................................................................................................................................. 7
Facer operation ................................................................................................................................................................... 7
Check alignment ................................................................................................................................................................. 8
Heating cycle....................................................................................................................................................................... 8
Fusion cycle ........................................................................................................................................................................ 8
Removing pipe .................................................................................................................................................................... 8
Weld quality check .............................................................................................................................................................. 8
Maintenance - daily checks.................................................................................................................................... 8
Maintenance - periodic ........................................................................................................................................... 9
General ............................................................................................................................................................................... 9
Temperature adjustment ..................................................................................................................................................... 9
Heater surface..................................................................................................................................................................... 9
Non-stick cloth replacement ................................................................................................................................................ 9
Heater failure....................................................................................................................................................................... 9
Hydraulic system ................................................................................................................................................................. 9
Hydraulic pumps ............................................................................................................................................................... 10
Clamp closing and locking control .................................................................................................................................... 10
Adjusting hydraulic pressure ............................................................................................................................................. 10
Synchronising the carriage cylinders ................................................................................................................................ 10
Hydraulic bleeding method ............................................................................................................................................... 10
Repairing carriage cylinder ............................................................................................................................................... 10
Pressure gauge calibration ............................................................................................................................................... 10
Temperature measurements ............................................................................................................................................. 11
Facer drive inspection ....................................................................................................................................................... 11
Bronze roller replacement ................................................................................................................................................. 11
Blade sharpening .............................................................................................................................................................. 11
Adjusting eccentric cam mechanism ................................................................................................................................. 11
Butt welding — general procedure ........................................................................................................................ 12
The basic welding process ................................................................................................................................................ 12
Weld test - destructive....................................................................................................................................................... 12
Weld failure trouble shooting ............................................................................................................................................ 12
PIPA Butt Welding Parameters ............................................................................................................................ 13
PE welding temperatures .................................................................................................................................................. 14
Heater plate temperature .................................................................................................................................................. 14
Measuring surface temperature ........................................................................................................................................ 14
Infra-red pyrometer suggestion ......................................................................................................................................... 14
Assembly drawings .........................................................................................................................................15-29
Welding tables .................................................................................................................................................30-31
®
FUSIONMASTER is a registered trademark of Dixon Industries Pty. Ltd. © August 2002.
revised June 2009
Page 1
Operating Safely
Safety precautions
Know the machine
This machine should only be used by an operator fully
trained in its use.
Read these operating instructions carefully. Learn the
operation, limitations and potential hazards of using
your butt fusion machine.
Report anything that doesn't look right, sound right,
smell right, feel right, or is in any way different from
what you expect, or that you think may be unsafe.
Pinch points
This machine has many moving parts that are
designed to apply a great deal of force when carrying
out its designed function. This especially refers to the
clamps, heater and facer. These cannot be guarded
without preventing the machine function.
Any bodily parts caught in the machine when the
hydraulics are operated could be crushed. Operators
must ensure that all persons in the vicinity of the
machine are kept well clear of moving parts during all
phases of the welding process.
Stability
Once in position, always apply the handbrake and/or
chock the wheels to prevent the machine from
moving. If the machine is used on a gradient, it may
be dangerously destabilised when the heater, facer and
clamps are opened. On uneven terrain, the stabiliser
beams should be extended and jacking screws
lowered on to timber support pads before opening the
heater, facer or clamps.
Electrical safety
Use only a qualified electrician to carry out electrical
maintenance work.
Connect electrical components only to a voltage
source that corresponds to that marked on the
components.
Do not operate the electrical equipment in wet
conditions.
Prevent electric shock by correctly grounding
electrical components. The green (or green/yellow)
conductor in the electric cable is the grounding wire
and should never be connected to a live terminal.
Earth leakage protection is built into the control panel.
The equipment is not explosion proof.
Never carry out butt welding in a gaseous or
combustible atmosphere.
Wear appropriate apparel
The heater operates at 200°C and contact can cause
serious burns. Wear gloves to prevent burns if
handling the hot plate.
®
Facer
The facing machine is powerful and the cutting blades
are sharp. To prevent serious injury the facer should
only be operated when it is securely located in the
pipe cutting position.
Do not attempt to remove shavings from the cutting
area while the facer is running.
Hydraulic pressure
A sudden hydraulic oil leak can cause serious injury or
even death if the pressure is high enough. Do not
search for oil leaks with the fingers because a fine jet
of pressurised oil could penetrate the skin causing
serious injury. Use a piece of cardboard to test for
leaks under pressure.
Avoid spraying oil into eyes when bleeding air from
the system by wearing safety glasses and keeping the
face clear of the area.
Pipe lifters
Never operate the pipe lifters without unclamping the
pipe or damage to the pipe lift structure will result.
Maintain equipment carefully
The machine has moving parts and/or parts that may
deteriorate with age. For best results carry out regular
cleaning and inspections of all machine components
and conduct necessary maintenance. Always
disconnect the power when adjusting, servicing or
changing accessories. Replace damaged electric
cables, or hydraulic hoses and fittings.
Transporting the machine
This equipment is not designed for on-road towing at
speed greater than 5kph. Any attempt to do so could
result in machine damage and/or personal injury.
Transportation should be by truck or similar, with the
equipment well secured, and supported by the
stabiliser feet
.
During transportation always ensure the heater, facer
and guard are secured as shown above to prevent
damage to the carriage hydraulic shaft, and/or the
heater and facer support brackets.
revised June 2009
Page 2
Limited Warranty
Limited Warranty
1.
Subject to the terms below, Dixon Industries Pty Ltd (“Company”) warrants to repair or replace at its option exworks Adelaide any product manufactured or repaired by it within 2 years from the date of shipment which are
found to be defective due to either faulty workmanship or use of faulty materials, provided that such defective
product is returned to the Company’s works at the customer’s expense, unless otherwise agreed.
2.
This warranty is limited solely to products manufactured or repaired by the Company. Products not
manufactured by the Company (such as pumps, gauges, motors, switches, etc.) are not covered by this warranty.
In relation to a repair, this warranty is limited to the Company’s cost of parts and labour to remedy a defective
repair.
3.
This warranty does not apply to any product that has been damaged by accident, misuse, neglect, use of an
electrical power supply that is incompatible with the design specifications of the product or repair or alteration
of the product by anyone other than the Company.
4.
A warranty claim must be made to the Company in writing within 14 days of the first occurrence of the event or
condition on which the claim is based. The claim must include proof of purchase and a detailed statement of the
manner in which the product has been used and the event or condition occurred. The Company’s decision to
admit or refuse any warranty claim shall be binding.
5.
Replacement parts provided to the customer before the right to a warranty claim is accepted by the Company
will be invoiced at the full cost of the parts, including applicable taxes and freight charges. If a warranty claim is
accepted, the cost of any replacement parts covered by the warranty claim which have been so invoiced will be
credited to the customer.
6.
All costs of returning product to the customer shall be paid by the customer.
7.
Other than provided in this warranty, the Company excludes any other responsibility or liability whatever to the
maximum extent permitted by law including liability for breach of contract, negligence or incidental,
consequential, indirect or special damages including without limitation, interruption to use of the product or any
other plant or equipment.
®
revised June 2009
Page 3
HF1000 Machine Description
ensuring rapid removal of plastic during the facing
operation.
The FUSIONMASTER® HF1000 machine is a high
productivity, top loading, pipe to pipe butt welder.
The main clamps are 1000mm inside diameter with
the top clamps being hydraulically opened, closed and
locked down. The hydraulics, heater and facer are
permanently mounted on the machine frame.
The frame is mounted on four pneumatic tyred wheels
to enable towing between welds at low speed. It is
steered from the moving clamp end.
The machine may be lifted by large forklift, or by
crane. (When lifting by crane, attach a spreader beam
(not supplied) to four lifting lugs at each corner of the
main frame.)
Machine length overall
3150mm
Width (heater/facer guard open)
3580mm
Width (heater/facer guard closed)
2170mm
Height (heater/facer guard closed)
1870mm
Heater
Pipe alignment
The fixed pipe clamps can be moved approximately
10mm in the vertical and the horizontal direction
independently by hydraulically actuated eccentric cam
mechanisms. This feature minimises misalignment
problems caused by pipe ovality and other
dimensional variations. It increases productivity by
significantly reducing joint setup times.
Facer
The facing head is driven by a powerful hydraulic
motor and is fitted with three cutting blades per side
®
The heater plate is hinged to the machine frame and
moved in or out of position hydraulically. The cast
aluminium heater plate has three circular elements to
ensure uniform heat distribution across the 1025mm
effective heating diameter (total power 10kw, 415v, 3
phase). Operating temperature of 220°C is reached
from 20°C in about 35 minutes. Temperature is
electronically controlled by an electronic temperature
controller located at the main electrical panel.
Replaceable non-stick cloths are used to cover the
heater faces to prevent hot plastic adhesion. The cloths
are secured by snap rings that enable quick and easy
field repair if the surface is damaged.
Heater/Facer Guard
The guard protects the heater from the effect of wind
and also protects operators from possible injury from
the heater or facer. It is manually lifted in/out of
position.
Stabilisers
Extendable beams with screw jacks are fitted on both
sides of the machine for stability when welding.
Pipe lifter
Independently controlled hydraulic pipe lifters located
at each end of the machine raise the welded pipe clear
of the clamps to enable the machine to be moved to
the next weld location without fully removing the
pipe.
revised June 2009
Page 4
Fittings holder
Operator controls
This accessory holds stub flanges by the outside
diameter and mounts into a main clamp.
Before starting machine
Reducing liners
Clamp liners for the HF1000 can be supplied to suit
any pipe size from 900mm to 630mm. There are four
rings to each liner size.
Liners can be machined to imperial dimensions on
request.
Power requirement
The HF1000 requires three phase, 415 volt power. The
recommended portable generator capacity for field use
is 35kva. The machine is connected via a 32A, 5 pin
Australian Standard plug.
Shipping container
The HF1000 machine is designed to fit inside a
standard 20 foot sea-container for ease of shipment
and storage.
Component weights
Operators should be thoroughly familiar with the
machine before turning on the power. The stabiliser
beams should always be extended and jacking screws
lowered on to timber supports or similar before
raising the heater, facer, or clamps.
Check the hydraulic oil level and top up if necessary
to the gauge 3/4 mark.
Electrical
Connect the machine to mains or generator power.
Open the control panel and check that all circuit
breakers are on.
The 10A circuit breaker isolates the hydraulic pump.
The 25A circuit breaker isolates the heater plate.
The 6A circuit breaker isolates the heater controls.
Phase
reversing
switch
Pump
isolator
Motor
overload
protection
Set at 7.5A.
Machine
approx. 2600kg
Heater (element pad only)
70kg
Fittings holder
72kg
Reducing liner set 1000-900mm (4 rings)
148kg
168kg
107kg
83kg
Heater
plate
isolator
Turn the
Heater
controller
isolator
RCD
Test plug.
DO NOT USE AS
SINGLE
PHASE
OUTLET!
at the control panel to ON. The
and RCD ON lights should illuminate. If not,
check if the RCD (residual current device) has tripped,
and reset it.
Check that the pump motor fan spins clockwise when
looking from above. If this does not occur, disconnect
the power supply, before reversing polarity with the
PHASE REVERSAL switch.
MAIN SWITCH
POWER ON
The HEATER switch controls power to the heater plate
and is illuminated when on.
The green HYDRAULIC PUMP button starts the pump
running. The red HYDRAULIC PUMP button stops the
pump.
If the RCD is tripped, always check for faults before
resetting.
Check that the TEMP CONTROLLER at the control panel
indicates
the
required
temperature
setting.
®
revised June 2009
Page 5
PIPE LIFT LH and PIPE LIFT RH
Pressure Gauges
MAIN PUMP 0-16,000 kPa
Indicates maximum pressure developed by the
pump.
CARRIAGE PRESSURE 0-160 bar (0-16,000 kPa)
Indicates the pressure in the main carriage
cylinders during facing or welding. This indicates
cylinder pressure
when the CARRIAGE
MOVE lever is not
in the neutral
position, and the
carriage is being
closed. There is no
pressure reading
when the carriage
travels
in
the
reverse direction.
Pressure
selector
The 3-position pressure selector enables selection of
one of the three carriage pressure regulators used
during the welding process.
Pressure regulators
Three regulators allow independent pre-setting of
different pressures for the carriage cylinders. Always
adjust the carriage pressure with the CARRIAGE MOVE
lever open.
It is suggested that one regulator be set at the facing
pressure; the second regulator be set at the bead up
and weld/cooling pressure; and the third regulator be
set at the heat soak pressure. This is often set to just
above the "drag" pressure.
With the hydraulic pump operating, regulate the
carriage pressure down to minimum pressure and
operate the various control levers (see descriptions
below) to ensure all are functioning correctly.
Hydraulic control levers
Actuate the pipe lifter at each end of the machine
independently.
CLAMP #1, #2, #3, #4
Raises and lowers each clamp independently into
position.
FACER LIFT
Moves the facer in and out of machine.
HEATER LIFT
Moves the heater in and out of machine.
TROLLEY MOVE
Moves the trolley which carries the heater and
facer.
Before lifting the heater or facer into the weld
zone, always ensure the trolley is in a position that
will not cause the heater or facer to come into
contact with the clamps or pipe.
FACER ROTATE
Starts or stops facer rotation. This should never be
operated unless the facer has been lowered into the
cutting position. The facer drive motor speed
cannot be varied.
CARRIAGE MOVE
Moves the carriage cylinders during facing or
welding. The speed of movement of the carriage
cylinders when moving the pipe ends together is
controlled by throttling the CARRIAGE MOVE lever.
Cylinder balance valve
The balance valve (shownbelow) must remain closed
at all times during machine operation. It must only be
opened for bleeding air from the carriage cylinders
(see maintenance section).
The
carriage
cylinders
are
connected
in
series to ensure
equal pressure
is carried by
both cylinders.
This prevents
the possibility
of distortion of the machine under load, ensures
optimum pipe alignment and maximises weld quality.
ALIGN IN - OUT
Actuates the eccentric pipe alignment mechanism
to move the fixed clamps horizontally.
ALIGN UP - DOWN
Actuates the eccentric pipe alignment mechanism
to move the fixed clamps vertically.
®
revised June 2009
Page 6
Using the HF1000
the spacer. Carefully close the top clamp over the
upper liners and bolt them into the top clamp.
Preparation
Drag pressure
1.
"DRAG" is the amount of pressure required to
overcome the friction acting inside the hydraulic
carriage cylinders plus the effort required to move the
pipe. Drag pressure must therefore be measured before
every weld and added to the calculated welding
pressure for the pipe.
Locate the machine, apply the hand brake and set
wheel chocks in position.
2. The stabilisers should
always be deployed
before opening the
heater,
facer
or
clamps
in
any
situation,
but
especially if the
machine is located on
a sloping surface.
Extend the stabiliser beams and wind the jack feet
down on to timber supports to spread the load.
3. Connect only to a 415v power source. Ensure the
output of any portable generator used is 415v +/20v and 50hz to protect the electronic temperature
controller from being damaged.
4. Check the hydraulic tank oil level is at least 3/4
full.
5. Open the heater/facer guard before opening the
heater or facer.
6. Power up and check all indicator lights and the
hydraulic pressures.
7. Test for air in the hydraulic system. Bleed as
necessary.
8. Clean the non-stick cloths before every weld with
clean dry paper or cotton cloth. Never use
synthetic cloth that could melt. Never use solvents
that could dissolve "dirt" and spread
contamination across the heating surface. Replace
cloths if damaged.
9. Check the heater surface temperature, and if
necessary adjust the temperature controller.
10. Instructions for the temperature controller are
located inside the electrical cabinet.
11. Check the facer cutting action (the shaving
thickness should be around 0.35mm).
12. Clean each pipe end and the cutter blades before
facing.
Installing fittings holder
Lift the fittings holder into the bottom clamp using a
soft sling through the central hole. Remove the sling
and close the top clamp to keep the fittings holder in
place.
Installing reducing liners
Fully open the top clamp.
Load liners into the
bottom clamp and bolt
them into place. Then
place a 100x25mm timber
spacer on top of the
bottom liners and place
the upper liners on top of
®
To determine the drag pressure, operate the CARRIAGE
MOVE lever and adjust a pressure regulator until the
carriage is just moving. This is the drag pressure
NB. The minimum carriage pressure achievable in the
HF1000 is 1000kPa due to back pressure in the
hydraulic system. Therefore drag pressure will always
be 1000kPa or greater.
Pipe loading and alignment
Load the pipes into the bottom clamps with about
80mm of pipe extending past the clamps into the weld
zone. Use external pipe supports to keep the
protruding pipe parallel with the machine base over
the whole length of the pipe. This eliminates external
bending loads on the machine and minimises drag on
the pipe. Close and lock each top clamp
independently. Move the pipe ends together and check
for alignment, (maximum misalignment 10% of wall
thickness).
To adjust out any misalignment, the fixed pipe
clamps can be axially
adjusted in two directions
by eccentric cams located
at the outer end of the
fixed clamps. To prevent
equipment
damage,
always move the pipe ends
slightly
apart
before
aligning the pipe.
If there is insufficient
clamp lock pressure to
prevent
the
pipe
sliding through the
clamp, reposition the
clamp latch to the
next adjustment hole
position.
Facer operation
Clamp latch
adjusting bolt
Clamp latch
Operate the TROLLEY MOVE lever to slide the
heater/facer trolley along ready to swing the facer into
position. Ensure the trolley is positioned so its
movement cannot be impeded during facing, and the
facer itself is clear of the clamps/pipe ends and will
not hit them when swung into position.
revised June 2009
Page 7
Operate the FACER LIFT lever to move the facer into the
weld zone. Ensure the stop rests against the carriage
shaft.
Set the carriage movement pressure to about 1500kPa.
Operate the FACER ROTATE lever to begin facing.
(Release this lever to stop the facer rotating.)
Operate the TROLLEY MOVE lever and the CARRIAGE
MOVE lever until the facer is in contact with the end of
both pipes/fittings. Optimum facing pressure and
sharp blades should produce shavings 0.3-0.5mm
thick. (Less pressure and/or worn blades will produce
thinner shavings.)
Do not overload the facer by applying excessive
carriage pressure. Carriage pressure should never
exceed “drag” plus 1,000kPa during the facing
operation.
When shavings are being produced continuously and
simultaneously from both pipe ends, move the pipe
ends out of contact with the facer before stopping
facer rotation. Lift the facer up out of the machine,
extending it fully to its “out” position.
Check alignment
Remove the facer and clear away all plastic cuttings
without contaminating the pipe ends. Do not touch the
cut surface or re-clean it.
Move the pipe ends together and re-check pipe
alignment
Always reface if it becomes necessary to rotate the
pipe in the clamps to improve alignment after initial
facing.
Heating cycle
Check the heater temperature and drag pressure before
every weld. Calculate weld parameters P1, T1, etc.
On completion of heat soak time, reverse the carriage
direction to “crack” the heater plate away from the
melted pipe and move the heater plate out of the weld
zone as quickly as possible.
The unique non-stick cloths allow a "peeling off"
action as the pipe is cracked away, minimising
adhesion of the melted pipe to the heater. It may
sometimes be necessary to operate the TROLLEY MOVE
lever to break the heater away from the pipe.
Caution:
Do not allow the heater plate to slide across the pipe
ends and distort the melted surface. Do not
contaminate the melted surface in any way.
Fusion cycle
Bring the melted pipe faces into contact with each
other gently without delay to minimise heat loss from
the weld zone. Build up to the required fusion
pressure gradually to avoid squeezing out too much
hot plastic. (Refer to the parameters table for
allowable times.)
Shrinkage will occur as the weld cools. Therefore it is
essential to keep the pump running, maintaining
carriage pressure during the cooling time, or pressure
will be lost from the carriage cylinders and a failure
may result.
Removing pipe
Always open the top clamps before activating the PIPE
LIFT levers to hydraulically assist removal of the
welded pipe clear of the bottom clamps.
Weld quality check
Inspect the uniformity of the bead size inside and out,
top and bottom of the pipe. It is advisable to monitor
and record times, temperatures and pressures at each
phase of every joint for future reference. (See section
on trouble-shooting weld failures.)
Operate the TROLLEY MOVE lever to slide the
heater/facer trolley into a position such that trolley
movement cannot be impeded during heating, and the
heater itself cannot strike the clamps or pipe ends
when swung into position. Then swing the heater plate
into the weld zone.
Move the carriage until both sides of the heater plate
are in contact with the pipe/fitting. Ensure the pressure
applied is the predetermined heating pressure P1.
Maintain pressure P1, until an initial melt bead has
formed completely around the pipe on both sides of
the heater plate. This commences the heat soak period.
At this time reduce pressure to just above drag
pressure. Failing to reduce pressure forces hot plastic
out of the joint zone and can lead to a "cold joint".
®
revised June 2009
Page 8
being trapped under the cloth. This vent should
always be kept clear.
Maintenance - daily checks
1.
Keep the machine and accessories clean and free
of dust and grease. Lubricate the pipe roller, and
steering arm grease nipples only. No other parts
of the machine require lubrication.
2. Inspect hydraulic components for leaks from
connections and seals. Overhaul fittings and seals
as necessary.
3. Check for air in the carriage cylinders (as
evidenced by shuddering, and/or “springing back”
of the rams). This must be removed by bleeding.
4. Check all pressure gauges operate and return to
zero.
5. Check the temperature at a number of points on
the surface of both sides of the heater plate.
Readings should be within 210-230°C.
6. Check for bare electric wires and repair damage
immediately.
7. Replace non-stick cloths if damaged in the weld
zone.
8. Facing blades should be sharp and have defect
free cutting edges to provide continuous swarf of
uniform thickness. Sharpen cutter blades if blunt,
or replace if chipped.
9. Look for “sloppy” movement in the cutter plates,
which is indicative of the need to adjust the facer
drive internally.
10. When using a portable generator, ensure its output
is 415v +/- 20v and 50hz, and check that the
pump motor fan spins clockwise when looking
from the top.
11. Check tyre pressures is 350-450 kPa.
Non-stick cloth replacement
Maintenance - periodic
2.
1.
2.
3.
4.
5.
Heater failure
1.
In addition to the daily checks, the following should
be carried out before commencing each new project,
or after 250 operating hours.
General
1.
2.
Check the hydraulic cylinder shafts for cuts or
dents likely to damage the hydraulic seals.
Check the machine frame, clamps and carriage
hydraulic shafts are not damaged or bent, which
could result in a sharp increase in drag pressure.
3.
4.
Temperature adjustment
The instructions for changing temperature controller
settings are given in the Assembly Drawing Section at
the end of this document.
Heater surface
1.
2.
Heater surfaces should be flat, smooth and free of
dents or gouges. Dress as necessary.
Heaters with non-stick cloths have a vent
machined in the edge of the casting to prevent air
®
The non-stick cloths should be replaced if they
become torn, contaminated or overheated.
Do not attempt to remove the cloths if the plate
temperature is more than 40°C because the snap
rings will not release above this temperature.
Detach the heater guard to allow access to the
heater plate, and extend the heater plate away
from the machine.
Use a screw driver to lever the snap rings out of
their securing grooves. Remove the old cloth.
Place a new cloth on one side of the plate and
press the snap ring back into the securing groove.
Two or three people are required to hold the snap
ring in place while a new cloth is being fitted.
This may be aided by using spring loaded clamps.
5.
If the heater does not power up, always first test
the power supply and connecting cable for
possible faults.
Check if the RCD has tripped. This may happen if
the machine has been used in a damp
environment, moisture may have condensed on
the element leads. Blow hot air into the bracket
connected to the element pad to drive out residual
moisture.
Other causes could either be failure of a heating
element, the temperature controller or other
electrical components.
There are three heater elements cast into the
HF1000 heater plate. The failure of an element
will result in a circular region around the plate
being much cooler than the rest of the plate. This
may be confirmed by an electrician checking each
element resistance, which should be 24ohms +/10%. If an element fails, the element pad must be
replaced.
If the failure is isolated to the electronic
controller, remove the protective cover from the
top of the controller, extract the existing
controller from its location, and plug an identical
replacement into the vacant slot.
revised June 2009
Page 9
Hydraulic system
electric pump
3.3kw, 415v, 3 phase
main pump pressure gauge
16,000kPa
carriage pressure gauge
100 bar (10,000kPa)
carriage pump relief pressure set
13,000kPa
carriage regulators max relief pressure
13,000kPa
cylinder area (for weld calculations)
4,940mm2
System oil capacity at 3/4 level
70 litres
Recommended oil:
Neodrol 46, Shell Tellus 22, or ISO viscosity 46
equivalent.
Hydraulic pumps
A variable displacement pump provides pressure to
the carriage cylinders.
A positive displacement pump drives the facer motor
and all other hydraulic cylinders.
Clamp closing and locking control
The operation of each clamp lift cylinder and each
clamp locking cylinder is independently controlled by
a combination of sequence and counterbalance valves.
Altering the motion or sequence of clamp
lift/locking should not be necessary. Any
adjustment should only be carried out in
consultation with the manufacturer.
damage to the cylinder shaft or bore. These possible
problems should be inspected and repaired as
necessary before attempting to bleed air. To bleed
carriage cylinders:
1. With the cylinder balance valve (in the line
between the 2 cylinders) closed, drive the
cylinders to the fully open position.
2. Open the cylinder balance valve then reverse the
directional control valve and drive the cylinders
to the fully closed position.
3. Repeat this cycle in each direction as many times
as it takes to remove all air. Top up the oil tank if
necessary. Use any reputable hydraulic oil of
“ISO 46” viscosity.
4. This will be evidenced by any change of the
directional control lever, and the resultant motion
of both cylinders, being immediate and exactly in
sequence. There should also be no clamp spring
back at the end of the cylinder stroke (either end)
on changing the directional control valve.
5. Close the cylinder balance valve to lock the
cylinders in phase.
Repairing carriage cylinder
1.
Adjusting hydraulic pressure
The maximum available carriage pressure is limited
by a relief valve in the pump and by 3 pressure
regulators in the 3-way selector valve. Increasing this
pressure should not be necessary, and any adjustment
should be done in consultation with the manufacturer.
The maximum pressure available to the facer motor
and pipe lift, heater lift, facer lift, trolley and
alignment motion cylinders is limited by a relief valve
located in each respective control valve block. These
are factory preset and should not be adjusted.
The speed of lift cylinder movements is controlled by
flow controllers located in the line to each cylinder.
These are factory set to safe working speeds and
should be adjusted with care.
There is no adjustment of facer drive pressure or
speed.
2.
3.
4.
5.
Synchronising the carriage cylinders
If air enters the cylinders, the carriage motion will
eventually become out of phase or jerky. This will
adversely affect the welding operation and entrapped
air should be bled from the cylinders.
The clamp cylinders are connected in series not
parallel. The cylinder balance valve in the line
between the clamp cylinders must be closed, except
when bleeding the system.
6.
7.
Before removing a cylinder for repairs, mark the
hydraulic lines to ensure they can be reconnected
to the correct ports. Then disconnect the hydraulic
lines and remove all the fasteners attaching the
clamp parts to the cylinders.
Remove the socket head cap screws from the
“shaft nut” attached to the end of the cylinder
shaft and the end frame plate. Leaving the other
shaft nut attached to the centre frame plate,
unscrew the shaft from both shaft nuts and
remove the cylinder.
To inspect the seals, unscrew the gland nut from
the end of the cylinder and remove the gland nut
and shaft. Also check that the piston is securely
pinned to the shaft and that there is no scoring of
the cylinder bore.
Replace any worn or damaged components as
required.
When reassembling, ensure the end frame plate
shaft nut is screwed on to the shaft until it just
tightens against the frame plate. Then turn it only
as much as necessary to line up with a fastener
hole and then replace all the fasteners loosely.
Tightening the shaft nut too much puts the end
frame plate under tension which could
dramatically increase the drag pressure.
Reposition the clamp parts and ensure everything
is properly aligned before tensioning any
fasteners.
After the cylinders have been emptied of oil they
must be bled of air.
Hydraulic bleeding method
The presence of air in the hydraulic cylinder(s) can
result from loose fittings, leaking cylinder seals, or
®
revised June 2009
Page 10
Pressure gauge calibration
Bronze roller replacement
1.
1.
2.
The carriage pressure gauge should be checked
periodically by fitting a test gauge of known
accuracy into the hydraulic circuit. A plugged Tee
piece is located behind the 3-way pressure valve
block for this purpose.
Industrial gauges do not retain their accuracy
indefinitely. If the test shows the gauge has an
error of more than 1% of Full Scale Deflection it
may need to be replaced. Alternatively it may be
more convenient to compensate by adjusting the
calculated welding pressure. This action will
depend on the quality requirement of the welding
project.
Temperature measurements
1.
2.
3.
The temperature indicates the internal plate
temperature only. Therefore it is essential
to check and record the surface temperature of the
heater plate before every weld. This is best
measured with either a contact pyrometer or a non
contact infrared pyrometer. The outer circumference of the heater should never be measured as
this is too far from the weld area.
Be aware that an insulating air gap can form
between the Teflon cloth and the hot plate.
Always ensure the cloth is forced into contact
with the hot metal surface when using an infrared
or non contact pyrometer or a false reading is
likely to occur. Never use an infrared pyrometer
on a shiny surface.
The pyrometer used to measure surface
temperature will require calibration to a procedure
as recommended by the pyrometer manufacturer.
Facer drive inspection
1.
2.
3.
4.
5.
Inspect the facer drive assembly by removing the
cover plate.
Tension the chain with the idler sprocket
eccentric adjustment.
Access the facer drive assembly by removing the
securing screws from the idler cutter plate and
removing the plate (approx. 70 kg).
Clean out any dirt or plastic cuttings that could
either damage the drive components, and/or
significantly reduce facing efficiency.
Check that the main drive sprocket is in contact
with all bronze rollers. Three rollers are
concentrically bushed and three are eccentrically
bushed. This enables bronze roller or sprocket
wear to be taken up by adjusting the three
eccentric guide rollers. These are adjusted in the
direction of chain rotation, until the sprocket is
supported by all six rollers. Once the rollers wear
beyond the point of any further adjustment,
replace the guide roller assemblies.
®
2.
3.
4.
5.
6.
7.
8.
9.
Remove the screws holding the idler cutter plate
and remove the cutter plate.
Detach the driven cutter plate from the main
sprocket by removing the sprocket screws and
carefully knocking the plate away from the
sprocket. (The cutter plate locates in a groove
machined into the sprocket face.)
Carefully note the location of the eccentric and
concentric bronze roller assemblies and remove
them.
Refit (new) concentric rollers.
Hang main sprocket.
Refit (new) eccentric rollers.
Adjust the eccentric rollers in the direction of
chain rotation, so that all six bronze rollers
support the main sprocket and the sprocket and
rollers all turn freely.
Fit the chain and idler sprocket. Tension the chain
by adjusting the eccentric bush in the idler
sprocket.
Refit the driven cutter plate to the main sprocket,
and test rotation before replacing the idler cutter
plate.
Blade sharpening
If chipped or damaged, the blades should be replaced.
If blunt, the high grade tool steel blades may be
sharpened with a die grinder. Shim the cutter blades if
they are sharp, but shavings are too thin.
Adjusting eccentric cam mechanism
If a gap appears between the eccentric tube and the
centre frame plate while the pipe is butted under
pressure, the eccentric clearance can be adjusted as
follows:
1. Remove the three M8 socket head cap screws in
the shoulder nut at the left hand end of the
machine.
2. Use a pin spanner to rotate the shoulder nut one
position (60°) clockwise and refit the M8 screws.
3. Re-check clearance with the carriage under
pressure and adjust again if necessary.
4. Do not over-tighten the shoulder nut. One
position (60°) rotation of the shoulder nut will
close gap approximately 0.35mm.
The manufacturer reserves the right
to vary the machine specification and
the contents of this document without
notice.
revised June 2009
Page 11
Butt welding – general procedure
Butt welding
procedure
–
general
The butt welding method of joining polyolefin pipe
requires application of a combination of appropriate
temperature, time and pressure to ensure a sound
weld.
Operators should take care to determine the
suitability of materials for butt welding. Join only
pipes and fittings made from the same raw materials,
eg PE to PE, PP to PP, PVDF to PVDF, etc.
The joint area must always be protected from adverse
weather conditions, eg dampness, excessive cold or
heat, or strong winds, which could lead to the pipe
wall developing non-uniformly heated zones.
The weld zone should be free of bending stress, free
of notches or similar damage, and be free of
contamination.
In the absence of an Australian Standard on butt
welding, a table of welding parameters is given on
the next page.
The basic welding process
1.
2.
3.
4.
5.
6.
Prepare the ends of the pipe or fittings to be
joined so they are clean and parallel to each
other.
Heat the ends at pressure P1 and for time T1 to
melt the plastic until a bead just forms
completely around both ends.
Heat soak the ends at pressure P2 and for time T2.
(Time T1 + T2 is critical to achieving good weld
quality and should never be shortened.)
Remove the heater plate and bring the pipe ends
gently into contact with each other within time
T3. (If T3 is too long, too much heat is lost from
the weld area allowing PE recrystallization to
commence prematurely.)
Raise the pressure gradually to pressure P3 within
time T4. (If pressure is applied too fast it can
cause too much melt to be forced out of the weld
area with adverse results.)
Maintain pressure at P3 for time T5 before
unclamping and removing pipe from the
machine. Never artificially accelerate the cooling
process.
Weld failure trouble shooting
Uniform bead.
Correct welding technique.
Crack down centre of bead.
Possible “cold weld" signified by
clean break through the middle of
the weld with a smooth appearance.
Could be due to
1. insufficient heat soak time or temperature, or
2. changeover time too long, or
3. excessive soak pressure, or insufficient fusion
pressure, or
4. no allowance for drag pressure, or drag pressure
too great eg due to pulling pipe up a gradient.
Misaligned pipe.
Maximum allowable is 10% of wall
thickness.
Care should also be taken to ensure pipes or fittings
being joined have the same diameter and wall
thickness or the probability of weld failure is
significantly increased.
Insufficient bead roll over.
Could be due to
1. insufficient heat soak time or temperature, or
2. changeover time too long, or
3. insufficient fusion pressure, or allowance for
drag pressure.
Unequal bead size.
Could be due to
1. unequal temperatures e.g. pipe
stored in the hot sun joined to pipe stored in the
shade;
2. unequal application of pressure possibly due to
air trapped in carriage cylinder;
3. if the bead is uniformly unequal around the
whole circumference, there could be a physical
difference in materials being joined eg melt flow
index.
Weld test - destructive
1.
2.
Cutting out and testing of trial welds is
frequently required to qualify the welding
machine, operator, welding parameters, pipe
material, or when the consequences of failure are
significant.
Tensile testing is widely used. A high proportion
of ductile versus brittle appearance in the
fracture area usually indicates weld acceptability.
®
revised June 2009
Page 12
Plastics Industry Pipe Association of Australia
Limited (PIPA) Butt Welding Parameters.
PIPA Butt Welding Parameters
Units
Heater plate temperature
°C
Pressure value: Bead up
P1
kPa
(Calculate value (see note 6) and add drag pressure to calculation.)
Approx. bead width after bead up
mm
4).
Bead up time
T1
second
Pressure value: Heat soak
P2
kPa
Heat soak time
T2
second
Max. changeover time
T3
second
5).
Max. time to achieve welding pressure
T4
second
smoothly using most of the time allowed to reach weld pressure.
Pressure value: Welding & Cooling
P3
kPa
(Calculate (see note 6). Always add drag pressure to calculation.)
Welding & cooling time: t<15mm
T5
minute
Welding & cooling time: t>15mm
T5
minute
Min. bead width after cooling
mm
Max. bead width after cooling
mm
Value
220 ± 15
175 ± 25
Comments
0.5 + 0.1t
t = wall thickness (see note
Approx. 6t
Drag only
15t
3 + 0.01D
Varies with ambient temp.
3 + 0.03D
Pressure should be increased
D = pipe diameter (see note
175 ± 25
10 + 0.5t
1.5t
3 + 0.5t
5 + 0.75t
Time in clamps
Time in clamps
Typical. (See note 2)
Typical. (See note 2)
Machine pressure
P1
P3
P2
Drag
pressure
Time
0
T1
T2
T3
T4
T5
Notes:
1. These parameters apply to the butt fusion of PE80 or PE100 polyethylene materials as specified in
AS/NZS4131.
2. These parameters may also apply to the butt welding of PE80 to PE100. This may result in slightly different
bead formation without reducing weld quality. If in doubt refer to the pipemaker.
3. Only pipes and fittings of the same diameter and wall thickness should be butt fused together.
4. t = mean pipe wall thickness calculated from AS4130 min/max values, rounded to the nearest mm.
5. D = mean pipe outside diameter calculated from AS4130 min/max values, rounded to the nearest mm.
6. Pressure calculation formula: {pipe annulus area, mm²}÷{hydraulic cylinder area, mm²}x{pressure value,
kPa}.
7. For ambient temperature > 25°C, cooling time must be increased by 1 minute per °C above 25°C.
8. For ambient temperature < 5°C, cooling time may be decreased by 1 minute per °C below 5°C.
Disclaimer (see www.pipa.com.au/Guidelines.html)
PIPA makes no warranty or representation regarding the information, opinions and recommendations contained in the Guidelines. Users of the
Guidelines are advised to seek and rely upon their own professional advice and assessment of the matters contained in the Guidelines and not rely
solely on the Guidelines in relation to any issue that may or might risk any loss.
In addition, PIPA excludes:
All conditions warranties and terms implied by statute general law or custom except where exclusion would contravene any statute; and
all liability to any user of the Guidelines for consequential or indirect damages or any other form of compensation or relief whatsoever for any acts or
omissions of PIPA arising out of or in connection with the use of the Guidelines irrespective of whether the same arises at law in equity or otherwise.
PIPA’s liability to any user of the Guidelines for any breach of a non-excludable condition or warranty is limited at PIPA’s option to any one of
resupplying replacing or amending that part of the Guidelines in respect of which the breach occurred.
®
revised June 2009
Page 13
Notes about heater plates
and temperature.
PE welding temperatures
The temperature range at which polyethylene pipe
should be welded is 220° ±15°C. This should be the
temperature between the interface of the heater surface
and the pipe material.
Temperatures greater than 240°C when coupled with
long heat soak times may result in diminution of the
anti-oxidants in the pipe, and ultimately failure of the
joint.
Cold joints will result if the weld temperature is too
low, or the heat soak time is too short, or the time
between removal of the heater and butting the pipes
together is too long.
Either situation will eventually lead to joint failure
Heater plate temperature
Heater plate temperature displays usually indicate the
internal temperature of the plate. However the actual
surface temperature may vary from that displayed for
a number of reasons.
1. The rate of heat lost from the heater surface will
depend on the design of the heater plate and the
type of temperature controller used. The surface
temperature could be up to 25°C cooler than the
display. This variation will be greatest on cold,
windy days - which is one reason for using a
shelter when welding.
2. The temperature will change as power is being
pumped into the heater. The temperature will be
highest just after the power cycles off, and lowest
just as it cycles back on.
3. The temperature is unlikely to be exactly the same
at every point on the surface, and there may also
be small variations from side to side, due to
manufacturing tolerances.
4. As heat is transferred into the pipe during heat
soak, the heater temperature initially falls but
eventually returns to the set point. As it is the
surface temperature that is important, it is
recommended to monitor the heater surface
temperature during the heat soak phase.
4.
5.
6.
system traps an insulating air layer between the
cloth and the heater surface.)
If a contact probe is used it should be held in
position for 3-5 seconds before the reading is
taken.
If an infra red pyrometer is used, care must be
taken to ensure its emissivity is correctly
calibrated for use on the non-stick cloth, AND
care must be taken to ensure no air is trapped
between the plate and the cloth or an incorrect
reading is likely to result (see suggestion below).
Never use an infra-red pyrometer to take a
reading from a shiny aluminium surface (such as
a FUSIONMASTER® heater without cloths, or
the outer edge of a heater plate) or a gross error
will result.
Infra-red pyrometer suggestion
Raytek infra-red pyrometers are good tools for reading
heater plate temperatures, but should always be used
with a "spot control adapter" (Dixon part number
AF000104).
The "spot control adapter" clips to the end of the
Raytek (no tools required). When pressed square
against the heater surface it correctly focuses the infrared beam, and when used on FUSIONMASTER®
heaters, it expels trapped air from beneath the nonstick
cloth,
ensuring
consistently
accurate
measurements.
Measuring surface temperature
1.
2.
3.
To ensure the temperature of the heater plate has
stabilised, wait 5 minutes after the heater has
reached set temperature before recording
measurements.
Take readings at several points (North, South,
East, West) on both sides of the heater, at the
diameter of the pipe being welded .
With FUSIONMASTER® heater plates using
non-stick cloth, it is essential to use a contact
probe which forces the cloth into contact with the
plate. (Incorrect readings may result if the cloth
®
revised June 2009
Page 14
soak time
P3
T5
+ measured drag
total welding & cooling pressure
welding & cooling time t >15mm
mm
mm
minute
kPa
kPa
kPa
second
second
second
kPa
kPa
kPa
kPa
mm
°C
24
16
39
2798
33
13
387
drag
2798
2.6
220
29
19
48
3469
33
13
483
drag
3469
3.2
220
32.2
PN4
33
1000
35
23
60
4295
33
13
603
drag
4295
4.0
220
40.2
PN6.3
26
1000
43
28
75
5302
33
13
752
drag
5302
5.0
220
50.2
PN8
PN6.3
21
1000
52
34
94
6507
33
13
935
drag
6507
6.2
220
62.4
PN10
PN8
17
1000
hydraulic cylinder area 4940mm²
22
15
35
2260
30
12
347
drag
2260
2.3
220
23.2
PN4
PN3.2
41
900
27
18
44
2816
30
12
436
drag
2816
2.9
220
29.1
PN4
33
900
32
21
54
3481
30
12
543
drag
3481
3.6
220
36.2
PN6.3
26
900
39
26
68
4291
30
12
677
drag
4291
4.5
220
45.1
PN8
PN6.3
21
900
47
31
84
5282
30
12
844
drag
5282
5.6
220
56.3
PN10
PN8
17
900
20
13
31
1792
27
11
310
drag
1792
2.1
220
20.7
PN4
PN3.2
41
800
24
16
39
2223
27
11
387
drag
2223
2.6
220
25.8
PN4
33
800
29
19
48
2752
27
11
483
drag
2752
3.2
220
32.2
PN6.3
26
800
35
23
60
3392
27
11
602
drag
3392
4.0
220
40.1
PN8
PN6.3
21
800
800
51
34
93
5078
27
11
927
drag
5078
6.2
220
61.8
PN12.5
PN10
13.6
appendix 1/2
42
28
75
4162
27
11
748
drag
4162
5.0
220
49.9
PN10
PN8
17
800
printed 27/04/2005
Based on AusPoly Industry Guideline POP003: Butt Fusion Jointing - issued 29/2/2000.
NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint .
3+0.5t
5+0.75t
Typical max. bead width after cooling
1.5t
+drag
175+/-25
3+0.03D
3+0.01D
15t
drag
+drag
175+/-25
0.1t
220+/-15
Typical min. bead width after cooling
adjust time depending on ambient conditions
P3
P3
welding & cooling pressure
T3
T2
soak pressure
T4
P2
total bead up pressure
pressure up
P3
+ measured drag
heater out
P1
P3
bead up pressure
allowable axial misalignment
mean heater surface temp
25.8
mm
mean wall thickness
t
PN4
Parameter
PN3.2
PE100
1000
PE80
mm
41
D
SDR
nominal pipe od
FUSIONMASTER1000 PE welding parameters.xls
soak time
P3
T5
+ measured drag
total welding & cooling pressure
welding & cooling time t >15mm
mm
mm
minute
kPa
kPa
kPa
second
second
second
kPa
kPa
kPa
kPa
mm
°C
19
12
28
1413
24
10
275
drag
1413
1.8
220
22
14
34
1755
24
10
344
drag
1755
2.3
220
23.0
PN4
33
710
26
17
43
2173
24
10
430
drag
2173
2.9
220
28.7
PN6.3
26
710
27
18
44
2227
24
10
441
drag
2227
2.9
220
29.4
PN8
PN6.3
21
710
38
25
66
3283
24
10
665
drag
3283
4.4
220
44.3
PN10
PN8
17
710
710
46
30
82
4003
24
10
824
drag
4003
5.5
220
54.9
PN12.5
PN10
13.6
17
11
24
1110
22
9
244
drag
1110
1.6
220
16.3
PN4
PN3.2
41
630
20
13
31
1381
22
9
305
drag
1381
2.0
220
20.4
PN4
33
630
24
16
38
1710
22
9
381
drag
1710
2.5
220
25.4
PN6.3
26
630
25
16
39
1751
22
9
391
drag
1751
2.6
220
26.1
PN8
PN6.3
21
630
34
23
59
2581
22
9
589
drag
2581
3.9
220
39.3
PN10
PN8
17
630
42
27
73
3151
22
9
731
drag
3151
4.9
220
48.7
PN12.5
PN10
13.6
630
50
33
90
3815
22
9
902
drag
3815
6.0
220
60.2
PN16
appendix 2/2
PN12.5
11
630
printed 27/04/2005
Based on AusPoly Industry Guideline POP003: Butt Fusion Jointing - issued 29/2/2000.
NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint .
3+0.5t
5+0.75t
Typical max. bead width after cooling
1.5t
+drag
175+/-25
3+0.03D
3+0.01D
15t
drag
+drag
175+/-25
0.1t
220+/-15
Typical min. bead width after cooling
adjust time depending on ambient conditions
P3
P3
welding & cooling pressure
T3
T2
soak pressure
T4
P2
total bead up pressure
pressure up
P3
+ measured drag
heater out
P1
P3
bead up pressure
allowable axial misalignment
mean heater surface temp
18.4
Parameter
PN4
mean wall thickness
mm
PE100
t
PN3.2
710
PE80
mm
41
D
hydraulic cylinder area 4940mm²
SDR
nominal pipe od
FUSIONMASTER1000 PE welding parameters.xls

HF1000 Operator Manual

Transcription

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