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BUTT FUSION MACHINE MODELS BASIC E

1. BASIC H Butt fusion machine for ODS 315 H base framework Both models are designed to carry out semi automatic butt fusion joints of PE pipe and fittings Both models are designed for the butt fusion system allowing the joint of polyethylene PE pipes and fittings It can also be used to joint other plastic resins PP PB PVDF in diameters between 63 and 225 mm BASIC E and between 160 and 315 mm BASIC H All you have to do is connect an electric base framework a heating plate and a trimmer to the unit s electric connectors The pipes fittings to be jointed have to be located in the base framework and are fixed by the grips The sides of both pipes fittings are faced via the trimmer and subject to heating via the heating plate Once the heating cycle has been completed both extremes are jointed applying a controlled strength and time as selected by the operator To make a joint consult the Fusion Parameters Table butt fusion parameters time temperature and strength according to the diameter and the wall thickness SDR of the pipe fitting to be jointed The technical data contained in this manual are purely informative and may be changed at anytime ACUSTER S A declines all responsibility for claims arising from misuse of the data contained herewith and or errors or omissions detected after publication This Manual must be considered as part of the unit Edition September 2003 Revision No 5 INTROD UCTION 5 A A A
2. Edition September 2003 Revision No 5 MA CHINE DESCRIPTION 21 A A A USER MANUAL BASIC E amp BASIC H ACUSTER CHAPTER 3 MODE OF USE 3 1 UNIT PREPARATION 3 1 1 General Prepare the machine components base framework trimmer and heating plate and connect the electrical cables to the respective connectors on the fusion control box for more information refer to Chapter 2 2 FUSION CONTROL BOX of this Manual Connect the BASIC machine to a 230 V 15 power source or to the corresponding voltage according to market requirement of alternating current For generator group specifications please refer to CHAPTER 6 TECHNICAL CHARACTERISTICS IMPORTANT The generator group electric connection where the control box mains is plugged must be normalized and fitted with differential and ground pin Do not unplug the mains by pulling on the cable The unit does not have a master switch Therefore once it is plugged in the display backlighting is activated and the following message is shown for a few seconds Model BASIC E Model BASIC H BASIC E Tet C BAS KCRA eete C SON Vo 2o 02 Sort Vol 02 Where BASIC E H Unit model T ttt C Heating plate working temperature as per most recent programming Soft V X xx The software version loaded on the unit Once the exhibition time has expired for the information or if STOP is pressed the display will show the following message Model BASIC E Model BASIC H BASTO
3. MAINTENANCE of this User Manual The trimming operation can be interrupted or reinitiated as many times as necessary Just switch off and on the push buttons Once the trimming is completed withdraw the trimmer from the base framework guiding axles Edition September 2003 Revision No 5 MODE OF USE 29 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 3 2 4 Visual control Put the trimmed pipes close to each other to perform the VISUAL CONTROL Measure the drag force again during the visual control phase Briefly press the key on the panel make certain that the force selected on the display is F 0000 N Using this procedure the DRAG FORCE necessary to move the pipe fitting of the base framework s moving body is measured the force message will go from F 0000 N to F N when the moving body moves Stop the movement by pressing STOP ATTENTION BASIC E In case the moving body reaches the travel end or the drag force is greater than 3000 N the display will show F 9999 N BASIC H Warning The drag force value could be affected by the hydraulic station oil temperature Retain the force shown on the display which should be added to the working forces in successive phases Visually check the trimming According to ISO 12176 1 the flatness of the sides of the pipes will have a maximum tolerance from 0 3 to 1 mm depending on the nominal diameter see following table P 0 3 mm for 4 lt 250 mm P
4. 0 5 mm for 4 250 to lt 400 mm Figure 19 If the tolerance of the specification to be applied does not comply trim again When the visual check is satisfactory place the moving body in the fully open position using the panel push button Edition September 2003 30 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 3 2 5 Heating plate setting Once the trimming and visual check phase has been completed select the heating force on the display corresponding to the diameter and SDR ofthe pipes fittings to be jointed refer to the Fusion Parameter Table for the BASIC E or BASIC H Select the F force using the panel push buttons Place the heating plate on the base framework guides between the pipes fittings approximately midway the electric cable should be on the grip clamping bolts side CAUTION Hot surfaces Figure 20 Place the movable body pipe fitting end close to the heating plate by pressing the lt push button on the panel Now briefly press the lt panel push button The sign y will be displayed and the moving body will close and will continue applying the force selected on the display for example 575N fusion force 300N drag force BASTC T 2 10 C t 00 00 F 0875NY The display also shows the temperature of the heating plate In the example the heating plate is selected at a 210 C working temperature If thet indication appears to the right of C
5. Figure 3b BASIC H 315 general view 1 A Fusion Control Box BASIC E and BASIC H made up of a plastic shell and a stainless steel tubular structure for transport and protection BASIC E only The front panel is equipped with a display screen and keyboard The connections to the base framework trimmer and heating plate are made through the multicontact circular connectors 2 1 A base framework ODS 200E 225E 8 E BASIC E The framework is made up of a stainless steel tubular structure for mounting on 4 silentblocks two aluminium fused bodies one fixed and one moveable The moving body slides along two chrome hardened guiding axles through ball bearings Each body mounts two aluminium fused grips which are easily removable The fixed body incorporates the electric motor of the movable body s actuator 2 2 A base framework ODS 315 H BASIC H The base framework is made up of four aluminium fused lower grips and four aluminium fused upper grips two of which are fixed and two are movable All four upper grips are easily removable The fixed outer lower grip is also removable in order to allow fitting mounting tees elbows and so The moving grips are driven by two double acting hydraulic cylinders High pressure hoses with quick plugs are supplied for the hydraulic station connection Edition September 2003 Revision No 5 MACHINE DESCRIPTION 1 1 A A A USER MANUAL UL BASIC E amp BASIC H ACUSTER 3 A PTFE lined al
6. TAMME ausammas 42 5 4 1 Trimmer faceplates esee 42 5 4 2 Adjustment ofcutters mmse 42 5 4 3 Driving electric MOTO sjedsscsciicnscssdiwessiveses 43 S44 Driving Delt Chaitiis cccsrvsseteissessssunerntens 43 5 5 Fusion control DoX sosnossersrsorsarnininiaiariiia 44 5 5 1 Electronic control module 44 5 5 2 Programme version updating 44 5 6 Hydraulic station BASIC H enmren 44 CHAPTER 6 TECHNICAL CHARACTERISTICS mmenmeeneenee 45 6 1 Fusion control DOK sis ccrstocsaccradieriesedisacreehaedonnninierss 45 6 1 1 General speeiCanOns ccsdesetssacvsarsdexnevaaesd 45 6 1 2 Generator group specifications 45 6 2 Base Tame wor imamine taa 46 6 3 TAA eest EEEE E aken aaa aata 47 6 4 Hleatneplldusemumauisamumsedms 48 6 5 Hydraulic SATION aasal 48 6 6 Size AD WEIS Da sscvsastoasenaatincivedsanesteiaaternssauiiontineen 49 6 6 1 Weights of various parts 49 6 6 2 Dimensions of various parts 49 6 6 3 Packing weight and dimensions 50 Edition September 2003 4 GENERAL CONTENTS Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER CHAPTER 1 INTRODUCTION 1 1 GENERAL The range of BASIC butt fusion machines consists of the following models BASICE Butt fusion machine for ODS200E ODS225E ODS 8 E base frameworks
7. USER MANUAL BASIC E amp BASIC H ACUSTER 1 2 DESIGN SPECIFICATIONS The butt fusion machines BASIC are designed according to the following specifications ISO 12176 1 Equipment for the polyethylene piping system Part 1 Butt fusion 1 3 GENERAL INFORMATION The development documentation production tests and shipping of the products herewith described have been made Complying with the respective safety rules and In accordance with the requirements of Acuster S A assurance quality WARNING The fusion control box can only be opened by the ACUSTER S A After sales Service In the case of the front and back covers opening or coming apart parts of electrical components which are not covered may be left exposed Only qualified personnel are authorised to intervene both for fusion and repairs These qualified personnel must be familiar with all the safety measures potential dangers and maintenance rules described in this Manual The safe use of the products described requires an appropriate means of transport storage installation and use a careful handling and the preestablished periodical maintenance follow up 14 MACHINE IDENTIFICATION 1 4 1 Serial Number Stamping All BASIC E and BASIC H components base framework heating plate trimmer and hydraulic station BASIC H only are identified by means of their own identification plate Edition September 2003 6 INTROD UCTION Revision No 5 USER M
8. external cleaning procedure there is no specific instruction regarding the electronic module Any adjustments should be carried out either by the ACUSTER S A After Sales Service 5 5 2 Updating program version The updating of the BASIC E and BASIC H units software must be performed exclusively by the ACUSTER S A After Sales Service 5 6 HYDRAULIC STATION MAINTENANCE Check the oil level with the stick there is an external viewer too Check weekly Should the level be too low refill with HV 46 oil according to the ISO 6743 4 HV specifications The scheduled maintenance for oil and filter is as follows FILTER Replace after every 500 working hours OIL Replace after every 2000 working hours or once a year filter oil REMARK Spare oil in 1 litre containers is available Edition September 2003 44 MAINTENANCE Revision No 5 USER MANUAL BASIC E BASIC H CHAPTER 6 AAA ACUSTER TECHNICAL CHARACTERISTICS 6 1 FUSION CONTROL BOX MODULE 6 1 1 General specifications Power supply Mains frequency Power consumption Generator output Protection class Working temperature Display Keyboard Power cable Electric connection 6 1 2 Generator group specifications Frequency Output power Voltage Intensity Voltage regulation Edition September 2003 Revision No 5 195 Vac to 265 Vac Nominal voltage 230 Vac 95 Vac to 140 Vac Nominal voltage 110 Vac 45 Hz to 65 Hz Nominal f
9. fused bodies one fixed and one moveable are mounted The moving body slides on two chrome hardened guiding axles on ball bearings Each body has two aluminium grips being the exterior one easily removable The diameter of the four pipe grips is machined to fit up to 200mm 225mm or 8 diameter pipes and fittings according to its version the clamping of different smaller diameters can be achieved by means of different sets of additional adaptors which are locked in place using Allen screws Both outer grips are removable for accommodating various fittings such as elbows tees etc The linear actuator the load cell and the encoder are installed on the fixed body Figure 7 ODS 225 base framework WARNING Always connect the base framework electric connector into the corresponding control box connector with the machine switched off Install the base framework cable connector with the nut properly tightened to ensure good contact between the pins For care and maintenance of the base framework please refer to CHAPTER 5 MAINTENANCE of this User Manual Edition September 2003 16 MA CHINE DESCRIPTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 2 3 2 BASE FRAMEWORK ODS 315 The base framework ODS 315 consists of four aluminium fused lower grips and four aluminium fused upper grips two of which are fixed and two movable The lower grips are held by supporting plates which are secured by two longi
10. insides and outsides of the pipes fittings to be jointed try and align them use the supporting rollers Tighten the locking bolts DO NOT overtighten Figure 16 Recommended layout After assembly place the facings of the tubes fittings together by pressing the lt push button on the panel Check the alignment The maximum alignment tolerance allowed according to ISO 12176 1 is 10 of the pipe s thickness Figure 17 Edition September 2003 Revision No 5 MODE OF USE 27 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 3 2 3 Pipes fittings trimming Measuring the drag force Place the moving body in the fully open position by holding down the button on the panel Briefly press the key on the panel make certain that the force selected on the display is F 0000 N Using this procedure the DRAG FORCE necessary to move the pipe fitting of the base framework s moving body is measured the force message will go from F 0000 N to F N when the moving body moves Stop the movement by pressing STOP ATTENTION BASIC E In case the moving body reaches the travel end or the drag force is greater than 3000 N the display will show F 9999 N BASIC H Warning The drag force value could be affected by the hydraulic station oil temperature Retain the force shown on the display which should be added to the trimming force Trimming phase NOTICE
11. is made up of a front panel consisting of an LCD display function buttons mains electric connectors for the base framework connection trimmer and heating plate WARNING All connectors must be installed for the unit to work properly Install the connectors correctly with the nuts properly tightened to ensure good contact between the pi 2 2 2 Exterior connections The BASIC E control module features the following exterior connections 1 Mains 2 Electrical connector to base framework 3 Electrical connector to heating plate 4 Electrical connector 24 Vdc trimmer 5 Schuko plug socket to 230 Vac trimmer Figure 5a BASIC E electronic module connections Edition September 2003 Revision No 5 MA CHINE DESCRIPTION 13 A A A USER MANUAL BASIC E amp BASIC H ACUSTER The BASIC H control module features the following exterior connections Figure 5b BASIC H Side view Figure 5c BASIC H Underneath view Heating plate base connector 230 Vac trimmer base connector 230 Vac Schuko plug base Mains with plug Hydraulic station base connector nk WN m 2 2 3 Front panel The front panel of the BASIC is made up of a plastic silk screened membrane which incorporates pushbuttons of the membrane variety The display screen is located on the upper left hand part of the panel It is identical on both models except of the model s name BASIC E or BASIC
12. motor as well Possible fault in one of the trimmer s push buttons Possible fault in the electronic component which controls the trimmer s operation through the push buttons TROUBLESHOOTING 35 A A A USER MANUAL BASIC E amp BASIC H AGUSTER 4 2 2 The base framework does not work BASIC E Ifthere is no movement of the base framework s moving body a verification by the following procedure is recommended 1 RA 3 4 First check the base framework s electrical connections to the fusion control box Press the chronometer button or the F push buttons to verify that the internal cable connecting the keyboard to the electronic plate is operating correctly Potential faulty on the 24 Vdc output voltage Linear actuator motor faulty 4 2 3 The ODS 225 V230 trimmer does not work 1 2 Check the bit controls Check the Schuko plug output by connecting another element which operates at 230Vac 4 2 4 The ODS 315 trimmer does not work BASIC H Check trimmer operation Connect the trimmer to the fusion control box and select the trimming mode Trimming Select the force to be applied with the F keys Start the trimming operation by making a briefly press onto lt key on the panel The sign y will be displayed and the moving body will began to close With the trimmer located onto the base framework guiding bars immediately press the trimmer push buttons Once the pipe fitting end of the mo
13. 4 3 2 Bull fusion prooedure suss 25 3 2 1 Preparation of the pipes and the machine 25 3 2 2 Assembly of pipes fittings 21 3 2 3 Pipes fittings CMMI kuskussi 28 3 2 4 Visual controls 30 3 2 5 Heating plateseliime summas 31 3 2 6 Fusion and cooling down eyele 32 3 2 7 Functional operations outline summary 33 CHAPTER 4 TROUBLESHOOTING aiiis niesie 35 4 1 ET e I P AAA US 35 Edition September 2003 Revision No 5 GENERAL CONTENTS 3 A 4 A USER MANUAL BASIC E amp BASIC H ACUSTER Page 42 NIIP CHECKS MIST TATA 35 4 2 1 The ODS 24 Vdc trimmer does not work 35 4 2 2 The base framework does not work 36 4 2 3 The ODS 230 Vac trimmer does not work 36 4 2 4 The ODS 315 trimmer does not work 36 4 2 5 The heating plate does not work 36 4 2 6 Mains voltage outside tolerance 37 4 2 7 Low oil level BASIC F 38 CHAPTER 5 MAINTENANCE rieiitviki aatal imal 39 5 1 General eie e E 39 211 J iroduelidhussammsmmseuamas 39 SA12 OT AED alia 39 5 1 3 Cleaning nei rana a 40 SAA REVISIONS a wossecsaceeascsuenpsinassonssnnstoncswesansdsaniess 40 5 2 Base Trae Ot ascxcasssscceedesddeassapieimasmiccasbantecsssanies 41 5 21 Linear ACI AIDI uskumine 41 5 2 2 Clamp APA DLETS kii teng kavas kaak akseakaaa 41 5 2 3 General cleaning and greasing 41 3 3 Heating PI lamama a lkaa a 41 5 4
14. AAA AGUSTER USER MANUAL BUTT FUSION MACHINE MODELS BASIC E BASIC H Edition September 2003 Revision No 5 Publication MU 78 03E At the time of the publication of this User Manual the software version is BASIC E v 2 03 BASIC H v 1 02 USER MANUAL A A A BASIC E amp BASIC H ACUSTER CONTENTS Page CHAPTER 1 TST OD UG TOI manna taa 5 1 1 Keelpillid 5 1 2 Design specifications rmeenenner 6 1 3 General MPO aon sonsssicctessssscssiassccseassicaenssoniseassnetes 6 1 4 Machine TAGI TIGAROM saavate nesters 6 1 4 1 Serial number stamping se 6 142 PAE A suusasammu T 1 5 Measures of protection against accidents 8 1 6 Declaration CE of conformity wse 9 1 7 G arantee orce erer AAA MA a area ES 10 CHAPTER 2 DESCRIPTION OF THE FUSION MACHNNE 11 2 1 Generalo p ATS 11 2 2 Butt fusion control BOX edssssonssvasuorsisssveesduenivesntsxenndve 13 221 Generalerna eass 13 2 2 2 Exterior CONMECHONG irina aasia ddak 13 225 Eronilde tim 14 2 3 Base frameWork vumudumamdma 16 2 4 Heating DIALS auruma 18 2 5 Trim ETa aa a E AE E EEEa 19 2 6 Hydraulic station BASIC H mmre 21 CHAPTER 3 MODE OF US Ersserssemenenirei ean n ER 22 3 1 Unit preparation sesssessesseesessressesessressessessresseese 22 2 11 CSCC Abas isa gaala a kasaka 22 3 1 2 Preliminary checks immenmeeenneeene 2
15. ANUAL A A A BASIC E amp BASIC H ACUSTER OUALITY CONTROL ACUSTER s a CONTROL DE CALIDAD MACHINE No MAQUINA N MAINTENANCE REVISIONS O REVISIONES MANUFACTURER S Juan de la Cierva 1 Polig Ind n 1 ADDRESS Tel 34 93 4703070 Sant Just Desvern Barcelona Figure 1 The quality control identification plate includes the fusion control box serial number The plate includes room for future maintenance date stamping 1 4 2 CE marking The fusion control box is supplied with the appropriate plate with the CE mark as the European Community norm indicates on the new Machine Security Regulation Board 98 37 CE dated 22nd June 1998 ACUSTER s CE omoto 07770000 o N SERIE 0 Juan de la Cierva 1 Polig Ind n 1 Tel 34 93 4703070 Sant Just Desvern Barcelona SPAIN Figure 2 Edition September 2003 INTRODUCTION 7 Revision No 5 A A A USER MANUAL BASIC E amp BASIC H AGUSTER 1 5 8 MEASURES OF PROTECTION AGAINST ACCIDENTS Please go by the following security measures Keep the fusion control box out of the reach of non authorised personnel non qualified personnel and children Protect the control unit from water rain snow etc When transporting the machine and during loading and unloading operations the appropriate precautionary measures must be taken to ensure that all machine components are completely secured in the vehicle and that they are free from impa
16. H Edition September 2003 14 MA CHINE DESCRIPTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER Figure 6 BASIC E front panel Where 1 LCD Display 20x2 2 Button with the following functions 2 1 Timer reset start stop 2 2 Validation of the heating plate working temperature 3 Buttons for increasing f and reduction of 3 1 Working force of the base framework 3 2 Heating plate working temperature 4 Opening button for the base framework moving body This activates the function if held down 5 Closure button for the base framework moving body It has the following functions 5 1 If held down it activates the closure function 5 2 If briefly pressed force F 0000 N closure function to read the drag force 5 3 If briefly pressed force F gt 0 N closure function and maintenance of the selected force trimming mode activation 6 STOP button with the following functions 6 1 It stops mobile body closure operation when acting with selected force 6 2 Itresetsthe force indicated on the display changing to F 0000 N 6 3 It establishes the F reading of the display during measurement of the drag force Edition September 2003 Revision No 5 MA CHINE DESCRIPTION 15 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 2 3 1 BASE FRAMEWORK ODS 200 225 8 The base framework ODS 200 225 8 consists of a stainless steel tubular structure on to which through four silentblocks the two aluminium
17. RE Tce C BASIC H A C ic 00 200 F 0000N t 00s 00 F 0000N Edition September 2003 22 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER Where BASIC E H Corresponds to the model T ttt C The working temperature of the heating plate connected This field of the display corresponds to the on screen messages which are Heating plate not connected or sensor outside tolerance 1 Heating plate temperature increasing VA Controlling force confirm temperature selection t 00 00 Time chronometer for the fusion cycle phases It is activated by the operator F 0000N Corresponds to the force value programmed by the operator selectable in intervals of 25 N The BASIC E fusion control box can be placed vertically or horizontally as required by the operator whereas the BASIC H fusion control box is attached to the transport trolley allowing to be positioned at operator s wish Butt fusions should only be performed by qualified personnel The work site where the machine is to be placed must be on a horizontal slopeless plane Protect the area where the joints are made from inclement weather conditions such as rain snow or wind When the temperature is below 5 C or above 45 C measures must be taken in the working area to provoke a temperature that ensures correct operation and that avoids interference with manual activity Figure 12 In order to achieve a more uniform temperature in the diameter
18. The trimming operation is fully automatic from software version v 1 9 on BASIC E fusion boxes Clean the outer surface of the pipes fittings ends with the adequate degreasing liquid Place the trimmer between the two pipes fittings to be jointed resting it on the base framework guides against the facing of the pipe on the fixed body and with the handle of the electric cable on the grip clamping bolts side Figure 18 Edition September 2003 28 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER Select the force to be applied with the F keys we recommend 200 250 N drag force drag of 300 N on the example Start the trimming operation by making a briefly press onto key on the panel The sign V will be displayed and the moving body will began to close BASIC 1 210 C t 00 00 F 0550NAY Immediately press the trimmer push buttons ODS 24 Vdc version or the individual push button ODS 315 version Once the pipe fitting end of the moving body has approached to the trimmer it will slightly open the trimmer will start up and the moving body will close with the programmed force increase or decrease the force according to the trimming operation Trim both ends until the shavings come off continuously from both sides The shaving thickness must be 0 2 mm at the most If the cutting is not correct check and adjust the cutters according to the procedure described in CHAPTER 5
19. amp BASIC H ACUSTER 2 4 HEATING PLATE The heating plate is made up of an outer PTFE lined aluminium base alloy body with an occluded electric resistor supplied by a cable from the Fusion Control Box It comes with an outer handle for ease of handling whose end mounts the electric cable The connection to the Fusion Control Box is done via an electric connector On the ODS 225 version the PTFE line is replaceable WARNING Always connect the heating plate electric connector into the corresponding control box connector with the machine switched off Install the heating element cable connector with the nut properly tightened to ensure good contact between the The heating plate temperature is automatically controlled from the Module by means of an internal temperature sensor The control is PID proportional integral differential An independent control thermometer is also provided NOTE For care and maintenance of the heating element please refer to CHAPTER 5 MAINTENANCE ofthis User Manual Edition September 2003 18 MACHINE DESCRIPTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 2 5 TRIMMER The trimmer version ODS 225 consists of an aluminium fused carter which covers and protects the two trimming discs Each disc is also provided with an adjustable cutting blade The trimming performance is carried out by simultaneously pressing the electric push buttons located on each hand
20. any other value Briefly press lt gt appearing F N Place the moving body in the open position Press STOP to halt Briefly press the closure push button and Pipes fittings cleaning press STOP before contact between pipes Drag measurement display Trimming Place trimmer into position Once the trimmer is placed into position Select force by pressing select the drag force 200 250 N Briefly press lt recommended Actuate the trimmer push The moving body is set into motion when lt buttons is pressed Visual control of the cut Start trimmer immediately by actuating its Remove the trimmer push buttons Repeat the trimming as many times as necessary and or increase force in accordance with the cut obtained Visual control F 0000 N pressing STOP While carrying out the visual control take the Briefly press lt gt opportunity to perform a new measurement of F N the drag force STOP to halt Once drag force has been performed finish CLOSE Press and hold lt manually moving the pipes fittings toward each other by pressing close button 1 Heating Select force by pressing Select Heating force from the Table in Place plate into position accordance with diameter and SDR Add drag Move toward by pressing force obtained Briefly press lt gt Manually move the pipes fittings toward the Bead visual control heating plate before briefly pressing lt gt 2 Heat soak Briefly press gt Interrupt Phase 1 once the i
21. c cylinders 100 bar 20 mm s maximum 3 8 flat ended quick plugs according to ISO 7241 1 A Series Edition September 2003 Revision No 5 USER MANUAL A A A BASIC E BASIC H ACUSTER 6 3 1 TRIMMER Driving electric motor 24 Vdc Power supply 24 Vdc nominal Electric motor power 465 W nominal Drive Via 2 push buttons safety switch Rotation speed 112 rpm Cutters regulation Fixing screws 3 mm Allen Adjusting shims Transmission belt i Poly V Electrical connection 3x2 5 mm cable 6 3 2 TRIMMER 230 V driver Mains power supply i 230 Vac nominal Electric motor voltage 720 W nominal Drive via 1 push button plus safety switch Rotation speed 60 rpm Cutters regulation a Fixing screws 3 mm Allen Adjusting shims Transmission Chain with tightener Electric connection Electric cable 3x2 5 mm Edition September 2003 Revision No 5 TECHNICAL CHARA CTERISTICS 47 AAA AGUSTER 6 4 HEATING PLATE Surface temperature Temperature regulation Independent temperature control Plate coating Power supply Plate power Electrical connection 6 5 HYDRAULIC STATION Mains power supply Maximum working pressure Safety valve gage Oil tank capacity Oil filter Type of oil Cylinder connections 48 TECHNICAL CHARACTERISTICS USER MANUAL BASIC E amp BASIC H From 180 to 240 C to be programmed according to material to be jointed PID type with Triac Analogical thermometer PTFE
22. ct during transportation Protect the electric cables and connections to the base framework trimmer heating plate and the cable that goes to the power supply from sharp objects All damaged cables must be replaced immediately by the After Sales Service of ACUSTER S A Always plug the control box to a power supply provided with differential and ground connection Do not expose the fusion control box to heavy weights All slight damage caused to the external frame or to other elements will have to be replaced immediately by the After Sales Service of ACUSTER S A The fusion control boxes which are not being used must be kept out of the reach of the non authorised personnel They will have to be kept in rooms of low humidity degrees and of restricted access Always use adequate working clothes For outside work it is recommended to use rubber gloves and boots with insulating soles In wet areas this advice is essential For indoor fusion jointing work adequate ventilation of the premises must be provided Before using the fusion control box its external condition will have to be checked as well as its working condition All components must be correctly assembled in order to guarantee the correct functioning of the unit The damaged components must be repaired or replaced by the After Sales Service of ACUSTER S A The fusion control box can only be opened by the After Sales Service of ACUSTER S A Should the fusion control box not
23. e 10 Trimmer ODS 315 WARNING Always connect the trimmer electric connector into the corresponding control box connector with the machine switched off Install the trimmer cable connector with the nut properly tightened to ensure good contact between the pins The trimmer cutting blades for both versions are made from hardened rectified steel There is a cutter on each side both of which are adjustable As stated in CHAPTER 3 MODE OF USE the swarf produced by the trimming cutters must not be over 0 2 mm thick If the cut is faulty either in thickness or in regularity the cutters should be adjusted NOTE For cutter adjustment care and maintenance of the trimmer please refer to CHAPTER 5 MAINTENANCE ofthis User Manual Edition September 2003 20 MA CHINE DESCRIPTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 2 6 HYDRAULIC STATION BASIC H The hydraulic station consists of the following components Figure 11 View of BASIC H hydraulic station on transport trolley Where 1 Transport trolley 2 Hydraulic station 3 BASIC H fusion control box The transport trolley is also used to keep and transport the trimmer and the heating plate Replace the hydraulic oil and filter following the maintenance schedule Spare oil in one 1 litre containers is available For care and maintenance of the hydraulic station please refer to CHAPTER 5 MAINTENANCE of this User Manual
24. grip The operating system also includes a safety switch which prevents the trimmer from operating in the event of this one not being mounted on its working position on the base framework bars The transmission of motion from the electric motor to the trimmer discs is performed by way of a Poly V belt version E 00 and upper The belt can be retightened by means of an eccentric tightener The electric motor is 24 Vdc and the power is supplied by means of a cable directly connected to the Fusion Control Box Its power is 465 W at 24 Vdc and it has an electronically controlled speed In the event of overcharging the trimmer there is a torque control which prevents the kinematic chain of the transmission from damaging limiting the trimmer s electric motor current it avoids overintensity Figure 9 Trimmer ODS 225 E 00 The trimmer version ODS 315 consists of aluminium fused carter witch covers and protects the two machining discs Each disc is also provided with an adjustable cutting blade The movement transmission of the driving motor to the trimmer discs is done via a ring gear a pinion and a chain The electric motor used has a power of 720 W at 230 Vac and the power is supplied by means of a cable directly connected to the Fusion Control Box It is fitted with a safety switch and a push button for operation Edition September 2003 Revision No 5 MA CHINE DESCRIPTION 19 A A A USER MANUAL BASIC E amp BASIC H ACUSTER Figur
25. h Exterior dimensions 1200 x 590 x 680 mm Base framework gross weight without clamp adaptors 127 kg Base framework transport s trolley gross weight optional 26 kg without cage 6 6 3 5 Pallet type packing for hydraulic station heating plate and trimmer BASIC H Contents Transport trolley with hydraulic station and BASIC H control box User Manual Publication No MU 78 03E Butt fusion parameters chart Publication Nos ANX 097 ANX 098 ANX 099 Heating plate 315 Trimmer 315 Exterior dimensions 750 x 570 x 980 mm Gross approximate weight 93 kg 111 Kg according to model Edition September 2003 Revision No 5 TECHNICAL CHARA CTERISTICS 5 1 A A A USER MANUAL BASIC E amp BASIC H ACUSTER RESERVED FOR NOTES Edition September 2003 52 TECHNICAL CHARA CTERISTICS Revision No 5
26. he European Parliamentary Directive 199 44 CE and the Council on 25 May 1999 General conditions of Guarantee 1 ACUSTER S A guarantees that this product has no manufacturing defect at the time of its purchase and extends this guarantee for the period of TWO years If the product proves defective during this period due to the materials or its assembly it will be repaired free of charge including the cost of materials labour and transport at Acuster S A s Technical Service The Guarantee is not valid in the following cases When the fault in the product is a result of Usual wear and tear due to usage Abuse or incorrect use of the unit Not following the instructions specified in this User Manual for connecting to a group generator Repairs carried out without authority from Acuster S A the taking apart or breaking of the unit s seal immediately renders the guarantee invalid Accidents natural disasters including lightning water action etc as well as any cause beyond Acuster S A s control In all claims against this guarantee information relating to the model date of purchase Serial number and any other additional information must at all times be stated Edition September 2003 10 INTROD UCTION Revision No 5 mr BASIC E amp BASIC H ACUSTER CHAPTER 2 DESCRIPTION OF THE FUSION MACHINE 2 1 GENERAL The range of BASIC butt fusion machines is made up of the following components
27. ion Tight up replacing the screws 2 Check the positioning with a ruler or a calliper the height h Carry out the trimming operation 5 If the shavings thickness were still incorrect repeat the operation Pr Flat Cutter versions ODS 225 and ODS 315 E 00 from Serial No 50 Where 7 2 it 1 Cutter 2 Fixing screw M5 3mm Allen key 3 Adjusting shim 0 1 mm thickness VEIN SERS pott ge AA OL ks A ja a Figure 21 Cutter adjustment Bear in mind that the cutter adjustment can vary according to the diameter of the pipe fitting to be faced having to be regulated in order to adapt to the job s specification Edition September 2003 42 MAINTENANCE Revision No 5 USER MANUAL A BASIC E amp BASIC H 5 4 3 5 4 4 ACUSTER Driving electric motor To check the function of the trimmer electric motor please refer to TRIMMER of the TEST MENU CHAPTER 4 TROUBLESHOOTING of this User Manual The ODS 225 trimmer version is driven by a 24 Vdc electric motor while the ODS 315 one is driven by a drilling machine of 230 Vac voltage Driving belt The transmission belt can be replaced if it should break The spare part reference is ODS 225 E 00 Part Poly V J9 ODS 315 Part chain with tightener Edition September 2003 Revision No 5 MAINTENANCE 43 A A A USER MANUAL BASIC E BASIC H ACUSTER 5 5 FUSION CONTROL MODULE MAINTENANCE 5 5 1 General Apart from the general
28. it means that the plate has still not reached the working temperature and the fusion control box will continue to supply the plate with energy until it reaches the temperature programmed If a question mark appears to the right of C it means that the heating plate is not connected or that the plate temperature sensor is outside the tolerance faulty The heating plate is fitted with an independent control thermometer for additional information Edition September 2003 Revision No 5 MODE OF USE 31 A A A USER MANUAL BASIC E BASIC H AGUSTER 3 2 6 The HEATING phase is begun wherein the fused material at the ends causes a bead to form which progressively reduces the length When the programmed length reduction for the relevant type of pipe is achieved making of the initial bead indicated on the Table depending on the diameter and SDR of the pipes fittings to be jointed briefly press the gt panel key The sign v will be gone from the display and t the movable body will keep still BASIC T 210 C t 00 00 F 0875N Next press the time key to begin the phase timing Once the heat soak time has expired open the moving body keeping the gt panel key pressed down to withdraw the heating plate from the base framework Fusion and cooling down cycle Press the panel key in order to bring together both pipe ends Immediately briefly press the panel key to validate the selected force The moving body will close
29. ition September 2003 24 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 3 2 BUTT FUSION PROCEDURE FOR PIPES AND FITTINGS 3 2 1 Preparation of the pipes and the machine Prepare the base framework for mounting the pipes fittings In order to do so adapt the diameter of the pipes fittings to be jointed via the corresponding adapters see list of available adapters in CHAPTER 6 TECHNICAL CHARACTERISTICS NOTE It is recommended to check the heating plate working temperature before beginning any work session When jointing pipes to fitting or fitting to fitting prepare the base framework for clamping the fittings The butt fusion fittings can be among others 90 45 or 30 elbows Reducers concentric or eccentric 90 bend Flange adaptor 90 Tees equal or reduced Caps BASIC E On the base framework ODS 200 225 8 both outer grips are removable To remove them loosen both grip clamping bolts 2 using a 10 mm Allen key supplied with the unit tool set NOTE Ifan adaptor is already mounted this should be removed in order to access the grip clamping bolts Where 1 Grip assembly 2 Looking bolt Allen type Figure 13 Removable outer grip Edition September 2003 Revision No 5 MODE OF USE 25 A A A USER MANUAL BASIC E amp BASIC H ACUSTER BASIC H On the base framework ODS 315 H the outer grip of the fixed body first grip o
30. l sensor could be faulty Edition September 2003 3 8 TROUBLESHOOTING Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER CHAPTER 3 MAINTENANCE 5 1 GENERAL 5 1 1 Introduction The BASIC fusion units have been designed and manufactured for a long life without the need for costly repairs and adjustments All that is required is careful handling when loading unloading and during transport and in general to keep the unit clean by following the recommended preventive maintenance The costs are very low and are soon written off given that the machine will be fully functional at all times This section includes a list of general upkeep and maintenance routine operations Should any problem arise please refer to CHAPTER 4 TROUBLESHOOTING in this User Manual However no action should be taken by unqualified personnel beyond these troubleshooting measures in order not to run the risk of seriously damaging the unit in particular the electronic control module WARNING All cleaning and maintenance operations and base framework heating plate trimmer and hydraulic station BASIC H only adjustments must be performed with the components disconnected from the unit 5 1 2 Storage If the unit is not to be used for a long period of time keep it in its box protected from dust moisture extreme temperatures direct sunlight and so on The complete unit can be stored on the warehouse floor or in pallet racks Editi
31. maintaining the force selected BASIC T 210 C t 00 00 F 0875NY Press the time push button twice the first is to reset the counter and the second to initiate the timing of the FUSION phase Once the fusion time indicated on the display according to the Table diameter and SDR of the pipes to be jointed has expired press the STOP push button on the panel Once the butt fusion cycle is complete press the time key twice the first is to reset the counter and the second to initiate the timing of the pressureless COOLING phase During this phase the moving body remains blocked and the clamps holding the pipe fittings must not be loosened until the cooling time indicated in the Table is over Edition September 2003 32 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 3 2 7 Functional operations outline summary PHASE SEQUENCE SEQUENCE DESCRIPTION Selection check Press and hold lt gt gt When plugging in the unit check heating Configuration Plug in unit plate programmed temperature Press 1 or to change To change the existing selection follow the Press timer Xto confirm described sequence Press STOP to return to menu Placement of pipes fittings OPEN Press and hold gt Manual procedures into the base framework CLOSE Press and hold lt Drag force measurement F 0000 N pressing STOP Force selected on the panel must be 0 N Press and hold to open Press STOP in the event of
32. mm Mains connection cable 4m Base framework connection cable 4m Trimmer connection cable 4m Heating plate connection cable 4m TECHNICAL CHARACTERISTICS 49 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 6 6 3 Packing weight and dimensions 6 6 3 1 Packing for BASIC E fusion control box Contents Fusion Control Box User Manual Publication No MU 78 03E Butt fusion parameters chart Publication Nos ANX 097 ANX 098 ANX 099 Exterior dimensions 410 x 330 x 320 mm Gross approximate weight 9 kg 6 6 3 2 Pallet type packing for base framework ODS 200 225 8 E Contents Base framework Tool set One 3 mm Allen key One 5 mm Allen key One 6 mm Allen key One 10 mm Allen key One 32 ratchet wrench One 26 mm socket wrench Exterior dimensions 1000 x 410 x 600 mm Gross approximate weight ODS 225E 68kg without clamp adaptors ODS 200 E 71 kg 6 6 3 3 Pallet type packing for heating plate trimmer ODS 200 225 8 E Contents Heating plate Trimmer Trimmer and heating plate holder Exterior dimensions 620 x 440 x 600 mm Gross approximate weight 39 kg Edition September 2003 50 TECHNICAL CHARACTERISTICS Revision No 5 USER MANUAL A A A BASIC E BASIC H ACUSTER 6 6 3 4 Pallet type packing for base framework ODS 315 H Contents Base framework Tool set One 3 mm Allen key One 5 mm Allen key One 6 mm Allen key One 10 mm Allen key One 4 ratchet wrench One 30 mm socket wrenc
33. n the right hand according to Figure 15 is removable to accommodate fittings To remove it loose the supporting plate 2 bolts a using a 6 mm Allen key supplied with the unit tool set 1 Set of outer grips 2 Grip supporting plate 3 Grip intermediate bar 4 Grip intermediate bar a b Supporting plate fixing bolt Intermediate bar fixing bolt al O Hal m Figure 15 Base framework 315 Frontal view Loosen the bar fixing bolts b using an 8mm Allen key supplied with the unit s tool set Afterwards dismount the supporting plate 2 Once this has been done dismount the intermediate bar 4 which is fixed by b bolts on both ends Remove the clamping grip 1 and the two intermediate bars 3 using a 27 mm head open end wrench Revert the above step instructions to assemble Edition September 2003 26 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 3 2 2 Assembly of pipes fittings Place the moving body in the fully open position by holding down the push button on the panel Open all the upper grips and place the pipes fittings into the machine equally distributing the distance and leaving space for the trimmer before mounting inspect the
34. n the display corresponds to the unit s last programming To modify it press the force 1 or F push buttons to increase or reduce the value Once the desired temperature is selected press the chronometer button W to confirm if this push button is not pressed the modified selection will not take effect Mains voltage outside tolerance If any of the following messages appear on the unit s display The message displayed on the left hand screen indicates that the supply voltage to the control box is lower than the allowed margin this function was introduced since the v1 6 software version on BASIC E The message displayed on the right hand screen indicates that the supply voltage to the control box is higher than the allowed margin this function is active within the first seconds the box is plugged to the mains In case the message is displayed on the screen switch the box off verify the supply and switch on again TROUBLESHOOTING 37 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 4 2 7 Low oil level BASIC H In case the hydraulic oil level is below the minimum allowed the following informative message will be displayed on the screen The message OIL is blinking on the screen indicating that the oil level is below the minimum correct working level that message is just informative and no interruption of the machine is done Refill the necessary oil quantity If the message is still displayed the oil leve
35. nitial bead Start the timer X indicated in the Table has been achieved Activate the timer 3 Heating plate removal OPEN Press and hold gt Manually open to a degree sufficient to Heating plate removal remove the heating plate 4 Force increase Bring together by pressing lt Manually bring the pipe ends together by Briefly press lt gt pressing lt gt Briefly press lt gt to validate the selected force Edition September 2003 Revision No 5 MODE OF USE 33 A A A USER MANUAL BASIC E amp BASIC H ACUSTER PHASE SEQUENCE SEQUENCE DESCRIPTION 5 Fusion Stop and restart timer X Actuate the timer twice once to stop it then start it again 6 Cooling off Press STOP Once the Fusion time specified in the Table Stop and restart timer X for the respective diameter and SDR has been reached stop the process Actuate the timer twice once to stop it then start it again Removal Stop timer X Once the cooling off forceless cooling time OPEN Press and hold gt specified in the Table has elapsed check the CLOSE Press and hold lt bead width and proceed to removal of pipes fittings from base framework Edition September 2003 34 MODE OF USE Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER CHAPTER 4 TROUBLESHOOTING 4 1 4 2 4 2 1 Edition September 2003 Revision No 5 GENERAL All maintenance and repair work of the butt fusion machine is to be carried o
36. of the pipes protect the fusion area from sunlight and inclement weather The opposite ends of the pipe or fitting facings to be butt jointed should be sealed and properly protected to minimise the effects of an excessively rapid cooling brought on for example by wind action Edition September 2003 Revision No 5 MODE OF USE 23 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 3 1 2 Preliminary checks temperature selection The fusion control box allows to select the following options BASIC E BASIC H the control box allows the heating plate working temperature to be programmed depending on the type of plastic resin to joint and or the applicable regulations The available programming range oscillates from 180 C to 240 C BASIC H Base framework model selection 315H 200H up to software version v1 01 only To modify the existing programming keep the lt gt gt push buttons on the panel pressed down as the unit is plugged in to the mains The display will show the following information F 0000 N OFF VA T 210 C BASIC E BASIC H Setting of heating plate working temperature The temperature indicated on the display corresponds to the most recent programming To modify it press the 1 or F buttons to increase or decrease the value Once the desired temperature is selected press the timer key W for validation if this key is not pressed the modification of the selection will not take effect Ed
37. on September 2003 Revision No 5 MAINTENANCE 39 A A A USER MANUAL BASIC E BASIC H ACUSTER 5 1 3 Cleaning Clean the fusion control box regularly using only a damp cloth NOTICE Do not clean the fusion control box with water under pressure by immersion in water o with compressed air Do not rub excessively the plastic shell for it could charge itself with static electricity Should the unit be very dirty clean it with a bit of alcohol do not use solvents or cleaning products containing trichloroethylene 5 1 4 Checks We recommend shipping the butt fusion unit to the ACUSTER S A After Sales Service for a yearly service Edition September 2003 40 MAINTENANCE Revision No 5 USER MANUAL A BASIC E amp BASIC H 35 2 5 2 1 5 2 2 3 2 3 5 3 ACUSTER BASE FRAMEWORK MAINTENANCE Linear actuator BASIC E Check for correct functioning of the kinematic transmission chain Any possible resistance may cause problems with the displacement which could affect the unit s performance and sensitivity Perform the verification by operating the panel s opening and closing push buttons Also perform a test for the drag force This value should not surpass 100N Clamp adaptors These additional parts have to be checked for cleanliness and correct seating before mounting Do not overtighten the Allen screws General cleaning and greasing Keep the base framework clean and in good w
38. orking order Clean after use Lubricate the guiding axles and cylinder stem with an oil cloth HEATING PLATE MAINTENANCE Clean from time to time to prevent PE particles or other plastic resins from adhering to the plate faces and forming an insulating coat which may affect the caloric performance For cleaning purposes only use white paper or a clean and dry fluff free 100 cotton cloth NEVER use Tangit isopropyl alcohol trichloroethylene above all ifthe heating plate is hot You can check the performance of the heating resistors with the help of the TEST MENU please refer to CHAPTER 4 TROUBLESHOOTING of this User Manual The display will show the temperature of the plate s probe as well as the power supplied The heating plate s temperature should be approximately 210 C at 23 C RT Edition September 2003 Revision No 5 MAINTENANCE 41 A A A USER MANUAL BASIC E BASIC H ACUSTER 5 4 TRIMMER MAINTENANCE 5 4 1 Trimmer faceplates Check for cutting performance The shavings must be uniform and never above 0 2 mm thick on both sides If the cut is faulty either in thickness or regularity the cutters must be adjusted First check the cutting height h by means of a calliper or gauge 5 4 2 Adjustment of cutters To adjust the cutters proceed as follows Release the cutter 1 using the screws 2 Once the cutter has been removed add or remove the necessary adjustment shims 3 Place the cutter back on posit
39. replaceable cloth 230 Vac nominal 110 Vac nominal 2000 W ODS 225 Version at 230 Vdc 1800 W ODS 225 Version at 110 Vdc 2300 W ODS 315 version 10x1 mn cable 230 Vac 110 Vac nominal 100 bar 110 bar 2 litres 5 litres according to model 25 microns 10 microns according to model HV 46 according to ISO 6743 4 HV 3 8 flat ended quick plugs according to ISO 7241 1 A Series Edition September 2003 Revision No 5 USER MANUAL BASIC E BASIC H 6 6 SIZE AND WEIGHT 6 6 1 Weights of various parts Control box Base framework without adapters Heating plate Trimmer Plate and trimmer support Transport trolley hydraulic station Total nett weight 6 6 2 Dimensions of various parts Base framework Heating plate Trimmer Fusion Control Box Electric cables length Edition September 2003 Revision No 5 AAA ACUSTER BASIC E BASIC H 8 Kg 8 kg 50 Kg 225 version 100 Kg 315 version 53 Kg 200 version 64 Kg 225 version 10 Kg 315 version 13 4 Kg 225 version 2172 Kg 315 version 3 Kg 225 version 35 Kg 63 Kg acc model 80 Kg 225 version 1744 Kg 192 4 Kg acc model 83 4 Kg 200 version 200 225 8 VERSION 315 VERSION length 960 mm 960 mm width 390 mm 550 mm height 400 mm 540 mm width 380 mm 470 mm depth 50 mm 70 mm height 545 mm 620 mm width 430 mm 500 mm depth 140 mm 370 mm height 580 mm 530 mm width 450 mm depth 470 mm height 460
40. requency 50 Hz 3500 W maximum 4 5 kVA monophase recommended Electronic regulation preferable IP54 At user s discretion LCD 2 lines x 20 characters backlit 6 tactile feeling membrane push buttons 3x2 5 mm cable 3 multicontact circular connectors Base framework BASIC E 20x13 Heating plate 20x6 24 Vdc trimmer BASIC E 20x3 230 Vac trimmer BASIC H 20x6 230 Vac trimmer BASIC E Schuko socket 50 Hz 4 5 kVA minimum 230 Vac 110 Vac 16 A minimum for 230 Vac 20 A min for 110 Vac Preferably electronic TECHNICAL CHARACTERISTICS 45 AAA AGUSTER 6 2 1 BASE FRAMEWORK 200 225 8 E Diameter range Fixing grips Clamp adapters Drive Maximum working force Displacement speed Electric connection USER MANUAL BASIC E amp BASIC H From 63 to 200 mm 225 mm 8 depending on model 26 mm socket wrench For 4 63 75 90 110 125 140 160 180 200mm 6 5 4 3 2 72 2 not included in the unit fixing screw 6mm Allen Lineal actuator at 24 Vdc 4000 N 20 mm s maximum 14x1 mn cable 6 2 2 BASE FRAMEWORK 315 H hydraulic drive Diameter range Fixing grips Clamp adaptors Drive Maximum working force Displacement speed Hydraulic connection 46 TECHNICAL CHARACTERISTICS From 90 to 315 mm 30 mm socket wrench For 90 110 125 140 160 180 200 225 250 and 280 mm pipe diameter not included in the unit fixing screw 5 mm Allen Two double action hydrauli
41. tudinal beams The four upper grips are easily removable and the fixed outer lower grip is also removable for accommodating various fittings such as elbows tees etc The movable grips are driven by two double acting hydraulic cylinders The pressure to the hydraulic cylinders is supplied by a hydraulic station through two high pressure flexible hoses connected by means of male female flat ends quick plugs The clamping of different smaller diameters can be achieved by means of different sets of additional adaptors which are locked in place using Allen screws alla D 5 YD E E o EEE HO Hoa H Hi Figure 8 ODS 315 base framework WARNING Always connect the electric connectors with the machine switched off The base framework ODS 315 installation is made by Connecting the two base framework hydraulic guick plugs into the hydraulic quick plugs hydraulic station male female female male Be sure that hydraulic station electric circular connector is properly connected into the corresponding control box base connector For care and maintenance of the base framework please refer to CHAPTER 5 MAINTENANCE of this User Manual Edition September 2003 Revision No 5 MA CHINE DESCRIPTION 17 A A A USER MANUAL BASIC E
42. uminium heating plate with electronic temperature control by means of an internal sensor PID A thermometer for control is also provided Versions of 225 mm and 315 mm 4 A trimmer BASIC E The standard trimmer is driven by a 24 Vdc electric motor and belt drive It incorporates two push buttons for functioning control and a safety switch An optional version of 230 Vac electric motor is also available BASIC H The trimmer for the base framework ODS 315 H the motor has 230 Vac It is chain driven and incorporates one push button for functioning control and a safety switch 5 A Hydraulic station BASIC H formed by an electric motor a hydraulic pump solenoid valves quick connectors as well as the required elements for the hydraulic performance of the base framework NOTE The hydraulic station is only eguipped with the BASIC H butt fusion machine Edition September 2003 12 MA CHINE DESCRIPTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 2 2 ELECTRONIC CONTROL MODULE 2 2 1 General The fusion control module consists of an ABS plastic case On BASIC E model the case is installed over a stainless steel tubular frame whereas the BASIC H box is attached to the transport hydraulic station trolley In its interior the Control Module features a 230Vac 24Vdc 110Vac 24Vdc according to model transformer as well as the electronics necessary for the butt fusion process The exterior of the module
43. ut by qualified personnel Full guarantees are obtained by shipping the unit to the ACUSTER S A After Sales Service both for the yearly revision and for repairing any fault that may have occurred in the unit UNIT CHECKS The simplicity of the unit s design makes costly inspections unnecessary To inform the operator of any potential malfunctions or faults there is a set of symbols that appear on the display when necessary Following is a short list of possible faults The ODS 24 Vdc trimmer does not work BASIC E 1 98 Press the base framework s operation push buttons open or close This is to verify that the 24 Vdc outlet which powers both the base framework s actuator and the trimmer is operative Check trimmer operation Connect the trimmer to the fusion control box and select the trimming mode Trimming Select the force to be applied with the F keys Start the trimming operation by making a briefly press onto lt key on the panel The sign v will be displayed and the moving body will began to close With the trimmer located onto the base framework guiding bars immediately press the trimmer push buttons Once the pipe fitting end of the moving body has approached to the trimmer it will slightly open the trimmer will start up and the moving body will close with the programmed force This operation is to verify the correctness of the 24 Vdc output voltage that feeds the linear actuator motor and trimmer
44. ving body has approached to the trimmer it will slightly open the trimmer will start up and the moving body will close with the programmed force Possible fault in the trimmer s push button Possible fault in the electronic component which controls the trimmer s operation through the push buttons 4 2 5 The heating plate does not heat up or does not maintain working temperature 1 2 First check the heating plate s electrical connections to the fusion control box Check the plate temperature on the display Also check plate temperature on the display if the question mark appears Edition September 2003 36 TROUBLESHOOTING Revision No 5 USER MANUAL A A A BASIC E amp BASIC H 4 2 6 Edition September 2003 Revision No 5 ACUSTER BASIC T ttt C 2 t 00 00 F 0000N The question mark Indicates that the heating plate is not connected or that the plate s internal sensor is outside tolerance faulty The temperature on the display does not match the working temperature to be used by the operator Check the machine s programmed temperature remember that the plate s working temperature can be programmed from 180 C to 240 C according to the type of plastic resin to be jointed and or applicable regulations With the unit disconnected keep the gt keys simultaneously pressed down Next the following information will appear on the display F 0000 N OFF VA T 210 C The temperature shown o
45. work properly it will have to be sent immediately to the After Sales Service of ACUSTER S A Edition September 2003 INTROD UCTION Revision No 5 USER MANUAL A A A BASIC E amp BASIC H ACUSTER 16 DECLARATION CE OF CONFORMITY ACUSTER S A Juan de la Cierva 1 Poligono Industrial N 1 08960 Sant Just Desvern Spain declare under our sole responsibility that the BASIC E and BASIC H butt fusion machines to which this declaration relates is in conformity with the following standards EN 292 1 1991 EN 292 2 1992 EN 294 1992 EN 563 1994 EN 60335 1 1994 EN 60335 2 45 1996 EN 55014 1993 EN 50081 1 1992 EN 50082 1 1992 ISO 12176 1 following the provisions of Directives 98 37 CE 73 23 CEE 89 336 CEE Sant Just Desvern 1 October 1998 Ramon Garcia Sole Technical Department Director Edition September 2003 Revision No 5 INTRODUCTION 9 A A A USER MANUAL BASIC E amp BASIC H ACUSTER 1 7 GUARANTEE Guarantee declaration All the BASIC E and BASIC H butt fusion machines are manufactured from high quality material and have been subjected to rigorous tests for resistance and working order as well as passing all the quality control tests required by the applicable normative see CE Declaration of conformity Regardless of whether an incident might occur during the period of guarantee we recommend a careful reading of the following general guarantee conditions established by t

BUTT FUSION MACHINE MODELS BASIC E

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