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CTF FRANCE Operating Manual

PPIIPPEEFFUUSSEE SSYYSSTTEEMM 0/43

BONDOUFLE - FRANCE

PIPEFUSE 160

Operating Manual



SUMMARY

1. TECHNICAL DATA 3

2. TAKE CARE WHEN USING THE UNIT 4

3. PIPEFUSE UNIT 5

4. WELDING CRITERIA 7 4.1. GENERALITY 7 4.2. DIFFERENTS STEPS ON THE BUTT WELDING 8 4.3. DIFFERENT STANDARDS 10

5. SAFETY 11

6. DIFFERENT RISKS 14

7. OPERATING TESTS , MAINTENANCE, FAILURES 15

8. WELDING INSTRUCTIONS 19 8.1. SET THE UNIT 19 8.2. SET COMPONENTS 19 8.3. STARTING 19 8.4. WELDING PREPARATION 19 8.5. DRAG FORCE REFERENCED ’’F ’’ 20 8.6. SCRAPER AND ALIGNEMENT 20 8.7. STEP 1 : BEAD UP 21 8.8. STEP 2 : HEATING 21 8.9. STEP 3 : HEATING ELEMENT EXTRACTION 21 8.10. STEP 4 : WELDING - COOLING 21 8.11. LISTE OF CONTROLS AND ACTIONS FOR USE OF THE SIMPLIFIED SEMI-AUTOMATIC MODE FOR IDENTICAL AND REPETITIF WELDS 22 8.12. PROTOFUSE OPTION 25

9. SCHEMAS 26 9.1. HYDRAULIC SCHEMA 26 9.2. HEATING ELEMENT SCHEMA 27 9.3. HYDRAULIC ELECTRICAL SCHEMA 27 9.4. SCRAPER ELECTRICAL SCHEMA RABOT 27

10. STANDARD 28 10.1. DVS 28

ANNEXE A – SPARES PARTS 32

ANNEXE B – FUSION PARAMETERS TABLE 45



1. TECHNICAL DATA 3

2. TAKE CARE WHEN USING THE UNIT 4

3. PIPEFUSE UNIT 5

4. WELDING CRITERIA 7 4.1. GENERALITY 7 4.2. DIFFERENTS STEPS ON THE BUTT WELDING 8 4.3. DIFFERENT STANDARDS 10

5. SAFETY 11

6. DIFFERENT RISKS 14

7. OPERATING TESTS , MAINTENANCE, FAILURES 15

8. WELDING INSTRUCTIONS 19 8.1. SET THE UNIT 19 8.2. SET COMPONENTS 19 8.3. STARTING 19 8.4. WELDING PREPARATION 19 8.5. DRAG FORCE REFERENCED ’’F ’’ 20 8.6. SCRAPER AND ALIGNEMENT 20 8.7. STEP 1 : BEAD UP 21 8.8. STEP 2 : HEATING 21 8.9. STEP 3 : HEATING ELEMENT EXTRACTION 21 8.10. STEP 4 : WELDING - COOLING 21 8.11. LISTE OF CONTROLS AND ACTIONS FOR USE OF THE SIMPLIFIED SEMI-AUTOMATIC MODE FOR IDENTICAL AND REPETITIF WELDS 22 8.12. PROTOFUSE OPTION 25

9. SCHEMAS 26 9.1. HYDRAULIC SCHEMA 26 9.2. HEATING ELEMENT SCHEMA 27 9.3. HYDRAULIC ELECTRICAL SCHEMA 27 9.4. SCRAPER ELECTRICAL SCHEMA RABOT 27

10. STANDARD 28 10.1. DVS 28



1. Technical Data

PIPEPUSE 160 Diameters 40 mm to 160 mm Material PE-HD, PP Power 2 100 W Power Supply 230V Alternative

50 / 60 Hz single phase

FRAME Weight 47 Kg Size 900x465x455mm Hydraulic Cylinder area

4,32 cm²

SCRAPER Weight 8 Kg Size 470x440x84mm Power 720 W HEATING PLATE

Weight 5 Kg Size 415x65x350 mm Electronical control 0°C to 300°C Power 1000 W HYDRAULIC Weight 24 Kg Size 500x330x330 mm Power 750 W Maximal Force 12750 N Hydraulic Oil TOTAL XV46 SUPPORT ELEMENTS

Weight 7 Kg Size 310x450x330 mm NOISE * Leq Leq = 79.dB(A) REDUCER

Weight of the complete set

17 Kg



2. Take Care when using the unit The range of PIPEFUSE manual unit is for the used in site with a heating element study for the welding of straight pipes and / or accessory made in Polyethylene (PE) or Polypropylene (PP), in a range of diameters. The diameter is obtained by adding reducers. ATTENTION 1 : This documentation must be read and understand by the user of the PIPEFUSE. Security,

safety of the user and other people are involved. ATTENTION 2 : The PIPEFUSE is a unit not realized to : The heating, welding or handling of not approriate materials, Done operations not describe in this documentation, Be used on an hazardous area. ATTENTION 2 : The PIPEFUSE unit must be used by trained and qualified operator.



3. PIPEFUSE unit

Frame : The Frame is build with the following components :

A movable part with 2 clamps mounted on hydraulic jacks, A fixed part with 2 clamps which can be positionned with a distance-piece, A re-enforced frame, Two lateral supports, Hydraulic part with fast connection.

Scraper : The electrical scraped is build with the following components :

Main corps of the scraper, Electrical motor with the electrical plug, The rotation parts with the blades, A sensor disposal to check if position on frame.

Hydraulic group

Frame

Heating element : Automatic model

Facing tool /scraper

Manual heating element



P f

C

BP

L

R

Heating Element : The heating element is build with following components :

Heating plate with a coated protection, Temperature indicator, Electrical connection, In option : Mechanical automatic extraction of the heating element.

Hydraulic : The hydraulic part is build with the following components :

Hydraulic motor, 2 connections hauses, BY PASS lever allowing to set the pressure referenced after « BP » A Manometer noted « M » allowing the pressures reading referenced « P » or « f » Pressure regulator referenced « R », A Opening, Closing lever referenced « L ». Opening / Closing are referenced « O-F », A Chronometer referenced « C ».

Clock Wise Anti-Clock Wise



4. Welding criteria Materials to be welded has to be compatible chemicaly and physicaly et physiquement, such compatibility is given by the manufacturer of pipe or accessory. Pipes must have the same thickness and diameter. Welding must respect the following rules : In case of mud, dust, wind, or cold temperature, the use of a tent (heated if needed) allows to have a

protected area for the weld. Use test on weld if the conditions are correctly prepare, Pipes extremities has to be clean rior the weld, Pipes extermities must be at the same temperature for the weld (a sun protection must be used in case), During the weld all mechanical stress must be prevent (especially during the cooling time), Extremities not involved on the weld must be closed to prevent cooling by wind effect, The used of roller is strongly recommanded to dicreased drag force.

4.1. GENERALITY

The principal of this technic of weld is to apply the element to be weld on a heated plate (during a specifical time and pressure). After having a specific tickhness of the bead, the heating plate is removed and the surface to be weld are set in contact (during a specifical time and pressure). Pressure Pressure Heating plate set in contact



4.2. DIFFERENTS STEPS ON THE BUTT WELDING

We differenciated 5 steps for a butt weld :

Bead up time, heating time, Heating element removal , Welding time, Cooling time.

Values of time and pressure are differents depending of the standard used. As an example and to explain the goal of the different steps : Pressure

P4 P1 P5 P2

Time t1 t2 t3 t4 t5 Bead Up Step : This step allows to create the bead and will allows the extraction of minors residues. This is done just after the preparation of the element to be weld (Positioning, scraping, Drag force calculation, setting of the welding temperature).



Heating step : This step allows the thermical propagation inside the elements to be weld. In general the pressure at this step is almost equal to zero (allowing only to compensate the drag force to prevent a separation of the heating element). Heating element removal : During this step the heating element must be removed a quick as possible in order to prevent lost of temperature or inclusion of elements as dust, sand … Welding step : During this step the final bead is create and molecular chain join together allowing a perfect joint. Cooling time step : The weld is done and during this step the components stay together to pervent stress or tensile chich can damaged or fragilized the weld.



4.3. DIFFERENT STANDARDS Values of time and pressure are differents depending of the standard used. Pressure P4

P1 P5 P5 P2

Time t1 t2 t3 t4 t5 e = thickness Dn = Diameter S = Surface fct( : fonction of

°C Heating element

P1 Bead up Pressure

t1 Bead up

Time

P2 Heating pressure

t2 Heating

time

t3 removal

P4 Welding Pressure

t4 Welding

time

P5 Cooling Pressure

t5 Cooling

time DVS 2207

1995 e<70 mm

200 °C -220 °C

0,15 Mpa 0,5-4 mm 0 Mpa 10 e fct(e) 0,15 Mpa fct(e)

DVS 2207 1986

e<50 mm

195 °C - 220 °C

0,15 Mpa 0,5-3,5 mm 0 Mpa 190 - xxxs fct(e) 0,15 Mpa fct(e)

WRCWIS e>20mm

230 °C 10°

0,15 Mpa Bead = 2mm

0 Mpa 10 e - 0,15 Mpa 10s 0,15 Mpa 50 e

DS/INF 200 °C -220°C

0,18 Mpa bead = 0,5 + 0,1e

0,01 Mpa 15e 3 + 0,01 Dn

0,18 Mpa 3 + 0,03 Dn

0,18 Mpa 10s + 0,5e

VEG 85 NEN 7200

210 °C 10°

0,18 Mpa bead = 0,5 + 0,1e

0 Mpa 12e 3 + 0,01 Dn

0,18 Mpa 3 + 0,03 Dn

0,18 Mpa 10s + 0,5e

Electrabel Becetel I

110-250mm

210 °C 10°

0,05 Mpa 10 e < 3s 0,3 Mpa Fct(S)

Electrabel Becetel I

250-315mm

210 °C 10°

0,05 Mpa 10 e < 3s 0,24 Mpa 10s 0,05 Mpa Fct(S)

GASTEC 210 °C 10°

0,18 Mpa bead = 0,5 + 0,1e

0,01 Mpa 12e 4 + 0,01 e

0,18 Mpa (4 +0,03 e)

3+e min 0,01 Mpa 1,5e min

GAZ NATURAL Si Dn =315

210 °C 15°

225 °C 15°

0,18 Mpa 1 – 2 mm or

2 – 3 mm si Dn>160

0,03 00,2

Mpa

Dn /2 + 30 10

Dn t3 110 4 <200 5 >250 6

0,18 Mpa > 10min 1,5e min with max

20min



A good idea is to keep track on a recording file the following data : Name of the operator and of the company, The type and number of the welding unit, Ambiant temperature and meteo conditions, Diameter and thickness of the pipes, Size of the bead, heating and welding times.

5. Safety In the respect of the documentations and the safety rules, elementaries precautions has to be taken to reduce the accident risks when using the unit and the associated components and also during handling and transport. To keep a high level of safety and of efficiency unit must be fully checked every 2 years. Power supply connection : The power supply box on site must have at least a protection level of 44 and to be in conformity with the IEC 17-13/1 et 17-13/4, especially must be included a Ground Fault Interruptor very sensitif with a reaction time of 0,4 seconde in case of earth dispersion, to protect the user of direct or indicrect contact. In addition thermical et magnetothermical disposals can be used. Such disposals must have a clear identification using ad hoc stickers. Power supply connection of tne unit : Connection between unit and Power supply box on site must be done with cable resistant mechanically and chemicaly in conformity with rules. Extension cord must respect the same issues. Power supply plugs must have at least a protection level of IP 67. Grounding : Only one ground connection must be used for all the site. Resistance must be adpated with the protection devices used and allows to prevent that no metallic part can be touch with a potential differential higher than 25V. The Grounding system must be realized and tested by a qualified crew and the installation must be sayed to related authority. It is only when this grounding is done that Class I equipment can be say safe for the electrical risks.



Using and storage of electrical equiments : To minimized risks, equipments must be used and stored correctly : Prevent the temporary use of primary connection out of standard, Prevent any contact with part having voltage, Do not disconnect the plug by pulling it, Do not handle, transport, equipment by the electrical cable, Do not let heavy, cutting, of high temperature fall on equipment Do not used on humid area. Check also that gloves, shoes, and others protections clothes are dry. Do not splach equipment, Check periodicaly the isolation of the equipment, Check cables isolation, especially on the area related to mechanical efforts, Prevent the used with extrems conditions (Temperature, humidity, storm, ...) If the equipment is used on a closed area with high humidity conditions, check the equipment used a 48 V

power supply or have a galvanic separation, Check at least once a month that the Ground Fault Interruptor work proprely, Check grounding by a qualified operator, Clean the equipement taking care of material used which can damaged isolation. Do not used abrasives,

gaz, … Store electricals on a dry area where none qualified people can not access, Prevent the used of explosif gaz, steams, smokes or dusts expect if the equipement is specify for it, After the end of use or during works interruptions check the power supply disconnection, Prior of a use check that the equipment is not damaged making dangerous the equipment. It is only by following this recommandations, and in conformity with safety rules (as IEC 64-8/7, 17-13/1 or 17-13/4) that the necessary precautions can be sayed taken. It is a necessity that the equipement user is trained by speciallized technicians. Do not do : Do not used fissured or deformed equipments especially in plastics. All penetration by the fissures can create an electrical chock. Before connection : Before connection of a equipment to the power supply check that the equipment is switch OFF. Moving parts : Check that all moving parts are correctly locked before transport or handling. Check for the butt welding equipment that the pipe are correclty locked so the unit can work proprely and the pipes can not fall which can be dangerous for the user.



Prevent to work on hazardous areas : In case of a work in an excavation, check that the excavation wall are safe enough to prevent drops of stones or muds which can damaged the equipement and be dangerous for the operator. Check also the water or others liquids penetrations on the work area which can be dangerous for the equipement and the operator. In case of work on a exiguous area the operator has to be supervized by somebody outside. Prevent the used on area with gaz, explosifs materials (class C1 or class C3Z1) which can create fire or explosion with all the assocatied risks. When using a lifting device to transport the equipment or a part of, check the locking, the size of the lifting device in regard with the weight and also that in case of break nobody can be hurt. When using in presence of liquid a used of Low voltage level is a adding safety for the operator. Do not used the equipment with pipes or accessory which allready being used to transport materials which can create injurious smokes dangerous for the operator. Smokes can be dangerous for the operator in this case a respirator has to be ready. Prevent to work on a area with smokes comming from vernish, grease, oil, which can irritae eyes and respiration. If such accident arrived, stop the job and a ventilation system must be used to clean the area. Taking care of the equipment : Clean and sharp tools bring a better efficiency and a more safe situation. Allways read the maintenance instructions regarding the tools. Replace immediatly all defect , break or damaged parts with original pieces.. Clothes : Do not wear large clothes or jelews which can be taken by the equipement and bring a dangerous situation for equipement and/or operator. Operator must allways wear :: Protection gloves, Work shoes, Working clothes, Protection glasses in cas of projection, Noise reducers (when using the scraper)

Do not have pieces of tissues coming outside from pockets. Prevent loose laces, long hairs, and all others parts which can be taken from the unit.



Keep the work area free and clean : A dirty work area is dangerous, keep this area clean and free as possible. Mud and grease cans create droping situations dangerous for the user. Check the unit rest on a flat and stable area to obtain a good weld and to prevent any danger for the user. Keep aways visitors : Keep at a safe distance visitors which can create dangerous for themselves and for the user. Check that the work site clearly indicated and protected to prevent visit of non-authorized people. Check that safety gates are proprely set. Never let a none trained people use the equipment.

6. Different Risks Equipement under pressure : The equipment under pressure can be used only by trained and qualified people. Two operators has to be present when using the equipment, one checking the hydraulic unit the other one handling scraper, heating element. The operator using the hydraulic unit has to be in front of the equipement in order to check allways the actions of the other operator and to have a full communication with him. Heating element : Heating plate can reach up to 250°C, it is a necessity to: Use protection gloves, Set the heating element of the storage part after the used off it, Allways let the heating element cool down before to try to transport it in order to prevent fire, At the end of the weld store the heating element on a area where nobody can touch it, Allways handle the heating element with the handle, Allways prevent any contact of the Heating element with the body, Allways unplug the heating element at the end of the weld, Never, never, never … touch the surface of the heating plate with hand. Scraper : Before scraping allways check the pipes extremities are clean, free of all sand, mud, or material. Such elements can damaged the blades and can be dangerous in regard with projection. At the end of scraping allways store the scraper after waiting the end of rotation. Allways handle with the handle without contact with the body. The scraper can be activate only when set on the welding equipement.



After set on the equipement step backward to safe distance. A blocked position of the main swicth allows this. Never modify or touch the micro-switch of the scraper which allows only the used in position. Hydraulic : Set the equipment rest on a flat and stable area where the equipment do not stop traffic. To transport the unit use the top rods.. Never set vertically the equipement : oil leak. All setiing and adjustement of the equipment must be done a qualified people limited on what are described on this documentation. Frame : Check that the pipes / accessories to be weld are proprely set and lock into the equipment, making the weld more accurate and without risk of fall. During the weld keep a safety distance in order to do not touch the equipment. In case of squeeze of between the clamp of the unit : DO NOT USED THE MAIN SWICTH ON/OFF, but open the equipement using the pressure lever. Before transport or handling of the equipment allways check that the clamp are proprely locked in order to prevent any fall. Respect the safety recommandations wrote on the equipment.

7. Operating tests , maintenance, failures The different risks can be summarized as :

Risks Risk Evaluation Actions Informations Electrocution Moderate risk with a

low probability Ground Fault Interruptor

See Safety p.12

Fall Risk with a low probability

Locking See Frame P 16

Clamps Squeeze off Moderate risk with a low probability

Indications on unit See Frame P 16

Burn due to fire or explosion

High Risk with a very low probability

Hand, clothes, safety See Hazardous area p 14

Burn due to heating element

Moderate risk with a low probability

Indications on equipment, Gloves

See Heating Element P 15

Parts taken by the equipement

Moderate risk with a low probability

Clothes, Indications See Clothes p.14

Projection in Eyes Moderate risk with a low probability

Glasses See Clothes p.14

Cut due to the scraper Moderate risk with a low probability

Gloves, Micro-Switch and main switch

See Scraper p.15



Deaf Risk with a low probability

Noise reducers See Clothes p.14

Check Power supply compatibility, Clean fast on connectors before connection ( use gasoil, and dry with a clean clothe), Allways set back

the protection caps if not needed. Operations must take care of sands or muds propagation to prevent damage on the equipement,

Check that the drop pressure is less than 2-3 bars when hoses pipes are disconnected, Check for hydraulic oil leaks. Frame : Check the jacks axes are clean, Check the locking ability of the clamps. Hydraulic : Oil contain on the equipment must be changed around every 1000 cycles (or at least once a year of the

equiemepnt if not so used), Recommanded oils : MOBIL DTE 26 ESSO NUPO HP 68 AGIP OSO 46 SHELL TELLUS 68 Check the pressure manometer ( indicator move smoothly) Check the operating state of the scraper micro-contact Check the operating state of the oil accumulator ( in case of proble the manomater indocator wil not

move smoothly). Scraper : Check the maximal thickness of the cut (0,2mm) Checks that the blades are sharp enough Heating element :

Before process to a weld, allways check and adjust the following items. All actions on electrical parts must be done by a qualified people the unit switch Off and unplug.



After each weld, when the heating element is warm, clean the Tefelon surface using Methyl alcool on a

clean towel. (used gloves), Check the teflon surface (not scraped) Check the heating element work proprely in regard with the thermometer and a calibrated one, Before the weld be sure the control lamp is on since more than 5 minutes In case of one of this fault it is a necessity to call the After Sales Service.

Problem Due to Solution Hydraulic oil leak Fast on connectors Lock or replace the fast on

connectors Hydraulic oil leak Jack leak Call after sales service Hydraulic do not work Câble débranché ou endommagé Vérifier la connexion, le système

électrique. Hydraulic do not work Micro contactor is not set Set the micro contactor to be

activated at 1/3 Hydraulic oil leak and low pressure

Fast on connectors Lock or replace the fast on connectors

Hydraulic oil leak and low pressure

Not enough oil Refill


Air inside the hydraulic circuit Connect together the hoses and work during 30 secondes.


Air inside the hydraulic jack Unscrew the screw of the jacks, apply a pressure up, oil start to leak, lock again the screws vis.


Dust inside the hydraulic circuit Call after sales service.

Scraper do not work No power supply or micro contactor is on open position

Check power supply and micro contactor.

Heating element do not work No power supply Check power supply. No enough temperature on the Heating element

Temperature dammaged Replace cable, replace heating element.

No enough temperature on the Heating element

Heating plate dammaged Replace heating element.



Steps Action Daily Montly Every 6 months

Yearly

M1 Power supply compatibility

M2 Power supply

M3 Fast on connectors cleaning

M4 Pressure Drop

M5 Hydraulic Oil leak

M6 Jacks cleaning

M7 Clamps Locking

M8 Oil Level

M9 Change oil M10 Manometer Pressure

M11 Micro-contactor

M12 Accumulator

M13 Scraper motor

M14 Thickness scraper

M15 Blades Sharpness

M16 Heating element cleaning

M17 Heating element Temperature

M18 Heating element surface



8. WELDING INSTRUCTIONS

8.1. SET THE UNIT Unload the unit from the transport trolley (if exist) and set on a flat area to prevent any slipping during the weld which can interfare on the weld quality.

8.2. SET COMPONENTS Set the hydraulic unit to have the pressure readable. Connect hydraulicaly and electricaly together scraper and Heating element to the the welding unit.

8.3. STARTING Check the power supply. Connect the hydraulic unit to the frame using fast on conenctors. Connect heating element and scraper to the electrical plugs. Set the temperature level (The temperature is electronicaly regulated).

8.4. WELDING PREPARATION Set the reduces shells in regard with the nominal diameter. Position the components to be weld letting less than 3 cm exiting of the clamps, set the up clamps and lock. Select the standard table norme (DVS, WIS, ...) in regard with the material and diemeter to be weld. Check the temperature of the heating element. A typical weld is based on the following steps : Bead up : This step allows the bead creation on a size depending of the table used. The size of the final

bead will depend of this size. Heating : During this step the propagation of the temperature is achieve on the components to be weld.

During this step a minimal pressure level is required. Heating element extraction : In this step the heating element is extrated before to set in contact the

elements to be welded. The extraction time must be as short as possible to prevent thermical dissipation and pollution (mud, sand) or oxydation of heated parts).

Welding : The surfaces of the elements are in contact together on a pressure set smoothly. Cooling : The cooling time at a fixed pressure level determined by the standard allows that no tensile

force or mechanical stress will decrease the quality of the weld. Note that the cooling pressure level is sometime the same than the welding pressure depending of the used standard..



8.5. DRAG FORCE REFERENCED ’’F ’’ Calculate the ’’f’’ drag force :

Set the’’BP’’ lever in closed position, clock wise, Set the’’R’’ pressure regulator to zero (0 to 100), Act on ’’L’’ level in close position’’F’’, and by smoothly turn the’’R’’ pressure regulator the

frame start to close, Read and note’’f’’ pressure indicated by ’’M’’ manometer indicator.

8.6. SCRAPER AND ALIGNEMENT In this step the faces of the elements to be weld are set parallel :

Let the closing finish so the surface of the elements will be in contact, Turn clock wize ’’R’’ pressure regulator up to display on’’M’’ manometer indicatior the pressure

’’P’’ indicated in the table for the weld and add to it the previous drag force ’’f’’ noted previously,

Set the ’’L’’ lever to open position ’’O’’: The mobile part will open allowing to set the scraper (the blades will be first checked) ,

Open on O the ’’BP’’lever, Switch On the scraper, Set ’’L’’ lever in closing position ’’F’’ , Set smoothly the ’’BP’’ lever to P to close the mobile part Maintain with this level between 6 to 10 Bars during the scraping, When the cut is continuous, set the ’’L’’ lever in opening position’’O’’: The mobile part will open Stop the scraper, Wait the end of the rotation before remove the scraper, Removed the cuts and clean, Set the’’L’’ lever in close position ’’F’’ , Check alignement (10% thickness) and the le parallelism of the surfaces to be welded (with a

maxiamum up to 0,5 mm below diameter 400mm), In cas of misalignement corrected with the clamps and process again all the previous steps, Set the’’L’’ lever in open position’’O’’: the mobile part open to allows heating element to be set,

ATTENTION : Surfaces to be welded do not have to be hand touch, in this case clean again.



8.7. STEP 1 : BEAD UP

After checking the temperature of the heating element, set it in poistion, Place and block the ’’BP’’ lever in close position P, Set the ’’L’’ lever to close position’’F’’, the mobile part will close to set under pressure the

surface to be welded to create the bead, Start the chronometer , Respect the recommanded size of the bead,

8.8. STEP 2 : HEATING

Stop the chronometer and start it for the step 2, Bring’’BP’’ lever on O to let only the drag force’’f ’’ indicated on’’M’’ manometer, Note the time to obtain the bead up step, The step’’Heating » is mainatin during the indicated time, At the end of this step, pass to next one.

8.9. STEP 3 : HEATING ELEMENT EXTRACTION

Open mobile part using ’’L’’ lever in position’’O’’ and ’’BP’’ lever, Remove the heating element, or let the heating element extarct it self if the unit is equipped with

an automatic disposal.

8.10. STEP 4 : WELDING - COOLING

Set’’L’’ level in closing poistion’’F’’ and smoothly close (clock wize) the ’’BP’’ lever to obtain the welding pressure. When the pressure ’’P’’ is reached start the chronometer for the step 4. Decrease pressure if needed for tyhe step 5 and start again the chronometer.

Attention : It is strictly forbiden to cool down the weld using water, air, or other In case of same type of weld for the same diemeters, surface, length, poistion and presentation of elements, when the drag force is the same, it is possible to reproduce the welds using the pre-set values and using only on ’’BP’’ lever for the steps (Scraping, closing in step 2 and step 4). The others steps are done only by opening-closing the mobile part using ’’L’’ lever.



8.11. LISTE OF CONTROLS AND ACTIONS FOR USE OF THE SIMPLIFIED SEMI-AUTOMATIC MODE FOR IDENTICAL AND REPETITIF WELDS

Pressure

P1 Bead Up P5 : Welding P6 : Cooling P6 P2 Chauffage Time

Drag force

t1 t2 t3 t4 t5 t6

Typical profil during a weld

PREPARATION : After the check : Compatibility of the power supply Electrical on hydraulic connection are done Frame is equipped with good reducers in regard with nominal diameter Blades are sharp Heating element plate are non scraped and without external components (Sand, mud) Having all the parameters

. Jack Surface : Sc, (S/cm2 indicated on the jacks)

. Used standard : DVS, UNI, GASTECH, etc…

. PE type PE : PE 80, PE 100, etc…

. Temperature

. Size, diameter and thickness of the elements 2 extremities to be welded are clean

Process as follows : On the chronometer (3 times and displays)

. Set to zero the 3 times

. Enter on time 2 the Heating time

. Enter on time 3 the Welding-Cooling time



Electro-hydraulic . Switch On . With O/F lever set the mobile part to a full open situation . Close and block the BY-PASS . Set to zeo the pressure regulator

Frame . install elements to be welded (check for ovalisation)

Heating element . Swicth on and adjust the temperature in regard with the standard used

Scraper . If the scraper is equipped with two speeds used the slow speed for large diameters

WELDING CYCLE :

Drage force (minimale force to move the mobile part with component) Set the O/F lever to close position Smoothly increase the pressure up to move the mobile part Note the value of the pressure on the manometer indicator

Memorization of the common pressure for the Bead Up and Cooling steps (Following the previous step) O/F lever in close position F, let the mobile part finish the closing of the frame Smoothly increase the pressure to reach the indicated force of the standard added with the drag force Lock the position using the nut when the pressure is reached THE PRESSURE IS MEMORIZED Open the frame using O/F lever in open position, up to full opening

Scraping Set the scraper inside the frame (tacking care of the micro-contactor) Start the scaper Open the BY-PASS, Set the O/F lever to close the mobile part on the scraper, Increase smoothly the pressure using the BY-PASS to display on the manometer the pressure to start the cut Wait to obtain a continuous cut on both faces Open the frame using O/F lever on Open position Stop the scraper and wait end of the rotation Unlock and removed the scraper Nota :



Using the locking system On specific equipment a 3 places locking system allows : - Set on the middle, symetrical scraping off the two faces - Set on one of the extremities of the system scraping only on one face up to the difference is scraped. Extremities Alignement Set the O/F lever to close the mobile part, Check the alignement, Adjust using the upper clamps, Set the O/F lever to open position, up a full open Open the BY PASS Heating Be sure the BY-PASS is fully open Set the O/F inc lose poistion, and smoothlu closed using the BY-PASS to ontain the pressure necessary for the closing of

the mobile part, check that it is the same than the previous drag force perssure. Open 2 cm from it initial position Place the Heating element after checking the temperature set is reached In case of automatic Heating element set it down and lock it Close fully the BY-PASS Using the O/F lever close the mobile part to set in contact elements and heating element plate, start chronometer 1 Wait the creation and the size of the bead Stop chronometer 1 when the size bead is reached Start the count down for the chronometer 2, and decreased the pressure to the value indicated by the BY-PASS During the count down, note the time indiated in the chronometer 1 Welding When the end of the count down is reached, set O/F lever to open allowing to extract the heating element (automaticaly

done when using an automatic extraction heating element) When the heating element is removed inverse the O/F lever to close the mobile part Smoothly apply the pressure using the by-pass up to obtain the total pressure Cooling Start on the same time the count down of chronometer 3 Wait the count down is finished : Weld is done Unlock the clamps and removed the weld Nota : - O/F lever can be set to neutral poistion to stabilize the pressure inside the hydraulic circuit - Control of the pressure is done use the manometer. A correction factor can be nessecary in regard with internal leak - In particular conditions, a releasing step of laterial is recommanded. Can be realized during the cooling time by

decreasing the pressure using the BY-PASS lever in regard with the indicated value.

REPRODUCTION :

When an end user is involved on the process by following the operations ; Opening, closing, starting the 3 preset time, and setting the BY-PASS lever with pressure control, mainly the drag force, this mode called simplified semi-automatic is adapted to work in site with repetition of welds with identical parametres.



A helpfull system to repeat of such weld can be used by creation downloading using our computerized system PROTOFUSE.

8.12. PROTOFUSE OPTION Recording and downloading control box Protofuse is dirtectly connected to a pressure sensor and to the heating element, controlling and regulating the temperature. Also it is used for time control of the steps. Allowing the reproduction of time and pressure of the different steps. After each new weld the previous values memorized are suggest and if exceedind on a gap, an error is indicated. As an option barcode can be added for data acquisition such operator or components tracability.



9. SCHEMAS

9.1. HYDRAULIC SCHEMA



9.2. HEATING ELEMENT SCHEMA Probe Pink Pink White 2 1 8 7 5 4 Relay 3 4 5 6 6 1 230V

9.3. HYDRAULIC ELECTRICAL SCHEMA Main switch Interruptor motor

Motor 230V

9.4. SCRAPER ELECTRICAL SCHEMA RABOT Micro contact Scraper Main Swicth Motor Scraper 230 V



10. STANDARD

10.1. DVS For all the calculation following symbols are used : S = Surface to be welded in mm² = Pi (Dn² - Di²) / 4 Sc = Jack Surface in mm²

P1 P5 P2

Time t1 t2 t3 t4 t5 e : Thickness du tube Dn : Nominal Diameter Di : Inside Diameter (Dn - 2e) Sc : Jack Surface in mm² (4,32cm², 5,88 cm², 8,46 cm²) b : Bead Size =0,5 + (0,1 e) mm T : Heating Element Temperature : See Table P1 : Bead Up =0,15 (S / Sc) x 10 (bar) P2 : Heating = 0,02 (S / Sc) x 10 (bar) P5 : Welding – Cooling = 0,15 (S / Sc) x 10 (bar) t1 : Bead - Up = See Table t2 : Heating = See Table t3 : Heating Element Removal = See Table t4 : Pressure Up maximum = See Table t5 : Welding = See Table


PPIIPPEEFFUUSSEE SSYYSSTTEEMM

29/43

ANNEXE A :

SPARE PARTS



Machine code Component name Drawing Number PIPEFUSE 160 TO PIPEFUSE 355

45° FRAME FRAME Table n. 1


FRAME WITH POSSIBILITY OF AUTOMATIC HEATING ELEMENT

FRAME Table n. 1



Component name Drawing number Cylinder Table n. 1/A

TABLE. 1/A CYLINDER NO. DESCRIPTION 1 Scraper ring 2 Bearing 3 Cylinder head 4 Rod seal 5 O Ring 6 Piston o ring 7 Seal 8 Cylinder housing 9 Piston stopper 10 Cylinder rod A Plug

TABLE. 1 FRAME NO. DESCRIPTION 1 Left side head 2 Screws 3 Nut 4+5 First lower – Upper clamp 6 Cylinder the rod 7 Fitting 1/4 8 cylinders 9 Quick coupling 1/4 10 Labels 11+12 Second lower- upper clamp 13 Screws 14+15 Third lower- upper clamp 16 Screws 17 Spacer 18 Bearing 19+20 Fourth lower – upper clamp 21 screws for cylinder locking 22 Brass bolt 23 Washer 24 The rod 25 Pivot 26 Stopper 27 Long screw 28 Spacer 29 screws 30 pin




MANUAL HEATING ELEMENT TYPE A

Table n. 2


AUTOMATIC MANUAL

HEATING ELEMENT Table n. 2



TABLE. 2 Heating Element No. DESCRIPTION 1 thermometer 2 screws 3 Ring 4 Thermometer box 5 Seal 6 screws 7 Connecting blocks 8 Handle 9 Cable housing 10 cable neoprene 11 Heating element 12 probe 13 Plate 14 Spacer 15 screws 16 Plate 17 Handles box 18 Handle 19 Thermostat cover 20 thermostat 21 Power light 22 screws 23 Thermostat box 24 relay 25 Connection 26 Cable housing 27 Cable neoprene 28 plug 29 Locking 30 Plate for box 31 Screw 32 Ring 33 Heat sink 34 Screw for relay

TABLE. 2 Heating Element No. DESCRIPTION 35 Screw 36 Heat dissipation 37 Protection plate 38 Heating element screw 39 Spring holder 40 Spring 41 Frame 42 Handle 43 Handle cover 44 Handle axis 45 Heating plate protection 46 Cap 47 Roller 48 Roller 49 Stopper 50 Opening sensor 51 Axis roller 52 Sensor rod 53 Handle axis 54 Handle triangle 55 56 Handle triangle axis 57 Connection with handle 58 Rod for handle 59 Handle 60 Axis for rod 61 Axis for spring 62 Spring 63 Ring 64 Connection plug 65 Connection 66 Thermometer cover plate 67 Heating Element screw




SUPPORT FOR

MANUAL HEATING ELEMENT

Table n. 2.A


SUPPORT FOR

AUTOMATIC HEATING ELEMENT

Table n. 2.A





TABLE. 2/A SUPPORT PT250 No.. DESCRIPTION 1 Transport handle 2 Nut 3 Ring 4 Roller axis 5 Roller 6 U 7 Spacer 8 Protection Plate 9 Thermoregulation support 10 Roller 11 Roller 12 Screw 13 Pipe 14 Cap 15 Enclosure for connection 16 Heating Element connection 17 Cable housing 18 Cable 19 Cable housing 20 Primary cable 21 Plug 22 Locking 23 Box Cover 24 Cable housing 25 Relay 26 Cable housing locker 27 Cable housing locker 28 Cable housing locker 29 Box 30 Light 31 Thermostat 32 Thermostat cover 33 Electrical plug 34 Box 35 Cable 36 Cable housing 37 Support frame




SCRAPER Table n. 3







TABLE 3 SCRAPER No. DESCRIPTION 1 Body 2 Bearing 3 Wheel 4 Flange 5 Screws 6 Disk 7 Screws 8 Blade 9 Screws 10 Screws 11 Cable stopper 12 Cable stopper 13 Screws 14 micro switch 15 Stopper pin 16 Spring 17 Seeger Ring 18 Pivot 19 Nut 20 Lever 21 Pawl 22 drill 23 Joint 24 Seeger ring 25 Bearing 26 Worm screw 27 Bearing 28 Bearing 29 Disk 30 Screws 31 Pawl 32 Pawl 33 Cable stopper 34 Terminal connector 35 Screws 36 Cover box 37 Screws 38 Gasket 39 Screws 40 Washer 41 Cable holder 42 Cable neoprene 43 Screws

TABLE 3 SCRAPER No. DESCRIPTION 44

45 Washer 46 Spacer handle 5 47 Stopper 48 Support for micro switch

box 49 Micro switch box 50 Cable stopper 51 Micro switch cable 52 Micro switch Cable holder 53 Screw 54 Screw 55 Ring 56 Locking rod 57 Locking chain 58 Screw 59 Gear axis 60 Chain Connecting link 61 Chain 62 Chain Sprocket (gear) 63 Plate 64 Screw 65 Locking screw 66 Locking nut 67 Screw 68 Distribution block 69 Locking pin 70 Engine 71 Handle screw 72 Handle 73 Gear 74 Tensor 75 Screw 76 Plate 77 Connectors 78 Connectors 79 Cable stopper 80 Handle Screw 81 Handle 82 Ring 83 Locking ring



MANUFACTURER

CTF FRANCE S.A.S

Zl les bordes 91070 BONDOUFLE - FRANCE

PhoneTel : 33(0) 1 69 91 48 00

Fax : 33(0) 1 69 91 48 19

Email: [email protected] Web : www.j-sauron.com



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