Manual Con Tablas OMISA

8/12/2019 Manual Con Tablas OMISA

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O.M.I.S.A. S.R.L.Via Carlo Porta, 9 20050 Sovico

(Milano) ITALY

USE AND MAINTENANCEINSTRUCTION MANUAL

Butt welding machine to weld pressure pipes andfittings in thermoplastic material

Welding machine type:

SP630Serial number:

Year of manufacture:

Version 1 / 2004


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Dear Client,

We congratulate You for choosing this O.M.I.S.A. weldingmachine !

We prepared this instruction manual in order You to fullyappreciate the top quality of our product.You will find into all the needed information and warning for a safeand proper use.We wish to advice You to read it before getting ready to use.We are sure it will be easy to acquire familiarity with Your newequipment using it for long time with great satisfaction.

Cordially O.M.I.S.A. S.R.L.


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Use and Maintenance Instruction Manual SP630 VERSION 1/2004

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INDEX

Pag.

General description of the machine. 4

Transport mean. 6

Technical features. 7

Safety instructions. 8

Work station environment condition. 8

Scheduled maintenance. 9

Contrary direction in using the machine. 10

Inconvenience and solution. 10

Disposal. 11

Welding setting. 12

Welding operation. 14

Example. 16

Welding parameter table 17

Technical drawings and list. 21

Electrical draft. 41

Hydraulic draft. 42

Declaration of conformity. 43

Warranty condition. 44

Text, diagrams and data are correct at time of going to print. In the interest of continuos improvement of our products,technical specifications are subject to alteration without prior notice.


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GENERAL DESCRIPTION OF THE MACHINE

The SP 630 welding machine was projected and manufactured for welding pipesand fittings in thermoplastic material of stated diameters.In this instruction manual we are suppling technical features about polyethylene(PE) and polypropylene (PP) pipes welding. For other materials it is needed tomake qualification test of the welding process in order to assure a perfectperformance.This welding machine is composed by: Basic machine. Thermoelement. Hydraulic unit. Electric planing tool. Steel box for thermoelement and electric planing tool. Reduction rings.

Basic machine:It is composed by a support frame; two hydraulic cylinders (resistant to corrosionand to accidental blows) parallel between them and opposed to axis of pipes toweld, which act as slide guide; four aluminium clamps containing the reductionsof each diameter of pipes and/or fittings to be welded, that make up twocarriages: one fixed and one moving of 630 mm diameter.The fixed carriage can vary its dimension by two combs which operate in outerpart of the clamps. In this manner the SP630 machine can make particularweldings (Ex.: tees, bends, flange necks).On the support frame two holes are made in order to allow an easy movement ofthe machine by using proper means (hooks, metal rope). In this way will beeasier to move the machine.The structure of the basic machine is atmospheric agent resistant.

Thermoelement:The thermoelment should be exclusively connected to its thermostat electric box .The heating plate is supplied with an electronic thermostat for keeping thetemperature stated at 215C during the testing stage.In order to adjust the thermoelement temperature, operate on the P button and

through the two button in order to increase or decrease the value shown(adjusted temperature). When the needed temperature is adjusted, operate onthe P button. The display show a lead on the reference - = + that indicate if theadjusted temperature is lower, same or higher than the one setted.

Fig.1


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The thermoelement is covered by PTFE (polytetrafluorethylene) between 30 and50 micron, that allow a better separation of the parts to be welded and at thesame time keep the thermoelement clean.Please note that in order to avoid risk of burns getting in touch with the hot plate,it is recommended to wear proper cloth (long trousers, long sleeved jacket,antiwarm safety gloves). Thanks to the use of a thermoinsulating material, theoperator shall not have any difficult handling the thermoplate in the proper zone,where a suitable temperature is always kept.It is recommended to disconnect current from the electric box, before connectingor disconnecting the thermoelement.Store the thermoelement in its proper box, when not used.

Hydraulic unit:The hydraulic unit placed on a frame has been realized to be as much handly

and solid as possible. The hydraulic unit permits through two hydraulic cylinders,the movement of a carriage. Every movement of the machine is well marked by awarning horn. The hydraulic unit can reach a maximum pressure of about 160bar and, thanks to a particular relief valve (valve A, pict 2), can be stated theexpected pressure with a sensivity of about 1 bar.The pressure formulation is countinuous and can get increasing or decreasingvalues; in the meantime the hydraulic unit of the welding machine, once fixed bycriterion the wished pressure for all welding stages, can keep steady the statedtemperature.This happens when the machine is switch off and in an automatic way, withoutany manual operation.

The hydraulic unit is equipped with a by-pass valve (valve B, pict 2), if it isopened, it makes the pressure decreasing (anticlockwise way rotation) while if itis closed, it makes the pressure increasing (clockwise way rotation) untill whenthe stated pressure is reached by closing it through the pressure adjustmentvalve. The by-pass valve makes the welding operation easier and reduce thepossibility of making mistakes during welding stages by the operator.

Electric planing tool:It allows a fast parallel plane surface butt of both the extremity of pipes and/orfittings to be welded. It is equipped with two safety devices: a mechanical oneand an electrical one. The first one allow to lock it to the basic machine, in orderto avoid that the electric planing tool comes out during its using.The second one (microswitch) avoid blade rotation when the electric planing toolis taken out from the basic machine.During planing operation it should be given a maximum pressure of 10-12 bar.Blades are placed 180 the one to each other. They are also sharpened on bothside. In order to use the second sharpened side it will be needed only to turnthem.In any case do not sharpen the blades, as it could cause a bad electric planingtool operation.Make sure that the panel you are using comply with the electric planing toolfeatures and that there is the earthing. Do not leave the equipment exposed toatmospheric agent and always store it in its proper steel box, when not used.


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Steel box for thermoelement and electric planing tool:It was manufactured in order to transport and store the thermoelement andelectric planing tool when not used.It allow to preserve in good condition this two equipment as also their bestperformance. It help also to keep the working station in order and makes easierthe welding operation.It is recommended to store thermoelement and electric planing tool in it when notused.

Reduction rings:The reduction rings are manufactured in aluminium moulds and they allow analmost complete clamping of the pipes and/or fittings to be welded, withoutdamage them.

TRANSPORT MEAN

The machine is supplied already mounted and in a position to work. In order toavoid damages during transportation, the machine is protected by a properpacking.

After receive it, unpack the machine and inform the transport company aboutfurther occurred damages. As you can note from the technical features, the greatweight of the machine and its parts, required a movement by using mechanicalmeans.


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TECHNICAL FEATURES:

Dimension:

Basic machine dimensions. 1200x900x900 mmBasic machine weight. 145 Kg

Thermoelement dimensions. 800x1050x60 mmThermoelement weight. 37,5 Kg

Hydraulic unit dimension. 550x450x330 mmHydraulic unit weight. 34 Kg

Electric planing tool dimensions. 830x230x1000 mmElectric planing tool weight 98 Kg

Flexible hydraulic pipes dimensions and weight. 4 m / 1,5 Kg

Reduction set total weight. 250 Kg

Electrical:

VoltageMaximum absorbed power. 400V / 50-60Hz / 10,65kW

Thermoelement. 400V / 50-60Hz / 8,1kW

Hydraulic unit pump. 240V / 50-60Hz / 0,75kWElectric planing tool. 240V / 50-60Hz / 1,8kW

Hydraulic:

Maximum working pressure. 160 bar

Hydraulic unit pump. 1,7cm 2,3l/min 1400g/min

Cylinders total thrust section. 1413mm

Manometer class, range and dimension. Cl.1 0 160 bar 100mm

Oil type and quantity. ISO 68 2,5l

General:

Carriage stroke. 242 mm

Electric planing tool transmission. chain

Electronic temperature adjustment. 50C 300C


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SAFETY INSTRUCTIONS

WARNING ! This instruction manual is intended for the maintenance and usingstaff of the SP630; therefore it is important that the operator reads the reporteddescription. Follow carefully the indication herewith enclosed in order to avoidunpleasant mistakes during welding operation and damages to the machine.

WORK STATION ENVIRONMENT CONDITION

The use of any mechanic and electric instrument, requires the observance ofsome basic rules:- Keep clean the work station and the equipment.- Do not use the machine with infiammable liquids, gas, chemical and/or

corrosive agents.

- Always make attention during welding machine operation.- The welding machine should be used by qualified personnel (in italy UNI9737) and should not remain unguarded.

- Take care of the feeding cables of the thermoelement, electric planing tooland hydraulic unit. They do not have to be knotted, crushed or turn aroundthe equipmant.

- Do not use extension if possible.- Make sure that the used electric panel comply with the electrical features

of the hydraulic unit and that it is equipped of earthing.- Store the thermoelement and electric planing tool in their proper steel box,

if not used.- Never touch and sharpen the electric planing tool blades, this operation

would cause a bad working of the electric planing tool as the blades wouldgo inevitably undersize.

- Always wear proper clothes. For maintenance operation long trousers,safety antiheat, anticuts gloves and safety shoes. For building siteoperation: helmet.

- Do not wear scarfs, necklaces, watches, rings or every object that canentagled.

- Do not leave the machine exposed to atmospheric agents. Do not use themachine with unfavourable conditions (snow, fog, rain, high humidity ratea.s.o.).

- Respect safety working regulations in force in every country you are goingto use the machine.

- Foresee proper mechanical means for movement.

This welding machine has been designed and manufactured according to theEuropean regulation in force and to the specific rules relevant to the butt weldingmachines for making butt welding joint of pipes and/or fittings in polyethylene(PE) for combustible gas, water and other pressure fluids transportation - UNI10565.


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SCHEDULED MAINTENANCE

As the welding machine is a simple equipment, the scheduled maintenanceoperation are not too much, listed as follows:

- Clean completely the machine at the end of any job, especially if it is along one.

- Check the PTFE covering of the heating plate and its cleaning condition;cleaning of thermoelement surfaces should be done with a soft cloth whenthe heating plate is still warm (make this operation carefully) using safetyantiheat gloves.

- Check periodically the hydraulic oil level and fill it if needed, using the typeof oil written in this instruction manual. However, the oil level shouldalways exceed the pump level.

- Keep clean the quick release couplings of the oil pipes, impurities insidethe hydraulic circuit can damage the pump and cause oil losses andsudden pressure decreasing in the circuit, even if it is equipped of a filter,so in order to avoid what above written cover the quick release couplingswith their proper plugs supplied with the flexible hydraulic pipes on thebasic machine and on the hydraulic unit.

- Make sure that the sliding cylinder shaft are always clean and well grease.- Check further oil losses from the cylinder, quick release couplings,

hydraulic pipes and fittings of the hydraulic unit.- Check the correct operation stages of the planing tool and during use

check the blades sharpening.- Check the correct operation of the clamps locking system.- Check the functionality and gauging of the test instrument (manometer,

hydraulic unit and electronic thermostat).

In order to make the maintenance operation is required:

- UNPLUG THE FEEDING CABLE FROM THE ELECTRICAL SUPPLY inorder to properly insulate the electrical plant of the welding machine.

- Do not remove protection parts from the mobile pieces, if you dont have tooperate on them. At the end replace them in their correct position.

In any case the welding machine should be subjected to a complete overhaulevery 2 years. In this occasion, all the test foreseen from the standard UNI10565 should be done again and should be confirmed the comply with theforeseen requirement declared by the manufacturer or by the institution in chargeto make these tests.


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CONTRARY DIRECTION IN USING THE MACHINE

The machine was designed for welding pipes and/or fittings in thermoplasticmaterial, so it should be NOT used for jointing other materials.The top part of the machine is NOT load bearing, so it can not bear heavy or walkon it.

INCONVENIENCE AND SOLUTION

INCONVENIENCE SOLUTION

The machine does not work. Check that:1. The electrical plant is connected and comply

with the machine technical features and

requirement.2. Switches at the beginning of the plug and onthe machine are closed.

3. The emergency stop devices aredisconnected.

4. The electrical plant is not averaged; ifneeded, make the plant checked byqualified staff.

The hydraulic unitdoes not work. Check that:

1. The electrical supply is connected andcomply with the welding machine technicalfeatures and requirement

2. The motor fuse is integral (harness box ofthe motor).

3. The distributor piston work correctly on themicroswitch.

The hydraulic unit does notIncrease pressure or doesnot keep steady pressure. Check that:

1. There are any oil losses in the circuit (pipes,quick release couplings, manometer,accumulator, a.s.o.)

2. The oil level of the hydraulic unit tank shouldexceed the pump level.

3. The by-pass valve of the hydraulic unitshould be closed.


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INCONVENIENCE SOLUTION

Check that:4. Disconnecting the hydraulic unit to the basic

machine by the oil pipes the problem shouldbe solved. The hydraulic unit increasepressure or keep it steady:

check the inner seal of both cylinders ofthe basic machine (send the machineback to the manufacturer or to anauthorized dealer).

5. Separate the hydraulic unit of the basicmachine disconnecting the oil pipes theproblem is not solved:

check the inner seal of both cylinders ofthe basic machine and the hydraulicparts of the hydraulic unit (send the basicmachine and hydraulic unit back to themanufacturer or to an authorized dealer).

Not correct thermoelementtemperature. Check that:

1. The thermoelement is duly connected to thethermostat electric box through themultipolar plug.

2. The temperature adjustment of theelectronic thermostat is the one required(Pag.4 thermoelement).

The electric planing tooldoes not face Check that:

1. The blades sharpening on the two rotationplate are in good condition.

DISPOSAL

As the machine is manufactured by normal metal material, in case of scraping itwill be needed only to deliver it to authorized scraping component separatingcentre.

The hydraulic oil should be sent to the disposal and reconditioning institution.


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WELDING SETTING

This welding machine is exclusively intended to weld pipe and/or fittings inthermoplastic material; any other use is improper and dangerous and shallabsolute exclude the manufacturer from any liability.

Before feeding the electric box, make sure that the electric panel comply to theregulations in force and corresponds to the electric requirements of the weldingmachine. After this operation, the thermoplate can be connected to the properoutlet on the electric box. Connecting the flexible oil pipes, check that the quickrelease couplings are clean.State the required temperature on the electronic thermostat depending on thematerial, diameter and thickness of the pipes and/or fittings to be welded (seepag.4 with reference to the thermoelement); then wait that the thermoelement

reach the stated working temperature. According to the pipes and/or fittings to be welded, insert the correspondentreductions inside the jaws. Make sure to fix them by using the supplied screwsand keys.Put the pipes and/or fittings to be welded inside the clamps and make sure thatthere is enough space for the following facing and heating operation and closemoderately the closing nut. Tightening or loosing the closing nut, it is possible torecover some defect on the pipe roundness; it is allowed a maximum differenceon the pipes concentricity of 10% of their thickness. Make sure that the pipes arewell clamped inside the jaws.Before proceeding to the real welding operation, it is necessary to make the

facing of pipes and/or fittings. Act on the distributor control lever of the hydraulicunit (lever C pict 2), near the manometer, until when the moving carriage iscompletely opened and turn completely anticlockwise the pressure adjustmentvalve (valve A pict 2)Then, insert the electric planing tool placing it on the two hydraulic cylindersshaft. Take the facing tool only by using the proper handle and never from therotation plates where blades are housed; remember to turn of 90 the antireleasedevice. Please also note that the electric planing tool is equipped with amicroswitch that prevent accidental starting of the electric motor and theconsequently blade plate rotation. Before proceeding to the facing operation, weadvice you to check the pipes and/or fittings to be faced. If needed, clean themfrom external parts (like little stones) that could damage the blade sharpening.Operate on the distributor control lever and at the same time turn clockwise thepressure relief valve until the carriage starts moving. When the pipes and/orfittings end get in touch with the electric planing tool, the pressure on themanometer MUST NOT BE HIGHER THAN 10 BAR.The planing operation is finished when the chip is countinuous and of the samethickness of the pipes and/or fitting. Take out the electric planing tool and store itin its proper box.


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Bring the two extremity to be welded in touch to each other giving a pressure alittle higher then the welding one, in order to check the correct pipes and/orfittings in the clamps closure, their concentricity and the right result of the planingoperation.

MOVEMENT PRESSURE ADJUSTMENT

Open the machine and return the pressure back to zero, turning completelyanticlockwise the pressure adjustment valve (valve A pict 2) and make sure thatthe by-pass valve (valve B pict 2) is completely closed.Place the distributor control lever (lever C pict 2) in position and slowlyturn clockwise the pressure adjustment valve (valve A pict 2), until when thecarriage starts moving; the pressure shown on the manometer during this stageis the movement pressure

The movement pressure must be added to the welding pressure shown onthe welding table and MUST BE TAKEN BEFORE EACH WELDING.The welding pressure is stated by adding the movement pressure and thewelding pressure indicated on the welding table.

Now the real welding operation can start that are developed in this main stages:

Approach and first heating, bead formation. Heating. Thermoelement extraction. Welding pressure reachment. Welding. Cooling.

We advice you to place the equipment in such way to work free within therequired time, to avoid wrong operation that will cause a bad result of welding; itis recommended to make some test before operating.


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WELDING OPERATION

Approach and first heating, bead formation

Make sure to reach the stated working temperature. Place the thermoelementbetween the two pipes and/or fittings to be welded, laying it to the slide guide inorder to use the automatic breakaway. In fact it will separate the two heated partsfrom the thermoelement when the heathing stage will be finished.Bring the end of the pipes and/or fittings in touch to the thermoelement to theprevious adjusted welding pressure (movement pressure + welding pressure) byacting on the distributor control lever of the hydraulic unit (lever C pict 2) inposition through the pressure adjustment valve (valve A pict 2). Makesure that the by-pass valve (valve B pict 2) is completed closed, until when thebead thickness required from the table is reached.

Then open the by-pass valve (valve B pict 2) turning it anticlockwise, in order todecrease the pressure up to approximative zero

Fig.2Heating

During this stage, the extremity to be welded will be kept in touch to thethermoelement for the time and pressure mentioned on the table.

Thermoelement extraction

When the heating time is passed, open the machine by operating on thedistributor control lever (lever C pict 2) in position , take out thethermoelement and store it in its proper box. Be careful to the high temperatureof the thermoelement. The time passed from the thermoelement extraction andthe jointing of the parts to be welded, MUST be as foreseen from the table.


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Welding pressure reachment

Place the distributor control lever (lever C pict 2) in position and turn

clockwise the by-pass valve (valve B pict 2) in order to reach the weldingpressure (movement pressure + table pressure) previously stated through thepressure adjustment valve (valve A pict 2). Increase pressure step by step andwithin the time required on the table.

After reaching the welding pressure, keep the distributor lever for about 10seconds in position and in the meantime, increase some bar of pressure,through the pressure adjustment valve (valve A pict.2). By using the adjustmentvalve bring the pressure immediately back to the stated pressure. Then leave thedistributor control lever; this will allow you to the stated pressure. Then leave thedistributor control lever; this will allow you to obtain a more steady pressure valueduring time. In any case if the pressure should decrease of some bar, reset it

acting on the distributor lever (lever C pict 2) giving short impulse to the position .

Cooling

During this stage, the welding pressure previously reached should be kept steadyfor the whole cooling time written on the table. It is not allowed to cool thewelding with water, air or other.

After passing the cooling time written on the table, reset pressure by actinganticlockwise on the by-pass valve (valve B pict 2) decreasing pressure near tozero.Now it is possible to take out from the basic machine the welded joint.

WARNING !

Before moving the equipment for next welding, make sure to disconnect all theelectrical network part and disconnect the different articles of the weldingmachine.

Repeat all operation above written for next welding.


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EXAMPLE:

Welding parameters for 450mm PE100 pipe, 26,7mm thickness PN10 SDR17,with reference to the UNI10967:2001 standard.

Thermoelement temperature. 230CMovement pressure ( P t ). 6 barBead / welding pressure of table ( P 1 e P 5 ). 37,7 barTotal pressure of stage 1 and stage 5 to adjustOn the hydraulic unit manometer ( P 1 + P t ) and ( P 5 + P t ). 43,7 bar

Welding cycle graphic with double pressure for butt welding of pipes and/orfittings in Polyethylene type PE 100 for 20mm thickness.

Stage 1: Approach and first heating, P 1 + P t (43,7bar) for enough t 1 in order toallow to both side to be welded the bead formation of about 3mm.Stage 2: Heating for t 2 (327sec.) at P 2 (5bar).Stage 3: Thermoelement extraction t 3 (less then 10sec.) time passed from thethermoelement extraction and get in touch of both sides.Stage 4: Welding pressure reachment, gradual increase of pressure to the P 5 +P t value (43,7bar) in order to avoid an exceed soft material exit from both nearsides. Anyhow the maximum time is t 4 (10sec.)Stage 5 e 6: Welding, keep the sides in touch to each other P 5 + P t (43,7bar) fort5 (10sec.), then decrease the pressure P 6 (12,6bar) and keep the two sides intouch to each other for t 6 (30min.)Fase 7: cooling, the welded joint can be taken out from the welding machine.During extraction and until complete cooling time t 7 (40min.), the joint should beprotected from atmospheric agents (rain, wind, excess sun radiance a.s.o.).


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Welding table refer to the UNI 10520 standardFor butt welding of PE pipes and fittings

Welding temperature 210C for thickness

12mm, 200C for thickness>

12mmPIPE DIAMETER 315 355 400 450 500 560 630

Wall thickness mm 12,2 13,7 15,4 17,4 19,3 21,6 24,3Inner diameter mm 290,6 327,6 369,2 415,2 461,4 516,8 581,4Welding surface mm 2 11600 14682 18598 23636 29131 36516 46216Bead / welding pressure bar 12,3 15,6 19,7 25,1 30,9 38,8 49,1Heathing pressure bar 1,6 2,1 2,6 3,3 4,1 5,2 6,5Bead thickness mm 2 2 2 2 2 3 3Heating time sec 146 164 185 209 232 259 292Thermoelement extraction time sec 8 8 9 9 10 10 11Pressure increase time sec 9 9 10 11 12 13 14

P N

4 / S D R

2 6

Cooling time min 15 17 18 20 22 25 27

PIPE DIAMETER 315 355 400 450 500 560 630Wall thickness mm 17,9 20,1 22,7 25,5 28,3 31,7 35,7Inner diameter mm 279,2 314,8 354,6 399 443,4 496,6 558,6Welding surface mm 2 16699 21137 26893 33990 41916 52586 66619Bead / welding pressure bar 17,7 22,4 28,5 36,1 44,5 55,8 70,7Heathing pressure bar 2,4 3 3,8 4,8 5,9 7,4 9,4Bead thickness mm 2 3 3 3 3 4 4Heating time sec 215 241 272 306 340 380 428Thermoelement extraction time sec 9 10 11 12 12 14 15Pressure increase time sec 11 12 13 14 15 17 18

P N

6 / S D R

1 7

, 6

Cooling time min 21 23 26 29 31 35 39

PIPE DIAMETER 315 355 400 450 500 560 630Wall thickness mm 28,7 32,3 36,4 41 45,5 51 57,3Inner diameter mm 257,6 290,4 327,2 368 409 458 515,4Welding surface mm 2 25801 32729 41588 52655 64934 81511 103041Bead / welding pressure bar 27,4 34,7 44,1 55,9 68,9 86,5 109,4Heathing pressure bar 3,7 4,6 5,9 7,5 9,2 11,5 14,6Bead thickness mm 3 4 4 5 5 6 6Heating time sec 344 388 437 492 546 612 688Thermoelement extraction time sec 13 14 15 16 18 19 21Pressure increase time sec 15 17 19 20 22 24 27

P N

1 0 / S D R

1 1

Cooling time min 32 35 39 44 49 54 60

PIPE DIAMETER 315 355 400 450 500 560 630Wall thickness mm 43,4 49 55,2Inner diameter mm 228,2 257 289,6Welding surface mm 2 37013 47081 59763Bead / welding pressure bar 39,3 50 63,4Heathing pressure bar 5,2 6,7 8,5Bead thickness mm 5 5 6Heating time sec 521 588 662Thermoelement extraction time sec 17 19 21Pressure increase time sec 21 24 26

P N

1 6 / S D R 7

, 4

Cooling time min 46 52 58


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Welding table refer to the UNI 10967 standardFor butt welding of PE100 pipes and fittings

Welding temperature 215C for thickness

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