BA - BH-160-250-315 - KPL 0714
BA - BH-160-250-315 - KPL 0714
BA - BH-160-250-315 - KPL 0714
1500050106
1500050107
OPERATION MANUAL
A
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2 3 4
B
4 3
1 2
C
1 2 3
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D
1 2 3 4
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2
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4
Intro
1. Brief 2
2. Special Description 2
3. Safety 2
3.1 Safety Marks 2
3.2 Precautions for Safety 2
3.3 Potential Dangers 4
4. Applicable Range and Technical Parameter 5
5. Descriptions 6
5.1 Basic frame 6
5.2 Hydraulic unit 6
6. Instruction for Use 6
6.1 Connection and preparation 7
6.2 Welding Steps 7
7. Timer and Temperature Controller 8
7.1 Timer setting 8
7.2 Instruction for Use 9
7.3 Temperature controller setting 9
8. Reference of Welding Standard (DVS2207-1-1995) 9
9. Frequent joints quality problems analyze 10
9.1 Maintenance 10
9.2 Inspection periods 11
9.3 How to adjust the deviation 11
10. Frequent malfunction analyses and solutions 13
11. Guarantee Clauses 15
12. Accessories list 16
12.1 SUPER-EGO BH 160 Value Butt Fusion Machine 16
12.2 SUPER-EGO BH 250 Value Butt Fusion Machine 17
12.3 SUPER-EGO BH 315 Value Butt Fusion Machine 18
ENGLISH 1
1. Brief
This manual is suit for SUPER-EGO BH 160/250/315 Value plastic pipe butt fusion welding machi-
ne. It’s suggested to read and follow carefully the following safety rules and maintenance rules
before operating the machine.
2. Special Description
Before operating the machine, anyone should read this description carefully and keep it
well to ensure the equipment and operator’s safety, as well as others’ safety.
1. The machine is used to weld pipes made from PE, PP, PVDF and cannot be used to weld ma-
terial without description, otherwise the machine may be damaged or some accident may be
resulted in.
2. Don’t use the machine in a place with potential hazard of explosion.
3. The machine should be operated by responsible, qualified and trained personnel.
4. The machine should be operated on a dry area. The protective measures should be adopted
when it is used in rain or on wet ground.
5. The machine is operated by 220V±10%, 50/60 Hz. If extended wire should be used, it should
have enough lead section according its length.
6. Before using the machine, fill 46# hydraulic oil. Make sure the hydraulic oil is enough for
working; the oil level should be 2/3 of the tank. Replace the iron oil tank cap by the red
plastic air bleed cap or the pressure cannot be hold.
3. Safety
3.1 Safety Marks
The following marks are fixed to the machine:
Hot! Keep distance from parts with this sign, for they are very hot!
Danger, Electrical shock! Parts with this sign have a danger of electricity leak. Be
careful when working here.
No approaching! Moving parts can crush. Keep fingers, feet, arms, legs, and head
out of the jaw area between the moving tables.
ENGLISH 3
When lift the machine to ditch, the weight of the machine should be within the rated lifting
weight, and person is forbidden staying under the lifting arm.
Avoid using the machine in the environment full of paint, gas, smoke and deoil, since the
infection of eyes and respiratory tract would be caused.
Do not put the machine in a dirty place.
10. Personnel safety while working
Remove jewelry and rings, and does not wear loose-fitting clothing avoid wearing shoe lace,
long mustache or long hair that may be hooked into the machine.
The following is the operation rules:
Wear earmuffs
Wear safety groove Never touch the surface of the heating plate
3. Planing tool
Before shaving the pipes, ends of pipes should be cleaned, especially clean the sand or other
draff crowed around the ends. By doing this, the lifetime of edge can be prolonged, and also
prevent the shavings are thrown out to danger people.
4 ENGLISH
4. Basic Frame:
Make sure the pipes or fittings are fixed correctly to get the right alignment. When joining
pipes, the operator should keep a certain space to the machine for personnel safety.
Before transporting, make sure all the clamps are fixed well and cannot fall down during
transportation.
Follow all the safety marks in the machine.
4. Applicable Range and Technical Parameter
ENGLISH 5
5. Descriptions
The machine consists of basic frame, hydraulic unit, heating plate, planing tool, and support.
Figure A
1 Hydraulic unit
2 Basic frame
3 Planing tool
4 Support
5 Heating plate
5.1 Basic frame
Figure B
1 Cylinder
2 Stub end device
3 Main clamp
4 Adjust screw
5.2 Hydraulic unit
Hydraulic unit (Figure C)
1 Direction valve
2 Pressure regulation valve
3 Pressure gauge
4 Swing check valve
5 Oil tank
6 Power cable
Hydraulic unit operation panel (Figure D)
1 Temperature controller
2 Ground fault interrupter
3 Voltmeter
4 Pressure gauge
5 Protection cover
6 Timer
7 T5
8 T2
Hydraulic unit sockets (Figure E)
1 Planing tool socket
2 Thermo couple interface
3 Heating plate socket
4 Data logger power
6. Instruction for Use
1. The whole equipment should be placed on a stable and dry plane to operate.
2. Before operation make sure the following things:
- The machine is in good conditions
- The power supply is the specified according to the butt fusion machine
- Power line is not broken or worn
- All instruments are normal
- The blades of planing tool are sharp
6 ENGLISH
- All necessary parts and tools are available
6.1 Connection and preparation
1. Connect the basic frame to hydraulic unit by quick couplers.
2. Connect the heating plate to the hydraulic unit with the special cable.
Connection the cable with electrical box Connection between the cable and heating plate
3. Install appropriate inserts to frame according to the outside diameter of pipes/fittings.
4. According to the requirements of fitting and welding process, set the temperature in tempe-
rature controller and set time in timer. (See section 7 this manual).
6.2 Welding Steps
1. Pipes
Before welding, firstly, check if the material and its pressure grade are the required ones.
Secondly check if there are scratches or fissures on the surface of pipes/fittings. If the depth
of scratches or fissures exceeds 10% of the wall thickness, cut the section of scratches or
fissures. Clean the pipe end’s surfaces with clean cloth to keep the pipe’s ends clean.
2. Clamping
Place the pipes/fittings in inserts of frame and keep the ends to be welded be the same
length (no effect on the planing and heating of the pipe). The pipe out of the basic frame
should be supported to the same central axial of clamps. Fasten the screws of clamps to fix
the pipes/fittings.
3. Adjust the pressure
Open fully the pressure regulation valve completely, lock the swing check valve tightly and
then push forward the direction valve meanwhile adjust the pressure regulation valve till the
cylinder begin to move, at this point the pressure in the system is the drag pressure.
Open the pressure regulation valve completely, lock the swing check valve tightly and then
push forward the direction valve meanwhile adjust the pressure regulation valve to set the
system pressure equals to drag pressure add butting pressure.
4. Planing
Open the pipes/fittings ends after turning swing check valve anti-clockwise to the end. Put
the planing tool between the pipes/fittings ends and switch it on, close the pipes/fittings ends
by acting on the direction valve meanwhile slowly turn swing check valve clockwise until
there are continuous shavings appearing on both sides. Turn the swing valve anti clockwise to
relief the pressure, in a moment later open the frame, switch off planing tool and remove it.
ENGLISH 7
Close the pipes/fitting ends and checks the alignment of them. The maximal misalignment
should not exceed 10% of the wall thickness, and it could be improved by loosening or tigh-
tening the screws of clamps. The gap between two pipe ends should not exceed 10% of wall
thickness; otherwise the pipes/fittings should be planed again.
Caution: The shavings thickness should be within 0.2 ~ 0.5 mm and it can be adjusted by
adjusting the height of the planing tool blades.
5. Heating
Clear the dust or slit on the surface of heating plate (Caution: Don’t damage PTFE layer on
the surface of heating plate.), and make sure the temperature has reached the required one.
Put the heating plate between the pipe ends after it reaches required temperature. Close the
pipes / fittings ends by operating direction valve and raise the pressure to specified pressure
by swinging pressure regulation valve till the bead reaches specified height.
Turn swing check valve anti-clockwise to reduce the pressure (not more than drag pressure)
and turn swing check valve in clockwise direction to the end.
Press the button “T2”, the soaking time begins to count and the time will count down to
zero by second, then the buzzer will buzz (see section 7).
6. Joining and cooling
Open the frame and take out the heating plate and close two melting ends as quickly as
possible.
Keep the bar of direction valve on the close position for 2 ~ 3 minutes, put the bar of direc-
tion valve on middle position and press the button (“T5”) to count cooling time until it is
over. At this point, the machine will give an alarm again. Relief the pressure, loose the screw
of clamps and then take out the jointed pipes.
7. Timer and Temperature Controller
If one of the parameters is changed, such as outside diameter, SDR or material of pipes, the
soaking time and cooling time should be reset according to the welding standard.
7.1 Timer setting
8 ENGLISH
7.2 Instruction for Use
ENGLISH 9
Wall Bead Bead Soaking Soaking Change- Pressure Welding Cooling
thickness height build-up time t2 pressure over time build-up pressure time t5
(mm) (mm) pressure (sec) (MPa) t3 (sec) time t4 (MPa) (min)
(MPa) (sec)
0 ~ 4.5 0.5 0.15 45 ≤ 0.02 5 5 0.15 ± 0.01 6
4.5 ~ 7 1.0 0.15 45 ~ 70 ≤ 0.02 5~6 5~6 0.15 ± 0.01 6 ~ 10
7 ~ 12 1.5 0.15 70 ~ 120 ≤ 0.02 6~8 6~8 0.15 ± 0.01 10 ~ 16
12 ~ 19 2.0 0.15 120 ~ 190 ≤ 0.02 8 ~ 10 8 ~ 11 0.15 ± 0.01 16 ~ 24
19 ~ 26 2.5 0.15 190 ~ 260 ≤ 0.02 10 ~ 12 11 ~ 14 0.15 ± 0.01 24 ~ 32
26 ~ 37 3.0 0.15 260 ~ 370 ≤ 0.02 12 ~ 16 14 ~ 19 0.15 ± 0.01 32 ~ 45
37 ~ 50 3.5 0.15 370 ~ 500 ≤ 0.02 16 ~ 20 19 ~ 25 0.15 ± 0.01 45 ~ 60
50 ~ 70 4.0 0.15 500 ~ 700 ≤ 0.02 20 ~ 25 25 ~ 35 0.15 ± 0.01 60 ~ 80
Remark: Bead build-up pressure and welding pressure in the form is the recommended interface
pressure, the gauge pressure should be calculated with the following formula.
Expressions:
Welding pressure = (Section of welding pipe ends)/(Total section of cylinders) × 0.15 +
drag pressure (MPa)
9. Frequent joints quality problems analyze
9.1 Maintenance
Heating plate coating
Please take care on handling the heating plate. Keep a certain distance away from heating plate.
Cleaning of its surface must be done with surface still warm by using a soft cloth or paper, avoid
abrasive materials in that might damage the coating.
At regular intervals check as follows
1. Clean the surface by using a quick evaporation detergent (alcohol)
2. Check the tightening of the screws and the cable and plug condition
3. Verify its surface temperature by using infrared-ray scanning
Planing tool
It is strongly suggested to keep always clean the blades and wash the pulleys by using a deter-
gent. At regular intervals, carry out a complete cleaning operation.
Hydraulic unit
Maintain it as follows
1. Check periodically the oil level
2. Replace totally the oil every 6 months
Keep tank and oil circuit clean!
10 ENGLISH
9.2 Inspection periods
Ordinary inspection ( • maintenance period)
9.3 How to adjust the deviation between heating plate and temperature controller
1. When temperature controller is stable, it reads 220 degrees
2. Test the heating plate, and the average temperature is 196 degrees
ENGLISH 11
3. At this time, we should have temperature controller deviation rectified. (deviation rectified
degree is -24 degree, 196 - 220 = -24), the method of deviation rectification is as follows:
a. Press keys „set“ and “↑” at the same time for three seconds
d. Press “set”, return to original show, and complete the temperature controller setting.
12 ENGLISH
4. When temperature displays 220 degrees stably, retest the surface temperature of heating
plate. If there is still deviation, please repeat the above deviation rectified operation.
ENGLISH 13
4 Cylinder leak 1. The oil ring is fault 1. Replace the oil ring
2. The cylinder or piston is dama- 2. Replace the cylinder
ged badly
5 The pressure 1. The core of overflow valve is 1. Clean or replace the core of
cannot be blocked over-flow valve
increased 2. The pump is leak 2. Replace the pump
or the
fluctuation is 3. The joint slack of pump is loo- 3. Replace the joint slack
too big sened or key groove is skid 4. Lock the valve
4. The pressure relief valve is not
locked
14 ENGLISH
5. Correct the temperature by but-
ton located on the temperature
controller.
6. The temperature fluctuate ab-
normally
4 Lose of The red light is shine, but the tem- Replace the temperature controller
control when perature still goes up, that is be-
heating cause the connector is fault or the
joints 7 and 8 cannot open when
get the required temperature.
5 Planing tool The limit switch is ineffective or Replace the planing tool limit
does not the mechanical parts of planing switch or minor sprocket
rotate tool are clipped.
ENGLISH 15
12. Accessories list
12.1 SUPER-EGO BH 160 Value Butt Fusion Machine
16 ENGLISH
12.2 SUPER-EGO BH 250 Value Butt Fusion Machine
ENGLISH 17
12.3 SUPER-EGO BH 315 Value Butt Fusion Machine
18 ENGLISH
Notes
19
SUPER-EGO TOOLS, S.L.U.
Ctra. Durango-Elorrio, km. 2
48220 Abadiano • SPAIN
www.super-ego.es
i0/07.2014