MULTIPURPOSE ELEKTROFUSION MACHINE
ELEKTRA 315
USE AND MAINTENANCE HANDBOOK M259
Rev.: 0
27/01/2012
MU000704
Ritmo S.p.A. è libera di apportare modifiche senza preavviso alle caratteristiche della macchina descritta in questo manuale e alle informazioni qui contenute. È vietata la riproduzione, anche parziale e sotto qualsiasi forma, di questo documento.
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Ritmo S.p.A. is free to modify the contents of this handbook, as well as the features of
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the machine described herein, at any time, without notice. All rights reserved. It is strictly prohibited to reproduce this document or part of it of it in any form whatsoever.
L’entreprise Ritmo S.p A. Se réserve le droit d’apporter, sans préavis, toutes les modifications qu’elle désirera aux caractéristiques de la machine décrite dans ce manuel ainsi qu’aux informations qu’il contient. La reproduction de ce document, même partielle, sous n’importe quelle forme, est strictement interdite.
Ritmo S.p.A. se reserva el derecho de hacer modificaciones sin previo aviso a las
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características de la máquina descrita en este manual y a las informaciones en él incluidas. Está terminantemente prohibida toda reproducción de este documento, incluso parcial o de cualquier otra
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A Ritmo S.p.A. pode efectuar sem pré‐aviso quaisquer modificações às características da máquina descrita no presente manual, bem como às informações nele inseridas. A cópia total ou parcial deste documento è severamente proibida, sob qualquer forma.
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Die hier angegebenen Daten sind öhne Gewähr und Ritmo S.p.A. behält sich Änderungen ohne Vorankündigung vor. Die Vervielfertigung, auch auszugsweise, dieses Dokumentes ist verboten.
S.p.A. Via A. Volta, 7 ‐ Z.I. Selve 35037 BRESSEO DI TEOLO (PD) ITALY Tel. +39.049.990.1888 Fax +39.049.990.1993
[email protected]
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Dear Customer
Thank you for having chosen a Ritmo machine. This handbook will show you all the features and operating instructions for the ELEKTRA 315. In this book you will also find all the information and suggestions needed to use the machine in a proper, safe and professional manner. We therefore recommend its complete reading before start using the machine. We also recommend to keep it for future consultations and/or new users. Please remember that this machine is a professional device; its use must be limited to skilled and certified personnel only. Certain of your complete satisfaction, Best regards, Ritmo S.p.A.
INDEX
Pag. Conformity declaration
3
Machine description
4
Parts description
5
Technical features
6
Safety precautions
7
Connections and Generator’s Features
9
Checks and Maintenance
10
General Fusion Procedures
11
Operating Instructions
13
Fusion Traceability
14
Fusion by Bar Code reading
16
Fusion by manual introduction of Bar Code
17
Fusion by manual introduction of Tension and Fusion Time
17
Printing and USB Connection
18
Setup and utility
18
Alarm Codes and their meaning
20
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MANUFACTURER’S CONFORMITY DECLARATION
Ritmo S.p.A. Via A. Volta, 7 ‐ Z.I. Selve ‐ 35037 BRESSEO DI TEOLO (PD) ‐ ITALIA Tel.++39‐(0)49‐9901888 FAX ++39‐(0)49‐9901993
Dichiara
that electrofusion machine ELEKTRA 315 object of the present document has been manufactured according to the following Standards and Regulations having legal value: 2006/42/CE 2004/108/CE 2006/95/CE UNI EN ISO 12100‐1 UNI EN ISO 12100‐2 CEI 44‐5 ISO 12176‐2 UNI 10566
(2005) (2005) (2008) (1996)
This declaration is void if any modification to the equipment is performed without previous written authorization by Manufacturer.
Il Legale Rappresentante
Bresseo di Teolo, lì 27/01/2012
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MACHINE’S DESCRIPTION ELEKTRA 315 is a Multipurpose Electrofusion Machine (in low voltage 8÷48V) capable of fusing any
brand of coupler available in the market, up to 315 mm.
Machine automatically sets correct fusion parameters by Optical Pen reading or manual introduction of Bar Code visible on the couplers (according to ISO13950 ). In case couplers do not show bar code, it is possible to manually introduce Tension and Fusion Time recommended by manufacturer.
ELEKTRA 315 has an internal memory for storage of fusion parameters (parameters used, couplers
features, etc… ). It is also possible to print out Fusion Data and download them to a PC.
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PARTS DESCRIPTION
13
12
14 5
11
10
9 6 6
7
8 1
2
3
4
ELEKTRA 315
Display 2. STOP key (exits from menu without saving data. Stops fusion process) 3. Menu scroll key + and ‐ (used to scroll through menu and to change the value of individual parameters) 4. OK key (begins fusion) 5. Handle wrapping 6. Lock wing nut scale 7. Serial printer/USB connector 8. On/Off switch 9. Plug + power cable 10.Barcode scanner 11.Fusion connectors 12.Barcode scanner case 13.Scanner connector 14.Control Panel 1.
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TECHNICAL FEATURES ELEKTRA 315 110V
230V
Diameters range
20 ÷ 315 mm
Weldable materials
PE / PP / PP‐ R
Machine dimensions (W x D x H)
263 x 240 x 300 mm
Suitcase transport dimensions (W x D x H)
405 x 285 x 340 mm
Machine weight
17 kg
Transport suitcase weight
3,8 Kg
Power supply
110 V
Frequency
±
15%
230 V
50 ÷ 60 Hz
Maximum absorbed power
4000W
Welding nominal current Duty cycle 60% (ISO 12176‐2)
60A
Working temperature
–10 °C ÷ + 40 °C
Wlding voltage
8 ÷ 48 V
Peak current
100 A
Precision of the ambient thermometer
± 1 °C
Protection degree
IP 54
Connectors diameter
F 4 ÷ 4,7 mm
Memory capacity
500 report
FEATURES • • •
Transport suitcase Manuale scraper Bar code reader + case
OPTIONS • • •
(1)
DB9M/USB A adapter (2) Building site serial printer kit (3) Transfer software
(1)
Adapter cable to serial/USB data transfer Includes serial cable and printer (3) Includes Ritmo Transfer Software cd‐rom (2)
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±
15%
SAFETY PRECAUTIONS
Carefully read instructions before use.
WARNING! When using electric tools, follow safety standards to avoid fire and electric
hazards.
KEEP WORKPLACE CLEAN. Untidiness on the workplace may be cause of accidents.
CAREFUL TO AMBIENT CONDITIONS. Do not expose electric tools or fusion machines to the
rain. Do not use electric tools or fusion machines in humid places. Make sure lighting is appropriate. Do not use electric tools or fusion machines near liquids or inflammable gases.
PROTECT YOURSELF FROM ELECTRIC HAZARD . Avoid contact with objects connected to earth.
Be careful not to touch electric cables.
KEEP UNAUTHORIZED PEOPLE AWAY FROM WORKPLACE. Electric tools and fusion machines
can be used only by authorized people. Keep unauthorized people away from workplace.
KEEP ELECTRIC TOOLS AND FUSION MACHINES IN A SAFE PLACE. Electric tools, fusion
machines and tools in general have to be stored in dry and safe places not reachable by unauthorized people.
DO NOT OVERWORK POWER TOOLS. Keep within limits given by manufacturer for the best
performance, for more time and in safe conditions.
ALWAYS USE SPECIFIC TOOLS AND ACCESSORIES ACCORDING TO THE JOB. Always use accessories compatible with fusion machine (be careful especially with power generators, extensions for power cables, fusion cable and adapters). Let power tools to cool down after
using for a long time. The use of tools or accessories different from the ones recommended by manufacturer may cause injuries to operator, affect performance of the fusion machine and other tools and void warranty.
DO NOT USE CABLES OF FUSION MACHINE OR OTHER TOOLS FOR INCORRECT PURPOSES. Do
not use cables to move machine around or to disconnect from power outlet. Protect cables and fusion machine from warm environments and from contact with sharp objects.
ALWAYS USE SPECIAL ALIGNERS. Always align pipes and fittings using special aligner. This
helps to perform a correct fusion and a safe job.
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WARNING! AVOID ACCIDENTAL STARTING OF POWER TOOLS OR FUSION MACHINE. Fusion
machine has to be disconnected from generator before turning this one on in order to avoid current peaks which can seriously damage electronic components of the machine. Keep machine disconnected from power supply when connecting adapters. Make sure switch is not in the ON Position when connecting power tools to power supply or generator (especially if tool is not equipped with safety switch). Do not carry power tools around while they are connected to power supply since they may start accidentally.
BEFORE STARTING FUSION PROCESS MAKE SURE FUSION MACHINE IS NOT DAMAGED. Before using fusion machine make sure safety devices are perfectly working. Make sure
power cable or fusion cable are not damaged or cut; check that connectors and adapters fit correctly and surfaces in contact are clean. Make sure machine’s frame is not severely damaged (water infiltrations may occur ).
MAINTENANCE AND SERVICE MUST BE BERFORMED BY AUTHORIZED SERVICE CENTRES ONLY. This machine is manufactured according to safety standards in force therefore
maintenance and service can be performed by authorized service centres only otherwise manufacturer declines all responsibilities and warranty is void.
DO NOT PERFORM ANY MODIFICATION TO THE MACHINE.
OPERATORS HAVE TO BE CAREFULLY TRAINED ON THE USE OF THE MACHINE.
USE NEW EQUIPMENT OR EQUIPMENT SERVICED BY AUTHORIZED SERVICE CENTRES AT ALL TIMES.
PRESCRIPTIONS DESCRIBED BY D. Lgs. 09/04/08 n° 81 REGARDING SAFETY IN THE WORKPLACE MUST BE FOLLOWED.
DO NOT USE MACHINE IN EXPLOSIVE ENVIRONMENTS ( when in presence of inflammable
gases or steams, etc.).
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CONNECTIONS AND GENERATOR’S FEATURES We remind you to follow what prescribed by laws UNI CEI and to respect D. Lgs. 09/04/08 n° 81
Fusion machine can work with alternating current between minimum value of 195V (94V for 110V version) and max value of 265V (127V for 110V version). Frequency may vary between 50Hz and 60Hz. Use earth connection at all times with differential switch on circuit breaker 16A (32A for 110V version) with “slow” curve. Power peaks when beginning fusion can reach 3500VA. Fusion machine can operate with an ambient temperature between –10 °C and +40°C. Dimensions of electrofusion couplers used will determine power required by generator. Power may vary also according to connections, cleanliness and connection’s conditions, as well as according to generator’s features.
WARNING: during fusion procedure DO NOT connect other tools to generator.
Generator’s power decreases of about 10% every 1000 m of altitude.
Use power cables with section of 2,5 mm2 (6 mm2 for 110V version) with a maximum length of 20 m. Cable has to be completely unwound and extended.
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CHECKS AND MAINTENANCE Before performing fusions and before connecting to power outlet, check the following: NOMINAL TENSION AND FREQUENCY : see technical features (page 6) OUTLETS AND EXTENTION CABLES: they must be suitable for the power absorbed by machine (
see page 6, 9) CABLES: isolation has to be intact, they have to be placed away from places where vehicles transit
and where they can be damaged . MACHINE BODY: it has to be isolated and placed steadily.
Keep machine and cables clean and dry. Before cleaning operations disconnect machine from power supply. Use a humid soft cloth with water and alcohol (avoid any kind of solvent). ELEKTRA 315 is an electronic equipment therefore it has to be handled safely avoiding impacts
and sudden temperature changes. To guarantee correct functioning for as long as possible, operators has to perform frequent checks to the following components : • • • •
Connectors and adapters Power cables and fusion cables Display Mechanical structure (frame, box).
In case of any anomaly machine has to be checked by manufacturer or by an authorized service centre.
In any case machine has to be serviced every 2 years by manufacturer or by an authorized service centre.
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GENERAL FUSION PROCEDURES
Quality of joint depends on the following instructions which have be followed carefully. HANDLING OF PIPES & FITTINGS
When fusing, temperature of pipes & fittings have to be similar to ambient temperature measured by machine’s probe. Therefore they cannot be exposed to strong wind or direct sunlight : their temperature may vary consistently from ambient temperature, affecting negatively fusion (pipe & fittings insufficient or excessive fusion). In case of high temperature, keep pipe & fittings away from direct sunlight and wait until their temperature is similar to ambient temperature. PREPARATION
Cut pipe’s edges straight, using special pipe cutters. Carefully try to eliminate pipe’s and fittings bends or ovalizations. CLEANING
Carefully scrape oxidized layers on pipe’s or fitting’s edges with special pipe scrapers. Make sure scraping is uniform and complete over surfaces to be fused exceeding the middle of the fitting of about 1 cm lack of this type of operation causes a superficial fusion only, since it prevents molecular interpenetration of parts and affects fusion’s result. Scraping methods like sand paper, emery wheel must be avoided. Take out coupler from its protecting packaging, clean the interior according to manufacturer’s instructions. POSITIONING
Insert pipe’s edges into the coupler. It is necessary to use an aligner for: making sure parts are steady during fusion and cooling phase; • avoid any sort of mechanical stress on the joint during fusion cycle and cooling; •
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FUSION
Fusion area should be protected from strong weather conditions, such as humidity, temperatures lower than ‐20° over +40°C, strong wind, direct sunlight. Pipes and fittings used have to be of the same material or compatible material. Compatibility between materials have to be guaranteed by manufactured.
COOLING
Cooling time depends on diameter of coupler and ambient temperature. It is important to follow times given by manufacturer of couplers used. To avoid mechanical stress on the joint ( bending, tractions, twisting) disconnected cables and aligners only when joint has completely cooled down.
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OPERATING INSTRUCTIONS TURNING ON THE MACHINE Press X button to switch on the machine, use the arrow buttons + and ‐ buttons to scroll through
the menu WELDING THROUGHT BAR CODE READING
(Pag. 16) READ BAR CODE
WELDING THROUGHT MANUAL INPUT OF BAR CODE
(Pag. 17)
TYPE BAR CODE
WELDING THROUGHT MANUAL INPUT OF WELDING VOLTAGE AND TIME
(Pag. 17)
Volt
sec
38,5
0540
PRINTS AND USB CONNECTION
(Pag. 18) PRINTS & USB
OPTIONS AND TOOLS
(Pag. 18) OPTIONS AND TOOLS
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BAR CODES ‐ TYPES AND READING
Before welding, you can read the bar codes attached to the coupler:
•
WELDING BAR CODE:
WELDING BAR CODE
The welding bar code gives the welding parameters related to the coupler: type, brand, welding voltage and time, diameter.
•
TRACEABILTY BAR CODE:
The traceability bar code gives the information related to the coupler: type, brand, material, diameter, SDR, production batch, etc.
TRACEABILITY BAR CODE
Please Note: These data will be saved in the machine’s memory, therefore consultable (printed or downloaded)
ACTIVATE/ DEACTIVATE TRACEABILITY
Scroll the main menu until OPTIONS & TOOLS is displayed. Press OK.
OPTIONS & TOOLS OPTIONS Go ton “Traceability” then press OK.
Traceability Notes
Traceability
Use + and – to activate/ deactivate traceability. Press OK to confirm.
DEACTIVATE
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ACTIVATE/ DEACTIVATE NOTES
Notes are useful when the operator needs to input a comment before starting (for example, he needs to set in the name of the job site).
OPTIONS & TOOLS Scroll the main menu until OPTIONS & TOOLS is displayed. Press OK.
OPTIONS Traceability
Go to “Notes” then press OK.
Notes
Note Use + and – to active / deactive notes. Press OK to confirm.
DEACTIVATED
GETTING READY TO WELD
Clean and scrape the pipe ends to be welded.
Position pipe/fittings/coupler on the aligners.
Insert the welding connectors into the coupler pins.
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WELDING THROUGH BAR CODE READING
Connect the laser scanner and go to “READ BAR CODE” display.
READ BARCODE
Step 1:
Keep the trigger pressed and make sure the laser beam aims at the welding bar code (see description on page 14). Important: in case of malfunction of the laser scanner, it is possible to work in manual mode (see page 17).
Junction type
Step 2:
The welding voltage and time, and the coupler data are displayed. If the information is correct, press OK to start the welding.
voltage diameter
brand
I CPL ELO 40.0V 110s 2 IPS OK ?
time
Step 3:
If Traceability is activated1, keep the trigger pressed and make sure the laser beams aims at the traceability bar code. If you do not
READ TRACEABILITY
wish to obtain the traceability, skip this step by keeping OK pushed for at least 2 seconds. STEP 4:
If Notes are activated2, use + and – to input the job site name or other notes. Press OK to proceed writing (there are 24 characters available). If you do not wish to obtain
Notes I>
traceability, skip this step by keeping OK for at least 2 seconds.
200
A successful welding displays the image show on the right. 1
to activate / deactivate instruction on page 14.
traceability
follow Welding n°
2
to activate / deactivate notes follow instruction on page 15.
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WELDING THROUGH MANUAL INPUT OF BAR CODE
Go to “TYPE BAR CODE” and press OK to access the input mode.
TYPE BARCODE Read the 24 digits code underneath the bar code and input them one by one using + and – (increase/ decrease value). Press OK to confirm and move to the next digit in the same manner. To erase the previous value, press STOP.
TYPE BARCODE
00000000 00000000 00000000
When the entire 24 digits code has been typed, press OK and move to the ext step ( Step 2) at page 16. WELDING THROUGH MANUAL INPUT OF WELDING VOLTAGE AND TIME Please note:
This mode require the knowledge of the welding voltage / time parameters, beforehand. If these are not know, contact the coupler manufacturer.
At the image shown on the right, press OK to access the input mode of voltage and welding time.
Volt
sec
38,5
0540
Volt
sec
38,5
0540
The cursor position itself on the first value of welding voltage. Press + and – (increase / decrease value) to input the requested voltage. Press OK to confirm and move to the next value . When the correct values are set, press OK and move to the next step (step 2) at page 16.
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PRINTS AND USB CONNECTION
Press OK to enter PRINTS & USB menu.
PRINTS & USB
Copy to USB:
PRINTS & USB 1/2
To download the welding data into a pen drive. Connect a pen drive and press OK to start downloading.
Copy to USB Print last
Print last:
To print the last welding report on a fast manner. Previous reports can also be printed, use + and – to visualize the desire report, then OK to print.
OPTIONS AND TOOLS
Press OK to enter OPTIONS & TOOLS menu.
OPTIONS & TOOLS
Traceability:
OPTIONS
Activates/ deactivates traceability of the coupler to be used. If activated, the bar code must be read and the information regarding the coupler’s manufacturer (as well as other data) will be displayed. The information will be printed and/or downloaded.
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Traceability Notes
OPTIONS
Notes:
Activates/ deactivates notes. If activated, the option will be displayed during the welding process.
Traceability Notes
18
1/3
Information:
OPTIONS
Displays useful information regarding the welder, such as: Overhaul • Serial number • Free memories • Firmware version •
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Informations Settings
Settings:
A 4‐digit code must be entered to allow access (one code per setting‐see page 22). Settings available are: Data/ Time • Pen/ Laser scanner option • Language • Celsius/ Fahrenheit option • Deletion of all reports (zero setting) •
OPTIONS
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Informations Settings
OPTIONS
Contrast:
To adjust display contrast.
Contrast
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ALLARM CODES AND THEIR MEANING Attention! The welding cycle is interrupted whenever an error code is displayed. The interruption may cause the deterioration of the material being welded. In no event shall Ritmo S.p.A be liable for any direct, indirect, incidental, or consequential damages of any whatsoever with respect to the use of pipes/ fittings involved in the welding cycles resulting in error codes.
5 – POWER SOURCE VOLTAGE Probable cause: Power source voltage out of range
Vmin= 195V÷Vmax= 265V (version ) ‐ Vmin= 90V÷Vmax= 130V (version) Solution: Verify the power source characteristics. 10 – POWER SOURCE FREQUENCY Probable cause: Power source frequency out of range
Fmin= 40Hz ÷ Fmax= 60Hz Solution: Verify the power source characteristics 20 – AMBIENT TEMPERATURE OUT OF RANGE Probable cause: Ambient temperature is out of range ( ‐20°C ÷ +40°C ) Solution: Protect the working site where the welding is taking place in order to reach an ambient
temperature within the allowable limits
25 – TRASFORMER OVERHEATED Probable cause: The temperature of the transformer is too high. Solution: Wait until the transformer has cooled off and then repeat the welding.
30 – WELDING VOLTAGE OUT OF CONTROL Probable cause: The power source is supplying an out‐of ‐range voltage Solution: Verify the power source characteristics.
20
35 e 40 – MACHINE OVERHEATED Probable cause: The machine reached a too high temperature after the welding cycle Solution: Wait until the machine has cooled off.
45 – CURRENT MAXIMUM VALUE WAS OUTPACED Probable cause: The heating wires inside the coupler are creating a short circuit Probable cause: The coupler diameter is bigger than allowed Solution: Repeat the welding with another coupler
50 – NOT REACHED THE MINIMUM VALUE OF WELDING CURRENT Probable cause: One or both welding cables were unplugged during the welding Solution: Reconnected the welding cables and repeat the procedure Probable cause: The heating wires inside the coupler are interrupted Solution: Repeat the welding with another coupler Probable cause: The coupler is too small (the electrical resistance is too high) Solution: Repeat the welding with a compatible coupler
55 – WELDING CYCLE INTERRUPTE BY THE OPERATOR Probable cause: The operator pressed the STOP pushbotton Solution: Repeat the welding
60 – SHORT CIRCUIT Probable cause: The coupler is damaged Solution: Repeat the welding with another coupler
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65 – LACK OF VOLTAGE AT THE POWER SOURCE Probable cause: Power supply cable unplugged Solution: Plug the power supplì cable Probable cause: The voltage supply was interrupted Solution: Wait until the service is restored Probable cause: The safty microswiches Solution: Re‐arm the safty microswiches
70 – HARDWARE ERROR Solution: contact an authorized service center
75 – COUPLER RESISTANCE ERROR Solution: Repeat the welding with another coupler
80 – OVERHAUL EXPIRED Solution: Contact an authorized service center
Attention! If the “ ATTENTION! FREE MEMORY: 5” message is displayed at the ignition of the
machine, follow the procedure on page 19 then type code (2110). If you do not do this and continue to use the machine, the last report will replace the first one in the memory, then the second report will be replaced, and so forth.
Special features • • • • •
Date/hour settings ‐ code 1000 Barcode scanner/light pen scanner choice ‐ code 1111 Language choice ‐ code 1100 Celsius/Fahrenheit settings ‐ code 1110 Reset welding report ‐ code 2110
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