PT 250 2008.12 Tecnodue PT250 User Manual
User Manual: Tecnodue PT250 User Manual
Open the PDF directly: View PDF .
Page Count: 36
Download | ![]() |
Open PDF In Browser | View PDF |
I.T.S. by Tecnodue PT 250 Edition 1208 Operating Manual I.T.S. Ital Trade Services PT 250 Operating Manual The technical data and information contained on this manual can be changed without any notice 2 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 The machine has been designed and constructed for the welding of PE, PP, PVDF and other thermoplastics pipes and fittings. I.T.S. Ital Trade Services S.r.l. Via Scarsellini 77 , 16149 Genova Italy Phone : +39-010-6423396 Fax : +39-010-6423513 E Mail : info@its-tecndoue.com Web Site : www.its-tecnodue.com Standard Components 1. Hydraulic Unit 2. Facing Tool 3. Basic machine 4. Heating Mirror 5. Support for facing tool and heating mirror On request can be supplied: 6. Light weight alloy reducing rings for pipes and fittings d. 63,50,75,90,110,125,140,160,180,200,225mm 7. Stub End Device 8. MDD (PT automatic mirror device) • Short spigot fittings clamp d. 250mm • Wooden transport box according to ISPM 15 • LDU (printing and storing data machine) • Electric board with automatic circuit breaker • Rollers 3 I.T.S. Ital Trade Services PT 250 Operating Manual SAFETY RULES ACCORDING TO DIRECTIVES CEE ( To be read carefully and apply while utilizing the PT 250 ) Due to the specific use, this machine cannot be supplied with all kind of fix and removable protections suitable to avoid any risk of accident. The machine, therefore, must be utilized, adjusted and keep in the perfect functioning conditions by skill operators. Warning - Rules – Obligations The use of machines composed by electrical components and movable parts, it's always a potential danger. In order to avoid any kind of accident caused by electrical or mechanical sources it' strongly suggested to read and follow carefully the following safety rules before operating the machine. TRANSPORT -.Basic Machine , Keep the maximum care while moving and it's suggested to utilize mechanical aids. -.Facing Tool ,supplied with transport's hook. Keep the maximum care while moving it and it's compulsory to utilize the handle also take care about the blades mounted in, it's compulsory use gloves. -.Heating Mirror ,supplied with transport's handles Keep the maximum care while moving it also keep the maximum care while utilizing it due to the high temperature involved always more than 200°C , it's strongly suggested to use suitable gloves. In order to move from one working place to the other , the facing tool and the mirror must located into the special support , this support is heavy therefore it's necessary to utilize the maximum care to move it -.Hydraulic unit, supplied with transport's frame. Keep the maximum care while moving it and in case utilize two person. Avoid to transport the components by holding from the cable and remember to use suitable gloves. ELECTRIC CONNECTIONS The machine is operated by 230 Volts therefore be sure that the power supply plug is supplied with the safety devices according to the standard requirements , also check that the power supply will be on the range of maximum 10% of the machine's nominal tension. While the facing tool is connected to the power supply do not leave it into the basic machine but place it into the special support. In this position, even if the start bottom is pushed the engine does not start. Check regularly the cables and the plug and in case substitute by qualify personnel. In case the heating mirror cable must be substitute the cable must be H07RN-F Before carry out a reparation or maintenance all the plugs must with plug out from the power supply ENVIRONMENTAL CONDITIONS The working area must be clean and duly lighted. It's very dangerous to utilize the machine in case of rain or in wheat conditions or close to flammable agents. CLOTHES Keep the maximum care while utilizing the machine due to the high temperature involved on the heating mirror always more than 200°C , it's strongly suggested to use suitable gloves. Avoid long clothes and avoid bracelets , necklaces that might be hooked into the machine. CORRECT MACHINE'S OPERATION Remember to check and read carefully the operating manual before utilizing the machine and the accessories. KEEP ALWAYS THE MAXIMUN ATTENTION After the heating mirror has been disconnected temperature will be hot for some minutes. Keep the maximum care while utilizing the facing tool. Be careful to the blades , it's strongly suggested to use suitable gloves. During the facing operation ( facing tool in movement ) it's forbidden to take out the shavings Avoid utilizing the machine after drinking or drugs use Take care that all the people around the machine are at safety distance While starting operating take care to avoid leave arms between the movable and fix trolleys. SQUASHING DANGER While starting operating take care to avoid leave legs or arms between the movable and fix trolleys. It's compulsory to be far from the basic machine ACOUSTIC POLLUTION The acoustic pollution of the drill engine is less than 85 dB ( value measured at 1 meter distance from the operator) Due to some particular cases such as too much pressure during the facing the noise should be increased , therefore it's suggested to utilize some protections. IMPORTANT !!!! Keep the maximum care reading and following the above Warning - Rules - Obligations the Ital Trade Services S.r.l. decline all responsibilities if are not followed totally Label on machine’s components showing potential dangers WEAR GLOVES 4 BURNS DANGER ELECTRIC DANGER SQUASHING DANGER I.T.S. Ital Trade Services PT 250 Operating Manual 1. Technical data Operating data Ambient temperature Humidity (without condensation) Transport and storing Temperature 0…50°C 95 RH% -10…60°C Electrical data Voltage Frequency Total power installed Heating mirror Facing tool Hydraulic unit 230 V 50 Hz 3.92 KW 17 A IP 54 2.3 KW IP 20 1.02 KW IP 44 0.6 KW Hydraulic data Maximum working pressure Cylinder’s section Pressure gauge Pressure gauge precision class Hydraulic unit engine revolutions Volumetric pump’s capacity Pump’s capacity Hydraulic oil Oil tank’s capacity 100 bar 5,89 cm2 0 - 100 bar Cl. 1.0 1400 rpm 1,2 cc/rev. 1.68 l/min ISO 46 1.5 liter Mechanical Data Facing tool transmission system Trolley maximum stroke Trolley slide bar diameter Distance between the cylinders centre Gear drive 145 mm 35 mm 360 mm Dimensions Basic machine Facing tool Heating mirror Hydraulic unit Support for facing tool and heating mirror 900 x 510 x 520 mm 650 x 480 x 85 mm 465 x 550 x 65 mm 445 x 320 x 270 mm 415 x 510 x 370 mm Weights Basic machine Facing tool Heating mirror Hydraulic unit Support for facing tool and heating mirror Wooden transport box Stub end device Reducing inserts complete set 45 Kg 14,5 Kg 10 Kg 26 Kg 12 Kg 55 Kg 6.5 Kg 63.5 Kg 5 I.T.S. Ital Trade Services 2. PT 250 Operating Manual General description and application field Hydraulic operated butt welding machines suitable for PE,PP,PVDF and other thermoplastics pipes and fittings. The self aligning frame and the compact dimensions make the machines highly suited for working in road constructions, ditches , aqueducts, gas ducts , sewers and irrigation systems. The machine is supplied complete of: 1) Basic machine d. 250 mm complete with a tools blue bag 2) Removable electric facing tool with safety switch 3) Removable PTFE coated heating mirror with a temperature control box. 4) Electro-hydraulic motor with accumulator and flexible hoses with quick couplings. 5) Support for facing tool and heating mirror 2.1 Basic machine The basic machine is composed by: • Two cylinders on which heads are mounted two complete clamps d. 250 mm • One movable clamp d.250 mm sliding on cylinder's stem and fixable in different positions by means of using the clamps connecting rods. • A stiffening bar • One side support clamp d.250 mm • A frame including the hydraulic circuit with the anti-drop quick couplings. • A heating mirror disconnecting device 2.2 Facing Tool The electric facing tool is composed by: • The facing tool body • Two disks where are mounted the blades • A drill engine with a safety pin that , while connected keep the facing tool hooked to the machine. • An handle with safety micro-switch allowing the engine starts only when the facing tool is fit into the machine, avoiding the start of the engine out of this position. 2.3 Heating Mirror The heating mirror is composed by: • The heating mirror coated with green color PTFE complete with thermometer (the thermometer does not depend upon the power supply and always survey the real temperature of the heating plate) and connecting box • The support suitable for the heating mirror and the facing tool where is located the connecting box • The electronic thermostat located on the connecting box . • LDU connector. (The below figure shows where the LDU connector is located ). LDU Connector 6 I.T.S. Ital Trade Services PT 250 Operating Manual 2.3.1 Electronic thermostat – different functions At each startup on the display will blink the writing ‘TEST’. This means that the thermostat is testing the connection between the probe and the heating mirror. If the test fails, the display will show 4 blinking upper scores (as per figure aside), in this case the probe or the connection between the thermostat and the heating mirror could be interrupted. If the test success, the display will show the real temperature of the heating mirror and the heating mirror warms up (the OUT1 red led is switched on) until the set point value (the selected temperature) has been achieved (central green light led). To display the actual set point value of the temperature stored by the thermostat, push the key P. The display will show alternately the writing ‘SP1’ and the set point value of the temperature. After 5 seconds the display will show again the real value of the heating mirror temperature To select a new value for the thermostat set point value (default value = 220°C): 1. Push the key P (The display will show alternately the writing ‘SP1’ and the set point value of the temperature) 2. By acting on the arrow keys UP and DOWN it is possibile to increase or decrease the set point value. 3. When you reach the desired value push the key P to confirm. 4. The display will show again the real value of the heating mirror temperature 5. When the heating mirror will reach the set point value on the display the central green light led will be switched on. Warning: On the thermostat display is always shown the actual value of the heating mirror temperature (and never the set point value!) Temperature of the welding mirror for welding PE DVS 2207-1 norm Mirror temperature (°C) 225 220 PE 100 215 210 205 PE80 200 0 195 0 10 20 30 40 50 60 70 pipe wall thickness (mm) Remember When welding PVDF, the temperature of the welding mirror should be adjusted for every wall thickness at 240°C +/- 8°C When welding PP, the temperature of the welding mirror should be adjusted for every wall thickness at 210°C +/-10°C 7 I.T.S. Ital Trade Services 2.4 PT 250 Operating Manual Hydraulic Unit The basic components of the hydraulic unit are the following: • Electric engine • Hydraulic pump • Oil tank • Hydraulic unit controls • Pressure accumulator • Pressure gauge • Metal frame 2. 4.1 Hydraulic Unit Controls The control lever A open and close the machine's trolley according to the position selected. Bring the lever A into position A2 (position with automatic return) the trolley is opening with the maximum pressure set up into the hydraulic unit In position A1 the lever shut down automatically the engine ( release position ). Bring the lever A into the position A3 ( position with hooking) the trolley is closing, the hooking of such position allow the operator handling. The hand wheel F of the pressure control allow the setting up of the pressure at the requested values by turning anti clockwise the pressure release , while turning clockwise the pressure increase . The pressure by pass lever E allow ,by turning anti clockwise the pressure releasing , while turning clockwise allow the pressure increasing by means of using the hand wheel F and fixing. If you completely clockwise turn the by pass valve, the pressure will be blocked and the hydraulic unit will maintain the same pressure in case of engine switched off. 8 I.T.S. Ital Trade Services PT 250 Operating Manual 2.4.2 How to use the hydraulic unit Operating Instructions In order to make easy the learning we shall proceed to the description step by step of all operations need in order to complete a welding according to the following description: Important ! Before begin the following operation be sure that: - The lever A is fixed into the special housing - Substitute the metal plug with the plastic black and red plug the plastic plug is supplied with the machine into a plastic bag. 01. Fit the two pipes to be weld ( see relative instructions ) 02. By turning the lever E anticlockwise bring the pressure to zero, checking the pressure gauge D 03. Turn clockwise the lever E until closing ( please avoid using an excessive strength ) 04. Bring the lever A into position A3 05. By turning clockwise the hand wheel F achieve the inertial pressure value ( value of pressure need in order to allow the trolley moving ) note the value of inertial pressure read into the pressure gauge D, then by still operating the hand wheel F , increase the inertial pressure value by the welding theoretical pressure value as per attached table. 06. Achieved the true welding pressure value ( inertial pressure plus theoretical welding pressure ) bring the lever A into position A2. 07. Fit the facing tool (see relative instructions ) 08. By acting on lever E anticlockwise achieve a pressure value of approx 5 bar more than the inertial pressure value checked and then proceed to the facing tool operation (taking care that the engine's overloading). 09. At the end of the facing operation bring the lever A into position A3 and remove the facing tool. 10. Fit the heating mirror taking care that the temperature of the surfaces is the one selected (see relative instructions) 11. Bring the lever A into A3 in order to have the bead formation as per attached table, this operation must be done with the true welding pressure value. 12. After bead formation act on lever E anticlockwise in order to bring the pressure to zero and proceed to the heating time as per attached table. 13. Elapsed the heating time at pressure zero bring the lever A into position A2 and remove the heating mirror and immediately bring the lever A into position A3 and acting on lever E clockwise put in contact the two pipes until achieving the true welding pressure value by checking the pressure gauge D. These operations must be done according to the time indicated into the attached table. 14. Bring the lever A into position A1 and keep such situation for all the cooling time indicated into the attached table, taking care that the pressure will not decrease too much, in case bring for a little while the lever A into position A3 and put back into position A1 15. Elapsed the cooling time by acting on lever E anticlockwise bring the pressure to zero. 16. Take away the pipes welded WE STRONGLY SUGGEST TO TRY MANY TIMES AND GET FAMILIAR TO THE UNIT BEFORE CARRYING ON WITH COMPLETE WELDING. A WRONG USE OF THE HYDRAULIC UNIT COULD COMPROMISE YOUR WELDINGS.. 9 I.T.S. Ital Trade Services PT 250 Operating Manual 3. Heating mirror disconnecting device You can configure the machine according to the kind of welding to be executed as per the following different ways: • Two fixed clamps and two moveable clamps Fig. 1 • One fixed clamp and three moveable clamps Fig. 2 You can change from a configuration to another in a quick way by simply acting on the two spacers and on the disconnecting device. In the first configuration of the machine the disconnecting devices is between the two moveable clamps and the two fixed clamps. The spacers are between the two fixed clamps. In the second configuration of the machine the disconnecting devices is between the three moveable clamps and the fixed clamp. The spacers are between the second and third moveable clamps. Figure 1.Configuration 2 moveable clamps + 2 fixed clamps Figure 2.Configuratione 3 moveable clamps + 1 fixed clamp Figure 3. On the left: The special shape of the spacers let a quick configuration of the machine. You can easily chage the spacer position without using any kind of tool. You can modify the distance between the clamps connected by the spacers. Fix the first clamp to the hole D and the second clamp in one of the holes A,B,C On the right (from above) Upper and lower spacer (interchangeable) and disconnecting device WARNING ! Only in two confirgurations you can use the disconnecting device with spacer! In the other configuration use only the spacer to avoid serious damages to the basic machine! 10 I.T.S. Ital Trade Services PT 250 Operating Manual How to change the configuration from two fixed clamps and two sliding clamps into one fixed clamp and three sliding clamps WARNING! You can only place the upper and lower spacers in the same clamps and using the same holes. It is strictly forbidden to put the spacer in different clamps and in different holes. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Configuration 2 moveable clamps + 2 fixed clamps Not completely close the trolleys Remove the heating mirror disconnecting device Lift the spacers as shown in the figure above By using your hands translate the third clamps as in the figure above Remove the spacers Place the spacers between the two central clamps By using your hands translate the moveable clamps until the clamp reaches the limit stop. Fix the spacers by pushing them down Place the heating mirror disconnecting device To fix the heating mirror disconnecting device open the trolleys Configuration 3 moveable clamps + 1 fixed clamp To configure the again the machine with 2 moveable clamps you must repeat the procedure above in a reverse sense. 11 I.T.S. Ital Trade Services 3.1 Beep-beep inserts reductions To use a beep-beep insert reduction To use a beep-beep reduction, fix it by lightly pushing the reduction in the direction shown as per figure aside. As you hear a ‘click’ sound the reduction is properly fixed. To remove the beep-beep reduction To safely remove the beep-beep reduction by means of a screwdriver turn to left the screw shown in the figure aside. As soon as the reduction is not anymore hooked to the clamp you can remove it. 12 PT 250 Operating Manual I.T.S. Ital Trade Services PT 250 Operating Manual 4. Butt welding in brief 4.1 Introduction Stated that the basic machine it's suitable for all kinds of pipe, fittings and stub end available on the nowadays market. Here follows all the different welding configurations of the machine: 1) Pipe with Pipe, standard configuration of the machine 2) Pipe with long spigot fitting, standard configuration of the machine 3) Pipe with short spigot fitting, to achieve this kind of welding it is strongly suggested to configure the machine with three moveable clamps and 1 fixed clamp. Furthermore you must use the upper fittings clamp to fix better the fittings to the fixed clamp 4) Fitting with short spigot stub end, to achieve this kind of welding it is strongly suggested to configure the machine with three moveable clamps and 1 fixed clamp. To fix the stub end you must use a special accessory called stub end device. Place the 4 brackets at the appropriate size punched on the stub end device. Fix the stub end by tighten the bolt of each bracket. The stub end device is supplied with a fixing ring and you can install it on each clamp of the machine. 5) Pipe with short spigot stub end, to achieve this kind of welding you can use two different configuration of the machine (5 or 6) 6) Pipe with short spigot stub end, to achieve this kind of welding you can use two different configuration of the machine (5 or 6) 1. PIPE WITH PIPE 4. FITTING WITH SHORT SPIGOT STUB END 2. PIPE WITH LONG SPIGOT FITTING 5. PIPE WITH SHORT SPIGOT STUB END 3. PIPE WITH SHORT SPIGOT FITTING 6. PIPE WITH SHORT SPIGOT STUB END 4.2 Machine's preparation It's strongly suggested to use pipe rollers for the sliding of the pipes to be welded and if it's possible positioning the machine with wooden table below, such cares will avoid additional efforts to the machine. a) Set up the working area so that welding is protected from the weather. Position the machine's components as per following figure and eventually utilize wooden panels b) Connect the flexible hoses of the hydraulic unit to the machine 13 I.T.S. Ital Trade Services c) d) e) PT 250 Operating Manual Connect the plugs to the power supply (Hydraulic unit, Facing tool and Heating mirror) after checking that the main power supply is within a 10% of the specified one “ Warning Heating Mirror start to warm up ! “ Select the correct temperature on the heating mirror In case fit the inserts of the diameter to be welded into the machine 4.3 Pipes positioning into the machine and facing operation a) b) c) d) e) f) Open the movable trolley of the machine by means of acting the lever A (hyd. Unit) and take it in position A2 Position the pipes into the machine taking care to leave enough space for the facing tool inserting Check the pipes alignment, in case adjust it by means of tighten or loosing the clamps bolts. The maximum misalignment could be lesser than 10% of the pipe or fittings wall thickness. In any case the misalignment cannot be over than 2mm. Clean the pipe ends Fit in the facing tool between the two pipe's ends to be faced, by means of connecting the facing tool into the special supports. Connect the safety pin and start the facing tool engine On the facing tool there is a facer stopper (see the figure aside). In case of one of the pipe ends has a small projection; the facer stopper let you select the only pipe to face. Put the facer stopper in the left or in the right hole to prevent the right or left facing. To face all the pipes put the facer stopper in the central hole. Warning!!!: Always check that the speed selector of the drill engine is in position 1 (lower speed) g) h) Slowly approach the pipes ends towards the facing tool by means of acting on the hydraulic control unit (lever A Table V ) keeping a value of pressure allowing the facing of the surfaces and avoiding an overload of the drill engine (a too much high pressure could burnt out the drill engine). When shavings from both sides will appear continuous and homogeneous , the facing operation is completed. Put in contact the two pipes ends to be welded and check if the eventual disjunction is within the values of the following table: Outside diameter mm < 400 > 400 Port mm 0,5 1,0 In case the above values cannot be fulfilled the facing operation must be repeat. 4.4 Inertial pressure measurement Before begin a welding cycle it is necessary to measure the inertial pressure. This value must be added to the pressure value shown in our welding tables. The inertial pressure value depends on welding operating conditions (ex.: length and weight of the pipe to drag, general condition of the machine, ambient temperature, etc.). To measure the inertial pressure follow these steps: a) Completely open the movable trolley of the machine by means of acting the lever A and take it in position A2 b) By turning the lever F (Hyd. Unit) anticlockwise bring the pressure to zero, checking the pressure gauge c) Turn clockwise the lever E (Hyd. Unit) until closing d) Bring the lever A (Hyd. Unit) into position A3 (the trolleys do not move because there is no pressure) e) By turning clockwise the hand wheel F note the inertial pressure value ( value of pressure need in order to allow the trolley moving ) by reading it into the pressure gauge 14 I.T.S. Ital Trade Services PT 250 Operating Manual 4.5 Welding cycle To obtain the best result we strongly suggest allowing the use of the machine only to experienced operators The welding phase is composed by 5 phases with 5 different times: PHASE 1 = t1 = Time requested for the bead formation with the specified wall thickness PHASE 2 = t2 = Time requested for the continual heating PHASE 3 = t3 = Time requested for the change over PHASE 4 = t4 = Time requested for bringing up the pressure PHASE 5 = t5 = time requested for cooling down Pressure-Time diagram for butt welding PHASE 1 = Heating up t1 a) b) c) Fit the heating mirror taking care that the temperature of the surfaces is the one selected Bring the lever A (Hyd. Unit) into position A3 in order to have the bead formation as per attached table, this operation must be done with the true welding pressure value: ( Inertial pressure + P1 ). Check the Bead formation wall thickness according to the attached welding table PHASE 2 = Heating up t2 a) After bead formation act on lever E (Hyd. Unit) anticlockwise in order to bring the pressure nearly to zero and proceed to the heating time t2 at pressure P2 PHASE 3 = Change over t3 a) Elapsed the heating time at pressure P2 bring the lever A (Hyd. unit) into position A2 and remove the heating mirror and immediately bring the lever A into position A3 and acting on lever E clockwise put in contact the two pipes PHASE 4 = Bringing up pressure t4 a) Achieve the true welding pressure value: (Inertial pressure + P1 = P5 ) by checking the pressure gauge, This operation must be done according to the time indicated into the attached welding table. PHASE 5 = Cooling Down t5 a) b) c) Bring the lever A into position A1 and keep such situation for all the cooling time indicated into the attached welding table, taking care that the pressure will not decrease too much Elapsed the cooling time by acting on lever E anticlockwise bring the pressure to zero. Take away the pipes welded Important !!! In case of any doubt please refer to the specific instructions 15 I.T.S. Ital Trade Services PT 250 Operating Manual 5. Welding Parameters for PE pipes & fittings DVS norm version 2207-1 Pressure-Time diagram for butt welding t1 = t2 = t3 = t4 = t5 = P1 = Time requested for the bead formation with the specified wall thickness Time requested for the continual heating Time requested for the change over Time requested for bringing up the pressure time requested for cooling down Pressure during the bead formation and the cooling down, this value is the result of the formula: Pipe section( cm2 ) x Material thrust coefficient( Kg./cm2 ) ____________________________________________________________ = bar Total machine cylinders section( cm2 ) P2 = Material thrust coefficient for PE s 63 Material thrust coefficient for PP 1,5 Kg./cm2 1,0 Kg./cm2 Total PT 250 cylinders section 5,89 cm2 Pressure during the continual heating, this value either for HDPE and PP is 0,1 Kg./cm2. Optical checking of butt welding result 16 I.T.S. Ital Trade Services PT 250 Operating Manual 5.1 Welding Parameters for PE & PP sheets,pipes & fittings according to DVS 2207-1 – 2207-11 Nominal Wall thickness Alignment mm Heating-up Bead height on heater plate at the end of the alignment time (alignment under 0.15 N/mm2) Heating-up time= 10 x wallthickness (heatingup 0.02 N/mm2) mm (minimum values) s Changeover time Joining pressure Cooling time under joining pressure p=0.15 N/mm2 0.01 S (maximum time) s Min (minimum values) MATERIAL PE Until 4.5 4.5 … 7 7 … 12 12 … 19 19 … 26 26 … 37 37 … 50 50 ... 70 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Until 4.5 4.5 … 7 7 … 12 12 … 19 19 … 26 26 … 37 37 … 50 0.5 0.5 1.0 1.0 1.5 2.0 2.5 45 5 45 … 70 5…6 70 … 120 6…8 120 … 190 8 … 10 190 … 260 10 … 12 260 … 370 12 ... 16 370 … 500 16 … 20 500 … 700 20 … 25 MATERIAL PP 135 5 135 … 175 5…6 175 … 245 6…7 245 … 330 7…9 330 … 400 9 … 11 400 … 485 11 ... 14 485 … 560 14 … 17 5 5…6 6…8 8 … 11 11 … 14 14 … 19 19 … 25 25 … 35 6 6 … 10 10 … 16 16 … 24 24 … 32 32 … 45 45 … 60 60 … 80 6 6…7 6 … 11 11 … 17 17 … 22 22 … 32 32 … 43 6 6 … 12 12 … 20 20 … 30 30 … 40 40 … 55 55 … 70 Example on how to calculate the cooling down (t5) time following the DVS NORM As per drawing above the time T corresponds to wall thickness value X in mm. To calculate this time (t5 in minutes) please follow the formula below: T = 6+ 10 − 6 ⋅ ( x − 4,5) 7 − 4,5 Example: If you want to calculate the cooling down time for a 6mm wall thickness pipe, you must simply substitute the variable X with the value 6: T =6+ 10 − 6 ⋅ (6 − 4,5) = 8,4 min 7 − 4,5 To calculate the other times (t3 and t4) you must use the same principle of linear interpolation. To obtain the t2 (in seconds) value use the formula below where the variable wt corresponds to the nominal wall thickness T2 (sec) = 10 ⋅ wt( mm ) 17 I.T.S. Ital Trade Services PT 250 Operating Manual 6. Welding Table for PE pipes DVS norm version 2207-1 The following tables show the values to be applied during the welding cycle as per previous instructions and graph. However in order to clarify once again the meaning of these values please kindly note: t1 = Time requested for the bead formation to be done with pressure value = P1 + inertial pressure t2 = Time requested for the continual heating to be done with pressure value = P2 + inertial pressure t3 = Time requested for the change over t4 = Time requested for bringing up the pressure at the value of pressure = P1 + inertial pressure t5 = time requested for cooling down to be done with pressure value = P1 + inertial pressure Important: Remember always to add the value checked of inertial pressure to the P1 and P2 values !!!!!!! PT 250 - DVS 2207-1 material PE80-100 Cyl. section cm P1 bead 2 P2 5,88 Welding range 90-250 mm SDR 41 D S T DIAMETER WALL THICK. TEMP. mm mm °C bar mm 90 110 125 140 160 180 200 225 2,2 2,7 3,0 3,4 3,9 4,4 4,9 5,5 220 220 220 220 220 220 219 218 1,5 2,3 3, 3,7 4,9 6,2 7,6 9,6 0,5 0,5 0,5 0,5 0,5 0,5 1,0 1,0 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0,1 0,2 0,2 0,2 0,3 0,4 0,5 0,6 22 27 30 34 39 44 49 55 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 250 6,1 217 11,9 1,0 0.. 0,8 61 0.. BEAD FORMATION bar Cyl. section cm2 PT 250 - DVS 2207-1 material PE80-100 P1 t2 HEATING UP bead P2 sec t3 t4 CHANGEOV. RAMP sec sec bar min 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 1,5 2,3 3, 3,7 4,9 6,2 7,6 9,6 6 6 6 6 6 6 7 8 6 6 11,9 9 D S T WALL THICK. TEMP. mm mm °C bar mm 90 110 125 140 160 180 200 225 2,7 3,3 3,8 4,2 4,8 5,5 6,1 6,8 220 220 220 220 219 218 218 216 1,9 2,8 3,7 4,6 6, 7,6 9,4 11,9 0,5 0,5 0,5 0,5 1,0 1,0 1,0 1,0 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0,1 0,2 0,2 0,3 0,4 0,5 0,6 0,8 27 33 38 42 48 55 61 68 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 250 7,6 215 14,7 1,5 0.. 1,0 76 0.. Cyl. section cm2 PT 250 - DVS 2207-1 material PE80-100 P1 t2 HEATING UP bar bead P2 sec t3 t4 CHANGEOV. RAMP sec sec bar min 5 5 5 5 5 5 6 6 5 5 5 5 5 5 6 6 1,9 2,8 3,7 4,6 6, 7,6 9,4 11,9 6 6 6 6 7 8 8 10 6 6 14,7 11 D S T WALL THICK. TEMP. t2 mm mm °C bar mm 63 75 90 110 125 140 160 180 200 225 2,3 2,7 3,3 4,0 4,5 5,1 5,8 6,5 7,2 8,2 220 220 220 220 220 219 218 217 216 215 1,1 1,6 2,3 3,4 4,4 5,5 7,2 9,1 11,2 14,2 0,5 0,5 0,5 0,5 1,0 1,0 1,0 1,0 1,5 1,5 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0,1 0,1 0,2 0,2 0,3 0,4 0,5 0,6 0,7 0,9 23 27 33 40 45 51 58 65 72 82 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 250 9,1 214 17,5 1,5 0.. 1,2 91 0.. HEATING UP bar P5 sec t3 t4 CHANGEOV. RAMP P5 t5 sec sec bar min 5 5 5 5 5 5 6 6 6 6 5 5 5 5 5 5 6 6 6 6 1,1 1,6 2,3 3,4 4,4 5,5 7,2 9,1 11,2 14,2 6 6 6 6 6 7 8 9 10 11 7 7 17,5 12 COOLING Warning!: in case of PE100 welding, temperature T must be increased to 220°c 18 t5 COOLING 5,88 Welding range 63-250 mm SDR 27,6 DIAMETER BEAD FORMATION t5 COOLING 5,88 Welding range 90-250 mm SDR 33 DIAMETER BEAD FORMATION P5 I.T.S. Ital Trade Services PT 250 Operating Manual Cyl. section cm2 PT 250 - DVS 2207-1 5,88 material PE80-100 D S T DIAMETER WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 2,4 2,9 3,5 4,2 4,8 5,4 6,2 6,9 7,7 8,7 9,6 °C 220 220 220 220 220 219 217 216 215 214 213 SDR 26 P1 bead P2 BEAD FORMATION bar 1,2 1,7 2,4 3,6 4,6 5,8 7,6 9,6 11,8 15, 18,5 mm 0,5 0,5 0,5 0,5 1,0 1,0 1,0 1,0 1,5 1,5 1,5 t2 HEATING UP bar 0.. 0,1 0.. 0,1 0.. 0,2 0.. 0,2 0.. 0,3 0.. 0,4 0.. 0,5 0.. 0,6 0.. 0,8 0.. 1,0 0.. 1,2 Cyl. section cm2 PT 250 - DVS 2207-1 sec 24 29 35 42 48 54 62 69 77 87 96 5,88 material PE80-100 D S T DIAMETER WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 2,9 3,4 4,1 5,0 5,7 6,4 7,3 8,2 9,1 10,2 11,4 °C 220 220 220 219 218 217 216 215 214 213 212 P1 bead P2 BEAD FORMATION bar 1,4 2, 2,8 4,2 5,4 6,8 8,9 11,3 13,9 17,6 21,7 mm 0,5 0,5 0,5 1,0 1,0 1,0 1,5 1,5 1,5 1,5 1,5 t2 HEATING UP 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. bar 0,1 0,1 0,2 0,3 0,4 0,5 0,6 0,8 0,9 1,2 1,4 Cyl. section cm2 sec 29 34 41 50 57 64 73 82 91 102 114 5,88 material PE80-100 D S T WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 3,0 3,6 4,3 5,2 6,0 6,7 7,6 8,6 9,5 10,7 11,9 °C 220 220 220 219 218 217 215 214 213 212 211 t3 t4 CHANGEOV. RAMP sec 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 5 5 5 5 5 6 6 6 7 7 sec 5 5 5 5 5 5 6 6 6 7 7 P5 t5 COOLING bar 1,2 1,7 2,4 3,6 4,6 5,8 7,6 9,6 11,8 15, 18,5 min 6 6 6 6 6 7 9 10 11 12 13 Welding range 63-250 mm SDR 22 PT 250 - DVS 2207-1 DIAMETER Welding range 63-250 mm t3 t4 CHANGEOV. RAMP sec 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 5 5 5 5 6 6 6 7 7 8 sec 5 5 5 5 5 6 6 6 7 7 8 P5 t5 COOLING bar 1,4 2, 2,8 4,2 5,4 6,8 8,9 11,3 13,9 17,6 21,7 min 6 6 6 7 8 9 10 11 13 14 15 Welding range 63-250 mm SDR 21 P1 bead BEAD FORMATION bar 1,4 2, 2,9 4,4 5,7 7,1 9,3 11,8 14,5 18,4 22,7 mm 0,5 0,5 0,5 1,0 1,0 1,0 1,5 1,5 1,5 1,5 1,5 P2 t2 HEATING UP bar 0.. 0,1 0.. 0,1 0.. 0,2 0.. 0,3 0.. 0,4 0.. 0,5 0.. 0,6 0.. 0,8 0.. 1,0 0.. 1,2 0.. 1,5 sec 30 36 43 52 60 67 76 86 95 107 119 t3 t4 CHANGEOV. RAMP sec 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 5 5 5 6 6 6 7 7 7 8 sec 5 5 5 5 6 6 6 7 7 7 8 P5 t5 COOLING bar 1,4 2, 2,9 4,4 5,7 7,1 9,3 11,8 14,5 18,4 22,7 min 6 6 6 7 8 9 11 12 13 14 16 Warning!: in case of PE100 welding, temperature T must be increased to 220°c 19 I.T.S. Ital Trade Services PT 250 Operating Manual Cyl. section cm2 PT 250 - DVS 2207-1 5,88 material PE80-100 D S T DIAMETER WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 3,6 4,3 5,1 6,3 7,1 8,0 9,1 10,2 11,4 12,8 14,2 °C 220 220 219 217 216 215 214 213 212 210 209 SDR 17,6 P1 bead P2 BEAD FORMATION bar 1,7 2,4 3,5 5,2 6,7 8,4 11, 13,9 17,2 21,7 26,8 mm 0,5 0,5 1,0 1,0 1,5 1,5 1,5 1,5 1,5 2,0 2,0 t2 HEATING UP bar 0.. 0,1 0.. 0,2 0.. 0,2 0.. 0,3 0.. 0,4 0.. 0,6 0.. 0,7 0.. 0,9 0.. 1,1 0.. 1,4 0.. 1,8 Cyl. section cm2 PT 250 - DVS 2207-1 sec 36 43 51 63 71 80 91 102 114 128 142 D S T WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 3,7 4,4 5,3 6,5 7,4 8,2 9,4 10,6 11,8 13,2 14,7 °C 220 220 219 217 216 215 214 212 211 210 209 P1 bead P2 BEAD FORMATION S T WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 4,6 5,5 6,6 8,1 9,2 10,3 11,8 13,2 14,7 16,5 18,4 °C 220 218 217 215 214 213 211 210 209 208 206 sec sec 5 5 5 6 6 6 7 7 8 8 9 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 5 5 6 6 6 7 7 8 8 9 bar 1,8 2,5 3,6 5,4 6,9 8,7 11,4 14,4 17,7 22,5 27,7 mm 0,5 0,5 1,0 1,0 1,5 1,5 1,5 1,5 1,5 2,0 2,0 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. bar 0,1 0,2 0,2 0,4 0,5 0,6 0,8 1,0 1,2 1,5 1,8 Cyl. section cm2 sec 37 44 53 65 74 82 94 106 118 132 147 t3 t4 CHANGEOV. RAMP sec sec 5 5 5 6 6 6 7 7 8 9 9 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5,88 5 5 5 6 6 6 7 7 8 8 9 t5 COOLING bar 1,7 2,4 3,5 5,2 6,7 8,4 11, 13,9 17,2 21,7 26,8 min 6 6 7 9 10 11 13 14 15 17 19 P5 t5 COOLING bar 1,8 2,5 3,6 5,4 6,9 8,7 11,4 14,4 17,7 22,5 27,7 min 6 6 7 9 10 11 13 14 16 17 19 Welding range 63-250 mm SDR 13,6 P1 bead BEAD FORMATION bar 2,2 3,1 4,4 6,6 8,5 10,7 14, 17,7 21,8 27,6 34,1 mm 1,0 1,0 1,0 1,5 1,5 1,5 1,5 2,0 2,0 2,0 2,0 P2 t2 HEATING UP bar 0.. 0,1 0.. 0,2 0.. 0,3 0.. 0,4 0.. 0,6 0.. 0,7 0.. 0,9 0.. 1,2 0.. 1,5 0.. 1,8 0.. 2,3 sec 46 55 66 81 92 103 118 132 147 165 184 t3 t4 CHANGEOV. RAMP sec sec 5 5 6 6 7 7 8 9 9 10 11 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 5 6 6 7 7 8 8 9 9 10 Warning!: in case of PE100 welding, temperature T must be increased to 220°c 20 P5 Welding range 63-250 mm t2 HEATING UP material PE80-100 D t4 RAMP SDR 17 PT 250 - DVS 2207-1 DIAMETER t3 CHANGEOV. 5,88 material PE80-100 DIAMETER Welding range 63-250 mm P5 t5 COOLING bar 2,2 3,1 4,4 6,6 8,5 10,7 14, 17,7 21,8 27,6 34,1 min 6 8 9 11 13 14 16 17 19 21 23 I.T.S. Ital Trade Services PT 250 Operating Manual Cyl. section cm2 PT 250 - DVS 2207-1 5,88 material PE80-100 D S T DIAMETER WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 5,7 6,8 8,2 10,0 11,4 12,7 14,5 16,4 18,2 20,5 22,7 °C 218 216 215 213 212 210 209 208 207 205 204 SDR 11 P1 bead P2 BEAD FORMATION bar 2,6 3,7 5,4 8, 10,3 13, 16,9 21,4 26,5 33,5 41,4 mm 1,0 1,0 1,5 1,5 1,5 2,0 2,0 2,0 2,0 2,5 2,5 t2 HEATING UP bar 0.. 0,2 0.. 0,2 0.. 0,4 0.. 0,5 0.. 0,7 0.. 0,9 0.. 1,1 0.. 1,4 0.. 1,8 0.. 2,2 0.. 2,8 Cyl. section cm2 PT 250 - DVS 2207-1 sec 57 68 82 100 114 127 145 164 182 205 227 D S T WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 7,0 8,3 10,0 12,2 13,9 15,6 17,8 20,0 22,2 25,0 27,8 °C 216 215 213 211 210 208 207 206 205 203 203 P1 bead P2 BEAD FORMATION S T WALL THICK. TEMP. mm 63 75 90 110 125 140 160 180 200 225 250 mm 8,5 10,1 12,2 14,9 16,9 18,9 21,6 24,3 27,0 30,4 33,8 °C 214 213 211 209 208 206 205 204 203 202 202 sec sec 5 6 6 7 8 8 9 10 11 12 13 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5 6 6 7 8 8 9 9 10 10 11 P5 t5 COOLING bar 2,6 3,7 5,4 8, 10,3 13, 16,9 21,4 26,5 33,5 41,4 min 8 10 11 14 15 17 19 21 23 26 28 Welding range 63-250 mm bar 3,1 4,5 6,4 9,6 12,4 15,5 20,3 25,6 31,6 40,1 49,4 mm 1,0 1,5 1,5 2,0 2,0 2,0 2,0 2,5 2,5 2,5 3,0 t2 HEATING UP 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. bar 0,2 0,3 0,4 0,6 0,8 1,0 1,4 1,7 2,1 2,7 3,3 Cyl. section cm2 sec 70 83 100 122 139 156 178 200 222 250 278 t3 t4 CHANGEOV. RAMP sec sec 6 7 7 8 9 10 10 11 12 14 15 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 5,88 material PE80-100 D t4 RAMP SDR 9 PT 250 - DVS 2207-1 DIAMETER t3 CHANGEOV. 5,88 material PE80-100 DIAMETER Welding range 63-250 mm 6 7 7 8 9 9 10 10 11 12 13 P5 t5 COOLING bar 3,1 4,5 6,4 9,6 12,4 15,5 20,3 25,6 31,6 40,1 49,4 min 10 12 14 16 18 20 23 25 28 31 34 Welding range 63-250 mm SDR 7,4 P1 bead BEAD FORMATION bar 3,7 5,3 7,6 11,3 14,6 18,3 24, 30,3 37,4 47,4 58,5 mm 1,5 1,5 2,0 2,0 2,0 2,0 2,5 2,5 3,0 3,0 3,0 P2 t2 HEATING UP bar 0.. 0,2 0.. 0,4 0.. 0,5 0.. 0,8 0.. 1,0 0.. 1,2 0.. 1,6 0.. 2,0 0.. 2,5 0.. 3,2 0.. 3,9 sec 85 101 122 149 169 189 216 243 270 304 338 t3 t4 CHANGEOV. RAMP sec sec 7 7 8 9 10 11 12 13 14 16 18 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 0.. 7 7 8 9 9 10 11 11 12 14 15 P5 t5 COOLING bar 3,7 5,3 7,6 11,3 14,6 18,3 24, 30,3 37,4 47,4 58,5 min 12 14 16 19 22 24 27 30 33 37 41 Warning!: in case of PE100 welding, temperature T must be increased to 220°c 21 I.T.S. Ital Trade Services PT 250 Operating Manual 7. Welding Parameters for PP pipes & fittings DVS norm version 2207-11 material PP SDR Cylinder section cm2 5,88 PP D S Temp. P1 bead P2 t2 t3 t4 P5 t5 mm mm °C bar Mm bar sec sec sec bar sec 63 75 90 110 125 140 160 180 200 225 250 1,8 1,9 2,2 2,7 3,1 3,5 3,9 4,4 4,9 5,5 6,1 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 0,6 0,7 1,0 1,5 2,0 2,6 3,3 4,1 5,1 6,4 7,9 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,1 0,1 0,1 0,2 0,2 0,3 0,3 0,4 0,5 0,6 0,8 135 135 135 135 135 135 135 135 141 151 161 5 5 5 5 5 5 5 5 5 5 6 material PP SDR 33 PP 6 0,6 360 6 0,7 360 6 1,0 360 6 1,5 360 6 2,0 360 6 2,6 360 6 3,3 360 6 4,1 360 6 5,1 418 6 6,4 504 7 7,9 590 2 Cylinder section cm 5,88 D S Temp. P1 bead P2 t2 t3 t4 P5 t5 mm mm °C bar Mm bar sec sec sec bar sec 63 75 90 110 125 140 160 180 200 225 250 2 2,4 2,8 3,5 3,9 4,4 5 5,6 6,2 7 7,8 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 0,7 0,9 1,3 2,0 2,5 3,2 4,1 5,2 6,4 8,1 10,1 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 1 0,1 0,1 0,1 0,2 0,3 0,3 0,4 0,5 0,6 0,8 1,0 135 135 135 135 135 135 143 153 162 175 186 5 5 5 5 5 5 5 5 6 6 6 material PP 22 41 SDR 26 PP 6 0,7 360 6 0,9 360 6 1,3 360 6 2,0 360 6 2,5 360 6 3,2 360 6 4,1 432 6 5,2 518 7 6,4 605 7 8,1 720 8 10,1 797 2 Cylinder section cm 5,88 D S Temp. P1 bead P2 t2 t3 t4 P5 t5 mm mm °C bar Mm bar sec sec sec bar sec 63 75 90 110 125 140 160 180 200 225 250 2,5 2,9 3,5 4,3 4,9 5,4 6,2 7 7,7 8,7 9,7 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 0,8 1,1 1,6 2,4 3,1 3,9 5,1 6,5 7,9 10,0 12,4 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 1 1 1 0,1 0,1 0,2 0,2 0,3 0,4 0,5 0,6 0,8 1,0 1,2 135 135 135 135 141 149 162 175 185 199 213 5 5 5 5 5 5 6 6 6 6 7 6 6 6 6 6 6 7 7 8 8 9 0,8 1,1 1,6 2,4 3,1 3,9 5,1 6,5 7,9 10,0 12,4 360 360 360 360 418 490 605 720 787 883 979 I.T.S. Ital Trade Services material PP PT 250 Operating Manual SDR 17.6 Cylinder section cm2 5,88 PP D S Temp. P1 bead P2 t2 t3 t4 P5 t5 mm mm °C bar mm bar sec sec sec bar sec 63 75 90 110 125 140 160 180 200 225 250 3,6 4,3 5,1 6,3 7,1 8 9,1 10,2 11,4 12,8 14,2 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 1,1 1,6 2,3 3,5 4,5 5,6 7,3 9,2 11,5 14,5 17,9 0,5 0,5 0,5 0,5 1 1 1 1 1 1 1 0,1 0,2 0,2 0,3 0,4 0,6 0,7 0,9 1,1 1,5 1,8 135 135 145 164 176 189 204 220 237 255 271 5 5 5 6 6 6 6 7 7 7 8 material PP SDR 11 PE 100 6 1,1 360 6 1,6 360 6 2,3 446 7 3,5 619 7 4,5 730 8 5,6 816 9 7,3 922 10 9,2 1027 11 11,5 1142 12 14,5 1269 13 17,9 1389 2 Cylinder section cm 5,88 D S Temp. P1 bead P2 t2 t3 t4 P5 t5 mm mm °C bar mm bar sec sec sec bar sec 63 75 90 110 125 140 160 180 200 225 250 5,8 6,9 8,2 10 11,4 12,8 14,6 16,4 18,2 20,5 22,8 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 210° 1,8 2,5 3,6 5,3 6,9 8,7 11,3 14,3 17,7 22,4 27,7 0,5 0,5 1 1 1 1 1 1 1 1,5 1,5 0,2 0,3 0,4 0,5 0,7 0,9 1,1 1,4 1,8 2,2 2,8 156 173 192 217 237 255 276 298 319 345 368 6 6 6 7 7 7 8 8 9 9 10 7 7 8 9 11 12 13 15 16 18 20 1,8 2,5 3,6 5,3 6,9 8,7 11,3 14,3 17,7 22,4 27,7 547 706 835 1008 1142 1269 1423 1577 1731 1929 2126 23 I.T.S. Ital Trade Services PT 250 Operating Manual 8. Maintenance 8.1 Basic machine It's strongly suggested to keep always the machine clean with particular care of the bolts and the cylinder's heads . Keep attention while insert the electric facing tool and the PTFE coated heating mirror avoiding to damage the machine's slide bars. 8.2 Facing tool It's strongly suggested to keep always clean the blades and wash the pulleys by using a detergent. At regular intervals carry out a complete cleaning operation with a internal lubrication as well , as per following instructions: - Remove the carter by enlighten the screws - Take out the shavings might be present - Enlighten the screws and remove the pulley and carry out the cleaning and the lubrication of the bearing . 8.3 Heating mirror Please take care on handling the heating mirror in order to avoid damages to the PTFE coating. Keep always clean the PTFE coated surfaces, cleaning must be done with surface still warm by using a soft cloth or paper, avoiding abrasive materials in that might damage the PTFE coated surfaces. To achieve this operation you must wear protective gloves At regular intervals we suggest you to: - Clean the surfaces by a quick evaporation detergent (alcohol) - Check the tightening of the screws and the cable and plug condition - Verify the temperature differences on the heating mirror surfaces according to the following table DVS norm 2208-1 here following table: WELDING SURFACE OF THE MIRROR < 250 cm2 250 …. 2000 cm2 2000 …. 5000 cm2 5000 …. 12000 cm2 > 12000 ∆Τ1 5 °C 7 °C 11 °C 13 °C 14 °C ∆Τ2 3 °C 3 °C 3 °C 3 °C 3 °C ∆ΤΤΟΤ 8 °C 10 °C 14 °C 16 °C 17 °C ∆Τ1 Maximum temperature difference on the mirror surface ∆Τ2 Temperature deviation for the adjustment ∆ΤΤΟΤ Maximum accepted difference on the mirror surface 8.4 Hydraulic unit The hydraulic unit does not need particular maintenance nevertheless the following instructions must be followed: 1. Check periodically the oil level and in case add with oil type: ESSO NUTO H 68,SHELL TELLUS 68,MOBIL DTE 26,AGIP OSO 46 The level should not be lower than 5 cm from the tank maximum level. A checking every 15 working days it's strongly suggested. 2. Replace totally the oil every 6 months or after 500 working hours. 3. Keep clean the hydraulic unit with particular care on the tank and quick couplings. 4. Avoid to operate with rain or high humidity (95 RH %) value and temperatures below 0°C or above + 50°C. 5. During the transport it's suggested to put the metal plug instead of the plastic one. 24 I.T.S. Ital Trade Services PT 250 Operating Manual 9. Troubleshooting and relative solutions 9.1 Basic machine a) The quick couplings can't be connected: Check if there's pressure on the hoses in case bring the pressure to zero ( see relative instructions ) Check if the quick couplings are clean b) The machine does not move in linear way: The above mentioned situation could happen in case of clash or in case the machine with the pipe assembled in has been fiercely moved. If the damaged part can be located proceed to the substitution, however if the trouble still remain, kindly contact the Customer Service c) The nut/s is/are seizure: Replace the complete tie rod bolt d) Oil leakage in the cylinders: Consult the Customer Service Dept. verify if it's necessary to replace the cylinders or just the gasket 9.2 Facing tool a) The engine does not start: Unplug the facing tool and check the electric connections and the safety micro-switch b) The engine is burnt out: In case it's need to replace the engine the following operations must be done: - Unplug the facing tool - Enlighten the screws connecting the engine to the facing tool, disconnect the safety micro-switch and wires - Remove the engine by means of pulling in upper direction, remove the joint from the drill - Screw the joint on the new engine - Mount the new drill engine by taking care to fix the joint gap in a proper way - Tighten the screws connecting the engine to the facing tool, connect the safety micro-switch and wires c) The blades do not remove material: Wear and tear of one cutting side enlighten the screws and turn the blades using the other side. Wear and tear of both cutting side of the blades replace with original spare parts. 9.3 Hydraulic unit a) The engine does not start: Check that the hydraulic unit engine is switched on The microswitch is damaged or wrongly adjusted - To adjust the microswitch you must enlighten the screws show in the figure below and bring the lever A to position A3. - Move the microswitch towards the internal of the hydraulic until the engine start and tighten the fixing screw. - Check that in position A1the engine is switched off. - In different case adjust the microswitch position again. b) The engine replacement: Check that the electric plug is disconnected Open the electric connections box and disconnect the micro-switch cable Enlighten the screws and take out the engine Take out the joints and insert them on the new engine Reassemble the engine taking care that the joints are perfectly located on the own housings Check the anti clockwise rotation of the electric fan 25 I.T.S. Ital Trade Services PT 250 Operating Manual c) If the hydraulic unit cannot increase the pressure reasons could be : - Check the oil level - The lever E is not closed. - Check if they are some leakage on hydraulic circuit. d) If the hydraulic unit cannot maintain a constant pressure reasons could be : - The lever E is not closed. - The accumulator is down or damaged. To replace the pressure gauge follows the below steps: 1. Bring the pressure to zero and enlighten the bolt 2. Take out the fitting and replace the damaged accumulator with the new one 3. Tighten the bolt 9.4 Hearting mirror a) 26 The heating mirror does not warm up: 1. Check if the light is switched off , in case check the plug 2. The light is switched on, probably a wire disconnected , check the contacts as follows: - Take off the plug from the power - Unscrew the nuts and take out the thermostat support - Unscrew the screws and remove the cap - Check all the electric connections and reassemble - Unscrew the screws and take out the cover - Check all the electric connections and reassemble 3. By utilizing a Tester check if all the resistances are in good condition ,if one or more are broken the heating mirror must be changed 4. By utilizing a tester check the working of the thermostat, in case substitute 5. For additional information on electric components, please refer to our Technical Dept. I.T.S. Ital Trade Services PT 250 Operating Manual 10. Drawings 10.1 Thermostat connection 10.2 Facing tool and hydraulic unit engines connection 27 I.T.S. Ital Trade Services 10.3 Hydraulic plan 28 PT 250 Operating Manual I.T.S. Ital Trade Services PT 250 Operating Manual 11. Exploded view and spare parts list 29 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Basic Machine , Code: PT250B PT 250 Basic Machine , Code: PT250B Pos. Code Description Qty Pos. Code Description Qty 1 2 3 4+5 6 7 8 9 10 11 12 13 14 15+16 17 18+19 20 21 22 23+24 25 26 27 28 PT250B01 PT250B02 PT250B03 PT250B04+05 PT250B06 PT250B07 PT250B08 PT250B09 PT250B10 PT250B11 PT250B12 PT250B13 PT250B14 PT250B15+16 PT250B17 PT250B18+19 PT250B20 PT250B21 PT250B22 PT250B23+24 PT250B25 PT250B26 PT250B27 PT250B28 side support screw TCEI UNI 5931 8.8 8x35 Nut fixing cylinder’s tie rod first clamp (04+05) cylinder’s tie rod quick coupling M/F 1/4 Tee fitting TN 96 10 LR Fitting TN 126 10 LR Danger label Upper Cylinder washer bonded 1/4 Technical data label Serial no. label Second clamp (15+16) 35.40 FB1 bush Third clamp (18+19) Back nut for spacer Screw TSPEI 5933 10.9 8x30z Spacer Fourth clamp c/w support (23+24) Screw TCEI UNI 5931 8.8 10x40z Beep beep coupler system Nut tie rods Washer for tie rods 1 2 8 1 8 1 2 2 2 1 4 1 1 1 2 1 3 3 2 1 2 16 8 8 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 PT250B29 PT250B30 PT250B31 PT250B32 PT250B33 PT250B34 PT250B35 PT250B36 PT250B37 PT250B38 PT250B39 PT250B40 PT250B41 PT250B42 PT250B43 PT250B44 PT250B45 PT250B46 PT250B47 PT250B48 PT250B49 PT250B50 PT250B51 Tie rod closer Tie rod pivot Screw STEI UNI 5923 45h 6x14z Front nut for spacer Screw TSPEI 5933 10.9 10x45z H. mirror disconnecting device pin H.mirror disconnecting dev. hooker H.mirror disconnecting dev. body Lower Cylinder Oil collector hose Black plastic plug 60x30 Covers ABS 22X2 Screw TCEI UNI 5931 8.8 8x16z Fitting TN 92 10 LR (1/4) transport pipe Stop limit label Ground support rivet tt UNI 9200 3x7 all ITS – TECNODUE label blind nut UNI 5721 8 m 10 z washer UNI 6592 m 10 z Third bar tie rod Third bar 8 8 8 3 3 1 1 1 1 2 4 4 4 2 2 2 2 4 1 1 1 1 1 PT 250 Upper Cylinder , Code: PT250B11 PT 250 Lower Cylinder , Code: PT250B37 Pos. Code Description Qty Pos. Code Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 PT250B1101 PT250B1102 PT250B1103 PT250B1104 PT250B1105 PT250B1106 PT250B1107 PT250B1108 PT250B1109 PT250B1110 PT250B1111 PT250B1112 Gasket GHK 313 35.0 43.6 5.3 38.0 35.30 FB1 bush Upper cylinder head Gasket I/GR 0350 NCR O-ring 3187 NBR 70 2.62x47.30 (134) Gasket ring Gasket E/GR 0400 NPS Cylinder’s housing Cylinder’s stem Stopper ring Screw TCEI UNI 5931 8.8 6x10 z Washer 6x12x1,5 2 2 2 2 2 2 1 1 1 2 2 2 1 2 3 4 5 6 7 8 9 10 PT250B3701 PT250B3702 PT250B3703 PT250B3704 PT250B3705 PT250B3706 PT250B3707 PT250B3708 PT250B3709 PT250B3710 Gasket GHK 313 35.0 43.6 5.3 38.0 35.30 FB1 bush Upper cylinder head Gasket I/GR 0350 NCR O-ring 3187 NBR 70 2.62x47.30 (134) Gasket ring Gasket E/GR 0400 NPS Cylinder’s housing Cylinder’s stem Stopper ring 2 2 2 2 2 2 1 1 1 2 Beep Beep coupler system, Code: PT250B26 PT 250 Gasket kit, Code: PT250B37KT Pos. Code Description Qty Pos. Code Description Qty 1 2 3 PT250B2601 PT250B2602 PT250B2603 Pivot for beep beep coupler system Hook for beep beep coupler system Spring for beep beep coupler system 1 1 1 1 4 5 7 PT250B3701 PT250B3704 PT250B3705 PT250B3707 Gasket GHK 313 35.0 43.6 5.3 38.0 Gasket I/GR 0350 NCR O-ring 3187 NBR 70 2.62x47.30 (134) Gasket E/GR 0400 NPS 2 2 2 1 30 I.T.S. Ital Trade Services PT 250 Operating Manual 31 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Hydraulic Unit , Code: PT160A PT 250 Hydraulic Unit , Code: PT160A Pos. Code Description Qty Pos. Code Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PT160A01 PT160A02 PT160A03 PT160A04 PT160A05 PT160A06 PT160A07 PT160A08 PT160A09 PT160A10 PT160A11 PT160A12 PT160A13 PT160A14 PT160A15 PT160A16 PT160A17 PT160A18 PT160A19 PT160A20 PT160A21 PT160A22 PT160A23 PT160A24 PT160A25 PT160A26 PT160A27 PT160A28 PT160A29 PT160A30 PT160A31 PT160A32 PT160A33 PT160A34 PT160A35 PT160A36 PT160A37 PT160A38 Hose R1T M 1/4 + FD 1/4 L=2500 Oil tank LT.1 washer ½ Plug 1/2 Filter UP 100 Screw TCEI uni 5931 8.8 8x85 zin Washer grower UNI 1751 m8 z Gear pump PS-1/1.25 S O-ring 2037 NBR 1.78x9.25 (012) O-ring 3106 NBR 2.62x26.65 (121) O-ring 4450 NBR 3.53x113.9 (246) Max pressure valve FPMDC15P35 Pump body HY 10 K3P0-01 ¼ BB Screw TCEI uni 5931 8.8 6x35 zin O-ring 2056 NBR 1.78x14.00 (015) Check valve RPC 04 / 2.5 00 00 Distributor shaft TC2 dr. C0618 Distributor block HD 104 Lever protection HD 104 By pass valve V03/M Handle Distributor lever HD 104 L.185 Complete distributor TC2 Pressure regulating valve VEN 06 Screw TCEI UNI 5931 8.8 4x10 z Washer UNI 6592 m 4 zin Nut UNI 7473 8 m4 Plastic cap Screw TCEI UNI 5931 8.8 4x35z Microswitch ASITZ 7141 Screw STEI UNI 5923 45h 10x14 z Nut UNI 5589 8 m 10 zin Spring latch Ball 5/16” Washer 1/4 Screw TCEI UNI 5931 8.8 8x70z Generic danger label Connector FT 299 44 M ¼” 2 1 1 1 1 2 2 1 1 1 1 1 1 4 2 1 1 1 1 1 1 1 1 1 2 6 2 1 2 1 2 1 1 1 9 2 1 1 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 PT160A39 PT160A40 PT160A41 PT160A42 PT160A43 PT160A44 PT160A45 PT160A46 PT160A47 PT160A48 PT160A49 PT160A50 PT160A51 PT160A52 PT160A53 PT160A54 PT160A55 PT160A56 PT160A57 PT160A58 PT160A59 PT160A60 PT160A61 PT160A62 PT160A63 PT160A64 PT160A65 PT160A66 PT160A67 PT160A68 PT160A69 PT160A70 PT160A71 PT160A72 PT160A73 PT160A74 PT160A75 Plug d. 8 Nipples M 1/4 Washer 18X1.5 accumulator L 01/8 with 20 g. oil Hydraulic unit control label Carter for valves protection Screws TBEI 10.9 6X10 z Serial number label Technical data label Carter Rivet tt uni 9200 3x7 all ITS - TECNODUE 80X25 label Screw TC CR UNI 6954 3.5X19 zin light switch 16A + cap Electric danger label Box FMA 63 / 71 Fan cover MEC 71 Fan MEC 71 Condenser 20MF Cable H07 RNF 2G1 TITANEX Engine MEC 71 HP 0.5 B14 230V 4P Cable H07 RNF 3G1 TITANEX Hollow screw Plug 1/4 Pressure gauge support Pressure gauge D.100 range 0-100 BAR Screw TCEI UNI 5931 8.8 6x16 zin Engine flange c.a. HP 0.33/0.5 FLCA71 Joint HP 0.33/0.50 Pump joint g. 1 x 0.27 reinf. Washer fl m 10x30x2,5 zin Screw TCEI UNI 5931 8.8 10x25 zin Support 18-20 Frame Unit model HY10 130 complete Nut DIN 6923 8 m 6 quick coupling M/F 1/4 1 1 1 1 1 1 4 1 1 1 4 1 4 1 1 1 1 1 1 32 0,35 1 3 1 1 1 1 8 1 1 1 2 2 4 1 1 4 1 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Facing Tool , Code: PT250F PT 250 Facing Tool , Code: PT250F Pos. Code Description Qty Pos. Code Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PT250F01 PT250F02 PT250F03 PT250F04 PT250F05 PT250F06 PT250F07 PT250F08 PT250F09 PT250F10 PT250F11 PT250F12 PT250F13 PT250F14 PT250F15 PT250F16 PT250F17 PT250F18 PT250F19 PT250F20 PT250F21 PT250F22 PT250F23 PT250F24 PT250F25 PT250F26 PT250F27 PT250F28 Generic danger label Electric danger label Plastic stub 142X3.6 Ring UNI 7434 c70 4 Bush Lever Pivot Nut Spring Facing tool stopper pivot Cable H07 RNF 3G1 Double insulating pipe 2x2.5mm2 P=10MM blue Cable stopper PG11 163/11 Switch Screw TCEI UNI 5931 8.8 5x35 zin Cable holder 604 / 6 Screw UNI 6107 4.8 3x8z Wheel for reducing gear 3 holes blade Screw tspi UNI 6109 4x12 a2 Screw TCEI UNI 5931 8.8 8x60 Left disk Screw TSPEI 5933 10.9 5x12 z Flange Bearing 16008 Rivets tt UNI 7346 2,5x6,5 brass label ITS - TECNODUE 80X25 Facing tool body PT 160 1 1 2 2 1 1 1 1 1 1 0,6 1 2 1 2 1 2 1 2 6 2 1 6 1 2 4 1 1 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 PT250F29 PT250F30 PT250F31 PT250F32 PT250F33 PT250F34 PT250F35 PT250F36 PT250F37 PT250F38 PT250F39 PT250F40 PT250F41 PT250F42 PT250F43 PT250F44 PT250F45 PT250F46 PT250F47 PT250F48 PT250F49 PT250F50 PT250F51 PT250F52 PT250F53 PT250F54 PT250F55 End connector M4 Washer fl UNI m 4x12x1.5 zin Facing tool stopper Screw spacer Washer fl UNI m 5x15x1,5 zin Insulating pipe 1.5mm2 P=8MM red Screw TCEI UNI 5931 8.8 5x25 z Cable H07 RNF 3G1,5 TITANEX Cable stopper PG11 Screw TCEI UNI 5931 8.8 4x10 zin Serial no. label Technical data label Box cover Terminal mm2 2,5 Terminal mm2 4 Double ins. pipe 2X1.5mm2 P=8MM black Cable stopper PG9 163/9 Stopper Screw TCEI UNI 5931 8.8 8x45 zin Right disk Bearing 51100 Bearing 6002 ZZ Screw for reducing gear Bearing 6003 ZZ Ring UNI 7437 c 70 35 Drill joint drill PERLES PSB 7 Qty 1 1 1 1 1 3 1 3,3 1 5 1 1 1 3 1 3 1 1 1 1 1 1 1 1 1 1 1 33 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Heating Mirror , Code: PT250T PT 250 Heating Mirror , Code: PT250T Pos. Code Description Qty Pos. Code Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 PT250T01 PT250T02 PT250T03 PT250T04 PT250T05 PT250T06 PT250T07 PT250T08 PT250T09 PT250T10 PT250T11 PT250T12 PT250T13 PT250T14 PT250T15 PT250T16 PT250T17 PT250T18 PT250T19 PT250T20 PT250T21 PT250T22 PT250T23 PT250T24 PT250T25 PT250T26 PT250T27 PT250T28 PT250T29 Thermometer o-ring 2200 NBR 1.78x50.52 (033) Danger and compulsory label Screw TCEI UNI 5931 a2 5x12 Thermometer holder cover Insulating red pipe D.5 1.5V 1 1 3 2 1 0,2 1 8 8 7 3 6 1 2 3,3 1 4 1 1 4 1 1 1 1 1 1 1 1 4 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 PT250T30 PT250T31 PT250T32 PT250T33 PT250T34 PT250T35 PT250T36 PT250T37 PT250T38 PT250T39 PT250T40 PT250T41 PT250T42 PT250T43 PT250T44 PT250T45 PT250T46 PT250T47 PT250T48 PT250T49 PT250T50 PT250T51 PT250T52 PT250T53 PT250T54 PT250T55 PT250T56 PT250T57 Screw TCEI UNI 5931 8.8 4x10Z Relay 230 VAC 30A Nut UNI 5588 m 4 zin Red female connector 6.35x0.8 Yellow insulating pipe 1 mm2 P=8MM Red insulating pipe 1,5 mm2 P=8MM 3 studs terminal 5 studs terminal Black flame retardant wire 1 mm2 Nut ISO M25x1.5 CE Brass nut PG11 169/11 Washer UNI 6593 m 4 Nut UNI 7473 8 m 4 Cable stopper PG11 Cable H07 RNF 3G1,5 TITANEX Female terminal Nut UNI 5588 m 3 brass Connector UTG 012-8S Connector 8 pins Screw TSPI UNI 6109 3x12 brass Screw TCI UNI 6107 3x10 brass Black plastic stub 99x2.5 Ring 3.5 type 0 Ring 3.5 type 1 Ring 3.5 type 2 Ring 3.5 type 3 Ring 3.5 type 5 Gasket for TLK38 thermostat 33X74 2 1 2 2 8 7 1 1 2 1 1 4 4 1 3,3 4 4 1 1 1 3 6 1 5 2 1 1 1 34 O-ring 2400 NBR 70 1.78x101.32 (045) Screw TCEI UNI 5931 a2 5x30 Washer grower UNI 1751 m5 z terminal mm2 2,5 terminal 4/6 mm2 Red cap for wire 2x1mm2 Handle with hole for cable st. Cable stopper M25 Cable H07 RNF 7G1,5 TITANEX Heating plate PT 250 Gasket Probe PT100 2+2 wires Spacer Gasket Box Rubber handle D. 30 Thermostat TLK38 Electric danger label ITS – TECNODUE 80X25 label Technical data label Serial no. label Thermostat box Screw TC CR 7687 4.8 4x16 zin I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Stub Device , Code: PT250S PT 250 Stub Device , Code: PT250S Pos. Code Description Qty Pos. Code Description Qty 1 2 3 4 5 PT250S01 PT250S02 PT250S03 PT250S04 PT250S05 Plateau PT 250 Cursor Screw STEI UNI 5927 45h 8x35 zin Bracket screw TCEI UNI 5931 8.8 8x20 zin 1 4 4 2 4 6 7 8 9 10 PT250S06 PT250S07 PT250S08 PT250S09 PT250S10 Fixing stub end bracket Screw STEI UNI 5927 45h 5x8 zin Upper stopper Screw STEI UNI 5923 45h 8x20 Screw for fixing s.e. braket 2 2 2 2 2 Pos. Code Description Qty Pos. Code Description 1 2 3 4 PT160TK01 PT160TK02 PT160TK03 PT160TK04 Screw TCEI UNI 5931 8.8 6x50 zin Socket wrench Setscrew wrench UNI 6753 s 4 Setscrew wrench UNI 6753 s 5 8 1 1 1 5 6 7 PT160TK05 PT160TK06 PT160TK07 Setscrew wrench UNI 6753 s 6 Plug ½ for hydraulic unit Screw driver Pos. Code Description Qty Pos. Code Description 1 PT250U01 Support 1 2 PT250U02 Black plug 60x30 PT 250 Tools kit, Code: PT250TK PT 250 Tools kit, Code: PT250TK PT 250 Support, Code: PT250U 1 2 Description Half wide ring av. sizes: 63,75,90,110,125,140,160,180,200,225mm Half narrow ring av. sizes: 63,75,90,110,125,140,160,180,200,225mm 1 1 1 PT 250 Support, Code: PT250U PT 160 Half reduction Pos. Qty Qty 4 PT 250 Short spigot fit. clamp, Code: PT250G Qty Pos. Code Description 1 PT250G02 Short Spigot fittings clamp Qty 1 35 I.T.S. Ital Trade Services PT 250 Operating Manual This manual has been printed on December 2008 The technical data and information contained in this manual can be changed without any notice 36
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Author : Administrator Create Date : 2009:05:05 12:56:05+02:00 Modify Date : 2016:09:22 00:29:34+08:00 Subject : XMP Toolkit : Adobe XMP Core 5.2-c001 63.139439, 2010/09/27-13:37:26 Producer : GPL Ghostscript 8.63 Keywords : Creator Tool : PDFCreator Version 0.9.6 Metadata Date : 2016:09:22 00:29:34+08:00 Document ID : e3cb24e9-3bbe-11de-0000-f6ce42bea240 Instance ID : uuid:7491cc19-ec2c-464c-bd2a-09e705fc26c0 Format : application/pdf Title : PT 250 2008.12 Creator : Administrator Description : Page Count : 36EXIF Metadata provided by EXIF.tools