Fusion G180110/220AFE Operating Manual Download Page 1

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Gator Automatic Butt Fusion

Range

Operating Manual

www.fusiongroup.com

Summary of Contents for G180110/220AFE

Page 1: ...Gator Automatic Butt Fusion Range Operating Manual www fusiongroup com...

Page 2: ...Poor practice during Butt Fusion 12 6 Preparation 13 6 1 Familiarisation with Equipment 13 6 2 Clamp Liners 13 6 3 Connections 13 7 Manual data entry 14 7 1 Data entry 14 8 Status bar 15 8 1 Standard...

Page 3: ...bles Menu option 04 35 13 6 Remove user history Menu option 05 36 13 7 Recover archived records Menu option 06 36 13 7 Daylight saving Menu option 07 36 14 User diagnostics menu 37 14 1 Test Calibrati...

Page 4: ...chine has been fitted with overload protection and a residual current device RCBO Always take care where you see the electrical warning labels displayed Only authorised engineers must attempt to open...

Page 5: ...eliminate the risk of injury the operator should ensure that all personnel are clear of the heater at this time If the emergency stop button is actuated during the heating cycle when the emergency sto...

Page 6: ...atic Butt Fusion Machine 2 1 Controller The controller keypad is located under the protective cover of the control unit lid Display Close button Down button Start or enter button Right button Alarm wa...

Page 7: ...cover and remove to gain access Emergency stop button Hydraulic hose connectors Input cable USB Socket Chassis socket Trimmer socket Heater socket Temperature sensor Scanner socket Printer socket Sock...

Page 8: ...sensitive electronic components located within the electronic control enclosure Do not attempt to open this enclosure there are no user serviceable parts inside 2 2 Heater Circuit breaker RESET button...

Page 9: ...Gator Automatic Butt Fusion Range Operating Manual EDOI6922 Page 9 of 44 Issue 02 2 3 Trimmer 2 4 Chassis Temperature Indicator Trimmer blade Securing fixture Clamp adjusters Fast clamps...

Page 10: ...damage to the hydraulic hoses such as deep gouges or leaks Check the hydraulic oil level top up with approved hydraulic oil refer to section 4 1 1 Oil check Ensure that the Barcode Reader is connected...

Page 11: ...here necessary assistance should be sought before carrying moving or lifting this equipment In particular if the equipment cannot be easily manually lifted mechanical assistance should be used When tr...

Page 12: ...discs and blades before use Ensure that when trimming a continuous ribbon of material of complete pipe wall thickness is produced from both pipe ends before stopping the trimmer and advancing to the f...

Page 13: ...s to the control unit are located on the rear of the control enclosure Electrical plugs and sockets are both sturdy and waterproof However care should be taken to ensure that the connections are alway...

Page 14: ...nnot be seen the box is in Edit Mode Insert Characters Characters will always be inserted to the left of the Edit cursor until the entry field is full The Edit cursor will move to the right as charact...

Page 15: ...ation entry fitting information and fusing screens Memory status Number of joints to next service Number of days to next service Time Date Input voltage 8 2 Backing up record to memory card This statu...

Page 16: ...e Download to PC status 8 5 Printing joint record This status bar is shown when sending data to printer in review joint record s and print joint record s modes Memory status Number of joints to next s...

Page 17: ...n 13 user menu 9 2 BlueBox If BlueBox has been enabled then a mobile device must be connected to the unit via Bluetooth with the BlueBox application open before the information entry screen is display...

Page 18: ...nd right buttons on the keypad Then press the green button on the keypad to select the character Repeat this until the required information is entered Then select press the green button on the keypad...

Page 19: ...l Diameter SDR Colour CONTINUE In order to ensure that the correct welding parameters are used for the jointing process the operator must select the correct parameters as detailed below The operator m...

Page 20: ...achine must be exercised Press to continue Press the green button to operate the automatic oil warm up sequence as prompted The hydraulic pump will operate for one minute and can be bypassed by pressi...

Page 21: ...chine detects that the trimmer is in position a beep will sound once confirming correct fitting and the display will change to Joint 97 233C Set up Load pipes PE63 250 SDR11 to continue 11 2 4 Pipe lo...

Page 22: ...and the clamp adjusters moved until the lever is in a vertical position the levers may then be pushed onto the top clamp Note that the adjusters should only be moved when the fast clamp levers are in...

Page 23: ...pt Joint 97 233C Auto trim cycle Remove the trimmer to continue PE63 250 SDR11 Unlock the trimmer by turning the twist locks anti clockwise Remove the trimmer and carefully replace it into the heater...

Page 24: ...s prompted check the two pipes align correctly and that pipe to pipe contact is evident around the entire joint circumference If acceptable press the green button to continue the process The control s...

Page 25: ...3C Check pipe Secure heater on chassis PE63 250 SDR11 Wait for correct temperature When the temperature is within the specified limits for that standard the display will show Joint 97 233C Check pipe...

Page 26: ...dicate Joint 97 233C Bead up Forming internal bead PE63 250 SDR11 Please wait After several seconds the display will also indicate Please wait Once the initial bead has correctly formed the pressure i...

Page 27: ...97 233C Fusion Target pressure 10Bar Achieved pressure 10Bar Time remaining 578seconds PE63 250 SDR11 11 5 6 Accepting the joint When the joint is complete the machine will prompt the operator for the...

Page 28: ...e Clamps or liners were not secure Press red button open the machine reset the pipes re secure the pipes ensuring they are fixed firmly then re trim and re check 6 Poor bead Bead not formed as expecte...

Page 29: ...23 No movement sensed Machine could not detect movement Hydraulic connectors not connected correctly LVDT cable not connected correctly Pipes not correctly supported Connect the hydraulic connectors...

Page 30: ...eater is not up Faulty heater plate detection switch Contact dealer 32 Abort during dwell Dwell phase aborted Emergency stop button pressed Power failed Ensure generator has enough fuel Do not switch...

Page 31: ...eft and right buttons on the key pad will adjust the LCD contrast in bigger steps To confirm the LCD contrast and exit press the green button Press the red button to exit without changing the contrast...

Page 32: ...6 select record s review print 13 3 4 USB drive Down loads the joint data to memory stick so the data can be viewed in Notepad Unicode Font must be used Connect the memory stick to the USB A connector...

Page 33: ...acter using the up down left and right buttons on the keypad Then press the green button on the keypad to select the character For more information see section 5 1 character entry screen If no match i...

Page 34: ...to the USB A connector on the rear of the computer See section 13 4 5 select record s data transfer 13 4 3 Minitran Download the joint data to Minitran so the data can be viewed on JointManager Conne...

Page 35: ...oint selection has be chosen scroll down to to proceed The status bar at the bottom of the screen will show the status of the download see section 9 status bar When joint data has been sent to USB dri...

Page 36: ...button to exit the Remove user history menu option 13 7 Recover archived records Menu option 06 Selecting this option will allow the user to recover records previously archived to the SD card Press th...

Page 37: ...tion then press green button to enter the menu option 14 1 1 Chassis diagnostics 01 This option allows the checking of chassis recognition and chassis operation 14 1 2 Trimmer diagnostics 02 This opti...

Page 38: ...ental protection IP54 Pipe joining parameters Gator 180 250 315 Minimum Maximum Diameter range Gator 180 63mm 180mm Gator 250 63mm 250mm Gator 315 90mm 315mm Joining pressure 10Bar 60Bar Heater remova...

Page 39: ...mensions Height Depth Width 180 Trimmer 382mm 260mm 445mm Heater 440mm 200mm 570mm Chassis without cradle TBC TBC TBC Chassis with cradle 560mm 430mm 323mm Controller 470mm 430mm 560mm 250 Trimmer 490...

Page 40: ...sion s policy of continued development and improvement we reserve the right to modify products without prior notice 17 Accessories Below is a list of accessories and Fusion order numbers Order No Desc...

Page 41: ...A 2 1 Upper case characters A B C D E F G H I J K L M N O P Q R S T U V W X Y Z A 2 2 Lower case characters a b c d e f g h I j k l m n o p q r s t u v w x y z When the green button is held down for...

Page 42: ...the selected character the following characters will be displayed Selected character Displayed characters Selected character Displayed characters A 4 Japanese A 4 1 Upper case characters A 4 2 Lower...

Page 43: ...ing documents Ref No Title Edn date BS EN ISO 12100 1 2 Safety of machinery Basic concepts general principles for design 2003 BS EN 61010 1 Safety requirements for electrical equipment for measurement...

Page 44: ...ting Manual EDOI6922 Page 44 of 44 Issue 02 Fusion Group Limited Smeckley Wood Close Chesterfield Trading Estate Chesterfield Derbyshire S41 9PZ Tel 44 0 1246 268666 Fax 44 0 1246 268052 Email sales f...

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