Ritmo BASIC 160 V1 Use And Maintenance Handbook Download Page 18

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2. WELDING GENERAL CRITERIA

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Control the joint:

Always follow the working procedures established by the National Legislation and regulations in force, as well as those learnt
during the training courses.

Summary of Contents for BASIC 160 V1

Page 1: ...Rev 0 16 10 2012 MU000838 USE AND MAINTENANCE HANDBOOK BASIC 355 V0 BASIC 315 V1 BASIC 250 V1 BASIC 200 V0 BASIC 160 V1...

Page 2: ...aux caract ristiques de la machine d crite dans ce manuel ainsi qu aux informations qu il contient La reproduction de ce document m me partielle sous n importe quelle forme est strictement interdite E...

Page 3: ...80 UNI 10520 PE 100 UNI 10967 HDPE DVS 2207 1 PP DVS 2207 11 Introduction 1 Product Introduction and Specifications 1 1 2 Welding General Criteria 2 1 Transport loading unloading handling and storage...

Page 4: ...ble Shooting 6 1 7 Safety Precautions 7 1 8 Workplace Hygiene 8 1 9 Welding Parameters 9 1 Pipe fitting features 9 1 How to calculate the welding parameters according to UNI 10520 PE 80 MRS 8 9 2 How...

Page 5: ...information and suggestions needed to use the machine in a proper safe and professional manner We therefore recommend its complete reading before starting using the machine We also recommend to keep i...

Page 6: ...315 125 355 Weldable materials HDPE PE 80 MRS 8 and PE 100 MRS 10 PP and other thermoplastics materials Ambient temperature range C from 5 to 40 PE 100 from 0 to 40 Power supply 220VAC 60Hz Maximum a...

Page 7: ...0 min Dimensions W D H mm 410 280 50 mm 16 1x11x2 in 470 50 490 mm 18 5x2x19 3 in 470 50 600 mm 18 5x2x23 6 in 696x175x700 mm 27 4x6 9x27 6 in Weight kg 3 Kg 6 6 lb 6 Kg 13 2 lb 8 Kg 17 6 lb 13 Kg 28...

Page 8: ...1 BASIC 355 V0 REDUCTIONS Diameters Weight 8 pcs diameter kg 40 4 6 Kg 10 1lb 50 4 4 Kg 9 7 lb 56 4 3 Kg 9 5 lb 63 4 2 Kg 9 3 lb 6 6 Kg 14 5 lb 75 4 0 Kg 8 8 lb 6 4 Kg 14 1 lb 10 6 Kg 23 3 lb 90 3 7 K...

Page 9: ...ES 1 4 300 190 490 11 8x7 5x19 3 340x182x542 13 4x7 1x21 3 7 15 4 9 19 9 TOOL FOR FLANGE NECKS Dimensions W D H mm 300 190 490 mm 11 8x7 5x19 3 in 340x182x542 mm 13 4x7 1x21 3 in Weight kg 7 Kg 15 4 l...

Page 10: ...s require extreme attention and must be done by means of suitable mechanical devices Transport and Loading Unloading It is essential to avoid deep scratches and or notches on the pipes fittings Do not...

Page 11: ...uments Timer Manometer Thermometer Verify their functionality Facer Verify its functionality Be sure the blades are sharp enough Heating plate Verify the integrity of the coating Use a digital thermom...

Page 12: ...2 WELDING GENERAL CRITERIA 2 3 Joint Make a test welding...

Page 13: ...e welding in case of rain high humidity strong wind very low or very high temperatures It is forbidden to raise the temperature of the welding by means of blowlamps or burners put in direct contact wi...

Page 14: ...islation and regulations in force h scratch notch depth 2 2 4 Cleaning Accurately clean the internal and external surfaces of the ends to be welded Use only the cleaning products recommended by the pi...

Page 15: ...2 WELDING GENERAL CRITERIA 2 6 9 P1 P2 P5 Pt t1 t2 t6 1 2 6 P1 Pt UNI 10520 DVS 2207 P2 t2 t3 P5 Pt t4 P5 Pt t5 t6...

Page 16: ...t until the beads reach the required width UNI 10520 or height DVS 2207 Phase 2 Heating Reduce pressure to P2 maximum value sufficient to keep the ends in touch with the heating plate for the entire t...

Page 17: ...20mm use the Simple Pressure cycle previous page The first four phases are identical with respect to the simple pressure cycle Phases 5 6 Welding The welding phase happens in two moments 1 Keep both e...

Page 18: ...WELDING GENERAL CRITERIA 2 9 Control the joint Always follow the working procedures established by the National Legislation and regulations in force as well as those learnt during the training course...

Page 19: ...ovable carriage 11 Heating plate release plaques 12 Lower piston rod 13 Clamp fastener 14 Dragging bars 15 Upper piston rod 16 Quick coupling connections 17 Upper jaw 18 Lower jaw Not featured in the...

Page 20: ...11 Power supply cable 12 Handgrip 13 Motor 14 Start push button green motor 15 Stop push button red motor 16 Blocking lever 17 Circuit breaker push button 18 Fork for piston rod support 19 Blade 20 Fa...

Page 21: ...3 PARTS DESCRIPTION 3 3 1 2 3 4 DIGITAL DRAGON 4 3 5 6 4 1 5 6 3 2...

Page 22: ...4 HEATING PLATE 7 Power plug 8 Handgrip 9 Welding temperature control thermometer independent from thermoregulator 10 Thermoregulator DIGITAL DRAGON see 4 3 11 Pin for piston rod support 12 Plate 1 2...

Page 23: ...3 PARTS DESCRIPTION 3 5 FACER HEATING PLATE SUPPORT 4 Handgrip 5 Heating plate housing 6 Facer housing 1 2 3...

Page 24: ...1 2 3 4 5 6 7 HYDRAULIC GEARCASE 8 Oil tank plug 9 Pressure discharge valve 10 Maximum pressure valve 11 Distributor lever 12 Oil pressure manometer 13 Hydraulic hoses 14 Quick coupling connectors 4 5...

Page 25: ...IMER 3 mode 2 Minutes seconds adjustment key in TIMER 1 and TIMER 2 modes 3 Reset key 4 Countdown start interrupt key 5 Multifunction key display adjustment hour alarm 6 TIMER keys T1 mode Minutes sec...

Page 26: ...un second by second Press key 4 to interrupt progressive counting Press key 4 again to recall the time previously set Press key 5 to display the hour hours minutes buffer blinks Press key 5 again to d...

Page 27: ...ASIC 200 3 4 5 6 7 Tool bag 8 A Allen key wrench used to assembly and disassembly the reductions only for BASIC 160 and BASIC 200 models 9 Socket wrench used to fasten the clamps 10 Use and maintenanc...

Page 28: ...4 OPERATING INSTRUCTIONS 4 1 HYDRAULIC CONNECTIONS...

Page 29: ...4 OPERATING INSTRUCTIONS 4 2 1...

Page 30: ...4 OPERATING INSTRUCTIONS 4 3 ELECTRICAL CONNECTIONS Control SPECIFICATIONS first see 1...

Page 31: ...4 OPERATING INSTRUCTIONS 4 4 220 10 BASIC 160 V0 220 2 1 5 2 5 50 75 BASIC 200 V0 220 2 1 5 2 5 25 50 BASIC 250 V1 220 2 1 5 2 5 25 50 BASIC 315 V1 220 2 2 5 4 25 50 BASIC 355 V0 220 2 4 6 25 50...

Page 32: ...refer to the plugging of the various components heating plate hydraulic gearcase facer to one single multiple socket BASIC 160 V0 220 V Cable section mm 2 1 5 2 5 Cable maximum length m 50 75 BASIC 2...

Page 33: ...by the temperature value of the heating plate increasing until the temperature set is reached OFF 4 OFF the thermoregulator is off Turn it on by pressing B for 4 seconds When the heating plate reaches...

Page 34: ...y 4 seconds C B F C Press C and B to change the temperature measure system Fahrenheit F Celsius C The value now set will halt to blink and will be memorized Error messages If one of the following mess...

Page 35: ...1 Set the time 3 3 Timer 1 Set the heating time t2 Timer 2 Set the welding time t5 Simple Pressure cycle or t6 Dual Pressure cycle 4 4 2 Push the distributor lever to the maximum and open the carriage...

Page 36: ...ushing Fasten the V screw to lock the reduction to the jaw Repeat the operation with the other jaw 250 BASIC 315 BASIC and 355 BASIC models Insert the reduction end see arrow inside the jaw s groove s...

Page 37: ...s A and the heating plate release plaques B as shown in the image below Insert the elements to be welded inside the clamps and fasten them B BASIC 160 BASIC 200 1a 2a 3a 4a B A B A A B Important The h...

Page 38: ...AND 4a Assembly the dragging bars A and the heating plate release plaques B as shown in the image below 1a 2a 3a 4a A B B BASIC 160 BASIC 200 B A B A 1a 2a 3a 4a A B Important The heating plate relea...

Page 39: ...4 OPERATING INSTRUCTIONS 4 12 Insert the elements to be welded inside the clamps and fasten them...

Page 40: ...4 OPERATING INSTRUCTIONS 4 13 4 6 1 M 4 6 2 4 6 3 FACING M...

Page 41: ...2 Turn on the facer by pressing the start push button green Approach and face both ends to be welded without overstressing the motor 4 6 3 As soon as you get a continuous and uniformed even chip on bo...

Page 42: ...4 OPERATING INSTRUCTIONS 4 15 Pt 4 7 1 4 7 2 4 7 3 Pt Pt Pt READING THE DRAGGING PRESSURE Pt 4 7 1 Push the distributor lever to the maximum and open the carriages completely...

Page 43: ...tributor lever to the maximum with gradual increasing force and rotate the maximum pressure valve in a clockwise and gradual manner until the movable carriage gets in motion Read the pressure Pt on th...

Page 44: ...the carriages and keep the distributor level pulled to the maximum Rotate the maximum pressure valve in a clockwise manner until the manometer shows that the pressure P1 Pt has been reached Push the d...

Page 45: ...4 OPERATING INSTRUCTIONS 4 18 P1 Pt UNI 10520 DVS 2207 P2 P2 t2 t2 1 t2...

Page 46: ...d depends on the standard being used Slowly release the distributor lever PHASE 2 Heating Unscrew the pressure discharge valve in a gradual manner until the maximum pressure P2 is reached P2 is suffic...

Page 47: ...4 OPERATING INSTRUCTIONS 4 20 tmax t3 PHASE 3 Removal of heating plate tmax t3 P1 Pt t4 t4...

Page 48: ...pressure Pull the distributor lever with gradual increasing force until you reach the pressure P1 Pt within the t4 time t4 5 t5 2 t5 PHASE 5 Welding Stabilize the pressure 5 sec Slowly release the di...

Page 49: ...4 OPERATING INSTRUCTIONS 4 22 t6 PHASE 6 Cooling Zeroize the pressure by unscrewing the pressure discharge valve completely Wait until the joint has cooled down before removing it from the machine t6...

Page 50: ...DING CYCLE The Dual Pressure cycle is used when welding PE 100 with thickness equal or superior to 20 mm When welding PE 100 with thickness inferior to 20 mm use the Simple Pressure cycle The first fo...

Page 51: ...4 OPERATING INSTRUCTIONS 4 24 P6 t6 2 t6 PHASE 6 Welding SECOND PART Discharge pressure down to P6 by unscrewing the pressure discharge valve Wait for the t6 time to end Timer 2 t6 t7...

Page 52: ...Wait until the joint has cooled down before removing it from the machine t7 Open the clamps and remove the welded pipe Unplug the machine from the power supply at the end of operations Disconnect the...

Page 53: ...ision liquids and dirt QUICK COUPLING CONNECTIONS AND CONNECTORS Keep connections and connectors clean at all times Prevent earth or sand in the hydraulic circuit by keeping the plugs on the connector...

Page 54: ...Use recommended oils only see page 5 for specifications Check the oil level once a month It must reach the level mark at the dipstick A Tank cap with oil dipstick HEATING PLATE Clean and place the he...

Page 55: ...ely abort the warranty Valid authorizations are done by writing bear Ritmo s stamp and a Ritmo s employee signature and are dated Unplug the machine from the power source before working on the electri...

Page 56: ...6 TROUBLE SHOOTING 6 2 1 h 2...

Page 57: ...ficient movement force PROBABLE CAUSE SOLUTION Air in one or both hydraulic cylinders 3 Position the gearcase at a h height gearcase ought to be higher than the chassis 4 Move the machine carriage bac...

Page 58: ...e on the electrical system Check the electrical system see electrical diagrams PROBLEM Pressure peaks wide and abrupt movements of the manometer needle PROBABLE CAUSE SOLUTION Membrane of the hydrauli...

Page 59: ...n the tank Add oil it must reach the level mark at the dipstick Air in the hydraulic circuit Unite the quick coupling connectors connections Activate the gearcase motor for 30 seconds by pulling the d...

Page 60: ...UTION Thermoregulator failure Replace the thermoregulator Thermoregulator failure Replace the thermoregulator PROBLEM The heating plate does not heat or it is impossible to adjust the temperature and...

Page 61: ...l system Check the power cable and replace it if worn out Safety microswitch inefficient or out of place Remove the protection plaque and replace the microswitch or adjust its position using A and B s...

Page 62: ...and maintenance herein Any other use shall be considered improper and is therefore forbidden as it may cause damage to the operator third parties other objects and or to the machine itself The Safety...

Page 63: ...67 SELV ELECTROCUTION HAZARD Parts involved HYDRAULIC GEARCASE FACER HEATING PLATE Be sure that the electrical specifications of the power supply correspond to the ones of the machine Earth the machin...

Page 64: ...tc Unplug the machine from the power source as soon as operations are over or even momentarily suspended Check the integrity of all components before using the machine Pay particular attention to the...

Page 65: ...rezza durante il movimento del carrello Attention When crushing happens immediately activate the distributor lever to OPEN the carriages the lever must go towards the manometer direction Be sure that...

Page 66: ...the machine when the facer is working Handle the facer with caution Always wear your safety gloves SPLINTERING HAZARD Part involved FACER Keep a safe distance from the machine when the facer is workin...

Page 67: ...7 SAFETY PRECAUTION 7 6 Always wear your safety glasses goggles...

Page 68: ...CER Keep a safe distance from the machine when the movable carriage is in motion or when the facer is working Remove all your bracelets and necklaces Gather up long hair Do not use loose clothing Alwa...

Page 69: ...not touch the welding bead or the areas around it while they are still hot Always wear your safety gloves FIRE HAZARD Part involved HEATING PLATE Do not use the machine in atmospheres subject to expl...

Page 70: ...s 09 04 2008 n 81 Healthcare and safety at work D Lgs 14 08 96 n 494 Mimimum safety and health requirements to be observed at temporary and mobile construction sites Do not admit unauthorised persons...

Page 71: ...8 WORKPLACE HYGIENE 8 2 CRUSH HAZARD Part involved LIFTING EQUIPMENT Always wear your safety helmets RISK OF INJURIES When MANUAL HANDLING Proper manual handling Improper manual handling...

Page 72: ...produce toxic and or explosive vapours when close to heat Handle with maximum care all toxic substances normally used during pre welding operations Keep them away from heat in general and from heated...

Page 73: ...sideration SDR D s S D s 1 2 1 SDR S 2 1 S SDR 1 2 SDR D s Standard Dimension Ratio S D s 1 2 1 SDR S 2 1 S SDR 1 2 SDR 41 33 27 6 26 22 21 17 6 17 13 6 11 9 7 4 6 S 20 16 13 3 12 5 10 5 10 8 3 8 6 3...

Page 74: ...he pipe fitting match with the nominal ones If they don t then the welding parameters must be calculated using the given formulas in this case be sure that the real dimensions respect the tolerance ra...

Page 75: ...12 HEATING PLATE TEMPERATURE T 210 C 10 C when s is in between 0 mm and 12 mm T 200 C 10 C when s is superior to 12 mm PHASE 1 Approach and pre heating A 0 5 0 1 s Approach and pre heating pressure A...

Page 76: ...l of heating plate t3 4 0 3 s sec Maximum time to remove the heating plate t4 4 0 4 s PHASE 4 Reach of welding pressure t4 4 0 4 s sec Time to reach the welding pressure P5 P1 t5 3 s PHASE 5 Welding P...

Page 77: ...to UNI 10520 Refer to the following paragraphs UNI 10520 UNI 10520 UNI 10520 UNI 10520 UNI 10520 UNI 10520 PHASE 1 Approach and pre heating As PHASE 1 of UNI 10520 Approach and pre heating pressure Be...

Page 78: ...PHASE 1 Approach and pre heating Approach and pre heating pressure A 0 5 0 1 s mm Bead width at the end of pre heating t2 60 10 s PHASE 2 Heating Maximum heating pressure t2 60 10 s sec Heating time t...

Page 79: ...reach the welding pressure 1 P5 P1 5 t5 10 5 PHASE 5 Welding TIME 1 P5 P1 bar Welding pressure 5 t5 10sec Welding time 5 2 6 t6 3 s 6 PHASE 6 Welding TIME 2 Welding pressure 6 t6 3 s min Welding time...

Page 80: ...ERS ACCORDING TO DVS 2207 1 HDPE PE HD DVS 2207 1 08 95 PE HD DVS 2207 1 08 95 HEATING PLATE TEMPERATURE PHASE 1 Approach and pre heating Approach and pre heating pressure 0 015 2 5 P1 D s s S spessor...

Page 81: ...P1 D s s bar P1 7 5 s mm Pipe fitting Height A mm up to 4 5 0 5 4 5 7 1 0 7 12 1 5 12 19 2 0 19 26 2 5 26 37 3 0 37 50 3 5 50 70 4 0 s mm Pipe fitting t2 sec up to 4 5 up to 45 4 5 7 45 70 7 12 70 12...

Page 82: ...Time to reach the welding pressure s mm Pipe fitting t3 sec up to 4 5 up to 5 4 5 7 5 6 7 12 6 8 12 19 8 10 19 26 10 12 26 37 12 16 37 50 16 20 50 70 20 25 s t3 4 5 5 4 5 7 5 6 7 12 6 8 12 19 8 10 19...

Page 83: ...up to 4 5 up to 5 4 5 7 5 6 7 12 6 8 12 19 8 11 19 26 11 14 26 37 14 19 37 50 19 25 50 70 25 35 s mm Pipe fitting t5 min up to 4 5 up to 6 4 5 7 6 10 7 12 10 16 12 19 16 24 19 26 24 32 26 37 32 45 37...

Page 84: ...PP DVS 2207 11 02 99 HEATING PLATE TEMPERATURE Temperature to be set on the thermoregulator T 210 C 10 C PHASE 1 Approach and pre heating Approach and pre heating pressure Bead height at the end of p...

Page 85: ...A mm up to 4 5 0 5 4 5 7 0 5 7 12 1 0 12 19 1 0 19 26 1 5 26 37 2 0 37 50 2 5 P1 10 s mm Pipe fitting t2 sec up to 4 5 up to 135 4 5 7 135 175 7 12 175 245 12 19 245 330 19 26 330 400 26 37 400 485 3...

Page 86: ...f welding pressure Time to reach the welding pressure s mm Pipe fitting t3 sec up to 4 5 up to 5 4 5 7 5 6 7 12 6 7 12 19 7 9 19 26 9 11 26 37 11 14 37 50 14 17 s t3 4 5 5 4 5 7 5 6 7 12 6 7 12 19 7 9...

Page 87: ...e fitting t4 sec up to 4 5 up to 6 4 5 7 6 7 7 12 7 11 12 19 11 17 19 26 17 22 26 37 22 32 37 50 32 43 s mm Pipe fitting t5 min up to 4 5 up to 6 4 5 7 6 12 7 12 12 20 12 19 20 30 19 26 30 40 26 37 40...

Page 88: ...HDPE DVS 2207 1 08 95 T a T t B D s SDR S NP P 1 P 5 P 2 P t P 1 P t A P 2 t 2 t 3 t 4 P 5 P t t 5 T t P t B A P 1 P t P 2 t 2 t 3 t 4 P 5 P t t 5...

Page 89: ...kness s mm SDR S NP P 1 P 5 bar P 2 bar P t bar P 1 P t bar A mm P 2 bar t 2 sec t 3 sec t 4 sec P 5 P t bar t 5 min Notes Legend T t Heating plate temperature P t Dragging pressure B Final bead width...

Page 90: ...PP DVS 2207 11 02 99 T a T t B D s SDR S NP P 1 P 5 P 2 P t P 1 P t A P 2 t 2 t 3 t 4 P 5 P t t 5 T t P t B A P 1 P t P 2 t 2 t 3 t 4 P 5 P t t 5...

Page 91: ...kness s mm SDR S NP P 1 P 5 bar P 2 bar P t bar P 1 P t bar A mm P 2 bar t 2 sec t 3 sec t 4 sec P 5 P t bar t 5 min Notes Legend T t Heating plate temperature P t Dragging pressure B Final bead width...

Page 92: ...setzlichen Richtlinien 2006 42 CE 2004 108 CE 2006 95 CE UNI EN ISO 12100 1 2005 UNI EN ISO 12100 2 2005 CEI 44 5 La presente dichiarazione perde ogni validit in caso di modifiche apportate al prodott...

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Page 95: ...tion d une machine qui n a pas t r vis e En aucun cas ne peut Ritmo S p A tre tenue pour responsable des ventuels dommages directs indirects accidentels ou consequentiels r sultants d une utilisation...

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