Pt 355 Manual

I.T.S. by Tecnodue

PT 355

Edition 2004

Operating Manual

I.T.S. Ital Trade Services PT 355 Operating Manual

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The technical data and information contained on this manual can be changed without any notice


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PT 355The 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 ItalyPhone : : +39-0106423396Fax : +39-0106423513E mail : [email protected] Site : www.its-tecnodue.com

Technical DataElectrical Data Mechanical dataVoltage 230 V Facing Tool Transmission System Gear DriveFrequency 50 Hz Trolley Maximum Stroke 150 mmTotal Power Installed 4,8 KW 22 A Trolley Slide Bar Diameter 35 mmHeating Mirror IP 54 3,00 KW Distance between the Cylinders center 440 mmFacing Tool IP 20 1,05 KWHydraulic Unit IP 44 0,74 KWHydraulic Data Operating DataMaximum Working Pressure 160 bar Outside temperature 0-50 °CCylinder's Section 8,46 cm2 Humidity (without condensation) 95 RH %Maximum Force 8300 NPressure Gauge 0-160 barPump's Capacity 2,5 l/min 1000 rpmHydraulic Oil ISO 68Oil Tank 2,5 lDimensions WeightBasic Machine 1,10x0,68x0,64 m Basic Machine 96 KgFacing Tool 0,44x0,58x0,86 m Facing Tool 29 KgHeating Mirror 0,60x0,65x0,39 m Heating Mirror 19 KgHydraulic Unit 0,48x0,32x0,27 m Hydraulic Unit 29 KgSupport for Facing Tool and Mirror 0,50x0,45x0,54 m Support for Facing Tool and Mirror 15 Kg

Transport Box 79 KgStub device 16 KgReducing Inserts Complete Set 77 Kg

Components:

1. Hydraulic Unit2. Facing Tool3. Basic Machine4. Heating Mirror5. Support for Facing Tool and Mirror6. Reducing Inserts7. Stub End Device


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SAFETY RULES ACCORDING TO DIRECTIVES CEE( To be read carefully and apply while utilizing the PT 355 )

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.

DANGERS TO THE OPERATOR COMING FROM EACH COMPONENT.Warning - Rules – Obligations

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.TRANSPORT-. Basic Machine, weight Kg.79, Keep the maximum care while moving and it's suggested to utilize mechanical aids.-. Facing Tool, weight Kg. 27,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 strongly suggested to use suitable gloves.-. Heating Mirror, weight Kg. 19,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 weight is Kg. 33 therefore it's necessary to utilize the maximum care to move it-. Hydraulic unit, weight Kg.28,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 supplyENVIRONMENTAL 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 even close to flammable liquids.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 MAXIMUM 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 machineACOUSTIC 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 acoustic 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


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PT 355Hydraulic operated butt welding machine 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:a. Basic machine d. 355 mmb. Removable electric facing tool with safety switchc. Removable PTFE coated heating mirror with support .d. Electro-hydraulic motor with accumulator and flexible hoses with quick couplings.On request can be supplied:-. Light weight alloy reducing rings for pipes and fittings d. 90,110,125,140,160,180,200,225,250,280mm 250,280,315mm-. Stub Device

a. Basic machine

Description and operating

The basic machine is composed by:- Two cylinders on which heads are mounted two complete clamps d. 355 mm- One movable clamp d. 355 mm sliding on cylinder's stem and

fixable in different positions by means of using the clampsconnecting rod, on left side to the side support clamp.

- One side support clamp d. 355 mm- A frame including the hydraulic circuit with the anti-drop quick

couplings.- A heating mirror disconnecting device

The machine is normally supplied on the above assembling , therefore the two clamps mounted on the cylinders will be called as "MovableTrolley" and the movable clamp together with the side support clamp as " Fixed Trolley".

Once , the machine is located on the suitable position for the welding to be done, the following operations should be carry out:1. Connect the flexible hoses quick couplings to the quick couplings located on the Movable Trolley of the machine2. Test the connections and the Movable Trolley's function by means on acting on the hydraulic unit control (see relative instructions).3. By acting on the hydraulic unit control located the Movable Trolley on full open position.3. Remove the upper part of the four clamps by enlighten the nuts4. Position the two pipes of d. 315 mm to be welded, one into the Fixed Trolley the other one into the Movable Trolley, by

means of the four upper part of the clamps ; take care to leave enough space between the two pipes ends in order to allow the facing tool inserting.

5. Check the alignment of the pipes by approaching together the pipes ends and in case by acting on the middle clamps nut (tighten orenlighten according to the requirement). In case turn around the pipes and repeat the operation.

6. Block the two pipes by tightening the external clamps nuts.7. Start the facing operation

ImportantIn case a welding of two pipes with diameter below 315 mm has to be carried out, it's necessary , after the point 4 of the aboveprocedure:- Select the reducing ring set ( 8 inserts ) corresponding to the diameter of the pipes to be welded.- Fit the two narrow inserts into the side support clamp slots and fix by the screws supplied.- Fit the six wide inserts into the remaining clamps slots and fix by the screws supplied.- Proceed with point 5 of the above mentioned procedure


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Particular casesStated beforehand that the basic machine on the above mentioned assembling it's suitable for all kinds of pipe to pipe welding.Other kind of welding are also possible such as : pipe and fitting ( 90°Elbow ,45°Elbow,Tee with short and/or long spigot ) providepipe and relative fitting would be mounted on the machine on proper way,in order to clarify this matter here below are reported the following examples :

Possible drawback's description and relative solutionsi. 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 )ii. 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 Dept.iii. The nut/s is/are seizure: Replace the bolt complete with nut removing the piniv. Oil leakage in the cylinders: Consulting the Customer Service Dept. verify if it's necessary to replace the cylinders or just the gasket

MaintenanceIt'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.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 woodentable below, such cares will avoid additional efforts to the machine.


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b. Facing Tool


The electric facing tool is composed by:-. The facing tool body-. Two disks where are mounted the blades-. A drill engine with supplied with a safety pin that while connected keep the facing tool hooked to the machine-. A safety micro-switch allowing the engine start only when the facing tool is fit into the machine , avoiding the start of the engine out of this position.

1. 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 ,takingcare that the pipe's ends are internally and externally clean from dust and sand.

2. Start the facing tool engine by means of pushing the push bottom and the pawl allowing the block of the push bottom, an additionalpress on the push bottom will release the pawl. It's strongly suggested to always use the lower speed of the engine.

3. Start the facing tool and slowly approach the pipes ends towards the facing tool by means of acting on the hydraulic control unitkeeping a pressure a little higher than the inertial pressure ( see Hydraulic Control Unit paragraph ).

4. While the pipes ends will be in contact with the facing tool the blades will start facing by removing material as shavings, when theseshavings from both sides will appear continuous and homogeneous , the facing operation is completed.

During this operation keep in mind to verify the engine performances , avoiding overloading by acting with pressure reduction in case the problem will appear. Might be happen that there's not removing material and shavings, in case increase the pressure. Usually the facing pressure can be set up by a value of 3-5 bar above the inertial pressure 5. Proceed to take away the pipes ends from the facing tool and switched off the facing tool engine, remove the facing tool and place it into the support. 6. Before carry out further operation remove all the shavings from the pipes and from the ground avoiding to dirty the faced pipes ends.

Possible drawback's description and relative solutions

MaintenanceIt'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- Clean and lubricate the chain utilizing specific products- Enlighten the screws and remove the pulley and carry out the cleaning and the lubrication of the bearing .

i. The engine does not start:1. Check the electric connections and the safety micro-switch2. In case it's need to replace the engine the following operations

must be done: 2a. Enlighten the screws connecting the engine to the reducing gear 2b. Disconnect the safety micro-switch connecting wires 2c. Remove the engine by means of pulling in upper direction 2d. To fit in the new engine just proceed on opposite, way , taking care to not strain the chain too much 2e. Connect the safety micro-switch connecting wires to the new engine after disconnect from the old one.ii. The blades does not remove material:1. Wear and tear of one cutting side enlighten the screws and turn

the blades using the other side.2. Wear and tear of both cutting side of the blades replace with

original spare parts.


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c. Heating Mirror (Table 2 )


The heating mirror is composed by:

-. The heating mirror coated with green colour PTFE complete with thermometer 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 .

On the display of the electronic thermostat, during the normal functioning , is displayed the heating mirror temperature.

á the key UP increase the temperature to be set up

â the key DOWN decrease the temperature to be set upP the key P allows to enter into the temperature programming

In order to set up a new temperature value , press gently the key P, on the display will appear the value set up , by means of using the keys UP e DOWNto select the new value and the Key P to save the value.When the heating mirror reach the new selected temperature on the thermostat you can see a green led switched on.

1. Connect the plug to the power supply and check if the light power on is switched on, wait until the heating mirror achieve theselected temperature, during this operation the two lights will be switched on. Once achieved the selected temperature the lightswill switched off and will switched on or off on when the thermostat would start in order to automatically keep the selectedtemperature.

2. Before to proceed to the first welding wait until the lights has been switched on and off three times, this allows the stabilization ofthe temperature on the heating mirror surface.

3. Take care to insert the heating mirror into the machine only after the facing operation has been completed, the lower part of theheating mirror is supplied with a stable to be insert into the slide bar of the machine's trolley and the upper part of the heating mirroris supplied with a support keeping the mirror in centred position.

After inserting, keep the heating mirror in vertical position till the contact between mirror and pipe ends to be welded.4. Elapsed the phase t2 Continual heating ( see the Welding Cycle Graph ) opening the machine's trolleys, the heating mirror will come

off one pipe end, in order to come off the other pipe end just give a blow on the handles , then take off the mirror and put it backinto the support.

ImportantThe heating mirror 's temperature during the working operations is always above 200 °C, therefore keep attention and utilize if possibleprotective gloves in order to avoid burns.


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Possible drawback's description and relative solutionsi. The heating mirror doesn’t 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.Temperature of the welding mirror for welding HDPE and PP

RememberWhen welding PVDF, the temperature of the welding mirror should be adjusted for every wall thickness at 230°C +/-10%

MaintenancePlease 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, avoidingabrasive materials in that might damage the PTFE coated surfaces.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:

WELDING SURFACE OF THE MIRROR ∆Τ∆Τ11 ∆Τ∆Τ22 ∆Τ∆ΤΤΟΤΟ

ΤΤ

∆Τ∆Τ1 1 Maximum temperature difference on the mirrorsurface

< 250 °C 5 °C 3 °C 8 °C ∆Τ∆Τ2 2 Temperature deviation for the adjustment> 250 °C 7 °C 3 °C 10 °C ∆Τ∆ΤΤΟΤ ΤΟΤ Maximum accepted difference on the mirror surface


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d. Hydraulic Unit (Table 4 )

General Description and Operating Instructions

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

Important !Before begin the operation be sure that:- The lever A is fixed into the special housing- Substitute the metal plug with the plastic black and red plug ( pos. 2 table IV ) the plastic plug is supply with the machine into a plasticbag.- Check the oil level and in case add as per instructions on maintenance paragraph.- Check if the power supply is the same indicated on the engine's label (Tolerance +/- 10%) In case of generator utilisation it's compulsory that the generator is supplied with a tension stabilizer- Start the engine by means of pushing the switch located sideways to the engineOnce all the above operations have been done the hydraulic unit is ready and it's therefore possible to proceed as per instructions on theparagraph d1

Possible drawback's description and relative solutions

i. Engine's 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 anticlockwise rotation of the electric fan

ii. Pressure accumulator's replacement: - Bring the pressure to zero and enlighten the bolt

- Take out the fitting and replace the damaged accumulator with thenew one- Tighten the bolt

iii. Pressure gauge's replacement: - Bring the pressure to zero - Enlighten the nut holding the pressure gauge - Replace the pressure gauge and tighten the nut


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iv. Hydraulic unit controls replacement: - Check that the electric plug is disconnected - Take out the micro switch by means of enlighten the screws - Enlighten the bolts and take out the hydraulic unit controls from the pump - Reassemble the new hydraulic unit controls taking care that the o-rings located on the lower part will be perfectly located into theirown housingsv. Flexible hoses replacement: - Bring the pressure to zero - Enlighten the fitting and replace the flexible hoses - Tighten the fittingvi. If the hydraulic unit cannot increase the pressure reasons could be : 1. The lever E is not closed. 2. The accumulator C is discharged or broken in this case replace with original spare part 3. Check if they are some leakages on hydraulic circuit.

d1. Hydraulic Unit Controls

General DescriptionThe control lever A open and close the machine's trolley according to the positionselected.Bring the lever A into position A2 (position with automatic return) the trolley is openingwith the maximum pressure set up into the hydraulic unitIn 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, thehooking of such position allow the operator handling.

A. Control LeverB. Micro switch protectionC. AccumulatorD. Pressure gaugeE. Pressure by passF. Pressure control 0-100 barG. Micro switchH. Micro switch screwsI. Engine connecting cable

The pressure by pass lever E allow ,by turning anticlockwise thepressure releasing , while turning clockwise allow the pressureincreasing by means of using the hand wheel F and fixing.The hand wheel F of the pressure control allow the setting up of thepressure at the requested values by turning anticlockwise the pressurerelease , while turning clockwise the pressure increase .


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Operating Instructions

In order to make easy the learning we shall proceed to the description step by step of all operations need in to complete a weldingaccording 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 D03. Turn clockwise the lever E until closing ( please avoid using an excessive strength )04. Bring the lever A into position A305. 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 A115. Elapsed the cooling time by acting on lever E anticlockwise bring the pressure to zero.16. Take away the pipes welded

Possible drawback's description and relative solutionsi. The engine does not start: 1. Check the electric connections 2. Double check that the switch positioned on the engine is in 'on' position 3. Bring the lever A into position A3 enlighten the screws H move the micro switch G towards the internal part of the support B ; if the engine start the micro switch G must be set up. To make such setting up please remember that with lever A in A1 position the engine is off and with lever A in A2 and A3 the engine is on. Keeping enlighten the screws H, by using the lever A in A1 move the micro switch G forward and towards until it's positioned where the engine is off. Tighten the screws H, bring the lever A in A2 and double check that the engine is on , repeat the same in position A2.ii. The pressure does not increase: 1. Check the oil level and in case add as per instructions on maintenance paragraph. 2. Check that the lever E is well fixed 3. Check if they are some leakages on hydraulic circuit.iii. The pressure does not remain at fixed value: 1. The lever E is not closed. 2. The accumulator C is discharged or broken in this case replace with original spare part 3. Check if they are some leakages on hydraulic circuit.

MaintenanceThe 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 value and temperatures below - 5°C or above + 40°C.5. During the transport it's suggested to put the metal plug instead of the plastic one.


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e. Heating mirror disconnecting device

Operating instructions

You can set up the machine in this two different ways acting on the spacers and disconnecting device:• Two fixed clamps and two sliding clamps Fig. 1• One fixed clamp and three sliding clamps Fig. 1a

In the first set up of the machine you will find the spacers fixed on the two fixed clamps and the disconnecting device between the centralfixed clamp and the central sliding clamp.To set up the machine for the second position, as per picture 1a, put the spacers between the third and second sliding clamps and thedisconnecting device between the sliding clamps and fixed clamp.

Sliding clamps Fixed clamps Sliding clamps Fixed clamp

Spacers

Disconnecting device

Figure 1 2 fixed clamps + 2 sliding clamps Figure 1a 1 fixed clamp + 3 sliding clamps

The spacer and disconnecting device specific shape let a swift set up.

You can set different distance between the two clamps simply by fixing the first clamp in the hole A and the second one in the holes B-C-D.

Important !The disconnecting device can be utilized only by means of assembling the spacers with their opposite holes (A and D).

2 Sliding clamps + 2 fixed clamps 3 sliding clamps + 1 fixed clamps


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How to change the set up from two fixed clamps and two sliding clamps into one fixed clamp and three sliding clamps:

1. By means of acting on the hydraulic unit close slighter the machine inorder to take out the disconnecting device;

2. Turn the two spacers (upper and lower);

3. Put forward the connected clamp in order to remove the two spacers;

4. Position spacers between the two central clamps;

5. Fix the disconnecting device on the fixed clamp;

6. By means of using the hydraulic unit approach the three slidingclamps toward the fixed clamp;

7. Fix the other side of the disconnecting device on the third slidingclamp;


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Butt Welding in brief

1.Machine's preparation 1a. Set up the working area so that welding is protected from the weather 1b. Position the machine's components as per following figure and eventually utilize wooden panels

1c. Connect the flexible hoses of the hydraulic unit to the machine 1d. 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 ! “ 1d. Select the correct temperature on the heating mirror 1e. In case fit the inserts of the diameter to be welded into the machine 2.Pipes positioning into the machine 2a. Open the movable trolley of the machine by means of acting the lever A Table V 2b. Position the pipes into the machine taking care to leave enough space for the facing tool inserting 2c. Check the pipes alignment in case adjust by means of tighten or loosing the clamps bolts 2d. Clean the pipe ends

3.Facing operation 3a. Open the movable trolley of the machine by means of acting the lever A Table V 3b. 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 3c. Connect the safety pin and start the facing tool engine 3d. 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. 3e.When shavings from both sides will appear continuous and homogeneous , the facing operation is completed. 3f. Proceed to take away the pipes ends from the facing tool and switched off the facing tool engine, remove the facing tool and place it into the support. 3g.Before carry out further operation remove all the shavings from the pipes and from the ground avoiding to dirty the faced pipes ends. 3h. 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 diametermm

Portmm

< 400 0,5> 400 1,0

In case the above values cannot be fulfilled the facing operation must be repeat.4.Inertial pressure measurement 4a.By turning the lever E Table V anticlockwise bring the pressure to zero, checking the pressure gauge 4b.Turn clockwise the lever E Table V until closing 4c.Bring the lever A Table V into position A3 4d.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


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Pressure-Time diagram for butt welding

t1 = Time requested for the bead formation with the specified wall thicknesst2 = Time requested for the continual heatingt3 = Time requested for the change overt4 = Time requested for bringing up the pressuret5 = time requested for cooling down

5.Heating up t1 5a.Fit the heating mirror taking care that the temperature of the surfaces is the one selected 5b.Bring the lever A Table V 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 ). 5c.Check the Bead formation wall thickness according to the attached welding table 6.Heating up t2 6a.After bead formation act on lever E Table V anticlockwise in order to bring the pressure to zero and proceed to the heating time at pressure P2. 7.Change over t3 7a.Elapsed the heating time at pressure P2 bring the lever A Table V 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 8.Bringing up pressure t4 8a.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. 9.Cooling Down t5 9a.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 9b.Elapsed the cooling time by acting on lever E anticlockwise bring the pressure to zero. 9c.Take away the pipes welded and leave them for the time t6 indicated on attached welding tableImportant !!!In case of any doubt please refer to the specific instructions


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Welding Parameters for HDPE pipes & fittings

Pressure-Time diagram for butt welding

t1 = Time requested for the bead formation with the specified wall thicknesst2 = Time requested for the continual heatingt3 = Time requested for the change overt4 = Time requested for bringing up the pressuret5 = time requested for cooling downP1 = 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 )

Material thrust coefficient for PE s 63 1,5 Kg./cm2

Material thrust coefficient for PP 1,0 Kg./cm2

Total PT 315 cylinders section 8,46 cm2

P2 = Pressure during the continual heating, this value either for HDPE and PP is 0,1 Kg./cm2.

Optical checking of butt welding result


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Welding Parameters for PE pipes and fittingsThe 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 pressuret2 = Time requested for the continual heating to be done with pressure value = P2 + inertial pressuret3 = Time requested for the change overt4 = Time requested for bringing up the pressure at the value of pressure = P1 + inertial pressuret5 = time requested for cooling down to be done with pressure value = P1 + inertial pressuret6 = time requested for cooling down the welded pieces out of the machineImportant: Remember always to add the value checked of inertial pressure to the P1 and P2 values !!!!!!!

material HDPE PN 2,5 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6

mm mm bar mm bar sec sec sec bar min min

90 2,2 1,1 0,7 0,1 26 5 5 1,1 5 3110 2,7 1,6 0,8 0,2 32 5 5 1,6 6 4125 3,1 2,1 0,8 0,3 37 5 5 2,1 6 5140 3,5 2,7 0,9 0,4 42 5 5 2,7 7 5160 3,9 3,4 0,9 0,5 47 5 6 3,4 7 6180 4,4 4,3 0,9 0,6 53 5 6 4,3 7 7200 4,9 5,3 1, 0,7 59 5 6 5,3 8 7225 5,5 6,7 1,1 0,9 66 6 6 6,7 9 8250 6,1 8,3 1,1 1,1 73 6 6 8,3 9 9280 6,9 10,5 1,2 1,4 83 6 7 10,5 10 10315 7,7 13,2 1,3 1,8 92 6 7 13,2 11 12355 8,7 16,8 1,4 2,2 104 7 7 16,8 13 15

material HDPE PN 3,2 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6


90 2,8 1,4 0,8 0,2 34 5 5 1,4 6 4110 3,5 2,1 0,9 0,3 42 5 5 2,1 7 5125 3,9 2,6 0,9 0,4 47 5 6 2,6 7 6140 4,4 3,3 0,9 0,4 53 5 6 3,3 7 7160 5 4,3 1, 0,6 60 6 6 4,3 8 8180 5,6 5,4 1,1 0,7 67 6 6 5,4 9 8200 6,2 6,7 1,1 0,9 74 6 6 6,7 9 9225 7 8,5 1,2 1,1 84 6 7 8,5 10 11250 7,8 10,5 1,3 1,4 94 6 7 10,5 11 12280 8,7 13,1 1,4 1,8 104 7 7 13,1 12 13315 9,8 16,7 1,5 2,2 118 7 8 16,7 13 15355 11,1 21,3 1,6 2,8 133 7 8 21,3 14 17

material HDPE PN 4 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6


90 3,5 1,7 0,9 0,2 42 5 5 1,7 7 5110 4,3 2,5 0,9 0,3 52 5 6 2,5 7 6125 4,9 3,3 1, 0,4 59 5 6 3,3 8 7140 5,4 4, 1, 0,5 65 6 6 4, 8 8160 6,2 5,3 1,1 0,7 74 6 6 5,3 9 9180 7 6,7 1,2 0,9 84 6 7 6,7 10 11200 7,7 8,2 1,3 1,1 92 6 7 8,2 11 12225 8,7 10,5 1,4 1,4 104 7 7 10,5 12 13250 9,7 13, 1,5 1,7 116 7 8 13, 13 15280 10,8 16,2 1,6 2,2 130 7 8 16,2 14 16315 12,2 20,6 1,7 2,7 146 8 9 20,6 15 18355 13,7 26,0 1,9 3,5 164 8 9 26,0 17 21


19

Welding Parameters for PE pipes and fittings


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6


90 5,1 2,4 1, 0,3 61 6 6 2,4 8 8110 6,3 3,6 1,1 0,5 76 6 7 3,6 9 9125 7,1 4,7 1,2 0,6 85 6 7 4,7 10 11140 8 5,9 1,3 0,8 96 6 7 5,9 11 12160 9,1 7,6 1,4 1, 109 7 8 7,6 12 14180 10,2 9,6 1,5 1,3 122 7 8 9,6 13 15200 11,4 12, 1,6 1,6 137 7 9 12, 14 17225 12,8 15,1 1,8 2, 154 8 9 15,1 16 19250 14,2 18,6 1,9 2,5 170 8 10 18,6 17 21280 15,9 23,4 2,1 3,1 191 9 10 23,4 19 24315 17,9 29,6 2,3 3,9 215 9 11 29,6 21 27355 20,1 37,5 2,5 5,0 241 10 12 37,5 23 30


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6


90 8,2 3,7 1,3 0,5 98 6 7 3,7 11 12110 10 5,6 1,5 0,7 120 7 8 5,6 13 15125 11,4 7,2 1,6 1, 137 7 9 7,2 14 17140 12,8 9,1 1,8 1,2 154 8 9 9,1 16 19160 14,6 11,8 2, 1,6 175 8 10 11,8 18 22180 16,4 14,9 2,1 2, 197 9 11 14,9 19 25200 18,2 18,4 2,3 2,5 218 9 11 18,4 21 27225 20,5 23,3 2,6 3,1 246 10 12 23,3 24 31250 22,8 28,8 2,8 3,8 274 11 13 28,8 26 34280 25,5 36,1 3,1 4,8 306 12 14 36,1 29 38315 28,7 45,7 3,4 6,1 344 13 15 45,7 32 43355 32,3 58,0 3,7 7,7 388 14 17 58,0 35 48


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6


90 12,5 5,4 1,8 0,7 150 8 9 5,4 16 19110 15,2 8, 2, 1,1 182 9 10 8, 18 23125 17,3 10,4 2,2 1,4 208 9 11 10,4 20 26140 19,4 13, 2,4 1,7 233 10 12 13, 22 29160 22,1 17, 2,7 2,3 265 11 13 17, 25 33180 24,9 21,5 3, 2,9 299 11 14 21,5 28 37200 27,6 26,5 3,3 3,5 331 12 15 26,5 31 41225 31,1 33,6 3,6 4,5 373 13 16 33,6 34 47250 34,5 41,4 4, 5,5 414 14 18 41,4 38 52280 38,7 52, 4,4 6,9 464 16 19 52, 42 58315 43,5 65,8 4,9 8,8 522 17 21 65,8 47 65355 49,0 83,5 5,4 11,1 588 19 24 83,5 52 74


20

PE 100 σσ 801.Welding of PE 100 σσ 80 pipe with wall thickness less than 20 mm

Welding CycleThe welding cycle is divided in 5 different phases :PHASE 1 : Bead Formation t1 PHASE 2 : Heating up t1 PHASE 3 : Change over t3 PHASE 4 : Bringing up pressure t4 PHASE 6 : Cooling Down under pressure t6

The following graphic show all the phases:

Pressure-Time diagram for butt welding of PE 100 � 80 pipe with wall thickness less than 20 mm

Important !!Remember always to add the value checked of the inertial pressure to all “P” ( P1,P2,P6 ) values in the tables

2.Welding of PE 100 � 80 pipe with wall thickness more than 20 mm

Welding CycleThe welding cycle is divided in 6 different phases :PHASE 1 : Bead Formation t1 PHASE 2 : Heating up t2 PHASE 3 : Change over t3 PHASE 4 : Bringing up pressure t4 PHASE 5 : Cooling Down under pressure P5 and t5PHASE 6 : Cooling Down under pressure P6 and t6

The following graphic show all the phases:

Pressure-Time diagram for butt welding of PE 100 s 80 pipe with wall thickness more than 20 mm

Important !!Remember always to add the value checked of the inertial pressure to all “P” ( P1,P2,P5,P6 ) values in the tables

t1 = Time requested for the bead formation with the specified wall thickness

t2 = Time requested for the continual heatingt3 = Time requested for the change overt4 = Time requested for bringing up the pressuret6 = Time requested for cooling downP2 = Pressure during the continual heatingP1 = Pressure during the bead formationP5 = Pressure during the cooling down

t1 = Time requested for the bead formation with the specified wall thickness

t2 = Time requested for the continual heatingt3 = Time requested for the change overt4 = Time requested for bringing up the pressuret5 = Time requested for cooling downt6 = Time requested for cooling downP2 = Pressure during the continual heatingP1 = Pressure during the bead formationP5 = Pressure during the cooling downP6 = Pressure during the cooling down


21

Welding Tables for PE 100 σσ 80

material PE 100 / σ/ σ 80 PN 4 Cylinder Section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 P6 t 6

mm mm bar mm bar sec sec sec bar min bar min

90 2,2 1,1 0,7 0,1 26 5 5 1,1 5110 2,7 1,6 0,8 0,2 32 5 5 1,6 6125 3,1 2,1 0,8 0,3 37 5 5 2,1 6140 3,5 2,7 0,9 0,4 42 5 5 2,7 7160 4 3,5 0,9 0,5 48 5 6 3,5 7180 4,4 4,3 0,9 0,6 53 5 6 4,3 7200 4,9 5,3 1, 0,7 59 5 6 5,3 8225 5,5 6,7 1,1 0,9 66 6 6 6,7 9250 6,2 8,4 1,1 1,1 74 6 6 8,4 9280 6,9 10,5 1,2 1,4 83 6 7 10,5 10315 7,7 13,2 1,3 1,8 92 6 7 13,2 11355 8,7 16,8 1,4 2,2 104 7 7 16,8 12




90 3,3 1,6 0,8 0,2 40 5 5 1,6 6110 4 2,4 0,9 0,3 48 5 6 2,4 7125 4,6 3,1 1, 0,4 55 5 6 3,1 8140 5,1 3,8 1, 0,5 61 6 6 3,8 8160 5,8 5, 1,1 0,7 70 6 6 5, 9180 6,6 6,4 1,2 0,8 79 6 7 6,4 10200 7,3 7,8 1,2 1, 88 6 7 7,8 10225 8,2 9,9 1,3 1,3 98 6 7 9,9 11250 9,1 12,2 1,4 1,6 109 7 8 12,2 12280 10,2 15,3 1,5 2, 122 7 8 15,3 13315 11,4 19,3 1,6 2,6 137 7 9 19,3 14355 12,9 24,6 1,8 3,3 155 8 9 24,6 16




90 4,3 2,1 0,9 0,3 52 5 6 2,1 7110 5,3 3,1 1, 0,4 64 6 6 3,1 8125 6 4, 1,1 0,5 72 6 6 4, 9140 6,7 5, 1,2 0,7 80 6 7 5, 10160 7,7 6,5 1,3 0,9 92 6 7 6,5 11180 8,6 8,2 1,4 1,1 103 7 7 8,2 12200 9,6 10,2 1,5 1,4 115 7 8 10,2 13225 10,8 12,9 1,6 1,7 130 7 8 12,9 14250 11,9 15,8 1,7 2,1 143 8 9 15,8 15280 13,4 19,9 1,8 2,7 161 8 9 19,9 16315 15 25,1 2, 3,3 180 9 10 25,1 18355 16,9 31,8 2,2 4,2 203 9 11 31,8 20

Heating Temperature : 215°C for wall thickness less than 20 mm230°C for wall thickness more than 20 mm


22





90 5,4 2,5 1, 0,3 65 6 6 2,5 8110 6,6 3,8 1,2 0,5 79 6 7 3,8 10125 7,4 4,8 1,2 0,6 89 6 7 4,8 10140 8,3 6,1 1,3 0,8 100 6 7 6,1 11160 9,5 8, 1,5 1,1 114 7 8 8, 13180 10,7 10,1 1,6 1,3 128 7 8 10,1 14200 11,9 12,5 1,7 1,7 143 8 9 12,5 15225 13,4 15,8 1,8 2,1 161 8 9 15,8 16250 14,8 19,4 2, 2,6 178 8 10 19,4 18280 16,6 24,3 2,2 3,2 199 9 11 24,3 20315 18,7 30,8 2,4 4,1 224 10 11 30,8 22355 21,1 39,2 2,6 5,2 271 10 10 39,2 10 (sec) 13,1 24




90 8,2 3,7 1,3 0,5 98 6 7 3,7 11110 10 5,6 1,5 0,7 120 7 8 5,6 13125 11,4 7,2 1,6 1, 137 7 9 7,2 14140 12,7 9, 1,8 1,2 152 8 9 9, 16160 14,6 11,8 2, 1,6 175 8 10 11,8 18180 16,4 14,9 2,1 2, 197 9 11 14,9 19200 18,2 18,4 2,3 2,5 218 9 11 18,4 21225 20,5 23,3 2,6 3,1 265 10 10 23,3 10 (sec) 7,8 24250 22,7 28,7 2,8 3,8 287 10 10 28,7 10 (sec) 9,6 26280 25,4 36, 3, 4,8 314 10 10 36, 10 (sec) 12, 28315 28,6 45,6 3,4 6,1 346 10 10 45,6 10 (sec) 15,2 32355 32,3 58, 3,7 7,7 383 10 10 58, 10 (sec) 19,3 35




90 10,1 4,5 1,5 0,6 121 7 8 4,5 13110 12,3 6,7 1,7 0,9 148 8 9 6,7 15125 14 8,7 1,9 1,2 168 8 10 8,7 17140 15,7 10,9 2,1 1,4 188 9 10 10,9 19160 17,9 14,2 2,3 1,9 215 9 11 14,2 21180 20,1 17,9 2,5 2,4 261 10 10 17,9 10 (sec) 6, 23200 22,4 22,1 2,7 3, 284 10 10 22,1 10 (sec) 7,4 25225 25,2 28, 3, 3,7 312 10 10 28, 10 (sec) 9,3 28250 27,9 34,5 3,3 4,6 339 10 10 34,5 10 (sec) 11,5 31280 31,3 43,3 3,6 5,8 373 10 10 43,3 10 (sec) 14,4 34315 35,2 54,8 4, 7,3 412 10 10 54,8 10 (sec) 18,3 38355 39,7 69,7 4,5 9,3 457 10 10 69,7 10 (sec) 23,2 43



23





90 12,3 5,3 1,7 0,7 148 8 9 5,3 15110 15,1 8, 2, 1,1 181 9 10 8, 18125 17,1 10,3 2,2 1,4 205 9 11 10,3 20140 19,2 12,9 2,4 1,7 230 10 12 12,9 22160 21,9 16,8 2,7 2,2 279 10 10 16,8 10 (sec) 5,6 25180 24,6 21,3 3, 2,8 306 10 10 21,3 10 (sec) 7,1 28200 27,4 26,3 3,2 3,5 334 10 10 26,3 10 (sec) 8,8 30225 30,8 33,3 3,6 4,4 368 10 10 33,3 10 (sec) 11,1 34250 34,2 41,1 3,9 5,5 402 10 10 41,1 10 (sec) 13,7 37280 38,3 51,5 4,3 6,9 443 10 10 51,5 10 (sec) 17,2 41315 43,1 65,2 4,8 8,7 491 10 10 65,2 10 (sec) 21,7 46355 48,5 82,8 5,4 11, 545 10 10 82,8 10 (sec) 27,6 52




90 15 6,3 2, 0,8 180 9 10 6,3 18110 18,3 9,3 2,3 1,2 220 9 11 9,3 21125 20,8 12,1 2,6 1,6 268 10 10 12,1 10 (sec) 4, 24140 23,3 15,1 2,8 2, 293 10 10 15,1 10 (sec) 5, 26160 26,6 19,8 3,2 2,6 326 10 10 19,8 10 (sec) 6,6 30180 29,9 25, 3,5 3,3 359 10 10 25, 10 (sec) 8,3 33200 33,2 30,8 3,8 4,1 392 10 10 30,8 10 (sec) 10,3 36225 37,4 39,1 4,2 5,2 434 10 10 39,1 10 (sec) 13, 40250 41,5 48,2 4,7 6,4 475 10 10 48,2 10 (sec) 16,1 45280 46,5 60,4 5,2 8,1 525 10 10 60,4 10 (sec) 20,1 50315 52,3 76,5 5,7 10,2 583 10 10 76,5 10 (sec) 25,5 55355 59 97,2 6,4 13, 650 10 10 97,2 10 (sec) 32,4 62



24

Welding Parameters for PP pipes and fittingsThe following tables show the values to be applied during the welding cycle as per previous instructions and graph. However in order to clarify once againthe meaning of these values please kindly note:t1= Time requested for the bead formation to be done with pressure value =P1+inertial pressuret2= Time requested for the continual heating to be done with pressure value=P2+inertial pressuret3 =Time requested for the change overt4 =Time requested for bringing up the pressure at the value of pressure = P1 + inertial pressuret5 =Time requested for cooling down to be done with pressure value = P1 + inertial pressuret6 =Time requested for cooling down the welded pieces out of the machineImportant ! Remember always to add the value checked of inertial pressure to the P1 and P2 values !!!!!!!

material PP PN 2,5 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm mm Bar mm bar sec sec sec bar min min90 2,2 0,7 0,7 0,1 36 5 4,,,6 0,7 3 3110 2,7 1,1 0,8 0,1 42 5 4,,,6 1,1 4 4125 3,1 1,4 0,8 0,2 47 5 4,,,6 1,4 5 5140 3,5 1,8 0,9 0,2 52 5 4,,,6 1,8 5 5160 3,9 2,3 0,9 0,3 57 5 4,,,6 2,3 6 6180 4,4 2,9 0,9 0,4 63 5 6,,,8 2,9 7 7200 4,9 3,5 1, 0,5 69 5 6,,,8 3,5 7 7225 5,5 4,5 1,1 0,6 76 6 6,,,8 4,5 8 8250 6,1 5,5 1,1 0,7 83 6 6,,,8 5,5 9 9280 6,9 7, 1,2 0,9 93 6 6,,,8 7, 10 10315 7,7 8,8 1,3 1,2 102 6 6,,,8 8,8 12 12355 8,7 11,2 1,4 1,5 114 7 8,,,10 11,2 13 13

material PP PN 4 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm mm Bar mm bar sec sec sec bar min min90 3,5 1,1 0,9 0,1 52 5 4,,,6 1,1 5 5110 4,3 1,7 0,9 0,2 62 5 4,,,6 1,7 6 6125 4,9 2,2 1, 0,3 69 5 6,,,8 2,2 7 7140 5,4 2,7 1, 0,4 75 6 6,,,8 2,7 8 8160 6,2 3,5 1,1 0,5 84 6 6,,,8 3,5 9 9180 7 4,5 1,2 0,6 94 6 6,,,8 4,5 11 11200 7,7 5,5 1,3 0,7 102 6 8,,,10 5,5 12 12225 8,7 7, 1,4 0,9 114 7 8,,,10 7, 13 13250 9,7 8,7 1,5 1,2 126 7 8,,,10 8,7 15 15280 10,8 10,8 1,6 1,4 140 7 8,,,10 10,8 16 16315 12,2 13,7 1,7 1,8 156 8 8,,,10 13,7 18 18355 13,7 17,4 1,9 2,3 174 8 8,,,10 17,4 21 21


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm mm Bar mm bar sec sec sec bar min min90 5,1 1,6 1, 0,2 71 6 6,,,8 1,6 8 8110 6,3 2,4 1,1 0,3 86 6 6,,,8 2,4 9 9125 7,1 3,1 1,2 0,4 95 6 6,,,8 3,1 11 11140 8 3,9 1,3 0,5 106 6 8,,,10 3,9 12 12160 9,1 5,1 1,4 0,7 119 7 8,,,10 5,1 14 14180 10,2 6,4 1,5 0,9 132 7 8,,,10 6,4 15 15200 11,4 8, 1,6 1,1 147 7 10,,,15 8, 17 17225 12,8 10,1 1,8 1,3 164 8 10,,,15 10,1 19 19250 14,2 12,4 1,9 1,7 180 8 10,,,15 12,4 21 21280 15,9 15,6 2,1 2,1 201 9 10,,,15 15,6 24 24315 17,9 19,7 2,3 2,6 225 9 16,,,20 19,7 27 27355 20,1 25, 2,5 3,3 251 10 16,,,20 25, 30 30


25

Welding Parameters for PP pipes and fittings


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm Mm bar mm bar sec sec sec bar min min90 8,2 2,5 1,3 0,3 108 6 8,,,10 2,5 12 12110 10 3,7 1,5 0,5 130 7 8,,,10 3,7 15 15125 11,4 4,8 1,6 0,6 147 7 8,,,10 4,8 17 17140 12,8 6, 1,8 0,8 164 8 10,,,15 6, 19 19160 14,6 7,9 2, 1,1 185 8 10,,,15 7,9 22 22180 16,4 10, 2,1 1,3 207 9 10,,,15 10, 25 25200 18,2 12,3 2,3 1,6 228 9 10,,,15 12,3 27 27225 20,5 15,6 2,6 2,1 256 10 16,,,20 15,6 31 31250 22,8 19,2 2,8 2,6 284 11 16,,,20 19,2 34 34280 25,5 24,1 3,1 3,2 316 12 16,,,20 24,1 38 38315 28,7 30,5 3,4 4,1 354 13 21,,,25 30,5 43 43355 32,3 38,7 3,7 5,2 398 14 21,,,25 38,7 48 48

material PP PN 12,5 Cylinder section cm2 8,46

D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm Mm bar mm bar sec sec sec bar min min90 10 3, 1,5 0,4 130 7 8,,,10 3, 15 15110 12,3 4,5 1,7 0,6 158 8 10,,,15 4,5 18 18125 13,9 5,7 1,9 0,8 177 8 10,,,15 5,7 21 21140 15,6 7,2 2,1 1, 197 9 10,,,15 7,2 23 23160 17,8 9,4 2,3 1,3 224 9 10,,,15 9,4 27 27180 20 11,9 2,5 1,6 250 10 10,,,15 11,9 30 30200 22,3 14,7 2,7 2, 278 11 16,,,20 14,7 33 33225 25 18,6 3, 2,5 310 12 16,,,20 18,6 38 38250 27,8 22,9 3,3 3,1 344 12 21,,,25 22,9 42 42280 31,2 28,8 3,6 3,8 384 13 21,,,25 28,8 47 47315 35,3 36,6 4, 4,9 434 15 26,,,35 36,6 53 53355 39,5 46,3 4,5 6,2 484 16 26,,,35 46,3 59 59


D S P1 bead P2 t 2 t 3 t 4 P5 t 5 t 6mm Mm bar mm bar sec sec sec bar min min90 12,5 3,6 1,8 0,5 160 8 10,,,15 3,6 19 19110 15,2 5,3 2, 0,7 192 9 10,,,15 5,3 23 23125 17,3 6,9 2,2 0,9 218 9 10,,,15 6,9 26 26140 19,4 8,7 2,4 1,2 243 10 16,,,20 8,7 29 29160 22,1 11,3 2,7 1,5 275 11 16,,,20 11,3 33 33180 24,9 14,3 3, 1,9 309 11 16,,,20 14,3 37 37200 27,6 17,7 3,3 2,4 341 12 16,,,20 17,7 41 41225 31,1 22,4 3,6 3, 383 13 21,,,25 22,4 47 47250 34,5 27,6 4, 3,7 424 14 21,,,25 27,6 52 52280 38,7 34,7 4,4 4,6 474 16 26,,,35 34,7 58 58


26

PT 355 Basic Machine , Code: PT355B PT 355 Basic Machine , Code: PT355BPos. Code Description Qty � Pos. Code Description Qty �

1 PT355B01 nut UNI 5721 5s m 10 z 6 0,58 27 PT355B27 screw TCEI UNI 5931 8.8 10x25 3 0,192 PT355B02 washer UNI 6592 m 10 6 0,03 28 PT355B28 connecting rod 2 0,673 PT355B03 connecting rod 3 5,12 29 PT355B29 fourth half Clamp lower 14 PT355B04 screw TCEI UNI 5931 8.8 4 0,16 30 PT355B30 fourth half Clamp upper 15 PT355B05 side support 1 263,97 31 PT355B31 nut 30x1,5 2 2,276 PT355B06 nut UNI 5721 5s m 8 z 6 0,29 32 PT355B32 side support 1 263,977 PT355B07 washer UNI 6592 m 8 6 0,03 33 PT355B33 nut tie rod 8 4,488 PT355B08 tie rod 6 5,60 34 PT355B34 washer tie rod 8 1,159 PT355B09 first half Clamp lower 1 35 PT355B35 tie rod 8 19,84

10 PT355B10 first half Clamp upper 1 36 PT355B36 tie rod pivot 8 3,0711 PT355B11 connecting pipe 3 16,03 37 PT355B37 pin 1 3,0112 PT355B12 hose 2 18,85 38 PT355B38 stopper 1 48,9913 PT355B13 quick coupling M/F 1/4 1 48,35 39 PT355B39 screw 2 4,4514 PT355B14 fitting TN 96 10 LR 2 24,48 40 PT355B40 rod 1 61,0215 PT355B15 fitting TN 126 10LR 2 3,55 41 PT355B41 washer 1 6,6916 PT355B16 washer 1/4 4 0,61 42 PT355B42 Lower Cylinder 1 311,2617 PT355B17 Upper Cylinder 1 320,58 43 PT355B43 fitting TN 92 10 LR (1/4 M) 2 2,5318 PT355B18 label 1 1,15 44 PT355B44 cap ABS 22X2 4 0,1619 PT355B19 label 1 1,06 45 PT355B45 screw TCEI UNI 5931 8.8 10x20 4 0,1920 PT355B20 label 2 0,19 46 PT355B46 plug 80x30 4 1,4121 PT355B21 second half Clamp lower 1 47 PT355B47 pipe transport 2 10,4322 PT355B22 second half Clamp upper 1 48 PT355B48 Label 2 1,1523 PT355B23 35.20 FB1 bush 2 1,92 49 PT355B49 label ITS - TECNODUE 160X50 1 4,5124 PT355B24 third half Clamp lower 1 50 PT355B50 rivet 3x7 4 0,0325 PT355B25 third half Clamp upper 1 51 PT355B51 ground support 2 52,3526 PT355B26 35.25 FB1 bush 2 3,42 Tie Rod complete Kit 1 28,51


27

Upper Cylinder , Code: PT355B17 Lower Cylinder , Code: PT355B42Pos

. Code Description Qty � Pos. Code Description Qty �1 PT355B1701 gasket GHK 313 35.0 43.6 5.3 38.0 2 2,11 1 PT355B4201 gasket GHK 313 35.0 43.6 5.3 38.0 2 2,112 PT355B1702 35.40 FB1 bush 2 2,78 2 PT355B4202 35.40 FB1 bush 2 2,783 PT355B1703 gasket I/GR 0350 NCR 2 10,53 3 PT355B4203 gasket I/GR 0350 NCR 2 10,534 PT355B1704 cylinder upper head 2 33,89 4 PT355B4204 cylinder upper head 2 33,895 PT355B1705 o-ring NBR 70 2.62x50.47 (136) 2 0,26 5 PT355B4205 o-ring NBR 70 2.62x50.47 (136) 2 0,266 PT355B1706 stopper 2 3,71 6 PT355B4206 stopper 2 3,717 PT355B1707 gasket E/GR 0420 NPS 1 8,77 7 PT355B4207 gasket E/GR 0420 NPS 1 8,778 PT355B1708 cylinder stem 1 83,71 8 PT355B4208 cylinder stem 1 83,719 PT355B1709 stopper 2 5,95 9 PT355B4209 stopper 2 5,9510 PT355B1710 cylinder housing 1 39,87 10 PT355B4210 cylinder housing 1 39,8711 PT355B1711 screw TCEI UNI 5931 8.8 6x10 2 0,10 PT 355 Gasket Kit ( 1 Cylinder ) 1 34,5312 PT355B1712 washer 6x12x1,5 2 0,10

PT 355 Gasket Kit ( 1 Cylinder ) 1 34,53


28

PT 355 Facing Tool , Code: PT355F PT 355 Facing Tool , Code: PT355FPos. Code Description Qty � Pos. Code Description Qty �

1 PT355F01 drill HB 723 S 1 1,66 25 PT355F25 pinion Z=10 1 13,222 PT355F02 cable stopper PG13,5 1 30,02 26 PT355F26 carter ring 1 12,033 PT355F03 box support 1 21,34 27 PT355F27 carter cover 1 2,084 PT355F04 box TAIS 62x80x38 3V x 1/2" 1 0,90 28 PT355F28 label 1 0,195 PT355F05 cable stopper 2 0,06 29 PT355F29 label 1 1,156 PT355F06 screw TCEI UNI 5931 8.8 4x10 9 2,34 30 PT355F30 label 1 1,067 PT355F07 terminal mm2 2,5 FORBOX 0,4 0,10 31 PT355F31 carter 1 7,788 PT355F08 plastic stub142X36 3 0,16 32 PT355F32 screw TCEI UNI 5931 8.8 8x50 4 0,199 PT355F09 holder 1015 / 10 1 0,03 33 PT355F33 screw TPS UNI 6109 a2 4x12 8 0,06

10 PT355F10 washer 5x15x1,5 1 0,06 34 PT355F34 blade 4 holes 2 18,8211 PT355F11 screw TCEI UNI 5931 8.8 5x10 1 11,81 35 PT355F35 disk 1 260,9312 PT355F12 pin 1 0,48 36 PT355F36 crown gear 1/2" X 3/16" Z=76 1 94,0513 PT355F13 s D.2.3 1 0,06 37 PT355F37 screw TPSEI 10.9 6x16z 4 0,0614 PT355F14 screw TCEI UNI 5931 8.8 4x12 z 1 0,03 38 PT355F38 screw TCEI UNI 5931 8.8 8x50 1 0,1915 PT355F15 washer 4x12x1.5 1 2,40 39 PT355F39 rivets 2,5x6,5 4 0,0316 PT355F16 chain D.1.6 0,2 2,27 40 PT355F40 label ITS - TECNODUE 80X25 1 3,3317 PT355F17 cableH07 RNF 3G1 0,8 2,27 41 PT355F41 facing tool support 1 333,9818 PT355F18 cable stopper 1 25,54 42 PT355F42 screw TCEI UNI 5931 8.8 8x30 1 0,1319 PT355F19 stopper 1 2,50 43 PT355F43 eccentric 1 51,0420 PT355F20 prolonged 1,5 0,06 44 PT355F44 label 1 0,1921 PT355F21 screw TCEI UNI 5931 8.8 5x35 2 8,74 45 PT355F45 bearing EST 16018 2 28,5822 PT355F22 pinion holder 1 1,98 46 PT355F46 disk 1 250,0523 PT355F23 joint 1/2'' x 3/16'' 1 12,06 47 PT355F47 Cable H07 RNF 3G1, 3,3 2,6624 PT355F24 chain 1/2" x 3/16" 1,2 1,60 48 PT355F48 strip TY5272MXR 6 0,96


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PT 355 Heating Mirror , Code: PT355T PT 355 Heating Mirror , Code: PT355TPos. Code Description Qty � Pos. Code Description Qty �

1 PT355T01 thermometer LIQ.DN.52. 1 48,35 30 PT355T30 box thermostat 1 36,482 PT355T02 o-ring NBR 70 1.78x50.52 (033) 1 0,29 31 PT355T31 screw 7687 4.8 4x14z 4 0,033 PT355T03 label 3 0,74 32 PT355T32 screw TCEI UNI 5931 8.8 4x8 2 0,064 PT355T04 screw TCEI UNI 5931 a2 5x12 2 0,10 33 PT355T33 relay 230VAC 30A 1 37,705 PT355T05 cover 1 25,60 34 PT355T34 nuts UNI 5588 CL 8 m 4 2 0,036 PT355T06 gasket D.5 1.5V 0,2 1,70 35 PT355T35 red female connection 6.35x0.8 5 0,267 PT355T07 o-ring NBR 70 1.78x101.32 (045) 1 0,42 36 PT355T36 blue female connection 6.35x0.8 8 0,268 PT355T08 screw TCEI UNI 5931 a2 5x30 8 0,16 37 PT355T37 yellow female connection 6.35x0.8 1 0,329 PT355T09 washer grower UNI 1751 m5 z 8 0,03 38 PT355T38 joint 1 0,29

10 PT355T10 terminal mm2 2,5 FORBOX 0,4 2,34 39 PT355T39 nut ISO M25x1.5 CE 1 1,2811 PT355T11 terminals 4/6 mm2 3 0,48 40 PT355T40 nut PG11 1 0,3812 PT355T12 cable stopper handle 1 4,45 41 PT355T41 washer UNI 6592 m 4 4 0,0313 PT355T13 cable stopper 2 3,68 42 PT355T42 nuts CL 8 m4 4 0,0314 PT355T14 cableH07 RNF 7G1,5 3,3 9,54 43 PT355T43 cable stopper 1 1,5715 PT355T15 heating mirror 1 704,06 44 PT355T44 cableH07 RNF 3G1,5 3,3 2,6616 PT355T16 spacer 4 0,77 45 PT355T45 protection 1 4,0317 PT355T17 probe PT100 OHM l MT 0.5 1 26,02 46 PT355T46 deviator 1 13,8218 PT355T18 spacer 1 17,89 47 PT355T47 relay support 40.51 / 52 / 61 1 9,7019 PT355T19 gasket 4 0,90 48 PT355T48 rod 1 5,0920 PT355T20 box 1 80,80 49 PT355T49 rivet 4x12 all 1 0,0621 PT355T21 rubber handle D. 30 1 2,46 50 PT355T50 insulated pipe 1 MM2 P=8 MM 4 0,0322 PT355T22 lamp 1 2,11 51 PT355T51 terminal 0,2 20,6123 PT355T23 lamp support 1 1,98 52 PT355T52 nut UNI 5588 m 3 4 0,0324 PT355T24 regulator 1 180,96 53 PT355T53 connector UTGO 12 8S 1 12,3825 PT355T25 label 1 0,19 54 PT355T54 connector 8 pins 1 15,8126 PT355T26 label ITS - TECNODUE 80X25 1 3,33 55 PT355T55 screw TSPI UNI 6109 3x12 1 0,0327 PT355T27 label 1 1,15 56 PT355T56 screw TC UNI 6107 3x10 3 0,0328 PT355T28 label 1 1,06 57 PT355T57 relay circuit 10A 24VDC 1 6,5329 PT355T29 label 1 1,06


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PT 315 Hydraulic Unit , Code: PT315A PT 315 Hydraulic Unit , Code: PT315APos. Code Description Qty � Pos. Code Description Qty �

1 PT315A01 hose R1T M 1/4 + FD 1/4 L=2500 2 36,00 33 PT315A33 rivet 3x7 4 0,032 PT315A02 oil tank LT.2 1 23,04 34 PT315A34 screw 1/4 GAS 1 2,273 PT315A03 washer 1/2 1 0,35 35 PT315A35 adaptor 90° 1/4 M 18X1.5 1 14,50

4 PT315A04 plug 1/2 1 1,31 36 PT315A36pressure gauge D.100 range 0-

160bar 1 106,565 PT315A05 o-ring NBR 70 5.33x107.20 (347) 1 1,89 37 PT315A37 washer 18X1.5 1 0,296 PT315A06 ring UP 100 1 13,34 38 PT315A38 accumulator L 01/8 con 20GR. olio 1 92,967 PT315A07 filter 150 M UP 100 1 20,80 39 PT315A39 screw 7981 3.5x19z 4 0,038 PT315A08 pump 2.5 1 253,12 40 PT315A40 switch 1 7,179 PT315A09 o-ring body kit UP 100 1 20,16 41 PT315A41 label 1 0,19

10 PT315A10 hydraulic complete UP100 mod.235 1 684,26 42 PT315A42 box 1 15,6211 PT315A11 pressure valve 1 101,09 43 PT315A43 condenser 20MF 1 28,8012 PT315A12 body pump 1 280,32 44 PT315A44 fan cover MEC 80 1 7,4613 PT315A13 distributor block HD 104 1 49,89 45 PT315A45 fan MEC 80 1 3,7114 PT315A14 o-ring NBR 70 1.78x11.11 (806) 3 0,06 46 PT315A46 cableH07 RNF 2G1 0,4 2,1815 PT315A15 nipples M 1/4 2 1,18 47 PT315A47 engine P80/4M HP1 B5/B14 V220 1 244,6716 PT315A16 washer 1/4 7 0,22 48 PT315A48 cableH07 RNF 3G1,5 3 2,6617 PT315A17 distributor TC2 1 716,93 49 PT315A49 label ITS - TECNODUE 80X25 1 3,3318 PT315A18 label 1 0,19 50 PT315A50 label 1 1,1519 PT315A19 bellow HD 104 1 5,09 51 PT315A51 washer 4 0,6420 PT315A20 screw TCEI UNI 5931 8.8 6x70z 4 0,19 52 PT315A52 label 1 1,0621 PT315A21 nut CL 8 m4 2 0,03 53 PT315A53 protection N°2 1 37,2222 PT315A22 micro ASITZ 7141 1 68,80 54 PT315A54 flange 1 51,9023 PT315A23 screw TCEI UNI 5931 8.8 4x30 z 2 0,10 55 PT315A55 joint HP 0.75/1 1 64,8024 PT315A24 pressure regulating valve VM03/M 1 68,93 56 PT315A56 support 20-22 4 0,8025 PT315A25 by pass valve V03/M 1 66,53 57 PT315A57 washer fl m 10x30x2,5 2 0,1026 PT315A26 by pass lever handle V03/M 1 13,44 58 PT315A58 screw TCEI UNI 5931 8.8 10x25 2 0,1927 PT315A27 distributor lever HD 104 L.185 1 8,54 59 PT315A59 frame 1 73,5028 PT315A28 connector FT 299 44 M 1/4'' 1 10,82 60 PT315A60 washer 6x12x1,5 4 0,1029 PT315A29 screw TCEI UNI 5931 8.8 6x20 4 0,06 61+62 fixing kit UP 100 1 20,4230 PT315A30 washer grower UNI 1751 m8 z 4 0,03 63 PT315A63 quick coupling M/F 1/4 1 48,3531 PT315A31 screw TCEI UNI 5931 8.8 8x25 4 0,1332 PT315A32 screw TPSEI 10.9 6x16z 4 0,06


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Electric Drawings

230V Single Phase


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This manual has been printed on May 2004

The technical data and information contained in this manual can be changed without any notice

Pt 355 Manual

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