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Tecnodue I.T.S. PT 500 Operating Manual

With revolving heating mirror & facing tool, rollers
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I.T.S. by Tecnodue
PT 500
WITH REVOLVING HEATING MIRROR & FACING
TOOL, ROLLERS
Ser. no. 1121 1744
Operating Manual

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Summary of Contents for Tecnodue I.T.S. PT 500

  • Page 1 I.T.S. by Tecnodue PT 500 WITH REVOLVING HEATING MIRROR & FACING TOOL, ROLLERS Ser. no. 1121 1744 Operating Manual...
  • Page 2 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual The technical data and information contained on this manual can be changed without any notice...
  • Page 3 Via Scarsellini 77 , 16149 Genova Italy Phone : +39-010-6423396 : +39-010-6423513 E Mail info@its-tecndoue.com Web Site www.its-tecnodue.com Standard Components 1. Hydraulic Unit 2. Facing Tool 3. Heating Mirror 4. Basic machine On request can be supplied: 5. Light weight alloy reducing rings for pipes and fittings d. 200,225,250,280,315,355,400,450mm Stub End Device •...
  • Page 4 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual SAFETY RULES ACCORDING TO DIRECTIVES CEE ( To be read carefully and apply while utilizing the PT 500 ) 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.

  • Page 5: Technical Data

    I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 1. Technical data Operating data Ambient temperature 0…50°C Humidity (without condensation) 95 RH% Transport and storing Temperature -10…60°C Electrical data Voltage 230 V±10% Frequency 50 Hz Total power installed 7.7 KW 39 A Heating mirror...

  • Page 6: Basic Machine

    I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 3. 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.
  • Page 7 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 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! How to change the configuration from two fixed clamps and two sliding clamps into one fixed clamp and three sliding clamps...
  • Page 8 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 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.
  • Page 9 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 3.2 Facing Tool The electric facing tool is composed by: • The facing tool body • Two disks where are mounted the blades • A motor with a reducing gear supplied •...
  • Page 10 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 3.3.1 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.

  • Page 11: Hydraulic Unit

    I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Hydraulic Unit The basic components of the hydraulic unit are the following: • Electric engine • Hydraulic pump • Oil tank • Hydraulic unit controls •...
  • Page 12 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 3.4.2 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:...
  • Page 13 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Back trolley The machine is equipped with a back trolley for moving the heating mirror and facing tool. Tailgate air cylinder will help to move the facing tool and heating mirror.
  • Page 14 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 4. Butt welding in brief 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: Pipe with Pipe, standard configuration of the machine Pipe with long spigot fitting, standard configuration of the machine...
  • Page 15 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror 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...
  • Page 16 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror 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...
  • Page 17 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 5. Welding Parameters for PE pipes & fittings DVS norm version 2207-1 Pressure-Time diagram for butt welding t1 = Time requested for the bead formation with the specified wall thickness t2 = Time requested for the continual heating t3 =...
  • Page 18 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Welding Parameters for PE & PP sheets,pipes & fittings according to DVS 2207-1 Nominal Wall thickness Alignment Heating-up Changeover time Joining pressure Cooling time under joining pressure p=0.15 Heating-up time= 10 x N/mm2 0.01...
  • Page 19 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror 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...
  • Page 20 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual SDR 27,6 Welding range bead DIAMETER THICKNESS EQUALISING HEATING CHANGEOV. JOINING COOLING <15° 15°-25°c 25°-40°c 0.. 0,3 0.. 6 0.. 0,4 0.. 6 10,9 0.. 0,5 0..
  • Page 21 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Machine PT 500 DVS 2207-1 rel. August 2015 Thrust section sq.cm. 14,13 Material PE SDR 26 Welding range bead DIAMETER THICKNESS EQUALISING HEATING CHANGEOV. JOINING COOLING <15°...
  • Page 22 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Machine PT 500 DVS 2207-1 rel. August 2015 Thrust section sq.cm. 14,13 Material PE SDR 17,6 Welding range bead DIAMETER THICKNESS EQUALISING HEATING CHANGEOV. JOINING COOLING <15°...
  • Page 23 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Machine PT 500 DVS 2207-1 rel. August 2015 Thrust section sq.cm. 14,13 Material PE SDR 11 Welding range bead DIAMETER THICKNESS EQUALISING HEATING CHANGEOV. JOINING COOLING <15°...

  • Page 24: Maintenance

    I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror 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.
  • Page 25 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual Suggested maintenances for PT 500 with rev. facing tool & heating mirror AT THE MACHINE DAILY WEEKLY MONTHLY YEARLY STARTUP IF NECESSARY Cylinder’s rod cleaning Quick couplers cleaning Basic machine cleaning Tie rod cleaning &...
  • Page 26 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 9. Troubleshooting and relative solutions 9.1 Basic machine 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...
  • Page 27 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 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...
  • Page 28 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 10. Drawings 10.1 Thermostat connection 10.2 Facing tool and hydraulic unit engines connection...

  • Page 29: Hydraulic Plan

    I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual 10.3 Hydraulic plan...
  • Page 30 I.T.S. Ital Trade Services PT 500 with revolving facing tool & heating mirror Operating Manual This manual has been printed on December 2021 The technical data and information contained in this manual can be changed without any notice...

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1121 1744