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Tecnodue I.T.S. PT 355 Operating Manual

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I.T.S. by Tecnodue
PT 355
Edition 1208
Operating Manual

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Summary of Contents for Tecnodue I.T.S. PT 355

  • Page 1 I.T.S. by Tecnodue PT 355 Edition 1208 Operating Manual...
  • Page 2 I.T.S. Ital Trade Services PT 355 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. Support for facing tool and heating mirror 5. Basic machine On request can be supplied: 6.
  • Page 4 I.T.S. Ital Trade Services PT 355 Operating Manual 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.

  • Page 5: Technical Data

    I.T.S. Ital Trade Services PT 355 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 Frequency 50 Hz Total power installed 5.13 KW 22.3 A Heating mirror IP 54 3.24 KW...

  • Page 6: Basic Machine

    I.T.S. Ital Trade Services PT 355 Operating Manual General description and application field Hydraulic operated butt welding machines suitable for PE,PP,PVDF and other thermoplastics pipes and fittings. The self aligning frame and the compact dimensions make the machines highly suited for working in road constructions, ditches , aqueducts, gas ducts , sewers and irrigation systems.
  • Page 7 I.T.S. Ital Trade Services PT 355 Operating Manual 2.3.1 Electronic thermostat – different functions At each startup on the display will blink the writing ‘TEST’. This means that the thermostat is testing the connection between the probe and the heating mirror. If the test fails, the display will show 4 blinking upper scores (as per figure aside), in this case the probe or the connection between the thermostat and the heating mirror could be interrupted.

  • Page 8: Hydraulic Unit

    I.T.S. Ital Trade Services PT 355 Operating Manual Hydraulic Unit The basic components of the hydraulic unit are the following: • Electric engine • Hydraulic pump • Oil tank • Hydraulic unit controls • Pressure accumulator • Pressure gauge • Metal frame 2.
  • Page 9 I.T.S. Ital Trade Services PT 355 Operating Manual 2.4.2 How to use the hydraulic unit Operating Instructions In order to make easy the learning we shall proceed to the description step by step of all operations need in order to complete a welding according to the following description: Important ! Before begin the following operation be sure that:...
  • Page 10 I.T.S. Ital Trade Services PT 355 Operating Manual 3. Heating mirror disconnecting device You can configure the machine according to the kind of welding to be executed as per the following different ways: • Two fixed clamps and two moveable clamps Fig. 1 •...
  • Page 11 I.T.S. Ital Trade Services PT 355 Operating Manual 3.1 Beep-beep inserts reductions To use a beep-beep inserts reduction To use a beep-beep reduction, fix it by lightly pushing the reduction in the direction shown as per figure aside. As you hear a ‘click’ sound the reduction is properly fixed.
  • Page 12 I.T.S. Ital Trade Services PT 355 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 Pipe with short spigot fitting, to achieve this kind of welding it is strongly suggested to configure the machine with three moveable...
  • Page 13 I.T.S. Ital Trade Services PT 355 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 14 I.T.S. Ital Trade Services PT 355 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 15 I.T.S. Ital Trade Services PT 355 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 = Time requested for the change over...
  • Page 16 I.T.S. Ital Trade Services PT 355 Operating Manual Welding Parameters for PE & PP sheets,pipes & fittings according to DVS 2207-1 – 2207-11 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 Bead height on heater wallthickness (heating-...
  • Page 17 I.T.S. Ital Trade Services PT 355 Operating Manual 6. Welding Table for PE pipes DVS norm version 2207-1 The following tables show the values to be applied during the welding cycle as per previous instructions and graph. However in order to clarify once again the meaning of these values please kindly note: t1 = Time requested for the bead formation to be done with pressure value = P1 + inertial pressure t2 =...
  • Page 18 I.T.S. Ital Trade Services PT 355 Operating Manual 8,46 PT 355 - DVS 2207-1 Cyl. section cm Welding range 90-315 mm material PE80-100 SDR 27,6 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 12,2 12,2 10,1 15,2...
  • Page 19 I.T.S. Ital Trade Services PT 355 Operating Manual 8,46 PT 355 - DVS 2207-1 Cyl. section cm Welding range 90-355 mm material PE80-100 SDR 21 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 10,1 10,1 10,7 12,8...
  • Page 20 I.T.S. Ital Trade Services PT 355 Operating Manual 8,46 PT 355 - DVS 2207-1 Cyl. section cm Welding range 90-355 mm material PE80-100 SDR 13,6 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 10,3 11,8 13,2 12,3...
  • Page 21 I.T.S. Ital Trade Services PT 355 Operating Manual 8,46 PT 355 - DVS 2207-1 Cyl. section cm Welding range 90-355 mm material PE80-100 SDR 7,4 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 12,2 14,9 16,9 10,2...
  • Page 22 I.T.S. Ital Trade Services PT 355 Operating Manual 7. Welding Parameters for PP pipes & fittings DVS norm version 2207-11 material PP SDR 41 Cylinder section cm 8,46 Temp. bead ° C 210° 210° 210° 210° 210° 210° 210° 210° 210°...
  • Page 23 I.T.S. Ital Trade Services PT 355 Operating Manual Cylinder section cm 8,46 material PP SDR 17.6 Temp. bead ° C 210° 210° 210° 210° 210° 10,2 210° 1027 11,4 210° 1142 12,8 210° 10,1 10,1 1269 14,2 210° 12,4 12,4 1389 15,9 210°...

  • Page 24: Maintenance

    I.T.S. Ital Trade Services PT 355 Operating Manual 8. Maintenance 8.1 Basic machine It's strongly suggested to keep always the machine clean with particular care of the bolts and the cylinder's heads . Keep attention while insert the electric facing tool and the PTFE coated heating mirror avoiding to damage the machine's slide bars. 8.2 Facing tool It's strongly suggested to keep always clean the blades and wash the pulleys by using a detergent.
  • Page 25 I.T.S. Ital Trade Services PT 355 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 26 I.T.S. Ital Trade Services PT 355 Operating Manual Check that the electric plug is disconnected Open the electric connections box and disconnect the micro-switch cable Enlighten the screws and take out the engine Take out the joints and insert them on the new engine Reassemble the engine taking care that the joints are perfectly located on the own housings Check the anti clockwise rotation of the electric fan...

  • Page 27: Thermostat Connection

    I.T.S. Ital Trade Services PT 355 Operating Manual 10. Drawings 10.1 Thermostat connection 10.2 Facing tool and hydraulic unit engines connection...

  • Page 28: Hydraulic Plan

    I.T.S. Ital Trade Services PT 355 Operating Manual 10.3 Hydraulic plan...

  • Page 29: Exploded View And Spare Parts List

    I.T.S. Ital Trade Services PT 355 Operating Manual 11. Exploded view and spare parts list...
  • Page 30 Third clamp (24+25) PT355B50 Ground support PT355B26 35.25 FB1 bush PT355B51 ITS – TECNODUE label PT355B27 screw TCEI UNI 5931 8.8 10x25 z PT355B52 rivet tt UNI 9200 3x7 all PT 355 Upper Cylinder , Code: PT355B17 PT 355 Lower Cylinder , Code: PT355B43 Pos.
  • Page 31 I.T.S. Ital Trade Services PT 355 Operating Manual...
  • Page 32 O-ring 4450 NBR 3.53x113.9 (246) PT315A49 Rivet tt uni 9200 3x7 all PT315A12 Max pressure valve FPMDC15P35 PT315A50 ITS - TECNODUE 80X25 label PT315A13 Pump body HY 10 K3P0-01 ¼ BB PT315A51 Screw TC CR UNI 6954 3.5X19 zin PT315A14 Screw TCEI uni 5931 8.8 6x35 zin...
  • Page 33 Screw TCEI UNI 5931 8.8 4x12 z PT355F40 Rivets tt UNI 7346 2,5x6,5 brass PT355F16 Washer fl UNI 6593 m 4x12x1,5 zin PT355F41 label ITS - TECNODUE 80X25 PT355F17 Facing tool stopper chain PT355F42 Facing tool body PT355F18 Cable H07 RNF 3G1 PT355F43 Screw TCEI UNI 5931 8.8 8x30 zin...
  • Page 34 Thermostat TLK38 PT355T52 Ring 3.5 type 0 PT355T24 Electric danger label PT355T53 Ring 3.5 type 1 PT355T25 ITS – TECNODUE 80X25 label PT355T54 Ring 3.5 type 2 PT355T26 Technical data label PT355T55 Ring 3.5 type 3 PT355T27 Serial no. label PT355T56 Ring 3.5 type 5...
  • Page 35 I.T.S. Ital Trade Services PT 355 Operating Manual PT 355 Stub Device , Code: PT355S PT 355 Stub Device , Code: PT355S Pos. Code Description Pos. Code Description PT355S01 Plateau PT 355 PT355S06 Fixing stub end bracket PT355S02 Cursor PT355S07 Screw STEI UNI 5927 45h 5x8 zin PT355S03 Screw STEI UNI 5927 45h 8x35 zin...
  • Page 36 I.T.S. Ital Trade Services PT 355 Operating Manual This manual has been printed on December 2008 The technical data and information contained in this manual can be changed without any notice...