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Tecnodue I.T.S. PT 250 Operating Manual

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I.T.S. by Tecnodue
PT 250
Edition 1208
Operating Manual

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Summary of Contents for Tecnodue I.T.S. PT 250

  • Page 1 I.T.S. by Tecnodue PT 250 Edition 1208 Operating Manual...
  • Page 2 I.T.S. Ital Trade Services PT 250 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. Basic machine 4. Heating Mirror 5. Support for facing tool and heating mirror On request can be supplied: 6.
  • Page 4 I.T.S. Ital Trade Services PT 250 Operating Manual SAFETY RULES ACCORDING TO DIRECTIVES CEE ( To be read carefully and apply while utilizing the PT 250 ) 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 250 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 3.92 KW 17 A Heating mirror IP 54 2.3 KW...

  • Page 6: Basic Machine

    I.T.S. Ital Trade Services PT 250 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 250 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 250 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 •...
  • Page 9 I.T.S. Ital Trade Services PT 250 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 250 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 250 Operating Manual How to change the configuration from two fixed clamps and two sliding clamps into one fixed clamp and three sliding clamps 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 12 I.T.S. Ital Trade Services PT 250 Operating Manual 3.1 Beep-beep inserts reductions To use a beep-beep insert 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 13 I.T.S. Ital Trade Services PT 250 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 14 I.T.S. Ital Trade Services PT 250 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 15 I.T.S. Ital Trade Services PT 250 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 16 I.T.S. Ital Trade Services PT 250 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 17 I.T.S. Ital Trade Services PT 250 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 18 I.T.S. Ital Trade Services PT 250 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 19 I.T.S. Ital Trade Services PT 250 Operating Manual 5,88 PT 250 - DVS 2207-1 Cyl. section cm Welding range 63-250 mm material PE80-100 SDR 26 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 11,8 11,8 18,5 18,5...
  • Page 20 I.T.S. Ital Trade Services PT 250 Operating Manual 5,88 PT 250 - DVS 2207-1 Cyl. section cm Welding range 63-250 mm material PE80-100 SDR 17,6 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 10,2 13,9 13,9 11,4...
  • Page 21 I.T.S. Ital Trade Services PT 250 Operating Manual 5,88 PT 250 - DVS 2207-1 Cyl. section cm Welding range 63-250 mm material PE80-100 SDR 11 bead DIAMETER WALL THICK. TEMP. BEAD FORMATION HEATING UP CHANGEOV. RAMP COOLING ° C 10,0 11,4 10,3 10,3...
  • Page 22 I.T.S. Ital Trade Services PT 250 Operating Manual 7. Welding Parameters for PP pipes & fittings DVS norm version 2207-11 material PP SDR 41 Cylinder section cm 5,88 Temp. bead ° C 210° 210° 210° 210° 210° 210° 210° 210° 210°...
  • Page 23 I.T.S. Ital Trade Services PT 250 Operating Manual Cylinder section cm 5,88 material PP SDR 17.6 Temp. bead ° C 210° 210° 210° 210° 210° 210° 210° 10,2 210° 1027 11,4 210° 11,5 11,5 1142 12,8 210° 14,5 14,5 1269 14,2 210°...

  • Page 24: Maintenance

    I.T.S. Ital Trade Services PT 250 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 250 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 250 Operating Manual c) If the hydraulic unit cannot increase the pressure reasons could be : Check the oil level The lever E is not closed. Check if they are some leakage on hydraulic circuit. If the hydraulic unit cannot maintain a constant pressure reasons could be : The lever E is not closed.

  • Page 27: Thermostat Connection

    I.T.S. Ital Trade Services PT 250 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 250 Operating Manual 10.3 Hydraulic plan...

  • Page 29: Exploded View And Spare Parts List

    I.T.S. Ital Trade Services PT 250 Operating Manual 11. Exploded view and spare parts list...
  • Page 30 PT250B21 Screw TSPEI 5933 10.9 8x30z PT250B46 rivet tt UNI 9200 3x7 all PT250B22 Spacer PT250B47 ITS – TECNODUE label 23+24 PT250B23+24 Fourth clamp c/w support (23+24) PT250B48 blind nut UNI 5721 8 m 10 z PT250B25 Screw TCEI UNI 5931 8.8 10x40z...
  • Page 31 I.T.S. Ital Trade Services PT 250 Operating Manual...
  • Page 32 O-ring 4450 NBR 3.53x113.9 (246) PT160A49 Rivet tt uni 9200 3x7 all PT160A12 Max pressure valve FPMDC15P35 PT160A50 ITS - TECNODUE 80X25 label PT160A13 Pump body HY 10 K3P0-01 ¼ BB PT160A51 Screw TC CR UNI 6954 3.5X19 zin PT160A14 Screw TCEI uni 5931 8.8 6x35 zin...
  • Page 33 Bearing 6003 ZZ PT250F25 Bearing 16008 PT250F53 Ring UNI 7437 c 70 35 PT250F26 Rivets tt UNI 7346 2,5x6,5 brass PT250F54 Drill joint PT250F27 label ITS - TECNODUE 80X25 PT250F55 drill PERLES PSB 7 PT250F28 Facing tool body PT 160...
  • Page 34 Thermostat TLK38 PT250T52 Ring 3.5 type 0 PT250T24 Electric danger label PT250T53 Ring 3.5 type 1 PT250T25 ITS – TECNODUE 80X25 label PT250T54 Ring 3.5 type 2 PT250T26 Technical data label PT250T55 Ring 3.5 type 3 PT250T27 Serial no. label PT250T56 Ring 3.5 type 5...
  • Page 35 I.T.S. Ital Trade Services PT 250 Operating Manual PT 250 Stub Device , Code: PT250S PT 250 Stub Device , Code: PT250S Pos. Code Description Pos. Code Description PT250S01 Plateau PT 250 PT250S06 Fixing stub end bracket PT250S02 Cursor PT250S07 Screw STEI UNI 5927 45h 5x8 zin PT250S03 Screw STEI UNI 5927 45h 8x35 zin...
  • Page 36 I.T.S. Ital Trade Services PT 250 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...