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MU-78-04 ODS & Track Automatic

1. 020 28 28 3 2 2 Unit connection and selection of the butt fusion 28 3 2 3 Operator and order identification 30 3 2 4 Preparation of the pipes and the machine 32 3 2 5 Fusion jointing 35 22220 ias 36 3 2 7 Selection of pipe material diameter SDR 36 3 2 8 Pipes fittings 38 3 2 9 Heating plate 41 3 2 10 Fusion and cooling down cycle 43 3 0 L1 43 3 2 12 End of butt fusion 44 3 3 Electrofusion uus ouk y dex FE CREAR n 45 3 3 1 INtrOGuctlOn cc cece cece cece seen eee n 45 GENERAL INDEX i 3 USER MANUAL ACUSTER ODS TRACK AUTOMATIC Page 3 3 2 Scraping pipe 45 3 3 3 Fitting 45 3 3 4 Unit 46 3 3 5 Operator and order identification 48 3 3 6 Fusion jointing 50 3 5 7 AUXINALY NUMER ices sauber d x m RERO TOR RC UN de d ic 5
2. Ra 91 5 5 oun 91 Sod 91 53 2 lhtethal i aai 91 5 5 3 Updating program 91 5 6 Hydraulic 91 CHAPTER 6 TECHNICAL 5 5 92 6 1 Fusion control dora ue dea ripe e oai 92 6 2 Base Taro WOEK AUS 93 6 3 Heating m 93 6 4 CTUM 94 6 5 Heating plate and trimmer holder 94 6 6 Hydraulic 5 95 6 7 Complete 96 6 8 Generator 96 6 9 Pallet type packing for fusion control box 97 6 9 1 Pallet type packing for fusion control box 97 6 9 2 Pallet type packing for base framework 97 6 9 3 Pallet type packing for heater trimmer and HS 97 Edition April 2014 4 GENERAL INDEX Revision No 11 4 USER MANUAL tl ODS TRACK AUTOMATIC ACUSTER CHAPTER 1 INTRODUCTION 1 1 GENERAL The machines ODS System and Track Automatic are designed for the use with polyethylene PE pipes fittings by electrofusion and butt fusion jointing systems Ther
3. MODELS TRACK TWIN S TRACK DYNAMIC S USER MANUAL CNC FUSION MACHINES Revision No 11 April 2014 Publication MU 78 04E DATOS DEL FABRI DISTRI BUI DOR Y SAT MANUFACTURER DI STRI BUTOR AND SERVI CE DATA ACUSTER GLOBAL S L U Tel 34 93 470 30 70 Juan de la Cierva 1 Fax 34 93 473 0077 Pol gono Ind del Sud Oest e mail info grupoacuster com 08960 Sant Just Desvern SPAIN NOTE At the time of the publication of this User Manual the current software version is V 6 67 The modifications carried out against the previous revision of this publication are indicated with on the right margin USER MANUAL CONTENTS CHAPTER 1 CHAPTER 2 CHAPTER 3 Edition April 2014 Revision No 11 4 ODS TRACK AUTOMATIC ACUSTER INTRODUCTION ii Ii cds 5 1 1 gt eee 5 1 2 Model Rang 6 ODS Sy SUC seis cena ate ay 6 152 2 Track Peck qaid 6 1 3 Design Specifications vk HK SR RCRR EXER REA EIE CREDERE 7 1 4 General 7 1 5 Machine 8 1 5 1 Serial number 8 GE AON RING tuti en EE 8 1 6 Me
4. Accessories bag Plastic casing Anchorage for cables holder bracket Metal casing EM D 2 S7 xd 7 e Boozer Figure 8d Plastic casing Metal casing Edition April 2014 Revision No 11 MACHINE DESCRIPTION 17 i USER MANUAL ACUSTER ODS TRACK AUTOMATIC 2 3 1 2 3 2 BASE FRAMEWORK ODS 225 ELECTRICALLY DRIVEN The base framework ODS 225 E consists of a stainless steel tubular structure on to which through four silentblocks the two aluminium fused bodies one fixed and one moveable are mounted The moving body slides on two chrome hardened guiding axles on ball bearings Each body has two aluminium grips being the exterior one easily removable The diameter of the four pipe grips is machined to fit up to 225mm diameter pipes and fittings the clamping of different smaller diameters can be achieved by means of different sets of additional adaptors which are locked in place using Allen screws Both outer grips are removable for accommodating various fittings such as elbows tees etc The linear actuator the load cell and the encoder are installed on the fixed body Figure 9 Base framework ODS 225 E WARNING Always connect the base framework electric connector into the corresponding control box connector with the machine switched off Install the base framework cable connector with the nut prope
5. USER MANUAL ODS TRACK AUTOMATIC Figure 6a Heater and Trimmer ODS225E Figure 6b Heater ODS TRACK 315 4 A trimmer Originally the ODS225 model is driven by a 24 Vdc electric motor and belt drive but the model 2014 is operated by a 230 110 Vac motor and chain drive It incorporates two push buttons for functioning control and a safety switch The trimmer for machines ODS TRACK 315 and ODS TRACK is activated via an electric motor of 230 or 110 Vac depending on the market with chain transmission It has a safety switch to avoid undesirable actions Figure 7 Trimmer ODS TRACK Figure 7b Heating plate and trimmer holder NOTE For the care and maintenance of the trimmer consult CHAPTER 5 MAINTENANCE of this same User Manual 5 A Hydraulic station formed by an electric motor a hydraulic pump solenoid valves quick connectors as well as the required elements for the hydraulic performance of the base framework NOTE There are two models of hydraulic station Hydraulic station 0 100 bar Hydraulic station 0 160 bar The hydraulic station of 0 160 bar is used with the Track Automatic 500 only whereas the hydraulic station 0 100 bar is used for the rest of models Please check Chapter 6 Technical Characteristics Edition April 2014 Revision No 11 MACHINE DESCRIPTION 15 Audi USER MANUAL A Grupo ODS TRACK AUTOMATIC 2 2 FUSION CONTROL BOX 2 2 1 General The Fusion C
6. Exterior dimensions cm eight without pipe adapters kg Set of basic pipe adapters ransport case dimensions cm 54 36 12 64 35 1764 35 17 81x46x24 76x44x36 6 3 HEATING PLATE Voltage Vac 230 110 Monophasic Power W 2000 230V 1800 110V 2100 230V 1800 110V Surface temperature Up to 250 C according to the pipe material used Independent temperature control Analogical thermometer Replaceable PTFE sheet Exterior dimensions cm 38x5x54 5 70x12x48 Net weight kg Edition April 2014 Revision No 11 TECHNICAL CHARACTERISTICS 93 Coating 4 USER MANUAL ACUSTER ODS TRACK AUTOMATIC Voltage Vac mono phasic 110 230 Power W 1800 1000 1900 2100 3100 3800 Up to 250 C according to the pipe material used Temperature regulation PID type with Triac PTFE line Exterior dimensions cm 27x6 64x8x110 Weight k 3 35 55 72 175 6 4 TRIMMER Voltage 24 Vdc Vac Monophasic Power W 700 1010 m 2 Push buttons 1 push button l Safety switch l FETTE UR switch Cutters Cutters 1 adjustable blade 1 Double 1 Double edge adjustable blade adjustable blade Transmission Poly V belt with Chain with Chain with tensor tensor eccentric tensor I 77 Exterior dimensions cm 654 434 0000 _ Voltage Vac mono phasic 110 230 Power W 720 500 1010 1010 1010 1100 Cutting blades Double edge
7. 91 USER MANUAL Grupo ODS TRACK AUTOMATIC CHAPTER 6 TECHNICAL CHARACTERISTICS 6 1 FUSION CONTROL BOX Classification acc to ISO 12176 2 P 4UES VKADX Input voltage 180Vac to 264Vac Nominal voltage 230 Vac 90 Vac to 140 Vac Nominal voltage 110 Vac 45 Hz to 65 Hz Nominal frequency 50 Hz Output power 3500 W maximum Generator output performance See clause 6 8 Generator specifications electronic regulation preferably Input fuse external 16 A at 230 Vac non applicable for 110Vac Protection fuse internal 20 A at 230 Vac 32 A at 110 Vac Degree of protection CEI 60529 Plastic casing 54 Class 11 Metal casing 54 Class Mechanical strength 62262 9 10 Joules 10 20 J oules Operating temperatures 10 to 50 C can be modified on request Temperature control NTC interior and exterior Acoustic signal Piezoelectric boozer Display Graphic LCD of 240x128 points in resolution 16 lines Keyboard 8 touch sensitive membrane push buttons Connection to a PC and printer special RS 232 serial Optic pen scanner Non intelligent infrared Laser scanner optional Connection to optic pen scanner PC printer Serial connector RS 232 Internal memory capacity 1000 fusion records Power cable 3x2 5 mm for 230Vac Schuko French type plug 4 m long 3x4 mm for 110Vac IEC 60309 type plug 4 m long 8 to 48 V galvanically separated Electrofusi
8. C 210 This informative option shows us the different temperatures to be borne in mind by the unit and operator room temperature is read by the external temperature sensor of the unit Finally the temperature on the heating plate is the one registered by the temperature sensor of the heating plate and is displayed on three fields INTERNAL TEMPERATURE TTT C APPLIED DIFFERENTIAL DD C SURFACE TEMPERATURE 210 C Press CANCEL to exit this option and go back to the menu of test of HYDRAULIC BUTT FUSION Edition April 2014 Revision No 11 TROUBLESHOOTING 85 4 7 7 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 4 VERIFICATION THE ACOUSTIC SIGNAL AND PUSH BUTTONS By selecting BUZZER PUSH BUTTONS from the Menu HYDRAULIC BUTT FUSION This option allows us to verify the BUZZER PUSH BUTTONS functioning of all push buttons arrows STOP and the three side push button as well as the buzzer With each press ing the pressed push buttons appears on screen along with the acoustic signal Press the central push button on the side to exit this option and go back to menu of test of HYDRAULIC BUTT FUSION PRESS PUSH BUTTONS ACCEPT END TEST PRESS OK IF ACOUSTIC SIGNAL IS ON 5 READING SYSTEM By selecting the option READING SYSTEM This informative option shows us on READING SYSTEM screen the data contained on the bar code system Once the bar code is read the corre
9. repercussions in the quality and reliability of the joint LOADING DATA MANUALLY If the system of fitting data introducing is manual once the fitting is connected to the control box cable terminals press MANUAL push button of FITTING DATA screen The following message will be showed on the display Edition April 2014 52 MODE OF USE Revision No 11 USER MANUAL i ODS TRACK AUTOMATIC ACUSTER Then the operator should select the FITTING DATA fitting voltage value and electrofusion time following the fitting manufacturer information The voltage showed on the screen will always be 39 5 V by default Press arrow to increase the value and arrow to reduce it A change of 0 5 V will be CANCEL obtained for each pressing VOLTAGE 39 5 V TIME 5555 S 20 231Volt 50Hz N 00001 Pressing access is gained to TIME Once in time parameter press and arrows in order to increase or decrease the electrofusion time Press ACCEPT to continue or CANCEL to go back to the previous screen Once the fitting data has been introduced via any of the two possible systems described above the display will show the following message The fitting description size and coded FITTING DATA resistance will be on the screen only in the case of bar code system has been XXXXXXXXXXXX d ddd used Ohm VV V Volt The REAL RES corresponds to the value R RR Ohm of the resistance read on the fitting SCRAPED AND CL
10. CONSULTATION ON DISPLAY OF THE UNIT By selecting the option CHECK BUTT FUSION RECORDS TWIN S DYNAMIC S Where CHECK BUTT RECORDS No NNNNN nnnn corresponds to the No NNNNN nnnn DD MM YY last fusion number made additional MATERIAL ddd SDRXX BLOCK OPERATOR XXXXXXX ORDER XXXXXXXXXXX number press to access previous fusions START HH MM END HH MM DD MM YY is the date in which fusion HEATER yyy C has taken place nN MATERIAL ddd SDRXX BLOCK FUSION FORCE corresponds to the material diameter and RED dd d mm SDR of the pipe fitting used and name of MESSAGE OF THE RESULT the Block used in the fusion ISO GN OPERATOR ORDER corresponds to the operator s number and order s number if this data has been entered if not dashes will appear START END refers to the starting and ending time of the fusion respectively TEMP HEATER corresponds to the room temperature and the heating plate s temperature DRAG FORCE FUSI ON FORCE corresponds to the drag force read and the fusion force programmed In MESSAGE OF THE RESULT the one corresponding to each case will appear CORRECT USER S INTERRUPTION etc In the event of having butt fusion records with traceability press gt to access the second screen Where CHECK BUTT RECORDS No NNNNN nnnn corresponds to the No NNNNN nnnn MM DD YY butt fusion number additional number queried COMPONENT 1 PIPEA BB ddd SDRCC COMPONENT 1 and 2 are t
11. Off CHANGE OF DATE TIME TRACEAB COMPULSOR On Off OPERATOR ID Z2 On Off AUXILIARY NUMBER On Off JOB ORDER ID Z4 On Off READER SYSTEM More More Third screen Fourth screen GENERAL GENERAL MEMORY OVERFLOW On Off RESET OPERATOR J OB On Off FORMAT MEMORY CARD PRINT SETUP CLEAR RAM More Edition April 2014 64 MODE OF USE Revision No 11 USER MANUAL ODS TRACK AUTOMATIC BUTT FUSION JOINTS First screen BUTT FUSIONS JOINTS CHANGE OF BLOCK CHANGE OF PIPE MATERIAL ON OFF PIPE RECORDS MATERIAL SELECTION On Off More Third screen BUTT FUSIONS JOINTS HYD BUTT FUSION TXXX POLYCONTROL Off On TRIMMER 24V On Off ELECTROFUSION First screen ELECTROFUSION MANUAL On Off Edition April 2014 Revision No 11 i e ACUSTER Second screen BUTT FUSIONS JOINTS CLEAN PIPE ENDS TRIM On Off CLEAN PIPE ENDS FUSION On Off ACCEPT REDUCED TIME On Off MOTOR WITH ENCODER On Off More MODE OF USE 65 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 66 SELECTION OF THE LANGUAGE The selection of the language is of free access PASSWORD 1 not required If the messages of the display appear in a non desired language please proceed to the change of language by selecting TOOLS from the Main Menu press ACCEPT to go back to Main Menu REMARK If the operator is identified via bar code system the language is selected automat
12. after a new unit Send software telecharge NOTICE The selection of CLEAR RAM has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Press ACCEPT to clear Ram If this selection in not performed the data stored on the Ram will not be updated because the new programme loaded through a PC has been directed to the unit safety memory By pressing CLEAR RAM from the SETUP menu the existing data in the Ram is replaced by the new one loaded on the safety memory The fusion records are kept stored in memory Edition April 2014 Revision No 11 MODE OF USE 71 4 ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC 13 SETTING IDENTIFICATION OF OPERATOR amp ORDER WHEN OBLIGATORY This option in the TOOLS SETUP GENERAL menu allows us to establish the delete setting of operator and or job order identification when they are obligatory OPERATOR ID 22 and or JOB ORDER ID Z4 selected ON according to the criteria established by the company NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Place the cursor on the RESET GENERAL OPERATOR JOB_ option By pressing ACCEPT the ON OFF selection is changed By selecting OFF the operator s and or job order s identification is kept till the change of date while pressing ON the identification
13. at random The list given therefore is restricted to activated diameters SDR ON and modifiable using the setup For a definition of the concept PIPE RECORD and the modification of pre determinated diameters SDR please refer to SELECTION OF BUTT FUSION SYSTEM in Section 3 4 3 of this Manual Press CANCEL to go back to the previous screen Press ACCEPT to validate command Edition April 2014 Revision No 11 MODE OF USE 37 4 ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC If the pipe cleaning is set as CLEAN PIPE ENDS TRIM the following message will appear on the screen Clean the outer and inner surfaces of the VISUAL CONTROL ends of the pipes fittings with an appropriate degreasing liquid Pressing YES continues with the trimming phase and pressing CANCEL returns the user to the previous screen PIPE ENDS CLEANED ISO 0110 SDR11 CANCEL 25 C 210 C 232 Volt 50Hz 00001 3 2 8 Pipes fittings trimming If you accept the previous selection the following message will appear on the display NOTE For electrically operated machines TRIMMING ODS225E be sure that the trimmer is properly setup START TRIMMING 24 Vdc motor ON 230 110V motor OFF During this phase the display will change the frequency by the current trimmer s ISO PE 8110 0811 CANCEL consumption That is for information 25 C 210 C 232 Volt 0 1 00001 purposes just for 24Vdc trimmer Place the trim
14. automatic are in conformity with the provisions of the following EC Directives based on the specified standards Directive Related standard Model 2006 42 CE 15012100 EN61310 1 2 3 TWIN S Machine Safety Directive EN13857 EN13732 1 EN60204 1 DYNAMIC S 2006 95 CE EN 60335 1 EN 60519 1 TWIN S Low Voltage Directive DYNAMIC S 2004 108 CE TWIN S EMC Directive DYNAMIC S 2002 95 CE TWIN S ROHS DYNAMIC S 2002 96 CE TWIN S WEEE DYNAMIC S TWIN S DYNAMIC S TWIN S EN 61000 6 2 EN 61000 6 4 EN 62321 1 ISO 12176 1 ISO 12176 2 ISO 12176 3 TWIN S DYNAMIC S TWIN S DYNAMIC S TWIN S ISO 12176 4 ISO TR 13950 Sant Just Desvern 1st April 2014 Jaume Puig General Manager eC Edition April 2014 Revision No 11 INTRODUCTION 11 ____ _ _ _ 4 i USER MANUAL ODS TRACK AUTOMATIC 1 8 GUARANTEE Guarantee declaration All the ODS System and Track Automatic fusion machines are manufactured from high quality material and have been subjected to rigorous tests for resistance and working order as well as passing all the quality control tests required by the applicable normative see CE Declaration of conformity Regardless of whether an incident might occur during the period of guarantee we recommend a careful reading of the following general guarantee conditions General conditions of Guarantee 1 ACUSTER GLOBAL S L
15. guarantees that this product has manufacturing defect at the time of its purchase and extends this guarantee for the period of TWO years If the product proves defective during this period due to the materials or its assembly it will be repaired free of charge including the cost of materials and labour at Acuster Global S L s Technical Service The Guarantee is not valid in the following cases When the fault in the product is a result of Usual wear tear due to usage Abuse or incorrect use of the unit Not following the instructions specified in this User Manual for connecting to a group generator Repairs carried out without authority from Acuster Global S L the taking apart or breaking of the unit s seal immediately renders the guarantee invalid Accidents natural disasters including lightning water action etc as well as any cause beyond Acuster Global S L s control In all claims against this guarantee information relating to the model date of purchase Serial number and any other additional information must at all times be stated Edition April 2014 12 INTRODUCTION Revision No 11 4 USER MANUAL 7 7 ODS TRACK AUTOMATIC RB STER CHAPTER 2 DESCRIPTI ON OF THE FUSI ON MACHINE 2 1 GENERAL fusion machines ODS System and Track Automatic are made up of the following components 1 Fusion Control Box containing the Electronic Control Module microprocessor display
16. is activated by default e g 80 CHANGE OF PIPE MATERIAL If on the RECORDS comprised the Block there 15 a different material from the one selected by default e g PE100 select the option CHANGE OF PIPE MATERIAL from the Setup Menu in order to change the selection of material by default ON OFF PIPE RECORDS Having selected the BLOCK it is possible ON OFF PIPE RECORDS to restrict the diameters and SDRs ACCEPT through the option ON OFF PIPE 110 SDR11 On RECORDS from the Setup Menu All you have to do 15 move the cursor with the arrows 9 pressing OFF as SDR11 On desired The selected OFF will not appear available when choosing the pipe 0817 to be jointed Press ACCEPT to go to previous screen Edition April 2014 Revision No 11 MODE OF USE 73 909 74 USER MANUAL ACUSTER ODS TRACK AUTOMATIC MATERIAL SELECTION TWIN S DYNAMIC S BOXES The last option of this screen is used to configure the unit in such a way that it allows the operator ON selection to choose the material in each butt fusion in addition to diameter and SDR When set to OFF the material is chosen via the CHANGE PIPE MATERIAL option on this same menu standard option The selection MATERIAL SELECTION is of free access PASSWORD Is not required Pressing ACCEPT toggles between BUTT FUSIONS J OINTS ON OFF for the field selected Once the desired selectio
17. keyboard computer and printer connections etc and a stainless steel tubular structure for transport and protection Figure 3a TWIN S plastic casing Figure 3b TWIN S steel casing Figure 3c DYNAMIC S The fusion control boxes TWIN S and DYNAMIC S are also composed of 2 A Base Framework The ODS 225 E version Figures 4a amp 4b it is made up of an stainless steel tubular structure for mounting on 4 silentblocks two aluminium fused bodies one fixed and one moveable The moving body slides along two chrome hardened guiding axles through ball bearings Each body mounts two aluminium fused grips being the exterior one easily removable The fixed body incorporates the electric motor of the moving body s actuator the loading cell and the encoder shift control sensor Figure TWIN S ODS 225 E general view Figure 4b DYNAMIC S 225 E general view Edition April 2014 Revision No 11 MACHINE DESCRIPTION 13 USER MANUAL ODS TRACK AUTOMATIC In the ODS TRACK 315 version Figure 5a the base framework is made up of four aluminium lower clamps and four aluminium upper clamps two of which are fixed and two are movable All four upper clamps are connected in pairs and the fixed outer lower clamp is also removable in order to allow fitting mounting tees elbows and so The moving clamps are driven by two double acting hydraulic cylinders High pressure hoses with quick plugs are supplied for the hydraulic statio
18. makes the operator and or job order identification optional the unit goes back to its previous setting that is the fusion unit will be able to carry out fusions with and without the operator and or job order identification indistinctively in the latter there will be no traceability of the job in process and his her operator this data will not be registered Edition April 2014 Revision No 11 MODE OF USE 49 4 i 7 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 3 6 Fusion jointing traceability 50 When the TRACEABILITY option on the SETUP GENERAL menu is enabled ON and after having pressed ACCEPT on the operator and job identification screen the following screen will appear When traceability is enabled ON two TRACEABILITY situations can occur a Optional traceability REQUIRED TRACEABILITY OFF b Required traceability REQUIRED TRACEABILITY ON The optional traceability selection allows the operator to optionally enter the traceability barcode data of the electrofusion fitting and or components the traceability barcode of the components that make up the electrofusion could be entered or not depending if they are available or not Once the fitting barcode has been entered the components to be coded will appear on the screen ranging from one to two according to the type of fitting ACCEPT will only appear on the screen with the optional traceability selection Pressing ACCEPT continues with the ele
19. of one or both of the options according to selection is kept till the unit is switched off Once the desired selection has been made press CANCEL to exit the option Edition April 2014 72 MODE OF USE Revision No 11 USER MANUAL hy ODS TRACK AUTOMATIC ACUSTER SELECTION OF THE BUTT FUSION SYSTEM TWIN S DYNAMIC S BOXES The fusion control units have the possibility of butt fusing different plastic resins 80 100 PP etc as well as programming the unit so that it can carry out fusion cycles according to different norms or specifications such 150 DVS Sedig s Electrabel WIS Water Industry Specification Transco BG etc As a preliminary condition in order to choose the desired butt fusion system this must be loaded into the unit s memory If not ask the manufacturer The selection BLOCK MATERIAL and ON OFF PIPE RECORDS 15 of free access PASSWORD is not required To choose the fusion system select the option BLOCK from the TOOLS SETUP BUTT FUSION JOINTS menu CHANGE OF BLOCK By selecting CHANGE OF BLOCK the screen shows the different options loaded into the unit which correspond to recognised butt fusion systems ISO Electrabel etc Each BLOCK has a series of PIPE RECORDS Each PIPE RECORD corresponds to material diameter and pipe wall thickness and it has the fusion and verification parameters When selecting a specific BLOCK the automatic selection of a material
20. out the trimming operation 5 If the shavings thickness were still incorrect repeat the operation N 5 Figure 26a Adjustment of cutters 225E Figure 26b Adjustment of cutters Track range Where 1 Cutter 2 Fixing screw 3 Adjusting shim 0 1 mm thickness One must also bear in mind that the adjustment of the blades may vary according to the diameter of the pipes fittings to be trimmed needing to be adjusted to adapt to the specific dimension of the pipe size used Edition April 2014 90 MAINTENANCE Revision No 11 4 USER MANUAL ny ODS TRACK AUTOMATIC ACUSTER 5 4 3 5 4 4 5 5 5 5 1 9 9 2 5 6 Electric motor drilling machine or motor For the trimmer to function the switches of the machine must be activated putting it on by means of the blockage button of the switch For this it is necessary that the trimmer be positioned in the area of work seeing that the safety switch which it is equipped impedes an inappropriate usage Check that the switches are working The ODS225 24V trimmer version is driven by a 24 Vdc electric motor while the ODS225 model 2014 and the rest belonging to the Track range are driven by a motor propeller of 230 110 Vac voltage according to market To check the function of the trimmer electric motor please refer to TRIMMER of the TEST MENU CHAPTER 4 TROUBLESHOOTING of this User Manual Driving belt chain The transmission belt
21. recognition of the two different type of base frameworks is automatically done once accepting locate pipes centrally from the electric butt fusion cycle the moving body will carry on an extra travel in order to recognise and automatically select the current electric framework used BUTT FUSIONS JOINTS Pressing ACCEPT the ON OFF selection is changed alternatively CLEAN PIPE ENDS TRIM On Off Select OFF if the electric base framework used is without encoder and CLEAN PIPE ENDS FUSION On Off ON when the linear actuator is with integrated encoder REDUCED TIME On Off MOTOR WITH ENCODER On Off More Once the desired option is selected press CANCEL to exit this menu SELECTING THE HYDRAULIC BASE FRAMEWORK TWI N S DYNAMI C S This option from the TOOLS SETUP BUTT FUSION JOINTS menu allows us to select the type of hydraulic base framework to be used The base frameworks hydraulically driven available are ODS 315 H TRACK 160 TRACK 250 TRACK 315 ODS TRACK 315 G TRACK 400 TRACK 500 In order to make proper butt fusion joints by selecting the HYDRAULIC BUTT FUSION option you need to previously select the correct the hydraulic base framework currently used BUTT FUSIONS JOINTS Pressing ACCEPT the selection is changed alternatively HYD BUTT FUSION TXXX Once the desired option is selected POLYCONTROL Off On press CANCEL to exit this menu TRIMMER 24 On Off Edition April 2014 MODE OF USE Revision No
22. the TOOLS general information of the machine If you press INFO the following information will come on the screen Where INFORMATION TWIN DYNAMIC LOGIC corresponds TWIN DYNAMIC LOGIC N ee XXXX SOFT vx x ENGLISH vx x eee ee ante DD MM YY prog CUSTOMER RO R1 1 ACCEPT the language selected and its version eC Newton mm SCANNER TXXX DD MM YY and HH MM the date and Z20 Z40 LBF 00000 LEF 00000 time LAST SERVICE dd mm yy CUSTOMER corresponds to the client s name owner of the unit RO R1 corresponds to both internal memory and Memory Card if equipped overflow on off RO selection the memory overflow is deactivated OFF and on R1 one is activated ON 1 indicates if the unit has selected equipped or not with the Memory Card reader MO displayed means that the Memory Card reader is not equipped and on MI it is C Newton mm selected units it is also possible F Lb and inches SCANNER corresponds to the scanner bar code reader selected also optic pen TXXX according to the hydraulic base framework selected 7160 T250 T315 T315G T400 T500 Z20 221 and 240 741 correspond to the option obligation of the operator and order identification LBF and LEF correspond to the last butt fusion done and electrofusion respectively dd mm yy is the date of the last service done to the unit Press ACCEPT to go back to the Main Menu Once in the Main Menu select ELECTRIC
23. the reach of the non authorised personnel They will have to be kept in rooms of low humidity degrees and of restricted access INTRODUCTION 9 10 USER MANUAL TER ODS TRACK AUTOMATIC ACUS Always use adequate working clothes For outside work it is recommended to use rubber gloves and boots with insulating soles in wet areas this advice is essential and other applicable personal protective equipment such as hard hat safety glasses etc For indoor fusion jointing work adequate ventilation of the premises must be provided Before using the fusion control box its external condition will have to be checked as well as its working condition All components must be correctly assembled in order to guarantee the correct functioning of the unit The damaged components must be repaired or replaced by the After Sales Service of ACUSTER GLOBAL S L The fusion control box can only be opened by the After Sales Service of ACUSTER GLOBAL S L Should the fusion control box not work properly it will have to be sent immediately to the After Sales Service of ACUSTER GLOBAL S L Edition April 2014 INTRODUCTION Revision No 11 Jh USER MANUAL 7 ODS TRACK AUTOMATIC ACUSTER 1 7 DECLARATION CE OF CONFORMITY ACUSTER GLOBAL 5 1 Juan de la Cierva 1 Poligono Industrial del Sud oest 08960 Sant Just Desvern Spain declare under our sole responsibility that the fusion machines ODS System and Track
24. 1 3 3 8 Preparation of the electrofusion 52 3 4 jo M 56 3 4 1 Access to restricted options Password 57 3 4 2 Fusion information fusion records 59 2 452 UNES SEUD 64 4 TROUBLESHOOTING 78 4 1 78 4 2 Unit checks Menu of 78 4 2 1 Electric butt 79 4 2 2 Quarc he ga ado 82 4 2 3 Hydraulic butt 84 CHAPTER 5 Vus ENSUITE 87 o GENEL Al TT eP u i 87 87 S T TT 97 Sides 88 CCC 88 5 2 base 89 ai 89 5 2 2 Hydraulic cylinders pressure hoses and plugs 89 52 3 Clamp 89 5 2 4 General cleaning and greasing 89 5 3 89 5 4 90 5 4 1 Trimmer face 15 5 90 5 4 2 Adjustment of 90 5 4 3 Electric d HO OE ure euh t bae do er PORE 91 94444 Driving
25. 11 USER MANUAL dl ODS TRACK AUTOMATIC ACUSTER POLYCONTROL OFF ON This option from the TOOLS SETUP BUTT FUSION JOINTS menu allows us to select the model of the fusion control box to be used TWIN S DYNAMI C S position OFF POLYCONTROL SMARTBOX position ON TRIMMER 24V ON OFF This option from the TOOLS SETUP BUTT FUSION JOINTS menu allows us select the trimmer model for ODS225 machines Trimmer ODS225 with 24Vdc motor setup ON Trimmer ODS225 with 230 110V motor setup OFF MANUAL ON OFF TWIN S BOXES By selecting this option from the TOOLS SETUP ELECTROFUSION menu allows us to activate ON or deactivate OFF the manual fitting programming on ELECTROFUSION NOTICE The selection of MANUAL has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Pressing ACCEPT the ON OFF selection ELECTROFUSION is changed alternatively MANUAL On Off Once the desired option is selected press CANCEL to exit this menu Edition April 2014 Revision No 11 MODE OF USE 77 4 rl USER MANUAL ur ACUSTER ODS TRACK AUTOMATIC CHAPTER 4 TROUBLESHOOTING 4 1 GENERAL All maintenance and repair work of the fusion machine is to be carried out by qualified personnel Full guarantees are obtained by shipping the unit to the ACUSTER GLOBAL S L After Sales Service both for the yearly revision and for repairing any fa
26. 110 V according to market requirement of alternating current For generator specifications please refer to CHAPTER 6 TECHNICAL CHARACTERISTICS IMPORTANT NOTES Models ODS225E T160 T250 T315 amp T315G They could be connected directly to the generator or mains socket plug Models 315 110V 400 and T500 They must be connected to the switch box socket plug the control box mains is plugged must be normalized and fitted with differential and ground pin Refer to the generator s User Manual Connection to the mains the building electric installation where the control box mains 15 plugged must be fitted with earth connection as well as circuit breaker type D EN 60898 Do not unplug the mains pulling on the cable Because the unit allows the use of an optic pen or scanner indistinctly connect the barcode reader to use and check the setup Refer to clause 3 1 6 Using the Barcode Reader Connection to a generator the generator electric connection where The fusion control box can be located either in the vertical or in the horizontal position as required by the operator Set the master switch in the ON position The display backlight comes on and this message appear on it In order to start the butt fusion process MAIN MENU select the first or the third option from the MAIN MENU Select ELECTRIC or HYDRAULIC BUTT FUSION depending on the base framework connected to the box ELECTRIC BUTT
27. 2 9 222 5 2 4 5 3 BASE FRAMEWORK MAINTENANCE TWI N S DYNAMI C S BOXES Linear actuator ODS 225 E Check for correct functioning of the kinematic transmission chain Any possible resistance may cause problems with the displacement which could affect the unit s performance and sensitivity Check via the MENU OF TEST please refer to CHAPTER 4 TROUBLESHOOTING of this User Manual Hydraulic cylinders pressure hoses and quick connectors Check periodically that the hydraulic cylinders do not exude oil and that the drain screws and their joint washer is firmly in place Check that the hydraulic hoses do not have any cuts or incisions that might cause an oil leak and that the quick connectors are clean and protected from dust and dirt maintain the oil circuit free from impurities Clamp adaptors These additional parts have to be checked for cleanliness and correct seating before mounting Do not overtighten the Allen screws General cleaning and greasing Keep the base framework clean and in good working order Clean after use Lubricate the guiding axles and cylinder stem with an oil cloth HEATING PLATE MAINTENANCE TWI N S DYNAMI C S BOXES Clean from time to time to prevent PE particles or other plastic resins from adhering to the plate faces and forming an insulating coat which may affect the caloric performance For cleaning purposes only use white paper or a clean and dry fluff free 10096 cotton cloth NEV
28. 2014 30 MODE OF USE Revision No 11 Jf USER MANUAL ODS TRACK AUTOMATIC ACUSTER OB ORDER IDENTIFICATION The job order identification can be done by means of Barcode system Manually The order identification will automatically be carried out by inserting the corresponding identification via barcode system or manually indistinctively From this moment the identification will be associated to the unit fusions made until 1 A new identification is entered 2 Entering the same identification a second time ON OFF system 3 Change of date at zero hours or switching off the unit the identification will be deleted according to the unit s setup OFF on the first case and on the second from the path TOOLS SETUP GENERAL RESET OB 4 The use of the options ON or OFF on JOB ORDER ID Z40 from the path TOOLS SETUP GENERAL OPTI ONAL OBLI GATORY IDENTIFICATION Obligatory identification In order to make compulsory the operator s and or job order identification select ON via the path TOOLS SETUP GENERAL OPERATOR ID 220 ON JOB ORDER ID 240 ON causing that the identification of operator and job order to be compulsory This option obliges the operator to identify the operator s and or job order number daily or when the units is switched on depending on the OFF or ON setup of option RESET OPERATOR J in order to access the fusion menus Optional iden
29. BUTT FUSION ELECTROFUSION or HYDRAULIC BUTT FUSION according to the model or type of fusion desired or TOOLS Edition April 2014 Revision No 11 MODE OF USE 25 hy USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 1 4 3 1 5 3 1 6 Contrast control of the unit s display The unit s display screen has an automatic contrast adjustment depending on the temperature and sunbeams effect on it However the operator can adjust the contrast making it darker or lighter to his her taste order to do so press the INFO key from the MAIN MENU see previous screen Pressing the upper button the contrast of the display increases whereas pressing the lower button it decreases Also within the electrofusion mode the contrast can be adjusted by means of the arrows t and Once the contrast has been selected the unit will continue to control it automatically according to the temperature The adjustment carried out by the operator loses its effect when switching off the machine Initial programming Before selecting the options ELECTRIC BUTT FUSION ELECTROFUSION and HYDRAULIC BUTT FUSION from the Main Menu check the need for initial programming such as Change of working language Option Obligation operator order identification Traceability use Optional and Required Change of the butt fusion system and material to use for the pipes fittings e Selection of the barcode reader system barcode reader scanner e Act
30. CHINE DESCRIPTION Revision No 11 USER MANUAL ODS TRACK AUTOMATIC 2 7 SWITCH BOX The Switch Box must be used to connect the heating plate and trimmer on models T315 110V T400 and T500 Figure 14a Switch Box Figure 14b Switch Box on the Fusion box To avoid that the high consumption of specially the heating plate and trimmer pass through the fusion box the Switch Box is used on the above mentioned models to provide a direct 230 110 Vac supply to both components So for such models the heating plate and trimmer are fitted with an special connector to be plugged into the corresponding Switch Box socket connector Then the Switch Box electric cables have to be plugged in the corresponding Fusion Box circular socket connector to receive the automatic signals The Fusion control mains must be plugged in the Switch Box socket connector and finally the Switch Box cable mains in the power Supply generator or mains Edition April 2014 Revision No 11 MACHINE DESCRIPTION 23 i ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC CHAPTER 3 MODE OF USE 3 1 UNIT PREPARATION 3 1 1 Unit connection Connect the fusion control box to a 230 V 15 power source or to 110 according to market requirement of alternating current For generator specifications please refer to CHAPTER 6 TECHNICAL CHARACTERISTICS IMPORTANT Models ODS225E T160 T250 T315 amp T315G They could be connected directly to the g
31. Contents Fusion control box User Manual Password 1 and Password 2 cards AcusWin CD Rom ODS transmission cable Scanner Electrofusion adapters 4 and 4 7 mm TWIN S only Steel casing For plastic casing models only Serial scanner for plastic casing models and USB scanner for metal casing models 6 9 2 Pallet type packing for base framework dimensions cm 99 5x41 5x60 100 60 60 Gross approximate weight kg 68 pipe adapters 86 pipe adapters Contents Base framework Base framework Set of tools 6 9 3 Pallet type packing for heating plate trimmer and hydraulic station Exterior dimensions 61 5x44 5x30 5 120x60x60 cm Gross approximate weight kg Contents Heating plate amp trimmer Heating plate amp trimmer holder holder Heating plate Heating plate Trimmer Trimmer Hydraulic station Edition April 2014 96 TECHNICAL CHARACTERISTICS Revision No 11 USER MANUAL uy ODS TRACK AUTOMATIC ACUSTER REMARKS Edition April 2014 Revision No 11 TECHNICAL CHARACTERISTICS 97
32. EANED YES whereas the INPUT DATA corresponds to the resistance and voltage values provided by the bar code 20 231Volt 50Hz N 00001 If the resistance value between the INPUT DATA and the REAL RES lie within the pre established tolerances by the fitting manufacturer the electrofusion cycle will be able to proceed If not the message RESISTANCE TOO LOW or RESISTANCE TOO HIGH will be displayed Press YES to continue The screen will change to Press YES or NOT according the fitting FITTING DATA installation used FITTING XXXXXXXXXXXX DIAMETER ddd R RR Ohm VV V Volt R RR Ohm CLAMP TOOL USED YES NO 20 231Volt 50Hz N 00001 Pressing either YES or NOT the use or not of the clamp tool will be recorded in the fusion records the following screen will be Edition April 2014 Revision No 11 MODE OF USE 53 USER MANUAL ACUSTER ODS TRACK AUTOMATIC FITTING DATA By pressing CANCEL you will go back to the initial electrofusion FUSION XXXXXXXXXXXX D AT A By pressing START the unit starts the R RR Ohm VV V Volt R RR Ohm electrofusion cycle providing the voltage START and intensity programmed by the fittings manufacturer and the fusion time established according to the CANCEL correction made depending on the room 20 231Volt 50Hz N 00001 temperature If there is a malfunction in the electrofusion process hot molten PE PP can be expelled in rare cases Therefore kee
33. ED TIME Only in the case that the cooling down time is ON the SIMULTANEITY can be done by pressing TWIN on the panel only for TWI N S Models When pressing TWIN on the screen SYSTEM STOPPED BUTT FUSION CYCLE the message shown on the side will appear Press ACCEPT and proceed to carry out an electrofusion by switching off transferring the machine and carrying out the operation or simply by selecting ELECTROFUSION from the main menu in the event of the unit not switched off FUSION UNSETTLED TURN OFF OR MENU ACCEPT 3 2 11 Simultaneity TWI N S only The simultaneity allows you to carry out an electrofusion with the same unit thus making the most of the time of usage of the machine Once the electrofusion and complementary operations have been completed connect the TWIN S again onto the base framework Select the main menu HYDRAULIC BUTT FUSION Once the operator order identification step has been completed the display can show the following screens Uncompleted cooling phase Completed cooling phase VERIFICATION VERIFICATION LAST FUSION IN COOLING TIME CHECK LAST UNSETTLED FUSION ttt s the first option uncompleted cooling phase the reconnection to the butt fusion menu has been quick and within the time of the cooling phase Therefore the message on the display informs that the unit is carrying out the cooling phase as well as the remaining time Wait until the cycle is finished Edition Apri
34. ER use Tangit isopropyl alcohol trichloroethylene above all if the heating plate is hot You can check the performance of the heating resistors with the help of the TEST MENU please refer to CHAPTER 4 TROUBLESHOOTING of this User Manual The display will show the temperature of the plate s probe the differential temperature as well as the surface temperature The heating plate s temperature should be approximately 210 C at 23 C RT Edition April 2014 Revision No 11 MAINTENANCE 89 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 5 4 TRIMMER MAINTENANCE TWI N S DYNAMI C S 5 4 1 Trimmer face discs Verify the correct cutting of the blades The shearing of shavings must be uniform and with a recommended thickness of between 0 2 and 0 3 mm on both sides If the cut is not correct both in terms of the thickness and evenness of the shavings proceed to adjust the blade s To do this dismantle the blade and supplement with gauges if necessary If the edge of the blade shows signs of wear or is nicked reverse the blade to the other side of the cut double edged blades 5 4 2 Adjustment of cutters To adjust the cutters proceed as follows l Release the cutter 1 using the screws 2 2 Once the cutter has been removed add or remove the necessary adjustment shims 3 3 Place the cutter back on position Tight up replacing the screws 2 4 Check the positioning with a ruler or a calliper the height h Carry
35. ETUP By selecting PRINT SETUP from the TOOLS SETUP GENERAL menu and pressing ACCEPT having been connected to a printer the setup with which the unit has come out of the factory will be printed NOTICE Do not connect or disconnect the printer cable connector when the unit 5 running The CPU printer communication component could be damaged The selection of setup printing has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER The printed data of the above mentioned setup using a serial printer correspond to All INFO screen data model Serial No software and language version date and time client s name memory overflow on off Memory Card option measuring units bar code reader hydraulic base framework selection operator s and job order information butt fusion and electrofusion counters status and date of last revision All On Off options from the Setup Menu All On Off options from the Service Menu as well as the calibration values Setup of the maximum and minimum temperature range for electrofusion Loaded blocks for butt fusion if the print out is made using a parallel printer if the Centronics connector is fitted on the fusion box additionally the pipe material the maximum and minimum temperature range setup and all the butt fusion parameters of all the loaded blocks in the unit are printed CLEAR RAM This option must be always done
36. FUSION ELECTROFUSION HYDRAULIC BUTT FUSION TXXX Chose ELECTRIC when using ODS225E machine only and HYDRAULIC for the rest TOOLS of models Edition April 2014 28 MODE OF USE Revision No 11 4 USER MANUAL Wh ur ODS TRACK AUTOMATIC ACUSTER When using an electrically operated machine ods225e check the correct trimmer setup on TOOLS SETUP BUTT FUSIONS JOINTS Refer to point 11 page 77 of this chapter When using an hydraulically operated machine check on the screen the base framework model displayed TXXX and modify it if not corresponds to the one connected to the unit T160 T250 To select different hydraulic base frameworks please refer to clause 3 4 TOOLS of this chapter Refer to the Chapter 6 Technical characteristics for the hydraulic base framework potentially available at this time CAUTION The butt fusion with a base framework of hydraulic driving requires the use of a hydraulic station Besides the connexions of the heating plate and trimmer previously described the base framework installation is made by Connecting the base framework electric circular connector into the connecting box s hydraulic station socket connector Connecting the hydraulic station electric circular connector into the corresponding control box socket connector Connecting the two base framework s hydraulic couplings into the hydraulic station hydraulic couplings male female female male NOTE In
37. HE DISPLACEMENT By selecting the first option DISPLACEMENT the following screen will appear By pressing the push buttons and DISPLACEMENT the moving body will open and close manually The lower part of the display RESET will show the displacement By pressing we reset the counter By pressing the moving body will AUTOMATIC Start uninterrupted opening and closing cycles which the encoder reader can be seen OPEN gt CLOSE POSITIONING mm Press CANCEL to exit this option and go back to the menu of test of HYDRAULIC BUTT FUSION Edition April 2014 84 TROUBLESHOOTING Revision No 11 USER MANUAL ODS TRACK AUTOMATIC 2 VERIFICATION OF THE TRIMMER 4 de ACUSTER By selecting the second option TRIMMER from the Menu HYDRAULIC BUTT FUSION Menu TRIMMER PUSH BUTTONS TEST OFF TRIMMER TEST 24 226 Volt 50 Hz First select PUSH BUTTONS TEST Press both push buttons on the trimmer If the circuit is correct the OFF on the screen will change into ON at the time of press ing the trimmer will not start If we select the TRIMMER TEST now the trimmer will start when pressing the push button Press CANCEL to exit this option and go back to the menu of test of HYDRAULIC BUTT FUSION 3 VERIFICATI ON OF THE TEMPERATURES By selecting TEMPERATURES from the HYDRAULIC BUTT FUSION Menu TEMPERATURES ROOM 21 INTERNAL 30 C HEATING PLATE TTT C DD
38. ME we can update the time the date and the day of the current week Where HH MM correspond to hour and CHANGE OF DATE TIME minutes DD MM YY correspond to day month and year and finally xxxxx co ut ea n DD MM YY DAY Changes Press ACCEPT to validate the change CANCEL to exit without modifying CANCEL anything INFORMATIVE NOTE The date could be also displayed on American system MM DD YY or the according to ISO YY MM DD The above selection is only done by Acuster global S L when the initial unit software loading From unit s software version v6 25 and AcusWin version v 5 3 0 the date and time will be automatically updated on the unit being taken from the PC s data when exporting fusion records Edition April 2014 Revision No 11 MODE OF USE 67 4 i 7 USER MANUAL ACUSTER ODS TRACK AUTOMATIC eo 68 OPTI ONAL OBLI GATORY IDENTIFICATION OF THE OB This option in the TOOLS SETUP GENERAL menu allows us to establish the option or obligation of the operator job identification according to the criteria established by the joints traceability NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER From software version v 6 67 this option becomes On by default on TWIN units equipped wit
39. ON JOINTS menu allows us to cancel or not the cooling down time phase number six of the butt fusion cycle NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Pressing ACCEPT the ON OFF selection is BUTT FUSIONS JOINTS changed alternatively By selecting OFF the fusion cycle is fully CLEAN PIPE ENDS TRIM On Off performed including phase 6 of cooling time planned on the pipe fusion record By selecting ON this phase is REDUCED TIME On Off interrupted and the cycle finishes with phase 5 of the fusion CLEAN PIPE ENDS FUSION On Off MOTOR WITH ENCODER On Off More Once the desired selection has been made press CANCEL to exit the option SELECTING THE LINEAR ACTUATOR TWIN S DYNAMIC S BOXES This option from the TOOLS SETUP BUTT FUSION JOINTS menu allows us to select the type of electric base framework to be used NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Edition April 2014 Revision No 11 MODE OF USE 75 4 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 76 The base frameworks electrically driven commercialized are e ODS 200 E with linear actuator and separated encoder e ODS 200 225 E with linear actuator with integrated encoder From the ELECTRIC BUTT FUSION the
40. RACK AUTOMATIC ACUSTER 4 VERIFICATION THE ACOUSTIC SIGNAL AND PUSH BUTTONS By selecting BUZZER PUSH BUTTONS from the Menu ELECTRIC BUTT FUSION This option allows us to verify the BUZZER PUSH BUTTONS functioning of all push buttons arrows STOP and the three side push button as well as the buzzer With each press ing the pressed push buttons appears on screen along with the acoustic signal Press the central push button on the side to exit this option and go back to menu of test of ELECTRIC BUTT FUSION PRESS PUSH BUTTONS ACCEPT END TEST PRESS OK IF ACOUSTIC SIGNAL IS ON 5 READING SYSTEM By selecting the option READING SYSTEM This informative option shows us on READING SYSTEM screen the data contained on the bar code system Once the bar code is read the corresponding data will be showed on screen Press CANCEL to go back to previous screen LOAD DATA Edition April 2014 Revision No 11 TROUBLESHOOTING 81 4 i P ACUSTER 4 2 2 Electrofusion TWI N S BOXES CD 2 92 USER MANUAL ODS TRACK AUTOMATIC Select ELECTROFUSION from the MENU OF TEST The following options will appear on screen ELECTROFUSION FITTING RESISTANCE TEMPERATURES READER SYSTEM BUZZER PUSH BUTTONS Select the desired option by moving the cursor with the arrows 9 amp and on the panel Press ACCEPT By pressing CANCEL we go back to the previous menu By s
41. RIMMER TEST when pressing the push buttons on the trim mer it will start the consumption being Shown on the screen TRIMMER TEST 24 C 226 Volt 50 Hz With no load operating conditions the consumption of the trimmer must be placed on the 4 or 5 A approximately As a protection the working limitation on load of the trimmer is 25 A at the most If in working conditions this value is exceeded the trimmer will stop and the message EXCESSIVE CONSUMPTION OF THE TRIMMER will appear on screen Press CANCEL to exit this option and go back to the menu of test of ELECTRIC BUTT FUSION 3 VERIFICATI ON OF TEMPERATURES Selecting TEMPERATURES from the Menu ELECTRIC BUTT FUSION This informative option shows us the TEMPERATURES different temperatures to be borne in mind by the unit and the operator ROOM 21 The room temperature is read by the 30 external temperature sensor of the unit The internal temperature is the recorded temperature inside the unit HEATING PLATE TTT C DD C 210 Finally the temperature on the heating plate is the one registered by the temperature sensor of the heating plate and is displayed on three fields INTERNAL TEMPERATURE TTT C APPLIED DIFFERENTIAL DD C SURFACE TEMPERATURE 210 C Press CANCEL to exit this option and go back to the menu of test of ELECTRIC BUTT FUSION Edition April 2014 80 TROUBLESHOOTI NG Revision No 11 4 i USER MANUAL r7 ODS T
42. Revision No 11 USER MANUAL ODS TRACK AUTOMATIC ACUSTER 3 4 1 Access to restricted options PASSWORD There are certain options whose access is protected order to have access to these options you need previous identification by means of a PASSWORD bar code The following LEVELS of access are established OPEN FREE ACCESS There is no need to enter a PASSWORD It allows access to 1 three fusion options ELECTRIC BUTT FUSION ELECTROFUSION HYDRAULIC BUTT FUSION INFO The two options in check fusion records Both send data to PC options Both printing options The change of language Entering a PASSWORD code Reading system optic pen scanner Hydraulic butt fusion 315H T160 T250 1T315 T315G T400 T500 0 Polycontrol 1 Change of Block Material ON OFF pipe records and Material selection on butt fusion 12 Choice of TRIMMER 24V ON OFF ee a AUTHORISED OPERATOR PASSWORD 1 Apart from the options OPEN LEVEL it allows access to 1 the options from MENU OF TEST except the option SERVICE OWNER DISTRIBUTOR PASSWORD 2 Apart from the options OPEN LEVEL and AUTHORISED OPERATOR it allows access to Both delete fusion records options Change of date and time Option Obligation operator order s identification Traceability and traceability requirement Auxiliary number Memory overflow Format Memory Card Print setup Cl
43. adjustable Exterior dimensions cm 46x47x55 36 26 45 41 36 42 46 47 55 62 16 90 62x23x98 35 5 6 5 HEATING PLATE AND TRIMMER HOLDER Exterior dimensions cm 29x27x56 42x41x37 Exterior dimensions cm 32x25 5x34 36x33x34 40x37x42 50x42x50 60x60x70 Weight kg am 65 13 Edition April 2014 94 TECHNICAL CHARACTERISTICS Revision No 11 USER MANUAL hy ODS TRACK AUTOMATIC ACUSTER 6 6 HYDRAULIC STATION Voltage Vac mono phasic 230 or 110 Power W 750 Maximum working pressure bar 100 160 Oil tank capacity 1 Aspiration filter microns 250 Exterior dimensions cm 60x32x40 Net weight kg 34 5 6 7 COMPLETE MACHINE Voltage Vac mono phasic 230 110 230 Total power kW 2 5 2 7 3 27 2 25 3 66 3 86 3 86 4 86 Nett weight w o pipe adapters kg 72 5 117 5 83 103 116 147 5 182 5 239 5 Nett weight w pipe adapters kg 80 136 93 127 134 5 166 217 5 without Fusion box 6 8 GENERATOR SPECIFICATIONS Voltage Vac mono phasic Advisable minimum power VA 4500 3000 4500 5000 6000 7500 Edition April 2014 Revision No 11 TECHNICAL CHARACTERISTICS 95 USER MANUAL Grupo ODS TRACK AUTOMATIC 6 9 PALLET TYPE PACKING FOR FUSION CONTROL BOX 6 9 1 Pallet type packing for fusion control box Exterior dimensions cm 49 5x38 5x49 5 Gross approximate weight kg 44 47 30 32
44. asures of protection against accidents 9 1 6 1 Safety alert 15 9 1 6 2 Safety measures and dangers 9 1 7 Declaration CE of ll 1 8 CUa ao ere errr TTT 12 DESCRIPTION OFT HE FUSION 13 2 1 E 13 2 2 FUSION 16 2 16 2 2 2 FOD DO EE 16 25253 17 2 2 4 dana qnte a ain 17 17 2 3 Base 18 2 4 Heating IT 19 2 5 1145 20 2 6 ON PUE Edad PE 22 2 7 esse T TM 23 MODE OF dirae 24 3 1 Unit 2 2 2 2 24 3 1 17 Unit CONNEC ON esien eE 24 3 1 2 Positioning of the unit in the work area 24 9 1 2 Start Up the UNE inaia 25 3 1 4 Contrast control of the unit s display 26 3 1 5 Initial 26 3 1 6 Using the barcode 26 3 2 Butt fusion
45. be displayed and it will show the parameters of FORCE and TIME on the co ordinate axis On the lower part of the screen the FUSION CYCLE corresponding phase number will appear as well as the duration of each one and the pipe length reduction obtained during the fusion PHASE xx 10 N 5 15 9110 SDR11 25 C 210 C 232 Volt 50 Hz 00001 Where in the example PHASE 1 Heating in this phase force F1 is exerted for the time T1 needed for forming bead B1 PHASE 2 Heat soak in this phase force F2 is exerted for time T2 PHASE 3 Withdrawal of heater plate in this phase the heating plate is withdrawn with a maximum time T3 from the separation of pipes fittings to the butt fusion joint of the elements to be fused PHASE 4 Force increase this phase represents the required time T4 to obtain force F5 PHASE 5 Butt fusion in this phase the force F5 is exerted for time T5 PHASE 6 Cooling in this phase the jointed elements are stationary for time T6 with no force this phase could be off by selection choice the first phase of the fusion process HEATING the fused material at the ends causes a bead to form which reduces the length between the moving body and the fixed one When the programmed length reduction for the relevant type of pipe is achieved making of the initial bead an acoustic signal informs that the next programmed phase HEAT SOAK has been activated During thi
46. branch saddles place a rounder on each side of the scraped area if the fusion is performed over a bar pipe If the joint is performed on a pipe from a roll the placement of an aligner rounder tool is indispensable Next install the fitting on the pipe If the fitting to be jointed is a coupler reducer or elbow remove it from its wrapping and without touching its interior install it on the scraped and cleaned pipe Now assemble the aligner and the other specially prepared pipe or fitting Electrofusion joints should only be carried out by qualified staff Protect the area where electrofusions area carried out from adverse weather conditions such as rain snow or wind Admissible temperatures range from 10 C to 40 C In order to achieve a uniform temperature in the whole diameter of the pipes protect the fusion area against sunrays or bad weather The quality of the joint depends substantially on the care taken in the preliminary preparation tasks scraping de greasing etc Figure 25 Edition April 2014 Revision No 11 MODE OF USE 45 4 ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 3 4 Unit preparation Connect the fusion control box to 230 V 15 power source or DANGER to 110V according to market requirement of alternating current For generator specifications please refer to CHAPTER 6 TECHNICAL CHARACTERISTICS IMPORTANT NOTES Connection to a generator the generator electric conn
47. can be replaced if it should break The spare part reference 15 ODS 225E Part Poly V 9 chain model 2014 Track range Part chain with tightener FUSION CONTROL MODULE MAINTENANCE General Apart from the general external cleaning procedure there is no specific instruction regarding the electronic module Any adjustments should be carried out either by the ACUSTER GLOBAL S L After Sales Service Internal battery The clock calendar battery can be replaced only by Grupo Acuster Service when used up it has an autonomy of between 2 and 2 5 years without using it and between 4 and 5 years depending on use see point 5 1 2 of this Chapter CAUTION The internal battery must be removed from the unit before the machine is pulled apart To do this the front cover needs removing and the battery pins installed in the CPU board cut out or unsoldered which is in turn mounted on the inside of the frontal cover itself Deposit the removed battery recycling containers of used batteries Updating program version Please refer to the User Guide AcusWin HYDRAULIC STATION MAINTENANCE Check the oil level with the stick Check weekly Should the level be too low refill with HM 46 oil according to the ISO 6743 4 Specifications The scheduled maintenance for oil and filters is as follows FILTERS OIL Replace after every 2000 working hours or once a year Edition April 2014 Revision No 11 MAINTENANCE
48. case of one of the two hydraulic couplings gets blocked by the blocked oil it is recommended to press the key POSITION from the Clamping Position Menu while the hydraulic olug is being connected The butt fusion joints must be done by qualified personnel The work site where the machine is to be placed must be on a horizontal scoreless plane Protect the area where the joints are done against adverse weather conditions such as rain snow or wind When temperatures drop below 5 C or rise above 45 appropriate measures will have to be taken in the working area in order to produce a temperature which ensures a satisfactory operation and which avoids any interference with the manual activities Figure 17 In order to achieve a uniform temperature in the whole diameter of the pipes protect the fusion area against sunrays or bad weather The opposite ends of the pipes and fittings to be butt fused must be properly sealed and protected in order to minimise an excessively quick cooling process which could be caused for example by the wind Edition April 2014 Revision No 11 MODE OF USE 29 77 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 2 3 Operator and job order identification Once the option has been accepted the following screen will come on the display The identification of the operator No will IDENTIFICATION MENU take place in this phase via a barcode system The job order No identification could be done b
49. cess key is lost automatically either when switching off the machine via the main switch or going back to the MAIN MENU Edition April 2014 MODE OF USE Revision No 11 USER MANUAL di ODS TRACK AUTOMATIC ACUSTER 3 4 2 Fusion information fusion records By selecting the first option FUSION I NFORMATI ON from the TOOLS menu you can access the following menu Now select BUTT FUSION JOINTS or FUSION INFORMATI ON ELECTROFUSION depending on what you want to access BUTT FUSION JOINTS Press ACCEPT to validate command and CANCEL to go back to previous menu ELECTROFUSI ON Selecting BUTT FUSION JOINTS Selecting ELECTROFUSION FUSION RECORDS FUSION RECORDS MENU CHECK BUTT RECORDS CHECK ELECTROFUSION RECORDS BUTT RECORDS TO PC ELECTROFUSI ON RECORDS TO PC ACCEPT BUTT RECORDS TO PRINTER PRINT ELECTROFUSI ON DELETE BUTT RECORDS DELETE ELECTROF RECORDS CANCEL The first option on both screens CHECK BUTT RECORDS and CHECK ELECTROFUSI ON are of free access and allows us to see the butt fusion records and the electrofusion records respectively directly on the screen If you press ACCEPT the record of the last fusion carried out will be displayed Press in order to access the previous records Press CANCEL to go back to the previous menu and MENU to go to the main menu Edition April 2014 Revision No 11 MODE OF USE 59 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 60 DIRECT
50. controlled speed In the event of overcharging the trimmer there is a torque control which prevents the kinematic chain of the transmission from damaging limiting the trimmer s electric motor current it avoids overintensity On the 230 110 V version the motor power is 700 W Figure lla Trimmer 005225 24Vdc Figure 11 Trimmer 005225 230 110V Edition April 2014 20 MACHINE DESCRIPTION Revision No 11 4 i USER MANUAL D 7 f ODS TRACK AUTOMATIC ACUSTER The trimmer version ODS TRACK consists of aluminium fused carter witch covers and protects the two face discs Each disc is also provided with one or two adjustable cutting blades The movement transmission of the driving motor to the trimmer discs is done via a ring gear a pinion and a chain The power to the electric motor is supplied by means of a cable directly connected to the Fusion Control Box It is fitted with a safety switch and a switch for operation Figure 12 Trimmer ODS TRACK 315 G WARNING Always connect the trimmer electric connector into the corresponding connector with the machine switched off Install the trimmer cable connector with the nut properly tightened to ensure good contact between the pins For care and maintenance of the trimmer please refer to CHAPTER 5 MAI NTENANCE of this User Manual The trimmer cutting blades are made from hardened rectified steel There are one or two blades on each side which are adjustabl
51. ctrofusion as desired ON OFF The electrofusion control box allows us the introduction of the fitting data by the following Systems e Bar code system Manually via operator Edition April 2014 46 MODE OF USE Revision No 11 4 i USER MANUAL Wh ODS TRACK AUTOMATIC ACUSTER To active the electrofusion Manual option please refer to point 3 4 3 Unit s setup of this Chapter access path TOOLS SETUP ELECTROFUSION MANUAL The option INFO allows us to have access to the general information in the machine as well as to the adjustment of the display s contrast However the display contrast can also be adjusted by means or UP and DOWN key arrows once entered in the ELECTROFUSION mode Now select the ELECTROFUSION option from the Main Menu and press ACCEPT to start The joints by electrofusion must be only carried out by qualified personnel Edition April 2014 Revision No 11 MODE OF USE 47 77 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 3 5 Operator and job order identification Once the option has been accepted the following screen will come on the display The identification of the operator No will IDENTIFICATION MENU take place in this phase via a barcode system The job order No identification could be done by barcode or keyboard introduction Press ACCEPT both if the identification ORDER No has or has not been made OPERATOR No INSERT DATA If the unit has the obligation to iden
52. ctrofusion process without traceability Pressing CANCEL returns to the previous screen Pressing MANUAL allows manual entry of component and fitting codes Code data entry via bar code reader Enter the fitting traceability code Once the FITTING code has been entered the code field names of the components will appear on the screen ranging from one to two according to the type of fitting to be electrofused Enter the traceability code of the components Press CANCEL to return to the very last code After completion of the last entry ACCEPT will once again appear on the screen Press to continue with the fusion jointing cycle Manual code data entry After pressing MANUAL ACCEPT will TRACEABILITY appear on the screen with a code string of 26 zeroes at the bottom These numbers can be changed individually via the keyboard Press to change values from 0 to 9 press to move the cursor right or left respectively 00000000000000000000000000 Edition April 2014 MODE OF USE Revision No 11 USER MANUAL 7 ODS TRACK AUTOMATIC EA 3 3 7 4 ur After having entered the fitting code press ACCEPT to validate it The code will be recorded on the next line after FITTING Upon entering the first code the ACCEPT option will disappear from the screen which will then display the field names of the following codes COMPONENTS Follow the same component code entry as was performed f
53. direct sunlight and so on The complete unit could be stored either on the warehouse floor or in pallet racks The autonomy of the internal battery lasts for between two years and two years and a half Should the storage time exceed this period control that the battery does not run out It is advisable to connect the fusion control box to the network and start it in order to check the internal battery functioning for example verify the time and date via the INFO NOTICE If the battery uses up its charge all the stored data in RAM memory will be lost fusion records machine s identification date time etc Edition April 2014 Revision No 11 MAINTENANCE 87 4 hy USER MANUAL ACUSTER ODS TRACK AUTOMATIC 5 1 3 Cleaning Clean the fusion control box regularly using only a damp cloth NOTICE Do not clean the fusion control box with water under pressure by immersion in water o with compressed air Do not rub excessively the plastic shell if applicable for it could charge itself with static electricity Should the unit be very dirty clean it with a bit of alcohol do not use solvents or cleaning products containing trichloroethylene 5 1 4 Checks We recommend shipping the butt fusion unit to the ACUSTER GLOBAL S L After Sales Service for a yearly service Edition April 2014 88 MAINTENANCE Revision No 11 4 USER MANUAL 7 7 ODS TRACK AUTOMATIC ACUSTER 5 2 5 2 1 9 2
54. e As stated in CHAPTER 3 MODE OF USE the swarf produced by the trimming blades must not be over 0 3 mm thick If the cut is faulty either in thickness or in regularity the blades should be adjusted NOTE For blades adjustment care and maintenance of the trimmer please refer to CHAPTER 5 MAINTENANCE of this User Manual The connection of the trimmer to the Fusion Control Box is done via an electric connector in the following way Models ODS225E T160 T250 and T315 Directly to the Fusion Control Box socket connector Models T315 110 T400 and T500 Into the Switch Box and then to the Fusion Control Box socket connector Edition April 2014 Revision No 11 MACHINE DESCRIPTION 21 4 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 2 6 HYDRAULIC STATION The hydraulic station consists of the following Figure 13 Hydraulic station on tubular frame Where 1 Hydraulic station 1 1 Male Female flat ends quick couplings according to ISO 7241 1 A Series 1 2 Oil refilling plug 1 3 Oil filter 2 Tubular frame 3 Control panel 3 1 Electric cable with circular connector 3 2 Socket circular connector Replace the hydraulic oil and filter following the maintenance schedule NOTE Spare oil in one 1 and five 5 litre containers is available For care and maintenance of the hydraulic station please refer to CHAPTER 5 MAINTENANCE of this User Manual Edition April 2014 22 MA
55. e are two fusion control box models available TWIN S and DYNAMIC S e Electrofusion gt Model of fusion control box TWIN S e Butt fusion gt Model of fusion control box TWIN S amp DYNAMIC S The range of TWI N S machines allows the making of the combined fusion of pipes fittings through the jointing systems mentioned above electrofusion plus butt fusion The range of DYNAMIC S machines are designed for butt fusion joints only By the electrofusion system the unit receives the relevant data of the fitting via the bar code system or by operator s manual introduction It provides in an automatic and controlled way the required time for the electrofusion of the diameter and type of fitting connected Once the operation is finished it stores in its memory the traceability of the fusion time diameter date time make and type of fitting room temperature operator No order No etc The butt fusion jointing models allow the jointing of polyethylene PE pipes and fittings though they can also be used to joint other plastic resins PP PB PVDF for diameters ranging between 63 and 500 mm depending on the model All you have to do is to connect a base framework a heating plate a trimmer and a hydraulic station if applies in the electric connectors to the fusion control box the pipes fittings to be jointed have to be put in the base framework and are fixed by the clamps The sides of both pipes fittings are faced via the trim
56. e identifications which correspond to the above listed Specifications All the fittings can be fused by electrofusion if the manufacturer encloses the programmed bar code system in accordance with ISO TR 13950 1 4 GENERAL INFORMATION The development documentation production tests and shipping of the products herewith described have been made Complying with the respective safety rules and In accordance with the requirements of Acuster Global S L assurance quality WARNING The fusion control box can only be opened by the ACUSTER GLOBAL S L After sales Service In the case of the front and back covers opening or coming apart parts of electrical components which are not covered may be left exposed Only qualified personnel are authorised to intervene both for fusion and repairs These qualified personnel must be familiar with all the safety measures potential dangers and maintenance rules described in this Manual The safe use of the products described requires an appropriate means of transport storage installation and use a careful handling and the preestablished periodical maintenance follow up Edition April 2014 Revision No 11 INTRODUCTION 7 USER MANUAL ODS TRACK AUTOMATIC 1 5 MACHINE IDENTIFICATION 1 5 1 Serial Number Stamping All TWI N S DYNAMIC S components base framework heating plate trimmer and hydraulic station if applies are identified by means of their own
57. e with the fusion jointing process or CANCEL to return to the previous point Auxiliary number If this option is enabled ON on the SETUP GENERAL menu and once ACCEPT has been pressed on the previous screen pipe placement or traceability according to configuration the following screen will appear Use the keyboard to enter the Auxiliary AUXILIARY NUMBER number The cursor will be placed at the first left digit Enter the number one digit at a time by pressing to change value 0000 from O to 9 press to move the cursor right or left respectively AUXILIARY NUMBER Press ACCEPT to continue with the fusion jointing process or CANCEL to return to the previous point Selection of the material optional the pipes fitting s diameter and thickness NOTICE Depending on the unit s setup MATERIAL SELECTION option OFF or ON for each fusion the operator must choose the following e the pipe or fitting s diameter SDR or the pipe or fitting s material diameter SDR depending on the job preferences Place the cursor on the material to be MATERIAL SELECTION selected by means of the push buttons and Please see NOTICE Press ACCEPT to validate command Press CANCEL to return to the previous screen Edition April 2014 36 MODE OF USE Revision No 11 USER MANUAL di ODS TRACK AUTOMATIC ACUSTER Once the material has been selected only if it is setup as
58. eading the connected scanner emits a red laser line of a particular length To capture the barcode data place the scanner so that the laser line coincides longitudinally with the barcode The distance will depend on the size of the barcode to read Once the scanner has been placed in position the laser line will stop flashing and remain fixed When this happens press any of the three buttons on the top of the scanner Figure 16a Example of using the optic pen Figure 16b Example of using the laser scanner Edition April 2014 Revision No 11 MODE OF USE 27 4 ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 2 BUTT FUSION PROCESS FOR PIPES AND FITTINGS TWIN S DYNAMIC S BOXES 3 2 1 Introduction The assembly jobs and the PE or other plastic resins network butt fusion should always be carried out by specifically trained personnel and strictly following the manufacturer s instructions both for the pipes fittings as well as the fusion equipment 3 2 2 Unit connection and selection of the butt fusion system from the Main Menu First prepare all machine components base framework heating plate trimmer and hydraulic station if applies and connect the electric connectors to the their corresponding control box connector for further information please refer to clause 2 2 FUSION CONTROL BOX and clause 2 7 SWITCH BOX of this User Manual Now connect the fusion control box to a 230 V 15 power source A DANGER or
59. ear RAM 10 Cleaning of the pipe ends before or after trimming 11 Reduced time 12 Motor with encoder 13 To make active or not the MANUAL electrofusion option 14 Change of setting on operator and or job order when the identification is compulsory Edition April 2014 Revision No 11 MODE OF USE 57 USER MANUAL FEE TER ODS TRACK AUTOMATI C 58 SERVICE PASSWORD 3 It is restricted to the technical service centres of ACUSTER GLOBAL S L Apart from the options OPEN LEVEL AUTHORISED OPERATOR and OWNER it allows access to T The Service option from the MENU OF TEST By selecting the option PASSWORD from the TOOLS or by requesting directly an option with Password the following message will appear on display Enter the corresponding PASSWORD PASSWORD via bar code see LEVELS of access mentioned above ENTER PASSWORD The message PASSWORD X OK will be displayed where X could be 1 2 or 3 according to the level used PASSWORD X OK In the case of introducing an incorrect bar code with incorrect information or which has been introduced in an unsatisfactory way the display will show the message WRONG PASSWORD OR WRONG READ flashing during 3 seconds Repeat the password bar code introduction Once the password is accepted press EXIT to validate command From this moment the restricted options that the introduced password level have opened will be accessible The effect of the ac
60. ecting the two base framework hydraulic quick couplings into the hydraulic Station hydraulic quick couplings male female female male 2 Connecting the base framework electric circular connector into the hydraulic Station connector 3 Connecting the hydraulic station electric circular connector into the corresponding control box connector WARNING Always connect the base framework electric connector into the corresponding control box connector with the machine switched off Install the base framework cable connector with the nut properly tightened to ensure good contact between the pins For care and maintenance of the base framework please refer to CHAPTER 5 MAI NTENANCE of this User Manual HEATING PLATE The heating plate is made up of an outer PTFE lined aluminium base alloy body with an electric resistor supplied by a cable from the Fusion Control Box the PTFE line is replaceable The connection of the heating plate to the Fusion Control Box is done via an electric connector in the following way Models ODS225E T160 T250 and T315 Directly to the Fusion Control Box socket connector Models T315 110V T400 and T500 Into the Switch Box and then to the Fusion Control Box socket connector Edition April 2014 Revision No 11 MACHINE DESCRIPTION 19 NM USER MANUAL ACUSTER ODS TRACK AUTOMATIC WARNING Always connect the heating plate electric connector into the corr
61. ection where the control box mains is plugged must be normalized and fitted with differential and ground pin Refer to the generator s User Manual Connection to the mains the building electric installation where the control box mains is plugged must be fitted with earth connection as well as circuit breaker type D EN 60898 Do not unplug the mains pulling on the cable Because the unit allows the use of an optic or scanner indistinctly connect the barcode reader to use and check the setup Refer to clause 3 1 6 Using the Barcode Reader The fusion control box can be located either in the vertical or in the horizontal position as required by the operator Set the master switch in the ON position The display backlight comes on and the following message 15 displayed Familiarize yourself with the push MAIN MENU buttons on the panel The four push buttons located below the display are used in general to move the cursor from the messages on screen whereas the three push buttons located ELECTRIC BUTT FUSION ELECTROFUSI ON HYDRAULIC BUTT FUSION TXXX on the right side are used to carry out functions according to what the display TOOLS indicates The push button STOP is used to interrupt sequences Before starting the electrofusion process selecting the ELECTROFUSI ON option from the main menu be sure to have selected the correct barcode reader optic pen or scanner and setup the manual ele
62. electing MENU we go to the MAIN MENU CHECKING OF THE READING OF THE FITTI NG S RESISTANCE By selecting the first option FITTING RESISTANCE FITTING RESISTANCE RESISTANCE RR RR Ohm VERIFICATI ON OF THE TEMPERATURES By selecting the second option TEMPERATURES TEMPERATURES ROOM 21 INTERNAL 30 C HEATING PLATE TROUBLESHOOTING TIT C DD C 0 C This option shows us the reading of the fitting s resistance RR RR or master resistance connected to the unit s elec trofusion cables For the reading adjustment please refer to the option SERVICE option only available for the ACUSTER GLOBAL S L After Sales Service Press CANCEL to go back to previous screen This informative option shows us the different temperatures to be borne mind by the unit and operator The room temperature is read by the external temperature sensor of the unit The internal temperature is the reading of the recorded temperature inside the unit Press CANCEL to go back to previous screen Edition April 2014 Revision No 11 USER MANUAL ODS TRACK AUTOMATIC READING SYSTEM 4 i de ACUSTER By selecting the third option READING SYSTEM READING SYSTEM LOAD DATA This informative option shows us on screen the data contained on the bar code system Once the bar code is read the corre sponding data will be showed on screen Press CANCEL to go back to previous screen This opti
63. em Manually The order identification will automatically be carried out by inserting the corresponding identification via barcode system or manually indistinctively From this moment the identification will be associated to the unit fusions made until 1 new identification is entered 2 Entering the same identification a second time ON OFF system 3 Change of date at zero hours or switching off the unit the identification will be deleted according to the unit s setup OFF on the first case and ON on the second from the path TOOLS SETUP GENERAL RESET OB 4 The use of the options ON or OFF on JOB ORDER ID Z4 from the path TOOLS SETUP GENERAL OPTI ONAL OBLI GATORY IDENTIFICATION Obligatory identification In order to make compulsory the operator s and or job order identification select ON via the path TOOLS SETUP GENERAL e OPERATOR ID Z2 ON e JOB ORDER ID Z4 ON causing that the identification of operator and job order to be compulsory This option obliges the operator to identify the operator s and or job order number daily or when the units is switched on depending on the OFF or ON setup of option RESET OPERATOR J OB in order to access the fusion menus Optional identification In order to make optional again the operator s and or job order identification selecting OFF via the path TOOLS SETUP GENERAL e OPERATOR ID Z2 OFF ORDER ID 24 OFF
64. enerator or mains socket plug Models T315 110V T400 and T500 They must be connected to the Switch Box socket plug Connection to generator the generator electric connection where the control box mains is plugged must be normalized and fitted with differential and ground pin Refer to the generator s User Manual Connection to the mains the building electric installation where the control box mains is plugged must be fitted with earth connection as well as circuit breaker type D EN 60899 Do not unplug the mains pulling on the cable 3 1 2 Positioning of the unit in the work area The fusion control box can be located either in the vertical or in the horizontal position as required by the operator Figure 15a Vertical position Figure 15b Horizontal position Edition April 2014 24 MODE OF USE Revision No 11 USER MANUAL ur ODS TRACK AUTOMATIC ACUSTER 3 1 3 Start up the unit Set the master switch in the ON position The display backlight comes on and this message appear on it MAIN MENU The first message in the unit is the MAIN MENU This menu allows us to choose the MAIN MENU options ELECTRIC BUTT FUSION ELECTROFUSION HYDRAULIC BUTT ELECTRIC BUTT FUSION FUSION and TOOLS Place the cursor on the word by means of the arrows and on the panel Then press the button ELECTROFUSION HYDRAULIC BUTT FUSION next to ACCEPT The option INFO allows us to access
65. esponding connector with the machine switched off Install the heating plate cable connector with the nut properly tightened to ensure good contact between the pins For care and maintenance of the heating plate please refer to CHAPTER 5 MAINTENANCE of this User Manual The heating plate temperature is automatically controlled from the Module by means of an internal temperature sensor The control is PID proportional integral differential An independent control thermometer may also be provided 2 5 TRIMMER The trimmer version ODS225 consists of an aluminium fused carter which covers and protects the two trimming discs Each disc is also provided with an adjustable cutting blade The trimming performance 15 carried out by simultaneously pressing the electric push buttons located on each hand grip The operating system also includes a safety switch which prevents the trimmer from operating in the event of this one not being mounted on its working position on the base framework bars On the version 24Vdc the transmission of motion from the electric motor to the trimmer discs is performed by way of a Poly V belt whereas on the 230 110V version model 2014 the transmission is through chain Both belt and chain can be retightened by means of an eccentric tightener The electric motor power Is supplied by means of a cable directly connected to the Fusion Control Box On the 24 Vdc version its power is 465 W and it has an electronically
66. from 0 3 to 1mm depending on the nominal diameter see following table P 0 3 mm for lt 250 mm P 0 5 mm for 250 to lt 400 mm 1 for 400 lt 630 mm 23 If the tolerance of the specification to be applied did not comply trim again By pressing the moving body 15 placed in the biggest opening position and the display goes back to the TRIMMING menu When the visual check 15 satisfactory press YES to continue with the cycle If the pipe cleaning is set as CLEAN PIPE ENDS FUSION the following message will appear on the screen Pressing YES continues with the butt VISUAL CONTROL fusion cycle Pressing CANCEL interrupts the butt fusion process and returns to the initial screen PIPE ENDS CLEANED DRAG 10 N ISO 0110 SDR11 CANCEL 25 C 210 C 232 Volt 50Hz 00001 Edition April 2014 MODE OF USE Revision No 11 4 USER MANUAL d p z ODS TRACK AUTOMATI C ACUSTER The moving body will open to the end There is a tolerance of 18 20mm for the trimming In case of this distance were exceeded an error message will be displayed EXCESSIVE PIPE FACING Open the moving body put the pipes close to each other and reinitiate the cycle from the trimming step 3 2 9 Heating plate setting Once the trimming and visual check phase has been completed the display will show the following indication If the heating plate is not within the START BUTT FUSION CYCLE mini
67. h BLUEBOX Place the cursor on the desired option GENERAL OPERATOR ID Z2 and or ORDER ID Z4 By pressing ACCEPT the ON OFF CHANGE OF LANGUAGE selection is changed alternatively By selecting OFF the operator s ENS DAE LE identification and or the order s is OPERATOR ID Z2 On Off optional while pressing the identification of one or both of the ORDER ID 74 On Off options according to selection is compulsory traceability implantation More With the set option optional OFF the information displayed on the screen INFO will be Z20 for the operator and Z40 for the job order With the set identification option obligatory ON the information displayed on the screen INFO will be Z21 for the operator and Z41 for the job order Once the desired selection has been made press CANCEL to exit the option Edition April 2014 MODE OF USE Revision No 11 4 USER MANUAL Wh ur ODS TRACK AUTOMATIC ACUSTER OOO TRACEABILITY IN ACCORDANCE WITH ISO 12176 4 AUXILIARY NUMBER The ODS fusion control boxes beginning with fusion control box software version 6 10 and AcusWin v5 0 allow performing complete fusion jointing traceability The following options are available selecting TOOLS SETUP GENERAL from the main menu NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER From softwa
68. he codes of COMPONENT 2 the component data returned PIPEA ddd SDRCC PIPE where A refers to straight or coiled BB corresponds to the pipe manufacturer initials 80 to the plastic resin ddd to the pipe diameter and SDR to the pipe wall thickness Press lt to exit the traceability screen and return to the previous one Press to access to previous fusion records and to access next ones Edition April 2014 MODE OF USE Revision No 11 USER MANUAL 7 ODS TRACK AUTOMATIC EA 4 ur By selecting the option CHECK ELECTROFUSI ON RECORDS TWI N S Where CHECK ELECTROFUSI ON RECORDS No NNNNN nnnn corresponds to the last fusion number made additional number press to access previous fusions DD YY is the date in which fusion ddd BBB has taken place CODED r rr REAL R RR START TEMP corresponds to the vv v V XX S ALIN NO YES starting time of the electrofusion and the VOLTAGE room temperature at the time MESSAGE OF THE RESULT No NNNNN nnnn DD MM YY START TEMP OPERATOR ORDER corresponds to the operator s number and order s number if this data has been entered if not dashes will appear MAKE TYPE ddd BBB correspond to the make of the fitting the type of fitting coupler saddle etc its diameter and the batch number if it has been codified by the fitting s manufacturer CODED REAL refers to the coded resistance cod
69. ically Should the language configurated on the bar code not be available in the unit the unit will continue to be setup in the working language which had been selected at the time Should there be a fault or temporary deprogramming of the unit the adopted language by default would be the first one that has been loaded into the machine The first option on the TOOLS SETUP GENERAL menu allows us to select the work language among those currently supported new languages my be introduced based on demand Now select the desired language by SELECT LANGUAGE placing the cursor on the chosen one using the arrows and on the panel EHI dass Then press the button next to ACCEPT to validate command CATALA vx X SPANISH vx x By selecting CANCEL we will go back to the MAIN MENU without changing the DEUTSCH vx x language More Edition April 2014 MODE OF USE Revision No 11 USER MANUAL ur ODS TRACK AUTOMATIC ACUSTER 2 DATE TIME UPDATING If the date time or day do not correspond to the present one proceed to the change by selecting TOOLS SETUP GENERAL from the Main Menu NOTICE The change of DATE TIME has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Select CHANGE DATE TIME from the SETUP menu by moving the cursor with the arrows t and on the panel Press ACCEPT to select By selecting the option CHANGE DATE TI
70. identification plate ACUSTER GLOBAL QUALITY CONTROL ACUSTERGLOBAL EQUIPO MAINTENANCE REVISIONES REVISIONS MANUFACTURER S Juan de la Cierva 1 Polig Ind del Sud oest ADDRESS Tel 34 93 4703070 Sant Just Desvern Barcelona Figure 1 The quality control identification plate includes the fusion control box serial number The plate includes room for future maintenance date stamping 1 5 2 CE marking The fusion control box is supplied with the appropriate plate with the CE mark as the European Community norm indicates on the new Machine Security Regulation Board 2006 42 CE dated 17th May 2006 ACUSTER GLOBAL CE o MODELO N SERIE Juan de la Cierva 1 Pol g Ind del Sud oes Tel 34 93 4703070 Sant Just Desvern SPAIN Figure 2 Edition April 2014 8 INTRODUCTION Revision No 11 4 USER MANUAL 77 7 ODS TRACK AUTOMATIC ACUSTER 1 6 MEASURES OF PROTECTION AGAINST ACCIDENTS 1 6 1 Safety alert symbols This User Manual employs the following safety alert symbols Indicates information considered important but not hazard related When appears this hazard alert sign in this manual carefully read what 1 Says Indicates a hazardous situation that if not avoided will result in death or serious injury CAUTION minor or moderate injury Hi Indicates a hazardous situation that if not avoided could res
71. ides Then release the push buttons The moving body will automatically open and stop the trimmer The shaving thickness must be 0 3 mm at the most NOTE If the cutting is not correct check and adjust the cutters according to the procedure described in CHAPTER 5 MAINTENANCE of this User Manual Once this operation has been made the display will show If the trimming is correct press VISUAL TRIMMING MAKE VISUAL CONTROL OR REPEAT TRIMMING VISUAL CTRL CANCEL 00001 9110 25 C 210 232 Volt ISO 50811 50 Hz Edition April 2014 Revision No 11 CONTROL to continue with the cycle Always keep A CAUTION hands clear of the clamps area If it is not correct keep on trimming until the tolerance of the sides of the pipes fittings is correct CANCEL will take us back to the CLAMPING POSITION MENU MODE OF USE 39 4 hy USER MANUAL ACUSTER ODS TRACK AUTOMATIC 40 The display will read as follows Inspection of the cut obtained VISUAL CONTROL With this operation the drag force is measured and displayed when it ts fully closed The position of the moving body is then saved in the memory in order to calculate the distance reduction of the fusion TRIMMING OK DRAG 10 N ISO 0110 SDR11 25 C 210 C 232 Volt 50Hz 00001 Visually check the trimming According to 15 12176 1 the flatness of the sides of the pipes will have a maximum tolerance
72. ified by the manufacturer and to the real value registered by the fusion unit vv v V xx s ALIN corresponds to the fitting s electrofusion voltage the fusion time whether a clamp tool has been used in the process or not In MESSAGE OF THE RESULT the one corresponding to the case appears OK USER S INTERRUPTION etc In the event of having electrofusion records with traceability press gt to access the second screen No nnnn corresponds to the CHECK ELECTROFUSI ON RECORDS electrofusion No additional No queried No NNNNN nnnn MM DD YY FITTING Type manufacturer initials FITTING material diameter and SDR TE BB PE80 ddd SDRCC COMPONENT 1 and 2 are the codes of COMPONENT 1 the component data returned ddd SDRCC PIPE where refers to straight COMPONENT 2 lt coiled BB corresponds to the pipe PIPEA ddd SDR CC manufacturer initials 80 to the CANCEL material ddd to the pipe diameter and SDR to the pipe wall thickness Press lt to exit the traceability screen and return to the previous one Press to access to previous fusion records and to access next ones Edition April 2014 Revision No 11 MODE OF USE 61 USER MANUAL Gru STER ODS TRACK AUTOMATIC 62 EXPORTING FUSION RECORDS For exporting fusion records through computer or memory stick please refer to the AcusWin User Guide RETRIEVAL OF FUSION RECORDS For the re
73. ing Select READER SYSTEM from the TOOLS SETUP GENERAL menu by moving the cursor with the arrows and on the panel Press ACCEPT to select By selecting this option we can change the reading device of the bar code system Place the cursor on the desired option by READING SYSTEM means of the arrows amp and on the panel BARCODE READER Press ACCEPT to validate the change and SCANNER CANCEL to exit without modifying 9 MEMORY OVERFLOW This option from the TOOLS SETUP GENERAL menu allows us to overwrite or not the existing fusion records on both the internal memory and Memory Card if equipped NOTICE This selection has a restricted access Enter PASSWORD 2 access Please refer to point 3 4 1 Access to restricted options of this CHAPTER Place the cursor on MEMORY OVERFLOW GENERAL option Press ACCEPT to select the desired MEMORY OVERFLOW Off option ON or OFF Selecting ON the unit will continue loading the fusion records even when the PRINT SETUP memory is full the first fusion records will be overwritten and lost FORMAT MEMORY CARD CLEAR RAM Selecting OFF the unit will be blocked when the memory capacity was full Once the desired option is selected press CANCEL to exit this menu Edition April 2014 70 MODE OF USE Revision No 11 4 USER MANUAL hy ODS TRACK AUTOMATIC ACUSTER FORMAT MEMORY CARD Please refer to the AcusWin User Guide PRINTING UNIT S S
74. is would cause a force miscalculation in later phases In all the movements made manually by the machine s moving body pressing the push buttons OPEN CLOSE the acoustic signal comes into action in order to warn of the movement of the machine Pressing CANCEL it takes you back to the main menu Selecting POSITION the display will show the following message Prepare the base framework for PIPES LOCATION mounting the pipes fittings In order to do so adapt the diameter of the pipes fittings to jointed via the corresponding adaptors see list of available adaptors in CHAPTER 6 TECHNICAL CHARACTERISTICS LOCATE PIPES CENTRALLY When jointing pipes to fittings or fittings to fittings prepare the base framework for clamping the fittings The butt fusion fittings can be amongst others 90 45 or 30 elbows Reducers concentric or eccentric 90 bend Flange adaptor 90 tees equal or reduced Caps Edition April 2014 32 MODE OF USE Revision No 11 i USER MANUAL ODS TRACK AUTOMATIC ACUSTER BASE FRAMEWORK ODS 225 On the base framework ODS 225 E both outer clamps are removable To remove them loosen both clamps bolts 2 using a 10 mm Allen key supplied with the unit tool set NOTE If an adaptor is already mounted this should be removed in order to access the clamp bolts Where 1 Clamp assembly 2 Looking bolt Allen type Figure 18 Removable
75. ivation or not of the reduced time cooling down time phase on butt fusion cycle 9 Change of date time As an informative option press I NFO please refer to previous screen To make changes on the unit s initial programming please refer to ooint 3 4 TOOLS of this CHAPTER Using the Barcode Reader If you read the fitting s data by using optical means optic pen or scanner connect the reader device into the corresponding connector and slide it barcode reader or put it in front of the fitting s bar code scanner NOTE FOR SERIAL SCANNERS NOT USB SCANNER Check previously through the INFO of the MAIN MENU the existing selection BARCODE READER SCANNER To change the selection please refer to point 3 4 TOOLS of this CHAPTER The serial scanner should be correctly setup case no data is captured by the device carry out the following barcode reading Edition April 2014 26 MODE OF USE Revision No 11 USER MANUAL ODS TRACK AUTOMATIC ACUSTER Optic pen The barcode reader pen works with greater efficiency when gently slid along the barcode and when the inclination in relation to the vertical is kept between 10 and 40 However the pen s working angle is bigger it be used between 0 and 50 in relation to the vertical The displacement speed during the reading is also a factor to be borne in mind as a general rule slide the reader neither too slowly nor too fast Laser scanner When r
76. l 2014 Revision No 11 MODE OF USE 43 ly USER MANUAL ACUSTER ODS TRACK AUTOMATIC In the second option the reconnection to the butt fusion programme is carried out once the cooling phase has finished The message on the display shows the question CHECK LAST UNSETTLED FUSION Press ACCEPT and the moving body will carry out the operation of verification in order to ensure that the pipes fittings are still mounted and fixed on the clamps Pressing CANCEL the fusion will be stored in the unit s memory as cancelled OPERATOR S VOLUNTARY INTERRUPTION CAUTION Should the pipes fittings be loosened from the clamps before time the electronic control unit would detect it causing the following message to be displayed PIPE FREE BEFORE COOLING This will be stored in the unit s memory If the SIMULTANEITY is not used the fusion cycle will carry on When the countdown of the programmed cooling time is finished the moving body will carry out the operation of verification to ensure that the pipes fittings are still mounted and fixed on the clamps 3 2 12 End of butt fusion joint If the full sequence herewith described has been carried out correctly in all its phases and the pipe length reduction lies between the programmed maximum and minimum the message CORRECT JOINT is displayed If not the message with the reason for the failure will appear The STOP key can be pressed any time during the fusion process in order to
77. l never be higher than the fusion force When champing pipes onto the base framework with precarious drag condition supporting rollers not used excessive length etc whose manoeuvring force is bigger than the above specified the moving body will be immobilised The display will show MOTOR OVERCHARGE t For the concept related with PIPE RECORD please refer to SELECTION OF THE BUTT FUSION SYSTEM of the point 3 4 3 of this User Manual After the assembling check the pipe fittings alignment The maximum alignment tolerance allowed according to ISO 12176 1 is 10 of the pipe s wall thickness Edition April 2014 34 MODE OF USE Revision No 11 USER MANUAL di ODS TRACK AUTOMATIC Spore Figure 21 Press CANCEL to go back to previous screen Pressing ACCEPT the moving body will carry out the drag force measurement for trimming and will be placed in the biggest opening position 3 2 5 Fusion jointing traceability When the TRACEABILITY option on the SETUP GENERAL menu Is enabled ON and after having pressed ACCEPT on the pipe location screen the following screen will appear When traceability is enabled ON two TRACEABILITY situations can occur MANUAL COMPONENT 1 a Optional traceability REQUIRED TRACEABILITY OFF b Required traceability REQUIRED TRACEABILITY ON COMPONENT 2 ACCEPT The optional traceability selection allows the operator to optionally enter the code data of the compo
78. mer and subject to heating via the heating plate Once the heating cycle has been completed both pipe ends are jointed applying a controlled strength time programmed in the unit s memory butt fusion parameters time temperature and force pressure Prior to the realization of the butt fusion the diameter and the wall thickness SDR of the pipe fitting to be jointed must be selected as well as other additional information such as operator No order No etc which may be obligatory or optional for traceability reasons The technical data contained in this manual are purely informative and may be changed at anytime ACUSTER GLOBAL S L declines all responsibility for claims arising from misuse of the data contained herewith and or errors or omissions detected after publication This Manual must be considered as part of the unit Edition April 2014 Revision No 11 INTRODUCTION 5 i ACUSTER 1 2 MODEL RANGE USER MANUAL ODS TRACK AUTOMATIC The ODS System and Track Automatic machine range available at the time of making this Manual are 1 2 1 ODS machines MODEL RANGE OF DIAMETERS MACHINE COMPONENTS TWI N S 225 63 to 225 TWI N S Control Box Base framework 225 E electric drive Trimmer 225 Heating plate 225 TWI N S 315 90 to 315 TWI N S Control Box Base framework 315 G hydraulic drive Hydraulic station Trimmer 315 Heating plate 315 DYNAMIC S 225 E 63 to 225 DYNAMIC S Control Box Ba
79. mer between the two pipes fittings to be jointed resting it on the base framework guides against the facing of the pipe on the fixed body and with the handle of the electric cable on the clamps bolts side Figure 22 AWARNING Press the push button FUSION UNITS AT 110V On fusion units at 110V when the trimmer push button is pressed the heating plate power supply is cut The feed to the heating plate is automatically activated few seconds after the push button is released Edition April 2014 38 MODE OF USE Revision No 11 USER MANUAL ODS TRACK AUTOMATIC ACUSTER WARNING Handle the trimmer with caution These is risk of being cut by the blades If for any reason the operator releases either of the trimmer push buttons however short a time the cycle will be interrupted Repeat the process by releasing and pressing both trimmer push buttons Simultaneously The trimmer is equipped with a position sensor that prevents it from starting up if is not placed on the guiding axles With the trimmer s push button pressed the moving body starts a closing cycle in which the required drag force is read Then the trimmer starts up and the moving body automatically approaches it The force exerted on the trimmer will depend on the one established on the corresponding pipe SDR and diameter selected plus the drag force of the pipes fittings Trim both ends till the shavings come off continuously from both s
80. mum and maximum tolerances established the RECORD the INVALID TEMPERATURE PLEASE WAIT message will come on The process will stop until the adequate temperature is PUT ON HEATING PLATE CORRECT TEMPERATURE attained For the concept related with PIPE DRAG 10 N RECORD please refer to SELECTION OF ISO PE 4110 508 11 CANCEL THE BUTT FUSION SYSTEM of the point 25 C 210 C 232 Volt 50Hz N 00001 3 4 3 of this User Manual The heating plate temperature control is automatically carried out via the electronic control unit However the heating plate is fitted with an independent thermometer for additional information It has a green indicator led which is on or off when it is on indicates that the heating plate is receiving power When the heater reaches suitable working temperature the display will Show the message CORRECT TEMPERATURE WARNING Hot surfaces Do not touch The use of protection gloves is recommended Place the heating plate on the base framework guides between the A DANGER pipes fittings approximately midway the electric cable should be on the clamp bolts side Pres ACCEPT from the panel The moving body closes and applies the programmed force for the pipe selected drag Figure 24 Edition April 2014 Revision No 11 MODE OF USE 41 ily USER MANUAL ACUSTER ODS TRACK AUTOMATIC When starting the fusion cycle the corresponding graphic to the phases of butt fusion will
81. n connection The base framework moving clamps have installed an encoder shift control sensor for distance control Figure 5a Base framework ODS TRACK 315 G Figure 5b Track Automatic The base frameworks belonging to Track Automatic machines Figure 5b consisting of a frame equipped with handles for transportation for those models whose weight allows this The frame incorporates four lower aluminium clamps and four detachable upper clamps made of aluminium too The securing together of the upper and lower clamps 15 achieved by use of securing braces equipped with handles which serve as spigots for large diameter sizes the upper clamps are locked by means of high nuts which require spanner to fix them The movement of the moveable clamps is achieved via two hydraulic cylinders of double effect connected to flexible high pressure hoses with quick connectors mounted on the ends base framework moving clamps have installed an encoder shift control sensor for distance control NOTE For the care and maintenance of the base framework consult CHAPTER 5 MAINTENANCE of this same User Manual 3 A Heating Plate Figure 6 consisting on a PTFE lined aluminium plate with electronic temperature control by means of an internal sensor PI D NOTE For the care and maintenance of the heating plate consult CHAPTER 5 MAI NTENANCE of this same User Manual Edition April 2014 14 MACHINE DESCRI PTI ON Revision No 11
82. n has been CHANGE OF BLOCK made press CANCEL to exit the option CHANGE OF PIPE MATERIAL ON OFF PIPE RECORDS MATERIAL SELECTION On Off More PIPE ENDS CLEANING TWIN S DYNAMIC S BOXES These two options allows us to settle the display of the message PIPE ENDS CLEANED before of after trimming according to applicable specification Select TOOLS SETUP BUTT FUSION JOINTS NOTICE Access to selecting this option 15 restricted Enter access PASSWORD 2 Refer to point 3 4 1 Restricted options access in this same section Pressing ACCEPT toggles between BUTT FUSIONS J OINTS ON OFF for the field selected Once the desired selection has been CLEAN PIPE ENDS TRIM On Off made press CANCEL to exit the option CLEAN PIPE ENDS FUSION On Off REDUCED TIME On Off MOTOR WITH ENCODER On Off More Selection options 1 Cleaning of pipe ends before trimming CLEAN PIPE ENDS TRIM On CLEAN PIPE ENDS FUSION Off Edition April 2014 MODE OF USE Revision No 11 USER MANUAL ur ODS TRACK AUTOMATIC ACUSTER 2 Cleaning of pipe ends after trimming CLEAN PIPE ENDS TRIM Off CLEAN PI PE ENDS FUSION On 3 Cleaning of pipe ends before and after trimming CLEAN PIPE ENDS TRIM On CLEAN PI PE ENDS FUSION On 4 No cleaning of pipe ends CLEAN PIPE ENDS TRIM Off CLEAN PIPE ENDS FUSION Off o REDUCED TIME ON BUTT FUSION CYCLE TWI N S DYNAMI C S BOXES This option from the TOOLS SETUP BUTT FUSI
83. nents pipes or fittings If entering component code data the codes of all the components that make up the fusion jointing must be entered in the case of butt fusion two ACCEPT will only appear on the screen with the optional traceability selection Pressing ACCEPT continues with the butt fusion process without traceability Pressing CANCEL returns to the previous pipe location screen Pressing MANUAL allows manual entry of component codes Manual Code Entry TRACEABILITY After pressing MANUAL ACCEPT will appear on the screen with a code string of 40 zeroes at the bottom These numbers can be changed individually via the keyboard Press or to change values from 0 to 9 press or to move the cursor right or left respectively COMPONENT 1 COMPONENT 2 00000000000000000000000000000000000000 Edition April 2014 Revision No 11 MODE OF USE 35 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 2 6 3 2 7 Enter the component traceability code If using the manual option press ACCEPT to validate the code The code will be recorded on the next line after COMPONENT 1 ACCEPT will once again disappear from the screen if using the manual option Repeat the process to enter COMPONENT 2 data The coding is in agreement with the criteria set forth in ISO 12176 4 If an incorrect code is entered the message INCORRECT READING OR INVALID DATA will appear at the bottom of the screen Press ACCEPT to continu
84. on is particularly useful when it is required to know the coded number from a bar code system specially when the fitting manufacturer does not provide that relevant information along the bar code sticker VERIFICATI ON OF THE ACOUSTIC SIGNAL AND PUSH BUTTONS Finally by selecting BUZZER PUSH BUTTONS from the Menu ELECTRIC BUTT FUSION BUZZER PUSH BUTTONS PRESS PUSH BUTTONS ACCEPT END TEST PRESS OK IF ACOUSTIC SIGNAL IS ON LAST PUSH BUTTON Edition April 2014 Revision No 11 This option allows us to verify the functioning of all push buttons arrows STOP and the three side push button as well as the buzzer With each press ing the pressed push buttons appears on screen along with the acoustic signal Press the central push button on the side to exit this option and go back to menu of test of ELECTROFUSION TROUBLESHOOTING 83 4 i hy USER MANUAL ACUSTER ODS TRACK AUTOMATIC 4 2 3 Hydraulic butt fusion TWIN S DYNAMIC S BOXES Select HYDRAULIC BUTT FUSION from the MENU OF TEST The following options will appear on screen First screen Second screen MENU OF TEST MENU OF TEST DISPLACEMENT READER SYSTEM TRIMMING TEST 230V TEMPERATURES BUZZER PUSH BUTTONS More Select the desired option by moving the cursor with the arrows and on the panel Press ACCEPT By pressing CANCEL we go back to the previous menu By selecting MENU we go to the MAIN MENU D VERIFICATI ON OF T
85. on voltage Electrofusion time Up to 5940 seconds 99 minutes Enter fusion data Automatic acc To ISO TR 13950 Manual according to setup Duty factor 20 to 10096 according to fitting s size Electronic temperature control Electrofusion cable 1x16 4 m long female terminals of diameter 4 mm Included accessories Front protection Accessories bag Scanner Password 1 and Password 2 cards ODS transmission cable for plastic casing only AcusWin CD Rom for plastic casing only Transport case Set of 4 and 4 7 mm electrofusion adapters Optional accessories Null modem cable DB9 F DB9 F for and printer connection Serial printer Dimensions Height 460 mm Width 450 mm Length 470 mm Net weight plastic casing steel casing 34 36 5 kg 20 22 5 kg Edition April 2014 92 TECHNICAL CHARACTERISTICS Revision No 11 USER MANUAL ODS TRACK AUTOMATIC ACUSTER 6 2 BASE FRAMEWORK range mm 63 225 90 315 Included pipe adapters 225x200 Set of pipe adapters available 63 75 90 110 125 140 90 110 125 140 160 not included with the machine 160 and 180 180 200 225 250 and 280 Operation Linear actuator at 24 Vdc 2 double acting hydraulic cylinders Maximum force pressure 100 bar o o S Included tools One 3 mm Allen key One 5 mm Allen key One 6 mm Allen key One 10 mm Allen key One 72 ratchet wrench One 26 mm socket wrench Exterior dimensions cm L 96xW 39xH 40 L 80xW 56xH 52
86. ontrol Box consists of and ABS plastic cupboard mounted on a stainless steel tubular structure On the model 2013 the exterior casing is made of steel The Fusion Control Box contains a power board the processor s board CPU and transformer as well as the electronics required for the fusion process previous identifications and registers of fusion records for its traceability It also has an outer front panel with graphic display function push buttons master switch fuse holder the mains RS 232 connector for bar code scanner PC and printer Type A USB connector model 2013 electric connectors for base framework connection trimmer heating plate and hydraulic station for TWI N S DYNAMI C S boxes and electrofusion cables for TWI N S boxes only WARNING connectors must be installed for the unit to work properly for butt fusion Install the connectors correctly with the nuts properly tightened to ensure good contact between the pins For the electrofusion as well as for processing fusion data via the printer or PC it is possible to use the Fusion Control Box Unit with only the mains connected 2 2 2 Front part The front part of the fusion control boxes are formed by a silkscreened plastic membrane which incorpo rates the tactile push buttons membrane type On the upper left side of the front part you can find the display Where Graphic display Push button STOP Function push buttons Selection pu
87. or the fitting After pressing MANUAL a code string of TRACEABILITY 40 zeroes appears at the bottom of the screen Each number can be changed individually via the keyboard Press f or to change values from 0 to 9 press or to move the cursor right COMPONENT 2 or left respectively FITTING XXXXXXXXXXXXXXXXXXXXXXXXXX COMPONENT 1 00000000000000000000000000000000000000 Once having entered the COMPONENT 1 code press ACCEPT to validate it The code will be recorded on the next line after COMPONENT 1 The ACCEPT option will disappear from the screen Repeat the process until completing the rest of the components The coding is in agreement with the criteria set forth in ISO 12176 4 If an incorrect code is entered the message INCORRECT READING OR INVALID DATA will appear at the bottom of the screen Press ACCEPT to continue with the electrofusion process or CANCEL to return to the previous point Auxiliary number When the AUXILIARY NUMBER option on the SETUP GENERAL menu is enabled ON and after having pressed ACCEPT on the previous screen pipes location or traceability according to the setting the following screen will appear Use the keyboard to enter the Auxiliary AUXILIARY NUMBER number These numbers can be changed individually by pressing or 9 to AUXILIARY NUMBER change values from 0 to 9 press or 0000 to move the cursor right or left respectively Press ACCEPT to continue with the f
88. outer clamp BASE FRAMEWORK HYDRAULI CALLY ACTUATED T315G TRACK RANGE On the base framework T 315 G the outer clamp of the fixed body first clamp on the right hand according to Figure 19 is removable to accommodate fittings To remove it loose the bolts b of the lower clamp 1 using a 6mm Allen key Figure 19 Removable outer clamp Edition April 2014 Revision No 11 MODE OF USE 33 ily USER MANUAL ACUSTER ODS TRACK AUTOMATIC Where Upper clamp Lower clamp Fixing bolt for lower clamp Connecting bolt for upper clamps Loosen the bar fixing bolts using an 8mm Allen key Afterwards dismount the Supporting plate 2 Once this has been done dismount the spacer bar 4 which is fixed by b bolts on both ends Remove the clamp 1 and the two spacer bars 3 using a 27 mm head open end wrench Revert the above step instructions to assemble Now open all the upper clamps and place the pipes fittings into the machine with both pipe ends touching and with approximately equal distance between the clamps before mounting inspect the insides and outsides of the pipes fittings to be jointed try and align them use the supporting rollers Tighten the locking bolts DO NOT overtighten 1m 1m 4m W RERE Figure 20 NOTE Once the selection of the diameter and SDR of the pipe has been made the maximum force will be given by the PIPE RECORD it wil
89. p at a safe distance from the fusion point during the electrofusion cycle and do not connect any other electric equipment during the process The time and the countdown till you get to zero will come on the display in seconds NOTICE For safety reasons should you not press the button START during the starting phase of the electrofusion after 40 seconds the process will be cancelled taking you back to the initial screen FUSION DATA FITTING DATA If during the fitting s fusion cycle there is an eventuality such as disconnection of a fitting s terminal increase decrease of voltage over the allowed limits by the machine an electric failure REAL RES R RR Ohm etc the electrofusion process will stop FUSION TIME ttt s and the corresponding message will be MESSAGE ERROR displayed 20 231Volt 50Hz N 00001 WARNING In order to guarantee a good electrofusion it is recommendable not to reuse a fitting in which the fusion cycle has been interrupted FITTING DATA If the electrofusion cycle is completed satisfactorily the message CORRECT FITTING XXXXXXXXXXXX JOINT will be displayed along with the DIAMETER ddd INPUT DATA R RR Ohm VV V Volt REAL RES R RR Ohm perceptive cooling time provided that it has been given by the fitting s manufacturer COOLING TIME tt min Press GO to carry out another elec CORRECT JOINT trofusion o
90. r abandon the menu 20 231Volt 50Hz N 00001 Edition April 2014 54 MODE OF USE Revision No 11 Ti USER MANUAL ODS TRACK AUTOMATIC ACUSTER The cooling time will be displayed only if the fitting manufacturer has loaded this information on the bar code This indicates the minimum waiting time that is required before pulling apart the gripping tools used aligner clamping tool etc For further information on the minimum waiting time for the drilling and pressure test please refer to the assembly instructions of the fitting s manufacturer respectively Edition April 2014 Revision No 11 MODE OF USE 55 4 i ACUSTER 3 4 56 TOOLS USER MANUAL ODS TRACK AUTOMATIC By selecting TOOLS from the MAIN MENU you can access the functions of consulting setup adjustment etc MAIN MENU ELECTRIC BUTT FUSION ELECTROFUSION HYDRAULIC BUTT FUSION TXXX TOOLS The following MENU will appear TOOLS FUSION INFORMATION SETUP MENU OF TEST PASSWORD MODE OF USE Select TOOLS by placing the cursor on the word by means of the arrows and on the panel Then press the button next to ACCEPT Choose the desired option among FUSION INFORMATION SETUP MENU OF TEST and PASSWORD by placing the cursor on the word by means of the arrows and on the panel Then press the button next to ACCEPT By selecting CANCEL you go back to the MAIN MENU Edition April 2014
91. re version v 6 67 this option becomes On by default on TWIN units equipped with BLUEBOX Pressing ACCEPT toggles between GENERAL ON OFF for the field selected When selecting TRACEABILITY OFF the unit operates as if this option were non existent When selecting TRACEABILITY ON the AUXILIARY NUMBER On Off unit allows entering fusion jointing component code data TRACEABILITY On Off TRACEABILITY OBLIG On Off READER SYSTEM More Setting AUXILIARY NUMBER to OFF causes the unit to operate this feature did not exist Setting AUXILIARY NUMBER to ON the fusion box allows entering a complementary number linked to the fusion number Once having set the traceability option to ON the following TRACEABILITY OBLIG option can now be toggled between ON OFF When selecting TRACEABILITY OBLIG OFF the unit allows the optional entering of fusion jointing component code data When selecting TRACEABILITY OBLIG ON the unit is configured to require entry of fusion jointing component code data Once the desired selection has been made press CANCEL to exit the option Edition April 2014 Revision No 11 MODE OF USE 69 7 7 USER MANUAL ACUSTER ODS TRACK AUTOMATIC SELECTION OF THE BAR CODE READING SYSTEM The fusion control units allow us to get the recorded data by the bar code system via Optic pen Scanner In order to do so you need to previously select one of the devices to be used when read
92. rly tightened to ensure good contact between the pins For care and maintenance of the base framework please refer to CHAPTER 5 MAINTENANCE of this User Manual BASE FRAMEWORK ODS TRACK HYDRAULI CALLY DRIVEN The base framework ODS TRACK consists of four aluminium lower clamps and four aluminium upper clamps two of which are fixed and two movable The lower clamps are held by supporting plates which are secured by a tubular frame provided by transport handles The four upper clamps are easily removable and are connected in pairs The fixed outer lower clamp is also removable for accommodating various fittings such as elbows tees etc The movable clamps are driven by two double acting hydraulic cylinders The pressure to the hydraulic cylinders is supplied by a hydraulic station through two high pressure flexible hoses connected by means of male female flat ends quick plugs The clamping of different smaller diameters can be achieved by means of different sets of additional adaptors which are locked in place using Allen screws The clamps displacement is monitored by an encoder shift control sensor Edition April 2014 18 MACHINE DESCRIPTION Revision No 11 Jp USER MANUAL NN ODS TRACK AUTOMATIC ACUSTER 2 4 i d in BO Figure 10 Base framework ODS TRACK 315 Always connect the electric connectors with the machine switched off The base framework Track Automatic installation is made by 1 Conn
93. s phase the moving body remains applying the programmed force onto the heating plate Ten seconds before the end of this phase the acoustic signal alerts the operator every second to withdraw the heating plate at the same time the moving body opens programmed according to PIPE RECORD for the concept related with PIPE RECORD please refer to SELECTION OF THE BUTT FUSION SYSTEM of the point 3 4 3 of this User Manual CAUTION Should the heating plate not be withdrawn within this time the moving body will close normally following the butt fusion cycle The display will show the following message HYDRAULIC BUTT FUSION MOTOR OVERCHARGE Press the ACCEPT key and reinitiate the butt fusion process from the beginning Edition April 2014 42 MODE OF USE Revision No 11 USER MANUAL di ODS TRACK AUTOMATIC ACUSTER 3 2 10 Fusion and cooling down cycle After the opening time has expired the moving body closes to start the programmed cycle BUTT FUSION TIME with force fusion force drag force The countdown time will be shown on the display along with the force exerted on the cycle and the joint length reduction This step is followed by the cycle COOLING TIME without force During this phase the moving body remains blocked and the clamps holding the pipe fittings must not be loosened until the cooling time is over This phase is omitted if ON option is selected from the TOOLS SETUP BUTT FUSION JOINTS REDUC
94. se framework 225 E electric drive Trimmer 225 Heating plate 225 DYNAMIC S 315 90 to 315 DYNAMIC S Control Box 1 2 2 Track Automatic machines 6 MODEL Track Twin S T160 Track Twin S T250 Track Twin S T315 Track Twin S T400 Track Twin S T500 Track Dynamic S T160 Track Dynamic S T250 Track Dynamic S T315 Track Dynamic S T400 Track Dynamic S T500 INTRODUCTION Base framework 315 G hydraulic drive Hydraulic station Trimmer 315 Heating plate 315 RANGE OF DIAMETERS 50 to 160 mm 63 to 250 mm 90 to 315 160 to 400 mm 250 to 500 mm 50 to 160 mm 63 to 250 mm 90 to 315 mm 160 to 400 mm 250 to 500 mm Edition April 2014 Revision No 11 i USER MANUAL d ODS TRACK AUTOMATIC ACUSTER 19 DESIGN SPECIFICATIONS The TWIN S and DYNAMIC S machines are designed according to the following Specifications 150 12176 1 Equipment for fusion jointing polyethylene systems Part 1 Butt fusion TWI N S DYNAMI C S 150 12176 2 Equipment for fusion jointing polyethylene systems Part 2 Electrofusion TWIN S 150 12176 3 Equipment for fusion jointing polyethylene systems Part 3 Operator s badge TWIN S DYNAMIC S 50 12176 4 Equipment for fusion jointing polyethylene systems Part 4 Traceability coding TWIN S DYNAMIC S e SO TR 13950 Plastic pipes and fittings automatic recognition of electrofusion systems TWI N S The TWI N S DYNAMI C S accepts all th
95. selectable the following screen will come on Place the cursor on the diameter to be DIAMETER SELECTION selected by means of the push buttons and Please see NOTE The information at the bottom of the screen is purely informative Press ACCEPT to validate command Press CANCEL to go back to the previous screen 200 ISO 25 C 210 C 232 Volt 50Hz 00001 In the example ISO block shown on the lower part of the screen corresponds to the selection previously done via CHANGE OF BLOCK of the SETUP BUTT FUSION JOINTS menu PE corresponds to the material selection done via CHANGE OF PIPE MATERIAL of the SETUP BUTT FUSION JOINTS menu or activating the material selection in each fusion via SETUP BUTT FUSION JOINTS menu depending on the unit s configuration Refer to BUTT FUSION SELECTION in Section 3 4 3 of this Manual Once the diameter has been selected the following screen will appear Place the cursor on the thickness to be THICKNESS SELECTION selected by means of the push buttons and f The information at the bottom of the screen is purely informative SDR11 ISO 55 SDR17 6 ISO 58 3 ISO d110 25 C 210 C 232 Volt 50Hz 00001 NOTE Originally the unit is programmed with PIPE RECORDS corresponding to diameters ranging from 63 to 500mm with different SDR depending on the diameter Using the option ON OFF PI PE RECORDS of the setup menu pipe sizes can be activated or deactivated
96. sh buttons Electric connectors 5a Connection to 24 Vdc trimmer 5b Connection to electric framework 5c Connection to hydraulic framework 5d Connection to 230 110 Vac trimmer 5e Connection to heating plate Ul UN rz Direct connection or through the Switch Box Refer to clause 2 7 Figure 8a TWIN S front side Edition April 2014 16 MACHINE DESCRIPTION Revision No 11 og USER MANUAL _ 7 ODS TRACK AUTOMATIC ACUSTER 2 2 3 Right side 2 2 4 2 2 5 the right side of the fusion control boxes looking at it from the front part the following elements are located 1 Master switch 2 Fuse holder with 16A to 230 Vac fuse Not used for 110 Vac 3 Mains cable with Schuko type plug or according to market requirements 4 Cable with room temperature sensor 5 Characteristics plate and CE Mark plate Figure 8b Plastic casing Metal casing Left side On the left side of the fusion control boxes looking at it from the front part the following elements are located 1 2 Electrofusion cables TWIN S with 4 mm terminals Serial connector RS 232 Round type for plastic and D Sub for metal casing connection to scanner PC and printer Connector USB A Metal casing Accessories bag Metal casing Figure 8c Plastic casing Metal casing Rear side On the rear side of the fusion control boxes the following elements are located 1 Cables holder
97. sor with the arrows and on the panel Press ACCEPT By pressing CANCEL we go back to the previous menu By selecting MENU we go to the MAIN MENU D DISPLACEMENT VERIFICATION If you select the first option DISPLACEMENT the following screen will appear By pressing the push buttons and DISPLACEMENT the moving body will open and close manually The lower part of the display RESET will show the displacement By pressing the moving body will be located on the fully close position while x AUTOMATIC the position counter is reset This option is used to check displacement controls OPEN CLOSE POSITIONING mm By pressing the moving body will start uninterrupted cycles of opening and closing in which the encoder reader can be seen Press CANCEL to exit this option and go back to the menu of test of ELECTRIC BUTT FUSION Edition April 2014 Revision No 11 TROUBLESHOOTING 79 4 i hy USER MANUAL ACUSTER ODS TRACK AUTOMATIC 2 VERIFICATION OF TRIMMER Selecting the second option TRIMMER from the menu ELECTRIC BUTT FUSION WARNING On ODS225E machines with 230 110 V trimmer refer to 4 2 3 Hydraulic butt fusion VERIFICATION OF TRIMMER First select PUSH BUTTON TEST Press TRIMMER both push buttons on the trimmer If the circuit is correct the OFF on the screen PUSH BUTTON TEST OFF changes to ON when pressing the trim mer will not start If you now select T
98. sponding data will be showed on screen Press CANCEL to go back to previous screen LOAD DATA Edition April 2014 86 TROUBLESHOOTING Revision No 11 4 USER MANUAL ly ODS TRACK AUTOMATIC GUPO ER CHAPTER 5 MAI NTENANCE 5 1 GENERAL 5 1 1 Introduction The ODS Track Automatic fusion machines have been designed and manufactured for a long life without the need for costly repairs and adjustments All that is required is careful handling when loading unloading and during transport and in general to keep the unit clean by following the recommended preventive maintenance The costs are very low and are soon written off given that the machine will be fully functional at all times This section includes a list of general upkeep and maintenance routine operations Should any problem arise please refer to CHAPTER 4 TROUBLESHOOTING in this User Manual However no action should be taken by unqualified personnel beyond these troubleshoot ing measures in order not to run the risk of seriously damaging the unit in particular the electronic control module WARNING All cleaning and maintenance operations and base framework heating plate trimmer and hydraulic station adjustments must be performed with the components disconnected from the unit 5 1 2 Storage If the unit is not to be used for a long period of time keep all the components in their respective boxes protected from dust moisture extremes of temperatures
99. stop the process The unit will be then ready to go back to the beginning of the trimming process Edition April 2014 44 MODE OF USE Revision No 11 USER MANUAL hy ODS TRACK AUTOMATIC ACUSTER NS 3 3 1 3 3 2 3 3 3 ELECTROFUSION PROCEDURE FOR FITTINGS TWIN S BOXES For units equip with BlueBox refer to the User Guide GU 78 09 I ntroduction The assembly jobs and the PE PP network electrofusion should always be carried out by specifically trained personnel and strictly following the manufacturer s instructions both for the fittings as well as the fusion equipment Scraping pipe surfaces First clean the surface to be scraped with a clean lint free dry cloth The length to be cleaned will depend on the size of the fitting to be used adding a minimum additional margin of 50 mm on each end Scrape the area of the pipe or pipes where the fitting to be joined will be installed The length of the scraping should be greater than that of the fitting IMPORTANT The scraping of the pipe should generate swarfs This ensures the elimination of the pipe s most exterior oxidation which would otherwise lead to a dissatisfactory electrofusion joint Next clean the scraped area with a de greasing towel or with a clean dry white cloth which does not shed lint dampened with isopropanol or recommended PE solvent Fitting installation For joints of tapping saddles and
100. tification In order to make optional again the operator s and or job order identification selecting OFF via the path TOOLS SETUP GENERAL OPERATOR ID 220 OFF JOB ORDER ID 240 OFF makes the operator and or job order identification optional the unit goes back to its previous setting that is the fusion unit will be able to carry out fusions with and without the operator and or job order identification in distinctively in the latter there will be no traceability of the job in process and his her operator this data will not be registered Edition April 2014 Revision No 11 MODE OF USE 31 4 7 7 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 2 4 Preparation of the pipes and the machine Once the operator order s identification or non identification has been carried out and after pressing ACCEPT on the screen IDENTIFICATION MENU the following message will come On By pressing and respectively the CLAMPING POSITION MENU manual opening and closing of the moving body s base framework is made Press the key POSITION to place the moving body in the right position to POSITION locate the pipes fittings on the clamps During this operation the flashing message POSITIONING will appear on CANCEL the lower part of the display POSITIONING Flashing IMPORTANT FOR ODS 225 E BASE FRAMEWORKS NEVER carry out the positioning operation with the pipes fittings mounted on the base framework clamps Th
101. tify the operator No and or job order No then the identification will be perceptive in order to access the programme of electrofusion OPERATOR IDENTIFICATION Operator identification is performed in accordance with ISO 12176 3 It can be carried out by means of Barcode system The operator will automatically be identified by inserting the corresponding identification via barcode system From this moment the identification will always be associated to the unit fusions made until 1 new identification is entered 2 Entering the same identification a second time ON OFF system 3 Change of date at zero hours or switching off the unit the identification will be deleted according to the unit s setup OFF on the first case and ON on the second from the path TOOLS SETUP GENERAL RESET OB 4 The use of the options ON or OFF on OPERATOR ID Z2 from the path TOOLS SETUP GENERAL REMARK The operator s identification foresees the automatic change of language according to the card or barcode entered Besides in the TWIN S units the language can also be selected via the path TOOLS SETUP GENERAL CHANGE OF LANGUAGE Please refer to SELECTION OF LANGUAGE of this Chapter Edition April 2014 48 MODE OF USE Revision No 11 Jf USER MANUAL ODS TRACK AUTOMATIC ACUSTER OB ORDER IDENTIFICATION The job order identification can be done by means of Barcode syst
102. tions the following screen will be displayed Use the arrows and to select the desired option Press ACCEPT and the printer process will start instantly in all options except in CHOOSE RANGE CANCEL will take you back to the ALL FUSIONS previous screen LAST FUSION FUSIONS OF THE DAY CHOOSE RANGE Should the printer not be connected have run out of paper or suffered any other eventuality the message PRINTER W O PAPER OR ERROR will appear on the screen e DELETION OF FUSION RECORDS The other two DELETE options of both FUSION RECORDS menus BUTT FUSION and ELECTROFUSION are used to rub off the storage of the existing records from the unit s internal memory The counter keeps track of the numbering NOTICE The deletion of the fusion records from the unit s memory has a restricted access Enter PASSWORD 2 access Refer to point 3 4 1 Access to restricted options of this CHAPTER Edition April 2014 Revision No 11 MODE OF USE 63 6 i USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 4 3 Unit s setup By selecting SETUP from the TOOLS menu you will access the menu Use the arrows and to select the desired option Press ACCEPT to access to the options of the selected menu CANCEL returns the user to the previous screen GENERAL BUTT FUSION JOINTS ELECTROFUSI ON GENERAL First screen Second screen GENERAL GENERAL CHANGE OF LANGUAGE TRACEABILITY On
103. trieval of fusion records exported through computer refer AcusWin User Guide If the exportation has been done through a memory stick the exported binary files dat can be added to the AcusWin database AcusWin version 5 4 9 or higher installed on the computer refer to AcusWin User Guide However if the software AcusWin is not installed on the computer or has a version lower than 5 4 9 the exported binary files dat can be converted to a csv format files from the web site www acuster com convert 1 Select the tab Add files dat 2 Browse and open the file or files where is or are copied 3 The file or files opened will be shown on the screen Click Start euro tan on fle hee been uploaded click 401KB aoa lt Cancel Start upload from the upper toolbar e Cancel upload deletes the file or FUBDOT dal 10 1 EL files uploaded 4 Click on the file on the example FUSOO1 dat the file will be downloaded in a CSV format file Comma Separated Values that can be open by any spreadsheet software like LibreOffice amp Microsoft Excel Google Docs 6 etc or imported from your own database Select Delete to remove the file or files downloaded 5 6 Exit the web site The upgrade of the software version can be done through the web site www acusterglobal com Downloads Other Documents Software Acuswin ODS Castellano gt PRINTING FUSION RECORDS If you
104. ult in death or serious injury Indicates a hazardous situation that if not avoided could result in 1 6 2 Safety measures and dangers Please go by the following safety measures Edition April 2014 Revision No 11 Keep the fusion control box out of the reach of non authorised personnel non qualified personnel and children Protect the control unit from water rain snow etc When transporting the machine and during loading and unloading operations the appropriate precautionary measures must be taken to ensure that all machine components are completely secured in the vehicle and that they are free from impact during transportation Protect the electrofusion cables electric connections to the base framework trimmer heating plate hydraulic pack and the cable that goes to the power supply from sharp objects All damaged cables must be replaced immediately by the After Sales Service of ACUSTER GLOBAL S L Always plug the control box to a power supply provided with differential and ground connection For hydraulically operated machines remember that a sudden hydraulic oil leak can cause serious or even a fatal injury if the pressure is high enough Do not expose the fusion control box to heavy weights slight damage caused to the external frame or to other elements will have to be replaced immediately by the After Sales Service of ACUSTER GLOBAL S L The fusion control boxes which are not being used must be kept out of
105. ult that may have occurred in the unit However and as a guide we enclose the checks that the operator could make to the unit through the MENU OF TEST 4 2 CHECKING OF THE UNIT MENU OF TEST To be able to check the performance of the different components of the unit select MENU OF TEST from the TOOLS menu NOTICE The selection of MENU OF TEST has a restricted access Enter PASSWORD 1 access Please refer to point 3 4 1 Access to restricted options of this User Manual Each one of these options allows us to MENU OF TEST carry out a test of the unit Select the desired option according to unit model from the first three by mov ing the cursor with the arrows and t on the panel and press ACCEPT ELECTRIC BUTT FUSION ELECTROFUSI ON HYDRAULIC BUTT FUSION TXXX By selecting CANCEL we go back to pre vious Menu SERVICE By selecting MENU we go back to the MAIN MENU The selection SERVI CE is restricted to the ACUSTER GLOBAL S L After Sales Service Edition April 2014 78 TROUBLESHOOTI NG Revision No 11 4 USER MANUAL ODS TRACK AUTOMATIC ACUSTER 4 2 1 Electric butt fusion TWIN S DYNAMIC S BOXES Select ELECTRIC BUTT FUSION from the MENU OF TEST The following options will appear on the screen First screen Second screen MENU OF TEST MENU OF TEST DISPLACEMENT READER SYSTEM TRIMMER TEMPERATURES BUZZER PUSH BUTTONS More Select the desired option by moving the cur
106. usion jointing process or CANCEL to return to the previous point Edition April 2014 Revision No 11 MODE OF USE 51 77 USER MANUAL ACUSTER ODS TRACK AUTOMATIC 3 3 8 Preparation of the electrofusion Having optionally executed the operator job identification operation and that of traceability and auxiliary number if enabled the following message will appear Connect the unit electrofusion cable FITTING DATA terminals into the fitting s connectors to be jointed The contact surfaces of both the fitting s connectors and cables terminal must always be clean FUSION DATA 20 231Volt 50Hz N 00001 NOTE We advise you to always use electrofusion adaptors even though the connection to the fitting may be possible directly Doing so the cable terminals are protected they do not wear out burn etc Enter the fitting s electrofusion data via the bar code system In the case to be active the manual option MANUAL would appear beside the central push button BAR CODE SYSTEM If you read the fitting s data by using optical means optic pen or scanner connect the reader device into the corresponding connector and slide it barcode reader or put it in front of the fitting s bar code scanner WARNING Make sure you always read the bar code corresponding to the fitting to be electrofused Should you not record the fitting s data this could cause into errors in the electrofusion process that would have
107. wish to have a hardcopy of the fusions carried out you can print the records by connecting e serial printer into the serial connector by means the serial transmission cable Printer setup for the first time Before using the serial printer on the electrofusion unit be sure that the printer s Switches are correctly selected The setup for a printer Citizen model CT S280 is the following The generic setup for an appropriate data print out on other printer s brands and models is Edition April 2014 MODE OF USE Revision No 11 USER MANUAL ur ODS TRACK AUTOMATIC ACUSTER XON XOFF 8 bits Parity NONE 19200 Bauds l Stop bit Printing Once this connection has been made start the Unit and the printer it is not necessary for the Electronic Control Module to have all the elements connected heating plate trimmer base framework CAUTION Do not connect or disconnect the printer cable connector when the unit is running The CPU printer communication component could be damaged To continue with the available options on the screen FUSION RECORDS the third option corresponds to BUTT RECORDS TO PRINTER and PRINT ELECTROFUSI ON depending on the model and selection made Both printing options are of free access and allow us having been previously connected to a standard parallel printer to print the fusion records in different ways If you press ACCEPT on either of the two printing op
108. y barcode or keyboard introduction Press ACCEPT both if the identification ORDER No has or has not been made OPERATOR No INSERT DATA If the unit has the obligation to identify the operator No and or job order No then the identification will be perceptive in order to access the programme of the butt fusion OPERATOR IDENTIFICATION Operator identification is performed in accordance with ISO 12176 3 It can be carried out by means of Barcode system The operator will automatically be identified by inserting the corresponding identification via barcode system From this moment the identification will always be associated to the unit fusions made until 1 new identification is entered 2 Entering the same identification second time ON OFF system 3 Change of date at zero hours or switching off the unit the identification will be deleted according to the unit s setup OFF on the first case and on the second from the path TOOLS SETUP GENERAL RESET OB 4 The use of the options ON or OFF on OPERATOR ID 720 from the path TOOLS SETUP GENERAL REMARK The operator s identification foresees the automatic change of language according to the barcode entered Besides in the TWIN S and DYNAMIC S units the language can also be selected via the path TOOLS SETUP GENERAL CHANGE OF LANGUAGE Please refer to SELECTION OF LANGUAGE of this Chapter Edition April

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MU-78-04 ODS & Track Automatic