620SC Butt Fusion System
Contents
1. be aware that potentially dangerous lateral and horizontal forces could exist within a length of pipe and should take precautions to guard against these forces Do not wear loose clothing jewelry or long loose hair near operating machinery Recommended Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 6 ad Kaka safety apparel includes gloves safety glasses safety shoes and hat or hair net Warnings and Cautions The purpose of Warnings and Cautions in this manual is to call the operator s attention to the possible danger of injury to personnel and dam age to equipment The hazard alert sign above appears in this manual When you see this sign carefully read what it says YOUR SAFETY IS AT STAKE Warning Indicates a potentially hazardous situa tion which if not avoided could result in death or serious injury and or damage to equipment Caution Indicates a potentially hazardous situa tion which if not avoided may result in personal injury and damage to equipment It may also be used to alert against unsafe practices Machine Operation Safety AN Warning Do not operate heater in the presence of a combustible atmosphere or in damp or wet conditions In this case heater should be brought to desired temperature then unplugged before taken into areas with a com bustible atmosphe2. Proper heating temperature is important in mak ing a good fusion joint The thermometer built into the heater tool indicates internal temperature and should be used only for reference To assure the pipe manufacturer s temperature specifications are met it is recommended that the surface tem perature of the heater be measured prior to initial use and at reasonable intervals thereafter A hand held surface pyrometer Connectra part number 28 8554 1200 10 can be used for mea suring this temperature Several areas should be checked to ensure even heat distribution Use the pyrometer to check temperature in the center and at several points around the edges Do not use temperature crayons Each reading should be 10 of each other Adjust temperature dial on control box as neces sary to obtain required surface temperature A N Caution Do not adjust heater above 550 F This may result in damage to heater com ponents and cause deterioration of non stick surface coating on face of the heater which can result in contaminated fusion joints Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 8 CONNECTRA Install correct liners as required when pipe smaller than 20 IPS is to be fused Place the liners into the clamp and insert the clevis pin to secure to the clamp or master liner L
3. fac ing pressure 5 Heating Pressure Knob Used to set desired heating pressure 6 Fusion Pressure Knob Used to set desired fus ing pressure 7 Facer Motor Control This lever is used to oper ate the facer 8 Directional Control Lever Used to move the moveable carriage Movement to the left brings the stationary and moveable clamps together Movement to the right separates the clamps 9 Carriage Pressure Gauge Indicates pressure in the function selected by the Function Selector Switch 3 10 System Pressure Gauge This gauge indicates system operating pressure 11 Carriage Speed Control This control is used to set the high speed or low speed necessary to join different brands of pipe Power Unit Controls Before starting the power unit the operator should be familiar with the HONDA engine operator s manual which contains details of operating and maintaining the engine Clamp Liners The clamp liners are sized to hold 20 IPS pipe Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 5 CONNECTRA For smaller pipe a combination of clamp liners are used They are held in place with the insertion of a clevis pin The 18 IPS liner must be inserted as a base for smaller sizes to 12 before installing appropriate liners Separation from the Cart Extension hyd
4. 0SC Butt Fusion System down by turning the facing pressure knob clock wise or counterclockwise to achieve a continuous facing ribbon Use no more pressure than the minimal amount required to produce this ribbon Facing is complete when the carriage and station ary clamp come into contact with the facer stops located on the guide rails Turn off the facer Do not open until facer stops rotating Then raise the facer clear of the pipe Pipe Fitting Alignment Remove all shavings and inspect the pipe ends to see that they are completely faced and free of chips or shavings Bring the pipe ends together and verify that alignment and squareness meet the pipe manufacturer s recommendations Note Do not touch faced surface of the pipe or fittings These surfaces must be kept free of dirt water body oil and other contaminants which may cause defects in the fusion It is important to remove all shavings from pipe ends and machine base Accumulated shavings can cause difficulty in proper operation of the unit and result in a faulty fusion of pipe Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 11 CONNECTRA If necessary repeat the facing operation and or adjust the pipe in the fusion jig until alignment meets the pipe manufacturers recommenda tions Check pipe alignment by closing t
5. 620SC Butt Fusion System Operator s Manual CONNECTRA equipment Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 620SC Butt Fusion System CON ECT RA Operator s Manual Table of Contents Description VE 3 Establish Dag sscsadsicsstasserasncadinseantticsssnendtactes 10 Features eet 3 Facing the Pipe a cescesssscocssessseatveanaseavdensssone 11 Specifications secssscssssscssssaiessesesdeacessseentendotarenselave 4 Pipe Fitting Alignment ssesccsssssecessees 11 Equipment Precautions reen 5 FUSING the Dipen 12 CONTO ee 5 Removing Pipe ssssssssssssessessesesisssssssssossnsesss 14 Power Unit Control 5 In the Ditch Pipe FUSION ssssssssssessssssssss 14 9 luet E 5 Mitered FuSIOnS EEN 14 Separation from the Cart wesc 6 Maintenance ENEE 14 Safety Precautions cccssssssessssssssssesusssesse 6 Guide Rods and Clamps en 14 Warnings amp Cautions sracctecsetecrceactestessicanacses 7 Hydraulic System E 15 Machine Operation Safety sscccsseeen 7 Facer Assembly sssssssesssesrsssessssesrsssssseseeressss 15 Operating Procedures EE 8 Heater Assembly s ssssssesrssessssssseresesrssessssesses 15 Preparation E 8 Power Unit Engine sssssessssssssesssrssessssseeessss 16 Load Pipe or Fittings neen 9 Replacement Acc Parts List e 17 Hydraulic Flow Pressure wesssssssssssssssssseee 9 FUSION Pressu
6. NTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE WHICH ARE EXPRESSLY DIS CLAIMED SELLER NEITHER ASSUMES NOR AUTHORIZES ANY OTHER PERSON TO MODIFY THESE TERMS AND CONDITIONS WARRANT SPE CIFIC APPLICATIONS OR ASSUME FOR SELLER ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ANY SELLER S PRODUCT OTHER THAN AS PROVIDED IN THIS WARRANTY Recommendations Any recommendations and suggestions provid ed by Seller concerning its products and the use thereof are based on tests and data believed to be reliable but are not intended to be com plete or exhaustive The user is responsible for determining the appli cability of governmental regulations relating to the use of the products and for all other aspects of the use of Seller s products Actual use of the products by others is beyond the control of Seller and Seller makes no warranty or other agreement expressed or implied regarding any aspect of such use Seller shall have no liability arising from the use of Seller s products by a third party Modifications Seller may improve or otherwise modify its products without any obligation to improve or otherwise modify in any way any products including any parts or accessories previously sold by Seller Distributors Seller s products are sold through authorized distribu tors who determine the price terms and conditions of sale Othe
7. SHIPPING i S SIZE WR Heater 4 000 16 7 S j S 17 0 With the use of optional reducing liners ke 65 0 MAX _ Specifications are subject to change without notice Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 4 CONNECTRA Equipment Information Controls The control box mounts on the cart It contains the on off switch and temperature control knob for the heater Voltage readout is provided for the heater The hour meter logs time in service Three power cords coming off the control box supply power for the heater system and hydraulic oil cooler plus re ceives power from the generator The numbering below corresponds to the number ing as shown on the hydraulic manifold 1 Operating Knob Turn to the set drag po sition when determining pressure required to overcome pipe drag Return to oper ate when ready to begin fusion operations 2 Drag Control Knob With Operate Knob 1 turned to set drag this knob is turned clockwise to compensate for drag caused by weight of pipe or other operating conditions 3 Function Selector Switch Used to select the functions of facing heating and fusion for the purposes of setting desired working pressures Operator s Manual 620SC Butt Fusion System 4 Facing Pressure Knob Used to set desired
8. and could result in an inferior fusion The melt can be pushed to the OD and out of the ID of the fusion bead creating a possible cold joint in the center sec tion of the fusion e Under pressuring the fusion joint could result in an inferior fusion due to insuf ficient interfacial contact in the melt area Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 13 CONNECTRA e Extreme care should be exercised to maintain pressure during the fusion operation even if bead exceeds desired width Reversing pressure can cause porosity in the fused area Maintain specified pressure until pipe cools Do not adjust controls until cooling time has elapsed Note Should power pressure be lost during the cooling period the fusion should be cut out and redone Move the directional control lever to the center po sition to release pressure Remove Pipe Note It is best not to test stress pull or rough handle newly fused pipe until the minimum cool ing time specified by the manufacturer has been reached Position facer heater assembly between sliding clamps to minimize potential damage to equip ment Open clamps Use the operating handle on both ends to raise pipe lifters under pipe This raises the pipe out of the clamp area permitting the pipe to be pulled out or the fusion machine to
9. anufacturer and or the owner of the pipeline Due to the variability of applications and service conditions no warranty expressed or implied is given in conjunction with the use of this data Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 18 CON EC H RA Operator s Manual 620SC Butt Fusion System CONNECTRA FUSION BUTT FUSION GAUGE PRESSURES 620SC MACHINE 7 854 sq in CECA DIPS PIPE ONLY pes Jop CT frf CT T o Nominal Actual 70 73 90 93 11 0 115 135 155 170 210 260 32 5 6 000 6 900 175 169 141 137 na mat os 86 79 el 53 a Interfacial Pressure 75 Combined Effective Cylinder Area 7 854 You must also add drag pressure This is the hydraulic pressure required to move the carriage while holding the pipe and is easily overlooked If two long pieces of pipe are being fused the drag factor can reach several hundred pounds This data is provided as a guide only and is believed to be accurate and reliable However the user should always use the recommendations and procedures of the pipe manufacturer and or the owner of the pipeline Due to the variability of applications and service conditions no warranty expressed or implied is given in conjunction with the use of this data Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Addre
10. be pulled along under the pipe In the Ditch Pipe Fusion If working in tight quarters such as a ditch the facer can be removed and the top clamps can be removed by pulling a pin in each Operator s Manual 620SC Butt Fusion System The off center handle of the machine cart permits pulling the cart fusion machine along under fused pipe Lower the clamps facer and heater with shroud before transporting machine Mitered Fusions Using special liner sizes mitered fusions can be made Pipe ends are faced at 11 25 Mitered clamp liners are accessory items Instruc tions for use accompany the liners Contact the factory for more information Maintenance Keeping the 620SC Butt Fusion System clean and lubricated is the most important part of field main tenance Mechanical linkages must operate free ly for the unit to work properly Keep mechanical linkages lightly lubricated at all times Guide Rods and Clamps Guide Rods are lubricated by the hydraulic sys tem The facer and heater pivot rod is lubricated at the factory and should not need any additional lubrication Keep guide rods clean and free from contaminants Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 14 CONNECTRA Hydraulic System Inspect the hydraulic hoses periodically for leaks or wear marks Chan
11. ctrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 7 CONNECTRA AN Caution Make sure the directional control lever is in the neutral or centered position before engine start up If hydraulics are engaged carriage could move unexpectedly and damage the heater shroud or result in personal injury Service the HONDA gasoline engine according to manufacturer s recommendations Refer to the HONDA Engine Owner s Manual Start engine Allow engine to run a few minutes to warm up before beginning the facing and fusing operation h Caution Engine speed has been set at the factory Do not change Damage to alterna tor and other equipment could result Operating Procedures Preparation Move the unit into position Make sure it is as level as possible Exceeding a 20 tilt will affect engine performance and possibly cause damage Set the brake on the right rear wheel Connect heater to receptacle on the back of the machine Permit sufficient preheating time to stabilize temperature reading on heater thermom eter This thermometer will indicate approximate surface temperature of the heater plates Set temperature recommended by the pipe manu facturer on the control dial Ah Caution Use on AC power source only If Operator s Manual 620SC Butt Fusion System used on direct current DC power the heater con troller of the heater tool will be damaged
12. er face clean with a cotton cloth Do not use polyester material It will stick to the sur face and damage the coating Should the heater plates become scratched or oth erwise marred remove them and return them to the factory for re coating They can be removed by removing the handle attachment and the butt plate screws around the perimeter Should the heater fail to heat properly it must be returned to the factory for repairs Check the heater electrical cable for wear Re place as needed if insulation is worn Some causes of heater plate malfunction include e Improper power source e Extension cord s too long e Extension cord s of inadequate load size e Generator running too slowly Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 15 CON EC i RA Operator s Manual 620SC Butt Fusion System Power Unit Engine The engine manufacturer s service manual pro vides instructions on care and maintenance of the power unit engine The operator should read this manual carefully before operating servicing or repairing the engine Check engine oil level in the crankcase before op erating and every two to three hours during use Follow manufacturer s recommendation of engine oil to use Use a good quality gasoline Change engine fuel air and oil filters as recom mended by manu
13. facturer s maintenance manual Follow engine manual recommendations for air fil ter replacement AN Caution Improper air filter installation can cause engine to ingest excessive dirt into engine and will void the warranty Cart Assembly Check air in tires periodically and maintain at 14 psi Lubricate wheel fittings periodically Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 16 CONNECTRA 620SC Bute Fusion System Replacement Accessory Parts Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 17 CON ECTRA Operator s Manual 620SC Butt Fusion System CONNECTRA FUSION BUTT FUSION GAUGE PRESSURES 620SC MACHINE 7 854 sq in CECA IPS PIPE ONLY IPS es_ Actual 273 9 720 1469 Interfacial Pressure 75 Combined Effective Cylinder Area 7 854 You must also add drag pressure This is the hydraulic pressure required to move the carriage while holding the pipe and is easily overlooked If two long pieces of pipe are being fused the drag factor can reach several hundred pounds This data is provided as a guide only and is believed to be accurate and reliable However the user should always use the recommendations and procedures of the pipe m
14. ge the hydraulic fluid and filter every 6 months or after each 500 operating hours whichever comes first Operation in an extremely dusty envi ronment necessitates more frequent changes When the hydraulic system requires changing drain as follows e Remove the drain plug on the bottom of the reservoir and dispose of the fluid properly e Replace the drain plug e Pill the reservoir with clean fluid and re place filter Use Chevron Rykon premium ISO68 hydraulic fluid approximately seven 7 gallons Note The oil is drained from any unit transport ed overseas due to shipping regulations Facer Assembly Keep hydraulic connections clean to avoid contam ination especially when hoses are disconnected Slow facing operation and rough pipe ends indi cate dull blades Replace dull blades Inspect facer blades regularly and replace as necessary Make sure power is disconnected when replacing facer blades When changing blades make sure blade slots are free of dirt and foreign material to Operator s Manual 620SC Butt Fusion System ensure proper blade seating AN Warning Facer blades are sharp and can cause a severe cut Handle blade and cutting head with great care Heater Assembly Read these instructions before performing any maintenance on the 620SC heater assembly Only a qualified technician should perform tool repair to ensure work is done in accordance with approved electrical standards Keep the heat
15. he clamps to bring the pipe ends together Carefully check pipe alignment and the fit of the faced surfaces This can be done by running a straight edge across the seam to determine if one edge is raised above the other e If one pipe end is slightly higher than the other lower it to the aligned posi tion by tightening the hold down clamp on that section of pipe Do not loosen hold down clamps to obtain alignment e If misalignment is side to side slight rotation of the shorter section will help bring them into alignment e When joining coiled pipe it may be necessary to rotate each end of pipe to make an S or U shape and re clamp the pipe to provide acceptable align ment Re face pipe ends If any of the above adjustments are necessary the facing operation must be repeated Bring pipe ends together applying force equal to or greater than the fusion force to be used Make sure the pipe does not slip When satisfactory alignment has been achieved separate the clamp assemblies to make room for insertion of the heater Operator s Manual 620SC Butt Fusion System Fusing the Pipe Recheck heater for proper temperature recom mended by pipe manufacturer Use surface py rometer to check temperature of heater face sur face If pyrometer indicates that temperature is not as recommended refer to instructions for set ting temperature before proceeding NOTE The heater is coated with a non stick sur face to mi
16. hout recourse any warranty on the Excluded Items which is provided by manufacturer thereof The warranty provided hereby does not apply to any product or component that has been repaired or altered by anyone other than Seller and does not cover any failure of the Products which Seller determines to have been caused due to abuse misuse negligence or normal wear and tear As a condition to the buyer s exercise of its rights under this warranty the Products must be returned to Seller s dock freight prepaid in Shaw nee Oklahoma within ten 10 days of the date of failure accompanied by a Return Goods Authorization available from Seller and information related to the claim Buyer s REMEDIES UNDER THIS WARRANTY ARE LIMITED to at Seller s sole option the replacement or repair of the Prod ucts determined by Seller to be defective or a refund of the purchase price less an allowance for services rendered by the Product prior to the warranty claim IN NO EVENT SHALL SELLER BE LIABLE FOR LOSS OF USE DAMAGE TO OR LOSS OF PRODUCTS OR SERVICES FAILURE TO REALIZE EXPECTED SAVINGS FRUSTRATION OF ECONOMIC OR BUSI NESS EXPECTATIONS LOST REVENUE OR PROFITS OR FOR ANY OTHER SPECIAL INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES EVEN IF THEY WERE FORESEEABLE OR SELLER WAS INFORMED OF THEIR PO TENTIAL Products repaired or replaced pursuant to this warranty will be delivered to buyer FOB Seller s dock in Shawnee Oklahoma THIS WARRA
17. iners are stamped upper and lower on the side Inspect facer blades for nicks scratches etc that might affect facing Replace if necessary Dis connect unit from power source before replacing blades When replacing facer blades make sure blade slots are free of dirt and foreign material so that the blades will seat properly AN Caution Facer blades are extremely sharp Load Pipe or Fittings Turn on off switch on the control box to the on position Move the directional control lever to the right to open the carriage assemblies P aS a Open all of the hold down clamps Load pipe in the stationary clamps Extend pipe past inside edge of clamp Tighten pipe using out er clamp A ratchet wrench is provided to aid in Operator s Manual 620SC Butt Fusion System tightening Tighten inner clamp hand tight Load pipe in moveable carriage clamps Extend pipe past inside edge of clamp In order to mini mize any ovality problems it is recommended that the two pipe sections be installed with the line up markings aligned Tighten pipe using outer clamp Tighten inner clamp hand tight Place the other two pipe ends on suitable pipe supports Hydraulic Flow Pressure The pressure gauge reading is affected by oil flow through the system Normally without the facer motor running the pumpis in a low flow condition which has a minimal effect on the pressure set tings in the system When the facer moto
18. ned Effective Cylinder Area 7 854 You must also add drag pressure This is the hydraulic pressure required to move the carriage while holding the pipe and is easily overlooked If two long pieces of pipe are being fused the drag factor can reach several hundred pounds This data is provided as a guide only and is believed to be accurate and reliable However the user should always use the recommendations and procedures of the pipe manufacturer and or the owner of the pipeline Due to the variability of applications and service conditions no warranty expressed or implied is given in conjunction with the use of this data Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 21 CONNECTRA Operator s Manual 620SC Butt Fusion System Statement of Warranty Warranty Disclaimers Georg Fischer Central Plastics LLC Seller war rants for a period of three 3 years from the date of invoice that the products sold under the order invoiced the Products will be free from defects in materials and workmanship except for items supplied to Sell er by other vendors in connection with the order The items to which the warranty does not extend the Excluded Items include without limitation electrical devices pumps controls and similar items Seller assigns to the buyer of the Products wit
19. nimize sticking and contamination of the molten plastic This coating should be wiped clean before fusing each joint using a clean soft rag Set the function selector switch to Fusing Place the heater in position between two pipe ends Move the directional control lever to bring the pipe ends against the heater Observe pipe ends Once the melt pattern begins to occur move the function selector switch to the Heating position then return the directional con trol lever to the center position The 620SC comes with a carriage speed control knob located on the left side of the manifold It can be used to adjust carriage speed depending on fusion conditions When the melt area conforms to what the pipe manufacturer recommends move the function selector switch to the Fusing position Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 12 CONNECTRA Note As pipe ends reach proper temperature a melt bead will form where the pipe ends contact the heater The size of the bead is often re ferred to by pipe manufacturers to determine if proper melt has been reached Move the directional control valve to the right to open the clamp assemblies The heater will tend to stick to one of the pipe fac es Grasp the heater handle and give it a sharp lat eral movement to
20. or the 620SC is 7 854 in Drag Factor Hydraulic fusion pressure required to move the carriage holding the pipe 30 psi is generally accepted as a minimum To find wall thickness To find ID WT OD ID OD WTx2 SDR To find carriage hydraulic gauge pressure psi Hydraulic Gauge Pressure OD ID2 x 7854 x IP_ Drag Factor PA The drag factor is an important parameter eas Operator s Manual 620SC Butt Fusion System ily overlooked If two long pieces of pipe are be ing fused the drag factor can easily reach several hundred psi Note This data is provided as a guide only and is believed to be accurate and reliable However the user should always use the recommendations and procedures of the pipe manufacturer and or the owner of the pipeline Due to the variability of applications and service conditions no war ranty or guarantee expressed or implied is giv en in conjunction with the use of this data Setting Heating Pressure Set the function selector switch to Heating Turn the heating pressure knob all the way coun terclockwise Setting Facing Pressure Set the function selector switch to Facing Turn the facing pressure knob clockwise to set about 50 100psi indication on the carriage pres sure gauge This may vary depending on pipe di ameter and SDR Establish Drag Set the operating knob to Set Drag With the directional control lever held to the left turn
21. ots out of the way Narrow lightweight facer with quick discon nect design Accommodates 6 through 20 IPS and 160mm through 500mm pipe sizes Dual hydraulic pipe lifters Modular design cart with locking wheel comes standard and delivers excellent field maneu verability Protected consolidated hydraulic controls with pressure adjustments Ported for DataConnect or other competitive data recorders Rugged design with no bells and whistles means less maintenance expense A superior piece of equipment at an extraordi nary price Limited three year warranty Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 3 CONNECTRA Sparta 620SC Butt Fusion System em em L d ANnITnmant GOUD Ju Specifications Carriage Unit Dimensions three clamp Length 45 62 inches 1 159 mm Width 48 39 inches 1 229 mm Height 33 75 inches 857 mm 120 4 SHIPPING SIZE Weight 766 pounds 347 5 kg Carriage Mounted on Frame Length 122 40 inches 3 109 mm Width 61 50 inches 1 562 mm Height 50 75 inches 1 289 mm Total Weight all components 2 500 pounds 1 133 9 kg Capacities Model 620SC 6 IPS thru 20 IPS Model 620SC 500mm 160mm thru 500mm Electrical data 70 9 MAX gt 240 VAC Single Phase Watts Amps 50 7
22. r No partial invalidity of this agreement shall affect the remainder This agreement shall be governed and construed in accordance with the laws of Oklahoma excluding its laws relating to conflicts of law The sole purpose of the exclusive remedy contained in the limited War ranty shall be to provide repair or replacement of failed products or to refund the purchase price of the failed product as explained above This exclusive remedy shall not be deemed to have failed of its essen tial purpose so long as Seller agrees to repair or replace the failed product or to refund the purchase price as explained above Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 22 CONNECTRA EES i 620SC Butt Fusion System l equipmel Notes Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 23 CONNECTRA Fusion Syste 620SC Butt Fusion System H equipmel Notes Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 24
23. r is run ning there is a higher flow rate in the system and a corresponding increase in return line pressure can be seen in the carriage pressure gauge It is important to set the following pressures with the factor motor not running During facing op erations there will be an increase in the carriage pressure due to the higher flows in the system Carriage force is not affected since the increase in pressure is applied on both sides of the hydraulic cylinder Setting Fusion Pressure Set the operating knob to Operate Turn the drag control knob all the way counter clockwise Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 9 CONNECTRA Set the function selector switch to Fusing Refer to pipe manufacturer s specifications for proper interfacial pressure necessary to fuse the pipe The fusion pressure chart provided with this manual is designed to compute the appropriate pressure settings for the 620SC Butt Fusion Sys tem Another method to calculate proper gauge pres sure is to use the following formula Where OD Outside diameter actual pipe diameter ID Inside diameter SDR Standard dimensional ratio WT Wall thickness IP Interfacial Pressure use pipe manufactur er s recommendation PA Combined effective piston area in for both cylinders PA f
24. raulic hoses make possible separa tion of the joining assembly from the cart if it has to be moved into the ditch e If desired the facer can be removed from the joining assembly by discon necting the hydraulic hoses and re moving the two hex bolts at the facer base a d e By removal of three bolts on each side of the joining assembly base it can be removed from the cart e If space restrictions in the ditch require the joining assembly can be made smaller by removal of the end station ary clamp Five bolts are removed from each side Removal of this clamp also makes possible fusing a section of pipe to a side outlet which has already Operator s Manual 620SC Butt Fusion System been saddle fused to another section of pipe Safety Precautions Read this manual carefully before attempting to operate this machine Working with extreme tem peratures and sharp facer blades can be danger ous if proper procedures are not followed Know proper fusion techniques Recommendations of pipe manufacturers regarding fusion tempera tures pressure and techniques must be known to ensure proper fusion joints Only responsible qualified trained personnel should operate this equipment Operating per sonnel should be familiar with the equipment its functions its potential hazards and proper pre cautionary measures To prevent tip over the fusion machine must be in a stable position The equipment operator should
25. re Heating plate temperature reaches 450 F 232 C Use caution when handling the plate to avoid burns Gloves are recommended This heat er is not explosion proof Be careful not to scratch the non stick coating on heater plates d e Operator s Manual 620SC Butt Fusion System Keep away from facing tool blades while equip ment is in operation and during positioning and retracting the facing tool Note Machine should be covered when used in inclement weather Do not force machine It will work better if operat ed within design limits Apply only slight pressure when facing Excessive pressure could damage equipment Maintain machine in top condition Use sharp facer blades and keep machine clean for best and safest performance Follow lubrica tion instructions contained in this manual Before moving unit secure the clamps and latch facer in the down position If facer is not properly latched damage to machine and or personal in jury could result Torque generated by the turning of the facer motor may cause it to move unexpect edly if not latched Secure heater carrier AN Warning Make sure facer is latched be fore turning on motor If not it may jump unex pectedly when turned on and could cause per sonal injury and or damage to the equipment Make sure all hydraulic hoses and electrical cords are connected Check hydraulic fluid level Toll Free 800 654 3872 Fax 800 733 5993 Website www conne
26. re Charts 18 Setting FUSION Pressure vassssssssssssssesssssen 9 Statement of Warranty Een 22 Setting Heating Pressure scccssssseccssees 10 Klek 23 Setting Facing Pressure sssscsscessseee 10 Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 2 Operator s Manual 620SC Butt Fusion System CONNECTRA equipment Description Features The purpose of this manual is to provide operating and maintenance instructions for the 620SC Butt Fusion System The 620SC Butt Fusion System fuses polyethylene pipe quickly and accurately The 620SC Butt Fusion System uses centerline applied fusion force to butt fuse 6 IPS through 20 IPS polyethylene pipe The machine also fuses metric pipe sizes from 160mm through 500mm Clamping jaws are sized for 20 IPS pipe Easily insertable liners are used for pipe sizes down to 6 and 160mm Clamp liners are available for 11 25 mitered fusions permitting fabrication of a 90 elbow in 6 through 18 IPS pipe sizes Copy information listed on your Warranty Card for your records Model No Serial No Date Received Distributor Fully powered self contained 20HP gasoline engine drives the hydraulic pump and electric generator Three and four clamp in ditch capabilities One heater for all pipe sizes that easily piv
27. ss 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 19 CON EC H RA Operator s Manual 620SC Butt Fusion System CONNECTRA FUSION BUTT FUSION GAUGE PRESSURES 620SC MACHINE 7 854 sq in CECA IPS PIPE ONLY 576 1175 Interfacial Pressure 60 Combined Effective Cylinder Area 7 854 You must also add drag pressure This is the hydraulic pressure required to move the carriage while holding the pipe and is easily overlooked If two long pieces of pipe are being fused the drag factor can reach several hundred pounds This data is provided as a guide only and is believed to be accurate and reliable However the user should always use the recommendations and procedures of the pipe manufacturer and or the owner of the pipeline Due to the variability of applications and service conditions no warranty expressed or implied is given in conjunction with the use of this data Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 20 CON EC i RA Operator s Manual 620SC Butt Fusion System CONNECTRA FUSION BUTT FUSION GAUGE PRESSURES 620SC MACHINE 7 854 sq in CECA DIPS PIPE ONLY ops Jors isr 1 Nominal Actual 7 0 7 3 9 0 140 1 889 85 18 00 19 500 1117 107 505 414 337 272 Interfacial Pressure 60 Combi
28. the Drag Control Knob clockwise until car riage starts to move toward facer and overcome any drag due to pipe or other operating condition Toll Free 800 654 3872 Fax 800 733 5993 Website www connectrafusion com Address 39605 Independence Shawnee OK 74801 USA Georg Fischer Central Plastics LLC Revised 4 2011 10 CONNECTRA Ime Return the operating knob to the Operate posi tion Drag pressure will now be automatically added to fusing heating and facing functions Except for drag these settings will not require change as long as the same type SDR and size of pipe are being fused Drag may have to be re set or at least checked depending on changes in length of pipe in carriage or other field conditions Facing the Pipe Clean the pipe ends making sure they are free of foreign material Inspect facer blades for sharp ness Replace if necessary When replacing blades make sure facer plates are free of dirt and foreign material so that the blades will seat properly Caution Facer blades are extremely sharp Handle with care when replacing Lower the facer into facing position Make sure it locks in position Set the function selector switch to the Facing po sition Pull the facer motor control toward you to operate facer Move the directional control lever to the left to bring the pipe ends to the facer As the pipe faces adjust facing pressure up or Operator s Manual 62
29. the left or right to dislodge the heater from the pipe Raise the heater into its shroud ma D Ze Ah Caution Heater tool is extremely hot and will burn exposed skin and damage clothing AN Caution It is important to turn off the heater before shutting down the engine If the engine is shut down with the heater on it could cause the capacitor on the generator to burn out or explode Operator s Manual 620SC Butt Fusion System Quickly inspect pipe ends to ensure melt is uni form If melt is not uniform and does not meet pipe manufacturer s recommendations the pipe must be re faced repeating at the facing operation Move the directional control lever to the left to close the carriage assemblies and to bring melted pipe ends into contact forming a double rollback bead as specified by pipe manufacturer Check carriage pressure gauge to make sure fu sion pressure meets manufacturer s require ments If it does not meet manufacturer s require ments the fusion will have to be cut out and a new fusion made AN Caution Let heater cool in its protective shroud Do not submerge into water for cooling Internal components will be damaged Note The exact amount of pressure to apply dur ing fusion is determined by following pipe man ufacturer s recommended procedures Check pipe manufacturer s literature to determine how the bead should appear e Over pressuring the fusion joint will cause the bead to be too large
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