bfm superweld operating instructions...if the pipe options displayed is not correct for the pipe to...

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OPERATING INSTRUCTIONS

FOR

HY-RAM SuperweldSuperweldSuperweldSuperweld FULLY AUTOMATIC BUTT FUSION

EQUIPMENT

1. Machine to be operated by trained personnel.

2. Instructions to be read before use.

Hy-Ram Mansfield Pelham Street Mansfield Nottinghamshire NG18 2EY Tel: 01623 422982 Fax: 01623 661022

Hy-Ram Bury 9 Portland Industrial Estate Portland Street Bury Lancashire BL9 6EY Tel: 0161 7641721 Fax: 0161 7620577

Hy-Ram Enfield Unit 2, Riverwalk Business Park Riverwalk Road Enfield EN3 7QN Tel: 0208 805 8010 Fax: 0208 805 6010

Hy-Ram Livingston 18 Napier Square Houstoun Road Trading Estate Livingston West Lothian EH54 5DG TEL: 01506 440233 Fax: 01506 440266

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CONTENTS How to change the settings and enter the parameters

Machine Components Basic Machine Component Ancillary Machine Components Machine Connections Hotplate Connection Trimmer Connection Chassis Connection Basic Machine Operation Manual Opening / Closing of Machine Automatic Cycle: Supervisor Mode/Set up Instructions Introduction to the Supervisor / Set up Mode Accessing the Supervisor Mode Automatic Cycle; Supervisor Mode / Set up Flow Chart Introduction to the Automatic Controls Accessing the Automatic Jointing Cycle Automatic Cycle Operational Flow Chart Risk assessment and safety information

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IMPORTANT! Ensure the machine is set on correct pipe option for the pipe to be welded. To change the specification of the pipe (Material, Diameter, SDR) refer to Supervisor Mode / Set up Instructions.

How to change the settings: Accessing the Supervisor Mode; Set up Instructions

The Supervisor Mode can be accessed from three different start points: (i) When first accessing the Auto Joint Cycle, (i.e. release stop button, press

Auto) the third screen seen will be:

HPPE - 200mm SDR 17.6 OK = Accept Change = -

If the pipe options displayed is not correct for the pipe to be welded, pressing the ‘ - ‘ button to change will change the screen prompting the operator to insert the printer lead.(refer to Fig. 10.0 ) The printer lead acts as the supervisors keys and once inserted the screen will change again.

(ii) Before accessing the Auto Joint Cycle, the operator may already be aware that the pipe option requires changing, or he may want to check the clock or change the job number etc. etc.

The Supervisor Mode can be accessed immediately by: -

• Inserting the printer lead

• Releasing the stop button

• Pressing the auto button

(iii) The Supervisor Mode can be accessed immediately by : -

• Using the bypass switch which is located in the inside of the controller, to find the switch undo the front catches and tilt the top half of the controller back. The black or silver is located on the underside of the top half of the controller.

TO ACCESS THE AUTOMATIC MODE RELEASE THE STOP BUTTON. PRESS THE AUTO BUTTON.

THE MACHINE IS NOW IN AUTOMATIC MODE

Refer to the Operating Instructions Flow Chart

Operating Instructions Flow Chart gives individual screen by screen displays and progresses the operator systematically through the jointing cycle with ‘on-screen’ instructions.

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COMPONENTS OF THE BASIC MACHINE

2.0 MACHINE COMPONENTS Basic Machine Components

The Standard SuperweldSuperweldSuperweldSuperweld Butt Fusion Machine consists of the following items :

Chassis Controller / Power Unit Hotplate Trimmer and Stand Ancillary Machine Components

Additional components which may be required or specified for Butt Fusion Jointing are: Generator (Refer to section 15.0 for recommended size) Liners for different pipe diameters Pipe Support Rollers Welding Tent Data Retrieval Printer Software Upgrade for downloading onto P.C. External Debeader Internal Debeader

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MACHINE CONNECTIONS The Power Unit / Controller should be connected to a suitable power supply and then all other machine components are connected to the rear of the power unit. (Fig 2.0.)

Hotplate Connection Trimmer Connection

Chassis Electrical Connection

Connect Power Unit to suitable generator Fig. 2.0 Hydraulic

Connection A Hydraulic Connection

B Hydraulic Connection C Hotplate Connection (Fig. 3.0)

Connect To: Hotplate Electrical Connection Hotplate Hydraulic Connection Male Hotpate coupling to female Power Unit coupling, either A or B

Note: The 400 bfm Superweld has 2x plugs to connect:

1. 1x rectangular plug fits to the automatic controller 2. 1x 32 amp 110v plug fits directly into the power source.

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Trimmer Connection

Connect To: Trimmer Electrical

Connection Fig. 4.0

Chassis Connection (Fig 5.0)

Connect To: Chassis Electrical Connection Chassis Hydraulic Connection Male Chassis Coupling to Female Power Unit Coupling A or B Chassis Hydraulic Connection Female Chassis Coupling to Male Power Unit Coupling C

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BASIC MACHINE OPERATION

Manual Opening / Closing of the Machine

Stop Button : Press to Stop Twist to Release Manual Open/Close Controls and Manual Pressure Control Knob

Ensure all machine connections have been made. Check ‘Power On’ LED is illuminated on controller Fascia Panel. Twist Stop Button clockwise to release. Pump motor will operate and ‘Pump On’ LED will be illuminated.

THE MACHINE IS NOW IN MANUAL MODE AND MANUAL OPERATION OF THE CHASSIS CAN NOW

TAKE PLACE.

Chassis clamps can now be opened and closed by using the open and close buttons. Manual mode pressure is varied by rotating the pressure control knob. Turning clockwise increases pressure and turning anti-clockwise decreases pressure.

IMPORTANT The Machine should only be used in the manual mode to open and close the chassis clamp as required when the machine is not in the automatic jointing cycle. (i.e. To open the clamps after a weld cycle has been

completed, in preparation for loading the next pipe to weld). Do not attempt to use manual control

buttons to carry out a weld cycle.

WARNING

AFTER THE CLAMPS HAVE BEEN MOVED IN MANUAL MODE, ALWAYS PRESS THE STOP BUTTON: This will switch the pump / motor off. If the pump / motor is left running for long periods of time, the hydraulic oil will become warm and this could result in the thermal cut out switch operating and inhibiting use of the machine.

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AUTOMATIC CYCLE : SUPERVISOR MODE/SET UP INSTRUCTIONS

Introduction to the Supervisor

Printer Socket Automatic Button (With printer lead connected, after releasing ‘Stop Button’, Pressing ‘Auto’ accesses ‘Supervisor Set Up Mode’ Stop Button Press to Stop Twist to Release

NB: These buttons are redundant on this machine (BFM 180 /250/315/400 Superweld)

The Supervisor Mode should be used for setting the machine up with the correct information, prior to welding. Once the information has been set (ie. pipe diameter, material, SDR) it is retained in memory and jointing can take place. The machine remains set with these conditions until the supervisor program is accessed again and the parameters are reset. Options available in Set Up Mode

Print out - Enables a maximum of 256 joint parameters stored in memory to be printed out. Joints information can be printed by :

1. Individual Joint 2. Batch of joints 3. All joints

Use +/- buttons to go to joint required for printout startpoint, press Accept. Then use +/- buttons to go to joint required for printout endpoint, press Accept. The printer will automatically print joint stored between startpoint and end point.

PC Transfer - This option is available at an extra cost

Reset Clock - Enables the clock and calendar to be set. NOTE! Digits within clock/calendar must be integer values. Any other value (ie >, +, ?) will inhibit machine operation.

Clear Memory -Enables the joint parameter information stored in memory to be cleared after downloading. Maximum amount of joints enabled to be stored in memory is 256.

Pipe Diameter - Enables preset options for pipe diameter to be selected within the machine range.

Pipe SDR - Enables preset options for pipe SDR to be selected.

Pipe Material - Enables preset options for pipe material to be selected.

Job Number - Enables an eight digit job number to be input for later download with joint parameters for memory.

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Operator Codes - Enables up to four, four digit operator codes to be selected. If one or more codes are set, then the Auto Jointing Cycle will require this code to be input prior to be being able to access the jointing cycle. If no codes are set (ie they are all at 0000), then the Auto Jointing Cycle will not ask for a code to be input and the jointing cycle is automatically accessed.)

WARNING

When entering operating codes, the codes should be entered from left to right. i.e. if two codes are required.

1. 1234 5678 0000 0000 = CORRECT 2. 0000 0000 1234 5678 = INCORRECT

If a code is entered incorrectly it will interfere with the auto cycle and prohibit welding.

Quit Program - Once all parameters have been set, operator should quit program (Press Accept on this screen to return to Automatic Jointing Cycle)

THE MACHINE IS NOW IN SUPERVISOR MODE AND ALL SET UP OPTIONS CAN BE ACCESSED

INTRODUCTION TO THE AUTOMATIC CONTROLS

Accessing the Automatic Jointing Cycle Automatic Control Buttons

Automatic Button (After releasing Stop Button, pressing Auto Button accesses Automatic Jointing Cycle) Stop Button Press to Stop Twist to Release ACCEPT, + and - Buttons for use in Automatic Jointing Cycle

Ensure that the machine is in the fully open position and the pipe has been clamped into the chassis. Each pipe should pertrude from the chassis clamps by at least 20mm in preparation for trimming.

The machine is now ready to access the Automatic Jointing Cycle and carry out a ‘Butt Welded Joint’.

Safety Information

When Chassis is operating, keep hands and loose clothing away from moving clamp.

TECHNICAL INFORMATION : TRIMMER

Weight

DESCRIPTION WEIGHT TRIMMER

KG

WEIGHT TRIMMER STAND KG

TOTAL WEIGHT

BFM 180 Superweld Trimmer 12 3 15




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Specification Input Voltage : Check Machine for power requirement 110v / 50Hz Amperage : Variable dependent on load Power : 0.55 kw Max. 110v

Blade Setting BFM 180 BLADE SETTING ONE 63 - 90mm Diameter Pipe

BLADE SETTING TWO 125 - 180mm Diameter Pipe

BFM 250 Only one blade setting for complete pipe range (90 - 125mm)

BFM315 Only one blade setting for complete pipe range (125 -315mm)

Loading Trimmer

To Load Trimmer into Chassis Engage Trimmer onto Chassis

Push downwards and ensure handle locks into position.

Safety Features A. Thermal Cut Out Switch The thermal cut out switch operates when the trimmer is overloaded. This overload situation can occur if excessive pipe force is used against the trimmer cutting faces. The thermal cut out switch protects the electric motor from damage.

In the event of the switch operating, the trimmer will cut out. To reset;

• Allow the trimmer at least 2 minutes to cool down

• Depress trimmer on/off switch

• Press thermal switch back downwards (use small screwdriver, pen etc.)

• Investigate reason for overload situation and correct

• Restart Trimmer with on/off switch.

Safety Cut Out Switch The safety cut out switch is to ensure that the Trimmer can only be operated when correctly mounted in the Chassis.

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In this position the safety cut out switch is engaged with the force of the trimmer lock off mechanism against the chassis tie bar.

Note: The Trimmer will not operate when out of the machine.

WARNING!

• When trimming assure hands and loose clothing are kept away from cutting discs.

• Only remove trimmer when it has completely stopped rotating.

• Always stand Trimmer on Trimmer Stand when not in use.

TECHNICAL INFORMATION: HOTPLATE

DESCRIPTION WEIGHT (KG)

BFM 180 Superweld Hotplate 17




Specification Input Voltage: Check machine for power requirements 110v 50Hz.

BFM 180 110V

BFM 250 110V

BFM315 110V

BFM400 110V

Amperage A

(Max.)

13.0 - 14.0

18.0 - 19.0

24.0 - 25.0

30.0-32.0

Power KW

1.5

2.0

2.7

3.3

The LED Indicator : System Amber LED : Amber LED (Power On) illuminates. Green LED : When correct temperature is reached the green LED (Ready) illuminates. Red LED : If Red LED (fault) illuminates, then a fault has arisen and the Hotplate has shut down. To reset, disconnect from power unit and then re-connect, Red LED should extinguish.

Should Red LED continue to illuminate consult engineer NB: The most common reason for the Red LED to be illuminated is a spurious voltage input to the power unit from the generator. Check quality and value of voltage output from generator. Hotplate Temperature

The Automatic Hotplate has three important settings.

(i) Temperature set point (233° + or - 3°c) or (225° - 240°c) dependant on specification

(ii) Green LED (Ready) illuminated band set point.

(iii) Voltage feedback to main controller adjustment

Refer to Hotplate set up instructions (section 11.0) for information on setting and resetting the Hotplate. All adjustments are carried out on the Hotplate PCB Board and power unit PSU Assembly The temperature of the Hotplate should be checked regularly. Temperature set point : 230 - 236°c

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Shows Hotplate position up

Hotplate in down position

Safety Information WARNING!

By its very nature, the Hotplate is hot. Be careful when handling and cleaning faces. Always ensure Hotplate faces are clean and in good condition to avoid joint contamination. Replace as necessary.

TECHNICAL INFORMATION: POWER UNIT / CONTROLLER General Specification Input Voltage: Check machine for power requirements 110v / 50Hz

BFM180 BFM250 BFM315 BFM400

Pump/Motor Power 0.55kw 0.55kw 1.1kw 1.1kw

Phase Single Single Single Single

Frequency 50/60Hz 50/60Hz 50/60Hz 50/60Hz

Recommended Hydraulic Fluid

OIL

CLIMATE

USEABLE VOLUME PER MACHINE

Hydraulic Mineral Oil VG32 (32cS Viscosity @ 40°c)

Winter Conditions in Central Europe

2.1L


Summer Conditions in Central Europe

2.1L


Summer/Tropical conditions in traditionally hot areas

2.1L

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Technical Features Thermal Cut Off Switch - Open Circuit 70°c Close Circuit 50°c Oil Level Switch - Oil level should be checked regularly. Never fill completely to top leave 10mm (1/2”) air gap. The printer has an automatic switch off time delay of 30 seconds to save battery life.

Ensure printer remains on during the complete diagnostics program. In the event that it automatically switches off, switch back on immediately. The diagnostic program will not run with the printer turned off.

Risk Assessment –

Hy-Ram Automatic Butt Fusion Machine

Hy-Ram Engineering Co. Ltd

Tel : + 44 1623 422 982 Fax : + 44 1623 661 022

Description of hazard and likely consequence:

Unauthorised use of equipment by untrained operatives Improper lifting of the machine Injury to operator in welding area due to improper use or malpractice Possibility of ‘trap’ injury in between moving chassis cradles Possibility of ‘trap’ injury on loading pipe, trimmer unit and hotplate Contact with trimmer blades resulting in minor or major cuts and lacerations Possible entanglement with moving and/or rotating parts – ‘de-gloving’ injury Contact with hotplate resulting in burn injuries Generator noise may result in ear damage Inhalation of exhaust fumes may result in respiratory problems Swarf removal may result in ‘crush’ injury

What controls you should have in place:

1. All operatives to be trained and certified. 2. Machine to be sited on suitable ‘even’ ground 3. Welding shelter exclusion zone applies 4. Audible sounders alert when automated process begins 5. All operatives issued with appropriate PPE and wearing enforced 6. Hotplate stored in guarded frame and handled with care 7. Generator sited in well ventilated area 8. Swarf removed with no controller button pushes

With all the above controls in place the risk rating is Risk Rating � Low� Moderate � Substantial � High �

bfm superweld operating instructions...if the pipe options displayed is not correct for the pipe to...

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