630 HF operator manual 0812

HF630
OPERATOR’S
MANUAL
DIXON INDUSTRIES PTY LTD
ABN 89 008 171 855
17 Frederick Road, Royal Park, South Australia, 5014.Tel: +61 8 8240 1555. Fax: +61 8 8240 5588
Email: sales@dixonind.com.au,
HF630 electric hydraulic butt welder
1.
2.
Safety considerations ............................................................................................................... 4
HF630 Machine Description ..................................................................................................... 5
2.1.
General Specification....................................................................................................... 5
2.2.
Heating Plate ................................................................................................................... 6
2.3.
Facer ................................................................................................................................ 6
2.4.
Pipe Alignment ................................................................................................................ 6
2.5.
Hydraulics ........................................................................................................................ 6
2.6.
Pipe Lifter ........................................................................................................................ 6
2.7.
Reducing Liners ............................................................................................................... 6
2.8.
Fittings Plate .................................................................................................................... 7
2.9.
Power Requirement ........................................................................................................ 7
2.10. Optional Wheel-Base ....................................................................................................... 7
2.11. High pressure welding ..................................................................................................... 7
3. The HF630 Controls .................................................................................................................. 8
3.1.
Electrical .......................................................................................................................... 8
3.2.
Phase Reversal ................................................................................................................. 8
3.3.
Hydraulic Controls ........................................................................................................... 9
4. Using the HF630 – single pressure low pressure method ...................................................... 10
4.1.
Preparation .................................................................................................................... 10
4.2.
Pipe Alignment .............................................................................................................. 10
4.3.
Drag Pressure ................................................................................................................ 10
4.4.
Facing............................................................................................................................. 10
4.5.
Re-Check Pipe Alignment .............................................................................................. 11
4.6.
Bead Up ......................................................................................................................... 11
4.7.
Heat Soak....................................................................................................................... 11
4.8.
Fusion Cycle ................................................................................................................... 11
4.9.
Pipe Removal ................................................................................................................. 11
4.10. Weld Quality Check ....................................................................................................... 11
5. Maintenance - Daily Check List .............................................................................................. 12
6. Maintenance - Periodic .......................................................................................................... 12
6.1.
General/Drag ................................................................................................................. 12
6.2.
Heater Plate ................................................................................................................... 12
6.3.
Heater Faults ................................................................................................................. 12
6.4.
Heater Plate Removal-Refitting ..................................................................................... 13
6.5.
Heater Temperature Adjustment .................................................................................. 13
6.6.
Temperature Controller Failure..................................................................................... 13
6.7.
Temperature Sensor Failure .......................................................................................... 13
6.8.
Heater Calibration ......................................................................................................... 13
6.9.
Heater Non-Stick Cloth Replacement ............................................................................ 14
6.10. Facer Drive Chain Tension ............................................................................................. 14
6.11. Facer Bronze Roller Replacement ................................................................................. 14
6.12. Cutter Blade Sharpening................................................................................................ 15
6.13. Maximum Hydraulic Operating Pressure ...................................................................... 15
6.14. Pressure Gauge Calibration ........................................................................................... 15
6.15. Synchronising The Carriage Cylinders............................................................................ 15
6.16. Hydraulic Bleeding Method ........................................................................................... 15
6.17. Adjusting eccentric cam mechanism ............................................................................. 16
6.18. Replacing Defective Carriage Cylinder Parts ................................................................. 16
7. Notes About Heater Plates And Temperature ....................................................................... 17
7.1.
PE Welding Temperatures ............................................................................................. 17
7.2.
Heater Plate Temperature ............................................................................................. 17
7.3.
Measuring Surface Temperature................................................................................... 17
8. Butt Welding Guidelines......................................................................................................... 18
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
9.
10.
11.
12.
Weld Failure Trouble Shooting ............................................................................................... 18
Warranty Policy ...................................................................................................................... 19
Machine Assembly Drawings ................................................................................................. 20
Butt Welding Tables (single pressure, low pressure) ............................................................. 38
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
1. Safety considerations
Know the machine
This machine should only be used by an operator fully trained in its use.
Read these operating instructions carefully. Learn the operation, limitations and potential
hazards of using your butt fusion machine.
Electrical safety
Use only a qualified electrician to carry out electrical maintenance work.
Connect electrical components only to a voltage source that corresponds to that marked on the
components.
Do not operate the electrical equipment in damp or wet locations.
Prevent electric shock by correctly grounding electrical components. The green (or green/yellow)
conductor in the electric cable is the grounding wire and should never be connected to a live
terminal. An earth leakage protection device is located in the control cabinet.
The equipment is not explosion proof. Never butt weld in a gaseous or combustible atmosphere.
Pinch points
This machine has many slow moving parts that are designed to apply a great deal of force when
carrying out its designed function. This especially refers to the clamps, heater and facer which
cannot be guarded without preventing the machine function.
Any bodily parts caught in the machine when the hydraulics are operated could be crushed.
Operators must ensure that all persons in the vicinity of the machine keep fingers and limbs well
clear of moving clamps, facer or heater to avoid crush injuries during all phases of the welding
process.
Facer
The facing machine is powerful and the cutting blades are sharp. To prevent injury the facer
should only be operated when it is securely located in the pipe cutting position.
The nature of the machine and welding process makes it impractical to guard the operational
area. Do not attempt to remove shavings from the cutting area while the facer is running.
Remove loose clothing or jewellery to prevent these items being dragged into moving parts.
Wear appropriate apparel
The heater operates at over 200°C and contact can cause serious burns. Always wear gloves
when handling the hot plate.
Hydraulic pressure
A sudden hydraulic oil leak can cause serious injury or even death if the pressure is high enough.
Do not search for oil leaks with the fingers because a fine jet of pressurised oil could penetrate
the skin causing serious injury. Use a piece of cardboard to test for leaks under pressure.
Avoid spraying oil into eyes when bleeding air from the system by wearing safety glasses and
keeping the face clear of the area.
Maintain equipment carefully
The machine has moving parts and/or parts that may deteriorate with age and require
maintenance. Regular inspection is recommended. For best results keep all machine components
clean and properly maintained. Always disconnect the power when adjusting, servicing or
changing accessories. Repair or replace damaged electric cables.
Transporting the machine
Dixon equipment mounted on wheels is not designed for on-road towing. Any attempt to do so
could result in machine damage and/or personal injury. Transportation should be by truck or
similar, with the machine well secured.
During transportation always ensure the heater surface is protected from coming in contact with
the cutter blades to prevent serious damage occurring.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
2. HF630 Machine Description
The FUSIONMASTER HF630 is designed
for “single pressure – low pressure” butt
welding of pipe in the range 630-355mm. It is a
robust machine built around a steel main frame
supporting hard chromed, high strength steel
guide shafts, and high strength cast alloy pipe
clamps and pipe alignment assembly. It is
ideally suited to joining pipe to pipe in the field.
The main clamps are 630mm inside diameter,
with the top half clamp being manually lifted
on and off and held in place with toggle bolts.
The hydraulic power pack, heater and facer are
permanently attached to the machine frame.
The machine is fitted with two lift points for
overhead lifting.
An optional wheel base can be quickly attached to the main frame.
2.1.
General Specification
Machine dimensions (without wheelbase)
Main clamp bore
Length overall
Width (heater extended behind machine)
Height (facer in raised position)
Component Weights
Machine
Fittings holder
Reducing liner set 560mm
Reducing liner set 500mm
Reducing liner set 450mm
Reducing liner set 400mm
Reducing liner set 355mm
Heater (element pad only)
Shipping crate with machine, liners & fittings holder
Shipping crate with wheel base
Hydraulic Specifications
Electric motor
Carriage cylinder maximum pressure
cylinder area (for weld calculations)
System oil capacity
Recommended hydraulic oil
Heater plate
Recommended genset for field operation.
Recommended grease for facer drive
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
630 mm
1,950 mm
1600 mm
1,900 mm
approx. 750kg
26kg
46kg
57kg
45kg
23kg
18kg
22kg
approx. 850kg
approx. 150kg
415v, 2.2kw, 3 phase
15,500kPa
2,027mm2
30 litres
Any brand with viscosity ISO 46
5kW, 415V, 3phase
15kva, 415V, 3 phase
Shell Alvania EP/LF2
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
2.2.
Heating Plate
The cast aluminium heater plate has three circular elements to ensure uniform heat distribution
across the effective heating diameter. The heater plate reaches the operating temperature of
220°C from 20°C in about 20 minutes. Temperature is controlled by an electronic temperature
controller located at the main electrical panel.
The heater plate is hinged to the machine frame and is manually moved in and out of position
with spring loaded assistance.
Replaceable non-stick cloths are used to cover the heater faces to eliminate hot plastic adhesion.
The cloths are secured by snap rings that enable quick and easy field repair if the surface is
damaged.
2.3.
Facer
The facing tool is hinged to the machine frame and is effortlessly moved in or out of position with
hydraulic assistance. A single blade cutting arrangement is driven by a powerful hydraulic motor
at 10 rpm, provides efficient, fast joint preparation.
2.4.
Pipe Alignment
An eccentric mechanism built into the fixed clamp end of the machine allows approximately 6mm
of pipe movement in two directions in the plane of the pipe joint. This feature helps to overcome
misalignment problems caused by pipe dimensional variations, and increases productivity by
reducing pipe alignment times.
2.5.
Hydraulics
Hydraulic power is provided by a 415V, 2.2kw, 3 phase motor driving dual pumps. Pump one
drives the carriage, facer lift and pipe lift cylinders. Pump two drives the facer motor.
Three pressure regulators control the Carriage Cylinder Pressure during the fusion process. The
regulators allow the operator to independently preset facing pressure, bead-up and/or weldingcooling pressure or drag pressure, depending on how the operator prefers to work. During travel
in the reverse direction (clamp opening), the regulators do not control pressure, nor does the
gauge register pressure.
A 3-way selector allows the operator to easily choose one of the pre-set pressures during the
weld process.
Carriage motion direction is controlled by pushing the directional control valve lever in the
required direction of travel.
2.6.
Pipe Lifter
Ejection of pipe from the HF630 is assisted by means of a hydraulic pipe lifter.
2.7.
Reducing Liners
Clamp liners for the HF630 can be supplied in either metric or imperial dimensions to suit any
pipe size down to 355mm. There are four wide rings to each liner size. The 560 and 500mm liners
nest into the main 630mm clamps; 450mm liners nest into 500mm, 400mm nest into 450mm and
355mm nest into 400mm.
A “knife edged” reducing clamps are available to hold 355, 400, 450
and 500mm short leg length elbows or tees. The reducers attach on to
the side of a 560mm reducing liner.
Note: The HF630 is not able to hold 560 or 630mm short leg
moulded elbows, or most short leg moulded Tees. Such fittings should
be purchased with long leg lengths to enable the Tee or elbow section
to protrude beyond the end clamp.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
2.8.
Fittings Plate
This accessory holds stub flanges by either I.D. or O.D. and mounts into the central main clamp.
2.9.
Power Requirement
The HF630 operates on three phase, 415V power. The recommended minimum portable
generator capacity for field use at sea level is 15kva. The machine is connected via a 20A, 5 pin
Australian Standard electrical plug.
2.10. Optional Wheel-Base
The optional wheel-base comprises two
wheels on a fixed axle and two wheels on a
steering axle. Each axle is mounted on a
frame which slides inside the machine base
frame and is pinned into position by M12
bolts. The wheel-base is designed to be
retro-fitted to older machines if required. It
is suitable for towing slowly between welds
at less than 10kph only: it is not suitable for
on road towing at speed.
2.11. High pressure welding
The HF630 is not designed for high pressure welding. However the high pressure method may be
used providing the combined welding + drag pressure for a particular job falls within the range of
the fitted pressure gauge.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
3. The HF630 Controls
Operators should be thoroughly familiar with the machine before turning on power.
3.1.
Electrical
The HF630 requires a 415 volt, 3 phase power supply. Connection to the power source is through
a 20 amp, 5 pin plug (i.e. 3 active, 1 neutral, 1 earth).
After connecting to external power ensure none of the circuit breakers in the control box are
isolated.
Control Box
Phase
reversing
switch
Motor
overload
protection
Set at 5A.
Test plug.
Do not use as
single
phase
outlet!
Pump
isolator
Heater
plate
isolator
Heater
controller
isolator
RCD
The hydraulic pump and heater plate electrics are operated by main switches on the control
panel, and isolated by circuit breakers in the electrical control box at the rear of the machine.
Before starting the pump, check the hydraulic oil level and top up if necessary.
Start the hydraulic pump by pressing the green button on the control panel. Stop the pump by
pressing the red stop button.
Switch on the heater at the control panel to power up the heater plate. Check that the
temperature controller indicates rising temperature.
3.2.
Phase Reversal
If the pump runs but no pressure is generated, check the pump motor fan is spinning clockwise
when viewed from above. If not, switch off the pump, open the orange control box and turn the
phase reversing switch to the off position. Wait until the motor has stopped spinning then move
the switch to the opposite position.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
3.3.
Hydraulic Controls
Control Panel
Pump
start
Temperature
controller
Carriage
cylinder
gauge
Facer pump
gauge
Carriage
pump gauge
Power
On/Off
Operating Levers
Heater
On/Off
Pump
stop
3-way
pressure
selector
adjust
Access to
system
pressure
relief
•
•
Facer rotate (press down)
Carriage move
in=left out=right
• Facer lift (up=up)
• Pipe lift (in=up out=down)
Facer Pump Gauge: Indicates facer drive motor pressure during facing.
Carriage Pressure Gauge: Indicates the carriage cylinder pressure during welding, etc.
Carriage Pump Gauge: Indicates maximum pressure available to carriage cylinders.
Pressure Selector: The 3-position pressure selector allows the operator to select one of the three
pre-set carriage pressure regulators used during the welding process.
Pressure regulators: Three regulators allow independent pre-setting of three different pressures
for the carriage cylinders.
Regulator Face: usually set at the carriage pressure for facing.
Regulator Heat: usually set at the carriage pressure for the heat soak process. This is often set to
the "drag" pressure.
Regulator Fuse: usually set at the carriage pressure for bead up and fusion.
NB. The regulators only control pressure as the carriage moves toward the centre of the machine.
Main Control Levers
Carriage Move: Push the lever in towards the control panel to move the carriage from right to
left. Pull the lever outwards to move the carriage from left to right.
Carriage speed increases with increasing pressure. Speed of travel can also be manipulated by
partially opening the Carriage Move lever.
The carriage cylinders are series-connected to ensure they carry equal loading. This prevents the
possibility of distortion of the machine under load and ensures optimum pipe alignment. Refer to
the maintenance section for bleeding instructions.
Facer Rotate: Push the lever down to start facer rotation. Ensure the facer is lowered into the
cutting position before commencing rotation.
Release the lever to stop the facer rotating. The facer rotational speed cannot be varied.
Facer Lift: Lift the lever up to raise the facing cutter. Push the lever down to lower the facing
cutter.
The speed of travel in each direction is controlled by 2 flow control valves.
Pipe Lift: Push the lever in towards the control panel to raise the Pipe Lifter. Pull the lever
outwards to lower the Pipe Lifter. Ensure the clamps have been removed from the pipe before
operating the Pipe Lifter.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
4. Using the HF630 – single pressure low pressure method
4.1.
Preparation
1.
Connect only to a 415v, 50Hz power source. Ensure the output of any portable
generator used is 415v ± 20v. Ensure any connecting plug has a neutral wire.
2. Power up and check all indicator lights and the hydraulic pressures.
3. Check for air in the hydraulic system and bleed if necessary (see maintenance
section).
4. Clean and/or replace the non-stick cloths. Clean the heater plate before every weld
with clean dry paper towel or cotton cloth - never use synthetic materials that may
melt.
5. Check, and if necessary adjust the heater surface temperature.
6. Install the correct reducing liners for the pipe to be welded.
7. Check the facer cutting action (the shaving thickness should be 0.30-0.40mm).
8. Before facing, clean inside and outside of each pipe end, and the cutter blades.
9. Record the drag pressure from the pressure gauge before every weld.
10. Add the drag pressure to the calculated pressure to determine the appropriate bead
up and fusion gauge pressures.
4.2.
TIP
Put the top clamp
over the pipe, then
engage the bottom
toggle bolt and
hold it in place,
then engage the
upper toggle bolt,
then tighten the
toggle nuts.
Pipe Alignment
Place the pipes in the clamp jaws with about 75mm of pipe extending past the clamps into the
weld zone. Tighten the clamp toggle bolts securely using a shifter to prevent the pipe from
moving when under hydraulic pressure. The outer ends of the pipe should be supported such
that any external bending loads on the machine are eliminated and drag pressure is minimised
Move the pipe ends together until they are almost touching, then check for misalignment
(maximum allowable misalignment is 10% of wall thickness). Reduce any misalignment to an
acceptable by adjusting the top and bottom fixed clamp eccentric adjusters.
(Adjustment will not be possible if the pipe ends are in contact and under pressure.)
Move the pipe end clear of the weld zone and record the drag pressure. Add this value to the
fusion pressure required to join the pipe (refer welding table).
4.3.
Drag Pressure
"DRAG" is the amount of pressure required to overcome carriage friction plus the effort required
to move the pipe. As drag pressure is a variable, it must be measured before every weld.
To determine the drag pressure, operate the Carriage Move lever and adjust a pressure regulator
until the carriage is just moving. This is the drag pressure. The HF630 drag pressure without pipe
loaded should be in the range 200-1000kPa.
If drag pressure is excessive it may adversely affect the weld. Drag may be reduced by one or
more of the following actions:
1.
2.
Use a low friction pipe support/roller system.
Ensure the pipe support/roller system maintains the whole length of the pipe level
with the machine base to prevent bending forces acting on the machine frame.
3. Minimise the amount of pipe being pulled. Welding machines are not designed to
pull multiple lengths of pipe.
4. Ensure neither the heater/facer rest bar nor the pipe lifter is obstructing carriage
movement
All of these techniques are always important, but become critical when working near the limits of
machine capacity.
4.4.
Facing
Move the pipe ends apart and slide the facer along its guide shafts until it cannot hit the clamps
or pipe ends when lowered into position. Operate the Facer Lift lever to lower it into position.
The facer lifting handle must always rest against the rest bar during facing.
Operate the Facer Rotate lever to start the facer rotating. Move the pipe ends into contact with
the facer and apply the minimum pressure necessary to achieve cutting until a continuous
shaving of plastic is simultaneously produced from both sides of the facer.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
Caution:
Take care not to overload the facer by applying excessive carriage pressure. Never
exceed 2,000kPa more than drag.
On completion of facing, reverse the pipe carriage away from the facer then stop facer rotation.
This prevents a step being produced in the faced ends. Raise the facer up and fully out of the
machine.
4.5.
Re-Check Pipe Alignment
Clear away all plastic cuttings without contaminating the pipe ends. Do not touch the cut surface
or re-clean it. Move the pipe ends together and re-check pipe alignment (maximum allowable
misalignment is 10% of wall thickness).
Always re-face the pipe ends if it becomes necessary to rotate the pipe in the clamps after initial
facing.
4.6.
Bead Up
Check the heater plate temperature before commencing each joint in case there has been any
failure of the power supply or temperature controller.
The heater plate will reach 220°C from ambient in about 20 minutes and will take a further 10
minutes to stabilise. It is recommended that the heater not be switched off between welds to
ensure temperature uniformity is maintained, and that the plate surface temperature is checked
before commencing each joint.
Place the heater plate between the pipe faces.
Move the carriage to bring the pipe faces into contact with the heater plate. Increase pressure to
the predetermined “bead-up” pressure.
Maintain pressure until an initial bead has formed completely around the pipe circumference on
both sides of the heater plate. The bead up time is variable, and is influenced by weather
conditions and pipe dimensions.
4.7.
Heat Soak
After bead up, reduce the pressure down to the drag pressure to maintain a slight positive
pressure between the pipe and the heater for the heat soak period. Failing to reduce pressure
forces hot plastic out of the joint zone and could lead to a weld failure.
On completion of heat soak time, reverse the carriage direction to “crack” the heater plate away
from the melted pipe, then move the heater plate out of the weld zone as quickly as possible.
(Refer to parameters table for allowable changeover time).
The unique non-stick cloths allow a "peeling off" action as the pipe is cracked away, minimising
adhesion of the melted pipe to the heater.
Caution:
Do not allow the heater plate to slide across the pipe ends and distort the melted
surface. Do not contaminate the melted surface in any way.
4.8.
Fusion Cycle
Bring the melted pipe faces into contact with each other immediately to minimise heat loss from
the weld zone. Smoothly build up to the required fusion pressure to avoid squeezing out too
much hot plastic.
Unless hydraulic pressure is maintained while the weld is cooling, shrinkage will occur and voids
may form in the weld zone. It is essential to run the pump and maintain the pipe in the clamps
and under pressure until the weld/cooling time is complete.
4.9.
Pipe Removal
Activate the Pipe Lift lever to raise the welded pipe clear of the bottom clamps.
Caution:
Always ensure the top clamps have been removed before activating the pipe lifter
or the lift device will be damaged.
4.10. Weld Quality Check
Inspect the uniformity of the bead size inside and out, top and bottom of the pipe. It is advisable
to monitor and record times, temperatures and pressures at each phase of every joint for future
reference. (See section on troubleshooting weld failures.)
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
5. Maintenance - Daily Check List
1.
Keep the machine and accessories clean and free of dust and grease. Do not
lubricate any HF630 components except for the facer drive (see later) and steering
axle.
2. Inspect hydraulic components for leaks from connections and seals. Overhaul seals
and fittings as necessary.
3. Check for air in the carriage cylinders (as evidenced by shuddering, and/or
“springing back” of the cylinders). Air in the hydraulics will adversely affect weld
quality and must be removed by bleeding (see later).
4. Check the pressure gauge needle returns to zero and does not stick.
5. Check the temperature of a number of points on the surface of both sides of the
heater plate. The reading at any point on either side of the heater plate surface
should not be more than ±10°C from the desired welding temperature. (Refer later
section on heater plates.)
6. Do electrical safety checks.
7. Replace non-stick cloths if damaged in way of the weld area.
8. Facing blades should be sharp and have defect free cutting edges to provide
continuous shaving thickness of 0.30-0.40mm. Shim worn blades if necessary;
sharpen cutter blades if blunt; replace cutter blades if chipped.
9. Feel for “sloppy” movement of the cutter plates. This indicates the need to adjust
the facer drive internally.
10. If using a portable generator, ensure its output is 3phase, 415 ± 20v and 50hz, to
protect electrical components from permanent damage.
6. Maintenance - Periodic
In addition to the daily checks, more detailed inspections of the key machine components should
be carried out before commencing each new project, or after 250 operating hours. Any faults
found should be corrected as described in this section.
6.1.
General/Drag
Check the hydraulic cylinder shafts for cuts or dents likely to damage the hydraulic seals.
Check the machine frame, main carriage guide shafts, hydraulic shafts and heater rest bars are
not damaged or bent such that excessive drag pressure results. Without pipe in the machine,
drag pressure should not exceed 1200kPa.
6.2.
Heater Plate
Heater surfaces should be flat, smooth and free of dents or gouges. Dress as necessary.
FUSIONMASTER heater plates have a vent machined in the edge of the casting to allow
entrapped air to escape from under the non-stick cloth. Clean out any build up of foreign
material from the air vent to prevent any adverse temperature effect.
Putting a pin-hole in the dead centre of the cloth will also assist with air release.
Caution:
Ensure heater plate non-stick surfaces are protected from damage during
transport.
6.3.
Heater Faults
If the heater does not power up it could be due to failure of the element pad, temperature
controller or other electrical components. Always use an electrician to check electrical
components, and always first test the power supply, electric cords and plugs before condemning
the heater plate.
1.
The RCD may trip out on first starting the machine due to moisture presence in the
heater after it has been used in a damp environment and then allowed to cool
down. This may be overcome by using a hot air gun to heat the element end
connections to drive out residual moisture. In extreme situations it may be
necessary to remove the heater plate from the machine, place it in an oven, and
bring its temperature up to 150°C for an hour or so.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
6.4.
2.
Surface temperature readings that are much lower than the set temperature in a
ring around the plate could indicate:
• Either, one of the 3 phases is not carrying power. First check that the heater
circuit breaker has not tripped. Then call an electrician to check the existence of
a faulty generator, electric cable, or other electrical component failure.
• Or, the failure of an electric element. This may be confirmed by an electrician
checking each element resistance, which should be 33ohms ± 10%. In the
unlikely event of an element failing, the element pad must be replaced.
3.
Surface temperature readings that vary by more than ±20° at random points or
from side to side in the same location would indicate the method being used to
measure the surface temperature is faulty. (See later section for more detailed
discussion on heaters and temperature measurement.)
Heater Plate Removal-Refitting
If the heater plate has to be removed for any reason, take careful note of the location and
orientation of the heater bracket mounting bushes during dismantling and always refit in the
same orientation.
6.5.
Heater Temperature Adjustment
The HF630 heater temperature is controlled by an
electronic controller located at the top of the
main control panel. It has been factory set to a
target value of 220°C. Use the UP or DOWN keys
to alter the target value then press ENT to store
the new value. After adjusting the target
temperature, always allow several minutes for the
controller to stabilise plate temperature before
welding.
Guidelines for changing other controller parameter settings are given in drawing TEMPCONTROL
which may be found at the back of this manual. However it will not normally be necessary to
change any controller parameters. The manufacturer’s instructions for the controller are located
in the orange electrical control box.
6.6.
Temperature Controller Failure
In the event of controller failure, remove the protective waterproof cover over the controller,
extract the existing controller from its location, and plug an identical replacement into the vacant
slot. (Some re-wiring may be required for very old machines.)
6.7.
Temperature Sensor Failure
Error message HHHH displayed at the temperature controller indicates failure of one or both
parts of the temperature sensing circuit, which consists of:
1.
2.
6.8.
a 300mm probe with K-type thermocouple that runs from the heater mounting
bracket into the heater plate. (The probe is the most likely source of failure and
should generally be replaced if the error HHHH occurs.)
a 2m cable that runs through the conduit from the heater mounting bracket to the
temperature controller inside the control box. (Check the conduit for damage as this
may indicate damage to the long thermocouple cable.)
Heater Calibration
The temperature display indicates the internal plate temperature, not the welding surface
temperature. It is essential to check and record the surface temperature of the heater plate
before every weld. This is best measured with either a contact pyrometer or a non-contact
infrared pyrometer. The outer circumference of the heater should not be measured as this is too
far from the weld area.
The pyrometer used to measure surface temperature will itself require calibration to a procedure
as recommended by the pyrometer manufacturer.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
Caution:
6.9.
Be aware that an insulating air gap can form between the Teflon cloth and the hot
plate. Always ensure the cloth is forced into contact with the hot metal surface
when using an infrared or non-contact pyrometer or a false reading is likely to
occur. Never use an infrared pyrometer on a shiny surface as a false reading will
occur.
Heater Non-Stick Cloth Replacement
The non-stick cloths should be replaced if they are torn, contaminated, or badly discoloured (due
to overheating) or lose their non-stick ability. This operation will require two people. Use the
following procedure.
TIP
Use
several
plastic
spring
loaded “bulldog”
clips to hold the
ring in place.
1.
2.
3.
Use a screw driver to lever the snap rings out of their securing grooves. This takes
very little force. Do not attempt to remove the snap rings if the plate temperature is
more than 40°C because they will not release.
Place a new cloth into position and reposition the snap ring over the cloth.
With one person holding the snap ring in the groove around one half of the plate
circumference, the second person uses a piece of wood or plastic to force the snap
ring completely into its groove around the rest of the circumference. (This may take
several attempts until some experience is developed.) Never use metallic objects to
force the snap rings back into position as this may result in accidental damage to
the cloth.
6.10. Facer Drive Chain Tension
Refer to Facer drawing.
1.
2.
3.
4.
5.
Access the facer drive assembly by removing the securing screws from the idler
cutter plate and removing the plate.
Clean out any dirt or plastic cuttings that could either damage the drive
components, and/or significantly reduce facing efficiency.
Check that the main drive sprocket is in contact with all four bronze rollers. Two
rollers are concentrically bushed and two are eccentrically bushed to enable bronze
roller or sprocket wear to be taken up by adjusting the eccentric guide rollers. These
are adjusted by loosening the holding bolts and rotating the bush in the direction of
chain rotation, until the sprocket is supported by all rollers. Once the rollers wear
beyond the point of any further adjustment, the guide roller & bearing assemblies
must be replaced.
Tension the chain by adjusting the eccentrically bushed idler sprocket as described
above.
Replace the chain if it cannot be tensioned because it is stretched.
6.11. Facer Bronze Roller Replacement
Refer to Facer drawing.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the screws holding the idler cutter plate and remove the cutter plate.
Detach the driven cutter plate from the main sprocket by removing the 12 sprocket
screws and carefully knocking the plate away from the sprocket. (The cutter plate
locates in a groove machined into the sprocket face.)
Carefully note the location of the eccentric and concentric bronze roller assemblies
and remove them.
Refit new concentric roller assemblies.
Hang main sprocket.
Refit new eccentric roller assemblies.
Adjust the eccentric rollers in the direction of chain rotation, so that all four bronze
rollers support the main sprocket and the sprocket and rollers all turn freely.
Fit the chain and idler sprocket. Tension the chain by adjusting the eccentric bush in
the idler sprocket.
Lubricate sparingly, and only with a high pressure grease e.g. Shell Alvania EP2.
Do not use graphite grease, molybdenum disulphide or similar, as they may run and
leak out of the facer, providing a potential weld contamination problem.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
10. Refit the driven cutter plate to the main sprocket, and test rotation before replacing
the idler cutter plate.
6.12. Cutter Blade Sharpening
If chipped or damaged, the blades should be replaced.
If blunt, the high grade tool steel blades may be sharpened with a tool&cutter grinder. Shim the
cutter blades if they are sharp, but shavings are too thin.
6.13. Maximum Hydraulic Operating Pressure
The maximum carriage pressure of the HF630 is limited to 15,500kPa by a relief valve in the
control valve block. Increasing this setting should only be done in consultation with Dixon
Industries.
Increasing the relief pressure to 15,500kPa in order to handle pipe up to PN25 may be necessary
in older machines which had a lower setting.
6.14. Pressure Gauge Calibration
Pressure gauges are easily damaged and may lose their accuracy. The carriage pressure gauge
should be checked (calibrated) periodically. The HF630 hydraulic circuit has a plugged T provided
at the rear of the 3-way valve block for this purpose.
Calibration options:
1.
2.
3.
Check the carriage pressure gauge against a known standard test gauge fitted into
the plugged T at the rear of the 3-way valve block.
Remove the carriage pressure gauge and have it checked by a NATA accredited test
centre.
Replace the pressure gauge with a new certified gauge from time to time.
6.15. Synchronising The Carriage Cylinders
If air enters the cylinders, the carriage motion will eventually become out of phase or jerky. This
will adversely affect the welding operation and air should be bled from the cylinders (see below).
The presence of air in the system could result from loose hydraulic fittings, damaged hydraulic
cylinder seals or shafts. These should all be inspected and repaired if necessary before bleeding
the system.
Caution:
The clamp cylinders are series connected
to ensure both cylinders apply equal
pressure.
Do
not
change
this
configuration without consulting the
manufacturer. The cylinder balance valve
(shown at right) in the line between the
clamp cylinders must remain closed
during normal operation. This valve is
only used when bleeding air from the
system.
6.16. Hydraulic Bleeding Method
The presence of air in the hydraulic cylinder(s) can result from loose fittings, leaking cylinder
seals, or damage to the cylinder shaft or bore. These possible problems should be inspected and
repaired as necessary before attempting to remove air.
To bleed carriage cylinders:
1.
Unbolt the clamp caps from the moving clamps to allow the cylinders freedom of
movement, and then rotate both cylinders until their inlet ports are pointing
vertically upward. This allows trapped air to rise to the top of the cylinders and
escape from the ports.
Do not omit step #1 or air will remain in the system.
2.
Open the cylinder balance valve in the line between the 2 cylinders, then drive the
cylinders to the right hand frame plate.
Close the cylinder balance valve then reverse the direction and drive the cylinders
fully in the opposite direction. Open the balance valve.
3.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
4.
5.
6.
7.
Repeat this cycle in each direction as many times as it takes to remove all air. This
will be evidenced by there being no “spring back” when the pressure is released at
the end of the cylinder travel in either direction.
Top up the oil tank if necessary, using any brand of oil with viscosity ISO 46.
Rotate the cylinders back to their original orientation and re-secure the clamps.
At the end of this process ensure the cylinder balance valve is closed to lock the
cylinders in phase.
6.17. Adjusting eccentric cam mechanism
If a gap appears between the eccentric tube and the centre frame plate when the machine is
under pressure, the eccentric clearance can be adjusted as follows (see drawing section of this
manual for exploded view):
1.
2.
3.
4.
Remove the three M8 socket head cap screws in the shoulder nut at the left hand
end of the machine.
Use a pin spanner to rotate the shoulder nut one position (60°) clockwise and refit
the M8 screws.
Re-check clearance with the carriage under pressure and adjust again if necessary.
Do not over-tighten the shoulder nut. One position (60°) rotation of the shoulder
nut will close gap approximately 0.35mm.
6.18. Replacing Defective Carriage Cylinder Parts
1.
2.
Before removing a cylinder for repairs, tag the hydraulic lines to ensure their
reconnection to the correct ports. Then disconnect the hydraulic lines.
Refer to the drawing section of this manual for further description about servicing
or replacing carriage cylinders.
Contact the manufacturer for information about any maintenance aspect not described in this
section.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
7. Notes About Heater Plates And Temperature
7.1.
PE Welding Temperatures
Polyethylene pipe is weldable at temperatures ranging from 180°C to 260°C. However butt fusion
parameters typically specify 220 ±15°C which is the required surface temperature of the heater
plate.
Temperatures greater than 240°C when coupled with long heat soak times may result in
diminution of the anti-oxidants in the pipe.
Cold joints will result if the weld temperature is too low, or the heat soak time is too short, or the
time between removal of the heater and butting the pipes together is too long.
Caution: Either situation may lead to premature joint failure.
7.2.
Heater Plate Temperature
Heater plate temperature displays generally indicate the internal heater temperature. Actual
surface temperature may vary from the display, and will also fluctuate, for the following reasons.
1.
2.
3.
4.
7.3.
Measuring Surface Temperature
1.
Note:
It is not physically
possible for heater
surface temperatures to
vary significantly from
one point to another. If
such a variation is
observed, it is most
likely to result from
using
an
incorrect
temperature measuring
technique.
The rate of heat loss from the heater surface depends on the design of the heater
plate and temperature controller. The surface temperature could be significantly
different to the thermometer indication. This variation will be greatest on cold,
windy days. Always use a shelter when welding in these conditions.
As power input cycles on and off the temperature will be highest just after the
power cycles off and lowest just as it cycles back on.
The temperature is unlikely to be exactly the same at every point on the heater
surface due to manufacturing tolerances.
As heat is transferred into the pipe during heat soak, the heater temperature
initially falls but eventually returns to the set point.
2.
3.
4.
5.
6.
7.
8.
9.
Always wait 5 minutes after the heater has first reached set temperature for the
temperature to stabilize before recording measurements.
Take readings at several points (at 3, 6, 9, 12 o’clock) on both sides of the heater, at
the diameter of the pipe being welded.
FUSIONMASTER heater plates are fitted with non-stick replaceable cloth. It is
essential to use a contact probe to force the cloth into intimate contact with the
plate. (Incorrect readings will result when the cloth system traps an insulating air
layer between the cloth and the heater surface.)
If a contact probe is used it should be held in position for several seconds before the
reading is taken.
If an infra-red pyrometer is used incorrect reading are likely to result unless:
the emissivity is set at 0.95 for use on the non-stick cloth;
the device is held square to the surface being measured;
the non-stick cloth is forced into intimate contact with the heater plate (see
suggestion below).
Never use an infra-red pyrometer to take a reading from a shiny aluminium surface
(such as a FUSIONMASTER heater without cloths, or the outer rim of a heater
plate) or an error will result.
Suggestion
Use a "spot control adapter" fitted to an Infra-red pyrometer for consistently
accurate measurements. When pressed squarely against the heater surface
the infra-red beam is correctly focused every time, and intimate contact
between the heater plate and non-stick cloth is assured.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
8. Butt Welding Guidelines
It is recommended that the following guidelines be downloaded from Plastics Industry Pipe
Association of Australia Ltd web site (www.pipa.com.au)
1. POP003 Butt Fusion Jointing of PE Pipes and Fittings - Recommended Parameters.
2. TP003 Specifying Butt Welding of Polyethylene Pipe Systems.
FUSIONMASTER welders are designed for the “single pressure – low pressure” fusion
method described in POP003.
The welding tables appended to the HF630 operating manual are based on POP003-SP-LP.
Operators should take care to determine the compatibility of materials for butt welding and only
attempt to weld pipes and fittings made of the same polymer, e.g. PE to PE, PP to PP, PVDF to
PVDF, etc.
The joint area must always be protected from adverse weather conditions, eg strong winds,
excessive cold or heat, or rain, which could lead to the pipe wall developing non-uniformly
heated zones and consequent failure issues.
The weld zone should be free of bending stress, free of notches or similar damage, and be free of
contamination.
9. Weld Failure Trouble Shooting
(Bead shapes are exaggerated for effect.)
Uniform bead correct welding.
NB the external bead is always more uniform than the internal bead.
Crack down centre of bead.
"Cold weld" signified by clean break through the middle of the weld
with a smooth appearance.
Could be due to insufficient heat soak time or temperature, or
changeover time too long, or excessive soak pressure, or insufficient
fusion pressure, or no allowance for drag pressure, or drag pressure
too great eg due to pulling pipe up a gradient.
Misalignment - maximum allowable 10% of wall thickness.
Care should also be taken to ensure pipes or fittings being joined
have the same diameter and wall thickness or the probability of weld
failure is significantly increased.
Insufficient bead roll over.
Could be due to insufficient heat soak time or temperature, or
changeover time too long, or insufficient fusion pressure, or no
allowance for drag pressure,
Unequal bead size.
Look for temperature gradients e.g. pipe surface in the hot sun vs
pipe in the shade, or heater plate hot spots.
Look for unequal application of pressure.
If unequal uniformly around the whole circumference, look for
physical difference in materials being joined eg melt flow index.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
HF630 electric hydraulic butt welder
10.
Warranty Policy
FUSIONMASTER Butt Fusion Equipment
1.
2.
3.
4.
5.
6.
7.
Subject to the terms below, Dixon Industries Pty Ltd “The Company”) warrants to
repair or replace at its option ex-works Adelaide any product manufactured or
repaired by it within 2 years from the date of shipment which are found to be
defective due to either faulty workmanship or use of faulty materials, provided that
such defective product is returned to the Company’s works at the customer’s
expense, unless otherwise agreed.
This warranty is limited solely to products manufactured or repaired by the
Company. Products not manufactured by the Company (such as pumps, gauges,
motors, switches, etc.) are not covered by this warranty. In relation to a repair, this
warranty is limited to the Company’s cost of parts and labour to remedy a defective
repair.
This warranty does not apply to any product that has been damaged by accident,
misuse, neglect, use of an electrical power supply that is incompatible with the
design specifications of the product or repair or alteration of the product by anyone
other than the Company.
A warranty claim must be made to the Company in writing within 14 days of the
first occurrence of the event or condition on which the claim is based. The claim
must include proof of purchase and a detailed statement of the manner in which
the product has been used and the event or condition occurred. The Company’s
decision to admit or refuse any warranty claim shall be binding.
Replacement parts provided to the customer before the right to a warranty claim is
accepted by the Company will be invoiced at the full cost of the parts, including
applicable taxes and freight charges. If a warranty claim is accepted, the cost of any
replacement parts covered by the warranty claim which have been so invoiced will
be credited to the customer.
All costs of returning product to the customer shall be paid by the customer.
Other than provided in this warranty, the Company excludes any other
responsibility or liability whatever to the maximum extent permitted by law
including liability for breach of contract, negligence or incidental, consequential,
indirect or special damages including without limitation, interruption to use of the
product or any other plant or equipment.
Disclaimer
As the conditions of use of welding equipment are outside the control of Dixon Industries, no
warranties are expressed or implied and no liability is assumed in connection with the use of butt
welding equipment or the butt welding guidelines or parameters.
The manufacturer reserves the right to vary specifications without notice.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd.
©August 2002
Revised August 2013
2x
typ. for upper & lower Pump
12
13
7
6
23
25
26
23
24
8
12
11
8
A
UNCONTROLLED DOCUMENT
typ. 4 places
14
CPL2.8
CPL3.8
5
17
17
19
2x
Assembly Part No. BF450648 (2x)
18
X
Facer Rotate Tank Outlet
Carriage Move Tank Outlet
Item 22 & 27 not shown for clarity
Section A-A
A
20
15
22
21
27
2
9
29
BF000152
BF000205
BF000102
BF000054
ref.
ref.
ref.
BF000090
BF630617
BF000052
BF000108
BF000326
BF000037
BF000200
BF000309
BF000002
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
BF630636
1
Update: 20/05/2014
Part No.
A.B.N. 89 008 171 855
Item
BF000203
2
ref.
BF630618
3
ref.
BF000122
4
not to scale
Drawn: SR
Scale:
BF630630
24
BF000193
BF000141
25
5
BF000157
26
BF630619
BF630634
27
6
BF000332
28
ref.
BF000121
29
7
BF000398
30
ref.
CAD File: U:\Inventor\HF630\630600\BF630635.idw
OPERATORS MANUAL ONLY
28
(scaled)
10
4 places
29
Detail X
4
2 places
28
3
HF630 Hydraulic Tank Assembly
Drawing Name:
replacement parts for Item 27
*Filter only (BF000697)
*O-Ring Kit (BF630634/0)
16
Hose Assy (cyan)
connect to Port Adaptor
on upper Pump and to
Carraiage Move Tank Outlet
Hose Assy (blue)
connect to Port Adaptor on lower Pump
and to Facer Rotate Tank Outlet
Pump/ Filter Assy, Part No: BF630632
QTY
1
1
1
1
2
1
1
4
1
1
1
4
4
2
1
1
2
2
2
1
3
1
8
4
4
4
1
6
6
2
www.dixonind.com.au
Copyright . No part of this drawing
may be reproduced in whole or in
part without the written permission
of Dixon Industries Pty. Ltd.
Part Name
Tank Weldment
Motor 2.2KW 415V 4POLE FL
Coupling Motor Half (mod.)
Set Screw M8x8
Suction Element EH/450/630
Bell Housing (modified)
Centre Ring (BF000185)
Port Adaptor 1/2BSP
Spider Elastic for SND65
Coupling Pump Half
Pump Double (630)
SHCS M6 x 20
Flat Washer M6
Nipple 1/2"BSPT x 1/2"BSPT
Nitrile Gasket
Fluid Level(Sight) Gauge
3/8 Hose
1/2"BSPT M x3/8'' EZICRIMP
3/4''JIC-F B/HEX EZICRIMP
Plug 1/4" BSPT
Slotted Pan Head M5 x 8
Filler/ Breather 450/630
Hex Nut M10
Threaded Rod M10
Flat Washer M10
Spring Washer M10
Return Line Filter 450/ 630
Hex Bolt M8 x 20
Flat Washer M8
Nipple 1/2BSP x 3/4 JIC
4.2
4.3
4.8
4.7
A
A
4.6 4.4 4.5
Clamp Assy, lower half - Kit Part No. BF630007A
UNCONTROLLED DOCUMENT
4.1
4
3
3.3
3.2 3.1
Clamp Assy, upper half Kit Part No. BF630013A
2.3
1
(scaled)
Detail X
2.2
A-A
2.5
525 MAX external
not to scale
Update: 21/03/2014
Drawn: SR
Scale:
275 MIN external
CAD File: U:\Inventor\HF630\630300\BF630300.idw
OPERATORS MANUAL ONLY
HF630 Clamp & Fittings Attachment
Drawing Name:
X
2.4
Clamp Block Assy, Kit P. No: BF630307
3 per Fitt. Plate, Qty per Assy listed only
2.1
2
BF000323
BF000275
BF000272
BF630304
BF630308
BF630307
BF630301
2.5
2.4
2.3
2.2
2.1
2
1
A.B.N. 89 008 171 855
Part No.
BF630013A
3
Item
BF630013
BF630007
4.1
3.1
BF630003
4.2
BF000267
BF000267
4.3
3.2
BF630066
4.4
BF630067
BF000027
4.5
3.3
BF630008
4.6
BF630007A
BF000514
4
BF630034
4.7
605 MAX internal
4.8
QTY
1
3
1
1
1
1
1
1
www.dixonind.com.au
Copyright . No part of this drawing
may be reproduced in whole or in
part without the written permission
of Dixon Industries Pty. Ltd.
Part Name
Fittings Plate
Clamp Block Assembly
Fittings Plate Block
Welded T-Bar
Flat Washer
Hex Nut
Set Screw
Clamp Assy, upper half
1
4
Clamp, upper half
2
Mounting Screw
1
1
2
8
2
2
2
2
2
Toggle Bolt Stop
Clamp Assy, lower half
Clamp, lower half
Clamp Cap
Mounting Screw
Toggle Pivot Pin
Retaining Ring
Toggle Bolt
Metric Plain Washers
Toggle Nut Assembly
355 MIN internal
4
BF630950P
Plain Liner Ring 630-500 & Screws
BF630945P
Plain Liner Ring 500-450 & Screws
BF630940P
Plain Liner Ring 450-400 & Screws
BF630935P
Plain Liner Ring 400-355 & Screws
3
UNCONTROLLED DOCUMENT
7
8
5
6
Part No.
BF6309500
1
Item
BF000279
BF6309450
3
2
BF000280
BF6309400
5
4
BF000281
BF6309355
7
6
BF000282
8
2
Part Name
Reducing Liner 630-500mm
Mounting Screw (630-500) 1/2BSW x 2 1/2
Reducing Liner 500-450mm
Mounting Screw (500-450) 1/2BSW x 3 1/3
Reducing Liner 450-400mm
Mounting Screw (450-400) 1/2BSW x 4 1/2
Reducing Liner 400-355mm
Mounting Screw (400-355) 1/2BSW x 5 1/2
1
QTY
2
2
2
2
2
2
2
2
M/P
M
P
M
P
M
P
M
P
15
Part No.
BF6309560
BF000278
LC6309355N
LC6309400N
LC6309450N
LC6309500N
BF000440
not to scale
Update: 27/03/2013
Drawn: SR
Scale:
Part Name
A.B.N. 89 008 171 855
Reducing Liner 630-560mm
Mounting Screw (630-560) 1/2BSW x 1 1/2
Narrow Liner Segment 630-355
Narrow Liner Segment 630-400
Narrow Liner Segment 630-450
Narrow Liner Segment 630-450
Narrow Liner Mounting Screw M8 x 65
12
CAD File: U:\Inventor\HF630\630900\BF6309Liner set.idw
OPERATORS MANUAL ONLY
HF630 Plain & Narrow Liners
Drawing Name:
Item
9
10
11
BF6309355N - Narrow Liner Ring 630-355 & Screws
BF630956P
Plain Liner Ring 630-560 & Screws
12
BF6309400N - Narrow Liner Ring 630-400 & Screws
13
BF6309450N - Narrow Liner Ring 630-450 & Screws
15
14
Screw Set per Liner Ring
13
BF6309500N - Narrow Liner Ring 630-500 & Screws
9
10
14
M/P
M
P
M
M
M
M
P
www.dixonind.com.au
Copyright . No part of this drawing
may be reproduced in whole or in
part without the written permission
of Dixon Industries Pty. Ltd.
QTY
2
2
2
2
2
2
8
11
P3
T5
T6
total welding & cooling pressure
minimum welding & cooling time in the clamps
cooling time out of clamps before rough handling
t+3
t+3
+drag
170+/-20
0.4t + 2
drag
minute
minute
kPa
kPa
kPa
second
second
second
kPa
kPa
kPa
kPa
mm
°C
19
19
2628
9
6
179
drag
2628
1.6
220
23
23
3269
10
6
224
drag
3269
2.0
220
20.4
PN4
33
630
28
28
4047
12
7
279
drag
4047
2.5
220
25.4
PN6.3
26
630
35
35
4975
15
7
347
drag
4975
3.2
220
31.6
PN8
PN6.3
21
630
42
42
6110
18
8
432
drag
6110
3.9
220
39.3
PN10
PN8
17
630
630
52
52
7459
21
9
536
drag
7459
4.9
220
48.7
PN12.5
PN10
13.6
63
63
9032
26
10
662
drag
9032
6.0
220
60.2
PN16
PN12.5
11
630
17
17
2078
8
5
159
drag
2078
1.4
220
14.5
PN4
PN3.2
41
560
21
21
2592
9
6
200
drag
2592
1.8
220
18.2
PN4
33
560
NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint .
P3
+ measured drag
PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER630
P3
welding & cooling pressure
0.1t + 4
T3
T4
heater out
P2
T2
soak pressure
soak time
pressure up
(11±1)t
P3
total bead up pressure
+drag
170+/-20
P1
P3
bead up pressure
0.1t
220+/-15
+ measured drag
allowable axial misalignment
mean heater surface temp
16.3
Parameter
PN4
mean wall thickness
mm
PE100
t
PN3.2
630
PE80
mm
41
D
SDR
nominal pipe od
Parameters based on PIPA Guideline POP003: 6.1 Sept 2011, Single Pressure - Low Pressure.
26
26
3194
11
6
248
drag
3194
2.3
220
22.6
PN6.3
26
560
31
31
3939
13
7
309
drag
3939
2.8
220
28.1
PN8
PN6.3
21
560
38
38
4835
16
7
384
drag
4835
3.5
220
35.0
PN10
PN8
17
560
46
46
5902
19
8
477
drag
5902
4.3
220
43.4
PN12.5
PN10
13.6
560
appendix 1/3
56
56
7128
23
9
587
drag
7128
5.3
220
53.4
PN16
PN12.5
11
560
HF630 hydraulic cylinder area 2027mm²
T5
T6
minimum welding & cooling time in the clamps
cooling time out of clamps before rough handling
t+3
t+3
+drag
170+/-20
0.4t + 2
0.1t + 4
(11±1)t
drag
+drag
170+/-20
0.1t
220+/-15
PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER630
P3
T4
pressure up
total welding & cooling pressure
T3
heater out
P3
T2
soak time
P3
P2
soak pressure
welding & cooling pressure
P3
total bead up pressure
+ measured drag
P1
P3
bead up pressure
+ measured drag
allowable axial misalignment
mean heater surface temp
16
16
1669
19
19
2059
8
6
5
7
178
drag
2059
1.6
220
143
drag
1669
1.3
220
16.2
PN4
33
500
23
23
2548
10
6
222
drag
2548
2.0
220
20.2
PN6.3
26
500
28
28
3147
12
7
277
drag
3147
2.5
220
25.2
PN8
PN6.3
21
500
34
34
3849
14
7
343
drag
3849
3.1
220
31.2
PN10
PN8
17
500
500
42
42
4704
17
8
426
drag
4704
3.9
220
38.7
PN12.5
PN10
13.6
51
51
5690
21
9
525
drag
5690
4.8
220
47.8
PN16
PN12.5
11
500
62
62
6821
25
10
645
drag
6821
5.9
220
58.7
PN20
PN16
9
500
15
15
1340
7
5
128
drag
1340
1.2
220
11.6
PN4
PN3.2
41
450
18
18
1670
8
5
160
drag
1670
1.5
220
14.6
PN4
33
450
NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint .
minute
minute
kPa
kPa
kPa
second
second
second
kPa
kPa
kPa
kPa
mm
°C
13.0
Parameter
PN4
mean wall thickness
mm
PE100
t
PN3.2
500
PE80
mm
41
D
SDR
nominal pipe od
Parameters based on PIPA Guideline POP003: 6.1 Sept 2011, Single Pressure - Low Pressure.
21
21
2066
9
6
200
drag
2066
1.8
220
18.2
PN6.3
26
450
26
26
2551
11
6
249
drag
2551
2.3
220
22.7
PN8
PN6.3
21
450
31
31
3124
13
7
309
drag
3124
2.8
220
28.1
PN10
PN8
17
450
38
38
3812
16
7
383
drag
3812
3.5
220
34.9
PN12.5
PN10
13.6
450
56
56
5535
23
9
582
drag
5535
5.3
220
52.9
PN20
PN16
9
450
appendix 2/3
46
46
4612
19
8
473
drag
4612
4.3
220
43.0
PN16
PN12.5
11
450
HF630 hydraulic cylinder area 2027mm²
68
68
6565
28
10
711
drag
6565
6.5
220
64.7
PN25
PN20
7.4
450
T5
T6
minimum welding & cooling time in the clamps
cooling time out of clamps before rough handling
t+3
t+3
+drag
170+/-20
0.4t + 2
0.1t + 4
(11±1)t
drag
+drag
170+/-20
0.1t
220+/-15
PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER630
P3
T4
pressure up
total welding & cooling pressure
T3
heater out
P3
T2
soak time
P3
P2
soak pressure
welding & cooling pressure
P3
total bead up pressure
+ measured drag
P1
P3
bead up pressure
+ measured drag
allowable axial misalignment
mean heater surface temp
13
13
1063
16
16
1326
7
5
5
6
143
drag
1326
1.3
220
114
drag
1063
1.0
220
13.0
PN4
33
400
19
19
1634
8
6
178
drag
1634
1.6
220
16.2
PN6.3
26
400
23
23
2017
10
6
222
drag
2017
2.0
220
20.2
PN8
PN6.3
21
400
28
28
2466
12
6
274
drag
2466
2.5
220
25.0
PN10
PN8
17
400
400
34
34
3010
14
7
340
drag
3010
3.1
220
31.0
PN12.5
PN10
13.6
41
41
3642
17
8
420
drag
3642
3.8
220
38.2
PN16
PN12.5
11
400
50
50
4372
21
9
517
drag
4372
4.7
220
47.0
PN20
PN16
9
400
61
61
5189
25
10
633
drag
5189
5.8
220
57.5
PN25
PN20
7.4
400
15
15
1041
7
5
127
drag
1041
1.2
220
11.5
PN4
33
355
NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint .
minute
minute
kPa
kPa
kPa
second
second
second
kPa
kPa
kPa
kPa
mm
°C
10.4
Parameter
PN4
mean wall thickness
mm
PE100
t
PN3.2
400
PE80
mm
41
D
SDR
nominal pipe od
Parameters based on PIPA Guideline POP003: 6.1 Sept 2011, Single Pressure - Low Pressure.
17
17
1293
8
5
158
drag
1293
1.4
220
14.4
PN6.3
26
355
21
21
1582
9
6
196
drag
1582
1.8
220
17.8
PN8
PN6.3
21
355
25
25
1951
11
6
245
drag
1951
2.2
220
22.3
PN10
PN8
17
355
31
31
2373
13
7
303
drag
2373
2.8
220
27.5
PN12.5
PN10
13.6
355
45
45
3439
19
8
458
drag
3439
4.2
220
41.7
PN20
PN16
9
355
appendix 3/3
37
37
2869
16
7
373
drag
2869
3.4
220
33.9
PN16
PN12.5
11
355
HF630 hydraulic cylinder area 2027mm²
48
48
3690
20
9
497
drag
3690
4.5
220
45.2
PN25
PN20
7.4
355
DIXON INDUSTRIES PTY LTD
ABN 89 008 171 855
17 Frederick Road, Royal Park
South Australia, 5014.
Tel: (08) 8240 1555
Fax: (08) 8240 5588