Operation Manual

For Hydraulic Butt Welding Machine

, LTD
CO.
L O GY
HN O
T EC
E L INE
F PIP
N DE
A
HEN
φ160，φ200，φ250
φ315，φ450，φ500
φ630，φ800，φ1000

Operation manual for butt welding machine i

 Operation Manual for Hydraulic Welding Machine
Hydraulic Type

1, Brief

The most popular and reliable welding method for HDPE pipe is Butt fusion welding. Butt fusion welding is thermal
jointing. The principle is to heat two pipe ends to designated temperature, and then fuse them together by application of
sufficient force. The quality of joints then depends on the quality butt welding machine, proper welding parameters and
experience of the welder.

This manual is for plastic pipe butt welding machine. It’s suggested to read and follow carefully the following safety rules and
maintenance rules before operating the machine.

2, Special Description
Before operating the machine, anyone should read this description carefully and keep it well to ensure the equipment and

LTD
operator’s safety, as well as others’ safety.

O. ,
2.1 The machine is used to weld pipes made from PE, PP, PVDF and cannot be used to weld material without description,
otherwise the machine may be damaged or some accident may be resulted in.
O G Y C
2.2 Don’t use the machine in a place with potential hazard of explosionNOL
H
ECtrained
2.3 The machine should be operated by responsible, qualified and
E T personnel.
I N
2.4 The machine should be operated on a dry area. ThLe protective measures should be adopted when it is used in rain or on
wet ground. P IPE
2.5 The machine is operated by 220V±10%,D EF 50 Hz. If extended wire should be used, it should have enough lead section
AN
according its length. HEN

3, Safety
3.1 Precautions for Safety
Take care when operating and transporting the machine according to all the safety rules in this instruction.
3.1.1 Notice when using
 The operator should be responsible and trained personnel.
 Completely inspect and maintain the machine per year for the safety and machine’s reliability.
 Dirty and crowed work site would not only lower working efficiency, but cause accident easily, so it is important to keep
work site clean and no other obstacles.
3.1.2 Storage of electrical equipment
For the min. dangers, all equipment must be used and stored correctly as follows:
※Avoid using temporary wire not complying with standard
※ Do not touch electrophorus parts
※ Forbid hauling off the cable to disconnect
※ Forbid hauling cables for lifting equipment

Operation manual for butt welding machine ii

 ※ Do not put heavy or sharp object on the cables, and control the temperature of cable within limiting temperature
(70℃)
※ Do not work in the wet environment. Check if the groove and shoes is dry.
※ Do not splash the machine
3.1.3 Check insulation condition of machine periodically
※ Check the insulation of cables specially the points extruded
※ Do not operate the machine under extreme condition.
※ Check if the leakage switch works well at least per week.
3.1.4 Clean and check the machine carefully
※Do not use materials (like abrasive, and other solvents) damaging the insulation easily when cleaning the machine.
※ Make sure the power is disconnected when finishing job.
※Make sure there is no any damage in the machine before reusing.
If only following above mentioned, the precaution can work well.
3.1.5 Starting
Make sure the switch of the machine is closed before powering it on.
3.1.6 Tightness of parts
Make sure the pipes are fixed correctly. Ensure that it can move well and prevent it from sliding down.
3.1.7 Work in environment with hazards
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◎When work in a ditch, check if there is fender which stop the earth or stones from
Y CO.falling down to the machine, and also
O L OG electric shock.
check if it has a water or other fluid leaking, if there be, the operator may get an
N
◎When lift the machine to ditch, the weight of the machine shouldCbe
T E H within the rated lifting weight, and person is forbidden
E
LIN gas, and smoke, since the infection of eyes and respiratory tract
staying under the lifting arm.
◎Avoid using the machine in the environment full P ofEpaint,
F PI
would be caused.
D E
N
◎Do not put the machine in a dirtyAplace.
HEN
3.1.8 Personnel safety while working
Remove jewelry and rings, and does not wear loose-fitting clothing avoid wearing shoe lace, long mustache or long hair that
may be hooked into the machine
3.1.9 Untrained person is not allowed to operate the machine anytime.
3.2. Potential Dangers
3.2.1 Butt fusion machine controlled by hand pushing:
This machine is only operated by professional person or others with a certificate for operation, otherwise unwanted
accident maybe caused.
3.2.2 Heating Plate
The max temperature can reach 270℃, so the following things should be noticed:

------Wear safety gloves

-------Never touch the surface of the heating plate

3.2.3 Milling Cutter
Before shaving the pipes, ends of pipes should be cleaned, especially clean the sand or other draff crowed around the ends.

Operation manual for butt welding machine iii

By doing this, the lifetime of edge can be prolonged, and also prevent the shavings are thrown out to danger people.
3.2.4 Main Frame:
Make sure the pipes or fittings are fixed correctly to get the right alignment. When joining pipes, the operator should keep a
certain space to the machine for personnel safety.
Before transporting, make sure all the clamps are fixed well and cannot fall down during transportation.
Follow all the safety marks in the machine.

Hot！Keeping distance from parts with this sign, for they are very hot!

Danger, Electrical shock

Parts with this sign have a danger of electricity leak. Be careful when working here.

No approaching! Moving parts can crush. Keep fingers, feet, arms, legs, and head out of the jaw area
between the moving tables.

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Caution, injure hand

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C
L O GY
O
CHN
4. Applicable Range and Technical
TE
Parameter

IN E
E L
PIP
D EF
AN
5
HEN 3

4
1
1， Basic Frame
2， Heating Plate
3， Million Cutter
4， Cylinder
5， Hydraulic Unit

Operation manual for butt welding machine iv

 Sheet 1

Type φ160

Materials PE，PP，PVDF

Max. range of diameter 63-160 mm

Ambient temp. －5～40℃

Power supply 220V±10 ％

Frequency 50 Hz

Total power 3.25 kW

Include：Heating plate 1.5 kW

Milling cutter motor 1.0kW

Hydraulic unit motor 0.75 kW

Dielectric resistance >1MΩ

Max. Pressure 4MPa

Total section of cylinders 15.3cm2

Hydraulic oil , LTD

40～50（kinematic viscosity）mm2/s, 40℃）
CO.
Max. Temperature of heating plate
L O GY 270℃

HN O
Difference in surface temperature of heating plate
T EC ±3℃

Basic Frame
E L INE
Size，mm 890*450*630

Hydraulic Unit
F PIPSize, mm 565*485*570

Total Weight N DE W.G., kg 112.5

E N A
H

Operation manual for butt welding machine v

 Sheet 2

Type φ200

Materials PE，PP，PVDF

Max. range of diameter 63-200 mm

Ambient temp. －5～40℃

Power supply 220V±10 ％

Frequency 50 Hz

Total power 3.55kW

Include：Heating plate 1.8kW

Milling cutter motor 1.0kW

Hydraulic unit motor 0.75 kW

Dielectric resistance >1MΩ

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Max. Pressure 4MPa

Total section of cylinders ,

O. 15.3cm 2

O G Y C
Hydraulic oil
OL
40～50（kinematic viscosity）mm /s, 40℃）
2

H N
Max. Temperature of heating plate T EC 299℃
E
E
Difference in surface temperature of heating plate
P LIN ±3℃
P I
Basic Frame
D EF Size，mm 890*530*620

Hydraulic Unit NA
N Size, mm 565*485*570
HE
Total Weight W.G., kg 120

Operation manual for butt welding machine vi

 Sheet 3

Type φ250

Materials PE，PP，PVDF

Max. range of diameter 90-250 mm

Ambient temp. －5～40℃

Power supply 220V±10 ％

Frequency 50 Hz

Total power 4.15 kW

Include：Heating plate 2.3 kW

Milling cutter motor 1.1kW

Hydraulic unit motor 0.75 kW

Dielectric resistance >1MΩ

Max. Pressure 4.5MPa

Total section of cylinders

, LTD
11.16cm2

Hydraulic oil CO.

40～50（kinematic viscosity）mm2/s, 40℃）

L O GY
Max. Temperature of heating plate
H NO 270℃

Difference in surface temperature of heating plate TEC ±3℃

E L INE
PIP
Basic Frame Size，mm 930*580*560

Hydraulic Unit D EF Size, mm 820*550*640

Total Weight EN
AN W.G., kg 146
H

Operation manual for butt welding machine vii

 Sheet 4

Type φ315

Materials PE，PP，PVDF

Max. range of diameter 160-315 mm

Ambient temp. －5～40℃

Power supply 220V±10 ％

Frequency 50 Hz

Total power 4.95 kW

Include：Heating plate 3.1 kW

Milling cutter motor 1.1kW

Hydraulic unit motor 0.75 kW

Dielectric resistance >1MΩ

Max. Pressure 5.0MPa

Total section of cylinders 12.56cm2

Hydraulic oil LTD

40～50（kinematic viscosity）mm2/s, 40℃）
,
CO.
Max. Temperature of heating plate
L O GY 299℃

Difference in surface temperature of heating plate H NO ±3℃

TEC
INE
Basic Frame Size，mm 1060*665*620
E L
PSize, mm
Hydraulic Unit
F PI 730*645*710

Total Weight D E W.G., kg 189

N
H ENA

Operation manual for butt welding machine viii

Sheet 5

Type φ450

Materials PE，PP，PVDF

Max. range of diameter 280-450 mm

Ambient temp. －5～40℃

Power supply 380V±10 ％

Frequency 50 Hz

Total power 9.1 kW

Include：Heating plate 6.5 kW

Milling cutter motor 1.1kW

Hydraulic unit motor 1.5 kW

Dielectric resistance >1MΩ

Max. Pressure 8.0MPa

Total section of cylinders 22.18cm2

Hydraulic oil LTD

40～50（kinematic viscosity）mm2/s, 40℃）
,
CO.
Max. Temperature of heating plate
L O GY 270℃

Difference in surface temperature of heating plate H NO ±3℃

TEC
INE
Basic Frame Size，mm 1170*740*610
E L
PSize, mm
Milling cutter/heating plate/trolly
F PI 890*610*1080

Hydraulic Unit D E Size, mm 940*480*750

N
H
Total Weight ENA W.G., kg 400

Operation manual for butt welding machine ix

Sheet 6

Type φ500

Materials PE，PP，PVDF

Max. range of diameter 280-500 mm

Ambient temp. －5～40℃

Power supply 380V±10 ％

Frequency 50 Hz

Total power 9.1 kW

Include：Heating plate 6.5 kW

Milling cutter motor 1.1kW

Hydraulic unit motor 1.5 kW

Dielectric resistance >1MΩ

Max. Pressure 8.0MPa

Total section of cylinders 22.18cm2

Hydraulic oil , LTD

40～50（kinematic viscosity）mm2/s, 40℃）
CO.
Max. Temperature of heating plate
L O GY 270℃

HN O
Difference in surface temperature of heating plate
T EC ±3℃

Basic Frame
E L INE
Size，mm 1200*800*870

Milling cutter/heating plate/trolly

F PIPSize, mm 900*620*1090

Hydraulic Unit N DE Size, mm 1010*480*755

E N A
Total WeightH W.G., kg 460

Operation manual for butt welding machine x

Sheet 7

Type φ630

Materials PE，PP，PVDF

Max. range of diameter 400-630 mm

Ambient temp. －5～40℃

Power supply 380V±10 ％

Frequency 50 Hz

Total power 10.1 kW

Include：Heating plate 7.5 kW

Milling cutter motor 1.1kW

Hydraulic unit motor 1.5 kW

Dielectric resistance >1MΩ

Max. Pressure 8.0MPa

Total section of cylinders 27.08cm2

Hydraulic oil , LTD

40～50（kinematic viscosity）mm2/s, 40℃）
CO.
Max. Temperature of heating plate
L O GY 270℃

HN O
Difference in surface temperature of heating plate
T EC ±3℃

Basic Frame
E L INE
Size，mm 1360*925*990

Milling cutter/heating plate/trolly

F PIPSize, mm 890*610*1080

Hydraulic Unit N DE Size, mm 940*480*750

E N A
Total WeightH W.G., kg 630

Operation manual for butt welding machine xi

Sheet 8

Type φ800

Materials PE，PP，PVDF

Max. range of diameter 630-800mm

Ambient temp. －5～40℃

Power supply 380V±10 ％

Frequency 50 Hz

Total power 14.7 kW

Include：Heating plate 11 kW

Milling cutter motor 1.5kW

Hydraulic unit motor 2.2kW

Dielectric resistance >1MΩ

Max. Pressure 8.0MPa

Total section of cylinders 31.8cm2

Hydraulic oil LTD

40～50（kinematic viscosity）mm2/s, 40℃）
,
CO.
Max. Temperature of heating plate
L O GY 270℃

Difference in surface temperature of heating plate H NO ±5℃

TEC
INE
Basic Frame Size，mm 1940*1230*1290
E L
PSize, mm
Milling cutter/heating plate/trolly
F PI 1150*760*570

Hydraulic Unit D E Size, mm 1020*490*760

N
H
Total Weight ENA W.G., kg 1211

Operation manual for butt welding machine xii

Sheet 9

Type Φ1000

Materials PE，PP，PVDF

Max. range of diameter 800-1000mm

Ambient temp. －5～40℃

Power supply 380V±10 ％

Frequency 50 Hz

Total power 25.2kW

Include：Heating plate 20 kW

Milling cutter motor 3kW

Hydraulic unit motor 2.2kW

Dielectric resistance >1MΩ

Max. Pressure 8.0MPa

Total section of cylinders

, LTD
41.18cm 2

CO.
Hydraulic oil
L O GY
40～50（kinematic viscosity）mm2/s, 40℃）

HN O
Max. Temperature of heating plate
T EC 270℃

Difference in surface temperature of heating plate NE ±5℃

P E LI
Basic Frame
F PI Size，mm 2240*1480*1580
D E
N A N
Milling cutter/heating plate/trolly Size, mm 1290*1010*1900
H
Hydraulic Unit
E Size, mm 1010*590*780

Total Weight W.G., kg 2000

Operation manual for butt welding machine xiii

5, Instruction for use
6.1 The whole equipment should be placed on a stable and dry plane to operate.
6.2 Before operation make sure the following things:
◎The machine is in good conditions
◎The power complies with the requirements according to the butt fusion machine
◎Power line is not broken or worn
◎All instruments are normal
◎The blades of milling cutter are sharp
◎All necessary parts and tools are available
6.3 Welding
6.3.1 Pipes
Before welding, firstly, check if the material and its pressure grade are the required ones. Secondly check if there are
scratches or fissures on the surface of pipes/fittings. If the depth of scratches or fissures exceeds 10% of the wall thickness,
cut the section of scratches or fissures. Clean the pipe end’s surfaces with clean cloth to keep the pipe’s ends clean.
6.3.2 Clamping
Place the pipes/fittings in inserts of frame and keep the ends to be welded be the same length (no effect on the Milling and
heating of the pipe). The pipe out of the main frame should be supported to the same central axial of clamps. Fasten the
screws of clamps to fix the pipes/fittings.
6.3.3 Milling , LTD
O.
O G Y C
Put the milling cutter between the pipes/fittings ends and switch it on, close the pipes/fittings ends by acting on the pushrod

C H NOL later, open the frame, switch off the milling cutter
until there are continuous shavings appearing on both sides. After a moment
and remove it.
E TE
P E L N The maximal misalignment should not exceed 10% of the wall
Close the pipes/fitting ends and checks the alignment ofIthem.
thickness, and it could be improved by loosening
F PIor tightening the screws of clamps. The gap between two pipe ends should
E
A N Dbe within
not exceed 10% of wall thickness; otherwise
Caution: The shavings thicknessNshould
the pipes/fittings should be planed again.
0.2~0.5 mm and it can be adjusted by adjusting the height of the milling
H E
cutter blades.
6.3.4 Heating
Clear the dust or slit on the surface of heating plate (Caution: Don’t damage PTFE layer on the surface of heating plate.), and
make sure the temperature has reached the required one.
Put the heating plate between the pipe ends after it reaches required temperature. Close the pipes/fittings ends by operating
the pushrod till the bead reaches specified height.
6.3.5 Joining and cooling
Open the frame and take out the heating plate and close two melting ends as quickly as possible.
When it reaches the required cooling time, loosen the screw of clamps and then takes out the jointed pipes.

Operation manual for butt welding machine xiv

 6, Reference for Welding Parameters

Bead
Wall Bead Soaking Soaking Change-over Pressure build Welding Cooling
build-up
thickness height time pressure time -up time pressure time
pressure
（mm） （mm） t2（sec） （MPa） t3（sec） t4（sec） （MPa） t5（min）
（MPa）
0～4.5 0.5 0.15 45 ≤0.02 5 5 0.15±0.01 6
4.5～7 1.0 0.15 45～70 ≤0.02 5～6 5～6 0.15±0.01 6～10
7～12 1.5 0.15 70～120 ≤0.02 6～8 6～8 0.15±0.01 10～16
12～19 2.0 0.15 120～190 ≤0.02 8～10 8～11 0.15±0.01 16～24
19～26 2.5 0.15 190～260 ≤0.02 10～12 11～14 0.15±0.01 24～32
26～37 3.0 0.15 260～370 ≤0.02 12～16 14～19 0.15±0.01 32～45
37～50 3.5 0.15 370～500 ≤0.02 16～20 19～25 0.15±0.01 45～60
50～70 4.0 0.15 500～700 ≤0.02 20～25 25～35 0.15±0.01 60～80

Remark ： Bead build-up pressure and welding pressure in the form is the recommended interface pressure, the gauge

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pressure should be calculated with the following formula.
Expressions:
O. ,
C
welding pressure =
Section of welding pipe ends
L
× 0.15 + drag pressure（MPa） O GY
N O
ECH
Total section of cylinders
T
E L INEjoint problems
7, General
F PIP
N DE
A
HENgood joint
◎Visually check：round bead,

◎Narrow and fall bead. Too high pressure while welding

◎Too small bead. Pressure is not enough while welding

◎There is a ditch between the welding surfaces. Temperature is

not enough or change-over time is too long while welding.

◎High & low bead. Different heating time or fusion temperature

causes that.

◎ Misalignment. Welding under the condition that the

misalignment exceeds 10% of pipe wall thickness while align the

two ends.

Operation manual for butt welding machine xv

 8, Maintenance
※ Heating plate coating
Please take care on handling the heating plate. Keep a certain distance away from heating plate. Cleaning of its surface
must be done with surface still warm by using a soft cloth or paper, avoid abrasive materials in that might damage the coating.
At regular intervals check as follows
1) Clean the surface by using a quick evaporation detergent (alcohol)
2) check the tightening of the screws and the cable and plug condition
3) Verify its surface temperature by using infrared-ray scanning
※ Milling cutter
It is strongly suggested to keep always clean the blades and wash the pulleys by using a detergent. At regular intervals, carry
out a complete cleaning operation.

9. Guarantee Clauses

1. The guarantee range refers to the whole machine.

2. Maintenance for malfunctions during normal utilization is free of charge within guarantee time that is 12 months

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3. The guarantee time starts with the date of delivery.

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4. Fees are charged in case of the following condition: C
L O GY
4.1 Malfunction caused by improper operation
N O
T ECH
4.2 Damages caused by fire, flood, and abnormal voltage E

P E LIN
4.3 Working exceeds its normal function
F PI
E
DA contract about the fees shall be abided if there is one.
A N
5. Fees are charged as actual expense.
HEN

Operation manual for butt welding machine xvi