SHD250

BUTT FUSION WELDING MACHINE

OPERATION MANUAL

WUXI SHENGDA PLASTIC PIPES WELDING MACHINE CO., LTD

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CONTENTS
1. Brief........................................................................................................................................... 2
2. Special Description ............................................................................................................... 2
3. Safety ........................................................................................................................................ 3
4. Applicable Range and Technical Parameter................................................................... 6
5. Descriptions............................................................................................................................ 7
6. Instruction for Use................................................................................................................. 9
7. Timer and Temperature Controller.................................................................................. 11
8. Reference of Welding StandardDVS2207-1-1995 ................................................ 12
9. Malfunctions Analyses and Solutions............................................................................ 13
10. Circuit & Hydraulic Unit Diagram .................................................................................. 16
11. Packing ListSeen in appendix.................................................................................. 16
12. Guarantee Clauses............................................................................................................ 17

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1. Brief
Along with the property of PE material continuous perfecting and raising, PE pipes are extensively used in
gas and water supply, sewage disposal, chemical industry, mine and so on.
For more than ten years, our factory has been researching and developing SH series plastics pipe butt fusion
machine that is suit for PE, PP, and PVDF. We have fulfilled the techniques requirements of ISO12176-1. Our
products have outstanding features in convenience, reliability, safety and lower price.
Today, our products include nine kinds and over than 20 types that can be applied to plastics pipe
construction and make fittings in workshop as follow:
SHS series socket welder

SJC series band saw

SHDS series manual butt fusion machine

SC series pipe cutter

SHD series butt fusion machine

Series special tools

SHDA series Auto-butt fusion machine

SHM series saddle fusion machine

SHG series workshop butt fusion machine

This manual is suit for SHD250 plastic pipe butt fusion welding machine. Its 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 operators safety, as well as others safety.
2.1 The machine is used to weld pipes made from PE, PP, PVDF and can not be
used to weld material without description, otherwise the machine may be damaged
or some accident may be resulted in.
2.2 Dont use the machine in a place with potential hazard of explosion
2.3 The machine should be operated by responsible, qualified and trained
personnel.
2.4 The machine should be operated on a dry area. The protective measures should
be adopted when it is used in rain or on wet ground.
2.5 The machine is operated by 220V10%,60 Hz. If extended wire should be used, it should have enough
lead section according its length.
2.6 Before using the machine, fill 46# hydraulic oil. Make sure the hydraulic oil is enough for working; the oil
level should be 2/3 of the tank. Replace the iron oil tank cap by the red plastic air bleed cap or the pressure
can not be hold.

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3. Safety
3.1 safety marks
The following marks are affixed to the machine:

HotKeep 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.

Caution, injure hand

Caution, heavy

3.2 Precautions for Safety

Take care when operating and transporting the machine according to all the safety rules in this instruction.
3.2.1 Notice when using
l

The operator should be responsible and trained personnel.

Completely inspect and maintain the machine per year for the safety and machines 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

3.2.2 Power
The electricity distribution box should have ground fault interrupter with relevant electricity safety standard. All
safety protection devices are indicated by easily understandable words or marks.
Earthing: The whole site should share the same ground wire and the ground connection system should be
completed and tested by professional people.
3.2.3 Connection of machine to power
The cable connecting machine to power should be mechanical concussion and chemical corrosion proof. If

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the extended wire is used, it must have enough lead section according to its length.
3.2.4 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
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
3.2.5 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.
Check the earthing of the machine by qualified personnel
3.2.6 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.
3.2.7 Starting
Make sure the switch of the machine is closed before powering it on.
3.2.8 Tightness of parts
Make sure the pipes are fixed correctly. Ensure that it can move well and prevent it from sliding down.
3.2.9 Work in environment with hazards
When work in a ditch, check if there is fender which stop the earth or stones from falling down to the machine,
and also check if it has a water or other fluid leaking, if there be, the operator may get an electric shock.
When lift the machine to ditch, the weight of the machine should be within the rated lifting weight, and person
is forbidden staying under the lifting arm.
Avoid using the machine in the environment full of paint, gas, smoke and deoil, since the infection of eyes and
respiratory tract would be caused.
Do not put the machine in a dirty place.
3.2.12 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
The following is the operation rules:

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---Wear safety groove

---Wear safety shoe
---Dress work clothes
---Wear safety glasses
---Wear earmuffs
3.2.14 Untrained person is not allowed to operate the machine anytime.
3.3. Potential Dangers
3.3.1 Butt fusion machine controlled by hydraulic unit:
This machine is only operated by professional person or others with a certificate for operation, otherwise
unwanted accident maybe caused.
3.3.2 Heating Plate
The max temperature can reach 270, so the following things should be noticed:
------Wear safety groove
-------Never touch the surface of the heating plate
3.3.3 Planing tool
Before shaving the pipes, ends of pipes should be cleaned, especially clean the sand or other draff crowed
around the ends. By doing this, the lifetime of edge can be prolonged, and also prevent the shavings are
thrown out to danger people.
3.3.4 Basic 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 can not fall down during transportation.
Follow all the safety marks in the machine.

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4. Applicable Range and Technical Parameter

Type

SHD250

Materials

PEPPPVDF

Max. range of diameter

250 mm

Ambient temp.

545

Power supply

220V10

Frequency

60 Hz

Total current

23 A

Total power

3.95 kW

IncludeHeating plate

2.1 kW

Planing tool motor

1.1 kW

Hydraulic unit motor

0.75 kW

Dielectric resistance

>1M

Max. Pressure

6 MPa

Total section of cylinders

11 cm2

Volume of oil box

3L

Hydraulic oil

4050kinematic viscositymm2/s, 40

Undesired sound

80~85 dB

Max. Temperature of heating plate

270

Difference in surface temperature of heating plate

Sizemm

860460420

Weight kg

46.3

Sizemm

640430440

Weightkg

56

Sizemm

460390500

Weightkg

19.5

Sizemm

60060450

Weightkg

7.2

Sizemm

400310600

Weightkg

7.8

Basic frame

Hydraulic unit

Planing tool

Heating plate

Supports
Total weightkg

137

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5. Descriptions
The machine consists of basic frame, hydraulic unit, heating plate, Planing tool, and support.

1. Hydraulic unit

2. Basic frame

Figure .1
3. Planing tool

4. Support

5. Heating plate

5.1 Basic Frame

1. Cylinder

Figure .2
2. Stub end device
3. Main clamp

4. Adjust screw

5.2 Hydraulic Unit

5.2.1 Hydraulic unit

Figure.3
1. Direction valve

2. Pressure regulation valve

3. Pressure gauge

4. Swing check valve

5. Oil tank

6. Power cable

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5.2.2 Hydraulic unit operation panel

1. Temperature controller
5. protection cover

Figure .4
2. Ground fault interrupter
6. Timer

3. Voltmeter
7. T5

4. Pressure gauge
8. T2

5.2.3 Hydraulic unit sockets

1. Planning tool socket

Figure 5
2. Recorder socket

3. Heating plate socket

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6. 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:
u

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 planning tool are sharp

All necessary parts and tools are available

6.3 Connection and preparation

6.3.1 Connect the basic frame to hydraulic unit by quick couplers.

6.3.2 Connect the heating plate to the hydraulic unit with the special cable.

Connection the cable with electrical box

Connection between the cable and heating plate

6.3.3 Install appropriate inserts to frame according to the outside diameter of pipes/fittings.
6.3.4 According to the requirements of fitting and welding process, set the temperature in temperature
controller and set time in timer. (See section 7 this manual).
6.4 Welding Steps
6.4.1 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 ends surfaces with clean
cloth to keep the pipes ends clean.
6.4.2 Clamping
Place the pipes/fittings in inserts of frame and keep the ends to be welded be the same length (no effect on

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the planning and heating of the pipe). The pipe out of the basic frame should be supported to the same
central axial of clamps. Fasten the screws of clamps to fix the pipes/fittings.
6.4.3 Adjust the pressure
Open fully the pressure regulation valve completely, lock the swing check valve tightly and then push forward
the direction valve meanwhile adjust the pressure regulation valve till the cylinder begin to move, at this point
the pressure in the system is the drag pressure.
Open the pressure regulation valve completely, lock the swing check valve tightly and then push forward the
direction valve meanwhile adjust the pressure regulation valve to set the system pressure equals to drag
pressure add butting pressure.
6.4.4 Planing
Open the pipes/fittings ends after turning swing check valve anti-clockwise to the end. Put the planning tool
between the pipes/fittings ends and switch it on, close the pipes/fittings ends by acting on the direction valve
meanwhile slowly turn swing check valve clockwise until there are continuous shavings appearing on both
sides. Turn the swing valve anti clockwise to relief the pressure, in a moment later open the frame, switch off
the planing tool and remove it.
Close the pipes/fitting ends and checks the alignment of them. The maximal misalignment should not exceed
10% of the wall thickness, and it could be improved by loosening or tightening the screws of clamps. The gap
between two pipe ends should not exceed 10% of wall thickness; otherwise the pipes/fittings should be
planed again.
Caution: The shavings thickness should be within 0.2~0.5 mm and it can be adjusted by adjusting the height
of the planning tool blades.
6.4.5 Heating
Clear the dust or slit on the surface of heating plate (Caution: Dont 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 direction valve and raise the pressure to specified pressure by swinging pressure
regulation valve till the bead reaches specified height.
Turn swing check valve anti-clockwise to reduce the pressure (not more than drag pressure) and turn swing
check valve in clockwise direction to the end.
Press the button T2 , the soaking time begins to count and the time will count down to zero by second, then
the buzzer will buzzsee section 7
6.4.6 Joining and cooling
Open the frame and take out the heating plate and close two melting ends as quickly as possible.
Keep the bar of direction valve on the close position for 2~3 minutes, put the bar of direction valve on middle
position and press the button (T5) to count cooling time until it is over. At this point, the machine will give
an alarm again. Relief the pressure, loose the screw of clamps and then take out the jointed pipes.

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7. Timer and Temperature Controller

If one of the parameters is changed, such as outside diameter, SDR or material of pipes, the soaking time
and cooling time should be reset according to the welding standard.
7.1 Timer setting
Press
set

The lamp T2 is on and the lamp T5 is off

Pressing
or

To set soaking time in second.

Press
set

The lamp T2 is off and the lamp T5 is on

Press
or

To set cooling time in second

Press
Set

Timer setting is over

7.2 Instruction for Use

Press
T2

Alarm when the soaking time counts down to zero.

Press
T5

Alarm when the cooling time counts down to zero

Press
and

Timer stops

7.3 Temperature controller setting

1) Press SET for more than 3 seconds till sd is shown in the upper window
2) Press or to change the value to specified (press or continuously, the value will plus or
minus automatically )
3) After setting, press SET to go back to monitoring and controlling interface

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8. Reference of Welding StandardDVS2207-1-1995

8.1 Because of difference in welding standard and PE material, the time and pressure vary in different phases
of welding. It suggests that the actual welding parameters should be offered by pipes and fittings
manufacturers.
8.2 Given welding temperature of pipes made from PEPP and PVDF by DVS standard ranges from180 to
270. Application temperature of heating plate is within 180230, and its max. surface temperature can
reach 270.
8.3 Reference standard DVS2207-1-1995
Bead pressure

Welding pressure

Soaking pressure
Time
t1

t2

t3

t4

t5

Pressure
Welding
build -up
pressure
time
MPa
t4sec
5
0.150.01

Wall
thickness
mm

Bead
height
mm

04.5

0.5

Bead
build-up
pressure
MPa
0.15

45

0.02

4.57

1.0

0.15

4570

0.02

56

56

0.150.01

610

712

1.5

0.15

70120

0.02

68

68

0.150.01

1016

1219

2.0

0.15

120190

0.02

810

811

0.150.01

1624

1926

2.5

0.15

190260

0.02

1012

1114

0.150.01

2432

2637

3.0

0.15

260370

0.02

1216

1419

0.150.01

3245

3750

3.5

0.15

370500

0.02

1620

1925

0.150.01

4560

5070

4.0

0.15

500700

0.02

2025

2535

0.150.01

6080

Soaking Change-over
Soaking
pressure
time
time
t3sec
t2sec MPa

Cooling
time
t5min
6

RemarkBead build-up pressure and welding pressure in the form is the recommended interface pressure,
the gauge pressure should be calculated with the following formula.
Expressions:
Section of welding pipe ends
welding pressure =
0.15 + drag pressureMPa
Total section of cylinders

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9. Malfunctions Analyses and Solutions

9.1 Frequent joints quality problems analyze:

Visually checkround bead, good joint

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.
9.2 Maintenance and inspection periods
9.2.1 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

Planing tool
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.
hydraulic unit
Maintain it as follows
1)

check periodically the oil level

2)

replace totally the oil every 6 months

Keep tank and oil circuit clean

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9.2.2 Maintenance & Inspection

Ordinary inspection
Item

Planning tool

Heating plate
Temp. control
system

Hydraulic
system

Description
Mill or replace the blade
Replace the cable if it is broken
Retighten mechanical connections
Rejoined the cable and socket
Clean surface of heating plate, recoat PTFE layer
again if necessary
Retighten mechanical connections
Checkout the temperature indicator
Replace the cable if it is broken
Checkout pressure gauge
Replace seals if the hydraulic unit is leak
Clean the filter
Make sure the oil is enough for operation
Change the hydraulic oil
Replace if the oil hose is breakage

Basic
Frame

Retighten screws in the end of frame axis

Spray antirust paint again if necessary

Power
Supply

Press the testing button of circuit protector to

make sure it can working normally
Replace the cable if it is broken

Inspect
before use

First
month

Every 6
months

Every
year

maintenance period

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9.3 Frequent malfunction analyses and solutions

During the using, hydraulic unit and electrical units may appear some problems. Frequent malfunction is
listed as follows:
Please use tools attached, spare parts or other tools with a safety certificate while maintain or replace parts.
Tools and spare parts without safety certificate are forbidden to be used.
Malfunctions of hydraulic unit
No

malfunction

The pump motor

does not work

The pump motor

rotate too slowly
with abnormality
noise

The cylinder works

abnormally

Cylinder leak

The pressure can

not be increased or
the fluctuation is
too big

malfunction analyzes
1.
2.
3.
4.
1.
2.
3.
4.

switch is fault.
Power source is not connected well.
The socket inside connection is loosen
The machine is not grounded correctly
The motor is overloaded
The motor is fault
The oil filter is blocked
The working voltage is instable

1.
2.
3.
4.
5.

The direction valve is damaged

There is air in system
The system pressure is too low
The quick coupler is blocked
The pressure relief valve is not locked

1. The oil ring is fault

2. The cylinder or piston is damaged badly
1.
2.
3.
4.

Solutions
1.
2.
3.
4.

Check the switch

Connect the power well
Check the connection
Check the earthing connection
1. Make sure the motor load is less that 3
MPa
2. Repair or replace the pump
3. Clean the filter
4. Check the instability of power
1. Replace the direction valve.
2. Move the cylinder several times to
outgo the air.
3. Adjust the system pressure
4. Replace the quick coupler
5. Lock the valve
1. Replace the oil ring
2. Replace the cylinder
1.

The core of overflow valve is blocked.

The pump is leak.
The joint slack of pump is loosened or key
groove is skid.
4. The pressure relief valve is not locked

2.
3.
4.

Clean or replace the core of

over-flow valve
Replace the pump
Replace the joint slack
4. Lock the valve

Malfunctions of electrical units

1

The machine does

not work

Ground fault switch

trips

1.
2.
3.
1.
2.
3.
1.
2.
3.

Abnormal
temperature
increasing

4.

The power cable is damaged

Source power is abnormal
The ground fault switch is closed
Power cable of heating plate, the motor of
pump and planing tool may be damaged
Electrical components are t affected with
damp
The higher-up power has not a ground fault
safety device
The temperature controller switch is open
The sensor pt100 is abnormal. The
resistance value of4 and 5 of heating plate
socket should be within 100~183
The heating stick inside heating plate is
abnormal. The resistances between 2and 3
should be within23. Insulation resistance
between head of heating stick and outside
shell must be more than 1M
Should the temperature controller readings
be more than 300, which suggest he
sensor may be damaged or the connection
is loosen. Should the temperature controller
indicate LL, which suggests the sensor have
a short circuit. Should the temperature
controller indicate HH, which suggests the

1. Check the power cable

2. Check the working power
3. Open the ground fault interrupter
1. Check the power cables
2. Check the electrical elements.
3. Check the higher-up power safety device

1. Check the connection of contactors

2. Replace the sensor

3.

Replace the heating plate

4. Replace the temperature controller

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circuit of sensor is open.

5. Correct the temperature by button located on
the temperature
controller.
6. The temperature fluctuate abnormally

Lose of control
when heating

The red light is shine, but the temperature still

goes up, that is because the connector is fault
or the joints 7 and 8 can not open when get the
required temperature.

Planing tool does

not rotate

The limit switch is ineffective or the mechanical

parts of planing tool are clipped.

5. Refer to the methods to set the

temperature
6. Check and replace the contactors if
necessary
Replace the temperature controller

Replace the planning tool limit switch or

minor sprocket

10. Circuit & Hydraulic Unit Diagram

10.1 Circuit unit diagram Seen in appendix
10.2 Hydraulic unit diagramSeen in appendix

11. Packing ListSeen in appendix

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12. 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
3. The guarantee time starts with the date of delivery.
4. Fees are charged in case of the following condition:
4.1 Malfunction caused by improper operation
4.2 Damages caused by fire, flood, and abnormal voltage
4.3 Working exceeds its normal function
5. Fees are charged as actual expense. A contract about the fees shall be abided if there is one.
6. Please contact us or our agent if any questions.
Wuxi Shengda Plastic Pipes Welding Machine co., Ltd
Tel: 86-510-85522321
Fax: 86-510-83217263
Email: cpy108@yahoo.com.cn
Website: http://www.buttfusion.cn

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