ALKATEM 8000 F User manual

MULTIPURPOSE ELECTROFUSION MACHINE
ALKATEM 8000 F
OPERATOR’S MANUAL
Rev.: 0
13/03/2014
MU000971

Dear Customer,
Thank you for choosing a machine from the ALKATEM range of products. This manual is designed to
illustrate the features and operating methods of your new electrofusion machine model ALKATEM
8000 F. It contains all the necessary information and prescriptions for correct and safe use of the
equipment by professional operators. Please read all parts of the manual carefully and keep it in a
safe place for future consultation and/or to transfer to any future owners/users of the machine.
We are confident that you will enjoy getting to know your new equipment and will be able to use
it profitably for many years to come.
All the best from, ALKATEM
INDEX
Pag.
Conformity Declaration
Machine’s Description
Parts Description
Control Panel
Side Panel
Technical Features
Safety Standards
Connections and Generator’s Features
Checks and Maintenance
General Fusion Procedures
Operating Instructions
Bar codes –types and reading
Welding mode: Bar code reading
Welding mode: Manual input of bar code
Welding mode: Manual input of welding voltage and time
Prints and USB connection
Options and tools
Alarm Codes and their meaning
Special features
3
4
5
6
6
7
8
10
11
12
14
15
17
18
18
19
19
21
23
2

MANUFACTURER’S CONFORMITY DECLARATION
ALKATEM
a company which implements a Quality System in compliance with the requirements of the UNI EN
ISO 9001 standards, as verified by the SGS ICS Services Co. for International Certification, and
certified under No. 96.061,
hereby declares
that the electrofusion machine ALKATEM 8000 F
Object of the present document has been manufactured according to the following Standards and
Regulations having legal value:
2006/42/CE
2004/108/CE
2006/95/CE
UNI EN ISO 12100
CEI 44‐5
ISO 12176‐2
UNI 10566
2010
2008
2013
This declaration becomes null and void in the event of any changes being made to the equipment
without the written and explicit manufacturer’s approval.
Legal Representative
13/03/2014
3

Machine’s Description
ALKATEM 8000 F is a Polyvalent Electrofusion Machine (in low voltage 8÷48V) capable of fusing
any brand of coupler available in the market.
Machine automatically sets correct fusion parameters by Optical Pen reading or manual
introduction of Bar Code visible on the couplers (according to ISO 13950 ). In case couplers do not
show bar code, it is possible to manually introduce Tension and Fusion Time recommended by
manufacturer.
ALKATEM 8000 F has an internal memory for storage of fusion parameters (parameters used,
couplers features, etc… ). It is also possible to print out Fusion Data and download them to a PC.
4

PARTS DESCRIPTION
1
2
8
3
4
7
5
6
1.
2.
3.
4.
5.
6.
7.
8.
Carrying case
Electrofusion machine body
Plug + power cable
Manual scraper
Fusion connectors
Barcode scanner
Barcode scanner case
Fusion cable
5

CONTROL PANEL
13
12
11
9
10
9.
10.
11.
12.
13.
Display
Menu scroll key ‐
OK key (begins fusion)
Menu scroll key +
STOP key (Exits from menu without saving data. Stops fusion process)
SIDE PANEL
14
15
16
14. Serial printer connector
15. USB port for Data Transfer to flash drive
16. ON/OFF switch
6

TECHNICAL FEATURES
ALKATEM 8000 F
230V
Max Working Range
Fusable Materials
Dimensions (W x L x H)
Weight
Required Tension
Frequency
Max power absorbed
Fusion nominal current
Duty cycle 60% (ISO 12176‐2)
Working temperature
Fusion tension
Max amperage
Ambient termometer accuracy
Degree of protection
Connector’s diameter
Fusion memories available
STANDARD EQUIPMENT
• Manual scraper
• Barcode scanner
EQUIPMENT ON REQUEST
20 ÷800 mm
PE / PP / PP‐R
530x450x230 mm
24,5 Kg
230V ±15%
50 ÷60 Hz
4800 W
90A
–20 °C ÷+40 °C
8 ÷48V
120A
±1 °C
IP54
F 4 ÷4,7 mm
500 report
•
•
(1)
(2)
Data transfer kit to serial portable (1)
Software data transfer (2)
include: serial printer + cable
include: CD‐ROM
7

SAFETY STANDARDS
Carefully read instructions before use.
WARNING! When using electric tools, follow safety standards to avoid fire and electric
hazards.
KEEP WORKPLACE CLEAN. Untidiness on the workplace may be cause of accidents.
CAREFUL TO AMBIENT CONDITIONS. Do not expose electric tools or fusion machines to the
rain. Do not use electric tools or fusion machines in humid places. Make sure lighting is
appropriate. Do not use electric tools or fusion machines near liquids or inflammable gases.
PROTECT YOURSELF FROM ELECTRIC HAZARD. Avoid contact with objects connected to earth.
Be careful not to touch electric cables.
KEEP UNAUTHORIZED PEOPLE AWAY FROM WORKPLACE. Electric tools and fusion machines
can be used only by authorized people. Keep unauthorized people away from workplace.
KEEP ELECTRIC TOOLS AND FUSION MACHINES IN A SAFE PLACE. Electric tools, fusion
machines and tools in general have to be stored in dry and safe places not reachable by
unauthorized people.
DO NOT OVERWORK POWER TOOLS. Keep within limits given by manufacturer for the best
performance, for more time and in safe conditions.
ALWAYS USE SPECIFIC TOOLS AND ACCESSORIES ACCORDING TO THE JOB. Always use
accessories compatible with fusion machine (be careful especially with power generators,
extensions for power cables, fusion cable and adapters). Let power tools to cool down after
using for a long time. The use of tools or accessories different from the ones recommended by
manufacturer may cause injuries to operator, affect performance of the fusion machine and
other tools and void warranty.
DO NOT USE CABLES OF FUSION MACHINE OR OTHER TOOLS FOR INCORRECT PURPOSES. Do
not use cables to move machine around or to disconnect from power outlet. Protect cables
and fusion machine from warm environments and from contact with sharp objects.
ALWAYS USE SPECIAL ALIGNERS. Always align pipes and fittings using special aligner. This
helps to perform a correct fusion and a safe job.
8

WARNING! AVOID ACCIDENTAL STARTING OF POWER TOOLS OR FUSION MACHINE. Fusion
machine has to be disconnected from generator before turning this one on in order to avoid
current peaks which can seriously damage electronic components of the machine. Keep
machine disconnected from power supply when connecting adapters. Make sure switch is not
in the ON Position when connecting power tools to power supply or generator (especially if
tool is not equipped with safety switch). Do not carry power tools around while they are
connected to power supply since they may start accidentally.
BEFORE STARTING FUSION PROCESS MAKE SURE FUSION MACHINE IS NOT DAMAGED.
Before using fusion machine make sure safety devices are perfectly working. Make sure
power cable or fusion cable are not damaged or cut; check that connectors and adapters fit
correctly and surfaces in contact are clean. Make sure machine’s frame is not severely
damaged (water infiltrations may occur ).
MAINTENANCE AND SERVICE MUST BE BERFORMED BY AUTHORIZED SERVICE CENTRES
ONLY. This machine is manufactured according to safety standards in force therefore
maintenance and service can be performed by authorized service centres only otherwise
manufacturer declines all responsibilities and warranty is void.
DO NOT PERFORM ANY MODIFICATION TO THE MACHINE.
OPERATORS HAVE TO BE CAREFULLY TRAINED ON THE USE OF THE MACHINE.
USE NEW EQUIPMENT OR EQUIPMENT SERVICED BY AUTHORIZED SERVICE CENTRES AT ALL
TIMES.
PRESCRIPTIONS DESCRIBED BY D. Lgs. 09/04/08 n° 81 REGARDING SAFETY IN THE
WORKPLACE MUST BE FOLLOWED.
DO NOT USE MACHINE IN EXPLOSIVE ENVIRONMENTS ( when in presence of inflammable
gases or steams, etc.).
9

CONNECTIONS AND GENERATOR’S FEATURES
We remind you to follow what prescribed
by laws UNI CEI and to respect D. Lgs. 09/04/08 n°81
Fusion machine can work with alternating current between minimum value of 195V and max value
of 265V. Frequency may vary between 50Hz and 60Hz.
Use earth connection at all times with differential switch on circuit breaker 16A with “slow”
curve. Power peaks when beginning fusion can reach 3500VA. Fusion machine can operate with an
ambient temperature between –20 °C and +40 °C.
Dimensions of electrofusion couplers used will determine power required by generator. Power
may vary also according to connections, cleanliness and connection’s conditions, as well as
according to generator’s features.
WARNING: during fusion procedure DO NOT connect other tools to generator.
Generator’s power decreases of about 10% every 1000 m of altitude.
Use power cables with section of 2,5 mm2with a maximum length of 20 m. Cable has to be
completely unwound and extended.
10

CHECKS AND MAINTENANCE
Before performing fusions and before connecting to power outlet, check the following:
NOMINAL TENSION AND FREQUENCY : see technical features (page 7)
OUTLETS AND EXTENSION CABLES: they must be suitable for the power absorbed by machine (
see page 7, 10)
CABLES: isolation has to be intact, they have to be placed away from places where vehicles transit
and where they can be damaged .
MACHINE BODY: it has to be isolated and placed steadily.
Keep machine and cables clean and dry. Before cleaning operations disconnect machine from
power supply. Use a humid soft cloth with water and alcohol (avoid any kind of solvent).
ALKATEM 8000 F electrofusion machine is an electronic equipment therefore it has to be handled
safely avoiding impacts and sudden temperature changes.
To guarantee correct functioning for as long as possible, operators has to perform frequent
checks to the following components :
• Connectors and adapters
• Power cables and fusion cables
• Display
• Mechanical structure (frame, box).
In case of any anomaly machine has to be checked by manufacturer or by an authorized service
centre.
In any case machine has to be serviced every 2 years by manufacturer or by an authorized
service centre.
11

GENERAL FUSION PROCEDURE
Quality of joint depends on the following instructions which have be followed carefully.
HANDLING OF PIPES & FITTINGS
When fusing, temperature of pipes & fittings have to be similar to ambient temperature measured
by machine’s probe.
Therefore they cannot be exposed to strong wind or direct sunlight : their temperature may vary
consistently from ambient temperature, affecting negatively fusion (pipe & fittings insufficient or
excessive fusion). In case of high temperature, keep pipe & fittings away from direct sunlight and
wait until their temperature is similar to ambient temperature.
PREPARATION
Cut pipe’s edges straight, using special pipe cutters. Carefully try to eliminate pipe’s and fittings
bends or ovalizations.
CLEANING
Carefully scrape oxidized layers on pipe’s or fitting’s edges with special pipe scrapers. Make sure
scraping is uniform and complete over surfaces to be fused exceeding the middle of the fitting of
about 1 cm; lack of this type of operation causes a superficial fusion only, since it prevents
molecular interpenetration of parts and affects fusion’s result. Scraping methods like sand paper,
emery wheel must be avoided.
Take out coupler from its protecting packaging, clean the interior according to manufacturer’s
instructions.
POSITIONING
Insert pipe’s edges into the coupler.
It is necessary to use an aligner for:
• making sure parts are steady during fusion and cooling phase;
• avoid any sort of mechanical stress on the joint during fusion cycle and cooling;
12

FUSION
Fusion area should be protected from strong weather conditions , such as humidity, temperatures
lower that ‐20 °C or over +40 °C, strong wind, direct sunlight.
Pipes & fittings used have to be of the same material or compatible material. Compatibility
between materials have to be guaranteed by manufactured.
COOLING
Cooling time depends on diameter of coupler and ambient temperature. It is important to follow
times given by manufacturer of couplers used.
To avoid mechanical stress on the joint (bending, tractions, twisting) disconnect cables and
aligners only when joint has completely cooled down.
13

OPERATING INSTRUCTIONS
SWITCH ON THE MACHINE
Press ON/OFF switch 16 to switch ON the machine, use + and –to scroll the menu
WELDING THROUGH BAR CODE
READING
(Pag. 17)
WELDING THROUGH MANUAL INPUT
OF BAR CODE
READ BAR CODE
(Pag. 18)
WELDING THROUGH MANUAL INPUT
OF WELDING VOLTAGE AND TIME
TYPE BAR CODE
(Pag. 18)
PRINTS AND USB CONNECTION
Volt
sec
38,5
0540
(Pag. 19)
PRINT & USB
OPTIONS AND TOOLS
(Pag. 19)
OPTIONS & TOOLS
14

BAR CODES –TYPES AND READING
Before welding, you can read the bar codes
attached to the coupler:
• WELDING BAR CODE:
The welding bar code gives the welding
parameters related to the coupler: type,
brand, welding voltage and time,
diameter.
• TRACEABILITY BAR CODE:
The traceability bar code gives the
information related to the coupler: type,
brand, material, diameter, SDR,
production batch, etc.
WELDING BAR CODE
TRACEABILITY BAR CODE’
Please Note:
These data will be saved in the machine’s memory, therefore
consultable (printed or downloaded).
ACTIVATE / DEACTIVATE TRACEABILITY
Scroll the main menu until OPTIONS &
TOOLS is displayed. Press OK.
Go to “Traceability” then press OK.
Use + and –to activate/deactivate
traceability. Press OK to confirm.
OPTIONS & TOOLS
OPTIONS
Traceability
Notes
1/3
Traceability
DEACTIVATED
15

ACTIVATE / DEACTIVATE NOTES
Notes are useful when the operator
needs to input a comment before
starting (for example, he needs to set
in the name of the job site).
Scroll the main menu until OPTIONS &
TOOLS is displayed. Press OK.
Go to “Notes” then press OK.
Use
+ and –to activate/deactivate notes.
Press OK to confirm.
OPTIONS & TOOLS
OPTIONS
Traceability
Notes
1/3
Note
DEACTIVATED
GETTING READY TO WELD
Clean and scrape the pipe ends to be
welded.
Position pipes/fittings/coupler on the
aligners.
Insert the welding connectors into the
coupler pins.
16

WELDING THROUGH BAR CODE READING
Connect the laser scanner and go to “READ
BAR CODE” display.
Step 1:
Keep the trigger pressed and make sure the
laser beam aims at the welding bar code
(see description on page 15).
Important: in case of malfunction of the laser
scanner, it is possible to work in manual mode (see
page 18)
READ BARCODE
Junction type
Brand
Step 2:
The welding voltage and time, and the
coupler data are displayed. If the
information is correct, press OK to start the
welding.
Voltage
Diameter
I CPL ELO
40.0V 110s
2 IPS
OK ?
Time
Step 3:
If Traceability is activated1, keep the trigger
pressed and make sure the laser beam aims
at the traceability bar code. If you do not
wish to obtain traceability, skip this step by
keeping OK pushed for at least 2 seconds.
Step 4:
If Notes is activated2, use + and –to input
the job site name or other notes. Press OK
to proceed writing (there are 24 characters
available). If you do not wish to obtain
traceability, skip this step by keeping OK
pushed for at least 2 seconds.
A successful welding displays the image
shown on the right.
to activate/deactivate traceability follow the
instructions on page 15.
2
to activate/deactivate notes follow instructions on
page 16.
1
OBTAIN
TRACEABILITY
Notes
I>
300
Welding n°
17

WELDING THROUGH MANUAL INPUT OF BAR CODE
Go to “TYPE BAR CODE” and press OK to
access the input mode.
Read the 24 digits code underneath the bar
code and input them one by one using + and
–(increase/decrease value). Press OK to
confirm and move to the next digit in the
same manner. To erase the previous value,
press STOP.
When the entire 24 digit code has been
typed, press OK and move to the next step
(Step 2) at page 17.
TYPE BAR CODE
TYPE BAR CODE
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
WELDING THROUGH MANUAL INPUT OF WELDING VOLTAGE AND TIME
Please note:
This mode requires the knowledge of the
welding voltage / time parame
ters,
beforehand. If these are not known, contact
the coupler manufacturer.
At the image shown on the right, press OK
to access the input mode of voltage and
welding time.
The cursor positions itself on the first value
of welding voltage. Press + and ‐
(increase/decrease value) to input the
requested voltage. Press OK to confirm and
move to the next value.
When the correct values are set, press OK
and move to the next step (Step 2) at page
17.
Volt
sec
38,5
0540
Volt
sec
38,5
0540
18

PRINTS AND USB CONNECTION
Press OK to enter PRINTS & USB menu.
PRINTS & USB
Copy to USB
To download the welding data into a pen
drive.
Connect a pen drive and press OK to start
downloading.
Print last:
To print the last welding report on a fast
manner. Previous reports can also be
printed, use + and –to visualize the desired
report, then OK to print.
OPTIONS & TOOLS
PRINTS & USB
1/2
Copy to USB
Print last
Press OK to enter OPTIONS & TOOLS menu.
OPTIONS & TOOLS
Traceability:
Activates/deactivates traceability of the
coupler to be used.
If activated, the bar code must be read and
the information regarding the coupler’s
manufacturer (as well as other data) will be
displayed. The information will be printed
and/or downloaded.
Notes:
Activates/deactivates notes.
If activated, the option will be displayed
during the welding process.
OPTIONS
Traceability
Notes
1/3
OPTIONS
Traceability
Notes
1/3
19