PLASTITALIA I Plast 105 User manual

Pag. 1
Multipurpose Electrofusion Control Unit (ECU)
Soldadora multifunciόn - Unidad de control de la soldadura
Saldatrice polivalente - Unità di controllo della saldatura
Soudeuse polyvalent - Unité de contrôle de soudage
Mehrzweck-Schweißgerät - Schweißsteuerung
Máquina de soldar polivalente - Unidade de controlo da soldadura
Višenamjenska upravljačka jedinica za elektrofuzijsko zavarivanje
I Plast
105 – 60 - 30
USER MANUAL
MANUAL DEL USUARIO
MANUALE D’USO
NOTICES D’UTILISATION
GEBRAUCHSANWEISUNG
MANUAL DE USO
UPUTE ZA UPORABU
DESIGNED AND MANUFACTURED IN ITALY
MU00001.EU Ed. 05 - 02.01.2015 Rev.01- 24.01.2017

Pag. 2
i) Mandatory legal framework - Normas de seguridad obligatorias – Quadro normativo obbligatorio -Cadre réglementaire
obligatoire – Gesetzesvorschriften - Quadro normativo obrigatório - Obvezni zakonodavni okvir
This electronic device refers to:
Este dispositivo electrónico cumple con las normas siguientes:
Questo dispositivo elettronico fa riferimento alla:
Ce dispositif électronique se réfère à:
Dieses elektronische Gerät bezieht sich auf:
Este dispositivo eletrónico tem como referência:
Ovaj elektronički uređaj odnosi se na:
•European Directive 2006/95/EC of the EUROPEAN PARLIAMENT and the COUNCIL of 12 December 2006 (Low Voltage
Directive);
•European Directive 2011/65/EC of the EUROPEAN PARLIAMENT and the COUNCIL of 8 June 2011 (Rohs);
•European Directive 2004/108/EC of the EUROPEAN PARLIAMENT and the COUNCIL of 15 December 2004 (EMC);
and it is made in accordance with the Security Rule applies within the Community. In case of maintenance and proper use, it does
not compromise safety of persons, domestic animals or property.
The following harmonized standards are applied for its production:
y está fabricado conforme a las reglas del arte en materia de seguridad válida dentro dela Comunidad.No compromete, en caso de
mantenimiento no defectuoso y de uso conforme a su destino, la seguiridad de las personas, de los animales domésticos o de los
bienes.
Se aplican a su producción, las siguientes normas armonizadas:
ed è costruita conformemente alla regola dell'arte in materia di sicurezza valida all'interno della Comunità, non compromette, in
caso di manutenzione non difettosa e di utilizzazione conforme alla sua destinazione, la sicurezza delle persone, degli animali
domestici o dei beni.
Sono applicate, per la sua produzione, le seguenti norme armonizzate:
et il est construit en conformité avec toutes les règles de l'art d’une bonne sécurité en vigueur dans la Communauté, il n'affecte
pas, dans le cas d’entretien irréprochable et d'utilisation conforme à sa destination, la sécurité des personnes, des animaux
domestiques ou des biens.
Sont appliquées à la production, les normes harmonisées suivantes:
und wurde fachgerecht unter Berücksichtigung der in der EG geltenden Sicherheitsvorschriften gebaut. Bei regelmäßiger, korrekter
Wartung und sachgemäßem Gebrauch stellt es keinerlei Beeinträchtigung für die Sicherheit von Personen, Haustieren oder Gütern
dar.
Die Herstellung erfolgt unter Anwendung folgender harmonisierter Normen:
e foi construída em conformidade com as boas práticas em matéria de segurança válidas dentro da Comunidade; não compromete,
em caso de manutenção não defeituosa e de utilização em conformidade com o seu destino, a segurança de pessoas, animais
domésticos ou bens.
Na sua produção, foram aplicadas as seguintes normas harmonizadas:
i proizveden je u skladu s Pravilom o sigurnosti koje se primjenjuje u Zajednici. Kod održavanja i pravilne uporabe, ne ugrožava
sigurnost ljudi, domaćih životinja i imovine.
Slijedeće usklađene norme primjenjuju se kod njegove proizvodnje:
•IEC 61000 - 6 - 2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial
environments;
•IEC 61000 - 6 - 3 Electromagnetic compatibility (EMC) - Part 6-3: Generic standards - Emission standard for residential,
commercial and light-industrial environments;
•IEC 61000 - 6 - 4 Electromagnetic compatibility (EMC) - Part 6-4: Generic standards - Emission standard for industrial
environments;
•IEC 60335-1 Safety of Household and Similar Electrical Appliances - Part 1: General Requirements
•IEC EN 61558-1 Safety of power transformers, power supplies, reactors and similar products Part 1: General requirements
and tests
•IEC EN 61558-2-6 Safety of transformers, reactors, power supply units and similar products for supply voltages up to 1
100 V Part 2-6: Particular requirements and tests for safety isolating transformers and power supply units incorporating
safety isolating transformers
The following standards are applied for its production:
Se aplican a su producción las siguientes normas voluntarias:
Sono applicate, per la sua produzione, le seguenti norme volontarie:
Sont appliquées, pour sa production, les normes suivantes volontaires:
Die Herstellung erfolgt unter Anwendung folgender freiwilliger Normen:
Na sua produção, foram aplicadas as seguintes normas voluntárias:
Slijedeće norme primjenjuju se kod njegove proizvodnje:
•ISO/IEC 17050-1 Conformity assessment -- Supplier's declaration of conformity -- Part 1: General requirements;

Pag. 3
•ISO/IEC 17050-1 Conformity assessment -- Supplier's declaration of conformity -- Part 2: Supporting documentation;
•ISO 12176-2 Plastics pipes and fittings – Equipment for fusion jointing polyethylene systems – Part 2 Electrofusion;
•ISO 12176-3 Plastics pipes and fittings – Equipment for fusion jointing polyethylene systems – Part 3 Operator’s badge;
•ISO 12176-4 Plastics pipes and fittings – Equipment for fusion jointing polyethylene systems – Part 4 Traceability coding;
•ISO 13950 Plastics pipes and fittings — Automatic recognition systems for electrofusion joints;
•DVS 2208-1 Welding of thermoplastics - Machines and devices for the heated tool welding of pipes, piping parts and
panels;
•UNI 10566 electrofusion machines and auxiliary equipment for the jointing of PE pipes and/or fittings using e-fittings, for
the supply of gaseous fuels, water and other fluids under pressure. Characteristics and requirements, testing,
maintenance and documents.

Pag. 4
ii) Declaration of conformity -Declaración de conformidad - Dichiarazione di conformità - Déclaration de conformité –
Konformitätserklärung - Declaração de conformidade - Izjava o sukladnosti
This declaration has been manufactured according to the European Directive 2006/95/EC Annex III, point B and it is void if any
modification to the equipment is performed without previous written authorization by Manufacturer.
La presente Declaración está elaborada en conformidad con la Directiva europea 2006/95/CE Anexo III punto B y pierde todo valor
en caso de modificaciones al objeto de esta declaración no aprobadas por escrito por el Fabricante.
La presente Dichiarazione è redatta secondo quanto indicato nella Direttiva Europea 2006/95/CE Appendice III, punto B e perde
ogni sua validità se l’oggetto della dichiarazione è modificato senza la nostra autorizzazione scritta.
Cette déclaration a été préparée conformément à la directive européenne 2006/95/CE figurant à l'annexe III, point B et n'est plus
valable si l'objet de la déclaration est modifié sans notre autorisation écrite.
Diese Erklärung wurde nach den Vorgaben der Europarichtlinie 2006/95/EG, Anhang III, Punkt B erstellt und verliert ihre Gültigkeit,
falls der Gegenstand der Erklärung ohne unsere schriftliche Zustimmung verändert wird.
A presente Declaração foi redigida de acordo com o indicado na Diretiva Europeia 2006/95/CE Anexo III, ponto B, e perde a
validade se o objeto da declaração for modificado sem a nossa autorização por escrito.
Ova deklaracija izdana je u skladu s europskom Direktivom 2006/95/EC Dodatak III, točka B, te je nevažeća ako je izvršena izmjena
na opremi bez prethodnog pisanog odobrenja od strane proizvođača.
11
Manufacturer – Fabricante – Produttore – Producteur – Hersteller - Fabricant: PLASTITALIA S.p.A.
Headquarters: Via Ferrara – 98061
Establecimiento: Brolo (ME) – Italia
Sede: Tel. ++39 0941 536311 – Fax ++39 0941 561476
Siège: Mail: [e-mail]
Sitz: Web: www.plastitaliaspa.com
Sede:
Sjedište:
Subject of the declaration hereto: I Plast 105 -I Plast 60 - I Plast 30
Objeto de la declaración:
Oggetto della dichiarazione:
Objet de la déclaration :
Gegenstand der Erklärung:
Objeto da declaração:
Predmet ove deklaracije:
Subject of the declaration has been manufactured according to the following documents:
El objeto de la presente declaración cumple con los siguientes documentos:
L’oggetto della dichiarazione è conforme ai seguenti documenti:
L'objet de la déclaration est conforme aux documents suivants:
Der Gegenstand der Erklärung stimmt mit folgenden Dokumenten überein:
O objeto da declaração está em conformidade com os seguintes documentos:
Predmet deklaracije proizveden je u skladu sa slijedećim dokumentima:
Directives
Standards
IEC EN
(Harmonized)
ISO
UNI EN ISO
IEC
other
DIRECTIVE 2006/95/EC OF THE EUROPEAN PARLIAMENT AND
OF THE COUNCIL of 12 December 2006
61000 – 6 – 2
12176 -2
17050 – 1
DVS 2208-1
61000 – 6 – 3
12176 -3
17050 – 2
UNI 10566
DIRECTIVE 2011/65/EC OF THE EUROPEAN PARLIAMENT AND
OF THE COUNCIL of 8 June 2011
61000 – 6 – 4
12176 -4
60335 – 1
60335-2-45
13950
DIRECTIVE 2004/108/EC OF THE EUROPEAN PARLIAMENT AND
OF THE COUNCIL of 15 December 2004
61558-1
61558-2-6

Pag. 5
Additional information: The manufacturer maintains a system of quality and environmental management according
with the requirements of UNI EN ISO 9001:2008 and UNI EN ISO 14001. EMAS Regulation
and BSI OHSAS 18001 are also applied.
Información adicional: El fabricante adopta un sistema de gestión de la calidad del Medio ambiente y cumple con
los requisitos de las normas UNI EN ISO 9001:2008 y UNI EN ISO 14001, se aplica también el
Reglamento EMAS y BSI OHSAS 18001.
Informazioni addizionali: Il produttore mantiene in atto un sistema di gestione per la qualità e ambientale conforme ai
requisiti della norma UNI EN ISO 9001:2008 e UNI EN ISO 14001, inoltre sono applicat1 il
regolamento EMAS e lo schema BSI OHSAS 18001.
Informations complémentaires: Le producteur met en place un système de management de la qualité et de respect de
l'environnement avec les exigences de la norme UNI EN ISO 9001:2008 et UNI EN ISO 14001,
EMAS réglementation et BSI OHSAS 18001 sont également appliquées.
Zusatzinformationen: Der Hersteller arbeitet mit einem Qualitäts- und Umweltmanagementsystem gemäß Norm
UNI EN ISO 9001:2008 und UNI EN ISO 14001, darüber hinaus werden die EMAS Vorschriften
sowie die BSI OHSAS 18001 Vorgaben angewendet.
Informações adicionais: O fabricante mantém em ato um sistema de gestão para a qualidade e ambiente em
conformidade com os requisitos da norma UNI EN ISO 9001:2008 e UNI EN ISO 14001. Além
disso, são aplicados o regulamento EMAS e o esquema BSI OHSAS 18001.
Dodatne informacije : Proizvođač održava sustav upravljanja kvalitetom i okolišem prema zahtjevima UNI EN ISO
9001:2008 i UNI EN ISO 14001. Primjenjuju se i Uredbe EMAS i BSI OHSAS 18001.
Place and Date: Brolo 15/01/2014
Lugar:
Luogo:
Lieu:
Ort:
Local:
Mjesto:
Name and position: Giorgio Caruso (Chief Executive Officer)
Nombre y cargo: Giorgio Caruso (Representante Legal)
Nome e funzione: Giorgio Caruso (amministratore delegato)
Nom et fonction: Giorgio Caruso (administrateur délégué )
Name und Funktion: Giorgio Caruso (Geschäftsführer)
Nome e função: Giorgio Caruso (Diretor Geral)
Ime ipoložaj : Giorgio Caruso (izvršni direktor)
Signature:
Firma:
Firma:
Signature:
Unterschrift:
Assinatura:
Potpis:

Pag. 6
iii) Introduction
Plastitalia S.p.A. is free to modify the features of the control unit described in this user manual and the information contained in it
without any notice. Updates of this manual are available on www.plastitaliaspa.com
All rights reserved, It is strictly prohibited to reproduce this document or part of it in any form whatsoever.
Dear Customer,
Thank you for choosing an electrofusion control unit (ECU) from the Plastitalia range of products. This manual is designed to inform
and illustrate the features and operating on the correct methods of your new electrofusion control box I Plast 105 / 60 / 30. It
contains all the technical information and documentation for correct and safe use of the equipment by qualified operators. Please
read all parts of the manual carefully and keep it in a safe place for future consultation of the ECU. The manual is designed to allow
an easy and immediate use of the ECU and for this reason it is divided into two parts. The first, which describes the basic functions
for the welding of electrofusion fittings and the second part - included into the digital supports - showing all the complex and
advanced functions that this new and unique electrofusion control unit is able to perform simplifying your work.
We are confident that you will enjoy getting to know your new Electrofusion Control Unit and will be able to use it profitably for
many years to come.
All the best from,
Plastitalia S.p.A.

Pag. 7
EN
Index
WE REMIND YOU THAT THE DESCRIPTION OF ALL ADVANCED FEATURES OF THIS EQUIPMENT ARE STORED IN THE PROVIDED
DIGITAL SUPPORT (MEMORY STICK OR CD).
i
Mandatory legal framework
pag. 2
ii
Declaration of conformity
pag. 4
iii
Introduction
pag. 6
1
Graphic signs
pag. 9
2
Product description
pag. 9
3
General warnings
pag. 9
3.1
Workplace warnings
pag. 9
3.2
Electric current warning
pag. 9
3.3
Personal safety
pag. 10
3.4
Operating and care of the electrofusion control unit
pag. 10
3.5
Authorization and operators
pag. 10
3.5.1
Fusion process preparation
pag. 10
3.5.2
Fusion process control
pag. 11
3.5.3
Safety distances during the fusion process
pag. 11
4
Identification plate
pag. 11
5
Technical data and dimensions
pag. 12
6
Technical file according to ISO 12176-2
pag. 14
6.1
classification
pag. 14
6.2
Simulated curve 24V
pag. 14
6.3
Duty Cycle
pag. 14
6.4
Additional infromations
pag. 14
7
Technical information
pag. 15
7.1
Function keys
pag. 15
7.2
Control panel
pag. 15
7.3
Connections
pag. 15
7.4
Accessories
pag. 16
7.4.1
Barcode wand
pag. 16
7.4.2
USB Memory Drive
pag. 16
8
Transporting and handling
pag. 16
9
Storage
pag. 16
10
Disposal
pag. 16
11
Functioning and use
pag. 16
11.1
Intended and non-intended use
pag. 16
11.2
Range of applications
pag. 17
11.3
Limits
pag. 17
11.3.1
Operating limits
pag. 17
11.3.2
Power
pag. 17
11.3.3
Extension supply cable
pag. 17
11.3.4
Environmental limits
pag. 18
12
Hazards
pag. 18
13
Training of personnel
pag. 18

Pag. 8
14
Instructions
pag. 18
14.1
Start-up, Emergency Stop, Reset
pag. 18
14.1.1
Start-up
pag. 18
14.1.2
Emergency Stop
pag. 20
14.1.3
Reset
pag. 20
14.2
Fusion start-up
pag. 20
14.2.1
Automatic fusion by Bar Code reading
pag. 20
14.2.1.1
Scanner usage
pag. 21
14.2.1.2
Verify data transferred and fusion start-up
pag. 21
14.2.2
Fusion by manual introduction of Bar Code
pag. 22
14.2.3
Fusion by manual introduction of Voltage and Fusion Time
pag. 24
14.2.4
Fusion cycle’s Emergency stop
pag. 25
14.2.5
Fusion cycle’s Reset
pag. 26
15
Plastfast
pag. 26
15.1 Mode of operation pag. 26
16
Fusion Procedure
pag. 27
17
Maintenance
pag. 28
18
Error Messages
pag. 28
19
Information on generators
pag. 29
20
Warning on generators use
pag. 30

Pag. 9
EN
1) Graphic signs used in this manual
Type
Grafic sign
Key word
Hazard Type
How to fix
Warning Risk
Generic
Follow safety provisions included in
this manual.
Electric shock
(death)
Disconnect the ECU from Voltage
before any operation that isn’t the use
described in this manual.
Prohibition Ban Serious injuries
(death)
Follow safety provisions included in
this manual.
Provision Obligation
Generic
Follow safety provisions included in
this manual.
Burn, scald
Use personal safety equipment. Follow
safety provisions included in this
manual.
2) Product description
I Plast 105 / 60 is a Multipurpose Electrofusion Control Unit (ECU) capable of delivering to electrofusion fittings the energy
required to carry out the fusion. This device has been designed for a professional use and controls with a frequency of 4 times
per second, that all the electrical parameters, both type: input and output, are in agreement between themselves and
coherent with those indicated by the manufacturer of electrofusion fittings. I Plast 105 / 60 / 30 works with fusion fittings like
"electrofusion" made of polyethylene, PE80, PE100, PE-X and PP. I Plast 105 / 60 / 30 can be used at ambient temperature
within the range -10; + 45 ° C. Utilization beyond these limits must be agreed in advance with our technical department.
ECU automatically sets correct fusion parameters by Scanner/Optical Pen reading or manual introduction of Bar Code visible on
the couplers (according to ISO13950 ). In case couplers do not show Bar Code, it is possible to manually introduce Voltage and
Fusion Time recommended by manufacturer.
I Plast 105 / 60 / 30 has an internal memory for storage of fusion parameters (electrical parameters, time, fittings features,
etc.). It is also possible to print out Fusion Data and download them to a PC for further processing and/or integration in proper
Data Base. Any use not mentioned in this manual is not allowed.
3) General warnings
Read all warnings and technical information carefully. Otherwise you can being involved in accidents at the workplace. Follow
all indications for health and safety at work. This manual is part of the product, Plastitalia S.p.A. cannot be call as responsible
for damages that are subsequent to the missed respect of the contents of this manual.
3.1) Workplace warnings
a) Keep the workplace clean and well lighted. Untidiness and darkness increase the possibility of accidents.
b) Do not use machine in explosive atmosphere, such as in the presence of flammable liquids, gases or dusts. Under
certain conditions, ECU may produce an electrical arc which could cause a fire.
c) Keep children and unauthorized people away.
3.2) Electric current warning
a) Electrical tools’ plugs should be placed properly into the sockets. Never modify plug on this ECU. Unmodified plugs and
sockets reduce the risk of electrical shock.
b) Avoid exposing to rain and water in general ECU. Contact with water increases risk of electrical shock.

Pag. 10
c) Do not abuse electrical cables. Do not use electrical cables to carry out ECU. Do not unplug by pulling on electrical
cable. Keep electrical cables away from heat, oil, sharp blades and moving parts. Damaged or twisted electrical cables
increase the risk of electrical shock.
d) Use an extension cable suitable for outdoor use. This reduces the risk of electrical shock.
e) Prevent unintentional ignition of ECU. Make sure the switch is turned OFF before plugging in power, lifting or carrying
the machine. Transportation when ECU’s switch is turned ON increases the risk of accidents.
3.3) Personal safety
a) Stay alert, it is important to use care with ECU. Do not use a power tool while you are tired or under the influence of
drugs, alcohol or medication. A single moment of inattention while operating power tools may result in serious personal
injury.
b) Use of personal safety equipment.
c) Do not underestimate ECU. Always keep a good balance. This can help to get more control in unexpected situations.
d) Dress properly. Do not wear loose clothing and jewellery. Keep hair, clothes and gloves away from electrically live
parts. Loose clothing, jewellery or long hair may touch electrically active components.
3.4) Operating and care of the electrofusion control unit
a) Do not force ECU. Use it properly for the application to be performed. Its proper use allows to make it work in the best
manner and with greater safety.
b) Do not use ECU if power switch does not work. Any power tool which cannot be controlled by the main switch is
dangerous and must be replaced.
c) Keep ECU out of reach of children and do not allow persons unfamiliar with the electrofusion machine to operate. ECU
may result dangerous in the hands of untrained users.
d) Maintenance. Visually inspect ECU. Any anomalous condition may affect the operations performed by the electrofusion
machine. If damaged, send it to an authorized service centre (list at www.plastitaliaspa.com).
e) Use ECU and its accessories in accordance with these instructions and in the manner intended for the particular type of
machine, taking into account the working conditions and the work to be performed. Use of ECU for operations different
from those intended in this user manual is forbidden.
3.5) Authorization and operators
a) ECU must be used by trained and authorized operators in accordance with national and international standards.
b) ECU is not intended for use by children, persons with limited physical or mental abilities or without experience and
knowledge of it, unless they are under the supervision of or instructed in its use by a person responsible for their safety.
Children must be supervised so that they do not play with this device.
3.5.1) Fusion process preparation
a) Read and follow the national and international regulations for the prevention of accidents related to welding on
construction sites.
b) Follow the installation instructions recommended by the manufacturer of the fittings.
c) Do not connect a fitting if its fusion parameters are not present in the ECU’s range.
d) Do not start the fusion process if the fusion parameters on the ECU’s screen do not correspond with those on the
fitting.

Pag. 11
EN
3.5.2) Fusion process control
a) The operator shall check ECU and the complete fusion process, including the cooling phase of the joint.
b) In case of smoke and/or loss of melted polyethylene stop immediately the process by pressing the red STOP button.
c) Be aware that the fusion of any material involves a risk of fire ignition. Inquire about how to alert the fire department
and/or providing a device for extinguishing of fires.
3.5.3) Safety distances during the fusion process
a) Avoid body contact with fittings or cables during fusion process. Keep a minimum safety distance of 1 meter.
4) Identification plate
On the rear part of the ECU is placed the identification plate. Following image is a template:
Data are:
−type
−manufacturing year and month
−largest welding diameter (Plastitalia fittings)
−voltage and frequency input
−power max (W)
−total weight
−classification (conform to ISO 12176-2)
−
serial number (bar-code and numerical code)

Pag. 12
5) Technical data and dimensions
Technical data I Plast 105 I Plast 60 I Plast 30
CEI EN 60335 – 1 Classification Class I Electronic device
ISO 12176-2 Classification
P
2
4 U S
2
V AK D X
P
2
3 U S
2
V AK D X
P21 U S2V AK D X
Max Working Range
(Plastitalia fittings)
1.200 mm
400 mm
160 mm
Fusable Materials PE / PEX / PP / PP-R
Transfer fusion parameters Scanner / Manual
Input Voltage 230 V AC, (180 V – 265 V)
Input Current 16 A
Input frequency 50 Hz (40 – 70 Hz)
Output Voltage 8 - 48 V AC
Output Current (@ 20 °C) 65 A > 20000 sec.
105 A max 1400 sec.
100% = 50A
60% = 70A
30% = 90A
100% = 15 A
60% = 30 A
30% = 40 A
Output Peak (electronically limited) 120 A 100 A 60 A
Nominal power 3600 W 2500 W 800 W
Working temperature range -10 °C + 50 °C
Protection IP54
Weight (cables included) 24 Kg 18,5 Kg 13 kg
Input cable (Length)
4,0 m 3,0 m
3,0 m
Plug type
16 A IEC 309 (overload 22
A per 1/ h)
16 A Schuko type 16 A Schuko type
Output cable 3,0 m 3,0 m 2,5 m
Welding Terminals 4,0 mm (4,7 mm adapters)
Display graphic, 128x64 Characters ( alphanum.), background lighting
Monitoring Functions
Input
Voltage / Current / Frequency
Output Voltage / Resistance / Contact / Short Circuit / Current
Other Software / Working Temperature / Service
Error messages Plain Text / Acoustic Signals
Kit User Manual
USB Memory Drive, Transport Case CD ROM, bulk bag for
transport

Pag. 13
EN
MEMORY DATA
Memory
I Plast 105
I Plast 60
I Plast 30
No. of reports 7500
Interface USB / RS232 / RADIO USB / RS232
Data format CSV –TXT (changeable to any format)
Data Retrieval
Fusion data Voltage / Current / Nominal/Actual fusion time / Mode / Resistance / Error
Messages
Data fitting Bar Code information (ISO 13950) / Type / Size / Manufacturer
Welding machine No. Series / No. Inventory / Last Service Date / Working Hours / Software
Welder
Bar Code (Plastitalia or ISO 12176-3) with functions control:
•identification
•manual setting
•system configuration
Traceability
No. work Max. 40-digits (alphanumeric) by Bar Code
Welder code ISO-12176-3
Weather conditions DVS 2207 / 2208
Fusion Bar Code ISO 13950
Traceability fitting code ISO 12176-4
1st pipe traceability code ISO 12176-4
2st pipe traceability code ISO 12176-4
3st pipe traceability code / Infotext ISO 12176-4
ACCESSORIES
Ancillaries (standard supply)
Manual scraper - 4,7 mm adapters
Optionals
I Plast 105 I Plast 60 I Plast 30
32 A Plug (IEC 309 - 40 A per 1/h)
16 A Plug (schuko type)
Barcode wand
16 A Plug (IEC 309)
Barcode wand
Barcode wand
DIMENSIONS (mm)
Code
fig. 1
fig. 2
I Plast
105
I Plast
60
I Plast
30
A
329
329
---
B
233
233
248
C
252
252
252
D
309
309
---
E
165
165
145

Pag. 14
6) Technical file according to ISO 12176-2
6.1) Classification
Type
Classification
IPlast 105
P24 U S2V AK D X
IPlast 60
P23 U S2V AK D X
IPlast 30
P21 U S2V AK D X
6.2) Simulated curve 24V (output voltage)
6.3) Duty cycle
6.4) Additional information
Soft Start: adaptive
Soft End:
Ambient Temperature Compensation: according to ISO 13950
Fitting Temperature Compensation: No
Data retrieval: 7500 fusion cycles

Pag. 15
EN
7) Technical information
7.1) Function keys
7.2) Control panel
LED Voltage Indicator
LED Ready Indicator
LED Error Indicator
7.3) Connections
ECU is connectable to voltage by means of plugs. These last are conform to their specific standards and supplied as
normal equipment. Do NOT change/alter plugs without written authorization from Plastitalia S.p.A..
The USB connector allow ECU’s connection to other equipment provided with equal connection system.
ECU is connectable to electrofusion fittings by means of the specific welding lead provided with welding terminals and
adapters . Do NOT replace welding terminals without written authorization from Plastitalia S.p.A..
Power On / Off
Menu Button
Cancel or Back Button
Option Button
Start Button
Menu Button
Confirm Button
Option Button
Stop Button
GRAPHIC DISPLAY
System connection plug / generator

Pag. 16
7.4) Accessories
7.4.1) Barcode wand
For the barcode wand’s technical features usable on this electronic device, please contact PLASTITALIA service
7.4.2) USB Memory Drive
Can be used memory drive (USB key) normally present on the market. In order to work properly with our device, technical
requirements are:
• ≥ 1 Gbyte memory capacity
• Formatting FAT 16/32
8) Trasporting and handling
ECU shall be transported using the supplied box ( or bulk bag in case of I Plast 30). Do not knock the machine and do not
damage the body. In case of damage or bruising, do not connect to the fusion power supply and contact the service centre. Be
very careful moving ECU. Switch off ECU using the switch (1) before disconnecting to the input voltage.
9) Storage
If possible, ECU have to be preserved in its supplied box or bulk bag. Avoid exposure to temperatures above 60 ° C and lower
than - 20 ° C. The storage place should be dry, not humid.
10) Disposal
PLASTITALIA obtained the Certification of its own Environmental Management System in conformity to ISO 14000 standards.
Moreover, it is voluntarily registered EMAS Regulation. This ECU and its packaging should be recycled respecting the
environment.
This symbol means: Do not throw the electrical tools in household waste.
According with the European Directives 2002/95/EC and 2002/96/EC - concerning the restriction of hazardous
substances (RoHS) and the treatment of electrical and electronic waste equipment (WEEE) and their application
to national rights - equipment and electrical tools that are no longer usable must be collected separately and
disposed respecting the environment. The owner of this machine must use the disposal method using in its
territory. Please note that there are the presence of aluminum (frame) and copper (transformer) between recyclable materials.
11) Functioning and use
11.1) Intended and non-intended use
This ECU have to be operated by only one qualified operator, educated and informed regarding residual safety risks coming
from its use. The control box is designed to operate in environmental and supply conditions indicated in the table showing
technical data (paragraph 5). It’s an electronic device which must be exclusively used to provide the required energy for
electrofusion fittings. The supply circuit must be connected to an electrical system with protection. The electrical circuit
supplying current to the fittings is a PELV (Protected extra low voltage) "low voltage security," and it can be used in areas
defined as "restricted conductors" (eg excavations with presence of humidity). PLASTITALIA is not responsible for any other
use not covered in this handbook.

Pag. 17
EN
Methods of fusion data transfer of the fitting to I Plast 105 / 60 / 30 are:
•By means of barcode (ISO 13950, type 2/5i, 24 digits)
Barcode contains all the instructions of the fitting’s manufacturer useful for a proper fusion. Barcode contains, among
others, the following information: manufacturer, type, diameter, voltage, fusion time (with the relative correction of
the time according to the ambient temperature) resistance and its tolerance, etc.
•Manually by selection of Bar Code numbers
In the case of the Barcode cannot be read by the optical reader (defective scanner) it is possible to insert, either
manually, all numbers that compose it.
•Manually by selection of fusion time and fusion voltage
Unlike what stated above, it is possible to directly insert the data relating to the fusion voltage and the fusion time
indicated on the fitting. The user must be aware that in this case ECU is unable to correct the fusion time according to
the ambient temperature.
11.2) Range of applications
I Plast 105 / 6 0 / 30 is a Multipourpose device able to weld all electrical fittings with an operating voltage (AC) between 8 and
48 V and at maximum of 50 ° C ambient temperature.
11.3) Limits
11.3.1) Operating limits
ECU(s) can operate within the following functional limitations:
Ambient T. C °(Celsius) Model of
Control Unit
Max peak current
required by the
fitting
Average current Maximum fusion
time* (minutes)
20
I Plast 105 120 A 65 A 330
120 A 105 A 23
I Plast 60 100 A 40 A 330
100 A
60 A
40
I Plast 30 60 A
15 A
60
60 A
30 A
25
* can vary according to environmental temperature
The cooling fan, not available on the I Plast 30, has an IP55 protection degree and it can operate in dusty and humid
environments. Its operation is due to the thermal load induced by the amount of energy required for the fitting and
the ambient temperature (it does not work with medium-small diameter fittings).
11.3.2) Power
If ECU is connected to a mains voltage of 230V - 16 A, the supply circuit must be equipped with a “slow” fuse and a
RCCB device (residual current-operated protective - circuit breaker).
The power supply circuit must be provided with a protective earth circuit.
Power the device only with a quality single-phase voltage 230 V AC 50 Hz. In case of using a generator, its power must
be adapted to the diameter of the fitting to be welded, taking care to choose models with harmonic current
distortions contained within 20%. If the generator is not in double insulation, the connection to earth must be
executed in accordance with the applicable regulations and legislation applicable in the country where the ECU is in
use.
11.3.3) Extension supply cable
If necessary, use an extension cable having the following features:

Pag. 18
Model of control unit LENGHT SECTION (230V)
I Plast 105
Up to 20m
3 x 4 mm
2
From 20 to 50m
3 x 6 mm
2
From 50 to 100m 3 x 10 mm2
I Plast 60
Up to 20m 3 x 2.5 mm2
From 20 to 50m 3 x 4 mm2
From 50 to 100m 3 x 6 mm2
I Plast 30
Up to 20m 3 x 2.5 mm2
From 20 to 50m 3 x 4 mm2
From 50 to 100m 3 x 6 mm2
IT IS FORBIDDEN TO EXTEND FUSION CABLES !!!
11.3.4) Environmental limits
This device is NOT designed to operate in explosive atmospheres
Important note:welding can generate magnetic fields around the electrofusion fittings. Verify that the surrounding
environment would be compatible. When performing welds, by using electrofusion fittings that are requiring high
power (e.g.: more than 40 A), you are request to check that ferrous masses and/or electromagnetic fields generated
by high voltages aren’t present in the surrounding welding area (e.g.: high voltage grids)
12) Hazards
The safe use of this machine depends on reading general instruction and on its care and maintenance. PLASTITALIA has used all
the known techniques to minimize any risk of electric shock providing by a commensurate insulation with the conditions of
use.
13) Training of personnel
Reading the technical information of this manual provide the necessary knowledge for a safe use of I Plast 105 / 60 / 30.
PLASTITALIA has a training center (tel.[phone]- fax [phone] - www.plastitaliaspa.com) from which you can
plan a specific training task. The presence of qualified welders in the fusion activity is a further guarantee of reliability.
14) Instructions
14.1) Start-up, Emergency Stop, Reset
14.1.1 ) Start-up
Before turning on the ECU do the following actions:
• Check the equipment, cables, plugs and adapters. Replace damaged parts;
• Fully unwind supply and fusion cables (including extension);
• Verify that the switch is OFF;
• Place the machine close to the joint to be fused so that it is firmly installed and staying securely on it’s rubber
feet. Carefully choose the control box place;
• If using a generator, start before connecting the ECU, if necessary, adjust the output voltage and wait until it is
stabilized.

Pag. 19
EN
• Connect the control box to the generator (or mains voltage);
• Press the switch on the ON position to start ECU
•After you have pressed the on / off button the display shows the following message
•In succession messages of start-up including prohibition of use in environments with explosive atmosphere.
•Pressing the < > buttons you can select the operations to be done:
proceed with the welding
displays memory data
system edit (see instructions in the USB memory drives)
provides information related to the control unit
fusion data export (see instructions in the USB memory drives)
go back to the switch on
Press OK button to confirm the choice. Press the Cbutton to go back to the previous view.
Power on/off switch in OFF
position
PRESS START
WELD! 10,48

Pag. 20
14.1.2) Emergency Stop
If necessary, at any time during use you can cause an emergency stop by pressing the on / off button to the OFF
position, or by pressing the STOP button.
Having pressed the on / off button to the OFF position (in any case after disconnecting the control unit from the power
source) after the following restart you will see this message: "Warning, Error, Power interrupted before the end of the
work". Press OK button to proceed and the display shows:
Having pressed the STOP button, you will see this message: "Error, STOP command! Welding Failed ". Press the OK
button to proceed and the display shows:
14.1.3) Reset
Reset Procedure to do after pressing the on / off button in the OFF position
•Unplug the fitting from the control box terminals (change or wait until the fitting is cool before another fusion
cycle; let pass the cooling time indicated on the fitting)
•Press START to activate the main screen
Reset Procedure to do after pressing the STOP button
•Unplug the fitting from the control box terminals (change or wait until the fitting is cool before another fusion
cycle; let pass the cooling time indicated on the fitting)
14.2) Fusion start-up
14.2.1) Automatic fusion by Bar Code reading
The display shows the highlighted icon COD:
Press the OK button and the display changes
Read the fitting bar code with the scanner
WELD ! 10,48