Ritmo ELEKTRA 400 User manual

MULTIPURPOSE
ELECTROFUSION MACHINE
OPERATOR’S MANUAL
M
M259 Rev.: 2 17/05/2010 MU000526

1
I
Ritmo S.p.A. è libera di apportare modifiche senza preavviso alle caratteristiche della macchina descritta in
questo manuale e alle informazioni qui contenute.
È vietata la riproduzione, anche parziale e sotto qualsiasi forma, di questo documento.
GB
Ritmo S.p.A. is free to modify the features of the machine described in this handbook and the information
contained in it without any notice.
All rights reserved. It is strictly prohibited to reproduce this document or part of it in any form whatsoever.
F
L’entreprise Ritmo S.p A. Se réserve le droit d’apporter, sans préavis, toutes les modifications qu’elle désirera aux
caractéristiques de la machine décrite dans ce manuel ainsi qu’aux informations qu’il contient.
La reproduction de ce document, même partielle, sous n’importe quelle forme, est strictement interdite.
E
Ritmo S.p.A. se reserva el derecho de hacer modificaciones sin previo aviso a las características de la máquina
descrita en este manual y a las informaciones en él incluidas.
Está terminantemente prohibida toda reproducción de este documento, incluso parcial o de cualquier otra
P
A Ritmo S.p.A. pode efectuar sem pré-aviso quaisquer modificações às características da máquina descrita no
presente manual, bem como às informações nele inseridas.
A cópia total ou parcial deste documento è severamente proibida, sob qualquer forma.
D
Die hier angegebenen Daten sind öhne Gewähr und Ritmo S.p.A. behält sich Änderungen ohne
Vorankündigung vor.
Die Vervielfertigung, auch auszugsweise, dieses Dokumentes ist verboten.
S.p.A.
Via A. Volta, 7 - Z.I. Selve
35037 BRESSEO DI TEOLO (PD)
ITALY
Tel. [phone]
Fax [phone]
[email protected]

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Dear Customer,
Thank you for choosing a machine from the ritmo range of products. This manual is
designed to illustrate the features and operating methods of your new
electrofusion machine model ELEKTRA. 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, Ritmo S.p.A.
T
TA AB BL LE E O OF F C CO ON NT TE EN NT TS S
P
Pa ag ge e
Conformity Declaration 3
Machine’s Description 4
Parts Description 5
Technical Features 7
Safety Standards 8
Connections and Generator’s Features 10
Checks and Maintenance 11
General Fusion Procedures 12
Operating Instructions 14
Fusion Traceability 15
Fusion by Bar Code reading 17
Fusion by manual introduction of Bar Code 18
Fusion by manual introduction of Tension and Fusion Time 19
Setup and Capabilities 20
Printing and USB Connection 21
Alarm Codes and their meaning 22
Operator’s badge mode (ISO 12176-3) 26
Operator’s/Supervisor’s badge mode (Custom) 27

3
MANUFACTURER’S CONFORMITY DECLARATION
Ritmo S.p.A.
Via A. Volta, 7 - Z.I. Selve - 35037 BRESSEO DI TEOLO (PD) - ITALIA
Tel.++39-(0)49-9901888 FAX ++39-(0)49-9901993 - C.P. 120 BRESSEO DI TEOLO
Declares
That electrofusion machine ELEKTRA
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 12100-1
(12/09)
UNI EN ISO 12100-2
(12/09)
CEI 44-5
CEI EN 60204-1:2006
ISO 12176/2 (2008)
This declaration is void if any modification to the equipment is performed without
previous written authorization by Manufacturer.
Legal Representative
Bresseo di Teolo, lì 17/05/2010

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Machine’s Description
ELEKTRA is a Multipurpose Electrofusion Machine (in low voltage 8÷48V) capable of
fusing any brand of coupler available in the market, up to 400mm for version
ELEKTRA400 and up to 800mm for version ELEKTRA 800 .
Machine automatically sets correct fusion parameters by 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 Tension
and Fusion Time recommended by manufacturer.
ELEKTRA 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.

5
PARTS DESCRIPTION
1. Lifting handle
2. Power cable
3. Fusion Connectors
4. Control Panel
5. Fusion Cable
6. Optical Pen for bar code reading
7. Scanner for bar code reading( optional )
1
2
5
3
4
6
7

6
CONTROL PANEL
A. Display
B. Numeric keyboard
C. Menu/Cursor scroll keys
D. ENTER key ( Confirms data set and proceeds to next step )
E. External temperature probe
F. Connector for Serial Printer / Data Transfer to PC
G. ON/OFF Switch
H. USB Port for Data Transfer to USB memory
I. STOP Key (Exits from menu without saving data. Stops fusion process )
J. START Key (Begins Fusion)
A
C D
E
F
G
H
J I
B

7
Technical Features
ELEKTRA 400
110V
ELEKTRA 400
230V
ELEKTRA 800
230V
Max Working Range 400 mm 400 mm 800 mm
Fusable Materials PE / PP / PP- R PE / PP / PP- R PE / PP / PP- R
Dimensions 358 x 285 x 302 mm 358 x 285 x 302 mm 358 x 285 x 302 mm
Weight (without transport case) 19,5 kg 19,5 kg 22,5 kg
Required Tension 110 V ±15% 230 V ±15% 230 V ±15%
Frequency 50 ÷ 60 Hz 50 ÷ 60 Hz 50 ÷ 60 Hz
Max power absorbed 2500W 2700W 3500W
Nominal current 22A 12A 16A
Fusion nominal current
Duty cycle 30% (ISO 12176-2) 75A 80A 100A
Fusion nominal current
Duty cycle 60% (ISO 12176-2) 65A 70A 90A
Fusion nominal current
Duty cycle 100% (ISO 12176-2) 55A 60A 80A
Working temperature –10 °C ÷ + 40 °C –10 °C ÷ + 40 °C –10 °C ÷ + 40 °C
Fusion tension 8 ÷ 48 V 8 ÷ 48 V 8 ÷ 48 V
Max amperage 100 A 100 A 120 A
Ambient termometer accuracy ± 1 °C ± 1 °C ± 1 °C
Degree of protection IP 54 IP 54 IP 54
Connector’s diameter F 4 mm F 4 mm F 4 mm
Adapter’s diameter F 4,7 mm F 4,7 mm F 4,7 mm
Fusion memories available 4000 reports 4000 reports 4000 reports
STANDARD EQUIPMENT
•Connectors adapters M 4 mm / F 4,7 mm
•Transport case
•Manualscraper
EQUIPMENT ON REQUEST
•Data transfer kit to serial portable printer (includes: serial printer + cable )
•Connection cable Machine to PC
•Data Transfer Software (Ritmo Transfer)
•Scanner for Bar Code reading

8
Safety Standards
¾Carefully read instructions before use.
¾WARNING! When using electric tools, follow safety standards to avoid fire and
electric hazards.
¾KEEP WORKPLACE CLEAN. Untidiness on the workplace may be cause of
accidents.
¾CAREFUL 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.
¾PROTECT YOURSELF FROM ELECTRIC HAZARD. Avoid contact with objects
connected to earth. Be careful not to touch electric cables.
¾KEEP UNAUTHORIZED PEOPLE AWAY FROM WORKPLACE. Electric tools and fusion
machines can be used only by authorized people. Keep unauthorized people
away from workplace.
¾KEEP 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.
¾DO NOT OVERWORK POWER TOOLS. Keep within limits given by manufacturer for
the best performance, for more time and in safe conditions.
¾ALWAYS 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.
¾DO 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.
¾ALWAYS USE SPECIAL ALIGNERS. Always align pipes and fittings using special
aligner. This helps to perform a correct fusion and a safe job.

9
¾WARNING! 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.
¾BEFORE 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 ).
¾MAINTENANCE 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.
¾DO NOT PERFORM ANY MODIFICATION TO THE MACHINE.
¾OPERATORS HAVE TO BE CAREFULLY TRAINED ON THE USE OF THE MACHINE.
¾USE NEW EQUIPMENT OR EQUIPMENT SERVICED BY AUTHORIZED SERVICE CENTRES
AT ALL TIMES.
¾PRESCRIPTIONS DESCRIBED BY D. Lgs. 09/04/08 n° 81 REGARDING SAFETY IN THE
WORKPLACE MUST BE FOLLOWED.
¾DO NOT USE MACHINE IN EXPLOSIVE ENVIRONMENTS ( when in presence of
inflammable gases or steams, etc.).

10
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
(94V for 110V version) and max value of 265V (127V for 110V version). Frequency
may vary between 50Hz and 60Hz.
Use earth connection at all times with differential switch on circuit breaker 16A
(32A for 110V version) with “slow” curve. Power peaks when beginning fusion can
reach 3500VA. Fusion machine can operate with an ambient temperature
between –10 °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 mm2(6 mm2for 110V version) with a
maximum length of 20 m. Cable has to be completely unwound and extended.

11
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 EXTENTION 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).
ELEKTRA 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.

12
General Fusion Procedures
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;

13
FUSION
Fusion area should be protected from strong weather conditions , such as
humidity, temperatures lower that -10°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.

14
Operating Instructions
Press button Gto turn
machine on.
Machine performs a self
testing to check correct
functioning.
If testing is ok display will
show what’s on side
picture *.
If testing reveals and error
an error code will be
displayed (see page 22 ÷
25).
* ELEKTRA might be set in a particolar condition which allows the use of the equipment
only through a code bar BADGE. Switching on the machine will display an entry
screen which can be unblocked only scanning the “operator” or “supervisor” code.
For further information see page 26.
Use keys C(½¾) to scroll main menu.
FUSION BY BAR
CODE READING
FUSION BY
MANUAL
INTRODUCTION
OF BAR CODE
FUSION BY
MANUAL
INTRODUCTION
OF TENSION AND
FUSION TIME
SETUP AND
UTILITIES PRINTING AND USB
CONNECTION
Page 17 Page 18 Page 19 Page 20 Page 21
26°C 218V 50Hz
Test fallito
For meaning of error
messages see pages
22 ÷25
Test O
K

15
FUSION TRACEABILITY
Before fusion procedure it
is necessary to decide
whether you want to use
machine’s bar code
reading system of
pipe/fittings in order to
have complete
traceability of fusion
completed. Fusion data
will be stored in
machine’s memory and
can be printed or
downloaded.
Scroll main menu until
arriving to SETUP AND
UTILITIES. Press ENTER to
access next step.
Select“Traceability”using
keys C(¿À).
Press ENTER
Press keys C(½¾) to
activate or deactivate
traceability.
Press ENTER to save
settings and go back to
menu.
OPZIONI
Scelta lingua
 Tracciabilità
Blocco memoria
Informazioni
Altre funzioni
TRACCIABILITÀ
ABILITATA
BAR CODE
Traceability
Pipe/fitting 1
BAR CODE
Traceability
Cou
p
le
r
BAR CODE
Traceability
Pipe/fitting 2
BAR CODE
Parameters Set Up

16
Press STOP to go back to main
menu.
COUPLER’S PREPARATION
Clean and scrape pipe end to
be fused.
Place pipe/fittings on special
aligners.
Place machine’s fusion
connectors 3in the coupler.
OPTIONS
Language selection
 Traceability
Memory stoppage
Informations
Other functions

17
FUSION BY BAR CODE READING
For more error messages see pages 22 ÷25.
EXTRA DATA
Type: XXXX
Trade:XXX
Diam.:20mm
V: 40.0
s: 34
Traceability
ACTIVATED
*
IS PIPE SCRAPED AND
ALIGNED ?
PRESS (start) TO
START FUSION (stop)
TO ABORT
Traceability
D
EACTIVATED
*
READ CODE OF FIRST
PIPE
READ CODE OF
SECOND PIPE
PIPE DEPTH
112 cm
Use keys C(½¾¿À) to chan
g
e
depth value to which pipe will be
buried. N.B. It is possible to
change unit measure cm to in.
READ CODE OF THIRD
PIPE
*see page 15

18
FUSION BY MANUAL INTRODUCTION OF BAR CODE
For more error messages see pages 22 ÷25.
INSERT CODE
9 5 0 7 0 6 3 1
0 6 3 8 4 0 1 8
0 5 0 6 5 7 5 1
Traceability
ACTIVATED
*
IS PIPE SCRAPED AND
ALIGNED ?
PRESS (start) TO
START FUSION (stop)
TO ABORT
Traceability
DEACTIVATED
*
READ CODE OF FIRST
PIPE
READ CODE OF
SECOND PIPE
PIPES DEPTH
112 cm
Use keys C(½¾¿À) to change
depth value to which pipe will be
buried. N.B. It is possible to
change unit measure cm to in.
READ CODE OF THIRD
PIPE
*vedere pag.15

19
FUSION BY MANUAL INTRODUCTION OF TENSION AND FUSION TIME
For more error messages see pages 22 ÷25.
37,0 0800
37,0 0800
Use keys C
(½¾¿À)to chan
g
e
values displayed.
Traceability
ACTIVATED
*
IS PIPE SCRAPED AND
ALIGNED ?
PRESS (start) TO
START FUSION (stop)
TO ABORT
Traceability
DEACTIVATED
*
READ CODE OF FIRST
PIPE
READ CODE OF
SECOND PIPE
READ CODE OF THIRD
PIPE
PIPES DEPTH
112 cm
Use keys C(½¾¿À
)
to chan
g
e
depth value to which pipe will be
buried. N.B. It is possible to
change unit measure cm to in.
*see page 15