CLEVELINGS BLUEBOX 1.0 Manuel utilisateur

Manufacturer: CLEVELINGS s.r.o.

K Pahrbku 1562, 763 61 Napajedla

Tel./fax. +420 573 033 029, mob.: +420 604 196 840

www.clevelings.cz, e-mail: info@clevelings.cz

USER MANUAL

1st generation

electrofusion welding units

Instrukcja 
 
 
1
Contents 
GENERAL INFORMATION ........................................................................................................................................................ 2 
1 Signs used in the instruction........................................................................................................................ 2 
2 Use............................................................................................................................................................... 2 
SAFETY.................................................................................................................................................................................... 3 
1 General safety systems................................................................................................................................ 3 
2 Workplace safety......................................................................................................................................... 3 
3 Electrical safety ........................................................................................................................................... 4 
4 Personnel safety .......................................................................................................................................... 4 
5 Use............................................................................................................................................................... 4 
6 Possible danger sources .............................................................................................................................. 4 
7 Power supply ............................................................................................................................................... 5 
8 Power generators........................................................................................................................................ 5 
9 Extension cords............................................................................................................................................ 6 
10 Servicing ...................................................................................................................................................... 6 
TECHNICAL SPECIFICATION ..................................................................................................................................................... 6 
1 Construction ................................................................................................................................................ 7 
1.1 Construction (outside) .........................................................................................................................7 
1.2 Front panel layout................................................................................................................................8 
1.3 Connection adaptors............................................................................................................................8 
1.4 Identification plates .............................................................................................................................9 
1.5 Barcode scanner...................................................................................................................................9 
1.6 Acoustic signal....................................................................................................................................10 
1.7 Keypad................................................................................................................................................10 
2 Start-up...................................................................................................................................................... 10 
2.1 Transport, packing and storage .........................................................................................................10 
2.2. Operating personnel..........................................................................................................................10 
2.3. Start-up procedure.............................................................................................................................10 
WELDING PROCESS............................................................................................................................................................... 11 
OPERATING INSTRUCTIONS .................................................................................................................................................. 12 
1 Starting messages ..................................................................................................................................... 12 
2 Welding......................................................................................................................................................13 
3 Settings...................................................................................................................................................... 15 
TROUBLESHOOTING ............................................................................................................................................................. 17 
MAINTENANCE ..................................................................................................................................................................... 19 
FINAL REMARKS.................................................................................................................................................................... 20 
FORBIDDEN ACTIONS............................................................................................................................................................ 20 
FIREFIGHTING INSTRUCTIONS............................................................................................................................................. 20 
 
 
 
 
 
 
 
 
 
 
 
 
 

1. GENERAL INFORMATION

NOTE

Before proceeding to work with the device make sure to read closely this user manual, which constitutes

integral part of the device. The instruction shall be used before work, during and after the launch and

anytime it’s deemed to be necessary.

Following above instructions is the only way to achieve three main objectives of this instruction manual i.e.:

•Optimization of work effects and performance of the device

•Protection against injuries

•Protection against damage and destruction of the device

1.1 Signs used in the instruction

Present instruction include following safety signs and warnings.

Symbol

Description

WARNING

This symbol refers to a direct threat to the life or health of a person.

Ignoring the warning results in serious injuries and may even have fatal consequences.

CAUTION

This symbol provides important information referring to proper operating of the device. Ignoring this

message might lead to a malfunction, damaging the material or damages done to the environment.

INFORMATION

This symbol provides instructions and valuable information. Such information will help you to use the

machine functions in optimal way.

1.2 Use

Electrofusion welding unit serves for joining of plastic pipes and fittings. Using the device for purposes other than the ones

described in this manual is forbidden and can be dangerous to the operator and assisting personnel or can lead to damaging the

device or other equipment located in the area.

In order to use the device accordingly make sure to follow:

•all recommendations included in this user manual

•general and detailed guidelines on electrofusion fittings

•applicable health and safety regulations, environmental protection regulations, legal regulations and all standards, laws

and directives in force in a given country

Electrofusion welding consist in joining two (PP, PE) pipe ends with the use of electrofusion fitting like e.g. couplers, tees,

reductions, saddles, etc. During welding process the device provides electric energy of strictly defined parameters to the resistance

wire located on the inner surface of the fitting. Electric energy is transformed into heat causing the polyethylene on the fitting and

fitting to melt and bond by filling up the space between both elements. After cooling and crystallization of polyethylene, the

connection is durable, firm and reliable.

Electrofusion welding process is performed correctly only if device applied for this purpose allows for full control of process

parameters such as:

•welding voltage

•duration of subsequent stages of welding process

Instrukcja

Stage of

process

Description

Preparation of pipes

Installation of pipe-fitting assembly in aligning tool

III

Welding

Cooling

2. SAFETY

2.1 General safety systems

WARNING

Every operator is obliged to read the user manual before

proceeding to work with the device. During work operator shall use

direct protection measures required in the workplace.

Electrofusion welding unit is designed accordingly with current regulations and shall be used exclusively for welding pipes and

fittings made of polyolefins. Electrofusion welding process does not pose any danger to the operator provided that the safety rules

are followed. However, using the device by unqualified personnel or not following the safety rules could lead to injuries.

All people not involved into the process shall make sure to maintain safe distance while the device is working.

Improper handling or improper use of the device could lead to:

•Threat to the health and life of the operator

•Damage to the electrofusion welding unit

•Decrease in work efficiency of the welding unit

•Obtaining low quality connections

2.2 Workplace safety

•Workplace shall be kept clean and properly lit. Disorder and improper lighting in the workplace can lead to accidents.

•Do not use power tools in the explosive zone areas with flammable gases, liquids or dusts. Power tools might generate

sparks which could ignite them.

•Do not allow children of any 3rd parties in the working area. Their presence could distract the operator which could lead

to losing control over the device.

WARNING

Device shall be used only by properly trained personnel with suitable qualifications. Using the device against

its original purpose is forbidden and might be dangerous to the operator and assisting personnel and could

lead to damaging the device or other equipment in the closest area.

CAUTION

Each unauthorized use of the device, use against its purpose or any interference into its construction will

result with immediate loss of warranty.

2.3 Electrical safety

•Power supply plug must fit the socket perfectly and cannot be modified in any way. Power tool that require protective

grounding cannot be powered through extension cords. Use of unmodified plugs and proper sockets significantly reduce

the risk of sustaining an electric shock.

•Avoid touching non-grounded elements, e.g. pipes. Grounding one’s body increases the danger of sustaining an electric

shock.

•Do not expose power tools to moisture or rain. The penetration of water inside the power tool increases the risk of

sustaining an electric shock.

•Power supply cable does not serve for: transport purposes, hanging or lifting the device, pulling the plug out of socket.

Protect the power supply cable against high temperatures, sharp edges, oils and moving elements. Damaged or entangled

cable increases the risk of sustaining an electric shock.

•During work on the outside, when it’s necessary to use extension cables make sure to use extension cables intended for

outside use. Using such type of extension cable decreases the risk of electric shock.

•If you are working in high humidity conditions use a circuit breaker. The use of a current protection switch reduces the risk

of electric shock.

2.4 Personnel safety

•Be attentive, pay attention to performed actions, take reasonable care while working with power tools. Do not use power

tools if you are tired or under the influence of drugs, alcohol or medication.

•Wear personal protective equipment and always safety goggles. The use of personal protective equipment such as non-

slip footwear, a protective helmet or hearing protection, depending on the power tool used, reduces the risk of injury.

•Eliminate the possibility of accidental start of the device. Before connecting to the power outlet and before touching or

moving the device make sure it’s turned off. Moving an electrical device with your finger on the switch or attempting to

connect to a power outlet while the equipment is turned on may lead to an accident.

•Avoid unnatural body positions during work. Ensure a safe standing position and keep your balance at all times. This will

allow you to better control the power tool in unexpected situations.

2.5 Use

•Do not overload the device. For each work use suitably selected tools. Properly selected tools allow for easier and more

confident work in desired power range.

•Do not use power tools with damaged power switch. Device that doesn’t allow for emergency shutdown at any given

moment poses a danger and shall get repaired.

•Before preparing the device for work, replacing accessories or putting the device back make sure to remove the plug

from power outlet. These safety precautions prevent from accidental start of the device.

•Unused power tools shall be stored away from the reach of children. Do not allow people unfamiliar with the device, or

this instruction manual, to operate it. Power tools in the hands of inexperienced personnel could be dangerous.

•Take care of the power tools. Damaged parts shall be replaced by authorized service centers. Many accidents are

attributed to improper maintenance.

•Use the device in accordance with these instructions. The operating conditions and the type of operation to be carried

out must be taken into account. Using power tools for other purposes than intended may lead to dangerous situations.

2.6 Possible danger sources

Electrofusion welding unit is an electrical device and thus it’s forbidden to:

•leave the device unattended

•use damaged device (casing, cables, extensions)

WARNING

Danger of sustaining an electric shock from elements under voltage. Danger to health and life.

Instrukcja

•service the device that is under voltage

•work with the device on voltage different that intended

•remove safety equipment during welding process

Electrofusion unit shall be used in accordance with general safety rules. There should be proper ventilation ensured in the place

of work and enough space for operation to be carried in safe manner. If the work is carried outside suitable measures shall be

taken to protect the device against weather conditions. It’s forbidden to use the device in the proximity of flammable substances,

explosive zones, excessively hot or cold conditions or in too high humidity or with high level of dust.

It’s forbidden to clean the device with the use of solvents or other aggressive substances which could permanently damage the

external surface or damage the plastic elements. Only trained personnel can use the device. All repairs shall be performed by

qualified personnel.

2.7 Power supply

1st generation electrofusion welding units are adapted to work with power supply AC 230V (+/-15%), 50Hz (+/-10%) from mains

or power generator. In case of working in outdoors conditions (construction site) electric sockets should ensure stable

parameters of power supply. Power generator or mains to which the device is connected should be equipped (depending on

model) with (delay) safety fuses 16A or 20A.

2.8 Power generators

Before connecting the device to power generator make sure it’s recommended for work on the building site. Follow the user

manual delivered with the generator. Connect the electrofusion unit to the generator at least 1 minute after starting the

generator. Do not connect other power tools to the generator during welding process.

After finishing the welding process firstly turn off the welding unit main switch, then unplug the device from generator and lastly

turn off the power generator. Following this sequence will protect the welding unit from damaging it with voltage peaks which

appear during start-up and shut down of power generator.

Required nominal power of the power generator depends on:

•fitting resistance and welding voltage

•outside conditions

•connection

WARNING

Danger of fire or explosion in case of contact with flammable materials.

INFORMATION

Before connecting the device to power outlet make sure the power supply parameters are within the range

of work of the device –195 do 265 V!

WARNING

230V power supply should have grounding wire, residual current circuit breaker and overcurrent protection. It’s

forbidden to connect the device to power outlets without neutral wire and grounding pin.

2.9 Extension cords

Poniższa tabela przedstawia zmianę wymaganego przekroju przedłużacza w zależności od jego długości.

Length

Cross-section

up to 50 m

2,5mm2

up to 100m

4 mm2

2.10 Servicing

3. TECHNICAL SPECIFICATION

*only when full cooling times are maintained

INFORMATION

Different types of power generators often show different regulating characteristics. As a result selecting the power

generator basing solely on nominal power might not be effective. When in doubt whether given power generator

is suitable for work with the electrofusion unit contact authorized service department.

INFORMATION

In order to minimize the risk of overheating the extension cord, make sure to unfold it!

WARNING

Repairs of power tools shall be performed by professionals and only with the use of original spare parts. This allows

to keep the devices safe in use.

Technical parameters

Type:

BLUEBOX 1.0

Approximate diameter range:

~160mm

Power supply [V]:

230

Input voltage [V]:

195 –255

Frequency range [Hz]

45 –55

Max. welding current [A]:

Max. fitting power [W]:

1450

Weight [kg]:

Protection class:

IP-54

Power supply cable [m]:

Welding cables [m]:

Dimensions [mm]:

390 x 240 x 160

Voltage regulation range [V]:

8 –44

Volt. regulation step of change [V]:

0,1

Welding time step of change [s]:

Cooling time step of change [min]:

Working temperature [°C]:

- 5 to + 40

Recommended power generator

[kW]:

Welding data registration and

traceability:

Memory capacity:

Instrukcja

3.1 Construction

Electrofusion welding units BLUEBOX 1.0 are equipped with ABS-made casing permanently embedded in steel transport box.. CPU

board, power board, transformer and display are all mounted inside the casing. CPU board is responsible for controlling the

functions of the device by measuring the voltage and current and controls the duration of subsequent stages of welding process.

Device is equipped with outside temperature sensor (located on output cables) and sensor of temperature of transformer which

control its temperature and prevents the device from overheating.

Basic elements of electrofusion unit and its control panel are shown below.

3.1.1 Construction (outside)

BLUEBOX 1.0

1. Adaptor

2. Adaptor connector

3. Outside temperature sensor

4. Output cables

5. Control panel

6. Main power switch

7. Metal transport box

8. M12 port for connectin the barcode scanner / printer

9. Acoustic signal

10. USB-B port (for communicaton with PC)

11. Identification plate

12. Power supply cable

3.1.2 Front panel layout

Control panel

1. Control panel sticker

2. Display

3. START button

4. STOP button

5. PRINT button

6. CONFIRM button

7. Navigation button

8. Alphanumeric keypad

9. Power supply diode

10. ‘Welding in progress’ diode

3.1.3 Connection adaptors

Electrofusion welding units are equipped with two output cables ended with threaded connectors on which adaptors are to be

mounted. In standard each device is delivered with set of two adaptors ø4 and two adaptors ø4,7.

Elecrofusion adapters

1. M8 thread

2. Adaptor housing

3. Adaptor socket

Instrukcja

3.1.4 Identification plates

Identification plate includes technical characteristics of given model and unique serial number of the device. The plate is attached

to the front part of metal transport case in models BLUEBOX 1.0.

3.1.5 Barcode scanner

Barcode scanner constitutes part of additional equipment options. It’s connected to the welding unit via M12 port. Barcode

scanner uses a laser beam to scan and decode the information contained in the barcode. Barcode scanner is activated when device

is in main menu or in barcode scanner mode. Just point the scanner at the barcode and press the read button. The barcode is

scanned by a red laser beam that must pass through the entire barcode, perpendicular to the barcode line, possibly through the

center of it. The barcode will not be read correctly if the red light beam does not pass through the entire barcode. Optimum

reading results are obtained when the scanner is placed in close proximity to the barcode.

Barcode scanner

Incorrectly printed or slightly damaged barcodes can be read by placing the scanner directly over the barcode, and then, with

the read button pressed, slide the scanner over the barcode. When the barcode is correctly read, the device will emit a sound

signal and the screen will display information about the decoded welding parameters.

INFORMATION

In order to allow for easier identification of adaptor size, adaptors 4,7mm are market with a groove on its housing.

Adaptors 4mm have plain housing with no marks.

INFORMATION

Before each welding process make sure to check the correctness of montage of adaptors on output cables.

Pay special attention on choosing the right adaptors in relation to the pins located on the fitting. In case wrong

adaptors are used it might happen that welding process will not start, will get aborted or will be carried in incorrect

way.

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