NTH 315

BUTT FUSION MACHINE

OPERATION MANUAL
 BUTT FUSION EQUIPMENT

CONTENTS

1. Brief ..................................................................................................... 2

2. Special Instructions............................................................................. 2

3. Safety .................................................................................................. 3

4. Applicable Range & Technical Parameters .............................. 6

5. Descriptions ...................................................................................... 7

6. Instruction for Use .......................................................................... 8

7. Timer & Temperature Controller ................................................ 10

8. Reference Welding Standards ................................................... 12

9. Malfunctions Analyzing & Solutions ........................................ 15

10. Electric & Hydraulic Diagrams ................................................ 23

11. Packing List ..................................................... 错误!未定义书签。

12. Warranty Clauses ........................................................................ 26

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 BUTT FUSION EQUIPMENT
1. Brief

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

socket welder Auto-butt fusion machine

saddle fusion machine band saw

workshop butt fusion machine manual butt fusion machine

series butt fusion machine

This manual is for the NTH-250astic pipe butt fusion welding machine. It is necessary to read and follow
carefully the following safety rules and maintenance rules before operating the machine.

2. Special Instructions

Before operating the machine, everyone responsible should read this section carefully, and keep it with the
machine in order to ensure the safety of the operator and equipment, as well as the safety of others.
2.1 The machine is used to weld pipes made from PE, PP, PVDF and can not be
used to weld material without description, otherwise the machine may be damaged
or an accident may result.
2.2 Do nOt use the machine in a place with potential hazard of explosion
2.3 The machine must be operated by responsible, qualified and trained personnel.
2.4 The machine should be operated on a dry area. Protective measures should be
adopted when it rains or the ground is wet.
2.5 The input power is 380V±10% 50 Hz, 400V±10% 50 Hz, or 415V±10% 50 Hz (as specified on the
machine identification plate). If an extended input line is used, it should have enough cross section.

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3. Safety

3.1 Safety Precautions

When operating the machine, instructions and safety rules must be followed carefully.
3.1.1 The operator must be responsible and correctly trained.
3.1.2 Completely inspect and maintain the machine for safety and reliability.
3.1.3 Power: The electricity supply must have a leakage switch according to the relevant electricity safety
standard.
Safety protection devices are indicated by easily understandable words or marks.
3.1.4 Connection of the machine to power
The cable connecting the machine to power must be intact and chemical corrosion resistant. If an extended
cable is used, it must have enough cross section according to its length.
3.1.5 Earthing: The whole site should share the same ground wire and the ground connection system must
be finished and tested by appropriate professionals.
3.1.6 Storage of electrical equipment
All equipment must be used and stored correctly as follows:
※ Avoid using temporary cable not complying with standard.
※ Do not touch electrically active parts.
※ Do not pull on the power cable to disconnect.
※ Do not use the cable to lift equipment.
※ Do not put heavy or sharp objects on the cables, and control the temperature of the
cable to below 70°C.
※ Do not work in a wet environment.
※ Do not splash the machine.
3.1.7 Check the insulation condition of the machine periodically
※ Check the insulation of the cables especially the exposed points.
※ Do not operate the machine under extreme conditions.
※ Check if the earth leakage switch works well at least weekly.
※ Check the earthing of the machine by qualified personnel.
3.1.8 Clean the machine carefully
※W hen cleaning the machine do not use materials which will damage the insulation (such as gas, abrasives,
and other solvents).
※ Make sure the power is disconnected when the job is finished.
※Make sure there is not any damage to the machine before reusing.
3.1.9 Operation after a shut-down:
Make sure the switch of the machine is in the off position before connecting power supply.
3.1.10 Tightness of parts
Make sure the pipes are fixed correctly. Ensure that they can move well and are prevented from sliding inside
the clamps.

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3.1.11 Working in an environment with hazards
When working in a ditch, check if there is shoring to stop the earth or stones from falling onto the machine,
also check if there are water or other fluids leaking. If there are, the operator may get an electric shock.
Avoid using the machine in an environment with paint, gas, smoke and diesel , as an infection of eyes and
respiratory tract could occur.
Do not place the machine in a location where dirt may contaminate the weld.
3.1.12 Personnel safety while working
Observe all requirements of the work site.
Remove jewellery and rings, do not wear loose-fitting clothing, avoid wearing shoe laces, a long moustache
or long hair that may be hooked into the machine.
The following is the operation rules:

---Wear safety gloves

---Wear safety shoes

---Dress work clothes

---Wear safety glasses

---Wear earmuffs

3.1.13 Keep the work site clean and tidy

A crowded, dirty and messy site is not favourable for working, so it is important to keep the site clean and tidy.
3.1.14 Untrained persons are not allowed to operate the machine at anytime.
3.2. Potential Dangers
3.2.1 Butt fusion machine controlled by hydraulic unit:
This machine is only to be operated by professional persons or others with a certificate for operation,
otherwise accidents may occur.
3.2.2 Heating Plate
The maximum temperature can reach 270°C, so note the following:

------Wear safety gloves

-------Never touch the surface of the heating plate

3.2.3 Planing tool

Before shaving the pipes, the ends of the pipes should be cleaned, especially remove sand or dirt from
around the ends. This will prolong the life of the blade edges.

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3.2.4 Basic Frame:
Make sure the pipes or fittings are fixed correctly to get the right alignment. When joining pipes, the operator
should keep a certain distance from the machine for personal safety.
Before transporting, make sure all the clamps are fixed well and cannot fall out during transportation.
3.2.5 Craneif crane provided
Check all parts of the crane to avoid danger.
Comply with all local requirements for such equipment.

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4. Applicable Range & Technical Parameters

Type NTH 315

Materials PE, PP, PVDF

Max. range of diameter 315mm

Environment Temperature －5~45 ℃

Power Supply ～220 V±10％

Frequency 50 Hz

Total current 10.8A

Total power 3.95 kW

Include ： Heating Plate 2.1 KW
Planing tool Motor 1.1 KW IP54
Hydraulic Unit Motor 0.75 KW IP54

Dielectric resistance >1MΩ

Max. Pressure 15MPa

Max. Temp. of Heating Plate 300 ℃

Difference in surface temperature of heating plate ±5℃

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5. Descriptions

The machine is comprised of basic frame, hydraulic unit, heating plate, Planing tool, and support.
5.1 The machine

1
3
2

6
4

Figure .1
1. Basic frame 2. Heating plate 3. Planing tool 4. Electrical box 5. Support 6. Hydraulic unit

5.2 Hydraulic Unit

3 4

5
2 1
Figure .2
1. Direction valve 2. Pressure regulation valve 3. Pressure gauge
4. Swing check valve 5. Oil tank

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6. Instruction for Use
6.1 All equipment should be placed on a stable and dry surface to operate.
6.2 Before operation make sure of the following things:
a) The power supply should fit the requirements according to the butt fusion machine
b) Power line is not broken or worn
c) The blades of planning tool are sharp
d) All instruments are normal
e) All necessary parts and tools are available
f) The machine is in good conditions
6.3 Connection and preparation
6.3.1 Connect the basic frame to hydraulic unit by quick couplers.

6.3.2 Connect the heating plate to the eclectic box with the special cable.

Connection the cable with electrical box Connection between the cable and heating plate
6.3.3 Install appropriate inserts to the frame according to the outside diameter of the pipes/fittings.
6.3.4 According to the requirements of the fitting and welding process, set the temperature in temperature
controller and set time in timer. (See section 7 this manual).
6.4 Operation.
6.4.1 Before welding, first check if the material, diameter and wall thickness are as required. Secondly, check
if there are scratches or fissures on the surface of pipes/fittings. If the depth of scratches or fissures exceeds
10% of the wall thickness, remove the section with scratches or fissures.
6.4.2 Clean the inside and outside surface of the pipe ends to be welded.
6.4.3 Place the pipes/fittings in the inserts of the frame. The pipe outside of the basic frame should be
supported to the same central height of the clamps. Fasten the clamping nuts to fix the pipes/fittings.

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6.4.4 Measure the drag pressure: open the pressure regulation valve completely, lock the swing check valve
tightly and then push forward the direction valve. Meanwhile adjust the pressure regulation valve until the
cylinder begins to move, at this point the pressure in the system is the drag pressure.
6.4.5 Open the pressure regulation valve completely, lock the swing check valve tightly and then push
forward the direction valve. Meanwhile adjust the pressure regulation valve to set the system pressure equal
to drag pressure plus welding pressure.
6.4.6 Separate the pipes/fittings ends after turning swing check valve in anti-clockwise direction to relieve the
pressure to lowest. Put the planing tool between the pipes/fittings ends and switch it on, close the
pipes/fittings ends by operating the direction valve of hydraulic unit and slowly turn the swing check valve in a
clockwise direction until there are continuous shavings appearing on both ends. Push the direction valve bar
to the middle position for a few seconds, and then open the frame, switch off the planing tool and remove
from the frame, and then turn the swing check valve clockwise to the end.
Caution: The thickness of shavings should be within 0.2~0.5 mm and can be adjusted by adjusting the height
of the planing tool blades.
6.4.7 Close the pipes/fitting ends and check the alignment. The maximum misalignment should not exceed
10% of the wall thickness, and it could be improved by loosening or tightening the clamping nuts. The
misalignment between two pipe ends should not exceed 10% of wall thickness; otherwise the pipes/fittings
should be planed again.
6.4.8 Remove dust or silt from the surface of the heating plate.
Caution: Do not damage the PTFE layer on the surface of heating plate.
Do not touch the pipe ends with hands or an oily/dirty cloth.
6.4.9 Put the heating plate between the pipe ends after it reaches the required temperature. Close the
pipes/fittings ends by operating direction valve and raise the pressure to the specified pressure by swinging
the pressure regulation valve until the bead reaches the specified height.
6.4.10 Turn the swing check valve anti-clockwise to reduce the pressure (not more than the drag pressure)
and turn the swing check valve in clockwise direction to the end.
Press the button “T2”. The heat soaking time begins to count down to zero by seconds, then the buzzer will
sound(see section 7)
6.4.11 Open the frame and take out the heating plate and close the two melted ends as quickly as possible
(within the changeover time).
6.4.12 Keep the bar of direction valve on the close position for 23 minutes, put the bar of direction valve on
middle position and press the button (“T5”) to count the cooling time until it is over. At this point, the machine
will give an alarm again. Relieve the pressure, loosen the clamping nuts and then take out the joined pipes.

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

Pressing
“set” The lamp T2 is on and the lamp T5 is off

Pressing
To set soaking time in seconds.
△or▽

Pressing
“set” The lamp T2 is off and the lamp T5 is on

Pressing
△or▽ To set cooling time in second

Pressing
Timer setting is over
“Set”

7.2 Instruction for Use

Pressing
“T2” Alarm when the soaking time counts down to zero.

Pressing
“T5” Alarm when the cooling time counts down to zero

Pressing Timer stops

“△”and“▽”

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7.3 Application of temperature controller

7.3.1 Setting temperature of heating plate

After switching on machine, the red value on a screen above of temperature controller shows the present
temperature of heating plate. And the green value on a screen below of temperature controller shows the
given temperature of heating plate. At the moment, press on and off on the temperature controller below for
increasing of decreasing temperature value. Then the green value on a screen below of temperature
controller will change accordingly.
7.3.2 Correction of deviation for heating plate temperature
Because of the difference of environmental temperature or the elapsing of time, actual temperature of heating
plate and displayed temperature of temperature controller may show deviation.
Correction method as followings:
Set heating plate temperature on a value. And power up to reach the displayed temperature on the
temperature controller above and keep on the temperature over 3 minutes.
Use high precision contact temperature measuring to test actual temperature of the surface of heating plate.
The difference between of this temperature value and temperature controller value is temperature
deviation(amusing the heating plate above temperature controller A degree. )
At the same time, press “set” and “▲” over 3 seconds. After up window shows “SI”, press “set” to screen
displaying ”SC”. Then press “▲” or “▼” modifying value to screen value below(set “+A” on the screen in this
sample). After finishing setting, press “set” several times to return to state of normal measurement and
control.(Without press any keys about 10 seconds, it will return to state of normal measurement and control
during setting the meter ).

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8. Reference Welding Standards
Because of different welding standards and PE materials, the time and pressure phases of the butt
fusion process will vary. It is recommended that welding parameters should be approved by the pipes
and fittings manufacture and/or the Specifying Authority
8.1 Reference Welding Standard DVS2207-1-1995
8.1.1 Welding temperature of pipes made from PE、PP and PVDF by DVS Standard ranges from180℃ to
230℃. Application temperature of heating plate is between 180℃～230℃, and its maximum surface
temperature can reach 270℃.
8.1.2 Reference standard DVS2207-1-1995

P Welding pressure
Bead pressure

Soaking pressure

Time

t1 t2 t3 t4 t5

Bead Pressure
Wall Bead Soaking Soaking Change-over Welding Cooling
build-up build -up
thickness height time pressure time pressure time
pressure time
（mm） （mm） t2（sec） （MPa） t3（sec） （MPa） t5（min）
（MPa） t4（sec）
0～4.5 0.5 0.15 45 ≤0.02 5 5 0.15±0.01 6

4.5～7 1.0 0.15 45～70 ≤0.02 5～6 5～6 0.15±0.01 6～10

7～12 1.5 0.15 70～120 ≤0.02 6～8 6～8 0.15±0.01 10～16

12～19 2.0 0.15 120～190 ≤0.02 8～10 8～11 0.15±0.01 16～24

19～26 2.5 0.15 190～260 ≤0.02 10～12 11～14 0.15±0.01 24～32

26～37 3.0 0.15 260～370 ≤0.02 12～16 14～19 0.15±0.01 32～45

37～50 3.5 0.15 370～500 ≤0.02 16～20 19～25 0.15±0.01 45～60

50～70 4.0 0.15 500～700 ≤0.02 20～25 25～35 0.15±0.01 60～80

RemarkBead build-up pressure and welding pressure in the form is the recommended interface
pressure, the gauge pressure should be calculated with the following formula.
2
Section of welding pipe ends(cm )
welding pressure = × 0.15 + drag pressure（MPa）
2
Total section of cylinders(9.12cm )

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8.2 Reference Standard DS/INF70-1992

S, pipe wall thickness in mm

D, outside diameter of pipe in mm
Temperature of heating plate 200℃～220℃
Heating pressure P1 HDPE 0.18 Mpa
MDPE 0.15 Mpa
PP 0.15 Mpa
Soak heating time t1 until the bead reaches (0.5+0.1s) mm
Soak heating pressure P2 About 0.01Mpa
Soak heating time t2 15 s
Change over time t3 Max. 3+0.01D s
t4 3+0.03D s
Welding pressure P5 equate to P1
Cooling time t5 when s≤10mm, t5= 10+0.5s min
S＞10mm,t5= 10+kss,ks as follows:

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8.3 Reference Standard PIPA POP003 - Australian Welding Specifications

8.3.1 Reference Standard PIPA POP003 – Welding Parameters for PE pipes and fittings.

Notes:

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1. These parameters apply to the butt fusion of PE80 or PE100 polyethylene materials as specified in
AS/NZS 4131.
2. These parameters may also apply to the butt fusion of PE80 to PE100. This may result in slightly
different bead formation without reducing weld quality. If in doubt, refer to the pipe manufacturer.
3. Only pipes and fittings of the same diameter and wall thickness should be butt fused together.
4. t = mean pipe wall thickness calculated from AS4130 min/max values, rounded to the nearest mm.
5. D = mean pipe outside diameter calculated from AS4130 min/max values, rounded to the nearest
mm.
6. Pressure calculation formula: pipe annulus area x pressure value
where pipe annulus area = π (D-t)t hyd. cylinder area
7. For ambient temperature >25ºC, cooling timer must be increased by 1 minute per ºC above 25 ºC. For
ambient temperature <5ºC, cooling time may be decreased by 1 minute per ºC below 5ºC

9. Malfunctions Analyzing & Solutions

Possible malfunctions and solutions are stated as below ：

9.1 Joint quality analysis（Reference）

◆ Correct joint

◆ Bead narrow and fallen. Pressure too high.

◆ Small bead. Not enough pressure

 Groove in the center of welding bead. Not enough

temperature or change-over time too long

 The materials have different heating times or

heating temperatures. This may indicate the
welding of PE80 and PE100 which is acceptable
according to pipe and fitting manufacturers’
instructions.

◆ Misalignment. Tolerances exceeds 10% of pipe wall

thickness

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9.2 Maintenance and inspection periods
9.2.1 Maintenance
※ Heating plate coating
Please take care handling the heating plate. Keep a certain distance away from the heating plate. Cleaning
the surface must be done whilst the surface is still warm by using a soft cloth or paper. Avoid abrasive
materials that might damage the coating.
At regular intervals check as follows:
1) Clean the surface by using a quick evaporation detergent (alcohol)
2) Check the tightening of the screws and the cable and plug condition
3) Verify the surface temperature by using infrared-ray scanning or a surface temperature gauge.

※ Planing tool
It is strongly suggested to keep the blades clean and wash the pulleys using a detergent. At regular intervals,
carry out a complete cleaning operation.
※ Hydraulic unit
Maintain as follows:
1) Check the oil level periodically
2) Completely replace the oil every 6 months

Keep tank and oil circuit clean

※ Electrical Connections
Electrical connections can come loose during shipping and handling.
Before first use, tighten terminals, contactors and connector blocks.
Retighten at least every 6 months, depending on how often the equipment has been moved.

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9.2.2 Maintenance & Inspection
Ordinary inspection

Inspect
First Every 6 Every
Item Description before
month months year
use

Sharpen or replace the blade

●
Replace the cable if it is broken or
Planning tool ● ●
damaged ● ●
Retighten mechanical connections
Cable, plugs and sockets ●
● ●
Clean surface of heating plate, recoat
Heating plate
PTFE layer if necessary ●
Retighten mechanical connections ●

Electrical Retighten electrical connections, terminals,

●
Connections contactors and connector blocks

Temp. control Check the temperature indicator ●

system Replace the cable if it is broken ● ●

Check pressure gauge

Replace seals if the hydraulic unit is ●
leaking ●
Hydraulic Clean the filter
system Make sure there is enough oil for ● ●
operation ● ● ●
●
Change the hydraulic oil
Replace the oil hose if broken or damaged
Basic Retighten screws in the end of frame axis ● ● ●
Frame Spray antirust paint again if necessary ●

Press the testing button of the circuit ●

Power protector to make sure it is working
Supply normally
Replace the cable if it is broken or damaged ●
●

“●”………… maintenance period

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9.2.3Calibrating the temperature controller.

1. When temperature controller is up to set temperature and stable, it reads in this example 220°C

2. Measure the temperature of the heating plate. In this example the temperature of the heating plate is 196°C

3. Disconnect the cable from the heating plate.

Calculate the difference between the actual heating plate temperature and the display on the temperature
controller (in this example the difference is -24°, 196 - 220= -24).
To correct this difference, proceed as follows:

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a. press keys "set" and “▲” at the same time for
three seconds

b. Press the “set” key twice. The display now shows the temperature controller’s factory set value in +/-
degrees.
In this example this value is +5.
Therefore the temperature controller needs to be adjusted by -19°C: ((5+ (-24) = (-19°))

c. Press “▼ ” until it displays “-19”

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d. Press the “set” key to return to the original display.

4. When temperature constantly displays 220°C, retest the surface temperature of the heating plate. If there
is still a difference in the temperatures, repeat the above procedure.

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9.3Malfunction analysis and solution
During operation, hydraulic unit and electrical units may indicate some problems. Possible malfunctions are
listed as follows:
Please use the tools supplied, spare parts or other tools with a safety certificate while maintaining or
replacing parts.

9.3.1 Malfunctions of hydraulic unit

No Malfunction Malfunction analysis Solutions

1. Switch is faulty. 1. Check the switch

The pump motor 2. Power source is not connected properly. 2. Connect the power properly
1
does not work 3. The socket inside connection is loose 3. Check the connection
4. The machine is not grounded correctly 4. Check the earthing connection
1. The motor is overloaded 1. Make sure the motor load is less than
The pump motor 3 MPa
rotates too slowly
2 2. The motor is faulty 2. Repair or replace the pump
with abnormal
3. The oil filter is blocked 3. Clean the filter
noise
4. The working voltage is unstable 4. Check the instability of power
1. The direction valve is damaged 1. Replace the direction valve.
2. There is air in system 2. Move the cylinder several times to
The cylinder expel the air.
3 works 3. The system pressure is too low 3. Adjust the system pressure
abnormally 4. The quick coupler is blocked 4. Replace the quick coupler
5. The pressure relief valve is not locked 5. Lock the valve
1.The oil ring is faulty 1. Replace the oil ring
4 Cylinder leak 2. The cylinder or piston is damaged 2. Replace the cylinder
The pressure 1. The core of overflow valve is blocked. 1. Clean or replace the core of
cannot be 2. The pump is leaking. over-flow valve.
5 increased or the 3. The joint slack of pump is loosened or key 2. Replace the pump.
fluctuation is too groove is slipping. 3. Replace the joint slack.
big 4. The pressure relief valve is not locked. 4. Lock the valve.

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9.3.2 Malfunctions of electrical units
1. The power cable is damaged 1. Check the power cable
The machine does
1 2. Source power is abnormal 2. Check the working power
not work
3. The ground fault switch is closed 3. Open the ground fault interrupter
1. Power cable of heating plate, the motor of 1. Check the power cables
pump and planing tool may be damaged 2. Check the electrical elements.
Ground fault switch 2. Electrical components are t affected with 3. Check the higher-up power safety device
2
trips damp
3. The higher-up power has not a ground fault
safety device
1. The temperature controller switch is open 1. Check the connection of contactors
2. The sensor （ pt100 ） is abnormal. The 2. Replace the sensor
resistance value of4 and 5 of heating plate
socket should be within 100~183Ω
3. The heating stick inside heating plate is
abnormal. The resistances between 2and 3 3. Replace the heating plate
should be within23Ω. Insulation resistance
between head of heating stick and outside
shell must be more than 1MΩ
Abnormal 4. Should the temperature controller readings
3 temperature be more than 300 ℃ , which suggest he 4. Replace the temperature controller
increasing sensor may be damaged or the connection
is loosen. Should the temperature controller
indicate LL, which suggests the sensor have
a short circuit. Should the temperature
controller indicate HH, which suggests the
circuit of sensor is open. 5. Refer to the methods to set the
5. Correct the temperature by button located on temperature
the temperature controller.
6. The temperature fluctuate abnormally 6. Check and replace the contactors if
necessary

The red light is shine, but the temperature still

Lose of control goes up, that is because the connector is fault Replace the temperature controller
4
when heating or the joints 7 and 8 can not open when get the
required temperature.

Planing tool does The limit switch is ineffective or the mechanical Replace the planning tool limit switch or
5
not rotate parts of planing tool are clipped. minor sprocket

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10. Electric & Hydraulic Diagrams
Electric diagram

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Hydraulic diagram

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ACCESSORES LIST
NTH—250/90 Butt fusion welding machine

Item Description Unit Qty Remark

1 Basic frame set 1
2 Inserts set 1 110mm～225mm
3 Hydraulic Unit set 1 Include high-pressure oil hose
4 Support set 1
5 Planning tool set 1
6 Heating plate set 1 Include connecting cable of heating plate
Attachment with machine

1 Tool box Pcs 1

2 Blade of planning tool Pcs 2
3 Ratchet wrench Pcs 1 24mm
4 Double open wrench Pcs 1 8～10
5 Double open wrench Pcs 1 17～19
6 Screwdriver Pcs 1 150mm
7 Special bolt for clamp Set 1 M6
8 Operation instruction Pcs 1
9 Conformity certificate Pcs 1
Spare parts
1 Temperature sensor Set 1 PT100
2 Startup capacitance Set 1 100UF
3 Work capacitance Set 1 25UF

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12. Warranty Clauses

1. The warranty range refers to the whole machine.

2. The supply of spare parts for malfunctions during normal utilization is free of charge within the warranty
period of 12 months
3. The warranty starts from the date of delivery.
4. Fees are charged in the case of the following conditions:
4.1 Malfunction is caused by improper operation
4.2 Damage is caused by fire, flood, and abnormal voltage
4.3 Operation exceeds normal function
5. Fees are charged as an actual expense. A contract about the fees shall be abided if there is one.
6. Please contact us or our agent with any questions.

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