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Fusion Gator Series User Manual

Fusion Gator Series
44 pages
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Gator Automatic Butt Fusion
Range
Operating Manual
www.fusiongroup.com

Table of Contents

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Fusion Gator Series Specifications

General IconGeneral
BrandFusion
ModelGator Series
CategoryPower Tool
LanguageEnglish

Summary

Safety Instructions

Electrical Safety

Electrical safety precautions, earthing, cable routing, and overload protection.

Thermal Hazard Precautions

Precautions for handling hot components and recommended protective gear.

Automated Operation Safety

Safety measures for automated movements, alarms, and emergency stops.

Safety Instructions

Trimmer and Heater Module Safety

Safety measures for trimmer and heater modules, including blade and hot component handling.

Hydraulic Fluid Health

Health and safety guidelines for contact with hydraulic fluids and lubricants.

Gator Component Overview

Controller and Keypad

Identification of the control unit, display, and keypad interface.

Main Machine Assemblies

Identification of Heater, Trimmer, and Chassis components.

Gator Component Overview

Control Unit Interior Access

Details on accessing the inside of the control unit, including clips and RCBO.

Gator Component Overview

Electrical Connections Identification

Identifies circuit breaker reset buttons, hydraulic pump, and electronics power supplies.

Gator Component Overview

Trimmer and Chassis Fixtures

Shows trimmer blade, securing fixture, and chassis clamp adjusters.

Scope of Operation

Maintenance and Care

User Pre-Operation Checks

Pre-connection checks for leads, connectors, and equipment integrity.

Hydraulic Oil Level Management

Procedure for checking and topping up hydraulic oil levels with approved oils.

Maintenance and Care

Storage and Transportation Guidelines

Guidance on storing and transporting the equipment safely to prevent damage.

Scheduled Servicing Requirements

Recommended intervals for product servicing by manufacturer or authorized agent.

Butt Fusion Best Practices

Recommended Fusion Procedures

Recommended procedures and checks for successful butt fusion operations.

Prohibited Fusion Practices

List of actions to avoid during the butt fusion process to ensure quality.

Equipment Preparation

Clamp Liner Installation

Instructions for fitting clamp liners for different pipe sizes and securing them.

System Connections Procedure

Steps for connecting electrical and hydraulic components to the control unit.

Manual Data Entry Operations

Character Entry Modes

Explanation of Select mode and Edit mode for character entry via keypad.

Character Input Interface

Description of the operator interface for character input and selection.

Status Bar Indicators

Standard Status Bar Display

Displays memory status, joints to next service, time, date, and input voltage.

Data Transfer Status Bars

Status bars indicating backup to memory card and data download to USB.

Status Bar Indicators

PC and Printer Data Output

Status bars for sending data to PC and thermal printer.

Minitran Data Transmission

Status bar indicating data transmission to Minitran.

Machine Operation Basics

Power-Up Sequence and Display

Steps involved in powering up the machine and initial system display.

BlueBox Mobile Connectivity

Instructions for connecting a mobile device via Bluetooth for BlueBox functionality.

Service Alarm and Lockout

Indicates when service is required and explains service lockout conditions.

Machine Operation Basics

Information Entry Fields

Prompts for operator, location, and project data entry using the keypad.

Jointing Process Steps

Pipe and Welding Parameter Selection

Screen for selecting pipe parameters and welding standards for the joint.

Jointing Process Steps

Automated Trim Cycle Overview

Overview of the automated trimming cycle and associated safety warnings.

Oil Warm-up and Trim Positioning

Procedure for oil warm-up and automatic machine positioning for trimming.

Jointing Process Steps

Trimmer Installation and Pipe Loading

Instructions for fitting the trimmer and loading pipes into the machine clamps.

Jointing Process Steps

Trim Cycle Execution and Feathering

Process of starting the trim cycle, tuning parameters, and feathering pipe ends.

Jointing Process Steps

Trim Completion and Swarf Management

Prompt after trim cycle, instructions for clearing swarf, and pipe inspection.

Automated Check Cycle Procedures

Pipe Slippage Verification

Machine closes to verify pipe slippage under pressure during the check phase.

Pipe Alignment Verification

Verification of pipe alignment and contact around the joint circumference.

Automated Join Cycle Steps

Heater Temperature and Preparation

System waits for correct heater temperature and prepares for bead formation.

Bead Formation and Insertion

Process of bead formation and inserting the heater plate between pipe ends.

Automated Join Cycle Steps

Bead-up and Heat Soak Phases

Execution of bead-up and heat soak phases with time remaining display.

Heater Plate Ejection

Heater plate is ejected at the end of the soak phase, triggering an alarm.

Automated Join Cycle Steps

Pressure Build-up and Fusion

Pressure builds to target, followed by fusion and cooling stages for joint solidification.

Final Bead Inspection and Acceptance

Operator inspects the final bead and confirms joint completion.

Error Message Troubleshooting

Trimmer, Clamp, and Heater Errors

Error messages related to trimmer function, clamp security, and heater operation.

Dwell Time and Drag Errors

Error messages concerning heater dwell times, removal times, and excessive drag.

Error Message Troubleshooting

Cycle Aborts and Pressure Errors

Error messages for cycle aborts, no movement sensed, pressure limits, and low oil.

Calibration and Balance Errors

Errors related to trimmer current, heater channel balance, and temperature calibration.

Error Message Troubleshooting

Heater Status and Dwell Phase Errors

Error messages for heater status detection and dwell phase issues.

User Menu Functions

LCD Contrast Adjustment

Procedure to adjust the LCD contrast settings for better readability.

Language Selection

Option to select the operating language of the control unit's computer.

User Menu Functions

Outputting Joint Records

Options to view or download joint data to screen, printer, USB, or PC.

Selecting Records for Transfer

How to select specific joint records for viewing or downloading to external media.

User Menu Functions

Joint Record Selection Criteria

Options for selecting records by range, status, or matching operator/project criteria.

JointManager Data Management

Sending Joint Data to Devices

Options to send joint data to USB drive, Minitran, or PC.

Selecting Records for JointManager

Choosing which joint records to transfer and view within JointManager.

JointManager Data Management

Data Transfer Selection Options

Options for transferring latest joints, all joints, a range, or the last fused joint.

System Settings and History

System Variable Management

Options to view or download system settings like serial number and software version.

User History and Daylight Saving

Options to erase user history and toggle the daylight saving time setting.

User Diagnostics Menu

Test and Calibration Functions

Access to test and calibrate various machine components for optimal performance.

Specific Component Diagnostics

Diagnostics for chassis, trimmer, heater, computer, hydraulic systems, and barcode scanner.

Technical Specifications

Supply, Power, and Environment

Details on input voltage, power requirements, operating temperature, and environmental protection.

Pipe and Joining Parameters

Specifications for pipe diameter, joining pressure, heater temperature, and SDR range.

Welding Standards and Sequence

List of approved welding standards and details of the joining sequence steps.

Technical Specifications

Communication Ports and Unit Weights

Information on communication ports, speeds, and the weights of machine components.

Machine Dimensions and Cable Lengths

Specifications for machine dimensions and lengths of input/output cables and hoses.

Rights and Accessories

Available Accessories List

List of available accessories including memory stick and chassis cradles with order numbers.

Appendix A: Character Entry Sets

Number and ABC Character Sets

Character sets for numerical input and the standard English alphabet.

Appendix A: Character Entry Sets

Russian, Japanese, and Symbol Characters

Character sets for Russian, Japanese languages, and available special symbols.

Declaration of Conformity

Compliance with Directives and Standards

Declares conformity with EMC and Machinery Directives and relevant safety and performance standards.

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