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Ritmo BASIC 160 V1 - User Manual

Ritmo BASIC 160 V1
95 pages
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Rev.: 0 16/10/2012 MU000838
ﺔﻧﺎﻴﺼﻟاو ماﺪﺨﺘﺳﻻا ﺐﻴﺘآ
USE AND MAINTENANCE HANDBOOK
BASIC 355 V0
BASIC 315 V1
BASIC 250 V1
BASIC 200 V0
BASIC 160 V1
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Summary

Introduction to the Manual

Technical Features and Specifications

Machine Specifications

Presents general specifications for different BASIC models.

Key Machine Features

Lists weldable materials, temperature range, and power.

Chassis Specifications

Details chassis dimensions and weight specifications.

Technical Features and Specifications (Continued)

Facer Specifications

Lists specifications for the facer component.

Heating Plate Specifications

Provides specifications for the heating plate.

Hydraulic Gearcase Specifications

Details specifications for the hydraulic gearcase.

Facer;Heating Plate Support

Describes the structure supporting the facer and heating plate.

Technical Features and Specifications (Continued)

Options and Reductions

Lists available options and reduction specifications.

Technical Features and Specifications (Continued)

Tool for Flange Necks

Describes the tool used for flange necks.

Welding General Criteria

Transport and Handling Criteria

Details criteria for transporting, handling, and storing pipes.

Pre-Welding Checks

Outlines checks and preparations required before welding.

Measuring Instruments Overview

Introduces essential measuring instruments for welding.

Welding General Criteria (Continued)

Pre-Welding Checks (Continued)

Details checks for Facer and Heating Plate before welding.

Welding General Criteria (Continued)

Weather Conditions for Welding

Specifies conditions to consider regarding weather during welding.

Setup Procedures

Outlines setup steps including pipe preparation and measurements.

Welding Cycles

Simple Pressure Welding Cycle

Details the stages and parameters of the simple pressure cycle.

Dual Pressure Welding Cycle

Details the stages and parameters of the dual pressure cycle.

Parts Description

Chassis Components

Lists and illustrates the parts of the chassis.

Parts Description (Continued)

Facer Components

Lists and illustrates the parts of the facer.

Parts Description (Continued)

Heating Plate Components

Lists and illustrates the parts of the heating plate.

Parts Description (Continued)

Facer;Heating Plate Support Components

Lists and illustrates the parts of the support structure.

Parts Description (Continued)

Hydraulic Gearcase Components

Lists and illustrates the parts of the hydraulic gearcase.

Parts Description (Continued)

Timer Components

Lists and illustrates the parts of the timer.

Operating Instructions

Countdown Function Operation

Explains how to use the countdown function of the timer.

Hours and Alarm Adjustment

Details how to adjust hours and set alarms on the timer.

Operating Instructions (Continued)

Hydraulic Connections

Instructions for connecting hydraulic hoses.

Operating Instructions (Continued)

Electrical Connections

Instructions for making electrical connections.

Operating Instructions (Continued)

Hydraulic Gearcase & Generator Set Connections

Details connections for the hydraulic gearcase and generator set.

Permitted Extensions

Specifies guidelines for using permitted extensions.

Operating Instructions (Continued)

Machine Start Up Procedure

Guides the user through the initial startup process of the machine.

Operating Instructions (Continued)

Temperature Setpoint Modification

Explains how to modify the temperature setpoint.

Changing Temperature Measure System

Details how to switch between Celsius and Fahrenheit.

Error Messages and Handling

Lists common error messages and their solutions.

Machine Shutdown Instructions

Provides steps for safely shutting down the machine.

Operating Instructions (Continued)

Setting Timer Values

Guides on setting heating and welding times on the timer.

Chassis Preparation

Details steps for preparing the chassis, including reductions.

Operating Instructions (Continued)

Welding Between Clamps (2 nd & 3 rd)

Instructions for welding between specific clamps.

Operating Instructions (Continued)

Welding Between Clamps (3 rd & 4 th)

Instructions for welding between specific clamps.

Facing Operation

Positioning the Facer

Explains how to correctly position the facer.

Turning on the Facer

Guides on starting the facer motor.

Stopping the Facing Process

Instructions on when and how to stop the facing operation.

Operating Instructions (Continued)

Reading Dragging Pressure (Pt)

Explains how to measure and record the dragging pressure.

Operating Instructions (Continued)

Simple Pressure Welding Cycle Setup

Guides on setting up the simple pressure welding cycle.

Operating Instructions (Continued)

Phase 1: Approach and Pre-heating

Details the first phase of the welding cycle.

Phase 2: Heating Process

Explains the second phase of heating in the welding cycle.

Operating Instructions (Continued)

Phase 3: Heating Plate Removal

Describes the process of removing the heating plate.

Phase 4: Reaching Welding Pressure

Details how to reach the required welding pressure.

Operating Instructions (Continued)

Phase 4: Reaching Welding Pressure (Continued)

Details how to reach the required welding pressure.

Phase 5: Welding Process

Explains the welding phase of the cycle.

Operating Instructions (Continued)

Phase 5: Welding Process (Continued)

Explains the welding phase of the cycle.

Phase 6: Cooling the Joint

Describes the cooling phase of the weld joint.

Operating Instructions (Continued)

Welding Completion Procedures

Outlines steps to take after welding is completed.

Dual Pressure Welding Cycle

Phase 5: Welding (First Part)

Details the first part of the dual pressure welding phase.

Operating Instructions (Continued)

Phase 6: Welding (Second Part)

Details the second part of the dual pressure welding phase.

Phase 7: Cooling the Weld

Describes the final cooling phase of the dual pressure cycle.

Maintenance

Quick-Coupling Connections Maintenance

Guidelines for maintaining quick-coupling connections and connectors.

Chassis Maintenance

Instructions for cleaning and protecting chassis components.

Hydraulic Gearcase Maintenance

Details oil replacement and level checking for the hydraulic gearcase.

Maintenance (Continued)

Heating Plate Maintenance

Procedures for cleaning and storing the heating plate.

Facer Maintenance

Instructions for periodic blade replacement and cleaning the facer.

Trouble Shooting

Chassis Troubleshooting: Oil Leakage

Addresses oil leakage issues in the chassis and its causes.

Trouble Shooting (Continued)

Chassis Troubleshooting: Lack of Pressure

Solves issues related to low pressure and insufficient movement force.

Trouble Shooting (Continued)

Hydraulic Gearcase Troubleshooting

Addresses issues with the hydraulic gearcase not working or pressure fluctuations.

Trouble Shooting (Continued)

Heating Plate Troubleshooting

Solves problems related to the heating plate not heating or temperature adjustment.

Facer Troubleshooting

Addresses issues when the facer is not working.

Safety Precautions

Introduction to Safety Precautions

Emphasizes the importance of safety for skilled personnel.

Electrical Hazards and Precautions

Highlights electrical risks and necessary safety measures.

Safety Precautions (Continued)

Electrocution Hazard Precautions

Details precautions to avoid electrocution hazards.

Safety Precautions (Continued)

Mechanical Hazards and Precautions

Covers mechanical risks like crushing and entrapment.

Crush Hazard Awareness

Warns about the crush hazard during machine operation.

Safety Precautions (Continued)

Cutting Hazard Precautions

Emphasizes safety when using the facer to avoid cuts.

Splintering Hazard Precautions

Warns about flying debris and the need for eye protection.

Safety Precautions (Continued)

Entanglement;Entrapment Hazard Precautions

Advises on avoiding entanglement with moving parts.

Thermal Hazards Awareness

Highlights risks associated with hot surfaces and parts.

Burning Hazard Precautions

Warns about the risk of burns from hot components.

Safety Precautions (Continued)

Fire Hazard Precautions

Advises on avoiding fire hazards in the work environment.

Workplace Hygiene

Handling Hazards Awareness

Warns about hazards related to lifting and manual handling.

Workplace Hygiene (Continued)

Crush Hazard During Handling

Specific warnings about crushing hazards during handling.

Risk of Injuries from Manual Handling

Details risks associated with improper manual handling techniques.

Workplace Hygiene (Continued)

Chemical Hazards and Precautions

Covers risks from toxic or explosive substances.

Noise Hazard Awareness

Warns about high noise levels and hearing protection.

Welding Parameters

Pipe;Fitting Features and Classification

Details pipe/fitting classification (SDR, S, NP) and dimensions.

Welding Parameters (Continued)

Calculate Welding Parameters (UNI 10520: PE 80)

Provides formulas and tables for calculating PE 80 welding parameters.

Welding Parameters (Continued)

Calculate Welding Parameters (UNI 10967: PE 100)

Provides formulas and tables for calculating PE 100 welding parameters.

Welding Parameters (Continued)

Calculate Welding Parameters (DVS 2207-1: HDPE)

Provides formulas for calculating HDPE welding parameters.

Welding Parameters (Continued)

Calculate Welding Parameters (DVS 2207-11: PP)

Provides formulas for calculating PP welding parameters.

Welding Report

HDPE Welding Report Form

Form for recording HDPE welding process details.

Welding Report (Continued)

PP Welding Report Form

Form for recording PP welding process details.

Welding Report (Continued)

General Welding Report Form

General form for recording welding process details.

Revision and Maintenance Requirements

Ritmo BASIC 160 V1 Specifications

General IconGeneral
Input Frequency50/60 Hz
Welding current range20-160A
Protection classIP21S
Power Factor0.73
Welding processMMA

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