WHD250 Worldpoly Operation Manual

WHD250/90
BUTT FUSION MACHINE

OPERATION MANUAL
Worldpoly Pty Ltd

Australia
CONTENTS
1. Brief ................................................................................................................................2
2. Special Instructions .....................................................................................................3
3. Safety .............................................................................................................................4
4. Applicable Range and Technical Parameters............................................................8
5. Descriptions ..................................................................................................................9
6. Instructions for use .................................................................................................... 11
7. Timer and Temperature Controller ...........................................................................14
8. Reference Welding Standards (DVS2207-1-1995, DS/INF70-1992,PIPA POP003)
..........................................................................................................................................16
9. Malfunction Analysis & Solutions ............................................................................22
10. Electric & Hydraulic Diagrams ................................................................................29
11. Packing list ................................................................................................................31
12. Warranty Clauses .....................................................................................................33
WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

1
1. Brief
PE pipes are extensively used in gas and water supply, sewage disposal, chemical
industry, mining and so on.
For more than 45 years, Worldpoly Pty Ltd has been directly involved in the PE pipe
industry including production of pipe and fittings, site welding and equipment supply.
Today we represent more than 15 years of research and development resulting in our WH
range of plastics pipe butt fusion equipment to suit PE, PP, and PVDF. We have fulfilled
the technical requirements of ISO12176-1.
Our products have outstanding features of convenience, reliability, safety and value.
Today, our welding and fabrication products include nine kinds and more than 20 models
which can be applied to plastic pipeline construction and workshop fittings production as
follows:
WHS socket fusion tools WHDA auto-butt fusion machines
WHM saddle fusion machines WJC band saws
WHG workshop butt fusion machines WC pipe cutters
WHD butt fusion machines Special tools
WHDS manual butt fusion machines
This manual is for the WHD250/90 plastic pipe butt fusion welding machine. It is
necessary to read and follow carefully the following safety and maintenance rules before
operating the machine.

2
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 cannot be used to
weld materials of any other description, otherwise the machine may be damaged or an
accident may result.
2.2 Do not use the machine in a place with a 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 220V±10% 50 Hz, 230V±10% 50 Hz, or 240V±10% 50 Hz (as
specified on the machine identification plate). If an extended input line is used, it should
have enough cross section.

3
3. Safety
3.1 Safety marks

The following signs are attached to the machine:
Hot
Do not touch parts with this sign. They are very hot!
Danger, Electrical Shock

Parts with this sign have electrical connections.
Be careful when working here.
Caution, hand injury possible
Caution!
Moving parts can cut or crush. Keep fingers, feet,
arms, legs, and head out of the jaw area between
the moving faces and away from the facing tool
blades.
Caution, suspended load.
Caution, heavy.

4
3.2 Safety Precautions
When operating the machine, instructions and safety rules must be followed
carefully.
3.2.1 The operator must be responsible and correctly trained.
3.2.2 Completely inspect and maintain the machine for safety and reliability.
3.2.3 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.
3.2.4 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.
3.2.5 Earthing: The whole site should share the same ground wire and the ground
connection system must be finished and tested by appropriate professionals.
3.2.6 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.
3.2.7 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.
3.2.8 Clean the machine carefully
※When 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.

5
3.2.9 Operation after a shut-down:
Make sure the switch of the machine is in the off position before connecting power supply.
3.2.10 Tightness of parts
Make sure the pipes are fixed correctly. Ensure that they can move well and are prevented
from sliding inside the clamps.
3.2.11 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.
3.2.12 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 are some operation rules:

---Wear safety gloves
---Wear safety shoes
---Wear work clothes
---Wear safety glasses
---Wear earmuffs

6
3.2.13 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.
3.2.14 Untrained persons are not allowed to operate the machine at anytime.
3.3. Potential Dangers
3.3.1 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.
3.3.2 Heating Plate
The maximum temperature can reach 270°C, so note the following :
------Wear safety gloves
-------Never touch the surface of the heating plate
3.3.3 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.
3.3.4 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.
FOLLOW ALL THE SAFETY MARKS ON THE MACHINE.

7
4. Applicable Range and Technical Parameters
Type WHD250/90
Materials PE PP PVDF
Maximum range of diameter 250 mm
Ambient temperature 5°C to +45
Power supply 220V±10 240V±10
Frequency 50 Hz 50 Hz
Total current 23 A 21.23A
Total power 3.95 kW 4.35 kW
Heating plate 2.1 kW 2.5 kW
Planing tool motor 1.1 kW 1.1 kW
Hydraulic unit motor 0.75 kW 0.75 kW
Dielectric resistance >1MΩ
Maximum Pressure 6 MPa

2 2
Total section of cylinders 11cm / 1100 mm
Volume of oil box 3L

Hydraulic oil 40 50 kinematic viscosity
2
mm /s, 40
Noise level 80~85 dB
Maximum Temperature of heating plate 270
Difference in surface temperature of heating plate ±5
Net Size mm 860×460×420

Basic frame
Net Weight kg 46.3
Net Size mm 640×430×440

Hydraulic unit
Net Weight kg 56
Net Size mm 460×390×500

Planing tool
Net Weight kg 19.5
Net Size mm 600×60×450

Heating plate
Net Weight kg 7.2
Supports Net Size mm 400×310×600
Net Weight kg 7.8

136.8
Total net weight kg

8
5. Descriptions
The machine consists of basic frame, hydraulic unit, heating plate, planing tool, and support.
Figure .1
1. Hydraulic unit 2. Basic frame 3. Planing tool 4. Support 5. Heating
plate
5.1 Basic Frame
Figure .2
1. Fixed clamps 2. Movable clamps 3. Clamping nuts 4. Quick coupler 5. Location plate
5.2 Hydraulic Unit
5.2.1 Hydraulic unit
Figure.3
1. Direction valve 2. Pressure regulation valve 3. Pressure gauge
4. Swing check valve 5. Oil tank 6. Power cable

9
5.2.2 Hydraulic unit operation panel
Figure .4
1. Temperature controller 2. Earth leakage device 3. Voltmeter 4. Pressure gauge

5. Protection cover 6. Timer 7. T5 button 8. T2 button
5.2.3 Hydraulic unit sockets
Figure 5
1. Planing tool socket 2. Data logger socket 3. Heating plate socket

10
6. Instructions 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) The power line is not broken or worn
c) The blades of planing tool are sharp
d) All instruments are normal
e) All necessary parts and tools are available
f) The machine is in good condition
6.3 Connection and preparation
6.3.1 Connect the basic frame to the hydraulic unit by quick couplers.
6.3.2 Connect the heating plate to the electric box with the special cable.
Connecting the cable with electrical box Connection between the cable and the 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).

11
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.
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.

12
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 2 3 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.

13
7. Timer and 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
The lamp T2 is on and the lamp T5 is off
set
Pressing
To set soaking time in seconds.
or
Pressing
The lamp T2 is off and the lamp T5 is on
set
Pressing To set cooling time in seconds

or
Pressing Timer setting is over

set
7.2 Instructions for Use
Pressing Alarm when the soaking time counts

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

Pressing
down to zero
T5
Pressing Timer stops

“ ”and“ ”

14
7.3 Temperature controller setting
Holding down“ ” and pressing “ ”to enter select mode.
Press “ or ” till “ConF” is indicated in PV. Press“ ”and then press “ or ” to input
password “20”and press “ ”again to enter “Configuration”
Press “ or ” till “Ptc” is indicated in “PV”, then press “ ” to ensure it

.
Holding down ” and pressing “ to enter select mode.
Press “ or ” till SEtP is indicated in PV, press to enter and after input the password “10”,
press “ ” to get into “Set Up”.
Press “ ” till “Pb-P” is indicated in SP. Press “ or to change the value in PV to “0”, and the
press “ ” to ensure. Holding down ” and pressing “ to enter select mode.
Press “ or ” till “OPtr” is indicated in “PV”, and then press “ ” to ensure that
Press “ ” again and “SP” is indicated in SP.
Press “ or ”to set the required temperature and then press “ ”, value in PV indicate the
current temperature and SP the required temperature.

15
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 .
8.1.2 Reference Standard DVS2207-1-1995
Bead Welding pressure

pressure
Soaking
pressure
Time
t1 t2 t3 t4 t5

16
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
Remark Bead build-up pressure and welding pressure in the form is the recommended interface
pressure, the gauge pressure should be calculated with the following formula.
Section of welding pipe ends

welding pressure = × 0.15 + drag pressure MPa
Total section of cylinders
8.2 Reference Standard DS/INF70-1992

P
P1 P5
t1 t2 P2t t4 t5
3

17
S, pipe wall thickness in mm
D, outside diameter of pipe in mm
Temperature of heating plate 200220
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
Ks
2.0
1.5
1.0
0.5
0 S (mm)
0 1 2 3 4 5 6
0 0 0 0 0 0

18
8.3 Reference Standard PIPA POP003 - Australian Welding Specifications
Butt Fusion Parameter Units Value Comments

Heater plate temperature Degree C 220 ±15
Pressure value: Bead up P1 kPa 175 ±25 Insert this value in the formula
(note 6) ,and add drag pressure
Approx. bead width after mm 0.5 +0.1t t = wall thickness (see note 4)
bead up
Bead up time T1 second Approx. 6t Varies with ambient temp.
Pressure value: Heat soak P2 kPa Drag only
Heat soak time T2 second 15t
Max. changeover time T3 second 3 + 0.01D D = pipe diameter (see note 5)
Max. time to achieve welding T4 second 3 + 0.03D Pressure should be increased
pressure smoothly using most of the time
allowed to reach welding pressure
Pressure value: Welding and P3 kPa 175 ±25 Insert this value in the formula
cooling (note 6), and add drag pressure
Welding & cooling time: T5 minute 10 + 0.5t Time in clamps
t<15mm
Welding & cooling time: T5 minute 1.5t Time in clamps
t>15mm
Min. bead width after cooling mm 3 + 0.5t Typical (see note 2)
Max. bead width after cooling mm 5 + 0.75t Typical (see note 2)
P
P1 P5
T
t5
t1 t2 P2t t4
3

19
8.3.1 Reference Standard PIPA POP003 – Welding Parameters for PE pipes and fittings.

20
Notes:
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

21
9. Malfunction Analysis & 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

22
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.

23
9.2.2 Maintenance & Inspection
Ordinary inspection
Inspect First
Every 6 Every
Item Description before
months year
use month
Sharpen or replace the blade
●
Replace the cable if it is broken or
Planing tool ● ●
damaged
● ●
Retighten mechanical connections
Cable, plugs and sockets ●
Clean surface of heating plate, recoat ● ●
Heating plate
PTFE layer if necessary
Retighten mechanical connections ● ●
Temp. control Check the temperature indicator ●
system Replace the cable if 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 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 circuit protector
●
Power to make sure it is working normally
Supply Replace the cable if it is broken or
●
damaged ●
“●”………… maintenance period

24
9.2.3 Calibrating 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:
a) Press the "set" and “ ” keys at the same time for 3 seconds

25
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 “ ” key until it displays “-19”
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.

26
9.3 Malfunction 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
2. Power source is not connected 2. Connect the power properly
1 The pump motor properly.
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
The pump motor 2. The motor is faulty than 3 MPa
2 rotates too 3. The oil filter is blocked 2. Repair or replace the pump
slowly with 4. The working voltage is unstable 3. Clean the filter
abnormal noise 4. Check the instability of power
1. The direction valve is damaged 1. Replace the direction valve.

3 The cylinder 2. There is air in system 2. Move the cylinder several times
works 3. The system pressure is too low to expel the air.
abnormally 4. The quick coupler is blocked 3. Adjust the system pressure
5. The pressure relief valve is not 4. Replace the quick coupler
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 2. Replace the pump
fluctuation is too key groove is slipping. 3. Replace the joint slack
big 4. The pressure relief valve is not locked 4. Lock the valve

27
9.3.2 Malfunctions of electrical units
1. The power cable is damaged 1. Check the power cable
The machine 2. Source power is abnormal 2. Check the working power
1 does not work 3. The ground fault switch is closed 3. Open the ground fault interrupter
1. Power cable of heating plate, the
motor of pump and planing tool may 1.Check the power cable
2 Ground fault be damaged
switch trips 2. Electrical components are affected 2. Check the electrical elements.
with damp
1. The temperature controller switch is 1.Check the connection of contactors
open
2. The thermocouple pt100 is 2.Replace the thermocouple
damaged. The resistance value of 7
and 9 of heating plate socket should
be within 100~183Ω
3. The heating element inside the 3. Replace the heating plate
heating plate is abnormal. The
resistances between 2, 4 and 6
3 should be within 68~120Ω.
Insulation resistance between head
of the heating element and outside
Abnormal shell must be more than 1MΩ
temperature 4. If the temperature controller readings 4. Replace the temperature controller
increase are more than 300°, which suggests
the thermocouple may be damaged
or the connection is loose. Should the
temperature controller indicate LL,
this suggests the thermocouple has a
short circuit Should the temperature
controller indicate HH, this suggests
the circuit of thermocouple is open
5. Correct the temperature by the button
located on the temperature 5. Refer to the methods to set the
controller. temperature
6. The temperature fluctuates 6. Check and replace the contactors
abnormally if necessary
The red light is on, but the temperature
4 Loss of control still goes up. That is because the Replace the temperature controller
when heating connector is faulty or the joints 7 and 8
cannot open when they get to the
required temperature.
5 Planing tool The limit switch is ineffective or the Replace the planing tool limit switch
does not rotate mechanical parts of the planing tool are or minor sprocket
broken.

28
10. Electric & Hydraulic diagrams
10.1 Electric diagram

29
10.2 Hydraulic diagram
30
11. Packing list
11.1 WHD250/90 Butt Fusion Machine
Item Description Unit Qty Remark
1 Basic frame set 1
2 Inserts set 1 90mm~225mm
3 Hydraulic Unit set 1 Includes high-pressure oil hose
4 Support set 1
5 Planing tool set 1
6 Heating plate set 1 Includes connecting cable of heating plate
7 Stub device set 1
Accessories supplied with machine
1 Tool box Pcs 1
2 Blades for planing tool Pcs 2
3 Ratchet wrench Pcs 1 24mm
4 Double open wrench Pcs 1 17 19
5 Screwdriver Pcs 1 150mm
6 Inner hex wrench Pcs 1
7 Special bolt for clamps Set 1 M6
8 Operation manual Pcs 1
9 Conformity certificate Pcs 1
Spare parts supplied with machine
1 Temperature controller Set 1
2 Special bolt for clamps Set 1 M6
3 Temperature sensor Pcs 1
4 Special screw bolt Set 2
5 Startup capacitor Pcs 1 25µf
6 Work capacitor Pcs 1 100µf
7 Fuse Pcs 1

31
11.2 Packing Dimensions
With layer clamps

Dimension with N.W G.W
Item Remark
packing mm kg kg
Basic frame
1 980×580×550 62 88
includes liner(225 90mm),
Heating plate, planing tool,
2 590×580×720 45 60 support, attachments
and spare parts
3 760×490×620 46 64 Hydraulic unit
Total: 0.80CBM 153 212
Steel stub device /

15 aluminium stub device
With 2 piece clamps

Dimension with N.W G.W
Item Remark
packing mm kg kg
1 980×580×550 52 72 Basic frame
2 45 60 Heating plate, planing tool, support,
590×580×720
attachments and spare parts
3 760×490×620 46 64 Hydraulic unit
Include a set of insert
4 560×510×480 40 54
(225 90 mm)
Total 0.94CBM 183 250
Steel stub device /

15
aluminium stub device

32
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.
Website www.worldpoly.com
AUSTRALIA
HEAD OFFICE
5 Saurin Lane,
Lysterfield 3156, Australia
Ph: +61 (0)3 9765 7777
Fax: +61 (0)3 9765 7776
Email sales@worldpoly.com
FACTORY
7/3 HiTech Place
Rowville 3178, Australia
MALAYSIA
REGIONAL SALES OFFICE
Kedah 08000, Malaysia
Ph: +60 (0)4 422 6094
Fax: +60 (0)4 422 5620
Mobile +60 (0)12 588 7880
Email rameiss.paker@worldpoly.com

33

WHD250 Worldpoly Operation Manual

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WHD250 Worldpoly Operation Manual

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WHD250/90

BUTT FUSION MACHINE

Worldpoly Pty Ltd

2. Special Instructions .....................................................................................................3

4. Applicable Range and Technical Parameters............................................................8

6. Instructions for use .................................................................................................... 11

7. Timer and Temperature Controller ...........................................................................14

8. Reference Welding Standards (DVS2207-1-1995, DS/INF70-1992,PIPA POP003)

9. Malfunction Analysis & Solutions ............................................................................22

10. Electric & Hydraulic Diagrams ................................................................................29

11. Packing list ................................................................................................................31

12. Warranty Clauses .....................................................................................................33

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

WHS socket fusion tools WHDA auto-butt fusion machines

WHM saddle fusion machines WJC band saws

WHG workshop butt fusion machines WC pipe cutters

WHD butt fusion machines Special tools

WHDS manual butt fusion machines

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

Before operating the machine, everyone responsible should read

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

3.1 Safety marks

Danger, Electrical Shock

Caution, hand injury possible

Caution, suspended load.

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

The following are some operation rules:

---Wear safety shoes

---Wear work clothes

---Wear safety glasses

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

------Wear safety gloves

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

3.3.3 Planing tool

FOLLOW ALL THE SAFETY MARKS ON THE MACHINE.

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

Maximum range of diameter 250 mm

Ambient temperature 5°C to +45

Power supply 220V±10 240V±10

Total current 23 A 21.23A

Total power 3.95 kW 4.35 kW

Heating plate 2.1 kW 2.5 kW

Planing tool motor 1.1 kW 1.1 kW

Hydraulic unit motor 0.75 kW 0.75 kW

Dielectric resistance >1MΩ

Maximum Pressure 6 MPa

Volume of oil box 3L

Noise level 80~85 dB

Maximum Temperature of heating plate 270

Difference in surface temperature of heating plate ±5

Net Size mm 860×460×420

Net Size mm 640×430×440

Net Size mm 460×390×500

Net Size mm 600×60×450

Supports Net Size mm 400×310×600

Net Weight kg 7.8

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

5.2 Hydraulic Unit

5.2.1 Hydraulic unit

WORLDPOLY AUSTRALIA www.worldpoly.com sales@worldpoly.com

1. Temperature controller 2. Earth leakage device 3. Voltmeter 4. Pressure gauge

5.2.3 Hydraulic unit sockets

1. Planing tool socket 2. Data logger socket 3. Heating plate socket