Automatic Butt Fusion Welding Machine Operation Guide

This step-by-step guide covers the full operation of Saemin/SKC Fully Automatic Butt Fusion Welding Machines, designed for PE, PP, and PVDF pipe welding in construction sites and workshops. All procedures comply with ISO, DVS, ASTM, and Chinese welding standards, ensuring safety and consistent weld quality.

1. Machine Overview & Applications

Saemin automatic butt fusion welders are built for:

• On-site and workshop welding of PE, PP, PVDF pipes and fittings
• Gas, water, and industrial piping projects
• Data logging for full weld traceability (ISO 12176 compliant)

Key Features:

• Rugged, compact frame ideal for outdoor construction
• Patented clamp mechanism for precise pipe alignment
• Auto heat plate ejection system to prevent sticking
• Ambient temperature compensation for consistent heating/cooling cycles
• Built-in printer + 4G data upload for weld record management
• Korea Gas Safety Certification for gas pipeline applications

Optional Accessories:

• Short flange welding dedicated clamps
• Flange adapters
• Single-sided clamps

2. Pre-Operation Safety & Setup

2.1 Power Supply Requirements

⚠️ Safety Tip: Always use a grounded power source. For single-phase units with power protection, wait 30 seconds after power-on for the system self-check.

2.2 Machine Connection Steps

1. Confirm the control box air switch is in the OFF position.
2. Connect the heater plate and planer cables to their dedicated sockets.
3. Turn on the air switch; the system will boot and enter the main menu in ~10 seconds.
4. Connect the hydraulic hoses between the control box and machine frame (only after the main menu loads).

3. Step-by-Step Welding Procedure

3.1 Welding Parameter Setup

1. Press the Fusion button to enter the parameter screen.
2. Verify/modify pipe material, size, wall thickness, project number, and operator ID.
3. Press Enter to confirm, then press Fusion again to proceed to facing.
4.  

3.2 Pipe Facing (Planing)

1. Secure the pipe in clamps, then place the planer between the ends.
2. Press Enter to start facing. The machine will automatically adjust pressure (factory-set to ~2MPa).
3. Stop when continuous shavings appear on both ends; inspect for no steps or uneven surfaces.
4.  

3.3 Alignment Check

1. The machine will automatically close the clamps to check alignment.
2. Confirm the pipe end gap is ≤0.3mm (per ISO standards).
3. If misaligned, re-face the pipes before proceeding.
4.  

3.4 Heating & Fusion Cycle

1. Place the heat plate between the aligned pipe ends.
2. Wait for the plate to reach the set temperature (210-225°C for PE).
3. Press Enter twice to start the cycle:
   • Initial Bead Formation: Machine applies pressure to form a uniform bead.
   • Soaking Phase: Maintains pressure for proper melting.
   • Heat Plate Removal: For non-auto-ejection models, follow voice prompts to remove the plate quickly.
   • Welding & Cooling: Machine applies fusion pressure, then enters cooling (do not disturb the machine).

4. Weld Data Management

Saemin welders automatically log and upload weld data for full traceability:

• Records include date/time, temperature, pressure, pipe specs, and pass/fail status.
• Data auto-uploads to the cloud server via 4G; retries automatically if signal is lost.
• Built-in GPS logs weld location (for project tracking; accuracy limited indoors).

5. Critical Safety Checks (3-Phase Machines)

Before using 380V machines, confirm the phase sequence:

1. From the main menu, press Fusion twice to enter the facing screen.
2. Press Enter twice to start the planer rotation.
3. Verify the planer spins in the correct direction (marked on the machine).
4. If incorrect, reverse any two power phases before operating.

6. Maintenance & Troubleshooting

Common Issues & Solutions

Daily/Monthly Maintenance

• Clean clamps, heat plate, and planer after each use.
• Inspect hydraulic hoses for leaks monthly.
• Calibrate heat plate temperature and pressure quarterly.

Need technical support?

Contact Saemin Service at

📱+86 181 0615 7609

📞400-618-3500 

📨frieda@pewelding.com for assistance with your automatic butt fusion welding machine.