Gator Automatic Butt Fusion

Range
Operating Manual

www.fusiongroup.com
 Gator Automatic Butt Fusion Range
Operating Manual
Contents
1 Safety instructions 4
1.1 Precautions when lifting 4
1.2 Risk of fire or explosion 4
1.3 Risk of electrical shock 4
1.4 Risk of burning. 4
1.5 Precautions specific to Automatic Butt Fusion Machines 4
1.5.1 Trimmer module 5
1.5.2 Heater module 5
1.5.3 Guidance when using hydraulic fluids 5
2 Getting to know your Gator 6
2.1 Controller 6
2.1.1 Inside the control unit 7
2.2 Heater 8
2.3 Trimmer 9
2.4 Chassis 9
3 Scope of Operation 10
4 Maintenance and Care 10
4.1 User maintenance 10
4.1.1 Oil check 10
4.2 Storage Guidance 11
4.3 Transportation Guidance 11
4.4 Servicing 11
5 Good practice for Automatic Butt Fusion 12
5.1 Good practice during Butt Fusion 12
5.2 Poor practice during Butt Fusion 12
6 Preparation 13
6.1 Familiarisation with Equipment 13
6.2 Clamp Liners 13
6.3 Connections 13
7 Manual data entry 14
7.1 Data entry 14
8 Status bar 15
8.1 Standard status bar 15
8.2 Backing up record to memory card 15
8.3 Sending data to USB memory device 15
8.4 Sending data to PC 16
8.5 Printing joint record 16
8.6 Sending data to Minitran 16
9.0 Machine operation 17
9.1 Power-up sequence 17
9.2 BlueBox 17
9.3 Service alarm 17
10 Information entry 18
11 Jointing process 19
11.1 Pipe selection 19
11.2 Automated trim Cycle 20
11.2.1 Oil Warm-up 20
11.2.2 Standard trim routine 20
11.2.3 Fit Trimmer 21
11.2.4 Pipe loading 21
11.2.5 Trim Cycle 22
11.3 Automated Check Cycle 24
11.3.1 Pipe slippage check 24
11.3.2 Pipe alignment check 24
11.4 Automated Join Cycle 25
11.4.1 Automatic bead-up stage 26
11.4.2 Automatic heat soak stage 26
11.4.3 Automatic heater plate removal 26
11.4.4 Automatic pressure build-up 27

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11.4.5 Automatic Fusion and cooling stage 27
11.5.6 Accepting the joint 27
12 Error messages 28
13 User menus 31
13.1 Adjust LCD contrast (Menu option 00) 31
13.2 Set language (Menu option 01) 31
13.3 Output joint record(s) (Menu option 02) 32
13.3.1 Send to 32
13.3.2 Screen 32
13.3.3 Printer 32
13.3.4 USB drive 32
13.3.5 PC 32
13.3.6 Select record(s) view/download 32
13.4 JointManager (Menu option 03) 34
13.4.1 Send to 34
13.4.2 USB drive 34
13.4.3 Minitran 34
13.4.4 PC 34
13.4.5 Select record(s) data transfer 34
13.5 System variables (Menu option 04) 35
13.6 Remove user history (Menu option 05) 36
13.7 Recover archived records (Menu option 06) 36
13.7 Daylight saving (Menu option 07) 36
14 User diagnostics menu 37
14.1 Test / Calibration (01) 37
14.1.1 Chassis diagnostics (01) 37
14.1.2 Trimmer diagnostics (02) 37
14.1.3 Heater diagnostics (03) 37
14.1.4 Computer diagnostics (04) 37
14.1.5 Hydraulic diagnostics (05) 37
14.1.1 Test scanner (07) 37
15 Specification 38
16 Rights 40
17 Accessories 40
Appendix A Gator Manual entry character set 41
A.1 Number character set. 41
A.2 ABC font set 41
A.2.1 Upper case characters 41
A.2.2 Lower case characters 41
A.3 Russian 42
A.3.1 Upper case characters 42
A.3.2 Lower case characters 42
A.4 Japanese 42
A.4.1 Upper case characters 42
A.4.2 Lower case characters 42
A.5 Symbol 42
Declaration of Conformity 43

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 Gator Automatic Butt Fusion Range
Operating Manual
1 Safety instructions
These operating instructions must be followed to ensure safe operation of the
Gator automatic butt fusion machine and operators must be fully conversant with
the safety instructions.
Fusion Group Limited can offer basic training and regular maintenance where
required.
Only use undamaged equipment that has been properly maintained and
calibrated. Refer to section 5 maintenance and care of this operating manual for
further information.

1.1 Precautions when lifting

Where necessary, operators are advised to request for assistance when carrying,
moving or lifting this equipment.

1.2 Risk of fire or explosion

Do not use this equipment in combustible gaseous environments.

1.3 Risk of electrical shock

This equipment must be connected to a suitable electrical earth supply.
Depending upon the model, this equipment requires a power
supply of 100V, 110V or 220V AC. Avoid walking or standing on
cables and ensure that cables are safely routed.
For safety purposes, this machine has been fitted with overload
protection and a residual current device (RCBO).
Always take care where you see the electrical warning labels displayed. Only
authorised engineers must attempt to open electrical enclosures.

1.4 Risk of burning.

The process of Butt Fusion Welding uses a heater plate that typically runs at
temperatures in excess of 200ºC. The use of heat resistant gloves is strongly
recommended, as is use of suitable eye protection.

1.5 Precautions specific to Automatic Butt Fusion Machines

This unit is automated and as such, uses moving linkages during its operation that
will move without operator intervention. Care must be exercised during automated
trim, check and jointing cycles. An audible alarm will be heard, as a warning, prior
to and during automated movements.
It is the responsibility of the control unit operator to ensure that all personnel are
clear of the equipment before activating the control for the automated cycle.
In the event of an emergency situation activate the emergency stop button that is
fitted to every machine and cuts all the power to the control system. The button
may be found at the top of the control box enclosure.
If necessary, the chassis clamps may be opened or closed using the silver
coloured open/close buttons.

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Operating Manual
1.5.1 Trimmer module
The trimming cycle is automatically controlled from the control unit. Operators
must ensure that all personnel are clear of the equipment and should exercise
due care and attention, when operating the equipment.
When manual handling of the trimmer is carried out, care must be taken to
eliminate the risk of injury from the cutting blades.
The trimmer module is fitted with a safety device that will prevent operation when
the unit is not positioned within the chassis.
Following the trim cycle, it is essential that the trimmer is removed before
attempting to remove swarf from the trimmed pipe ends.
Care should be taken when adjusting or replacing trimmer blades.

1.5.2 Heater module

At the end of the heating cycle, the heater plate is automatically ejected. To
eliminate the risk of injury, the operator should ensure that all personnel are clear
of the heater at this time.
If the emergency stop button is actuated during the heating cycle, when the
emergency stop button is reset the heater plate can be ejected by pressing the
silver open chassis button.
High temperatures are required to fuse polyethylene; therefore, operators are
reminded to take care when handling the heater. The use of heat resistant gloves
is strongly recommended.

1.5.3 Guidance when using hydraulic fluids

To avoid the possibility of skin disorders, repeated, or prolonged contact with
lubricants and industrial oils must be avoided.
Eyes: Irrigate immediately with copious quantities of water for several
minutes.
Skin: Wash thoroughly with soap and water as soon as possible.
Infrequent, or short term contact requires no immediate action
Ingestion: Send patient to hospital, or obtain medical attention immediately.
DO NOT induce vomiting.
Aspiration: If aspiration occurs, or is suspected, send the patient to hospital,
or obtain medical attention immediately.

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 Gator Automatic Butt Fusion Range
Operating Manual
2 Getting to know your Gator
The four main components of the Automatic Butt Fusion Machine:

Trimmer Automatic
Control Unit
Heater

Chassis

2.1 Controller
The controller keypad is located under the protective cover of the control unit lid.

Display

Input voltage
warning light Alarm warning
light
Up button
BlueBox LED’s
Return button
Right button

Start or enter
button
Left button
Down button

Close button
Open button

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 Gator Automatic Butt Fusion Range
Operating Manual

Heater
socket Chassis Trimmer USB
socket socket Socket

Emergency
stop button

Temperature
sensor
Hydraulic
hose
connectors

Input cable

Socket Scanner
protective socket Printer
covers socket Protective
covers

2.1.1 Inside the control unit

Two clips secure the protective cover to the main body of the control unit
enclosure. Unclip the cover and remove to gain access.

Hydraulic oil level indicator

(unscrew this cap to check and
top-up the hydraulic)

RCBO (Lift the cover to access the 'Test' and reset

switches of the RCBO protection device)

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Circuit breaker RESET buttons

Hydraulic pump power supply
Electronics power supply

There are sensitive electronic components located within the electronic

control enclosure. Do not attempt to open this enclosure – there are no user
serviceable parts inside.

2.2 Heater

Securing
fixture

Heater/trimmer
stand

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 Gator Automatic Butt Fusion Range
Operating Manual

Temperature
Indicator

2.3 Trimmer

Securing
fixture
Trimmer
blade

2.4 Chassis
Clamp
adjusters

Fast
clamps

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 Gator Automatic Butt Fusion Range
Operating Manual
3 Scope of Operation
This equipment is designed specifically for the purpose of butt fusion jointing of
polyethylene pipes and should not be utilised for any other operation.

4 Maintenance and Care

4.1 User maintenance
Prior to connecting the unit to a supply always:
 Ensure that the all lead and hydraulic hose connectors are clean and free of
damage.
 Visually inspect the controller, trimmer, heater and chassis for signs of damage.
 Ensure that the mains input plug is not damaged and remove any dirt.
 Check there is no damage to the input, trimmer, chassis and heater cables
such as torn insulation or deep gouges.
 Check there is no damage to the hydraulic hoses such as deep gouges or
leaks.
 Check the hydraulic oil level top up with approved hydraulic oil, refer to section
4.1.1 Oil check.
 Ensure that the Barcode Reader is connected (Do not connect after the supply
is turned on as the box or the scanner could be damaged).
 Ensure that the unit has been appropriately maintained and calibrated.

Never use the control unit if plug, leads or enclosure are damaged, the service
agent or Fusion Group Limited must carry out maintenance and service.
Do not attempt to open the enclosures - there are no user serviceable parts
inside.

4.1.1 Oil check

Check the oil level prior to powering up.

Approved hydraulic Oils

If the hydraulic oil level is low, use only Fusion approved hydraulic oils with Gator
machines:
Castrol Hy-Spin AWS22 Total Azolla AZ22 ESSO NUTO H22
BP Energol HLP22 Texaco Rando HD22 Mobil DTE 22
Derwent 22 Shell TELLUS 22 Duckhams Zircon 3

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Operating Manual
4.2 Storage Guidance
It is recommended that when not in use, the equipment should be stored in a
clean dry area. Metallic containers are not recommended, as they are prone to
causing severe condensation that may affect sensitive electronic components.

4.3 Transportation Guidance

Lifting heavy equipment – before attempting to lift any equipment, please ensure
that it can be safely lifted without assistance. Where necessary, assistance should
be sought before carrying, moving or lifting this equipment. In particular, if the
equipment cannot be easily manually lifted, mechanical assistance should be
used.
When transporting the equipment, care should be taken to secure all units to
avoid unnecessary damage. Heater units should be secured on the heater stand
provided to give additional support.

4.4 Servicing
To ensure safe operation and performance are maintained, this product should be
checked at intervals of no longer than 6 months, either by the manufacturer or an
authorised service agent.
For technical information contact the manufacturer; Fusion Group Limited, via
telephone on +44(0) 1246 268666.

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Operating Manual
5 Good practice for Automatic Butt Fusion
5.1 Good practice during Butt Fusion
 In cold temperatures the chassis should be opened and closed manually
approx. 10 times in quick succession following the automatic warm up routine.
 Always ensure that the equipment is calibrated and properly maintained.
 Always weld inside a shelter on a suitable baseboard or ground sheet.
 Where possible, site the equipment on clear level ground.
 Always ensure pipes are aligned correctly and supported on pipe rollers to
minimise drag.
 Cover open pipe ends to eliminate wind chill to the heater and joint interface.
 Clean pipe surfaces (inside and out), pipe ends and clamps before inserting
pipe into the machine.
 Position pipes into the clamps with the pipe marking uppermost and aligned.
 Wash the heater plate when cold before every welding session and perform
dummy welds when hot to remove fine particles from the heater surface. On
pipe sizes above 180mm, two dummy welds should be made at the start of
each session.
 Perform dummy welds after changing from one pipe size to another, also if the
heater plate has been allowed to cool.
 Clean trimmer discs and blades before use.
 Ensure that when trimming, a continuous ribbon of material, of complete pipe
wall thickness is produced from both pipe ends before stopping the trimmer
and advancing to the feathering operation.
 Always wait for the trimmer to stop rotating before removing it from the
machine.
 Replace the trimmer in the stand provided.
 Remove shavings from pipe ends and chassis.
 Check visually that both pipe ends are completely trimmed.
 Always check pipes for alignment ensuring no gaps exist between the two pipe
ends around the entire circumference of the abutted pipes.
 On completion of satisfactory alignment checks, proceed with the welding
cycle without delay.
 Number/code the joint and bead using an indelible marker.
 After FULL cooling time has elapsed, remove either external or internal bead
and carry out quality checks.

5.2 Poor practice during Butt Fusion

 Do not attempt to open the computer enclosure – there are no user
serviceable parts inside.
 Do not use damaged equipment.
 Do not attempt to weld pipes of different material, diameter or SDR.
 Do not leave shavings inside pipe or on the chassis.
 Do not introduce dirt onto trimmed pipe ends whilst removing swarf.
 Do not touch trimmed pipe or fitting ends.
 Do not remove pipes from the machine before the complete cooling time has
elapsed.
 Do not cut corners in any part of the welding cycle.
 Do not attempt to install pipe until fully cooled.

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 Gator Automatic Butt Fusion Range
Operating Manual
6 Preparation
6.1 Familiarisation with Equipment
Before applying power to the machine, operators should be familiar with all
aspects of machine control and have read and understood this Operating Manual.
Before commencing a jointing cycle, operators should ensure that the generator
used has sufficient fuel to complete operations.

6.2 Clamp Liners

Liner sets are invariably supplied with Gator machines. Liners are used to clamp
pipes of diameter smaller than the nominal
machine size. For example, a Gator250 may be
supplied with a liner set 250x180 to
accommodate 180mm diameter pipe. The
liners may also be nested so that for 125mm
pipe, 250x180 and 180x125 liners may be
stacked together to form 125mm clamps.
Each liner set will be supplied with appropriate
fixing screws that and should be secured to
both top and bottom clamps. Allen keys are
supplied to facilitate fixing. Please ensure that the correct length fixings are used
otherwise, the machine may not function correctly.

6.3 Connections
Connections to the control unit are located on the rear of the control enclosure.
Electrical plugs and sockets are both sturdy and waterproof. However, care
should be taken to ensure that the connections are always clean, dry and free
from damage. Protective sheathes are provided for the sockets when the
corresponding plug is disconnected.
Hydraulic connections for the chassis should be free from contaminants before
inserting the respective hydraulic hose. The connections may be disconnected by
pulling back the knurled outer cover of the hose fitting.
 Connect the heater to the socket on the control unit.
 Connect the chassis flying lead to the socket on the control unit.
 Connect the trimmer unit to the socket on the control unit.
 Connect the control unit supply lead to the power supply. Prior to
connection ensure that the electrical supply is earthed and suitably rated
for that quoted on the machines rating plate. The individual component
power requirements are listed in section 16 Specification of this Manual.
 Open the cover and test the function of the RCBO device.
 Switch the machine on using the trip switch of the RCBO. Make sure that
the Emergency Stop button is not activated.
 Wipe clean the hydraulic connectors on the hoses and the control unit.
Connect the hoses to the Auto Controller.

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 Gator Automatic Butt Fusion Range
Operating Manual
7 Manual data entry
Manual data entry is required at various points in the operation of the unit.

7.1 Data entry

There are two modes for character entry - Select mode and Edit mode. On
activating Manual Data Entry the box is in Select mode.
Select mode – Characters/Actions are selected using the up, down, left and right
buttons to move the Select cursor to the required icon. The selected
character/action is accepted by pressing the green button.
Edit mode – To select Edit mode move the Select cursor to  and press the
green button, the Select cursor goes off (indicating Edit mode). The Edit cursor
can then be moved within the edit string by using the left and right buttons. To
insert a character, exit Edit mode (by pressing the green button, the Select cursor
will re-appear over the  icon) and select the required character as normal.
Edit Cursor - If the Edit cursor cannot be seen the edit position is to the right of
the last character in the entry field.
Select Cursor – If the Select cursor cannot be seen the box is in Edit Mode.
Insert Characters - Characters will always be inserted to the left of the Edit
cursor until the entry field is full. The Edit cursor will move to the right as
characters are inserted.
Delete Characters - Characters to the left of the Edit cursor can be deleted at any
time by pressing the red button. The Edit cursor will move to the left as each
character is deleted (until the Edit cursor is at the left most position).
Extended Character - On certain fonts and characters, if the green button is held
down for at least three seconds, the extended characters will be shown. Once the
extended character pop-up is displayed, selection is carried out as described in
Select Mode. NOTE: if the pop-up has been displayed and the extended character
is not required, pressing the red button will exit the pop-up without adding the
extended character. See appendix A.
Restricted Entry Fields – If the entry field requires specific characters, selection
is restricted to those characters.
Edit Operator
---------------------------------------
A B C D E F 1 2 3 
G H I J K L 4 5 6
M NO P Q R 7 8 9
S T U V WX , 0 .
Y Z ⌴+ -

 - Accept text and exit (Action) - Delete the text string (Action)
- Select Edit Mode (Action) - Change font being used (Action)
- Switch between upper and lower case characters. (Action)
⌴ - Space character.

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8 Status bar
The status bar is shown at the bottom of most of the screens showing information
on the service period and input supply.
Each bar on the memory status indicates approximately 80 joint records.
The spanner between the number of joints and the days to next service will flash,
when either the number of joints or the days to next service are less than 21.

8.1 Standard status bar

This status bar is shown when in information entry, fitting information and fusing
screens.

1000 182 10:10 10:05:14 230 GTR2

Memory status
Number of joints to next service
Number of days to next service
Time
Date
Input voltage

8.2 Backing up record to memory card

This status bar is shown when backing up to memory card when joint is complete.

1000 182 SD

Memory status
Number of joints to next service
Number of days to next service
Back up to memory card status

8.3 Sending data to USB memory device

This status bar is shown when sending data to USB memory device (in review
joint record(s), print joint record(s) and fast data transfer modes).

1000 182
Memory status
Number of joints to next service
Number of days to next service
Download to USB status

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 Gator Automatic Butt Fusion Range
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8.4 Sending data to PC
This status bar is shown when sending data to PC (in review joint record(s), print
joint record(s) and fast data transfer modes).

1000 182 PC

Memory status
Number of joints to next service
Number of days to next service
Download to PC status

8.5 Printing joint record

This status bar is shown when sending data to printer (in review joint record(s)
and print joint record(s) modes).

1000 182

Memory status
Number of joints to next service
Number of days to next service
Printing status

8.6 Sending data to Minitran

This status bar is shown when sending data to Minitran (in fast data transfer
mode).

1000 182 CF

Memory status
Number of joints to next service
Number of days to next service
Downloading to Minitran status

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 Gator Automatic Butt Fusion Range
Operating Manual
9.0 Machine operation
9.1 Power-up sequence
Once the equipment is connected as described in Section 6.3, connect the
machine to a suitable power supply and switch on.
When the system is switched on, the LCD (Liquid Crystal Display) indicates the
following message for approximately 4 seconds and a short audible tone will
sound.
Fusion Group

12:35:10 03/09/14

This display indicates the current time, date and if configured, the owner details.
If ISO12176-3 login method have been enabled the unit will be inoperable until a
valid operator barcode is scanned. The screen will either prompt for a valid
operator barcode, when a valid operator barcode is scanned to the unit before the
information entry screen will be displayed. If the red button is pressed the user
menu will be displayed see section 13 user menu.

9.2 BlueBox
If BlueBox has been enabled then a mobile device must be connected to the unit
via Bluetooth with the BlueBox application open, before the information entry
screen is displayed. Refer to mobile device operating instruction for connecting
via Bluetooth. For further details contact Control Point on +44 (0)1246 262422 or
email [email protected].

9.3 Service alarm

This indicates that either, the number of joints made or the number of days since
the last service has been exceeded. The unit is in need of a service and contact
should be made with nearest service centre.
If Service Lockout has been disabled - press the green button to carry on using
the box. Service required will be recorded on the joint data until the unit is
serviced and the service period been reset.

! Service Required!
Contact
Fusion Group
+44 (0)1246 268666
+44 (0)1246 268052
Press ● to continue

If Service Lockout has been enabled - the unit is inoperable until it has been
serviced and the service period has been reset.

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! Service Lock Out !
! Service Required!
Contact
Fusion Group
+44 (0)1246 268666
+44 (0)1246 268052
! Service Lock Out !

10 Information entry
The unit will prompt for entry of operator, location, optional data 1, optional data 2,
optional data 3 and project - if enabled - as follows:
Project screen
<Operator>
<Location>
<Optional Data 1>
<Optional Data 2>
<Optional Data 3>
<Project>
Continue
Press ● To confirm

Scroll onto the field required by using the up and down buttons on the keypad.
When the appropriate field is highlighted, either press the left or right buttons to
select one of the last five entries for the particular field or press the green button
to enter the edit screen. On pressing the green button the following screen will be
displayed.
Edit Operator
---------------------------------------
A B C D E F 1 2 3 
G H I J K L 4 5 6
M NO P Q R 7 8 9
S T U V WX , 0 .
Y Z ⌴+ -

Scroll to the appropriate character using the up, down, left and right buttons on
the keypad. Then press the green button on the keypad to select the character.
Repeat this until the required information is entered. Then select ‘’ press the
green button on the keypad to return to information entry screen. For more
information see section 7.1 character entry screen.
After entering project the edit project joint number screen will be displayed. If a
previous project has been selected then the next project joint number will be
displayed on edit project joint number screen. The project joint number can be
made up of letters and numbers. The box will increment the number but not the
letters. Any letters AFTER the number will be lost for the following joint.
If ISO12176-3 operator login method entry is enabled and a valid operator
barcode has been scanned then the operator information will be displayed.
Note: that the operator, location, optional data 1, optional data 2, optional data 3
project and project joint number information is retained for subsequent joints. If
any of operator, location, optional data 1, optional data 2, optional data 3 and
project are not required then leave them empty or enter a ‘space’ character.

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Up to 5 previously entered items of data are maintained for re-use. This ‘History’
data can be accessed by pressing the left or right scroll buttons.
When all the relevant information has been entered scroll down to ‘Continue’ then
press the green button to proceed to the fitting information screen.

11 Jointing process
11.1 Pipe selection
After traceability information has been entered or bypassed, the screen will
display the jointing screen to allow the operator to change details relating to the
pipe joint. Please note that the jointing details previously selected will be stored
within this screen.
Welding parameters
DVS2207-1

Material
Diameter
SDR
Colour

CONTINUE

In order to ensure that the correct welding parameters are used for the jointing
process, the operator must select the correct parameters as detailed below.
The operator may accept the pipe parameters and proceed to the next stage by
pressing the green button.
Should the pipe or welding specification be incorrect, use the up and down
buttons to highlight the parameter to change then press the green button and
select the correct parameter.
If the standard selected is WIS4-32-08 or GIS/PL2-3 (GB) a pop up screen is
displayed allowing the operator to select either straight or coiled pipe.
Coiled Pipe?


▲▼Scroll ●Select

Always ensure that the pipe selected matches the pipe to be welded and that the
selected welding standard is in accordance with the requirements of governing
authority for that installation.
Once the pipe parameters have been confirmed the following pop up window will
appear.

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 Gator Automatic Butt Fusion Range
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i
Heater temperature
233°C

Approx. weld time

20m 21s (DP)
Press ● to continue

11.2 Automated trim Cycle

In accordance with safety regulations, a warning light and audible alarm are
operated before and during all automatic cycle movements.
In certain parts of the cycle, pressing the red button will allow the operator to step
the cycle back to the previous operation.

11.2.1 Oil Warm-up

All models feature an oil warm-up sequence that is activated when the ambient
temperature is below 0ºC. When active a pop up window will be displayed:
! Oil is cold

Machine must be exercised

Press ● to continue

Press the green button to operate the automatic oil warm-up sequence as
prompted. The hydraulic pump will operate for one minute and can be bypassed
by pressing the green button during the sequence.

11.2.2 Standard trim routine

All models feature a facility to automatically position the machine to a pre-set
position, ready for the trimming cycle.
The display will indicate:
Joint:97 [  /233C]
Set up

Load trimmer & pipes

PE63 250 SDR11

Note that the top line of the display indicates the current joint number, the actual
and target heater temperature (indicated here with  to signify that the heater has
reached the target temperature). The bottom line shows the selected pipe type. At
this point the machine can be manually opened and closed using the open and
close buttons (Refer to Section 2.1).

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11.2.3 Fit Trimmer
Remove the trimmer from the heater/trimmer stand and position onto the locator
block between the two centre clamps. Location pegs will allow the trimmer to sit
flush onto the blocks.
1

To avoid contact with the fast clamp levers, note that the trimmer must be placed
with the motor positioned over the clamp adjusters.
To secure the trimmer into the machine, push down on each securing fixture (1)
and then rotate the fixture by twisting clockwise through 90º (2). Note that this
procedure will also be used to secure the heater to the locator blocks.
When the machine detects that the trimmer is in position, a beep will sound once,
confirming correct fitting and the display will change to:
Joint:97 [  /233C]
Set up

Load pipes

PE63 250 SDR11

● to continue

11.2.4 Pipe loading

Release the toggle levers from the top clamps and lift each clamp to unhook from
the clamp adjusters on the opposite side. Remove the top clamps and ensure that
the correct liners are fitted to all of the clamps (Refer to Section 6.2).
If the auto trim set-up function has been used, feed the pipe ends into the
machine until each pipe end is in contact with the trimmer disc. If the auto trim set-
up function has not been used, the pipe should be positioned slightly away from
the trimmer disc. Note that the shortest pipe should always be fixed to the moving
end of the machine. It is good practice to ensure that the pipe details printed along

2
1

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 Gator Automatic Butt Fusion Range
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the two pipes are aligned and placed to the top of the machine.

To secure the pipe, place the clamp over the pipe and raise the edge to ensure
that the clamp adjusters are hooked under, onto the clamp. The clamp should
then be firmly pushed onto the pipe and the fast-clamp toggle levers (1) placed
over the edge of the clamp it may be necessary to release the clamp adjusters (2)
– particularly on oval pipe. When fastening the pipe into the machine, the toggle
levers should be set so that only a reasonable force needs to be applied to fasten
the toggle lock.
As a guide when fastening, the fast clamp levers should be lifted in the direction
indicated and the clamp adjusters moved until the lever is in a vertical position –
the levers may then be pushed onto the top clamp. Note that the adjusters should
only be moved when the fast-clamp levers are in the released position.

11.2.5 Trim Cycle

When the pipes have been secured in place, press the green button and the
machine will start the trimmer motor. The LCD will display:
Joint:97 [  /233C]
Auto trim cycle

PE63 250 SDR11

Please wait

The machine will open and then tune the trimming parameters for around 5
seconds indicating:
Joint:97 [  /233C]
Auto trim cycle

Tuning trim parameters

PE63 250 SDR11

Please wait

The software control monitors the trimmer and if certain parameters are found to
be excessive, the machine will indicate that the machine requires service. This
warning will remain visible for approximately 10 seconds or until the green button
is pressed.
When the trimming parameters have been tuned, the display will indicate:

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Joint:97 [  /233C]
Auto trim cycle

Trimming

PE63 250 SDR11

Please wait

The system will then gradually increase the system pressure to move the pipes
onto the trimmer in a controlled manner. When a small amount of pipe has been
trimmed from the pipe ends, the display will indicate:
Joint:97 [  /233C]
Auto trim cycle

Feathering off to finish

PE63 250 SDR11

When the green button is actuated, the LCD display will indicate “feathering off to
finish” while the pipe ends are being finely “feathered”, to avoid a step on the pipe
end.
The motor will stop and the display will indicate that the trim cycle is complete.
The machine will open and the prompt:
Joint:97 [  /233C]
Auto trim cycle

Remove the trimmer to continue

PE63 250 SDR11

Unlock the trimmer by turning the twist locks anti-clockwise. Remove the trimmer
and carefully replace it into the heater/trimmer stand. As the trimmer is removed,
a short audible tone will be heard. The machine is now ready for the pipe slippage
and alignment check stage.
Once the trimmer has been removed, clear all swarf away from the pipe ends. It is
good practise to remove the swarf from the bottom of the chassis to avoid
dragging contaminants over the trimmed pipe ends.
When the swarf has been removed check the pipe ends to ensure that the
surfaces are sufficiently trimmed and free from dirt and defects. If the surfaces are
unsatisfactory; press the red button to return to the trimming stage.
Warning! Take extreme care not to touch the pipe ends at this stage and as soon
as the pipes have been checked, proceed to the next stage.

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11.3 Automated Check Cycle
After trimmer is removed, the LCD will indicate:
Joint:97 [  /233C]
Check

Ready for check

PE63 250 SDR11

Press ● to continue

11.3.1 Pipe slippage check

When the green button is pressed the machine will close until the pipe ends make
contact.
The machine will then automatically apply 20% above the maximum process force
to ensure that the pipes will not slip during the jointing phases. If any slippage is
detected, the machine will abort and show an appropriate error message.

11.3.2 Pipe alignment check

If no slippage is detected, the display will indicate:
Joint:97 [  /233C]
Check pipe

Check alignment is OK

PE63 250 SDR11

As prompted, check the two pipes align correctly and that pipe to pipe contact is
evident around the entire joint circumference. If acceptable, press the green
button to continue the process. The control system will again check for slippage
before opening. Do not open the fast-clamp levers at this stage, otherwise the
machine with recognise there is a fault.
If the operator suspects there is a problem with pipe alignment or contact,
pressing the red button will return to the check screen. Ultimately, if there is a
problem, the pipe should be readjusted and re-trimmed.
After the ‘check’ and prior to the ‘join’ phase, the pipe ends will be separated. If
the process was started with a very low heater temperature, the chassis will not
open until the heater has reached the required temperature. Secure the heater
onto the chassis and wait until the heater is at the correct temperature before
pressing the green button when prompted.

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11.4 Automated Join Cycle
The machine automatically controls all aspects of the Butt Fusion Welding cycle.
At the start of the join cycle, the system will wait until the correct heater
temperature is achieved. Whilst the temperature is out of the specified limits (in
this example the heater temperature is at 225ºC with a target of 233ºC), the
display will indicate:
Joint:97 [225C/233C]
Check pipe

Secure heater on chassis

PE63 250 SDR11

Wait for correct temperature

When the temperature is within the specified limits for that standard, the display
will show:
Joint:97 [  /233C]
Check pipe

Secure heater on chassis

PE63 250 SDR11

Press ● to continue

Remove the heater from the stand and secure to the chassis as described in
section 11.2.4. Press the green button and the display will indicate:
Joint:97 [  /233C]
Bead up

Insert heater plate

PE63 250 SDR11

Using the two black handles either side of the heater, push the heater plate down
between the two pipe ends. The display will change to:
Joint:97 [  /233C]
Bead up

Ready to join

PE63 250 SDR11

Press ● to continue

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Press the green button to continue the jointing process. The machine will display
the following and will gradually build up the pressure in order to move the pipe.
When the machine starts to move, the line pressure is measured and both the
peak and dynamic drag pressure values are stored for calculating subsequent
welding pressure.

11.4.1 Automatic bead-up stage

When the pipes come into contact with the heater plate, the display will indicate:
Joint:97 [  /233C]
Bead up

Forming internal bead…

PE63 250 SDR11

Please wait

After several seconds the display will also indicate, “Please wait”.
Once the initial bead has correctly formed, the pressure is reduced ready for the
heat soak phase.

11.4.2 Automatic heat soak stage

During the heat soak phase the display indicates the soak time remaining, as
shown below:
Joint:97 [  /233C]
Soak

Time left 100 seconds

PE63 250 SDR11

11.4.3 Automatic heater plate removal

At the end of the soak phase the alarm will sound and the machine will open and
eject the heater. During automatic heater plate ejection, the display indicates:
Joint:97 [  /233C]
Soak

Ejecting heater

PE63 250 SDR11

When the heater has been ejected, the machine will close.

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11.4.4 Automatic pressure build-up
When the molten pipe ends come into contact with each other, the pressure builds
up to the target welding pressure plus the drag pressure value measured
previously.

11.4.5 Automatic Fusion and cooling stage

The automatic fusion and cooling stages allow the joint to form and become solid
before the clamps can be removed. During these stages, the display shows:
Joint:97 [  /233C]
Fusion

Target pressure 10Bar

Achieved pressure 10Bar
Time remaining 578seconds

PE63 250 SDR11

11.5.6 Accepting the joint

When the joint is complete the machine will prompt the operator for the bead to be
inspected by showing the following:
Joint:97 [  /233C]

Is final bead OK

PE63 250 SDR11

If the bead is okay, press the green button. If not, press the red button.
Finally, the display will show:
Joint:97 [  /233C]

Joint 97 complete

PE63 250 SDR11

Pressing the green button will prompt for entry of an operator code to start the
next joint.
Manually aborting the cycle
At any stage the jointing cycle can be aborted by pressing the emergency stop
button, this should only be in emergencies.

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12 Error messages
During the welding cycle, the controller monitors the system for problems which could potentially result in poor joints. In the event of
such a problem, or if an unexpected event occurs, a message is issued indicating its nature. The following shows the failure modes,
likely causes and remedies.
The error message numbers have been retained from previous ABF products for consistency. Some of the old error messages have
been removed since they no longer apply. Also included in the chart are other general faults.
Mode Message Reason Possible cause Remedy
1 Not cutting Trimmer has not reached Blunt blades Sharpen or replace the blades.
end point in allowed time No blades fitted Fit blades.
Trimmings are clogging the Press red button, open the machine and remove
blades swarf from blades.
Poorly set blades Adjust the blade settings.
5 Clamps loose Unexpected clamp Clamps or liners were not secure Press red button, open the machine, reset the
movement was detected pipes, re-secure the pipes ensuring they are
during the CHECK stage fixed firmly, then re-trim and re-check.
6 Poor bead Bead not formed as Wrong pipe parameters were Press red button. Select the correct pipe type;
expected in the allowed selected start joint again.
time
7 Long dwell (heater) Excessive heater plate Heater stuck in non-up position Check heater and machine for obstructions.
removal time experienced Heater up switch faulty Contact supplier.
8 Long dwell time Excessive heater plate Heater not ejected quickly enough Check heater and machine for obstructions.
removal time experienced Machine movement obstructed Ensure pipes are well supported throughout the
welding process.
11 Heater plate present The heater plate has been Heater inserted in error Press the machine open key to eject the heater
detected at an and then follow the screen prompts.
inappropriate stage
12 Trimmer present The trimmer has been Trimmer positioned in error Remove the trimmer and follow the screen
detected at an prompts.
inappropriate stage
13 Excessive drag The measured drag Poorly supported pipes Support the pipes using pipe support rollers
exceeds 60 bar

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Mode Message Reason Possible cause Remedy

16 Cool time short The machine has detected Clamps were loosened Press red button and abort the joint.
unexpected clamp prematurely
movement during the
welding cycle
17 Abort before joining Join cycle aborted Emergency stop button pressed Ensure generator has enough fuel. Do not
Power failed switch off during process
18 Abort during beadup Bead phase aborted Emergency stop button pressed Ensure generator has enough fuel. Do not
Power failed switch off during process
19 Abort during soak Soak phase aborted Emergency stop button pressed Ensure generator has enough fuel. Do not
Power failed switch off during process
20 Abort during fusion Fusion phase aborted Emergency stop button pressed Ensure generator has enough fuel. Do not
Power failed switch off during process
21 Abort during cooling Cooling phase aborted Emergency stop button pressed Ensure generator has enough fuel. Do not
Power failed switch off during process
23 No movement sensed Machine could not detect Hydraulic connectors not Connect the hydraulic connectors
movement connected correctly Connect the LVDT cable correctly
LVDT cable not connected Use pipe support rollers
correctly Pipes not correctly
supported
24 Pressure out of limits Pressure achieved does Blocked hydraulic line filter Replace the filter
not match that expected Pressure control system error Contact supplier
25 Low oil Low oil detected Controller not level Ensure that the controller is positioned on level
Oil needs topping up ground
Top up with approved oil
27 Trimmer current error The measured trimmer Trimmer system jammed Remove blockage
current is not as expected Current calibration fault Contact dealer.
28 Heater channels not The two heater plate Faulty thermocouple in heater. Contact dealer.
balanced temperature measurements Water ingress in plug or socket. Spray with WD40, shake out excess and allow
differ by more than 5 ºC Calibration fault. to dry
Contact dealer
29 Heater temperature high Heater plate temperature Overshoot when heating up from Allow time for temperature to settle
higher than specification cold Wrong welding standard configured
limit Wrong welding standard selected Contact dealer
Calibration fault

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Mode Message Reason Possible cause Remedy

31 Heater UP/DOWN status The machine has detected Faulty heater plate detection Contact dealer
that the heater is not up. switch.
32 Abort during dwell Dwell phase aborted Emergency stop button pressed
Power failed Ensure generator has enough fuel. Do not
switch off during process
33 Abort during beadup Expansion phase aborted Emergency stop button pressed
(Expansion) Power failed Ensure generator has enough fuel. Do not
switch off during process

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13 User menus
The User Menu allows the user to view and download joint data and System
Variables, change contrast and erase the history data. To enter the User Menu,
press the red button when in the information entry screen. Use the up and down
buttons to highlight the required menu option then press the green button to
select.

13.1 Adjust LCD contrast (Menu option 00)

Selecting this option will allow the LCD contrast to be adjusted from the keypad.
Pressing the up and down buttons on the keypad will adjust the LCD contrast in
small steps. Pressing the left and right buttons on the key pad will adjust the LCD
contrast in bigger steps. To confirm the LCD contrast and exit press the green
button. Press the red button to exit without changing the contrast.
Adjust LCD contrast

◄▼ = - ▲► = + ● = ■ = 

13.2 Set language (Menu option 01)

If enabled for user menu selecting this option will allow the User to set the
operating language of the Gator computer.
Using the up and down button on the keypad select the required language. To
confirm the language selected and exit, press the green button. Press the red
button to exit without setting the language.
Select Language
001 English
002 Français
003 Español
004 Deutsch
005 Italiano
006 Portugues
010 Svenska
▲▼Scroll, ● Select , ■ = Exit

If not enabled for user menu selecting the following screen will be displayed if set
language is selected.
! Warning !
Not enabled
Press ● to continue

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13.3 Output joint record(s) (Menu option 02)
Selecting this option allows the operator to view joint data on the screen or
download joint data to memory stick. View downloaded joint data in Microsoft ®
Notepad from output joint records option.
Review joint(s)
Send to: Screen

Select record(s):
Last joint
From 24
To 24
● to Proceed

13.3.1 Send to
First use the up and down buttons to select ‘Send to’ then using the left and right
buttons to select the destination for the joint data.

13.3.2 Screen
Display the joint data on the screen. See section 13.3.6 select record(s)
view/download.

13.3.3 Printer
Send joint data to thermal printer. Connect printer to green printer socket on the
rear of the computer. See section 13.3.6 select record(s) review/print.

13.3.4 USB drive

Down loads the joint data to memory stick so the data can be viewed in Notepad
(Unicode Font must be used). Connect the memory stick to the USB ‘A’ connector
on the rear of the computer. See section 13.3.6 select record(s) view/download.

13.3.5 PC
Down loads the joint data to PC so the data can be viewed in Notepad. Connect
the green plug on the universal data transfer lead to the green printer socket on
the rear of the computer and connect the other end of the universal data transfer
lead to the serial port of the PC. See section 13.3.6 select record(s) review/print.

13.3.6 Select record(s) view/download

Using up and down buttons scroll to ‘Last joint’. Using the left and right buttons
select the required joint selection choosing from.

13.3.6.1 Last joint

This gives the last joint fused. See section 13.3.6.7 sending data view/download.

13.3.6.2 All joints

This gives all the joints in the database. See section 13.3.6.7 sending data
view/download.

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13.3.6.3 Joint range
Allows a range of joints to be selected by scrolling down to ‘From’ or ‘To’ then
using the left and right buttons on the keypad to select the joint range. See section
13.3.6.7 sending data view/download.

13.3.6.4 All complete

This gives all the complete joints in the database. See section 13.3.6.7 sending
data view/download.

13.3.6.5 All incomplete

This gives all the incomplete joints in the database. See section 13.3.6.7 sending
data view/download.

13.3.6.6 Matching criteria

This gives joint data for an operator and/or project by scroll to operator or project
press green button to enter criteria the following screen will be displayed.
Operator
---------------------------------------
A B C D E F 1 2 3 
G H I J K L 4 5 6
M NO P Q R 7 8 9
S T U V WX , 0 .
Y Z ⌴+ -

Scroll to the appropriate character using the up, down, left and right buttons on
the keypad. Then press the green button on the keypad to select the character.
For more information see section 5.1 character entry screen. If no match is found
the following screen is displayed:

Operation cancelled:
No matching record

Press ● to continue

See section 13.3.6.7 sending data view/download.

13.3.6.7 Sending data view/download

When the required joint selection has been made scroll down to ‘● to proceed’
then the relevant information will be given.
If the destination is the screen one joint at a time will be displayed. Use the up and
down buttons on the keypad to scroll up and down the joint data. Press the green
button to tab across to see the information that runs off the side of the screen.
Use the left and right button to move on to the next joint. Press the red button on
the keypad to exit.
When joint data has been sent to USB drive the screen will display complete
‘press ● to continue’. The status bar at the bottom of the screen will show the
status of the download see section 9 status bar.

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If the database is empty the following screen is displayed.
Review Joint(s)

No records!

■ to Proceed

13.4 JointManager (Menu option 03)

Selecting this option allows the operator to download joint data to USB drive,
Minitran or PC and view joint data on JointManager.

USB drive OK
Send to: USB drive

Select record(s):
Latest joints
From 1
To 24
● to Proceed

13.4.1 Send to
First use the up and down buttons to select ‘Send to’ then using the left and right
buttons to select the destination for the joint data.

13.4.2 USB drive

Download the joint data to a memory stick so that the data can be viewed on
JointManager. Connect the memory stick to the USB A connector on the rear of
the computer. See section 13.4.5 select record(s) data transfer.

13.4.3 Minitran
Download the joint data to Minitran so the data can be viewed on JointManager.
Connect the green plug on the Minitran to the green printer on the rear of the
computer. See section 13.4.5 select record(s) data transfer.

13.4.4 PC
Download the joint data to PC so the data can be viewed in JointManager.
Connect the green plug on the universal data transfer lead to the green printer on
the rear of the computer and connect the other end of the universal data transfer
lead to the serial port of the PC. See section 13.4.5 select record(s) data transfer.

13.4.5 Select record(s) data transfer

Using up and down buttons scroll to ‘Latest joints’. Using the left and right buttons
select the required joint selection choosing from.

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13.4.5.1 Latest joints
Download joint data that has not yet been downloaded. If all the joints have been
downloaded ‘No new joints.’ will be displayed under ‘latest joints’. See section
13.4.5.5 sending data transfer.

13.4.5.2 All joints

Downloads all the joint data, which is stored in the database. See section 13.4.5.5
sending data transfer.

13.4.5.3 Joint range

Allows a range of joints to be selected by scrolling down to ‘From’ or ‘To’ then
using the left and right buttons on the keypad to select the joint range. See section
13.4.5.5 sending data transfer.

13.4.5.4 Last joint

Downloads the last joint fused. See section 13.4.5.5 sending data transfer.

13.4.5.5 Sending data transfer

When the required joint selection has be chosen scroll down to ‘● to proceed’. The
status bar at the bottom of the screen will show the status of the download see
section 9 status bar.

When joint data has been sent to USB drive, PC or Minitran the screen will display
complete ‘press ● to continue’.

If the database is empty the following screen is displayed.

Fast Data Transfer

No records!

■ to Proceed

13.5 System variables (Menu option 04)

Selecting this option allows the operator to view the current system settings, e.g.
serial number, property off, software version, joint number and the set options, on
the screen or download current system settings to memory stick to view joint data
in Microsoft® Notepad.
Use the up and down buttons on the keypad to scroll up and down the system
variables. Press the green button to tab across to see the information that runs off
the side of the screen. Press the red button on the keypad to exit system
variables. This information may be asked for when contacting Fusion Group.

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View On Screen
Send to:
Screen

System Variables

● to Proceed

Refer to section 13.3.1 for how to select other Send to: destinations for the
System Variables data. The first screen of information is shown below.
System Variables
Serial No.: SBOX30002
Plant Number: -
Property Of: FUSION GROUP
Software: 1.2
Voltage: 230v
Joint No. information:
Total 35
▲Scroll▼ ■Exit ●Tab

13.6 Remove user history (Menu option 05)

Selecting this option will allow all the user history to be erased.
Press the green button to proceed and erase the user history. Press any other
button to exit the Remove user history menu option.

13.7 Recover archived records (Menu option 06)

Selecting this option will allow the user to recover records previously archived to
the SD card.
Press the green button to access the archived files, then use the up, down and
green button to select the archive file to be recovered. When the green button is
pressed the computer will prompt the user to connect a memory stick, it will then
proceed to transfer the selected data to the memory stick.
Pressing the red button will cancel to procedure.

13.7 Daylight saving (Menu option 07)

Selecting this option will allow the user to toggle the daylight saving.
Press the green button to access the daylight saving option, then press the green
button to add or remove an hour from the time. Press the red button to exit
daylight saving.

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14 User diagnostics menu
To enter the user diagnostic menu turn on the unit, when the logo screen is
displayed press the red button then press the red button again.

14.1 Test / Calibration (01)

The options in test / Calibration allow the operator to test relevant parts of the
Gator machine.
Press the green button to enter the test / calibration menu option then use the up
and down buttons to select the relevant menu option then press green button to
enter the menu option.

14.1.1 Chassis diagnostics (01)

This option allows the checking of chassis recognition and chassis operation.

14.1.2 Trimmer diagnostics (02)

This option allows the checking of the trimmer operation.

14.1.3 Heater diagnostics (03)

This option allows the checking of the heater operation.

14.1.4 Computer diagnostics (04)

This option allows the checking of the computer operation.

14.1.5 Hydraulic diagnostics (05)

This option allows the checking of the hydraulic operation.

14.1.1 Test scanner (07)

The test scanner option allows the barcode scanner to be tested.
Scan a barcode then the barcode and the length of the barcode will be displayed
on the screen.

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 Gator Automatic Butt Fusion Range
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15 Specification
Supply Gator 180, 250 & 315
Minimum Typical Maximum
Input voltage 110V 97v 110v 150v
220V 195v 230v 265v
Input frequency 40Hz 50Hz 60Hz

Power requirements 180 250 315

Trimmer 750 watt 750 watt 750 watt
Heater 1500 watt 1800 watt 3300 watt
Controller 1200 watt 1200 watt 1200 watt
Generator 3.5 KVA 4 KVA 6 KVA
Note: Due to software control, the maximum power demand = Heater + Controller.

Environment Gator 180, 250 & 315

Minimum Maximum
Operating temperature -10°C +40°C
Storage temperature -15°C +45°C
Environmental protection IP54

Pipe & joining parameters Gator 180, 250 & 315

Minimum Maximum
Diameter range Gator 180 63mm 180mm
Gator 250 63mm 250mm
Gator 315 90mm 315mm
Joining pressure 10Bar 60Bar
Heater removal time 1.3s 3.5s
Heater temperature 110V 233°C
Heater temperature 220V 205°C, 210°C, 215°C, 220°C, 225°C & 233°C
SDR range 7.25, 7.4, 9, 11, 13, 13.6, 17, 17.6, 21 26, 33, 67
Welding standards DVS2207-1 WIS4-32-08
GIS/PL2-3 (GB) Osaka Gas
Japan Toho Gas
S/EM-044-E Part 1 UK WIR 90°C Fastweld
Fusion FW Landfill DVS-215°C
DS/INF (Insta) DVS2207-11 Polyprop.
UNI 10520 Gaz du France
Mesco UNI 10967
TSG HKCG (BG)
ISO21307 SLP ISO21307 DLP

Joining sequence details Gator 180, 250 & 315

Automatic Manual
Trim 
Check (slippage) 
Check (Alignment) 
Bead-up phase 
Soak phase 
Heater removal 
Pressure build-up 
Fusion phase 
Cooling phase 

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Communication ports Gator 180, 250 & 315
USB 
Bluetooth 
Printer/PC 

Printer port transmission Gator 180, 250 & 315

Protocol RS232
Speed 1200 Baud
Parity None
Data bits 8
Stop bits 1

Unit weights 180 250 315

Trimmer 12Kg 14.5Kg 19Kg
Heater 17Kg 21.5Kg 29.5Kg
Chassis (without cradle) 39Kg 45Kg 62Kg
Chassis (with cradle) 44Kg 51Kg 68.5Kg
Controller 46Kg 46Kg 46Kg
Gross weight 119Kg 133Kg 163Kg

Dimensions Height Depth Width

180 Trimmer 382mm 260mm 445mm
Heater 440mm 200mm 570mm
Chassis (without cradle) TBC TBC TBC
Chassis (with cradle) 560mm 430mm 323mm
Controller 470mm 430mm 560mm
250 Trimmer 490mm 290mm 450mm
Heater 800mm 250mm 530mm
Chassis (without cradle) 390mm 500mm 660mm
Chassis (with cradle) 430mm 650mm 760mm
Controller 470mm 430mm 560mm
315 Trimmer 560mm 290mm 550mm
Heater 900mm 250mm 630mm
Chassis (without cradle) 460mm 625mm 690mm
Chassis (with cradle) TBC TBC TBC
Controller 470mm 430mm 560mm

Cable and hose lengths Gator 180, 250 & 315

Input 5m
Trimmer 5m
Heater 5m
Chassis 5m
Hydraulic hoses 5m

Standards Gator 180, 250 & 315

ISO12176-1 
ISO12176-3 
ISO12176-4 

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 Gator Automatic Butt Fusion Range
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16 Rights
Due to Fusion's policy of continued development and improvement, we reserve
the right to modify products without prior notice.

17 Accessories
Below is a list of accessories and Fusion order numbers:
Order No. Description
742182 Memory stick
23070 180 Chassis cradle
22481 250 Chassis cradle
12668 315 Chassis cradle

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Appendix A Gator Manual entry character set
The Gator character sets are shown below:

A.1 Number character set.

0123456789.-+,⌴ (⌴ - represents a SPACE).

A.2 ABC font set

A.2.1 Upper case characters

ABCDEFGHIJKLMNOPQRSTUVWXYZ

A.2.2 Lower case characters

abcdefghIjklmnopqrstuvwxyz
When the green button is held down for more than 3 seconds when on the
selected character the following characters will be displayed.
Selected Displayed Selected Displayed
character characters character characters
A ÀÁÂÃÄÅĀǍĂĄ a àáâãäåāǎăą
C ÇĆĈĊČ c çćĉċč
D Ď
E ÈÉÊËĒĔĖĘĚ e èéêëēĕėęě
G ĜĞĠĢ g ĝğġģ
H Ĥ h ĥ
I ÌÍÎÏĨĪĬĮİ i ìíîïĩīĭį
J Ĵ j ĵ
K Ķ k ķ
L ĹĻĿŁ l ĺļŀł
N ÑŃŅŇŊ n ñńņňŋ
O ÒÓÔÕÖØŌŎŐ o òóôõöøōŏő
R ŔŖŘ r ŕŗř
S ߌŜŞŠ s śŝşš
T ŢŤ t ţ
U ÙÚÛÜŨŪŬŮŰŲ u ùúûüũūŭůűų
W Ŵ w ŵ
Y ÝŶŸ y ỳÿŷ
Z ŹŻŽ z źżž

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A.3 Russian

A.3.1 Upper case characters

A Б B Г Д E Ж З И Й K Л M H O П P C T У Ф X Ц Ч Ш Щ Ъ ЭЮ Я

A.3.2 Lower case characters

а б в г д е ж з и й к л м н о п р с т у ф х ц ч ш щ ъ эю я
When the green button is held down for more than 3 seconds when on the
selected character the following characters will be displayed.
Selected Displayed Selected Displayed
character characters character characters
Ъ ЬЫ ъ ьы

A.4 Japanese

A.4.1 Upper case characters

ア カ サ タ ナ ハ マ ヤ ラ ワ – ゛°

A.4.2 Lower case characters

ァヵサッナハマャラヮ-゛゜
When the green button is held down for more than 3 seconds when on the
selected character the following characters will be displayed.
Selected Displayed Selected Displayed
character characters character characters
ア イウエオ ァ ィゥェォ
カ キクケコ ヵ

サ シスセソ サ
タ チツテト ッ チッテト
ナ ヌニネノン ナ
ハ ヒフヘホ ハ
マ ミムメモ マ
ヤ ユヨ ャ ュョ
ラ リルレロ ラ
ワ ヲ ヮ

A.5 Symbol
!¿#$%&’()*`/:;<=>?@[]^{|}~°±μΩ

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 Gator Automatic Butt Fusion Range
Operating Manual

Declaration of Conformity

Declaration of Conformity
EC In accordance with EN ISO 17050-1:2004

We Fusion Group Limited

Of Fusion House
Chesterfield Trading Estate
Chesterfield
Derbyshire S41 9PZ
England

In accordance with the following Directives(s)

2004/108/EC The Electromagnetic Compatibility Directive

2006/42/EC The machinery Directive
Hereby declare that:

Product(s) Model Number(s)

Gator 180 110/220V 50Hz G180110/220AFE
Gator 250 110/220V 50Hz G250110/220AFE
Gator 315 110/220V 50Hz G315110/220AFE
Gator 400 (Mk2)110/220V 50Hz G400MK2110/220AFE
Is in conformity with the applicable requirements of the following documents:

Ref No: Title: Edn/date

BS EN ISO Safety of machinery. Basic concepts, general principles for 2003

12100-1&2 design
BS EN 61010-1 Safety requirements for electrical equipment for measurement, 2001
control and laboratory use. General requirements
BS EN 982 Safety of machinery. Safety requirements for fluid power 1996
systems and their components. Hydraulics
EN 61000-6-2 Electromagnetic compatibility (EMC). Generic standards. 2005
Immunity for industrial environments
EN 61000-6-4 Electromagnetic compatibility (EMC). Generic standards. 2007
Emission standard for industrial environments

To maintain compliance with the appropriate Directives, this equipment shall only be used on
electrical supplies independent of direct connection to domestic premises.
This declaration shall become invalid if modifications are made to the equipment without prior
written approval from the manufacturer.

EDOI6922 Page 43 of 44 Issue 02

 Gator Automatic Butt Fusion Range
Operating Manual

Fusion Group Limited

Smeckley Wood Close
Chesterfield Trading Estate
Chesterfield
Derbyshire
S41 9PZ

Tel: + 44 (0) 1246 268666

Fax: + 44 (0) 1246 268052

Email: [email protected]
Web: www.fusiongroup.com

EDOI6922 Page 44 of 44 Issue 02