Betriebsanleitung - Asahi America Inc.
SP 250
OPERATION & MAINTENANCE
MANUAL
Version: 0003
Asahi/America
2005
Connected loads: 230VAC +10/-15%, 20/25A, 50/60Hz
Table of contents:
1 General information on the manual 4
2 Safety regulations 4
2.1 The user’s obligations 5
2.2 The personnel’s obligations 5
2.3 Regulations for operation 5
2.4 Safety devices 6
2.5 Maintenance, repair and inspection 6
3 Product description 7
3.1 Field of application and predefined usage 7
3.2 Technical description and technical characteristics 7
4 Construction and initial operation 8
4.1 Operating elements and components 8
4.2 Installation of SP 250 10
4.3 Power supply and connection of the SP 250 tool 10
4.4 Right of use 11
5 Operation and Welding 12
5.1 Selection of welding method 12
5.2 Preparing SP 250 12
5.3 Program description 13
5.4 Working process 16
5.5 Error and system message 31
6 Weld quality and welding parameters 34
6.1 Welding bead 34
6.2 Weld failures 34
6.3 Welding parameters 36
6.4 Weld labelling 36
7 Maintenance 37
7.1 Fuses 37
7.2 Lubrication 37
7.3 Repair of failures 38
7.4 Servicing, Seminars & SP-DATA 38
8 Transportation and storage 39
8.1 General information 39
8.2 Unpacking of SP 250 39
8.3 Packing of SP 250 39
8.4 Storage 40
9 Equipment and accessories 40
10 SUPPLEMENT 41
10.1 Spare parts and expendable material 41
10.2 Installation guidelines for AGRU PURAD high-purity pipeline systems 42
10.2.1 Design and pipe installation 42
10.2.2 Admissible products 42
10.2.3 Receiving inspection of products 43
10.2.4 Storage of material and components at the place of installation 43
10.2.5 Clean room clothing 43
10.2.6 Welding and installation 43
11 Attestation of conformity 45
12 Guarantee Claims 46
1 General information on the manual
In this manual you will find the answers to all important questions about the construction and the safe operation of your welding machine SP 250. You are obliged to study it carefully, in order to avoid damages and injuries as well as to provide for the proper functionality.
At the same time we kindly ask you to inform us about faults, deficiencies and problems which might occur during operation. This will help us to watch the steady improvement of our products and the operating instructions.
Subject to changes without announcement.
Thank you.
Symbols
Below you find the explanations of the symbols used in this manual to ensure an easy understanding and safe handling of the equipment.
[pic]
Safety sign
The general hazard warning sign is marking texts, containing special safety rules. Ignorance may be hazardous to the health of persons.
[pic]
Important information
Marking of texts, containing important information.
1. Execution
Marking of texts, describing the execution of actions.
• Enumeration’s
Marking of enumeration’s.
2 Safety regulations
The equipment has been designed for the welding of AGRU-products as to the best of our knowledge. However, we are not liable for an improper welding seam quality or possible damages arising thereof.
This state-of-the-art welding machine has been designed pursuant to the commonly accepted safety regulations. Nevertheless, the machine might cause some danger to the operator or persons staying next to it.
Changes to improve the system are possible without special notice.
2.1 The user’s obligations
The user is obliged to...
have the machine operated only by persons, familiar with the basic rules on working place safety, who have been trained at the machine and proved by their signature that they have read and fully understood the safety regulations and warning signs laid down in the operating instructions.
have the machine operated only by persons, who have been trained by AGRU or a duly authorised representative organisation, finally having obtained a valid welding certificate for SP-welding machines.
have controlled the personnel’s safety concern at regular intervals.
hand out the operating instructions, if the welding equipment should be passed over and owned by another person/organisation or if it is leased, as well as to underline its importance.
take care of observing the safe working conditions and the required perfect technical condition of the machine.
This machine has been designed for the welding of AGRU material. For welding of other brands no experimental values are available and we are not able to warrant for any such suitability of the welding machine whatsoever.
2.2 The personnel’s obligations
All persons directed to operate the machine are obliged to:
observe the fundamental rules on safety and the prevention of accidents.
read through the chapter on safety and warning signs in the operating instructions.
get informed on the functioning of the machine before usage.
operate the machine only when it is in a technically perfect condition and to report defects and damages to the responsible user or operator.
use the machine only for the specifically laid down purposes.
2.3 Regulations for operation
The machine shall be connected to the mains supply only after completion of installation.
In emergencies, where human beings and/or equipment are endangered, immediately press the EMERGENCY-striking key of the operating control unit or turn off the main switch.
After welding procedures and during breaks disconnect the machine and remove the access card. Further, take care that only authorised personnel are admitted.
According to the VDE 0100 the equipment may be operated only via current dividers equipped with FI-protective switches.
The SP 250 is designed as a single-operator welding set. Operation by more than one person is not allowed. When the machine is switched on, only one responsible operator may stay in the working place.
Before the individual functional movements will be activated, the operator has to finish all required preparing (see chapter 5: Operating and Welding) and provide for the perfect function course.
The planing tool rotates during operation and is equipped with sharp knives!
[pic]
- Wear tight clothes and possibly a hair-net, but no jewels or ornaments.
- Do not reach into the running planing tool!
Carriages work semiautomatically!
[pic]
- Do not reach into stationary and movable machine parts or the clamped pipe ends!
- Do not place objects on ways for shifting.
The heating element is getting very hot during operation!
[pic]
- Do not touch the heating element and the protection cover.
- Do not leave the heating element unattended.
- Mind a sufficiently safe distance from inflammable materials.
Do not clean the machine with compressed air, because dirt would be delivered into the guides and planing chips blown onto the heating plate!
[pic]
When PVDF and ECTFE-chips are heated-up, hydrofluoric acid may be generated!
Sufficient ventilation should be available!
At butt welding the required teflon plates have to be mounted to the heating element; all welding parameters have to be altered accordingly.
2.4 Safety devices
6. Main switch with EMERGENCY function
In OFF-position the machine is currentless and idle.
7. EMERGENCY-striking key at operating control unit.
If pressed (locked) all drives are currentless and idle.
8. Position switch (proximity switch).
The individual functions are released only in the corresponding initial or working positions.
9. Each critical control command activated over the touchscreen has to be simultaneously acknowledged by the RELEASE-key.
10. The lateral transport lock secures the planing tool and the heating element when the machine is moved or transported.
11. The crank geometry prevents the planing tool from uncontrolled swivelling during planing.
2.5 Maintenance, repair and inspection
Only personnel and organisations authorised by AGRU are permitted to open the SP 250, to adjust and repair it.
Use only original spare parts and wearing parts.
Perform maintenance and inspection work in due time.
After finishing maintenance work control the functions of safety devices.
Amendments, attachments and/or reconstruction work is allowed only by prior permission of the manufacturer.
3 Product description
3.1 Field of application and predefined usage
The welding machine SP 250 is designed exclusively for InfraRed welding (non-contact butt welding) and heating element-butt welding of plastic pipes and plastic fittings. Only the welding parameters which are shown on the display (pre-set values!) may be welded and stored respectively.
[pic]
It is not allowed to alter the welding parameters given by AGRU!
Predefined usage first of all implies the observance of all regulations laid down in the operating instructions.
Any usage going beyond it is not deemed predefined and appropriate. In such cases, the risk is borne only by the operator. The manufacturer is not liable for any damages resulting thereof.
3.2 Technical description and technical characteristics
The welding machine SP 250 is designed as a semiautomatic device with an electronic joining pressure control.
There is an external operating control unit with a touchscreen for the interactive operation and for the input and output of welding parameters. All parameters relevant for the welding process are stored and processed for the complete documentation by means of an optional PC-program. All aluminium parts are anodised to enable operation under clean-room conditions.
|General characteristics | |
|Type of machine |AGRU SP 250 |
|Weldable materials |PVDF, PP and ECTFE |
|Weldable pipe dimensions |from OD 75 to 250 mm |
|Welding pressure range |from 40 to 2000 N ±10% |
|Dimensions (W x H x D) |approx. 980 x 1370 x 1150 mm |
|Transport case (W x H x D) |approx. 1030 x 1420 x 1220 mm |
|Total weight |approx. 598 kg |
|Weight of the machine |approx. 515 kg |
|Connected loads |230VAC +10/-15%, 20/25 A, 50/60Hz, |
|Electrical connection |1-phase, 1/N/PE, min. 3x4mm², fuse protect. max.25A |
|Power input of heating element |max. 4500 W |
|Heating element temperature |from 100°C to 500°C ±2% in pipe area |
|Power input of planing tool |max. 750 W |
|Planing tool speed |approx. 20 to 30 rpm |
|Storage temperature |0°C – 50°C |
|Noise limit |below 70dB(A) |
|Place of application |workshops, industrial sites and clean-rooms |
|Ambient conditions |- according to DVS for welding areas |
| |- Temperature: from +10°C to +35°C |
| |- protection all elements from moisture |
Table 3.1: Technical characteristics of SP 250
4 Construction and initial operation
1 Operating elements and components
6 5 3 4 5 8 6 12 10 9 7 19 20 21 16 14 15 22
Fig. 4.1: Construction of SP 250
|No. |Parts of SP 250 |Notes |
|1 |Machine panel |Fig. 4.2, Connections |
|2 |Operating control unit |Fig. 4.3, Operation of SP 250; detachable |
|3 |Heating element | |
|4 |Planing tool | |
|5 |Inner clamping jaws |Stationary |
|6 |Outer clamping jaws |Movable and detachable, fixation by clamping lever |
|7 |Stationary clamping unit |Height and lateral adjustment for offset compensation by means of handwheels |
|8 |Movable clamping unit |Movements to right or left by means of electrical drive |
|9 |Carriage for planing tool and heating |Forward/backward movement by electrical drive |
| |element |Movements to right or left by shifting lever |
|10 |Transport lock |Fixation of planing tool and heating element during transport |
|11 |Adjusting legs |Alignment of SP 250, not illustrated |
|12 |Bubble level |Shows degree of alignment |
|13 |Wheels |Removable, not illustrated |
|14 |Shifting levers |Movement of heating element and planing tool |
|15 |RELEASE-key |Release of functions of movement |
|16 |Box |Store of accessories |
|17 |Printing unit |Optional, for printing of weld tags; detachable |
|18 |Nitrogen purging |Optional, not illustrated |
|19 |Wheel of alignment |Adjusting of the vertical offset |
|20 |Wheel of alignment |Adjusting of the horizontal offset |
|21 |Fixing lever of alignment |Fixation of the vertical and horizontal offset. |
| | |From series W22599-200 no more longer used! |
|22 |Rocker arm |Support/mounting of the touch panel and printer (optionally) |
29 25 24 26 23 28 27
Fig.4.2: Machine panel of SP 250
|No. |Parts of machine panel |Notes |
|23 |Main switch |Switching off the machine (with EMERGENCY-function) |
|24 |Shock-proof plug |Voltage supply to printer |
|25 |Small plug connectors |Control of nitrogen purging |
|26 |Glass tube fuse |Protection of nitrogen purging |
|27 |Safety cut-out |Protection of power elements |
|28 |Mains cable |Connection to mains supply (network!) |
|29 |PC-cable |Connection to operating control unit |
33 30 34 31 32 39 35 36 38 37
Fig.4.3: Operating control unit
|No. |Parts of operating c. unit |Notes |
|30 |Touchscreen |Program operation and indication |
|31 |EMERGENCY-striking key |Stopping engines in dangerous situation |
|32 |RELEASE-key II |Release of functions of movement (only for SP 110!) |
|33 |PCMCIA-Slot |For entry card/memory card (keycard) |
|34 |Buzzer |Acoustical indication during welding procedure |
|35 |LED-signal |Lighting up green, if voltage supply is okay |
|36 |Keyboard interface |Connection of a keyboard for servicing possible |
|37 |Serial interface |No function |
|38 |Parallel interface |Data transfer to printer (LPT) |
|39 |Machine interface |Data transfer to control unit and supply of operating control unit |
4.2 Installation of SP 250
General information
Unpacking of SP 250 (see chapter 8, Transportation)
Check delivery as to its completeness and possible shipping damages. Report shipping damages and/or missing parts to AGRU. (Scope of delivery see chapter 9, Equipment and Accessories)
Mount machine onto a solid, plane area and align it horizontally by means of the adjusting legs.
Release the transport lock for planing tool and heating element.
Swing out the rocker arm and tighten hand screw.
Install the operating control unit and - if available - the printing unit to the rocker arm and fix it by means of the clamping lever acc. to position shown in Fig.4.1.
[pic]
Never touch the touchscreen with sharp or sharp-edged objects (such as screwdrivers, etc.).
[pic]
Use the wheels only for small movement onto a solid, plane area. During operation always align the machine with the adjusting legs.
4.3 Power supply and connection of the SP 250 tool
A 1-phase mains lead of the following characteristics is required for the machine operation:
230VAC +10/-15%, 50/60Hz
Protection is max. 25A
Minimum mains lead cross section is 3x4mm² (1/N/PE)
Maximum mains lead length is 10 m from the FI-switch
Before you plug in the mains lead and start the machine by the main switch it is required to:
Check and/or restore the electrical connections of heating element, operating control unit, printing unit - if available - and nitrogen purging. If necessary, protect them by means of locking bows. The most important plug connectors are marked in different colours. (Fig. 4.4).
Fig. 4.4: Plug connectors of SP 250
Check position of safety cut-outs (inspection glass) - it has to be ON.
Check position of EMERGENCY-striking key - it has to be unlocked (Fig. 4.5).
Check position of main switch - it has to be OFF.
Connect with mains lead and switch on SP 250 by main switch (position ON).
[pic]
After a short time the starting image appears on the touchscreen with the AGRU logo (see chapter 5.4, Working Process).
Fig. 4.5: Functional description of EMERGENCY-striking key
4.4 Right of use
An access card is required for the purpose of the operator’s identification and external data storage (keycard).
Uncover PCMCIA-slots.
Carefully insert the keycard with the printed side facing upward (until you reach point of resistance) and cover slot (during operation the card always remains in the slot).
[pic]
SP 250 can be operated only by means of a valid keycard.
5 Operation and Welding
5.1 Selection of welding method
By means of these selector keys you can choose the desired welding method. IR stands for infrared- or non-contact butt welding and CONTACT stands for the conventional butt welding method.
According to your selection the SP welding machine automatically sets the required welding parameters and controls the temperature of the heating element.
The conventional butt welding (contact) method corresponds to the currently valid requirements of the regulations of the DVS (German welding society). The parts to be joined are aligned under pressure on the heating element (contact with the heating element), pre-heated without pressure and joined at a specific pressure and time.
With non-contact welding no alignment time is required and heating may be started immediately. This is done over a specifically defined gap between the heating element and the part to be welded. Thus, a possible contamination of the welding surfaces can be minimised, leading to a substantially higher purity of welding. After the pre-heating time you proceed the same way as with butt welding.
5.2 Preparing SP 250
General information
Installation of reducing inserts
The reducing inserts for the different corresponding pipe dimensions are kept in the storage box.
Open all four clamping jaws completely and place the inserts (4 x 3 pcs. of each dimension) according to the constructional conditions (1 ½-insert and 2 ¼-insert per clamping jaw).
Arrange remaining inserts in the storage box in proper order.
[pic]
As the fixation of the inserts and the mechanical locking is carried out by magnetic force, no instruments are needed to change the inserts. For removal of the inserts you only have to surmount the magnetic force.
Do not press the reducing inserts into the clamping jaws!
Adjustment of outer clamping jaws
The position of the outer clamping jaws can be adjusted as required by the part to be welded.
Release both clamping levers, position clamping jaw (or detach it) and reclamp it.
Starting of printer
Refer to supplied original sample of operating instructions.
Butt welding (optionally)
Installation of insert plates for butt welding
[pic]
The movement of the heating element is only with the help of a special button on the image heating element possible (see chapter 5.4, Working process).
Install the tefloncoated aluminium plates on either side of the cold heating plate.
Fix them with the supplied countersunk head screws.
[pic]
Never use insert plates in operating mode infrared welding, as the coating would be destroyed in this case.
5.3 Program description
This program description is applicable to welding program SERVO 20, version no. 2.01.
[pic]
Check first, whether this program version has been installed on your operating control unit (see image LOGO)! If this is not the case, please contact the technical service of AGRU.
Operational procedures, setting and indication of welding parameters are performed via touchscreen. The operator is guided through all of the welding procedures by the interactive program flow.
In the first part of the welding program the operator has to carry out different inputs and settings. At the same time according to these given values all necessary parameters are calculated or selected automatically from the stored tables.
The particular welding is performed in the second part of the program. Here the operator’s task is to perform preparing and activate the corresponding control functions.
After welding you may print out welding seam tags with a special printer (optional). All parameters, relevant for the welding process, are stored in the operating control unit and available for further processing.
Operating levels
An access coding in form of 4 operating levels is provided to ensure the troublefree operation of the machine. According to the code of the keycard only specific system accesses and system functions are released (see Table: 5.1) The first figure of the keycard serial number refers to the operating level.
|Operating level |Operator’s code |Note |Inhibited system access |
|1 |AGRU1 |Manufacturer |N/A |
|2 |AGRU2 |AGRU |Hardware set-ups |
|3 |AGRU3 |Distributor, Operator |Hardware set-ups |
| | | |Welding parameter set-ups |
|4 |freely selectable 5-digit |Welder |All, but welding control |
| |character code | | |
Table 5.1: Operating levels
• Program symbols and their functions
Depending on the active program position on the monitor you will see the corresponding status images with input and output symbols. By pressing onto the input symbol the assigned function is activated.
[pic]
To release the control functions of movements, it is necessary to press the green RELEASE-key simultaneously. If required, the operator is assisted both visually (information line) and acoustically (by a horn).
[pic]
Do not touch the touch panel surface with sharp or sharp-edged objects!
Turn image BACK:
You can turn the page back by pressing this
key.
Selector keys:
The keys with above characters serve for the selection of conditions (heating element, ON/OFF....), parameters (welding method, material, wall thickness) and menu options.
The input keyboard has also been equipped
with selector keys.
Turn image FORWARD:
You can turn the page forward by pressing this key.
Sliding button:
Parameter adjustments are selected by changing the sliding button position. (printer switch off or number of tags to be printed after welding,..).
Dynamic pictures:
Dynamic pictures change depending on the actual condition (infrared welding or butt welding). This is also true for select displays and diagrams.
Numerical displays:
These output fields serve for the display of machine or welding characteristics in numerical form.
Keys to control clamping jaws:
[pic]
By these keys the movements (OPEN/CLOSE) of the movable clamping jaws are controlled.
Display lights:
These output fields serve for the display of releases and activated functions (jaw closed,....).
Multifunctional keys:
Various control functions may be released by this input field (planing tool movements, switching-on...) The graphics display and functions alter depending on the actual function.
Stop key:
This special control key serves for switching off and interrupting control functions (joining, putting planing tool into front position,...).
[pic]
No EMERGENCY-function!
Information line, signalising and warning window:
Information on operational conditions of machine and control directions is given in an information line in the upper screen section. Inquiries and system notes are indicated in windows with blue background, warnings and disturbances in windows with red background.
If necessary, information outputs are accompanied by acoustic signals and must be acknowledged to continue the program.
5.4 Working process
Fig. 5.1: Survey of program-backed welding procedure:
Fig. 5.1a: Flow chart of welding process
Abb. 5.1b: Flow chart of welding process
LOGO: Initial image
After switching on the machine, the initial image LOGO appears.
It is possible to choose between the system level (image SYSTEM) or welding level (image
INFO 1). Hardware and software characteristics are illustrated for your information.
SYSTEM: Select menu for system functions
The select menu allows to enter system functions. Released functions are marked in green colour. Authorised users will obtain information on the application of system functions from the technical service of AGRU.
[pic]
Only persons authorised by AGRU are allowed to make use of the system functions.
INFO 1: Initial image of welding level
Apart from the indication of welding characteristics this image includes several image changing functions. The desired number of lag printouts can be chosen by the sliding button.
INFO 2: Selection and indication of stored welding characteristics.
In this picture you can examine the characteristics of stored welding. You can read-in files from the keycard or directly from the memory of the operating control unit. After selection of a file and its transfer the welding data are indicated. As an alternative, you can perform a manual input of a file name.
ADDRESS: Input of address
The place of welding is entered over the keyboard block; it is automatically taken over at returning to image INFO 1.
ROOM: Input of room characteristics
In this picture the environmental characteristics have to be entered. The selected room type is marked by the signal lamp. On return to image INFO 1 the set characteristics are taken over automatically.
MATERIAL: Input of material
You can select one of the given materials (e.g. PVDF) by the menu keys. When changing to image DIAMETER, the setting is taken over automatically.
DIAMETER: Input of diameter
You can select one of the given pipe diameters (e.g. 110 mm) by the menu keys. When changing to image WALL THICKNESS the setting is taken over automatically.
WALL THICKNESS: Input of wall thickness
You can select one of the given pipe wall thickness (e.g. 5.3 mm) by the menu keys. When changing to image HEATING ELEMENT, the setting is taken over automatically.
After setting the environmental and material characteristics in the first part of the program the particular welding process is started now:
HEATING ELEMENT: Setting of heating parameters
After selection of the desired welding method the heating element parameters are loaded auto-matically and starts to heat up. The input of the heating element temperature by hand is with the corresponding access possible (Temp-HAND).
To mount the insert plates onto the heating element it is necessary to move it ahead (only for butt-welding method!).
← Move the tool unit (heating element/planer) right till the
stop (Hand lever)
← Move heating element into position AHEAD (Heating element FORW. + RELEASE-key)
← Mount the tefloncoated plates onto cold the heating element
← Fix them with the supplied countersunk head screws
[pic]
Never use insert plates in operating mode infrared welding, as the coating would be destroyed in this case.
← Move heating element in position BACK (Heating element BACK + RELEASE-key).
[pic]
Check your power supply.
For standard supply (230 Volt +10/-15%, 16 Ampere, 50-60Hz) a 20 Ampere protection is required (position LOW - image heating element). To reduce the time to reach the desired heating element temperature it is possible to change the current for heating from 16 Ampere to 20 Ampere (position HIGH). In that case you must have a protection of 25 Ampere for your power supply!.
← Switching on of heating element (ON/OFF-button, button turns green)
The heating-up process is started and after the desired temperature is reached (release lamp turns green) the count down of the REMAINING TIME begins (time to elapse until the heating element reaches a constant temperature).
After expiry of the remaining time turn to image INFO 3 (NEXT)
[pic]
Changeover to INFO 3 is released only after expiry of the REMAINING TIME!
Time total needed for heating up is about 30 minutes.
[pic]
If necessary, clean heating element with non frayed paper.
Make non frayed paper available!
Consider the ambient conditions:
← The welding must not be carried out at direct sun irradiation and at draught.
← The ambient temperature must not be below +10°C and over +35°C.
INFO 3: Display of welding parameters
In this picture all relevant welding parameters are indicated that have been entered or calculated.
After control of parameters change to image PLANING TOOL (NEXT).
On changing an inquiry window appears with the most important material data.
After repeated control acknowledge by OK (image changing is concluded) or NOT OK and repeat or correct setting of material (BACK).
[pic]
The entered pipe parameters must comply with the pipes to be welded!
Always clean the machine, the planer blades and the planer knifes before each welding only with non frayed paper!
PLANING TOOL: Controlling
In this picture/program section the planing of the pipe ends is handled.
[pic]
To provide a troublefree procedure, the different working positions have to be commenced exactly. The touchscreen display is adapted automatically!
[pic]
All control functions may be interrupted by function stop (STOP + RELEASE-key).
Move tool till stop into position LEFT (Hand lever)
Move movable clamping unit into position OPEN
(Clamping unit-OPEN + RELEASE-key)
These steps can be ignored, if the units already find
themselves in starting position.
[pic]
When moving the clamping unit, the RELEASE-key
has to be kept pressed until the end position is reached,
otherwise a warning signal will appear. After arriving at
the end position the clamping unit is halted automatically!
Move planing tool into position ALIGNING
(Planer Symbol® + RELEASE-key)
← Move clamping unit into position PLANING
(Clamping unit-CLOSED + RELEASE-key).
← Place workpieces so that pipe ends touch the planing tool
plates and clamp them. The locking force of the
individual clamping jaws can be adjusted over the milled nut.
(Tighten the outside clamping jaws with more force to save
the pipe for moving up than the inside clamping jaws. These
are only used for Alignment).
When the locking force is too high, the workpiece and the clamping jaws can be damaged!
[pic]
Move movable clamping unit into position OPEN
(Clamping unit-OPEN + RELEASE-key)
Move planing tool into position AHEAD
(Planer Symbol® + RELEASE-key)
Switch on planing tool (Planing disc symbol +
RELEASE-key)
Move clamping unit into position PLANING
(Clamping unit-CLOSED + RELEASE-key)
The work piece is guided automatically by the movable
clamping unit and maintains the planing pressure.
[pic]
Take away chip material that accumulates behind the planing disc regularly. The chips can cause that the planing tool engine will block or undergoes higher wear!
[pic]
Do not put your hand into the stopped or rotating planing disc!
Danger of injury by sharp rotating knifes!
Danger! Clothing may be caught!
Wear tight-fitting clothes, if necessary wear a hairnet!
The process is ended, when no chips are left to be removed and the clamping units have come close to the mechanical stops of the planing tool.
Move movable clamping unit into position OPEN (Clamping unit-OPEN + RELEASE-key)
[pic]
At the end position the planing tool is switched off automatically!
Move planing tool into position BACK (Planer Symbol〈 + RELEASE-key)
At the end position an inquiry window appears. Perform a visual control of the planing process.
If acknowledged by OK, the image automatically turns to OFFSET CONTROL.
If acknowledged by NOT OK, the planing process has to
be repeated!
See image planing (page 25)!
OFFSET CONTROL: Alignment of pipes
In this part of the program the work pieces are aligned to each other.
Move movable clamping unit into position JOINING
(Clamping unit-CLOSED + RELEASE-key)
Release lateral clamping lever under the stationary clamping
unit as well as hand wheel for height adjustment.
Set height and lateral adjustment with both
hand wheels until work piece offset is compensated.
Fix lateral clamping lever under the stationary clamping
unit and fix hand wheel for height adjustment.
Place end caps onto pipe ends.
At the end position an inquiry window appears (see page 26):
If you acknowledge by OK, open clamping unit and
after reaching the end position, automatically the
image change to START WELDING.
Move movable clamping unit into position
START WELDING
(Clamping unit-OPEN + RELEASE-key)
If you acknowledge by NOT OK, you will have to repeat
the offset compensation or, if required, the planing (BACK)!
Move movable clamping unit into position OPEN
(Clamping unit-OPEN + RELEASE-key)
See planing and/or offset control!
JOINING: Pre-heating and joining
In this part of program the pre-heating and joining of the work piece are handled. This process is carried out nearly fully automatically.
Move tool unit (heating element/planer) till right
mechanical stop (Hand lever)
Starting of welding process (Function START +
RELEASE-key), automatically the heating element
moves into position AHEAD and movable clamping unit
into position PRE-HEATING (after reaching the control
pressure – green light – depress the release-key)
The time counter for pre-heating time begins to count down
and a signal horn is sounded 10 sec. before time runs out.
Move movable clamping unit into position WELDING
(RELEASE-key). Automatically, the heating element
moves into position BACK and movable clamping unit
into position JOINING (after reaching the built up pressure,
depress the release-key).
The time counter for the cooling time begins to count down and after expiry of the time (signal horn) the image turns to VISUAL automatically.
If the welding process is ended before joining or if the adjustment process lasts too long, then after acknowledgement (OK) of the error signal the image is automatically turned to the next: PLANING TOOL.
Open clamping unit (POS + RELEASE-key)
Move heating element into position BACK (POS + RELEASE-key
See planing tool sequence!
[pic]
Plane only cooled down pipe ends!
If the welding process is ended during the cooling-down phase, then after acknowledgement (OK) of the error signal the image is automatically turned to the next: VISUAL.
VISUAL: Final image of data and bead quality check
In this image the stored welding parameters are shown. It is required to carry out a welding seam evaluation.
Take out the welded work piece and check the weld.
[pic]
For the evaluation criteria see chapter 6, Weld Quality.
After acknowledgement (OK or NOT OK), the image is automatically turned to HEATING ELEMENT; at the same time the weld tag is printed out (option).
If no printer is connected, it is necessary to acknowledge the inquiries, until the image turns to the next: HEATING ELEMENT.
Marking of weld
The tag, printed by the optionally available printer, has to be fastened next to the weld. It documents the proper execution of the welding.
The pipe area to affix the tag shall be free from dust and grease
(if required, clean prior to sticking) to provide for proper and safe
adhesion (tag is destroyed on removal).
[pic]
Place tag next to the weld for good visibility!
5.5 Error and system message
The Tables 5.2a/b contain error messages, edited by the red transmission window of warnings. These warnings must confirmed by the operator.
|Error no. |Message/Description |Clearance |
|01 |NO PLACE for DATA |Delete data of operating control unit on system level. Before deletion |
| |The internal memory of the operating control unit is |the data should be stored on a PCMCIA-card. |
| |full. | |
|02 |TOO MUCH FILES |Reduction of selected files. |
| |The free target memory is insufficient for the data to | |
| |be copied. | |
|03 |NO MEMOcard plug in |Insert keycard into PCMCIA-slot. |
| |No keycard in PCMCIA-slot. | |
|04 |ERROR FLASHcard |Contact technical service of AGRU! |
| |No access to internal memory of operating control unit. |(serious system failure) |
|05 |NO OPERATORcode |Insert keycard with valid operator code into PCMCIA-slot or newly |
| |Operator code is invalid or file unreadable. |encode the card on the system level. Should the message appear again, |
| | |check the card. |
|06 |ERROR TEMPERATURE |Wait until desired temperature is reached and the remaining time has |
| |Heating element has still not been released. |expired. |
|07 |NO INPUT |Enter data. |
| |Operator has tried to change to the next image without | |
| |input. | |
|08 |NO DATASAVE |Contact technical service of AGRU! |
| |No datasave possible! |(Serious system error) |
|09 |NO PRINTER |Connect printer or switch it on and acknowledge error. The program |
| |Printer is not connected or switched on, though in image|tries four printing starts. In case of another negative result, the |
| |INFO 1 the printer has been activated. |program is continued. |
|10 |TENSILE FORCE |Decrease the tensile force of the pipe and repeat the program cycle. |
| |The evaluated tensile force is too high. | |
|11 |EMERGENCY STOP |Unlock EMERGENCY-striking key. |
| |EMERGENCY-striking key is locked. | |
|12 |ENDPOSITION |Clear away positioning errors and activate the function once more. |
| |A control function has been activated in spite of | |
| |improper end positions of carriages. | |
|13 |HARDWARE SOFTWARE |Contact technical service of AGRU! |
| |The hardware (machine) is not compatible with the | |
| |software (operating control unit). | |
Table 5.2a: Error code
|Error no. |Message/Description |Clearance |
|14 |NO DATAREAD |Contact technical service of AGRU! |
| |System files on internal memory not available or unable |(New installation of system files required.) |
| |to read. | |
|15 |SystemERROR |Contact technical service of AGRU! |
| |No access allowed to parallel interface. |(Check operating control unit.) |
|16 |NO COMMUNICATION |Check plug-in connection and/or PC-cable. |
| |Disturbance or interruption of data transfer between | |
| |operating control unit and machine | |
|17 |WRONG OPERATORCODE |See Chapter 5.3, Program Description |
| |Operator tried to activate inaccessible system | |
| |functions. | |
|18 |MOTOR 1 TEMPERATURE |Acknowledge error and let motor cool down. If the message appears again |
| |Motor temperature of movable clamping unit is too high. |and again, have the motor checked. |
|19 |MOTOR 2 TEMPERATURE | |
| |Non applicable! | |
|20 |MOTOR 3 TEMPERATURE |Acknowledge error and let motor cool down. If the message appears |
| |Motor temperature of carriage for planing tool and |repeatedly, have the motor checked. |
| |heating element is too high. | |
|21 |MOTOR 4 TEMPERATURE |Acknowledge error and let motor cool down. If the message appears again |
| |Motor temperature of planing tool drive is too high. |and again, have the motor checked.. |
|22 |MACHINE STOP |Acknowledge error message and end welding procedure or repeat it. |
| |Welding procedure has been stopped manually or after | |
| |expiry of adjustment time. | |
|23 |NO SAVE OLD DATA |Contact technical service of AGRU! |
| |No storage of historical data possible. |(Check operating control unit). |
|24 |INADEQUATE POWER |Check mains lead! |
| |Supply voltage is too low. |(Non-permissible line length or cross section) |
|25 |WRONG KEYCard |Report, when trying to create a new operator card with AGRU4 |
| |No access | |
|26 |WRONG CODE |AGRU1 to AGRU3 are secured operator codes. |
| |Create a new operator code |Only AGRU4 are recordable! |
|27 |NOT IN LIST |Input of correct file name |
| |File not found | |
|28 |WRONG VERSION |Contact technical service of AGRU! |
| |Invalid format of file | |
|29 |POWER OFF |Switch on heating element |
| |Heating element switched off | |
Table 5.2b: Error code
Table 5.3 contains important messages, which are issued by the information line (red background).
|Message/Description |Clearance |
|Press Button |Press the green RELEASE-key and simultaneously activate the desired |
| |function over the touchscreen. |
|OPEN CLAMP |Open movable clamping unit. |
Table 5.3: Messages in information line
6 Weld quality and welding parameters
(valid for IR- and heating element-butt welding)
Materials: PVDF, PP, ECTFE and PP-natural
[pic]
6.1 Welding bead
Ideally (normally) built-up welding bead
6.2 Weld failures
Below you find possible reasons for non-conform quality evaluated by the welder (by visual control according DVS 2202 Part 1).
With all weld failures due to the mentioned causes it is required to repeat the welding.
Cracks
Cracks, parallel or cross to the weld. Cracks may occur:
• in the weld
• in the basic material
• in the heat affected zone
Cause: Material defect
Bead notches
Continuous or local notches in longitudinal direction of the weld with the notch root in the basic material, for example caused:
by insufficient joining pressure
if pre-heating time is too short
if cooling time is too short
Cause: Pipe dimension or type of material inadequately set, end caps not applied!
Notches and striae
Marginal notches in basic material, longitudinal or cross to the weld, for example caused by:
clamping tools
inappropriate transportation
faulty preparation of welding seam
Offset of joining areas > 10%
The joining surfaces are offset, differences in thickness are not compensated.
Cause: Offset compensation not realised.
Angular deviation
for example by:
machine malfunction
faulty alignment
Cause: Pipe supports inadequate (e.g. at great distances)
Narrow, excessive welding bead
Excessive and sharp-edged welding bead locally or all along weld length or weld circumference, caused by inadequate welding parameters, in particular by:
excessive joining pressure
Cause: Pipe dimension or type of material inadequately selected.
Non-uniform welding bead
Non-angular joining surfaces resulting in diversely built-up welding beads locally or all along the weld length, caused for example by:
faulty preparing of weld (improper planing)
acceptable variation of the too beads b1 ≥ 0,5 x b2
Bonding failure
No bonding or insufficient bonding on joining surfaces, locally or all
along the weld cross section, caused for example by:
• contaminated joining surfaces
• oxidised joining surfaces
Bubbles(1)
Voids on the joining surface, caused for example:
• if joining pressure is too low
• if cooling time is too short
Cause: Pipe dimension or type of material inadequately selected.
Pores caused by inclusions of foreign matters
Individual, largely distributed or locally frequent pores or inclusions, caused for example by:
• vaporescence during welding (water, solvents,....)
• dirty heating element (heating element-butt welding)
(1) Note: At higher wall thicknesses (OD > 110 mm) especially for PVDF-material sporadic bubbles occasionally occures outside the joining (bead) area.
Extensive mechanical tests and pressure tests acc. DVS- and ISO-standard have shown, that this has no influence to the joint quality. In case that bubbles are occuring only in the bead area and not in the meld zone, this joints can be verified as good joints.
6.3 Welding parameters
All welding parameters, such as pre-heating time, pre-heating temperature, joining distance, joining pressure and cooling time are pre-set by the computer and correspond to the regulations of the DVS. All of them are recorded completely and indicated on the touchscreen and/or stored to be retrieved at any time. Additionally, they can be stored on a PCMCIA-card and evaluated by the SP-DATA-program.
The equipment is designed and programed to weld the following components:
- Pipes, fittings and valves manufactured acc. ISO, CEN or DIN-standard
|Materialtype |Dimensionrange (OD) |SDR- (Pressure-) rating |
|PVDF, PVDF-HP |75 – 250 mm |SDR 33, SDR 21 |
|ECTFE, ECTFE-HP |75 – 160 mm |SDR 21 |
|PP, PP-HP, PP-natural |75 – 250 mm |SDR 11 |
- Other dimensions, pressure ratings (SDR) and material types can be programed acc. Request and check of the technical suitability. For more information please contact AGRU.
6.4 Weld labelling
One part of quality assurance is the marking of the weld by a
safety tag. In addition to general data for identification the
quality code is printed on the tag.
After proper welding the code WELDP.OK is edited.
Failures or deviations are indicated by a eight-digit numerical code (0 = no failure, 1 = failure). In Table 5.4 you find the explanations of the code functions.
|Digit |Function |Digit |Function |
|Bit 0 |Joining pressure |Bit 4 |Joining path (pipes slipping through) |
|Bit 1 |Heating element temperature |Bit 5 |Data transfer |
|Bit 2 |Emergency stop (EMERGENCY-key) |Bit 6 |No fuction |
|Bit 3 |STOP-function |Bit 7 |Visual control |
Table 5.4: Quality code
|Bit 0 |Bit 1 |Bit 2 |Bit 3 |Bit 4 |Bit 5 |Bit 6 |Bit 7 |
|0 |1 |0 |0 |0 |0 |0 |0 |
e.g. temperature failure:
For each welding 0 to 3 tags can be selected and printed (see page 14).
7 Maintenance
At proper operation the welding machine SP 250 is nearly maintenance-free!
[pic]
Pull out mains plug before you perform any kind of cleaning or maintenance work!
Before starting work clean SP 250 by means of fluffiness paper and cleansing agent.
Wipe touchpanel and heating element only by means of slightly moist fluffiness paper.
Never apply compressed air at the machine.
7.1 Fuses
[pic]
Basically, first it is required to define the cause and fix the fault before the safety cut-out is replaced and started up again (Table 7.1)!
|Marking |Type/Notes |
|F1 |B 10A, safety cut-out for planer |
|F2 |B 20A, safety cut-out for heating mirror |
|F3 |B 10A, safety cut-out for power pack and socket |
|F4 |T 0.2A, glass tube fuse 5x20mm for nitrogen purging |
Table 7.1: Fuses on machine panel
Additional fuses are contained within the machine (see service instructions). However, only persons duly authorised by AGRU are allowed to open the machine.
7.2 Lubrication
Observe the following rules:
The guides and threaded drives must always exhibit a visible grease film.
Greasing again shall be performed at least every year!
You should prefer repeated greasing in partial quantities to a single greasing again at the specified time.
Lubricants
All of the ball screw guides have to be lubricated by means of lithium base grease of consistence class 2.
|Manufacturer |Brand name |Running distance/lubric.interval |
|Mobil |Mobilex 2 |100km |
|Texaco |Multifak 2 |100km |
|Esso |Beacon 2 |100km |
|Klüber |Staburags NBU 12/300 KB |200km |
Table 7.2: Lubricants (examples)
All ball screws and fine pitch screws have to lubricated by means of roller bearing grease type KP2K according to DIN51825.
7.3 Repair of failures
In the list below (Table 7.3) some disturbances are treated, their possible causes and clearance. In case they cannot be cleared away or they are not mentioned below or if the machine components are defective, please contact the technical service of AGRU.
|Failure |Cause |Clearance |
|Planing tool running tightly, planing surfaces |Planing tool knifes are dull. |Replace planing tool knifes. |
|won’t get plane really, chatter marks. | | |
|Planing tool doesn’t work. |Safety cut-out turned off. |Switch on safety cut-out. |
|Heating plate surface has come into contact with| |Clean cold heating element only with paper (sharp |
|plastic. | |objects would damage the surface!) |
| | |Leave heating element switched-on. Plastic evaporates |
| | |by itself within a short period of time. |
|Welding temperature not reached. |Safety cut-out turned off. Mains |Switch on safety cut-out. |
| |voltage too low. |Check mains lead (dimensions). |
| | | |
| |Connection SP 250 => heating element is|Check plug connectors. |
| |defect- | |
|No display shown after starting. |Safety cut-out turned off. |Switch on safety cut-out. |
| |Connection SP 250 => |Check plug connector. |
| |operation control unit is defect. | |
|Printer does not react. |Connections are defect. |Check plug connection. |
|Control commands are not executed. |Position is incorrect. |See chapter 5, working process. |
Table 7.3: Failures of SP 250
4 Servicing, Seminars & SP-DATA
[pic]
After 1500 welding operations and/or annual servicing intervals are required.
AGRU is also providing seminars for customers. These training consists of:
- Use of the tool
- Maintenance of the tool
- Verification of the joint quality
- SP-DATA software package (This program is specially designed for the organisation, management and evaluation of the stored welding parameter reports using a PC or notebook. For more information about this program please contact AGRU.)
For immediate service, questions regarding this tool/manual or more information, please contact AGRU Kunststofftechnik GmbH.
Phone: +43 7258 790 324; Fax: +43 7258 790 430
e-mail: anwt@agru.at
8 Transportation and storage
8.1 General information
Transportation of complete SP 250 to be carried out only in original packing.
Avoid pushes and concussions during packing and transportation.
Due to the construction of basic frame, the packed machine can be shifted with a forklift. No additional wooden pallets are necessary.
Transportation of SP 250 is also possible by plane.
[pic]
Two men’s work is required for dismounting and mounting of the packing.
8.2 Unpacking of SP 250
Open the locks (1) and remove the front part of the packing (2).
Unscrew the lateral screws (3) and remove carefully the main part of the packaging (4).
Fig. 8.1: Unpacking of the SP 250
8.3 Packing of SP 250
Before dismounting of SP 250:
Move heating element and planing tool back into transport position.
Move movable clamping unit outside to the right (zero position) in order to relieve load cell.
[pic]
After switching off the SP 250 wait for 2 hr. at least and let heating element cool down.
Clean machine.
Fasten heating element and planing tool in transport position by means of a locking screw.
Disconnect all the electrical connections.
Dismount operating control unit, printing unit (if applicable) and nitrogen purging unit.
Stow all dismounted parts into the designated position (box).
Roll up connection cables, coming directly from the SP 250 and lay them onto the machine.
Fold down rocker arm (7) and tighten hand screw.
Close clamping jaws and clamp them.
Close the box with the dismounted parts and lock it (6).
Put the main part of the packaging (4) over the machine and fix it with the screws (3).
Put the front part of the packaging (2) onto the metal supports (5) and close the locks (1).
8.4 Storage
Store the SP 250 in the transport case in dry and weathering-resistant condition.
Avoid high fluctuations of temperature - possible build-up of condensed water.
As for the permissible storing temperature see chapter 3, technical description and characteristics.
9 Equipment and accessories
The scope of delivery comprises the parts mentioned below:
Welding machine SP 250
|Quantity |Description |
|1 pc. |Base frame with mounting and carriages |
|1 pc. |Heating element SP 250 |
|1 pc. |Planing tool SP 250 |
|1 pc. |Electronic unit |
|1 set |Clamping jaws SP 250 (4 pcs.) |
|1 pc. |Operating instructions |
|1 pc. |Operating control unit (Touchscreen) |
|1 set |Reducing inserts (4 rings, three-piece per ring) for the following pipe dimensions: |
| |75, 90, 110, 125, 140, 160, 180, 200, 225 mm |
|1 set |Sealing caps (4 pcs. each) for the following pipe dimensions: |
| |75, 90, 110, 125, 140, 160, 180, 200, 225, 250 mm |
|1 pc. |Entry/memory card (PCMCIA) mode level 3 |
|1 pc. |Packing case |
Options
|Quantity |Description |
|1 pc. |Printer with transformer installed, operating instruction and accessories |
|1 roll |Special tags (1000 pcs.) |
|1 pc. |Enlargement of butt welding equipment |
|1 roll |Thermoribbon |
|1 pc. |Nitrogen purging unit |
|1 pc. |PC-program for welding data documentation (SP-DATA) |
10 SUPPLEMENT
10.1 Spare parts and expendable material
|Quantity |Description |Type/Notes |
|1 set |Reducing inserts SP 250 |OD75 |
|1 set | |OD90 |
|1 set | |OD110 |
|1 set | |OD125 |
|1 set | |OD140 |
|1 set | |OD160 |
|1 set | |OD180 |
|1 set | |OD200 |
|1 set | |OD225 |
|1 set | |OD250 |
|1 pc. |Plane knife SP 250 |hardened |
|1 pc. |Heating cartridge SP 250 |10H7x305mm, 280mm heated |
|1 pc. |Thermal probe SP 250 |6H7x145mm, Pt100 special |
|1 pc |Heating element SP 250 |coated |
|1 pc. |Enlargement of butt welding equipment SP 250 |2x mounting plates, tefloncoated, incl. Screws |
|1 pc. |Operating control unit |Touchscreen |
|1 pc. |PCMCIA-card |S-RAM, 64K-Byte (AGRU4) |
|1 pc. |PCMCIA-card |S-RAM-1M-Byte (AGRU3) |
|1 pc. |Rocker arm, long |600 mm, (for operating unit and printer) |
|1 pc. |Transport case SP 250 | |
|1 pc. |Transformer for printer |230VAC/14VAC, 56VA |
|1 roll |Tags |1000pcs., 25x40mm, narrow, polyacrylic sheet |
|1 roll |Thermoribbon |33mmx91m, polyester resin |
|1 pc. |Printer cable |100 cm, parallel |
10.2 Installation guidelines for AGRU PURAD high-purity pipeline systems
Material: PVDF-HP, PP-HP and ECTFE-HP
10.2.1 Design and pipe installation
• There should be only a minimum of welds and fittings. If possible, avoid expansion loops in overhead all elevated or low pipeline sections. Ventilating valves and drain valves should be furnished with pipelines. In unavoidably low pipeline sections install drain valves.
• Unless otherwise agreed, install valves in a plug or cap on the discharge side.
• Pipe clips must be installed in a way appropriate for plastic considering the installation guidelines acc. to DVS 2210 part 1. In order to keep stresses low within in the system, only injection-moulded components specifically dimensioned for the intended use shall be applied as fixed points.
• The number of detachable connecting elements (flanges, screwed connections) shall be minimised. Prefer welded connections to detachable connections.
• Install flanged joins in stress-free condition. Apply cleaned sealing (e.g. Frank profiled flange sealing of EPDM/PTFE-HP adequately cleaned and packed), realising an efficient sealing appropriate for plastic with low starting torque’s.
• Branches from the main line to a branch line with dimensions changing should possibly be performed with zero dead-legs or the least possible by way of tees with reduced branches or by injection-moulded instrumentation parts.
• Dead-leg sections should be minimised directly by way of using bypass loops or installation of a minimum-flow line with return function.
• The inner system volume should be minimised by installing zero dead-leg valves, and highly-integrated assembly/arrangement of component parts as well.
• The ultra pure water system shall exhibit a continuous flow rate at a minimum speed of 0.5 m/s.
• The system should be protected from backflow/back stroke.
• Suitable component parts should be chosen at points for sampling and constitutional indication, which also depend on the methods of analysing and testing. The components should not have dead spaces at all or only the minimum admissible number and enable sampling directly in the volume flow (instrumentation fitting, bacteria sampling fitting etc.).
• Observe a vibration-reduced installation of pumps.
• Provide devices for disinfection (e.g. zero dead-leg injection valves). Sensible components as ion exchange resins must be secured before coming into contact with the corresponding reagents).
10.2.2 Admissible products
• The material specification comprises pipes, fittings, valves, and flow meters, which come into contact with super-clean/ultra-pure water.
• Preferably, the raw material used for all the different systems/components should be made of identical moulding materials.
• Pipes, fitting and valves made of PVDF shall be in accordance with ISO 10931 parts 1,2,3 and 4. For pipes and fittings made of PP DIN 8077/8078 shall be applicable.
• Only pipes and fittings with the specific permission by DIBT are admitted for usage.
• All components must be fabricated in clean rooms (min. class 1000) and cleaned by ultra pure water before packaging. Packaging has to be carried out in clean rooms (min. class 100).
• All extruded and injection-moulded components must have been furnished with a test certificate according to DIN EN 10024 3.1 B.
10.2.3 Receiving inspection of products
• After cleaning all components must be packed and delivered to the place of installation.
• The double packing should be opened only shortly before the pre-assembly or final assembly. This does not apply to the incoming quality control (IQC), performed in a temporary clean room. After opening for the purpose of incoming control or pre-assembly the machine must be packed again properly; the components shall remain double-packed for further storage.
• Re-packing should correspond to the standard of the original packing, otherwise the material shall be rejected or exposed to repeated cleaning.
• When pipes or fittings are brought into the temporary clean room, the outer packing is removed on entering the clean area.
10.2.4 Storage of material and components at the place of installation
• Before pre-assembly or final assembly all the delivered material should be stored in a confined specific area, adjacent to the clean room for processing.
• All incoming components for installation should be kept for intermediate storage in their original packages in a dust-free place at room temperature, protected from sunlight. Pipe material shall be stored horizontally - for this supports are necessary up to OD 63 mm at distances of at least 0.5 m. From OD 75 mm on supports should be at 1 m distances.
10.2.5 Clean room clothing
The clothing mentioned below must always be worn in the clean room and in the temporary clean room as well. It must not be worn outside these areas. Damaged parts of clothes shall be replaced immediately.
• Clean room dress
• Helmet
• Plastic apron
• Protective shoes
• Protective mask
• Gloves with band
• Safety goggles or screen
10.2.6 Welding and installation
• Laying and installation may be performed only by authorised plastic welders (examination of welders acc. to DVS 2212 part 1, subgroup 18).
• The certified plastic welder should possibly have got some experience in the installation of high-purity-piping systems in the semi-conductor industry. However, it is also possible to perform on-site welding training of qualified specialists, who have not been experienced in HP-pipeline welding so far.
10.2.6.1 Pre-assembly
• Pre-assembly shall take place on site in a separate, temporary clean room of class 10.000.
• This room shall at any time be operated at an overpressure of 15 Pa.
• Although the components are handled in a clean room, they shall be kept closed, when they are not processed. Sealing should be by means of PE-sheets or caps.
• Assembly and packing should be performed within the clean room on a clean workbench with a surface made of stainless steel or polypropylene.
• Contamination of the inner surfaces of pipes and components should be avoided by careful handling.
• If possible, pipe sections should be produced in the clean room, in order to minimise the amount of field welding.
• In the temporary clean room and in the entrance area no „particle-emitting“ material is admissible, such as paper, cardboard or wood. If required, components should be stored in plastic containers.
• Tacky mats should be placed at the entrance and exit, and replaced if necessary.
• Packing have to be removed in the entrance area.
10.2.6.2 Instruments and equipment
• Make available specifically selected clean-room instruments, which have to be stored separately and are allowed exclusively for the installation of HP-plastic piping systems.
• Always consider that the heating areas must be clean and free from any material residues, which could lead to discoloration and impure joining areas.
• The instruments have to be cleaned at the beginning of each shift.
• Only clean room wipers (clean and fluffiness) should be used.
• All instruments, connecting equipment and heating elements, having direct contact, have to be tefloncoated or made of stainless steel, in order to avoid contamination with metals or greases during the joining process (this is non-applicable for IR-welding).
• All instruments and areas in the clean room must be kept free from chips. It is left for the QSV to stop any procedures which affect the quality of installation. Preparing and execution of welds.
10.2.6.3 General information on the welding technique
• The welding procedures and handling of the welding equipment, recommended by the manufacturer and laid down in the operating instructions have to be observed.
• The procedure shall be agreed upon between the quality system manager (QSV) and the system manufacturer well before installation.
• Also, on qualification of the welding process the acceptance criteria for the welds and test welding are defined (coupons).
• Cutting into length should be performed by means of pipe cutters equipped with a cutting wheel. The cutting tools should be especially suitable for this system and always kept clean.
• Cutting into length and working of the faces shall take place in clean rooms of class 1000.
10.2.6.4 General rules on installation
• The quality level of the materials should be maintained - from delivery up to the finished project.
• No smoking or eating is allowed during working time.
• Incoming control of material and marking of quality level according to the user’s standards of marking and labelling.
• No use of gas-heated instruments is allowed.
• Pipe fitters and helpers, who are concerned with the manufacture and installation of the piping system, must always wear clean room clothes and gloves.
• Clothes and gloves must be replaced during the shift, in case if they are worn out or damaged by extraordinary contamination.
• Do not touch the inner surface of any kind of pipe component - neither in gloves.
• Valves and fittings must be further processed directly after unpacking and protected from contamination at any single moment.
• Pipes and components shall be handled carefully to avoid damaging or scratching of the outer surfaces.
• The system should be purged by a filtered nitrogen stream, which is interrupted during welding. Mark IR-welding joints by an adhesive clean tag, if possible, directly (with SP 110 an SP 250).
11 Attestation of conformity
The manufacturer:
Ing. Wilfried HUFNAGL, Volkgasse 8, 1130 Wien
Confirms that the following described machine:
Welding machine SP 250
Corresponds to the requirements of the following European Standards:
89/392/EWG (Machine)
89/336/EWG (Electromagnetic compatibility)
73/23/EWG (Low voltage)
The following harmonised Standards have been used at the design and construction of the machine:
EN 50081-1: 1991; EN 50082-1: 1991
ÖNORM EN 292-1: 1992-03; ÖNORM EN 292-2: 1995-07
ÖVE EN 60204-1: 1993-02
Vienna, 15. 03. 1998
Ing. Wilfried Hufnagl
12 Guarantee Claims
GUARANTEE CLAIMS AND COMPENSATION FOR AGRU-WELDING EQUIPMENT SERIE SP
1. Guarantee
1.1 AGRU is obliged to repair or change immediately all parts, which are damaged or useless as a result of worse material, incorrect construction or insufficient design. The kind of performance and the place of repair are only decided from us. The replaced parts will be our property.
1.2 Other guarantee claims of the buyer are excluded - also special or tacitly promised properties of the delivery („dicta et promissa“).
1.3 If not agreed separately, we will only pay costs which resulted from the repair or the replacement of the claimed parts in our workshops.
1.4 The buyer is obliged at the loss of all guarantee claims to inform us writtenly about the appeared damages.
1.5 The guarantee period is 6 months. It begins with the dispatch of the shipment ex works.
1.6 The guarantee period acc. 1.5 will not be elongated by the repair or acceptance, neither for the main delivery nor for the new parts, also in case of the replacement of new parts into the main delivery.
1.7 The buyer is obliged to return the claimed goods or the claimed parts for the repair or replacement on request to us or a from us determined third party; in that case, the buyer takes the costs and danger of transport to us, as well as the transport of the repaired or replaced parts back to him.
1.8 The guarantee excludes damages as a result of natural wear and tear, poor maintenance, disregard of working instructions, excessive stressing, unsuitable working supports, chemical or electrolytical influences, as well as owing to other reasons, which are not based on our faults.
1.9 The guarantee expires if the buyer or a third party perform changes or repairs on the delivery without our written consent; moreover, if the buyer does not perform suitable measures immediately in order to contain the damage and if we can repair the fault.
1.10 From the begin of the guarantee, the vendor takes no further liability than mentioned in this article, also not for damages whose reason is before the danger transition.
1.11 This equipment is developed and designed for the welding of AGRU-piping systems acc. to the best of our knowledge and belief. AGRU takes no liability for faulty welding joints and resulting damages, whatever it concerns.
1.12 We have no experiences about the weldability of the equipment with competitor products. According to this, we cannot take over liabilities or other guarantees for the suitability of the equipment with manifold products.
1.13 Basically, it is agreed that the operator of the machine has to observe absolutely the corresponding operation instructions, specially the welding guidelines and directions from AGRU.
2. Compensation
2.1 The compensation duty concerns us only if a gross mistake can be proved. Compensation for an escaped profit is excepted in any case. If the damage appears in the from us delivered part, we are obliged to perform the change only within the scope of the guarantee.
2.2 The purchased part offers only the security which can be given on the basis of approval regulations, operation instructions and regulations from our part about the handling of the goods, specially with regard to possibly prescribed checks and other given advises.
2.3 All compensation claims from faults on deliveries and/or works have to be maintained legally within the contractual decided guarantee period, otherwise expired - if the fault is not accepted expressly.
3. Place of fulfilment and legal domicile
3.1 Place of contract and fulfilment is Bad Hall / Austria, also in case that the transition is agreed for another place.
3.2 The buyer is not allowed to give his contract rights to a third party without our consent.
3.3 The contract will be courteously in its conditions also in case that some items will get ineffective.
3.4 The contact is subordinated to the Austrian Law.
3.5 For all indirect and direct disagreements resulting from this contract, the factually responsible court of justice of the company AGRU is responsible. The buyer could also call another court of justice, which is responsible for him.
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Heating
element
Operating control unit
Printer
Mains supply -> SP 250
Printer transformer -> SP 250
Operating control unit -> Printer
Indication of heat errors
SP 250 ->
Operating control unit
GREEN
SP 250 -> Nitrogen purging
SP 250 ->
Heating element
RED
optionallyy
Nitrogen purging
SP 250
LOCKED
UNLOCKED
Change to
OFFSET CONTROL
Function STOP
6
5
Clamping unit CLOSED
Clamping unit OPEN
Change to PLANING TOOL
Function stop
4
[pic]
[pic]
Clamping unit CLOSED
Planing tool pressure
Clamping unit OPEN
Change to
INFO 3
Function stop
Planing tool control
Shifting way
Spec. welding pressure
Pre-heating time
Pipe characteristics
Joining pressure
Cooling time
Change to HEATING ELEMENT
Change to PLANING TOOL
Pressure ramp
Release of heating temperature
Warm up time for heating element
Display of active method
Change to WALL
THICKNESS
Change to
INFO 3
ON/OFF-key for heating element
Selection of welding method
Change to image
DIAMETER
Change to HEATING ELEMENT
Select menu
Display of selected wall thickness
Change to
MATERIAL
Change to WALL THICKNESS
Select menu
Display of selected diameter
Change to
INFO 1
Change to DIAMETER
Select menu
Display of selected material
Clean room
Confirmation of input
Selection of clean room class
Selection of environment
Standard room
Confirmation of input
Keyboard for address input
Display of address input
Selected file
Selection of file
Number of stored data
Take-over and indication of selected file
Change to
INFO 1
Selection of memory medium
Open windows for manual input of file name
Welding characteristics
Pressure curve
Change to
INFO 2
Number of tag printouts per welding
Change to
LOGO
Change to MATERIAL
Protocol characteristics
Change to ROOM
Change to ADDRESS
Operator code
Establish machine settings
Test printer
Set system time
Copy and delete Data
Change to
INFO 1
Establish welding table
Change to
LOGO
Informationline
Program version
Change to
INFO 1
Change to
SYSTEM
Machine characteristics
Track force
Function START
Time counter
Welding curve
7
8 Wird der Schweißvorgang vor dem Fügen abgebrochen oder dauert der Umstellvorgang zu lange so
erfolgt nach Bestätigung der Fehlermeldung ein automatischer Wechsel in das HOBEL.
Welding characteristics
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Check inquiry
tag
Weld No. No.of tag
Date Time
Machine number
Pipe characteristics
Quality code
T
y
p
e
[pic]
b2
2
3
[pic]
[pic]
1
7
6
5
3
2
1
4
Language selection
Operator card information
Selection of current for heating
Indication of ambient temp.
Indication of power supply
Move heating element
Indication of heating element temperature
Desired pressure curve
Heating element temperature
Pipe characteristics
Joining pressure nominal
Total welding time
Error code
Joining pressure actual
Shrinkage distance
[pic]
Pre-heating control pressure
[pic]
b1
[pic]
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35 Green St.
Malden, MA 02148
asahi-
Phone: 781-321-5409
Fax: 781-321-4421
Email: asahi@asahi-
35 Green St.
Malden, MA 02148
asahi-
Phone: 781-321-5409
Fax: 781-321-4421
Email: asahi@asahi-
................
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