1 Grundlegende Sicherheitshinweise
Contents
1. gt Caution iN Parts Under Power After opening the machine or removing the cover parts of it are accessible that may be under power The device may be opened exclusively by an authorized service shop Pipe Facing Tool Start the pipe facing tool only when it is in its working position When facing pipes do not wear jewelry if needed wear a hair snood or net It is forbidden to remove shaving from the machine while the facing process is running Make sure nobody is present in this danger zone Heating Plate When working with the machine be extremely cautious while the heating plate is operating Since the heating plate and its guard presents a very high temperature during the welding process it must not be operated if unobserved and sufficient distance has to be ensured to combustible materials in its surroundings Do not touch the heating element or the heating element guard Danger of Bruises and Injury Do not remain in the danger zone while the machine opens or closes and be sure not to have your hands between the moving and the fixed parts of the machine agru SP 110 S User s Manual Version December 2006 Ensuring Acceptable Work Conditions is dangerous to operate in a humid environment or close to The work zone has to be clean and has to have proper lighting It Caution flammable liquids In regard of this acceptable work conditions have to be ensured e g sufficient distance from the machine to o2. NE RONE MENU AAE 19 SEENDE e EE AETA EA AAAA E T A T A O A EEAS ETA A 21 Senice and Repa COM ACE maa anan iea ane aa aaea aer 22 agru SP 110 S User s Manual Version December 2006 1 Introduction Dear Customer Thank you very much for purchasing our product We are confident that it will meet your expectations The development manufacture and check of the infrared welding machine has been guided by our concern to offer a unit characterized by superior operation safety and user friendliness The unit was manufactured and checked according to state of the art technology and widely recognized safety regulations To ensure maximum operation safety please conform to the appropriate messages in this booklet and the regulations for the prevention of accidents Carefully read the User s Manual to avoid damage to the machine or hard ware in its environment as well as injury This manual is applicable to the following machines agru SP 110 S Thank you 2 Safety Messages This User s Manual contains important instructions for operating safely the infrared welding machine agruSP110S Every person who operates the ma chine will have to conform to the instructions of this manual The machine has been developed and checked with respect to welding AGRU materials For welding other makes no experiential data are available and or no liability or warranty can be assumed for the fitness and the reliable operation of the machine 2 1 The U
3. all the weld All Reports ing reports stored in system memory to be printed While the machine transfers the re ports a countdown indicates how many of them remain to be printed or transferred By Commission Number By Date The options By Commission Number and By Date lead the operator to the next screen in which arrow buttons can be used to browse through the reports in system memo ry to select the desired commission or date from which reports should be printed or trans Display 18 ferred see Display 19 The options show the first available commission number or date and once the desired one is found the selection has to be confirmed by Ok to start the transfer to prin ter or PC MA EE agru SP 110 8 26 05 05 15 33 If the machine displays a Printer not Ready UU error message after you touched the Ok button the printer has to be switched to on line mode Check for potentially damaged connections from the machine to the printer or the PC If you transfer the data to a PC make sure that the correct baud rate and interface type are set on the PC gt gt Depending on the printer used O make sure Auto Carriage Return and or Auto Line Feed are Info enabled if necessary so as to print the reporting protocol in the Display 19 correct format After successful printing the machine displays a message telling the welder that printing was o k 5 2 Showing Reports i
4. instance if only one wall thickness is defined for a given pipe diameter the wall thickness selection screen will not show Moreover when you select an additional material this has to be confirmed by entering the so called selection code see sub section 4 3 Default materials can be welded with out entering this code The machine must never be used to weld pipe materials diameters and thicknesses other than those available in the key I3 welding data screens The manufacturer is in no circumstances Important liable for damage or consequential damage that occurs as a result of deviations from these pipe data or of modifications or attempted modifications to the control software Furthermore this will cancel any claims to warranty expressed for the machine To make a material available in this screen it has to be entered previously with all its technical welding parameters in the configuration menu Welding PFA pipes is subject to a valid license for this pipe ma E terial Therefore when this material is selected either from the default materials or from the additional materials if defined a Info message to this effect is displayed The license key is disclosed either by the manufacturer or the distributor of the machine or when you purchase the PFA pipes and can then be entered in the machine parameters In all screens that allow changing the key data for the welding operation by touching the Additional Data button
5. should also be used to store the machine The machine has to be stored in a dry location be clean or has to be cleaned and be locked against unwanted operation Infrarot StumpfschweiBmaschine 2 8 Identifying the Machine Typ agru SP 110 S es ae a m Nr 11006011 Each machine is identified by a name plate It shows the machine model Netz 230V IP54 50 60Hz 1700W Typ the serial number Nr and the manufacturer Hersteller agru Kunststofftechnik Ing Pesendorfer Str 31 A 4540 Bad Hall CE Tel 43 7258 7900 3 Product Description and Principles of Operation 3 1 Intended Use The agru SP 110 S Welding Machine is designed exclusively for welding plastic pipes and fittings using the infrared welding technique butt welding without contact Only the welding parameters shown on the touchscreen display prepro grammed by the manufacturer or defined by the user can be selected for a welding operation Any modification of the welding parameters contained in the control software is strictly prohibited It is also part of the intended use to conform to the instructions provided in the User s Manual The manufacturer can in no circumstances be held liable for I3 damage or consequential damage that occurs as a result of the Important non compliance with the procedures described in the User s Manual the modification of the manufacturer programmed welding parameters or non intended use Any such deviation or modification
6. the preset time Enter the desired date and time of day on the keypad after each input the machine moves on to the next field automatically then touch the Disabled button This button shows the current status of the automatic heating when you touch it it changes from Disabled to Version December 2006 agru SP 110 S User s Manual 21 Display 22 Enabled as the automatic heating feature is now on II Enabling the automatic heating feature should be the last action before you leave the worksite For it causes the power supply to Important the heating element to be stopped it cools down and the screen displays only the automatic heating data Any further action with the machine requires automatic heating to be disabled first This can be done by touching either the Cancel button or the Enabled button which changes back to Disabled after this status change If automatic heating is neither canceled nor disabled it makes sure that the heating element starts heating at the preset time of day and switches itself off when doing so 7 Service and Repair Contact Asahi America Inc 35 Green St Tel 781 321 5409 Malden MA 02148 Fax 781 388 4749 Web www asahiamerica com E mail asahi asahi america com O We reserve the right to change technical specifications of the unit without prior notice Info 22 agru SP 110 S User s Manual Version December 2006
7. will cancel any and all warranties under which the product may be 3 2 Machine Description The machine can be used as an in shop installation and with anodized alu minum components it is also suited for clean room applications The ma chine enables users to enter the data that are relevant for the welding process and for the traceability of the welded joint From the entered welding parameters it calculates the applicable forces and temperatures and con trols the welding process automatically All welding and traceability data are entered either directly on a touchscreen panel or read from a bar code using a scanning wand The welding process in monitored in its entirety and saved to a welding report All welding reports can the be printed or transferred to a computer with a suitable pipeline net work management software such as DataWork agru 6 agru SP 110 S User s Manual Version December 2006 Using the menus displayed on the touchscreen the machine can be custo mized to the application in hand see section 4 3 Configuring the Machine 3 2 1 Component Overview Heating Element and Guard Facing Tool Position Handle of Facing Tool Fixed and Mobile Carriage of Machine Frame Scanning Wand Touchscreen Panel Set Screws for Compensation of Small Horizontal or Vertical Alignment Gaps Confirmation Button for Two Hand Mode Steps 3 2 2 Touchscreen Control Panel agru SP 110 S 26 05 05 15 09 Status Bar Title B
8. 0 5 26 05 05 15 02 0133 0018 dard welding process that will first launch the heat soaking phase or by pressing the Pre Heat button can pre heat the pipe butts before the welding process proper If he _ a touches the Pre Heat button he has to de cide in the next screen whether the left hand side the right hand side or both pipe butts are pre heated Touching Cancel will return the machine to the previous screen If in the control software the pre O heating time is set to 0 seconds the machine will skip to the heat Info soaking phase of the regular Both sided welding in all cases Display 13 E Using the pre heating feature is acceptable only for welding fittings of traditional materials or Important fittings to fittings pre heating is designed to be used only when the fitting is securely fastened While the welding procedure is starting with or without pre heating the machine controls and monitors constantly the temperature of the heating element and the welding force and time Nominal values and tolerance ranges are defined by the key data for the welding operation previously entered or confirmed If a value is not within the applicable tolerance thresholds the machine shows an error message to this effect and the welding process is aborted agru SP 110 S 26 05 05 15 09 Nom Force N Actual Force N 4 6 4 Heat Soaking Phase In the first welding phase the pipes close in on the
9. December 2006 agru SP 110 S User s Manual defined materials have already been entered and saved previously the unit shows a Material Input screen that resembles Display 8 Use the arrow keys in the upper area of the screen to Material switch back and forth between the various additional pipe materials currently in memo ry For every pipe material up to three pipe diameters can be defined and for each di ameter up to two wall thicknesses or SDR values By touching one of the Input but tons on this screen the key parameters for welding this material can be edited Touching the leftmost Input button in Display 8 will allow entering changing or deleting the welding parameters for 50 mm PE pipe with a 2 3 mm wall Using the second Input button from the left the welding parameters for 50 mm PE pipe with another wall thickness can be entered and all other Input buttons allow entering the parameters for PE pipe with other diameters Display 8 Options for Welding Parameters i a New Parameters As soon as one of the Input buttons was touched Display 9 shows From this screen Edit Parameters it is possible to edit in various ways the spe Bait Parameters cific data branch of which the Input button Delete Parameters was used to access Display 9 The button New Parameters allows entering from Lakas Sela Donp eka y scratch all welding parameters for th
10. Overview The welding process is performed as follows e Pipes are clamped into the frame depending on the form of the component to be welded this may mean that the outer clamps have to be re adjusted or that reducer inserts have to be inserted e Pipe ends are worked using the pipe facing tool until the machine tells you that facing is successfully completed e Pipe alignment is checked and confirmed on the touchscreen Semi automatic insertion of the heating element when inserting it the heating element has to be clean e After the heating element was inserted the pipes close in automatically at the predefined force e When the carriages close in they also align the heating element ex actly in between the pipe butts e At the same time the pipe butts are heated to the predefined tem perature e When the heat soaking phase is over the pipes are moved apart and the heating element is removed automatically e Once the heating element is removed the pipes close in again au tomatically e This is followed by a steady force increase until the fusion force is reached e The pipe then cools down at the predefined force e After the cooling time is over the force is automatically removed from the carriages and the pipe or fitting can be taken out of it 4 Operation 4 1 Check out Turning on Selecting the Display Language Place the machine on a level surface and ensure it cannot slide Sufficient distance has to be kept to o
11. PVDF welding touch the New button and Diameter 110mm move on to section 4 4 Wall thickness 2 1mm e change the machine settings in the con figuration menu touch the Menu but ton e to read a new welder ID code using the scanning wand or e display the date for the next scheduled Display 5 maintenance on the screen by touching New button for some time The first five options of the configuration menu are immediately accessible the other options will be displayed only after an access code for the ma chine the so called selection code was entered see Display 6 The menu has the items listed in the following table To toggle between various possi ble settings or to open a sub menu for a given menu item touch the appro priate button Some of the buttons next to menu option change their color when Info they were pressed and are then displayed as though the button is held down In this case the held down button mean that this menu option is the selected option The Configuration Menu contains the options listed in the following table Version December 2006 agru SP 110 S User s Manual 11 Display 6 Description Setting Data to be Entered Number of Tags Menu In a sub menu the number of tags to be printed for sticking them onto the welded pipes can be selected Show Reports Menu In a sub menu it is possible to select a job number in order to display the welding reports of this commi
12. Proweld Equipment Owner amp Maintenance Manual SP 110 S ASAHI AMERICA 35 Green Street PO Box 653 Malden MA 02148 Tel 781 321 5409 Fax 781 321 4421 Toll Free 800 343 3618 www asahi america com asahi asahi america com Direct Sales East 800 232 7244 Central 800 442 7244 West 800 282 7244 Contents 4 2 3 4 5 6 7 ee a NAA PAP 3 Oalety IMStructiOnS and Messages origi aaa aaa AA AJA 3 Zo medse s Manabat aaa aa aaah aa ied daa Aa 3 227 SEXING ILC ONS aa Aa AA a aa AN 4 28 ode Messages aa an a eae e 4 Sd lel dala anan an AA a nadaan 5 2 5 SONCE ANG FE Dall sc a Aa AA AA ANG 5 2 0 ransp Storage Si Omen ian kahan ed NAA an abah Nana UNAG AA 5 2 Identifying the Hydraulics Welding Control UI 6 Understanding the Matching cerere Fentress sigalot ada A ieee tes de Ana ted ahead doen aes hee pad 6 SA Machine Component a a se Ba Ana uy ae tec ee GNG KABA Bp 7 GEEAE deula bg alie 8 3 3 Welding Al aieka lea Gala 9 Opera Nama AA AGE E 9 4 1 Check out Turning on Selecting the display language ma a 9 4 2 Entering traceability data for the joint 10 4 3 Gonigurnno Me IMAGING ssori se a a eee ean toned mena 10 4 4 Changing key data of the WeIGING cccccccccccccsssseceecceeseceeccseueees a 11 4 5 Definition of the key data for additional materials rss 13 4 0 WENG Pr06E 55 NANANA PAGAN ALADIN Ka PANUNG Fre DONING IP elegia 19 5 1 ae
13. and Nom Force N Actual Force N Multifunctional Area changes depending on context of display Nom Temp C Display of data on welding E progress aldeak be Parameter menus to configure operation settings EZEZ von gd Input keyboards SM actual Time s Error messages Notes Navigation Bar with User Inter face Buttons Version December 2006 agru SP 110 S User s Manual 7 3 2 3 Ports and Switches Buzzer On Off Switch Power Supply Cord Temperature Sensor Emergency Stop Switch Scanning Wand Nitrogen Rinse Port Fuse Parallel Port Serial Interface Printer Power Supply 230 V Power Outlet 3 2 4 Specifications agru SP 110 S Power Characteristics Voltage 230 V Frequency 50 60 Hz Total Rated Power 1 58 kW 6 8 A Heating Element 1 35 kW Facing Tool 0 24 kW Welding Operation Specs Lo Welding Force 10 500 N Speed of Facing Tool approx 45 rpm Ambient Temperature operation 0 C to 40 C 82 F to 104 F Ambient Temperature storage 5 C to 50 C 23 F to 122 F Operating Range 20 110 mm 3 4 4 1 8 Dimensions W x D x H Machine placed in the transport box 830 x 1080 x 730 mm 32 2 3 x 42 1 2 x 32 2 3 Machine only 675 x 900 x 680 mm 26 9 16 x 35 3 8 x 24 4 5 Weight approx 90 kg 198 U S Ibs in box approx 140 308 U S lbs Maximum Carriage Stroke 145 mm 5 3 4 8 agru SP 110 S User s Manual Version December 2006 3 3 Welding Process
14. e deleted only after another safety warning was confirmed New Page in Menu _ specific key data for the joint to be welded Additional Materials Mw In a sub menu the key data for welding can be defined for pipe materials that are not available yet In the welding individual start screen see To do so touch the New button The screen that allows selecting the material of NAA PA the pipes that are going to be welded is then displayed on the touchscreen panel see Display 7 To select a material touch the Display 5 it is possible to change the weld appropriate button on the screen Default Materials are those pipe materials that are defined by default when the machine Addit Material EL CT is shipped Additional Materials if any are those pipe materials that were defined by the Add Data user in the definition screens accessible from the appropriate configuration menu option Display 7 12 agru SP 110 S User s Manual Version December 2006 see section 4 5 The maximum number of additional materials is three When the appropriate button was touched to select a pipe material the screen changes and displays the selection of pipe diameters with default and additional diameters just as for the materials Finally a third similar screen allows selecting the appropriate wall thickness Note that a screen will not appear if it would not make sense to display it For
15. ed if not in proper state of repair Before welding the welder is required to make sure that the state of the machine is in order Is During transport the heating element has to be secured with the transport lock at all times When installing the machine remove Important the transport lock before applying power to the machine 2 5 Warranty Warranty claims may be raised only if the conditions for warranty given in the General Terms and Conditions of Sale and Shipment obtain Further more the provisions and instructions contained in the User s Manual have to have been respected 2 6 Service and Repair As the machine is used in applications that are sensitive to safety considera tions it may be serviced and repaired only on our premises or by partners who were specifically trained and authorized by us Thus constantly high standards of operation quality and safety are maintained Version December 2006 agru SP 110 S User s Manual Is Non compliance with this provision will dispense the manufacturer from any warranty and liability claims for the unit Important and any consequential damage All machines that are new or newly programmed during maintenance or upon request is wished are shipped with the most recent software version 2 7 Transport and Storage During transport the machine must be at all times in the transport box it is shipped in Ensure that the heating element is locked during transport The transport box
16. eports stored in memory use the appropriate option in the configuration menu see sub section 4 3 Upon touching this button a safe ty warning asking if you really want to delete them appears on the screen and has to be confirmed to effectively delete the reports currently in memory 6 System Data 6 1 Setting the Date and the Time of Day When the Date Time sub menu was se lected in the configuration menu see sub section 4 3 the screen shows what is repro duced in Display 21 Set Date Time The time of day and the date can be set us ing the keypad shown on the touchscreen panel 6 2 Enabling Automatic Heating When the Automatic Heating sub menu was selected in the configuration menu see sub section 4 3 the screen shows what is reproduced in Display 22 This feature allows preprogramming a date and time of day when the heat ing element must start heating up This gives you the possibility e g to enter this evening a time for the following morning and then to start welding right after arriving at the worksite instead of waiting for the heating element to reach the appropriate temperature Display 21 For the automatic heating feature to work the welding machine has to be connected to the power supply and be switched on all the Date EE OS DS Time 06 20 time from preprogramming a time of day to the start of heating Both power supply failure and switching the machine off result in loss of
17. eroing calibration of the carriage position when it is switched on including when Important power is re applied after it was switched off using the emergency off button it is critical to zero the facing tool prior to the facing operation proper failing what it is not possible to ensure a joint of appropriate quality When the facing tool handle is located at Position 1 the machine asks the operator to close in the carriage see Display 10 This is done by touching the Move on button and simultaneously holding down the green confirma tion push button on the machine front Then follow the steps the machine indicates on the screen determine the facing road clamp in the pipes and move the facing tool to Position 2 the facing position Remember that every action that makes the carriage close in or pull away has to be confirmed in two hand mode with the appropriate button on the touchscreen panel and the confirmation push button on the machine front Before starting the facing process proper you can determine the facing road i e the distance that the carriage must travel during facing To change Version December 2006 agru SP 110 S User s Manual 15 the value displayed on the screen when the process reaches this step use the and buttons The travel length must be a minimum 3 mm After you changed the facing road you have to clamp in the pipes anew During facing the machine displays nominal and actual force along
18. he LED icon in the welding diagram that belongs to the welding phase with the malfunction turns red Distance Error The errors listed in the following table can be displayed on the screen Display 17 18 agru SP 110 S User s Manual Version December 2006 la Data Imput b System Clock Error The internal clock of the machine is defective re set the clock in the configuration menu System Error Malfunction in the control system of the machine power to the machine has to be turned off and unplugged immediately and the machine has to be sent to the manufacturer or an authorized service point for check and repair Type of Error Printer not Ready The printer or PC connected to the machine is not ready no communication faulty cable or if serial interface bad interface configuration Unit Maintenance Due The recommended service interval for the machine is over It should be sent to the manufacturer or an authorized service point for scheduled maintenance and service No Function Available A control touchscreen button switch was used for which no function is defined c Weiding Process Ambient Temperature Error The ambient temperature is out of the acceptable range from 0 C through to 40 C welding is not possible Distance Error The stroke of the carriage at facing change over or joining does not correspond to the expected distance it should travel welding has to be repeated Force Error The app
19. heating element with the defined welding force and are thereby warmed During the entire duration of the heating phase they continue to soak heat from the heating mirror without touching it Nom Temp C Actual Temp C Nom Time s Actual Time s Display 14 On the touchscreen the welding progress diagram indicates in which phase the welding currently is green LED icon In case of malfunction the welding process can be aborted by touching the Cancel button If the machine detects a malfunction the color of the LED icon for the appopriate phase changes from green to red agru SP 110 5 26 05 05 dre 4 6 5 Change over Phase At the end of the heat soaking phase the Carriages are moved apart automatically The heating mirror is removed from in between Nom Force N Actual Force N the pipes and the carriages close in again both actions occur automatically The welding progress diagram on the touchscreen indicates in which phase the welding currently is see Display 15 Version December 2006 Nom Temp C Actual Temp C Nom Time s Actual Time s agru SP 110 S User s Manual Display 15 The welder has to monitor the change over and must abort welding by touching Cancel in case a malfunction occurs 4 6 6 Joining Phase In the joining phase or fusion phase the machine increases the applied force in accordance with the force ramp calculated for the weld This fee oF moe m
20. is branch in the data tree of which the Input button was touched Data input proceeds as described at the beginning of section 4 5 from the name of the pipe material through to the temperature the facing force Touch the Edit Parameters button to change the value of a single welding parameter in the appropriate data branch Touching this button will let you access a screen in which the parameter you want to change can be selected from all the key data that need to be defined From that screen an input screen is accessed in which the value can be changed then confirm the change by touching the Ok button The Delete Parameters button can be used to delete that branch of the data tree of which the Input button was used to access Display 9 Delet ing has to be confirmed in another safety message and then the key data for welding the material from joining force to plate temperature are deleted along with the appropriate wall thickness or SDR If this wall thickness or SDR is the only one left for the pipe diameter in question then the diameter is deleted from the data tree too And if the thus deleted diameter is the only one left for this pipe material the entire tree including the material itself is deleted By touching the Delete Parameters Completely button it is possible to delete the parameter of all additional user defined pipe materials Here too deleting i
21. it is possible to access the additional traceability data and change them as needed 4 5 Definition of Key Welding Data for Additional Materials The configuration menu see section 4 3 has an option Additional Mate rials which allows defining the key data the machine should use when welding pipes of a material that is not currently available in the machine If no additional operator defined pipe material has been saved to system memory the unit displays an input screen that allows entering the name of the material for which the key data for welding it shall be defined Enter the name on the touchscreen keyboard see Display 4 and confirm it by touch ing the Ok button The machine moves on to the next input screen in which a pipe diameter for this material has to be entered on the numeric keypad see Display 2 After having confirmed this input by Ok once more another screen allows entering the wall thickness for this material and size After the wall thickness the pressure level per SDR has to be entered in the next screen After this define the key welding parameters for the material just entered e g 50 mm PE pipe with a wall 2 3 mm thick SDR 22 To de fine them the unit guides the operator through a series of input screens in which the following can be entered joining force heat soaking time cooling time plate temperature force ramp facing force Confirm every entered value by touching Ok Version
22. lied force is out of tolerance welding has to be repeated Power Supply Failure In the course of the last welding operation a power supply failure occurred welding has to be repeated Emergency Stop The welder has turned the machine off using the Emergency Stop switch If this was done because of a malfunction of the machine it must not be turned on again unless it is beyond doubt that it works properly Mirror Temperature Low The mirror temperature is out of tolerance and cannot be adjusted as long as this error is not cleared welding or repeating a welding operation is not possible 5 Printing Welding Reporting The machine is equipped with a dual interface that gives you the opportunity to connect a common desktop printer directly to it or to export the data via a RS232 cable to a PC with DataWork agru installed 5 1 The Print Menu and Printing Transferring Reports When a data communication cable is connected while the standard data screen see Display 5 is showing the machine displays the print menu According to the selection made on this menu data will be sent to the con nected device to the a printer for print out or to a PC for further processing and archiving Version December 2006 agru SP 110 S User s Manual 19 agru SP 110 S 20 05 02 a Touch the appropriate button to select print ing All Reports printing By Commission Number or printing By Date The option All Reports causes
23. mperature difference between the welded and the open pipe butt may cause a suction effect to form which would then cool the bead thereby negatively affecting the quality of the welded joint A small offset between the pipes can be readjusted using the adjustment set screws located at the front of the machine If the alignment offset is too large or if there is too large or too uneven a distance between the pipe butts touch the Face Ends button to re adjust the pipes in the clamps and start the facing process again In both cases the machine moves the car riages apart to allow for inserting either the heating mirror or the facing tool 4 6 3 Pre heating the Pipe Butts and Inserting the Heating Element chine tells the welder first to reposition the facing tool and heating element assembly to the right The carriage rail features a posi tioning utility that clicks it into place when it is in the correct position for inserting the heat ing element As all actions before this one has to be confirmed in two hand mode touching the appropriate button on the touch screen and holding down the confirmation push button on the front of the machine When the facing heating assembly is in the ready to heat position the machine shows the display asking the welder to insert the heating plate see Display 12 16 agru SP 110 S User s Manual Display 12 Version December 2006 Then the welder can either start the stan sp 11
24. n Memory Reprinting Tags Using the appropriate option of the configura tion menu see section 4 3 it is possible to display on the screen the welding reports saved to memory A screen like the one in Display 20 appears It is similar to the weld ing and traceability data overview shown at the end of each successful welding opera tion The Error field reads Ok if no error occurred and contains the acronym PH for sPre Heat if the welding operation was per formed with the pre heating feature agru SP 110 S Near the left edge of the Report Info screen you will find a list of all welding reports cur rently in memory Above this list the number of the selected report is given before the Display 20 20 agru SP 110 S User s Manual Version December 2006 slash along with the total number of reports in memory after the slash To move the selector bar through the list touch the scrollbar arrows to the right of the list The longer you touch them the faster the bar scrolls through the list To display the welding and traceability data of the selected report touch the Select button after having selected it in the list This will populate the fields in the right hand part of the screen with the values saved to the selected welding report To reprint an extra tag of this welding operation for sticking it onto the pipe touch the Tag button 5 3 Deleting Reports from Memory To delete the r
25. om a is also indicated on the touchscreen panel 4 6 7 Cooling Phase machine moves on automatically to the cool ing phase see Display 16 The cooling down is displayed as a countdown During Eee cooling the applied joining force is constantly Welding Progress monitored Nom Temp C Nom Force N s Actual Temp C 4 6 8 End of Welding After a successful welding operation which 150 Nom Time s can also be recognized in the welding 18 Actual Time s diagram the applied force is removed from the pipes and they can be taken out of the clamps Display 16 When the welding process is finished the machine displays an overview with the applicable welding and traceability data that will be saved to the report the screen resembles the one in Display 20 and asks the welder to remove the pipes and visually check the quality of the joint In case he finds that the joint is of poor quality although the machine did not alert him to any welding error he can manually classify the welding result as poor by touching the Error button This causes the machine to mark the joint as poor rather than good in the the welding report 4 7 Aborted Welding Process All welding relevant data are constantly monitored while the welding process is adjust them the welding process is aborted after a given period of time The error that made the welding abort is displayed on the screen see Display 17 Additionally t
26. on change the machine displays either a numeric keypad see Display 2 or an commission No alphanumeric keyboard see Display 4 TO mamasa aaa confirm and save your data input to memory AA FA touch the Ok button Ewozsa Additional Data Addresses Depending on the software i A P ASTNM db db b db db db db eb b ek version installed in your machine Info some screens may differ slightly In8t21ting Company e ABCD CORP on your machine from the reproductions in this manual Display 3 10 agru SP 110 S User s Manual Version December 2006 When the traceability data were entered the machine displays the first input screen of the welding process proper see start the welding process and to customize all control actions on the touchscreen panel 4 3 Configuring the Machine In the first input screen of the welding process proper Display 5 the key data of the last welding are shown material diame ter and wall thickness of the welded pipe Furthermore the status bar at the top of the screen shows the date time of day and also either the current ambient temperature or the power supply voltage or the welder s name or code In Display 5 the welder has the possibility to e immediately start a welding process that will be performed with the same welding parameters as the previous welding touch the Ok button and move on to section 4 6 e enter new pipe related data for the next Material
27. s possible only after cofirming it in a safety message After deleting them only the default materials with which the machine is shipped remain 14 agru SP 110 S User s Manual Display 9 Version December 2006 O If the material that was used in the last welding operation is deleted then the next welding operation of necessity requires a Info new material to be selected for welding 4 6 Welding Process IS The welding machine operates in two hand mode at any time For AEA EO that may put the operator s hands at risk of injury because the carriage starts moving the operator must confirm the step on the touchscreen and use the second hand to keep pressed the green confirmation push button on the machine front 4 6 1 Facing the Pipe Butts In the input screen reproduced in Display 5 when the Ok button was touched the weld ing process proper starts by the insertion of Display 10 the pipe facing tool The machine alerts the e Zeroing the facing tool position before clamping the pipes e Securing the pipes in the clamps und determining the facing road e Facing the butts First the machine asks the operator to insert the facing tool in Position 1 for securing the pipes Slide the facing tool in between the carriages of the machine so as to place the position handle into the rest that is labeled Facing Ok Pos 1 at the facing tool support Display 11 IS While the machine automatically performs a z
28. ser s Manual The User s Manual is presented according to sections which explain the different functions of the machine All rights in particular the right to copy or reproduce in print or electronic form and distribute as well as to translate are reserved and subject to prior written authorization Version December 2006 agru SP 110 S User s Manual 2 2 Explaining Icons The following expressions and icons are used in this User s Manual to refer to safety related issues Caution IT Important O Info This icon indicates that non compliance may result in a hazardous situation that possibly causes bodily injury or material damage This icon indicates important messages related to the correct use of the machine Non compliance may cause problems of operation and damage to the machine This icon indicates tips and useful information for using the machine more efficiently and more economically 2 3 Safety Messages Protect the power supply cord from cutting edges Have an authorized ser vice shop replace damaged cables or lines immediately The machine has to be operated with a 230 V 50 60 Hz power supply with safety fuse or breaker of 16 A maximum If power is connected through a power line manifold the power supply has to feature an earth leakage circuit breaker The length of the power supply cord must not exceed 10 m 30 feet from the circuit breaker gt Caution gt Caution gt Caution
29. ssion In report display mode it is also possible to print a label tag for this welding once again see section 5 2 Unit of Length Menu In a sub menu the unit of length used for displaying and mm inch saving welding data can be selected Temperature Unit Menu In a sub menu the temperature unit used for displaying C F and saving welding data can be selected New Page in Menu Automatic Heating In a sub menu a time for instance on the following morning can be pre set when the heating element will start heating up automatically see sub section 6 2 Alarm Sound In a sub menu the alarm sound that the machine emits to validate the execution of a given step in the process can be enabled or disabled New Page in Menu Memory Control ON OFF if ON Machine stops when the memory is full if OFF Machine overwrites the oldest report when the memory is full Machine Parameters In a sub menu the machine number can be entered and the temperature of the heating mirror and the weld ing force can be zeroed calibrated Access to this sub menu requires an additional access code that is available from the manufacturer distributor Date Time M In a sub menu date and time can be set Delete Reports M in a sub menu it is possible to delete all welding reports currently in memory To access this sub menu the so called selection code is required see at the beginning of this sub section the reports will b
30. ther areas in the workshop especially to those in which combustible materials are used in order for the heating element tem perature of up to 500 C 930 F not to be hazardous Depending on the piece that is going to be welded the outer clamps may have to be repositioned or removed To do so loosen the locking bolts and either remove the clamp or re adjust it and secure it by tightening the locking bolts again If the diameter of the pieces to be welded is smaller than the clamp insert the reducer inserts This can be done without using any tools since the inserts are fastened in the clamps by magnetic attraction ie Pipe clamps and reducer inserts have to be clean or must be cleaned before welding starts To insert or remove the inserts do Important not use heavy tools hammer wrench They may damage the inserts and the magnets I3 The surfaces of the heating plate have to be free of grease and Important clean or they have to be cleaned Version December 2006 agru SP 110 S User s Manual Is Make sure all connectors are tight in their sockets and make sure SP 110 5 After preparing the machine for welding and connecting the power supply cord that the machine is operated only if Important the conditions for safe and intended use are met see also section 2 to the mains power supply the machine is turned on using the On Off switch The wel come screen as reproduced in Display 1 ap pears on the touchscreen panel To
31. ther functional areas of the workshop Power Supply Only through Line with Protective Grounding ES Conductor Important The machine has to be operated exclusively with a power supply line equipped with a protective grounding conductor as a power supply without this safety element may cause severe machine damage If the machine is operated through a power supply without a grounding conductor this will void any and all warranty under which the product may be Is Power Only to Operational Machine Power must never be applied to the machine before it is Important completely installed and ready for operation User s Manual Q The User s Manual has to be available at any time on the site where the machine is used If the User s Manual should come to Info be incomplete or illegible replace it without delay Feel free to contact us for assistance 2 4 Welder and Operator Obligations The machine may be operated exclusively by persons who are familiar with the applicable regulations the guidelines for the prevention of ac cidents and the User s Manual The machine may be operated only when observed Welders must have been introduced properly to operating the machine or must have participated in a dedicated training The operating owning company en gages to check at reasonable intervals if the machine is operated by the welders with the intended use and under proper guidelines of safe work The machine must never be operat
32. uch the appropriate flag to select the display language that the machine will use After the language was selected the machine imp Chi GAK E EZ E takes the user to the welder code entry PLASTICS Bi Be x ERIK 1 screen Without a valid welder identification code it is impossible to start welding processes on the machine since the heating element re fuses to heat up unless a valid code is entered Enter the welder identification code by typing it on the touchscreen and saving it to memory by touching the Ok button If a bar code for the welder code is available you can also read it from the bar code using the scanning wand All inputs for which a bar code is available can be entered from the Info bar code using a scanning wand Is Entering data on the touchscreen must always be performed with the Important bare finger Using objects ballpoint pens screwdrivers etc may cause unrecoverable damage to the surface of the touchscreen 4 2 Entering Traceability Data for the Joint After the welder identification code was entered the traceability data for the joint have to be entered The machine displays the traceability data for the last joint that was welded see Display 3 which can be re used for the next welding operation by simply touching the Ok button If traceability data are not the same as for the last joint change the data that are different en ee by touching the appropriate Change butt
33. with the effec tive facing road so far achieved When the pipe butts are faced the machine shows an end of facing mes sage see Display 11 Visually check the pipe butts and if they are o k confirm by Facing Ok The machine moves the carriage apart to let you remove the facing tool If the result of facing is poor the process can be repeated after touching the Face Ends button To face the butts once again in most cases the pipes have to be re adjusted in the clamps O When pipe facing is successfully finished it is recommended not to touch the pipe butts with your bare hands To avoid fatty layers Info on the pipe use special pipe handling towels 4 6 2 Checking Pipe Alignment When the pipe butts are level to satisfaction it has to be checked if the pipes align properly to each other or if there is an offset Similarly as for facing the touchscreen tells the welder that this is the next step and the carriage can be closed in on the other pipe by the Start button When the pipe butts are next to each other two additional buttons appear besides Cancel the Face Ends button and the Alignment Ok button If the pipes align properly confirm by touching the Alignment Ok button and to start the welding process the machine will tell you to move the car riage apart and to close the pipe butts at the far end from the heating ele ment with caps confirm this by Ok Without end caps the te
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