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Proweld™ Equipment Owner & Maintenance

Manual

SP-110 IR Fusion

Power Requirements: 230VAC +10/-15%, 16A, 50/60Power Requirements with Transformer: 110 VAC, 30 Amp.

Caution: Must use a dedicated circuit and do not use extension cords longer than 30 feet.

35 Green Street, PO Box 653, Malden, MA 02148Tel: (781) 321-5409 - Fax (781) 321-4421 - Toll Free: (800) 343-3618

www.asahi-america.com - [email protected] Sales: East (800) 232-7244 / Central (800) 442-7244 / West (800) 282-7244

Table of Contents

1 Introduction-----------------------------------------------------------------------------------------------------------3

2 Safety Regulations-------------------------------------------------------------------------------------------------32.1 The customer’s obligations-------------------------------------------------------------------------------------42.2 The operator’s obligations--------------------------------------------------------------------------------------42.3 Operating regulations--------------------------------------------------------------------------------------------42.4 Important Safety Precautions------------------------------------------------------------------------------ 52.5 Safety devices-----------------------------------------------------------------------------------------------------52.6 Maintenance, repair and inspection-------------------------------------------------------------------------5

3 Product Description------------------------------------------------------------------------------------------------63.1 Machine Use--------------------------------------------------------------------------------------------------------63.2 Technical specifications-----------------------------------------------------------------------------------------6

4 Machine Parts and Installation---------------------------------------------------------------------------------74.1 Machine Parts------------------------------------------------------------------------------------------------------74.2 Installation-----------------------------------------------------------------------------------------------------------9

5 Operation and Welding------------------------------------------------------------------------------------------115.1 Selection of welding method---------------------------------------------------------------------------------115.2 Preparing SP-110-----------------------------------------------------------------------------------------------115.3 Program description--------------------------------------------------------------------------------------------125.4 Working process-------------------------------------------------------------------------------------------------155.5 Error and system message-----------------------------------------------------------------------------------30

6 Weld quality and welding parameters---------------------------------------------------------------------336.1 Welding bead-----------------------------------------------------------------------------------------------------336.2 Weld failures------------------------------------------------------------------------------------------------------336.3 Welding parameters--------------------------------------------------------------------------------------------366.4 Weld labelling-----------------------------------------------------------------------------------------------------36

7 Maintenance---------------------------------------------------------------------------------------------------------377.1 Fuses---------------------------------------------------------------------------------------------------------------377.2 Lubrication---------------------------------------------------------------------------------------------------------377.3 Repair of failures-------------------------------------------------------------------------------------------------377.4 Servicing-----------------------------------------------------------------------------------------------------------38

8 Transportation and storage-----------------------------------------------------------------------------------398.1 General information---------------------------------------------------------------------------------------------398.2 Unpacking of SP-110-------------------------------------------------------------------------------------------398.3 Packing of SP-110----------------------------------------------------------------------------------------------398.4 Storage-------------------------------------------------------------------------------------------------------------39

9 Spare Parts List---------------------------------------------------------------------------------------------------4010 Attestation of Conformity--------------------------------------------------------------------------------------46

ASAHI/AMERICA,INC. 2 SP-110 2-01-08 Rev AEngineering & Rental 48 pages

1 Introduction

In this manual you will find operating instructions, safety precautions for the SP-110 IR welding equipment. Please read this manual carefully in order to avoid damage to the tool and personal injury. Please inform us of any problems or faults that occur during operation so that we may improve our products. This manual is subject to changes without notice, please contact Asahi/America for the latest version.

Thank you for your business. We look forward to providing you superior welding technology.

Symbols

Below are of the symbols used in this manual.

Safety Precaution

Disregarding may cause personal injury or machine damage.

Important Information

Operator Action

2 Safety Regulations

The equipment has been designed for the welding of piping systems manufactured by Asahi/America and AGRU of Austria. We are not liable for improper welding or damages resulting thereof. We do not warrant the welding or suitability of any other brands without our authorization.

We have designed the machine according to standard safety regulations however this machine may present danger to the operator or those nearby.

This machine may require updates or service by the manufacturer at any point in time.


2.1 The Customer’s Obligations

The customer is obliged to: Ensure the machine is operated only by persons familiar with the basic work place safety and

regularly maintain work site safety. Ensure the machine is operated only by persons who have been trained by Asahi/America and

have obtained a valid welding certificate for SP-welding machines. Provide this operating manual to all tool operators or users. Maintain the proper and safe operating conditions of this equipment. Notify Asahi/America of any

issues immediately. Contact Asahi/America to confirm welding compatibility of any other brands or materials.

2.2 The Operator’s Obligations

All operators of the machine are obliged to: Observe basic workplace safety rules. Read this manual including the chapter on safety and warning signs. Be properly trained on machine operation before using. Operate the machine only when it is in working condition and report any problems or damage to

the appropriate person. Use the machine only for its intended purposes.

2.3 Operating Regulations

The machine shall be connected to the main power supply only after proper set up. In emergencies, where human beings and/or the equipment are endangered, immediately press

the EMERGENCY button to turn off the main power. After work shifts and during breaks, turn off the power and disconnect the machine. Remove the

operator card from the control panel. Only allow authorized personnel to come into contact with the machine.

According to the VDE 0100, the equipment may be operated only via current dividers equipped with FI-protective switches.

The SP-110 is designed as a single-operator welding unit. Operation by more than one person is not allowed. When the machine is turned on, only one responsible operator may stay in the work area.

The operator must properly follow all preparation phases before activating functions that initiate machine movement. Refer to Chapter 5, Operation and Welding.


2.4 Important Safety Precautions The planing tool rotates during operation and is equipped with sharp blades!

- Wear tight clothing and a hair-net if necessary. Do not wear jewelry.- Do not touch the planing tool when it is operating!

Clamp carriages move semi-automatically!

- Do not reach into the automated areas of the machine at anytime while the machine is on.

- Do not place objects on moving parts.

The heating element is very hot during operation!

- Do not touch the heating element and the protective cover.

- Do not leave the heating element unattended.- Keep a safe distance from flammable materials.

Do not clean the machine with compressed air, because dirt may be blown onto the guides and planing chips onto the heating plate!

When PVDF, ECTFE and PFA material is heated-up, hydrofluoric acid may be generated!

- Maintain sufficient ventilation in the workspace!

When butt welding, the required Teflon plates have to be mounted to the heating element. All welding parameters have to be altered accordingly.

2.5 Safety Devices

The following features are incorporated for your safety: Turn the Main power switch to the off position to make the machine idle and stop electrical

current. Strike the EMERGENCY key to immediately discontinue operation.

If pressed (locked), the machine is idle without electrical current. The proximity switches control the positions of various parts on the tool. Control panel commands which activate moving parts require simultaneous touching of the

RELEASE key and control panel. The planing tool and heating element are secured by a lateral transport lock during machine

transportation. The planing tool is prevented from uncontrolled swivelling by the crank geometry.

2.6 Maintenance, Repair and Inspection

Please adhere to the following maintenance procedures:


Only Asahi/America’s technicians and authorized agents are permitted to open the tool for adjustments and repairs.

OEM parts should be used. Maintenance and inspection should be performed on a regular basis. After completing maintenance work, all safety devices should be checked. Changes or modifications to the equipment are only allowed with authorization of Asahi/America.


3 Product Description

3.1 Machine Use

The SP-110 welding machine is designed exclusively for Infra Red (IR) non contact and contact butt welding of plastic pipe and fittings. Only the preset welding parameters which are shown on the display may be used and stored.

Do not alter the welding parameters given by Asahi!

3.2 Technical Specifications

The SP-110 is a semi-automatic welding machine with a pressure controlled fusion process.The machine utilizes an external touch screen control panel for operation. Individual weld data is automatically stored and may be downloaded for use with our optional PC program. All aluminium parts are anodized to enable operation under clean room conditions.

General characteristicsType of machine AGRU SP-110Weldable materials PVDF, PP, ECTFE and optional PureBond® PFAWeldable pipe dimensions from OD 20 to 110 mmWelding pressure range from 10 to 500 N ±10%Dimensions (W x H x D) approx. 580 x 625 x 670 mm (23 x 25 x 27 inches)Transport case (W x H x D) approx. 1075 x 740 x 715 mm (43 x 29 x 28 inches)Total weight approx. 163 kg (358 pounds)Weight of the machine approx. 98 kg (215 pounds)Connected loads 230VAC +10/-15%, 16A, 50/60Hz,Electrical connection 1-phase, 1/N/PE, min. 3x2,5mm², fuse protect. max.16APower input of heating element max. 1600WHeating element temperature from 100°C to 500°C ±2% (212°F to 932°F) in pipe areaPower input of planing tool max. 300WPlaning tool speed approx. 45rpmStorage temperature 0°C - 50°C (32°F - 122°F)Noise limit below 70dB(A)

Place of application- Clean rooms, fabrication shops and job sites Machine is not to be used in trenches or other environments where it may be damaged or contaminated.

Ambient conditions- according to DVS for welding areas- Temperature: from +10°C to +35°C (50°F to 95°F)- protect all elements from moisture

Table 3.1: Technical characteristics of SP-110


4 Machine Parts and Installation

4.1 Machine Parts

14 5 6 11 13 1 8 7 3 18 17 10 4 9 12 19

Fig.4.1: Construction of SP 110

No. SP-110 Parts Notes1 Electrical panel See Fig. 4.2, Connections2 Control panel See Fig. 4.3, Controls operation; detachable3 Heating element4 Planing tool5 Inner clamps Stationary6 Outer clamps Adjustable and detachable, fixed by clamping lever7 Left clamp carriage Alignment controlled by # 17 & 18; carriage does not travel8 Right carriage lock Secures alignment adjustment and carriage9 Right clamp carriage Movement automated by machine

10 Travel arm Manual movement of heating element and planer11 Transportation lock Secures planing tool and heating element during transportation12 Levelling legs Levels machine13 Bubble level Shows machine level 14 Travel arm handles Manual movement of heating element and planer15 Printer Optional, for printing of weld labels; detachable; not shown16 Nitrogen purge Optional, not shown17 Horizontal alignment knob Adjusts horizontal alignment18 Vertical alignment lever Adjusts vertical alignment with a cam lever19 Support arm Supports touch screen and printer


26 22 23 21 20 25 24Fig.4.2: Electrical panel

No. Electrical Panel Parts Notes20 Main switch Turns machine on and off21 Printer plug Power supply to printer (2 A)22 Nitrogen plugs Controls nitrogen purge23 Nitrogen fuse Protections nitrogen purge24 Circuit Breakers Protection of power elements25 Power cable Connects to main power supply 26 Control panel cable Connects to control panel PC27 Temperature probe Reads ambient temperature, not illustrated

31 28 32 29 30 37 33 34 36 35Fig.4.3: Control Panel

No. Control Panel Parts Notes28 Touchscreen Displays operation program, touch controlled 29 EMERGENCY shut off Stops machine in emergency situations30 RELEASE button Safety button to be held during various machine processes31 PCMCIA slot Holds memory/operator card32 Buzzer Warning sounds during machine processes33 LED signal Illuminates green if power supply is ok34 Keyboard connection Allows keyboard to be connected for factory service35 Service Connection For factory use only36 Printer connection Data connection to printer37 Machine connections Data connection to machine

Never touch the touchscreen with sharp or sharp-edged objects (such as screwdrivers, etc.).


4.2 Installation

4.2.1 Delivery Inspection

Upon delivery, check machine for any possible shipping damages and that all equipment is included. Report shipping damages to the freight carrier or Asahi/America immediately. Report missing equipment to Asahi/America or your local distributor. The following chart illustrates the equipment that is included with the machine.

SP-110 Standard Shipping ListQuantity Description1 pc. Welding machine1 pc. Support arm1 pc. Control Panel1 pc. Printer1 set Clamp inserts,12 inserts per size, for the following sizes:

20, 25, 32, 40, 50, 63, 75 and 90 mm; stored in separate case1 set End caps, 2 pcs. per size, for the following sizes:

20, 25, 32, 40, 50, 63, 75, 90 and 110 mm 1 pc. Power transformer, 110/230 V1 pc. Machine transportation case 1 pc. Wooden shipping crate1 pc. PCMCIA card level 31 pc. Operating manual

Note: Optional accessories not mentioned.

4.2.2 Unpacking of SP-110

Open the locks and remove the packing upper part. Take out all accessories. Lift the SP-110 by “lifting handles” out of the packing lower part. Do not lift by planer or heater extension arms, as this will damage the tool. Put the packing upper part back onto the crate and fix it with locks. Plug in connections correctly (see page 8 in provided SP-110 Instruction Manual).

4.2.3 Initial Set Up

Mount machine onto a solid, level area and align it by means of the levelling legs (#12). Release the transportation lock (#11) for planing tool and heating element. Attach the support arm (#19) and tighten hand screw. Attach the control panel (#2) and printer (#15) to the support arm and fix it by the clamping levers.

A PCMCIA card is required for controlling operator identification and storing and transferring data.

Uncover PCMCIA slot. Carefully insert the card with the printed side facing up and cover slot. During operation, the card

must remain in the slot and the tool can only be operated by a valid card.


4.2.4 Electrical Set Up

Check that the main power switch is in the off position. Before you plug the main power supply and turn on the machine, please observe the following procedure:

A 1-phase mains lead of the following characteristics is required for the machine operation: 230VAC +10/-15%, 50/60Hz (A step-up transformer 110/230 V is supplied by Asahi/America) Protection is max. 16A Minimum mains lead cross section is 3x2,5mm² (1/N/PE) Maximum mains lead length is 10 m from the circuit breaker.

Connect the power cable to the transformer. Connect the control panel cable to the machine. Connect the printer cable to the control panel. Check all electrical connections to the control panel, heating element, printer and planer. If

necessary, protect them by means of locking device. If applicable, secure the locking device.

Fig. 4.4 shows a basic electrical connection schematic. The most important electrical connections are highlighted.

Fig 4.4: Electrical Connections Schematic

Check that the position of circuit breakers is in the on position Check that the position of EMERGENCY shut off button is unlocked (See Fig. 4.5).

Fig.4.5: Positions of EMERGENCY shut off button

Turn on the main power switch. An AGRU image will appear on the touchscreen of the control panel.


LOCKEDUNLOCKED

Heatingelement

Operating control unit Printer

Main supply -> SP-110

Printer transformer -> SP-110

Operating control unit -> Printer

SP 110 ->Operating control unitGREEN

SP 110 -> Nitrogen purging

SP-110 ->Heating elementRED

optional

Nitrogen purging

SP- 110

5 Operation and Welding

5.1 Selection of welding method

You can choose the desired welding method by means of these selector keys. 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 bead-up 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 minimized, 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-110

General information Installation of clamp reducer inserts

The clamp reducer inserts for the different corresponding pipe dimensions are kept in the plastic case.

Open all four clamping jaws completely and place the inserts (4 sets 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 plastic case in proper order.

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 overcome the magnetic force.

Do not press the clamp 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 printerRefer to supplied original sample of operating instructions.


Butt welding (optional)

Installation of insert plates for butt welding

Install the Teflon-coated aluminium plates on either side of the cold heating plate. Fix them with the supplied countersunk head screws.

Never use insert plates while operating in IR mode, as the coating would be destroyed from the high temperature.

5.3 Program description

This program description is applicable to welding program SERVO 20, version no. 2.01.

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 Asahi/America.

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.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 prepare and activate corresponding control functions. After welding, you may print out welding labels with a special printer (optional). All parameters relevant to the welding process are stored in the operating control unit and available for further processing.

Operating levels

A four level operator access code is utilized to ensure trouble free operation of the machine. See Table 5.1 for access granted with each level. The first figure of the key card serial number refers to the operating level.

Operating level Operator’s code Note Inhibited system access1 AGRU1 Manufacturer N/A2 AGRU2 AGRU Hardware set-ups3 AGRU3 Operator, Distributor,

QC-personnelHardware set-upsWelding parameter set-ups

4 freely selectable 5-digit character code

Welder All, but welding control

Table 5.1: Operating levels

Program symbols and their functionsThe touch screen panel provides several buttons that when pressed, activate specific functions.

As a safety precaution, it is necessary to press the green RELEASE-key simultaneously with the desired machine movement button. The operator is reminded both visually (information line) and acoustically (by a horn).


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:

Adjustments are selected by changing the sliding button position (printer switch off or number of lables 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:

The movements (OPEN/CLOSE) of the movable clamping jaws are controlled by these keys.

Display lights:

These output fields serve for the display of releases and activated functions (jaw closed,...).

Multifunctional keys:

Various control functions may be activated 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,...).

No EMERGENCY-function!

Information line, signalizing 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 a blue background, warnings and disturbances in windows with a 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

Fig. 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: Selection menu for system functions

The select menu allows you to enter system functions. Available functions are marked in green color. Authorized users will obtain information on the application of system functions from the technical service of Asahi/America.

Only persons authorized by Asahi/America are allowed to make use of the system functions.

Machine characteristics Change to

SYSTEM

Change toINFO 1

Program version

Information line

Language selection

Operator card information

Change toLOGO

Establish welding table

Copy and delete Data

Set system time

Test printer

Establish machine settings

Operator code

INFO 1: Initial welding level menu

Apart from the indication of welding characteristics, this image includes several menu changing functions. The desired number of tag printouts can be chosen by the sliding button.

INFO 2: Selection and indication of stored welding characteristics.

In this menu you can examine the characteristics of stored weld data. You can read 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.

Change to ADDRESS

Change to ROOM

Protocol characteristics

Change to MATERIAL

Change toLOGO

Number of tag printouts per

welding

Change toINFO 2

Pressure curve

Welding characteristics

Open windows for manual input

of file name

Selection of memory medium

Change toINFO 1

Take-over and indication of selected file

Number of stored data

Selection of file

Selected file

ADDRESS: Input of address

The place of welding is entered over the keyboard block; it is stored after pressing Enter.

ROOM: Input of room characteristics

In this menu, the environmental characteristics have to be entered. The selected room type is marked by the signal lamp. The settings are stored after pressing Enter. These settings are only for documentation and have no influence on the welding parameters.

Display of address input

Keyboard for address input

Confirmation of input

Change to INFO 1

Standard room

Selection of environment

Selection of clean room class Confirmation of

input

Clean room

MATERIAL: Input of material

You can select one of the given materials (e.g. PVDF) by the menu keys. Confirming the input by pressing NEXT will automatically save the selection.

DIAMETER: Input of diameter

You can select one of the given pipe diameters (e.g. 110 mm) by the menu keys. Confirming the input by pressing NEXT will automatically save the selection.

Display of selected material

Select menu

Change to DIAMETER

Change toINFO 1

Display of selected diameter

Select menu

Change to WALL THICKNESS

Change toMATERIAL

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. Confirming the input by pressing NEXT will automatically save the selection.

After setting the environmental and material characteristics in the first part of the program, the particular welding process is started:

HEATING ELEMENT: Setting of heating parameters

After selection of the desired welding method, the heating element parameters are loaded automatically and heating begins. The input of the heating element temperature by hand is possible with the corresponding access (Temp-HAND).

Display of selected wall

thickness

Select menu

Change to HEATING ELEMENT

Change to imageDIAMETER

Selection of welding method

ON/OFF-key for heating element

Change toINFO 3

Change to WALLTHICKNESS

Display of active method

Heating element warm up time

Indication of heating element

temperature

Indication of ambient temp.

Indication of power supply

Check your power supply.

230VAC +10/-15%, 50/60Hz Protection is max. 16A Minimum mains lead cross section is 3x2,5mm² (1/N/PE) Maximum mains lead length is 10 m from the Breaker

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 expiration of the remaining time, turn to menu INFO 3 by pressing NEXT.

Changeover to INFO 3 is released only after expiry of the REMAINING TIME!Time total needed for heating up is about 20 minutes.

If necessary, clean heating element with lint free cloth.

Make lint free cloth available!

Take care for safe current supply!

Consider the ambient conditions: The welding must not be carried out in direct sun light or in a location where there might be a

draught. The ambient temperature must not be below +10°C (50°F ) and over +35°C (95°F).

INFO 3: Display of welding parameters

In this display all relevant welding parameters are indicated that have been entered or calculated.

After control of parameters, change to PLANING TOOL menu by pressing 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 by pressing BACK.

The entered pipe characteristics must comply with the pipes to be welded!

Always clean the machine, the planer blades and the planer knives before each welding with lint free cloth only!

Desired pressure curve

Pressure ramp

Change to PLANING TOOLChange to

HEATING ELEMENT

Cooling time

Joining pressure

Pipe characteristics

Pre-heating time

Spec. welding pressure

Pre-heating control pressure

PLANING TOOL: Controlling

In this menu, the planing of the pipe ends is handled.

To provide a trouble free procedure, the different working positions have to be properly achieved. The touch screen display is adapted automatically!

All control functions may be interrupted by the stop function (STOP + RELEASE-key).

Move planing tool to the left stop (Hand lever) Move movable clamping unit into position OPEN

(Clamping unit-OPEN + RELEASE-key)

These steps can be ignored if the units are already in the starting position.

When moving the clamping unit, the RELEASE-key

must remain 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 ALIGNING position (Hand lever)

Move clamping unit into PLANING position(Clamping unit-CLOSED + RELEASE-key).

Place work pieces so that pipe ends touch the planing tool plates and clamp them. The locking force of the individualclamping jaws can be adjusted over the milled nut.

2

1

Shifting way

Planing tool control

Function stop

Change toINFO 3

Clamping unit OPEN

Planing tool pressure

Clamping unit CLOSED

(Tighten the outside clamping jaws with more force than the inside clamping jaws to keep the pipe from moving up. These are only used for alignment).

When the locking force is too high, the work piece and the clamping jaws can be damaged!

Move movable clamping unit into OPEN position(Clamping unit-OPEN + RELEASE-key)

Move planing tool into AHEAD position (Hand lever) Switch on planing tool (Planing disc symbol +

RELEASE-key) Move clamping unit into PLANING position

(Clamping unit-CLOSED + RELEASE-key)

The work piece is guided automatically by the movableclamping unit and maintains the planing pressure.

Take away chip material that accumulates behind the planing disc regularly. The chips can cause the planing tool engine to stop or undergo higher wear!

Do not put your hand into the stopped or rotating planing disc!

Danger of injury by sharp rotating knives!

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 OPEN position (Clamping unit-OPEN + RELEASE-key)

At the end position the planing tool is switched off automatically!

Move planing tool into BACK position (Hand lever)

At the end position an inquiry window appears. Perform a visual control of the planing process.

3

If acknowledged by OK, the image automatically turns to OFFSET CONTROL (alignment). If acknowledged by NOT OK, the planing process has to be repeated! See image planing (page 26)!

OFFSET CONTROL: Alignment of pipes

In this part of the program the work pieces are aligned to each other.

Move movable clamping unit into JOINING position(Clamping unit-CLOSED + RELEASE-key)

Release lateral clamping lever under the stationary clampingunit as well as hand wheel for height adjustment.

Set height and lateral adjustment with bothhand wheels until work piece offset is compensated.

Fix lateral clamping lever under the stationary clamping unitand fix hand wheel for height adjustment.

Place end caps onto pipe ends.

At the end position, an inquiry window appears (see page 27): If you acknowledge by OK, open clamping unit and after

reaching the end position, the menu automatically changesto START WELDING.

Move movable clamping unit intoSTART WELDING position(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 OPEN position (Clamping unit-OPEN + RELEASE-key) See planing and/or offset control!

5

4

Function stop

Change to PLANING TOOL

Clamping unit OPEN

Clamping unit CLOSED

JOINING: Pre-heating and joining

In this part of program, the pre-heating and joining of the work piece are handled. This is a nearly fully automated process.

Move tool unit into RIGHT position until stop (Hand lever) Start the welding process (Function START +

RELEASE-key) Move heating element into AHEAD position until stop

(Hand lever + RELEASE-key), when reaching front stop,the moveable clamping unit closes automatically into PRE-HEATING position (keep holding RELEASE-key until achieving control pressure - green light turns off).

The time counter for pre-heating begins to count down and a signal horn is sounded 10 sec. before time runs out (to avoid signal horn press RELEASE-key). If you press the release-key during pre-heating and the pre-heating time runs out, the moveable clamping unit opens automatically.

Move heating element into BACK position until stop(Hand lever + RELEASE-key)

The moveable clamping unit closes automatically and builds up the joining pressure (keep holding RELEASE-key until achieving joining pressure - green light turns off).

The whole joining process must be carried out as

quickly as possible

Asahi-America recommends pressing the RELEASE-key from the 10 second heating warning until achieving the joining pressure (see touchscreen). The fusion process is fully automatic; the movement of the tool unit (heating element/planer) has to be performed manually.

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Function STOPChange toOFFSET

CONTROL

Track force

Function START

Time counter

Pressure curve

Heating element temperature

Pipe characteristics

Joining pressure nominal

Total welding time

Error code

Joining pressure actual

Fusion shrinkage

To avoid any incidents, ensure that no one else is in the relative fusion and clamping area.The time counter for the cooling time begins to count down and after expiration of the time, the menu proceeds to VISUAL CONTROL automatically.

If the welding process is ended before joining or if the tool removal process lasts too long, then after acknowledgement (OK) of the error signal, the menu automatically returns to PLANING TOOL process.

Move movable clamping unit into OPEN position (RELEASE-key) Move heating element into BACK position (Hand lever) See planing tool sequence!

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 returned to the VISUAL CONTROL menu.

VISUAL CONTROL: Final menu of data check

In this menu, 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.

For evaluation criteria, see chapter 6, Weld Quality.

After acknowledgement (OK or NOT OK), the menu is automatically returned to HEATING ELEMENT; at the same time the weld label is printed out (option).

If no printer is connected, it is necessary to acknowledge the inquiries, until the menu returns to HEATING ELEMENT.

Marking of weld

The label, 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 label shall be free from dust and grease (if required, clean prior to sticking) to provide for proper and safeadhesion (label is destroyed on removal).

Place label next to the weld for good visibility!

Welding characteristics

Error code

Check inquiry

Tag

5.5 Error and system message

Tables 5.2 a/b contain error messages, edited by the transmission window of warnings.

Error no. Message/Description Clearance01 NO PLACE FOR DATA

The internal memory of the operating control unit is full.

Delete data of operating control unit on system level. Before deletion, the data should be stored on a PCMCIA-card.

02 TOO MUCH FILESThe free target memory is insufficient for the data to be copied.

Reduction of selected files.

03 NO MEMO CARD PLUG INNo keycard in PCMCIA-slot.

Insert keycard into PCMCIA-slot.

04 ERROR FLASH CARDNo access to internal memory of operating control unit.

Contact technical service of Asahi/America!(serious system failure)

05 NO OPERATOR CODE Operator code is invalid or file unreadable.

Insert keycard with valid operator code into PCMCIA-slot or newly encode the card on the system level. Should the message appear again, check the card.

06 ERROR TEMPERATUREHeating element has still not been released.

Wait until desired temperature is reached and the remaining time has expired.

07 NO INPUT Operator has tried to change to the next image without input.

Enter data.

08 NO DATA SAVENo data save possible!

Contact technical service of Asahi/America!(Serious system error)

09 NO PRINTERPrinter is not connected or switched on, though in image INFO 1 the printer has been activated.

Connect printer or switch it on and acknowledge error. The program tries four printing starts. In case of another negative result, the program is continued.

10 TENSILE FORCEThe evaluated tensile force is too high.

Decrease the tensile force of the pipe and repeat the program cycle.

11 EMERGENCY STOPEMERGENCY-striking key is locked.

Unlock EMERGENCY-striking key.

12 ENDPOSITIONA control function has been activated in spite of improper end positions of carriages.

Clear away positioning errors and activate the function once more.

13 HARDWARE SOFTWARE The hardware (machine) is not compatible with the software (operating control unit).

Contact technical service of Asahi/America!

Table 5.2a: Error code

Error no. Message/Description Clearance14 NO DATAREAD

System files on internal memory not available or unable to read.

Contact technical service of Asahi/America! (New installation of system files required.)

15 SYSTEM ERRORNo access allowed to parallel interface.

Contact technical service of Asahi/America! (Check operating control unit.)

16 NO COMMUNICATION Disturbance or interruption of data transfer between operating control unit and machine

Check plug-in connection and/or PC-cable.

17 WRONG OPERATORCODEOperator tried to activate inaccessible system functions.

See Chapter 5.3, Program Description

18 MOTOR 1 TEMPERATUREMotor temperature of movable clamping unit is too high.

Acknowledge error and let motor cool down. If the message appears again and again, have the motor checked.

19 MOTOR 2 TEMPERATURENon applicable!

20 MOTOR 3 TEMPERATUREMotor temperature of carriage for planing tool and heating element is too high.

Acknowledge error and let motor cool down. If the message appears repeatedly, have the motor checked.

21 MOTOR 4 TEMPERATUREMotor temperature of planing tool drive is too high.

Acknowledge error and let motor cool down. If the message appears again and again, have the motor checked.

22 MACHINE STOPWelding procedure has been stopped manually or after expiration of adjustment time.

Acknowledge error message and end welding procedure or repeat it.

23 NO SAVE OLD DATANo storage of historical data possible.

Contact technical service of Asahi/America! (Check operating control unit).

24 INADEQUATE POWERSupply voltage is too low.

Check mains lead!(Non-permissible line length or cross section)

25 WRONG KEYCARDNo access

Report, when trying to create a new operator card with AGRU4

26 WRONG CODECreate a new operator code

AGRU1 to AGRU3 are secured operator codes.Only AGRU4 are recordable!

27 NOT IN LISTFile not found

Input of correct file name

28 WRONG VERSIONInvalid format of file

Contact technical service of Asahi/America!

29 POWER OFFHeating element switched off

Switch on heating element.

Table 5.2b: Error code

Table 5.3 contains important messages, which are issued by the information line (red background).

Message/Description ClearancePRESS 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)

This section describes some basic quality criteria to follow. For further detailed information, please consult Asahi/America’s High Purity QA/QC manual.

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 zoneCause: 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 shortCause: Pipe dimension or type of material inadequately set, end caps not applied!

b1 b2

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 realized.

Angular deviation

for example, by: machine malfunction faulty alignmentCause: 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 pressureCause: 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 two 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 shortCause: 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)

Bead Sizes

When inspecting completed welds on an SP tool, the following items should be evaluated:

The bead formation and uniformity. The previous pages provide information on what factors to look for when inspecting.

Weld label. On each label the words –WELDP.OK –need to be present. This indicates that all the Welding Parameters were conducted according to the procedure

Weld label. If the weld label indicates an error, it will appear in a numeric sequence of zeros and ones. The position of a one indicates the exact root cause of the error. See the chart and explanation below of error checking (Table 5.4)

Weld label. On each label, the material, diameter and wall thickness should be checked. These items must match the pipe that the weld label is attached. Any difference indicates that wrong parameters were entered into the touch panel and the pipe was welded at the incorrect settings.

If errors do appear on the weld label, the actual weld production can be verified on the touch panel by searching for the weld number. To conduct this information, go to the Weld data screen located on the first input screen (Same screen as where the project name is entered.)

By visually inspecting the weld and verifying the label accuracy, a joint can be certified. While no machine or system is foolproof, combining the automation of the SP equipment with a solid operating and inspecting procedure should yield positive results.

In some cases, customers may want to inspect bead sizes. While measuring bead sizes is not a guarantee of weld quality, this is another option to verify that the beads are in specification. The measurement of bead size is not required, but the below chart has been made available for PVDF per customer request.

SP-110 EquipmentPVDF Only

Size Pressure rating

HeightMin

HeightMax

WidthMin

WidthMax

½” 20mm 230 0.0157 0.055 0.050 0.120¾” 25mm 230 0.0157 0.060 0.050 0.1301” 32mm 230 0.0157 0.067 0.060 0.1351 ¼” 40mm 230 0.0276 0.070 0.075 0.1601 ½” 50mm 230 0.0276 0.080 0.075 0.1702” 63mm 230 0.0276 0.080 0.075 0.1702 ½” 75mm 230 0.0315 0.085 0.085 0.1753” 90mm 150 0.0315 0.092 0.075 0.1904” 110mm 150 0.0315 0.092 0.075 0.190Charts are for SP Equipment OnlyCharts are for PVDFValues are based on ambient welding temperatures of 20 to 25 C

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 an SP-DATA-program.

6.4 Weld labelling

One part of quality assurance is the marking of the weld by asafety tag. In addition to general data for identification, the quality code is printed on the tag.

After proper welding, the code WELDP.OK is printed.

Failures or deviations are indicated by an eight-digit numerical code (0 = no failure, 1 = failure). In Table 5.4, you find the explanations of the code functions.

Digit Function Digit FunctionBit 0 Joining pressure Bit 4 Joining path (pipes slipping through)Bit 1 Heating element temperature Bit 5 Data transferBit 2 Emergency stop (EMERGENCY-

key)Bit 6 No function

Bit 3 Normal stop (STOP-function) Bit 7 Visual controlTable 5.4: Quality code

e.g. temperature failure:

For each welding, 0 to 3 tags can be selected and printed (see page 13).

Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 70 1 0 0 0 0 0 0

Weld No.No. of tag

DateTimeMachine numberPipe characteristicsQuality code

Type

7 MaintenanceWith proper operation and regular service, the SP equipment will operate trouble free.

Turn off and remove the power supply before you perform any cleaning or maintenance!

Clean the equipment with a lint free cloth and cleaning agent before starting maintenance. Wipe touch panel and heating element only with a slightly moist lint free cloth. Never blow compressed air on the machine.

7.1 Fuses

Before replacing a fuse and starting up the machine, find and fix the original problem.

Marking Type/NotesF1 B 6A, safety cut-out for planerF2 B 10A, safety cut-out for heating mirrorF3 B 6A, safety cut-out for power pack and socketF4 T 0,2A, glass tube fuse 5x20mm for nitrogen purgingTable 7.1: Fuses on machine panel

7.2 Lubrication

Observe the following rules: The guides and threaded drives must always exhibit a visible grease film. Additional grease shall be added at least once yearly. For best maintenance, regularly grease in

small quantities.

Lubricants All of the ball screw guides have to be lubricated by means of lithium based grease of

consistency class 2.

Manufacturer Brand name Running distance/lubric interval

Mobil Mobilex 2 100kmTexaco Multifak 2 100kmEsso Beacon 2 100kmKlüber Staburags NBU 12/300 KB 200kmTable 7.2: Lubricants (examples)

All ball screws and fine pitch screws have to be lubricated by means of roller bearing grease type KP2K according to DIN51825.

7.3 Troubleshooting

Table 7.3 lists common problems and their solutions. Contact Asahi/America immediately if this table does not address your issue.

Problem Cause SolutionPlaner running tightly, pipe surfaces not fully planing, chatter marks apparent.

Planer blades are dull. Replace planer blades.

Planer doesn’t work. Safety cut-out turned off. Switch on safety cut-out.Heating plate surface has been contaminated with plastic.

Clean cold heating element only with cloth (sharp objects will damage the surface!)Leave heating element switched-on, and allow plastic to burn off.

Welding temperature not reached.

Safety cut-out turned off.

Supply voltage too low.

Connection SP 110 => heating element is defective.

Switch on safety cut-out.

Check supply voltage and connections.

Check plug connectors.

No display shown after starting. Safety cut-out turned off.

Connection SP 110 =>operation control unit is defective.

Switch on safety cut-out.

Check plug connector.

Printer does not operate. Connections are defective. Check plug connection.Control commands are not executed.

Position is incorrect. See chapter 5, working process.

Table 7.3: Common Troubleshooting

7.4 Service

The SP-110 equipment should be serviced every 3000 welds or at a minimum annually. It is recommended the tool be serviced every 3 months.

For immediate service or questions regarding this tool/manual or for more information, please contact Asahi/America, Inc.

8 Transportation and storage

8.1 General information

The SP-110 should be transported only in its original packing. Avoid rough handling during packing and transportation. When transported by a loading machine (forklift or stacker), the packed machine must be placed

on a pallet. The SP-110 may be transported by plane. During shipping and storage, the transportation case should be wrapped to protect from moisture. Call the Asahi Tool Rental Department direct if unclear or have further questions at (781) 388-

4618.

A minimum of two people are required for handling the equipment.

For unpacking procedures, see Section 4.2.2.

8.2 Packing the SP-110

Before Dismantling the SP-110:

After turning off the SP-110, wait at least 1 hour to allow the heating element to cool before packing back into transport box.

Follow the checklist provided with each tool to confirm all items shipped with the equipment are returned. (i.e. spare blades, misc. tools & wrenches)

Move heating element and planing tool back into transport position. Move movable clamping unit outside to the right (zero position) in order to relieve the load cell. Clean machine. Fasten heating element and planing tool in transport position by means of locking screw. This is

critical to avoid damage during transit! Disconnect all electrical connections. Dismantle touch panel and printer. Roll up connection cables, coming directly from the SP-110 and lay them into machine. Fold down rocker arm and tighten hand screw. Close clamping jaws (pipe clamps) and clamp them down. First put the SP-110 into the transport case. Then stow away all the accessories at foreseen

position. Attach upper part of the transport case and fasten it by the side locks. Put black transport case into wooden shipping crate. Put transformer into wooden shipping crate.

Shut the door to the wooden shipping crate and secure it with the bolt. If using multiple tools, please pack each tool in their designated (stenciled serial #) wooden

shipping crate (Tool sn # should match wooden crate sn # )

8.3 Storage

Store the SP-110 in the transport case in dry and weather-resistant conditions. Avoid high fluctuations of temperature – possible build-up of condensed water will rust tool. As for the permissible storing temperature see chap. 3, technical specifications.

9 Spare Parts List

10 Certificate of Conformity

The manufacturer:

Ing. Wilfried HUFNAGL, Volkgasse 8, 1130 Wien

Confirms that the following described machine:

Welding machine SP 110

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 harmonized Standards have been used in the design and construction of the machine:EN 50081-1: 1991; EN 50082-1: 1991ÖNORM EN 292-1: 1992-03; ÖNORM EN 292-2: 1995-07ÖVE EN 60204-1: 1993-02

Vienna, 15. 03. 1998

Ing. Wilfried Hufnagl

Tool Department Contacts

Asahi/America35 Green St, Malden, MA 02148

Phone: 1-800-343-3618 or 781-321-5409 Fax: 781-388-4749

[email protected]

Equipment Rental

Rental Equipment Manager

[email protected]

Rental Administration, Billing & Returns

[email protected]

Field Technician/Onsite Training

[email protected]

Technical Service

High Purity, Double Wall or Industrial Piping

[email protected]

35 Green Street, PO Box 653, Malden, MA 02148Tel: (781) 321-5409 - Fax (781) 321-4421 - Toll Free: (800) 343-3618

www.asahi-america.com - [email protected] Sales: East (800) 232-7244 / Central (800) 442-7244 / West (800) 282-7244

Betriebsanleitung · Web viewOwner & Maintenance . Manual. SP-110 . IR Fusion. Power Requirements:...

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