CNC 2000 ECO-w
Contents
1. On Off Switch Welding Process Diagram MENU Arrow Keys ENTER Key Interface for printer PC connection ESC Key OPEN Key REDUCE PRESSURE Key INCREASE PRESSURE Key Version April 2005 H RNER Schweisstechnik GmbH HORNER Nieder Ohmener Str 35325 M cke Germany SCHWEISSTECHNIK Emergency Stop button is pressed it disables the power supply to the facing tool the heating element and the hydraulics Power is further supplied to the micro controller board the display screen keeps working When it was pressed the Emergency Stop push button remains locked When the hazard is cleared the button has to be unlocked Important by turning it clockwise It is also possible to move the trolley on the frame manually 3 2 Technical Specs H rner CNC 2000 ECO w Voltage 230V Frequency 50 Hz Total Rated Power 5 5 kW 30A Heating Element 3 7 kW Facing Tool 1 5 kW Hydraulics 0 74 kW Heating Element Facing Tool Hydraulics Operating Range 90 315 mm Hydraulic Characteristics Operating Pressure max 110 bar Oylinder 6 47 m Ambient Temperature 5 C bis 50 C Hydraulic Oil HLP 32 Dimesions and Weight Total Machine Dimensions 1220 x 900 x 1500 mm Weight 250 kg Maximum Trolley Stroke 210 mm 3 3 Preparing to Weld Pipes and Fittings Depending on the type of welding operation the standard clamps mounted on the trolleys of the butt welding machine may have to be replaced by Tee elements or Y elements2. t CE Conformity Conformit CE EG Richtlinie 89 336 EWG EG Niederspannungsrichtlinie 73 23 EWG Andere Normen Other Standards Autres normes EN 50081 1 Generic Emission Standard 03 93 EN 50082 1 Generic Immunity Standard 03 93 EN 60335 1 IEC 335 1 1995 Bei einer nicht mit uns abgestimmten nderung der Maschine oder einer Reparatur von Personen die nicht von uns im Hause geschult und autorisiert wurden verliert diese Erkl rung ihre G ltigkeit Any and all modifications of the device without our prior approval and any repairs by persons who were not trained and authorized by us shall cause this declaration to become void En cas de modification apport e l appareil sans notre accord pr able ainsi que de r paration effectu e par des personnes non form es et agr es par non soins cette d claration deviendra caduque M cke Atzenhain AL den 01 04 2005 Hans Strasser Name und Unterschrift des Befugten Leitung Fertigung Ort und Datum Name and signature of the authorized Head of Manufacture Place and date Nom et signat du responsable Direction de Fabrication Lieu et date vi marusnuusenuaneuf unuensinakusuuastansuuas uit Acht rr nen ADipt GE E Aare und Untersch ft des Befugten tng Eta un ng Name and sign re of the authori ead of ee AA Nom et signature du responsable Direction de D veloppement
3. section 4 Dia gram 14 shows a Y with a 45 angle welded as described above after the first and after the second welding Diagram 11 operation l TI Li an ae KS x lt y P E d s i 3 oa S Diagram 12 d Po d Ta a 3 34 Welding right angles Tees pos we JE To weld Tees replace the standard pipe clamps with the Tee elements Remove bolts G D and 2 E and take the standard clamps from the the Diagram 13 machine trolleys This allows free access to the support panels see Diagram 5 Welding a Tee will require that two welds will be performed Start the operation by welding the 90 elbow To do so place the Tee element intended for the left hand side on the left hand support panel and make sure that for securing the Tee clamp element to the trolley holes A B C and D of the base of the Tee element see Diagram 15 align with holes 4 5 12 and 15 of the left hand support panel Holes A B C and D of the base of the Tee element intended for the right hand side have to align with holes 1 2 10 and 12 of the right hand support panel After the machine was prepared welding proper proceeds as explained in section 4 Diagram 17 shows a 90 elbow first weld ing for a Tee that was welded as described above After the first welding oper ation the 90 elbow is cut placed into the Tee clamp element and connected to the straight pipe by using the same welding proce dure Diagram 18 shows a Tee
4. 3 3 1 Welding Elbows from Pipe Segments Using the standard pipe clamps it is possible to weld elbows of up to 45 from segments of pipe The standard clamps are secured to the support panel on the trolley of the machine using bolts G D and E see Diagram 1 To weld an elbow from segments loosen bolts G D and E and tip the clamp fronts toward each other around the pivoting point G Bolts D and E will remain in the slots prepared for this operation To place the clamps in the correct po Go A A Fixation Bolts of the Support Panel x lie B Fixation Bolts of the Support Panel WE 4 n C Support Panel ar ru D Fixation Bolts of the Pipe Clamp o 1 E Fixation Bolts of the Pipe Clamp no d I F Angle Scale a G Fixation Bolts of the Pipe Clamp A e 0a pivoting point Diagram 1 Version April 2005 CNC 2000 ECO w User s Manual EN 9 HORNER SCHWEISSTECHNIK Diagram 3 HURNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany sition for the intended angle use the angle scale F for orientation To weld elbows up to 30 place D and E as shown in Diagram 2 to weld elbows larger than 30 as shown in Diagram 3 After the machine was prepared weld ing proper proceeds as explained in section 4 Diagram 4 shows an elbow welded from several segments of pipe with several welding operations 3 3 2 Welding Ys with a 60 Angle To weld Ys replace the standard pipe clamps with the Y clam
5. 50mm Wallthickness 22 7mm Straight welding Display 5 SELECT PIPE MATERIAL gt PE80 PE100 PP Display 6 ENTER PIPE DIMENSION Pipe diameter 0250mm Wallthickness 22 7mm Display 7 ENTER PIPE DIMENSION Pipe diameter 0250mm SDR ZO Display 8 SELECT WELDING TYPE gt Straight Welding Elbow Welding T Element Display 9 Y 45 ELEMENT 21 Welding 2 Welding Display 10 ENTER ANGLE Angle 30 Display 11 EN 15 HORNER SCHWEISSTECHNIK After the machine was prepared the welding parameters for the following weld were entered see section 4 3 and confirmed by pressing the ENTER key the machine starts the welding process by facing the pipe ends see Display 12 4 4 1 Facing the Pipe Ends To ensure the pipe ends are level insert the pipe facing tool into the machine Clicking its handle into place in its working position turns it on automatically The machine will then bring the pipes to the facing tool at the predefined pressure Use the INCREASE PRESSURE and REDUCE PRESSURE keys to adjust the pressure during facing manually Pipe facing should continue until shaving forms a continuous blade that rolls twice or three times around the pipe ends so the butts are level Facing is stopped by pressing the ENTER key The machine automatically retracts the pipes If you discover after the facing process that the butts are still not level start over open the m
6. HORNER SCHWEISSTECHNIK User s Manual Butt welding Machine for Workshop Applications CNC 2000 ECO w HURNER SCHWEISSTECHNIK GmbH Nieder Ohmener Str 2 D 35325 Micke Tel 49 0 6401 91 270 Fax 449 ECH 9127 39 Version April 2005 E Mail info huerner st de Web http www huerner st de H RNER Schweisstechnik GmbH HORNER Nieder Ohmener Str 35325 M cke Germany SCHWEISSTECHNIK 1 neie ON 5 2 Safety Instractloris EE 5 2 1 The User s Manuals ae ee Edel 5 2 2 Explaining Icons true nee 5 2 5 Safety MESSAGES EE 5 2 4 Ec 6 2 5 Service and Repair sorrentina M 7 2 6 Transport Storage Shipment recti etre asa e Eas T 2 7 Identitying the Machine EE 7 3 Understanding the Machine idus iore untae lel ted tn EE en edet Een 7 3 1 Machine Components A 8 3 1 1 Component OVOrviBW cicer eek esae IE RE pese Rises 8 3 1 2 Control Panel Components nennen nennen nennen 8 3 1 3 Emergency Stop Switch on the Control Panel 8 3 2 Miel EE 9 3 3 Preparing to Weld Pipes and Fittings RENE 9 3 3 4 Welding Elbows from Pipe Segments n soseeesseseseeesineeressrnternnreneernnsrenerrensrnne 9 3 9 2 Welding Ys with 60 Angle iiim aa ae ae 10 3 3 3 Welding Ys with 45 Angle ssssssseeenenmemm enne 11 3 9 4 Welding right angles Tees inier near 12 3 9 5 Welding ere EE 13 4 OPS FAT OI m 13 4 1 Check out Turning the Machine On 13 4 2 Default Configuration of the
7. IK Put in heat plate 222 C NOM 16 5bar 221 C ACT 0 5bar Display 18 Bead height 2 0mm Bead buildtime 68 s 230 C NOM 16 5bar 229 C ACT 2 5bar Display 19 HEAT SOAK PHASE Heatsoak time 168 s 230 C NOM 16 2bar 229 C ACT 3 2bar Display 20 Remove plate Change over 8s 230 C NOM 16 5bar 220 MEE A Clee ras Display 21 JOINING PHASE 230 C NOM 16 5bar 229 C ACT 3 5bar Display 22 COOLING PHASE Cooling time over 229 C ACT 0 0bar Display 23 EN 17 HORNER HURNER Schweisstechnik GmbH Nieder Ohmener Str SCHWEISSTECHNIK 35325 M cke Germany end of welding be pressing the ENTER key Pressure will then be switched off from the machine WELDING STOPPED 4 5 Welding Aborted Error Build up pres All welding relevant data are constantly monitored while the welding process GE keen is running If one or more of the parameters are out of tolerance and cannot Display 24 be controlled to adjust the welding process is aborted after a given period of time In these cases the error that made the welding process abort is displayed see Display 25 In addition the corresponding LED flashes The error message has to be confirmed by pressing the ENTER key The errors listed in the following table are recognized and displayed on the screen a ZT TE IL DET T o o Cnfiguration Menu to reset the clock Heating Sensor d
8. It is possible that the main switch located on the mounting box inside the right hand leg of the machine has to be turned into the On position to have the machine under power 4 2 Default Configuration of the Machine and the Set up Menu Display 2 shows the report number number before the slash and the weld number after the slash that will be attributed to the next welding operation The weld number which identifies the incremented number of weld e g of a given commission shows only if this function has been enabled in the Con DE Se POLK figuration Menu x Ce 2000 ERAN x X Version 1 05PD x XXXXXXXXXXXXXXXXXXXX To bring the machine in the open or the closed position trolley moved Di g isplay 1 apart or closed in when no welding procedure is running use the OPEN and the INCREASE PRESSURE keys Info Next Welding Time g 10892 Date 08 03 05 Prot No 0014 0005 Display 2 Version April 2005 CNC 2000 ECO w User s Manual EN 13 HORNER HURNER Schweisstechnik GmbH Nieder Ohmener Str SCHWEISSTECHNIK 35325 M cke Germany The Configuration Menu is accessible by pressing the MENU key when Dis play 2 shows on the screen When the operator presses the MENU key the screen asks to enter a selection code see Display 3 This is an access code that authorizes the operator to select and change machine parameters in the appropriate configuration menus Z it The selection code can be entered using bo
9. Machine and the Set up Menu 13 5 10 Entering Applicable Welding Parameters AA 15 4 4 Welding ee 15 4 4 1 Facing tlie Pipe Ends ret tote tite tomes tite lei 16 4 4 2 Checking Pipe Aligntrient iacuit titre carers c een 16 4 4 3 Changing Welding Parameter 16 4 4 4 Inserting and Monitoring the Heating Element 16 4 4 5 Bead Build up Phase REENEN 17 44 6 Heat SOAKING el 17 4 4 7 Change over Phase nennen enne nnne nnns entres entre niter nnne 17 4 4 8 Joining Phase tiet aurei one Ral eee adn eee alas 17 AAG Cooling PlhiaS6 tiere ee Ee epu rede poete MO cip ees Roe ua RERO 17 4 4 10 End of Welding iie inneren di ant eqs eee erac at eae en nec eR 17 4 5 Wolding Re m 18 5 Printing Welding Reporter ana 18 5 1 Printing the Print Men 19 6 Service and MEET Ee d 19 Version April 2005 CNC 2000 ECO w User s Manual EN 3 HORNER HURNER Schweisstechnik GmbH Nieder Ohmener Str SCHWEISSTECHNIK 35325 M cke Germany 4 EN CNC 2000 ECO w User s Manual Version April 2005 H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany 1 Introduction Dear Customer Thank you very much for purchasing our product We are confident that it will meet your expectations and hope that it will contribute to your professional success The development manufacture and check of the heating element butt welding machine has been guided by our concern to offer a device characterized by superior o
10. Y element W have to be aligned with the holes 1 2 12 10 of the right hand support panel see Diagram 11 i IM TM On V A j DA 0x eL OE bog u De M CL For the first welding operation for making a Y with a 45 angle cut the pipes as shown in Diagram 12 Leave 10 mm more length than needed at the centerline where the pipes face each other This extra length will be removed by facing before the second welding The second welding operation is also performed analogous to a Y with a 60 angle place both Y clamp elements onto the left hand support panel and place one standard clamp onto the right hand support panel see Diagram 13 Make sure that the holes E B and A of the base of Y element Z align with the holes 4 2 and 7 of the left hand support panel and the holes A B and E of the Version April 2005 CNC 2000 ECO w User s Manual Diagram 10 EN 11 HORNER HURNER Schweisstechnik GmbH Nieder Ohmener Str SCHWEISSTECHNIK 35325 M cke Germany base of Y elements W align with the holes 9 6 and 12 of eee ee W I Ce the left hand support panel The standard pipe clamp for Pa e e E 1 wet vr welding elbows has to be placed onto the right hand sup 3 f reji ere E port panel in such a way that the angle scale shows 45 _ E V see Diagram 1 Ec E sux eed Ke E HN ge Ge 2 After the machine was prepared in both cases the welding i operations proper proceed as explained in
11. achine completely insert the facing tool thereby launching pipe facing automatically When facing is properly done pipe alignment has to be checked 4 4 2 Checking Pipe Alignment Press the ENTER key to have the machine place the pipes together automati cally On the screen Display 13 the maximum acceptable alignment gap be tween the pipes is shown If the pipes align properly this has to be confirmed by pressing the ENTER key If the gap is too large re adjust the pipes in the clamps and start the facing process again as needed To do so place the machine in the open position first using the OPEN key Then insert the facing tool launching the facing process by clicking the handle into place in its working position You can abort the welding process by pressing ESC 4 4 3 Changing Welding Parameters IWhen pipe alignment was checked the machine moves on automatically to Display 14 if the Manual Input option is enabled in the Configuration Menu In Display 14 the welder can keep the welding parameters from the last weld by pressing the ENTER key or he can adjust them to his specific purposes by pressing the ESC key see Display 15 If the parameters for the next welding process are entered manually the UP and DOWN arrow keys are used to select the line the is to be changed and the new value is typed on the keypad The parameters are saved and applied by pressing the ENTER key the machine moves on from Display 15 to Display 16
12. chine then moves on automatically to the heat soaking phase e After the heat soaking phase the machine automatically moves the trolleys apart and the welder can remove the heating element Version April 2005 CNC 2000 ECO w User s Manual HORNER SCHWEISSTECHNIK StumpfschweiBmaschine Typ CNC 2000 ECO w Maschinennr 05441019 H rner Schweisstechnik Nieder Ohmener Str D 35325 Miicke CE Tel 49 6401 91270 EN 7 HORNER SCHWEISSTECHNIK HURNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany e After the heating element was removed the machine automatically joins the pipes together This is followed by a steady pressure increase until the fusion pressure is reached e The pipe then cools down at the predefined pressure e After the cooling time is over pressure is automatically removed from the pipe and the pipe can be taken out of the frame 3 1 Machine Components 3 1 1 Component Overview 3 1 2 Control Panel Components 3 1 3 Emergency Stop Switch on the Control Panel An Emergency Stop push button is provided on the control panel for inter rupting the welding process if needed to prevent hazardous situations If the 8 EN CNC 2000 ECO w User s Manual Pipe clamps standard clamps shown Heating Element Facing Tool Facing Tool Motor Scanning Wand Control Panel Machine Base Operation Lamp Display Keypad Emergency Stop
13. ding machine increments by 1 for each subsequent weld Additional Data ON OFF To be entered before every welding 20 alphanumeric characters Monitor Ambient ON OFF if ON Ambient temperature will be checked when machine is Temperature turned on if OFF No check of ambient temperature If the ambient temperature is below 0 C no welding process should be started or suitable steps should be taken Manual Input ON OFF if ON It is possible to change the welding parameters manually if OFF manual change of welding parameters impossible Automode ON OFF if ON Build up time included in the control software is used the build up phase will be ended automatically if OFF the build up phase has to be ended manually by pressing the ENTER key Guideline Selecting the welding standard sub menu Set Clock Setting the time of day and date sub menu Choose Language Setting the display printer language sub menu 14 EN CNC 2000 ECO w User s Manual Version April 2005 H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany 5 10 Entering Applicable Welding Parameters After having entered if enabled the traceability data such as Commission Number Welder ID Code etc you can start entering the welding data proper or you can use the parameters from the preceding weld After it was turned on the machine goes on from Display 2 to Display 5 when you press the ENTER key To keep the all displayed welding para
14. e Display 11 When entering the angle to be welded enter the full angle in degrees that the elbow should have do not enter half the angle value The standard pipe clamps of the machine too have to be aligned with Important the full angle value on the scale on the support panels rather than with half the intended value See section 3 3 for a detailed overview on how to prepare the machine for welding elbows Tees Ys and crosses Info Using the entered parameters on pipe material pipe dimension and type of welding the machine calculates the required pressures welding phase dura tion and the temperature of the heating element After you have entered the parameters they are displayed once again for verification The data shown can still be changed by pressing the UP arrow key to go back one step at a time and access the screen in question Confirm these values by pressing ENTER in order to go on to the welding process proper 4 4 Welding Process Before you start welding the machine has to be prepared for the intended type of welding If necessary the standard pipe clamps have to be adjusted to the correct angle scale on the support panels or they have to be replaced with the Tee element or Y elements See section 3 3 to learn how the special elements are placed onto the support panels and adjusted Version April 2005 CNC 2000 ECO w User s Manual HORNER SCHWEISSTECHNIK Pipe material PE80 Pipe diameter 02
15. e relevant parameters during the welding process e Generating a report summarizing the welding process The machine can be used both as on site and as in shop installation Upon entering the type of plastic the pipe diameter and the wall thickness the machine calculates all the parameters that are critical for the welding process taking into account the applicable national welding standards DVS INSTA The entire welding process is automatically controlled monitored and saved to a report The saved welding data can subsequently be transferred directly to a printer or to a PC with DataWork DataWork GIS installed The pipe and traceability data needed can be entered using both the film pro tected alphanumeric keypad and a barcode scanning wand For various applications the machine can be specifically configured in the Configuration Menu see section 4 2 Configuring the Machine The welder performs the welding process in the following manner e Pipes are clamped into the frame if welding elbows Tees or Ys only after cutting the pipes for construction e Pipe ends are worked using the pipe facing tool e Pipe alignment is checked following the information on the display e The heating element is inserted after cleaning it and checking the tempe rature e After the heating element was inserted the pipes close in automatically at the predefined build up pressure e During the build up phase the weld bead builds up e The ma
16. ect a common PC printer directly to it or to export the data via a RS232 cable to a PC with DataWork or DataWork GIS installed 18 En CNC 2000 ECO w User s Manual Version April 2005 H RNER Schweisstechnik GmbH HORNER Nieder Ohmener Str 35325 M cke Germany SCHWEISSTECHNIK Technical Specs of the Interface e Parallel Centronics e Serial RS232 Baud Rate 19200 Baud Data Bits 8 Stop Bits 2 Transfer Protocol X ON X OFF 5 1 Printing the Print Menu When a data communication cable Centronics Serial is connected the ma chine displays the Print Menu Data will be sent according to the selection to the a printer or to a PC Use the UP DOWN arrow keys to switch between Print all Protocols and Print Commission No and press ENTER to confirm your selection of a print mode XXX PRINT MENU xxx gt Print all protocols Print commission no The Print all Protocols mode causes all the report protocols stored in system memory to be printed off The Print Commission No mode leads the operator automatically to the next screen where the commission number to be printed is selected see Display 26 Display 25 If the Print Commission No mode is selected in the Print Menu the first avail able commission number is displayed Use the UP DOWN arrow keys to display one after the other the commission numbers stored in system memory Select Deine comission ne one of them and press ENTER to send the data from this commiss
17. efective Heating element not connected check connector socket Temperature Sensor defective Ambient temperature sensor is defective c Welding Process Temperature low Heating element temperature will be increased automatically Temperature high Heating element temperature will be reduced automatically Error Changeover It took too long to retract the mirror and bring the pipes to joining welding will have to be repeated Ambient Temperature high Ambient temperature outside the range from 0 C to 50 C Ambient Temperature low Ambient temperature outside the range from 0 C to 50 C Error Drag Pressure Impossible to determine the drag pressure maybe pipes will have to be clamped once again Error Build up Pressure Calculated maximum pressure too high impossible to start welding maybe pipes will have to be clamped once again Error Heat Soak Pressure Heat soaking pressure too high impossible to re adjust Error Joining Pressure Joining pressure too high or too low impossible to re adjust Cooling Stopped Operator has stopped the cooling time by pressing the ESC key Power Supply Failure In the course of the last welding a power supply failure occurred welding has to be repeated Error Plate Temperature Plate temperature is out of tolerance impossible to re adjust the temperature maybe the ambient temperature was too low 5 Printing Welding Reports The machine is equipped with a dual interface that gives you the opportunity to conn
18. ers Manual have to obtain CNC 2000 ECO w User s Manual H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany Version April 2005 H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany 2 5 Service and Repair Asthe machine is used in applications that are sensitive to safety considerations it may be serviced and repaired only on our premises or by subcontractors and partners who have been specifically trained and authorized by us Thus constantly high standards of operation quality and safety are maintained Non compliance with this provision will dispense the manufacturer from any warranty and liability claims for the machine and any con sequential damage Info 2 6 Transport Storage Shipment The machine is shipped on a palette When loading or unloading the machine ensure it is not tipped excessively During transport the pipe facing tool and the heating element have to be in the working position and to be secured properly in order to prevent them from tilting up 2 7 Identifying the Machine Each machine is identified by a name plate It shows the machine model Typ the serial number Maschinennr and the manufacturer The first two digits of the serial number represent the year of manufacture 3 Understanding the Machine The machine is a butt welding machine for plastics which has basically three functions e Controlling the welding process e Monitoring all th
19. ion only to OTTELE the printer or PC t4 t t 4 4 If the machine displays a Printer not Ready error message after you pressed Display 26 ENTER 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 to select the correct baud rate and interface type Depending on the printer used make sure Auto Carriage Return and or Auto Line Feed are enabled if necessary so as to print the reporting protocol in the correct format nfo 6 Service and Repair Contact H rner Schweisstechnik Nieder Ohmener Str Tel 49 0 6401 9127 0 35325 M cke Germany Fax 49 0 6401 9127 39 Web www huerner st de Mail info huerner st de Version April 2005 CNC 2000 ECO w User s Manual EN 19 CERTIFICATE MANAGEMENT SERVICE The Certification Body af T V Management Service GmbH certifies that a H rner Schwei technik GmbH HORN E R Nieder Ohmener Str SCHWEISSTECHKHIK D 35325 M cke has established and applies a Quality Management System for Development sale and manufacture of welding devices used in pipeline construction applications as well as the development and the manufacture of flow monitoring systems and engineering plastics gt i c Liu ce e am St c LL CC Lui 3 F et Se e r EL n LA St H4 e ail E Di An audit was perfor
20. is forbidden to remove shaving from the machine while the facing process is still 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 used Since the heating plate presents a tempera ture of more than 200 C during the welding process it is absolutely necessary that operators wear suitable protective gloves Please note that the heating plate will remain hot for a while after it was turned off Danger of Bruises and Injury Do not remain in the danger zone while the machine opens or closes and be sure not to have you arms or hands between the moving and the fixed trolley of the machine Acceptable Work Conditions The work zone has to be clean and has to have proper lighting It is dangerous to operate in a humid environment or close to inflam mable liquids In regard of this acceptable work conditions have to be ensured e g sufficient distance between the machine and other functional areas of the workshop User s Manual 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 be incom plete or illegible replace it without delay Feel free to contact us for assistance 2 4 Warranty Warranty claims may be raised only if the conditions for warranty given in the General Terms and Conditions of Sale and Shipment obtain Furthermore the conditions contained in the Us
21. ld that needs to be performed will connect the angle just welded to the straight pipe in the Y This requires placing both Y clamp elements onto the left hand support panel see Digram 8 For securing them to the trolley align holes C D and G of Y element Z with holes 1 17 3 of the support panel Align holes C D and G of the base of Y element W with holes 10 14 and 11 of the support panel Then place the _ HORNER SCHWEISSTECHNIK standard pipe clamp on the right hand support panel secure Neon it to holes 5 7 and 11 and tip its front toward the centerline as far as possible After the machine was prepared welding proper proceeds as explained in section 4 Diagram 9 shows a Y with a 60 angle that was welded as described above 3 3 3 Welding Ys with a 45 Angle To weld a Y with a 45 angle the procedure is analogous to welding a 60 angled Y see section 3 3 2 First the 45 angle is welded then the straight pipe is connected to this angle Start by removing the standard pipe clamps from the support panel and mount the Y clamp elements Here too make sure that the holes in the base of the Y elements see Diagram 10 are aligned with the proper holes of the support panel see Diagram 5 for securing the clamps to the trolleys The holes B A H and of the base of Y element Z have to be aligned with the holes 4 5 12 15 of the left hand support panel and the holes B A H and of the base of
22. med Report No 70005562 Proof has been furnished that the requirements according to ISO 9001 2000 are fulfilled The certificate is valid until 2007 01 18 Certificate Registration No 12 100 14555 TMS Murch z 042 1 28 Crutscher Akkreelibenm nga ge 25 FE cg I RS Updr cien Gacy TOM Maespament amp aranc Gma Unter shinee nips TUN Shddeusstarel 2dkbatrzsit afg BS Dr s03528 Miinchen TiaA zM 7 9z2 ZERTIFIKAT amp CERTIFICATE 4 E JJ ad kk G KONFORMITATSERKLARUNG Declaration of Conformity D claration de conformit Wir We Nous H RNER Schwei technik Nieder Ohmener Str D 35325 M cke Atzenhain erkl ren in alleiniger Verantwortung dass das Produkt declare under our sole responsibility that the product d clarons sous notre seule responsabilit que le produit CNC 2000 ECO w Heizelement Stumpfschwei maschine f r die Verarbeitung von Kunststoffrohren und formteilen Heating element butt welding machine for processing plastic pipes and fittings Machine souder bout bout l ment chauffant pour l assemblage des tubes et raccords en plastique auf die sich diese Erkl rung bezieht mit den folgenden Normen oder normativen Dokumenten bereinstimmen to which this declaration relates are in conformity with the following standards or standardizing documents auxquels se r f re cette d claration sont conformes aux normes et documents de normalisation suivants CE Konformit
23. meters for the following welding press the ENTER key the welding will start immediately If data have to be changed for the next welding press ESC The first step consists of selecting the appropriate pipe material using the UP DOWN cursor keys see Display 6 Use the ENTER key to confirm you selection of the pipe material The machine goes on automatically to the next menu item entering the pipe dimesions This screen see Display 7 asks the welder to enter the diameter the wall thickness or the standard dimension ratio SDR of the pipe that is going to be welded This is done moving the cursor character by character and into the next line using the RIGHT arrow key To be able to enter the SDR first press the DOWN arrow key when they cursor is in the Wall thickness line To apply the values entered press the ENTER key Finally the type of welding is also part of the welding parameters see Display 9 Here too use the UP and DOWN arrow keys to select the kind of welding that is going to be performed and confirm your selection by pressing the ENTER key The available options are Straight welding Elbow welding T Element Y 45 Element Y 60 Element and Cross If a Y element welding is selected in this menu the welder has to specify furthermore if the welding is the first or the second for making this Y see Display 10 If a elbow welded from pipe segments is selected the angle the elbow is going to have has to be entered se
24. on indicates tips and useful information for using the machine more efficiently and more economically Info 2 5 Safety Messages Protect the power supply cord and the pressure lines from cutting edges Have an authorized service shop replace damaged cables or lines immediately e The device may be operated and serviced exclusively by authorized staff who have been trained on it Version April 2005 CNC 2000 ECO w User s Manual HORNER SCHWEISSTECHNIK EN 5 HORNER SCHWEISSTECHNIK e The machine may be operated only when observed e Before operating the machine always check for damaged parts and have them repair or replace by an authorized service shop as needed e The protective caps on the interface and the pressure lines have to be in place during transport so as to prevent contaminants and humidity from entering the machine e EVU wiring regulations VDE provisions DIN CE regulations and national laws will have to be respected e Without prior authorization by the manufacturer no modifications may be made to the device Caution Caution Caution Caution Caution Info 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 protect the facing surfaces from dirt and damage It
25. onds see Display 20 A signal is audible during the final 10 seconds of heat soak immediately before the change over During the Heat Soaking Phase LED 3 flashes LED 1 and LED 2 are steadily lit During this phase the pressure applied while the pipes soak the heat from the plate and the plate temperature are constantly monitored and controlled 4 4 7 Change over Phase After the full heat soaking time the pipes retract automatically The heating element has to be removed as fast as possible see Display 21 During the Change over Phase LED 4 flashes all previous LEDs are steadily lit The machine then places the pipes automatically together again 4 4 8 Joining Phase In the Joining Phase the machine increases pressure in accordance with the pressure ramp calculated for the weld see Display 22 During this phase LED 5 flashes all previous LEDs are steadily lit 4 4 9 Cooling Phase When the full joining pressure is reached the machine moves on automatically to the Cooling Phase see Display 23 The cooling down is displayed as a countdown During cooling the joining pressure applied is constantly monitored During this phase LED 6 flashes all the previous LEDs are steadily lit 4 4 10 End of Welding A double buzz indicates that the cooling time has ended Furthermore the green LED is steadily lit to indicate a successful welding process Confirm the Version April 2005 CNC 2000 ECO w User s Manual HORNER SCHWEISSTECHN
26. or from Display 16 back to the welding process The parameters set manually are kept in memory when the machine is turned off Only the pressure values are calculated individually for each welding process If the pipe dimensions change all parameters Important have to be set once again The machine recognizes the change of dimension and leads the operator directly to the menu that allows changing the parameters 4 444 Inserting and Monitoring the Heating Element The machine controls and monitors constantly the temperature of the heating element If the temperature is not within the tolerance thresholds the machine shows an error message to this effect in the first line of the display Furthermore the upper and lower thresholds of the tolerance range are indicated in the fourth line along with the current actual temperature see Display 17 16 EN CNC 2000 ECO w User s Manual H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany Facing pipe ends Display 12 Check pipe alignment Max gap 2 5mm Display 13 Do you want to use data of previous welding ESE lt Display 14 Heating pr 030 5bar Heatsoakpr 010 5bar Heat soak 0120 s Change over 0005 s Display 15 Cool time 0900 s Pr build up 0010 s Heat temp 0223 C Display 16 Plate temp too low 222 210 9C 292 t Display 17 Version April 2005 H RNER Sch
27. p elements Remove bolts G D and E and take the standard clamps from the the machine trolleys This allows free access to the support panels see Diagram 5 Welding a Y will require that two welds will Diagram 4 be performed Start by welding the 60 angle in the Y To do so place Y element Z on the left hand support panel and Y element W on the right hand support panel Make sure that for securing the Y clamp element to the trolley holes A F and H of the base see Diagram 10 of element Z align with holes 6 8 and 13 of oi rl t 5 i D dia xS Mes a y eo ans aor M CX e D A Sg m D EN val SA vn Ge n G et du L T UM ME D TE SIE org oz amp E fut SIE gia oip d gH n ot GC Diagram 5 W I a T Jo the left hand support panel a me i A AN Holes A F and H of the base TIERS qul kr of element W have to align ie J Dos with holes 4 8 and 13 of the 7 We soji Dod i right hand support panel see N E s Diagram 6 wood V Ga su mj X I n zd HS M EPI Bu s JI A ff ss After the machine was pre Ta Ten LO a ES j pared welding proper pro E E M di A WW ceeds as explained in sec Diagram 6 Sw ech us 10 EN Diagram 7 CNC 2000 ECO w User s Manual Version April 2005 H RNER Schweisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany tion 4 Diagram 7 shows a 60 angle in a Y that was welded as described above far The second we
28. peration safety and user friendliness The device 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 mes sages in this booklet and the regulations for the prevention of accidents This manual is applicable to the following machines CNC 2000 ECO w Thank you 2 Safety Instructions This User s Manual contains important instructions for operating safely the heat ing element butt welding machines H rner CNC 2000 ECO w Every person who operates the machines will first have to read this Manual 2 1 The User s Manual The User s Manual is presented according to sections which explain the dif ferent functions of the machines All rights in particular the right to copy and distribute as well as to translate are reserved The copy or reproduction in print or electronic form is subject to the prior written authorization by HURNER Schweisstechnik M cke Germany 2 2 Explaining Icons The following expressions and icons are used in this User s Manual to refer to safety related issues This icon indicates that non compliance may result in a hazardous situation that possibly causes bodily injury or material damage Caution ES icon indicates important messages related to the correct use of the machine Non compliance may cause problems of operation Important and damage to the machine This ic
29. th the keypad and the scanning wand to read the operator code Enter Select Code Display 3 After entering an incorrect code three times the machine returns CONFIGURATION SELECTION CODE automatically to the ready to weld screen Display 2 If the access 415311 code for selecting and changing values that was entered is correct Important the Configuration Menu shows on the screen as in Display 4 In the Configuration Menu use the UP and DOWN arrow keys to select a spe cific configuration option The option can then be set to On or Off using the RIGHT arrow key The M displayed for the Set Clock Choose Language irm alias Te and Guideline options indicates that a sub menu can be accessed by pressing Welder Code d on the MENU key Memory Contr on Display 4 When you press the ENTER key the settings will be saved and ap plied Press ESC to quit the configuration menu without saving any Important modifications The Configuration Menu contains the options listed in the table below Description Setting Data to be entered Commission Number ON OFF To be entered before every welding 32 alphanumeric characters O Welder ID Code N OFF To be entered before every welding ISO welder identification code 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 Weld Number ON OFF To be entered before the first wel
30. weisstechnik GmbH Nieder Ohmener Str 35325 M cke Germany As soon as the nominal temperature is reached Display 18 shows By inserting the heating element you make the machine move on to the Build up Phase At this time the pipes are placed together automatically and the calculated pressure during bead build up is applied 4 45 Bead Build up Phase IDuring the Build up Phase LED 1 flashes to indicate the progress of the welding process As soon as the build up pressure is achieved as shown in Display 19 the display indicates both the maximum bead height and the time so far used for build up During this phase the build up pressure and the heating element temperature are constantly monitored When the bead height indicated on the display is reached the operator has to press the ENTER key to terminate the Build up Phase The machine then continues automatically to the Heat Soaking Phase As long as the nominal pressure of the Heat Soaking Phase is not reached yet LED 2 flashes while LED 1 is steadily lit The machine reduces pressure automatically Build up Phase will be terminated automatically at the end of the bead build up time included in the control software If this is not the Important case the end of the Build up Phase has to confirmed manually ES If the Automode option is enabled in the Configuration Menu the 4 4 6 Heat Soaking Phase The time for soaking heat is displayed as a countdown showing the remaining sec
31. welded as described above after the second welding operation Diagram 14 Diagram 15 12 EN CNC 2000 ECO w User s Manual Version April 2005 H RNER Schweisstechnik GmbH HORNER Nieder Ohmener Str 35325 M cke Germany SCHWEISSTECHNIK 3 3 5 Welding Crosses In principle the procedure for welding crosses is analogous to welding Tees see section 3 3 4 However three welding operations will be needed in this case After the standard pipe clamps were replaced with the Tee clamp elements AS Diagram 17 the first two steps of this kind of welding consist of welding two 90 elbows Then both elbows will be cut along the outer angle to face each other and will be placed in this state into the Tee clamp elements The third and last welding then forms a cross out of the two elbows 4 Operation EEN e E E P OW D 4 1 Check out Turning the Machine On d Ss Diagram 18 Before the control unit is turned on check the oil level of the hydraulics and fill up HLP 32 hydraulic oil as needed Important Ese The surfaces of the heating plate have to be free of grease and clean or they have to be cleaned Important Es Make sure all connectors are tight in their sockets and make sure that the machine is operated only if the conditions for safe and intended Important USe are met see also section 2 After connecting the power supply cable to the mains power supply the machine is turned on using the On Off switch
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