SP -S - ASAHI/America,Inc.
Contents
1. the material of the pipes that are going to be welded is then displayed on the touch screen panel see Display 7 To select a material touch the appropriate button on Default Material the screen PUDF ECTFE Default Materials are those pipe materials that are defined by default when the machine J is shipped Additional Materials if any are those pipe materials that were defined by the Addit Material mci d 3 user in the definition screens accessible from the appropriate configuration menu option see section 4 5 The maximum number of additional materials is three Display 7 Version June 2010 agru SP 250 S User s Manual EN 15 ASAHI AMERICA When the appropriate button was touched to select a pipe material the screen changes and displays the selection of pipe diameters with default and additional diameters just as for the materials Finally a third similar screen allows selecting the appropriate wall thickness Note that a screen will not appear if it would not make sense to display it For instance if only one wall thickness is defined for a given pipe diam eter the wall thickness selection screen will not show Moreover when you select an additional material this has to be confirmed by entering the so called selection code see sub section 4 3 Default materials can be welded without entering this code The machine must never be used to weld pipe materials diam eters and thicknesses other than thos2. close in the carriage see Display 10 This is done by touching the Move on button and simultaneously holding down the green confir mation push button on the machine front Then follow the steps the machine indicates on the screen determine the facing road clamp in the pipes and have the machine move the facing tool to Position 2 the facing position Remem ber that every action that makes the carriage close in or pull away has to be confirmed in two hand mode with the appropriate button on the touchscreen panel and the confirmation push button on the machine front Before starting the facing process proper you can determine the facing road i e the distance that the carriage must travel during facing To change the value displayed on the screen when the process reaches this step use the and buttons The travel length must be a minimum 4 mm After you changed the facing road you have to clamp in the pipes anew During facing the machine displays nominal and actual force along with the effective facing road so far achieved When the pipe butts are faced the machine shows an end of facing message see Dis play 11 Visually check the pipe butts and if they are o k confirm by Facing OK The machine moves the carriage apart to let you Display 11 18 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA remove the facing tool If the result of facing is poor the process can be repeat
3. connected device to the a printer for print out or to a PC for further processing and archiving Touch the appropriate button to select print ing All Reports printing By Commission Number or printing By Date AGRU SP 258 5 24 06 2010 l 23 Display 18 The option All Reports causes all the weld ing reports stored in system memory to be printed While the machine transfers the reports a countdown indicates how many of them remain to be printed or transferred The options By Commission Number and By Date lead the operator to the next screen in which arrow buttons can be used to browse through the reports in system memory to select the desired commission or date from which reports should be printed or transferred see Display 19 The options show the first available commission number Display 19 22 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA or date and once the desired one is found the selection has to be con firmed by OK to start the transfer to printer or PC If the machine displays a Printer not Ready error message after you touched the Ok button the printer has to be switched to on line mode Check for potentially damaged connections from the machine to the printer or the PC After successful printing the machine displays a message telling the welder that printing was o k 5 2 Showing Reports in Memory Reprinting Tags ration menu see sectio
4. 18 4 6 2 Checking Pipe Alignment AAA 19 4 6 3 Pre heating the Pipe Butts and Inserting the Heating Element 19 4 6 4 Heat Soaking SAREA 20 46 5 Changeover Sa 20 466 JONNI SEA 20 406 7 Cooling PIAS isi ssi ozi en reta aak EE erare teak 20 4 6 8 ENO Welding m e Et e mad ce EEE 20 4 7 Aborted Welding Process tenti ee re rk aie nk petes paa dn 21 5 Printing and Transferring Welding ESPOS rrura 22 5 1 The Print Menu and Printing Transferring Reports 22 5 2 Showing Reports in Memory Reprinting Tags rrua 23 5 8 Deleting Reports from Memory errua 23 6 System ia desietan te ei iare 23 6 1 Setting the Date and the Time of Day rra 23 6 2 Enabling Automatic aA 24 7 ilaia Sa 24 8 Service and Repair Contact iul reete eld ue ra dE Ex Re tue 25 ASAHI AMERICA Version June 2010 P O Box 653 35 Green Street Malden MA 02148 Tel 800 343 3618 781 321 5409 Fax 800 426 7058 Website www asahi america com Email asahi asahi america com agru SP 250 S User s Manual EN 3 ASAHI AMERICA Caution The machine has to be operated exclusively with a power supply line equipped with a protective grounding conductor as a power supply without this safety element may cause severe machine damage If the machine is operated through a power supply without a grounding conductor this will void any and all warranty under which the product may be agru SP 250 S User s Manual Version June 2010 1 Intr
5. cooling time is over the force is automatically removed from the carriages and the pipe or fitting can be taken out of it 4 Operation ES e to the first use of the machine the transport locks that avoid longitudinal and Important transverse movement of the console sup porting the facing tool and the heating ele ment have to be removed see photographs on page 9 An Allen wrench for removing the transverse lock is included with the ma chine The control software of the machine moni tors the transport lock status When the machine is turned on with the locks in place welding cannot be started and an error message shows see photograph on this page Whenever the machine is moved the transport locks have first to be installed Damage due to the fact that the machine was Important moved without installed transport locks is not eligible for war ranty The transport lock may be installed and removed only when the machine is turned off Damage due to non compliance with this provision will also disqualify from warranty 4 31 Check out Turning on Selecting the Display Language Place the machine on a level surface and ensure it cannot slide Suffi cient distance has to be kept to other areas in the workshop especially to those in which combustible materials are used in order for the heating element temperature of up to 500 C 930 F not to be hazardous Depending on the piece that is going to be welded the outer clamps may have t
6. data on welding 588 Mom Temp COC progress 496 Actual Temp LOCI Parameter menus to l configure operation settings ERI Hom Time Cs Input keyboards 18 Actual Time Cs PUDF 258 14 2 Error messages Notes Navigation Bar with User Interface Buttons Version June 2010 agru SP 250 S User s Manual EN 9 ASAHI AMERICA 3 2 3 Ports and Switches er E Fuse of Nitrogen A m Control 7 Power Supply to Printer USB B Interface for connection to PC Nitrogen Control USB A Interface for connection to tag printer or a USB stick Scanning Pen Buzzer On Off Switch Scanning Pen Port Ambient Temperature Sensor The machine can be used as an in shop installation and with anodized aluminum components it is also suited for clean room applications The machine enables users to enter the data that are relevant for the weld ing process and for the traceability of the welded joint From the entered welding parameters it calculates the applicable forces and temperatures and controls the welding process automatically All welding and traceability data are entered either directly on a touch screen panel or read from a bar code using a scanning pen The welding process in monitored in its entirety and saved to a welding report All welding reports can the be printed or transferred to a computer with a suitable pipeline management software such as DataWork agru Using the menus displayed on the
7. of the regular welding in all cases Info tings of traditional materials or fittings to fittings pre heating is designed to be used only when the fitting is securely fastened Important EN Using the pre heating feature is acceptable only for welding fit Version June 2010 agru SP 250 S Users Manual EN 19 ASAHI AMERICA While the welding procedure is starting with 3 or without pre heating the machine controls and monitors constantly the temperature of the heating element and the welding force and time Nominal values and tolerance ranges are defined by the key data for the welding operation previously entered or con firmed If a value is not within the applicable tolerance thresholds the machine shows an error message to this effect and the welding process is aborted 4 6 4 Heat Soaking Phase In the first welding phase the pipes close in on the heating element with the defined weld ing force and are thereby warmed During the entire duration of the heating phase they Display 13 continue to soak heat from the heating plate AGRU SP 258 5 24 06 2010 14 23 without touching it eto On the touchscreen the welding progress diagram indicates in which phase the weld ing currently is green LED icon In case 288 Mom Force EH of malfunction the welding process can be 19r Actual Force CHI aborted by touching the Cancel button If the machine detects a malfunction the color 500 Hom Temp C
8. or electronic form and distribute as well as to translate are reserved and subject to prior written authorization 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 haz ardous situation that possibly causes bodily injury or material mage Caution ES s icon indicates important messages related to the correct use of the machine Non compliance may cause problems of Important operation and damage to the machine This icon indicates tips and useful information for using the machine more efficiently and more economically Info Version June 2010 agru SP 250 S User s Manual ASAHI AMERICA EN 5 ASAHI AMERICA 2 3 Safety Messages Protect the power supply cord from cutting edges Have an authorized service shop replace damaged cables or lines immediately The machine has to be operated with a 400 V 50 60 Hz power supply with safety fuse or breaker of 32 A If power is connected through a power line manifold the power supply has to feature an earth leakage circuit breaker The length of the power supply cord is 4 m 13 feet The length of an extension cable will preferably not exceed 10 m 30 feet Caution Caution Caution Caution Caution ES Important ES Important Important 6 EN Parts Under Power After opening the machine or removing the cover parts
9. screen keeps the display that asks the welder to remove the welded joint from between the clamps If automatic heating was enabled no matter whether by the Enabled Disabled button alone or in combination with the Last Welding button it makes sure that the heating element starts heating at the preset time of day and switches itself off after reaching the set temperature 7 Service and Repair As the machine is used in applications that are sensitive to safety con siderations it may be serviced and repaired only on our premises or by partners who were specifically trained and authorized by us excepting the maintenance steps given below Thus constantly high standards of operation quality and safety are maintained 24 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA SS Non compliance with this provision will dispense the manufac turer from any warranty and liability claims for the unit and any Important consequential damage All machines that are new or newly programmed during maintenance or upon request are shipped with the most recent software version Lubrication of Ball Guide Bushings Runner Blocks Drive Spindle The 4 ball guide bushings of the support console of the facing tool and heating element and the 2 runner blocks of the heating element and 4 runner blocks of the facing tool as well as the 4 runner block of the mov able carriage of the machine see the photos and the machine descrip
10. training The operating owning company engages to check at reasonable intervals if the machine is operated by the welders with the intended use and under proper guidelines of safe work e The machine must never be operated if not in proper state of repair Before welding the welder is required to make sure that the state of the machine is in order tS During transport the support console of the heating plate and facing tool has to be secured with the transport locks at all Important times When installing the machine remove the transport locks before applying power to the machine 2 5 Warranty Warranty claims may be raised only if the conditions for warranty given in the General Terms and Conditions of Sale and Shipment obtain Fur thermore the provisions and instructions contained in the User s Manual have to have been respected The term of warranty under which the welding machine is shipped is 12 months from the date of purchase if the machine is bought as a new machine from the date of first use if the machine is used independently of purchase e g when lent or if it is not bought as a new machine At the date of shipment the service and maintenance interval is also set to 12 months 2 6 Transport and Storage During transport the machine must be at all times in the transport box it is shipped in Ensure that the console with heating plate and facing tool is locked during transport The transpor
11. ASAHI AMERICA User s Manual Infrared Welding Machine SP S P O Box 653 35 Green Street Malden MA 02148 Tel 800 343 3618 781 321 5409 ASAHI AMERICA Fax 800 426 7058 Website www asahi america com Email asahi asahi america com ASAHI AMERICA Contents 1 aes dies conte 5 2 Salety Messages e O 5 2 1 The Users Manual ED 5 2 2 Explaining ICONS c 5 2 3 Safety Messages rrua 6 2 4 Welder and Operator Obligations rra 7 2 5 Mz MM 7 2 6 Transport and Storage ioi ieee a Um UE MR ee ne 7 2 7 Identifying the Machine errua 7 3 Product Description and Principles of Operation rr 8 3 1 WME MASA USS c 8 3 2 Machine BIST Te g oj i o IER 8 3 24 Component Sua erc eren rens AEE ea i na ga oae py senna ERE Eaa 8 3 2 2 Touchscreen Control Panel iiit tertie Ee ded Age opas dar eien 9 3 2 9 Ports and SWIECI68 uite teret ere pnta c nee erare teak zea 10 324 SPOCHICAONS C Eat 10 3 3 Welding Process Overview rra 11 4 OperatioM E LC 12 4 1 Check out Turning on Selecting the Display Language s 12 4 2 Entering Traceability Data for the JO 13 4 3 Configuring the AEA 14 4 4 Changing Key Data of the MISIO rr 15 4 5 Definition of Welding Parameters for Additional Materials 16 4 6 WOIGING PLOCOSS c 17 4 6 1 Facing the Pipe SA
12. OC of the LED icon for the appopriate phase 436 Actual Temp COC changes from green to red 329 Hom Time Pa 4 6 5 Change over Phase Actual Time s bae At the end of the heat soaking phase the carriages are moved apart automatically The heating mirror is removed from in between the pipes and the carriages close in again both actions occur auto matically The welding progress diagram on the touchscreen indicates i hich ph th Idi tly i Display dT he welding currently s ee GRU SP 250 S 24 06 2010 1423 purra The welder has to monitor the change over and must abort welding by touching Cancel in case a malfunction occurs E H Baa Did 4 6 6 Joining Phase GR actual Force DO In the joining phase or fusion phase the 508 Hom Temp COC machine increases the applied force in ac 588 Actual Temp CCI cordance with the force ramp calculated for p Saw Mom Time Cs the weld This phase is also indicated on the touchscreen panel a Actual Time Cs PUDF 298 14 2 Display 14 4 6 7 Cooling Phase When the full joining force is reached the machine moves on automatically to the cooling phase see Display 16 Display 15 The cooling down is displayed as a countdown During cooling the ap plied joining force is constantly monitored 4 6 8 End of Welding After a successful welding operation which can also be recognized in the welding diagram the applied force is removed from the pipes and they can be ta
13. abled Whatever this setting the sound will be heard to indicate the imminence of the change over phase Select Language Menu In a sub menu the language in which display texts and reports are edited can be selected New Page in Menu Memory Control ON OFF if ON Machine stops when the memory is full if OFF Machine overwrites the oldest report when the memory is full Machine Parameters In a sub menu the machine number can be entered and the temperature of the heating mirror and the welding force can be zeroed calibrated Access to this sub menu requires an additional access code that is available from the manufacturer distributor Date Time In a sub menu date and time can be set Delete Reports In a sub menu it is possible to delete all welding reports currently in memory To access this sub menu the so called selection code is required see at the beginning of this sub section the reports will be deleted only after another safety warning was confirmed New Page in Menu Additional Materials Menu In a sub menu the key data for welding can be defined for pipe materials that are not available yet 4 4 Changing Key Data of the Welding In the welding individual start screen see Display 5 it is possible to change the weld specific key data for the E ae joint to be welded To do so touch the New AGRU SP 258 5 24 66 2018 14 23 button The screen that allows selecting
14. ameter up to two wall thicknesses or SDR values By touching one of the Input buttons on this screen the parameters for welding this material can be edited Touching the leftmost Input button in Display 8 will allow entering changing or deleting the welding parameters for 250 mm PVDF pipe with a 14 1 mm wall Using the second Input button from the left the welding parameters for 250 mm PDVF pipe with another wall thickness can be entered and all other Input buttons allow AGRU SP 250 5 24 06 2010 14 23 tnt f v6 entering the parameters for PVDF pipe with other diameters As soon as one of the Input buttons was touched Display 9 shows From this screen it is possible to edit in various ways the specific data branch of which the Input button was used to access Display 9 The button New Parameters allows entering from scratch all welding parameters for the branch in the data tree of which the Input button was touched Data input proceeds as described at the beginning of section 4 5 from the name of the pipe material through to the facing force Display 8 Touch the Edit Parameters button to change the value of a single welding parameter in the appropriate data branch Touching this button will let you access a screen in which the parameter you want to change can be selected from all the key data that need to be defined From eee that screen an input screen is accessed in which the value c
15. an be changed then confirm the change by touching the Ok button The Delete Parameters button can be used to delete the branch of the data tree of which the Input button was used to access Display 9 Deleting has to be confirmed in another safety message and then the key data for welding the material from joining force to plate tem perature are deleted along with the appropriate wall thickness or SDR If this wall thickness or SDR is the only one left for the pipe diameter in Display 9 question then the diameter is deleted from the data tree too And if the thus deleted diameter is the only one left for this pipe material the entire tree including the material itself is deleted By touching the Delete Parameters Completely button it is possible to delete the parameter of all additional user defined pipe materials Here too deleting is possible only after cofirming it in a safety message After deleting them only the default materials with which the machine is shipped remain If the material that was used in the last welding operation is deleted then the next welding operation of necessity requires a new material to be selected for welding Info 4 6 Welding Process IZ De welding machine operates in two hand mode at any time For any step in the welding process that may put the operator s Important Version June 2010 agru SP 250 S User s Manual EN 17 ASAHI AMERICA hands at risk of inj
16. d on the screen Sese EO spem OOS Clock Error The internal clock of the machine is defective re set the clock in the configuration menu Transport Lock The transport locks were not removed before switching the machine on see sections 3 and 4 1 Power Supply Error The rotating field of the power supply plug is incorrect Two phases have to be inverted see section 3 3 It is also possible that excessive or insufficient voltage was detected before or during the welding process System Error Malfunction in the control system of the machine power to the machine has to be turned off and the machine unplugged immediately and it has to be sent to the manufacturer or an authorized service point for check and repair Printer not Ready The printer or PC connected to the machine is not ready no communication faulty cable or if serial interface bad interface configuration Unit Maintenance Due The recommended service interval for the machine is over It should be sent to the manufacturer or an authorized service point for scheduled maintenance and service No Function Available A control touchscreen button switch was used for which no function is defined Version June 2010 agru SP 250 S User s Manual EN 21 ASAHI AMERICA Type of Error Description continued c Welding Process S Ambient Temperature Error The ambient temperature is out of the acceptable range from 0 C through to 40 C w
17. e Lis and switching the machine off result in loss of the preset time Display 22 Enter the desired date and time of day on the keypad after each input the machine moves on to the next field automatically then touch the Disabled button This button shows the current status of the automatic heating when you touch it it changes from Disabled to Enabled as the automatic heating feature is now on Enabling the automatic heating feature should be the last action tS before you leave the worksite For it causes the power supply to the heating element to be stopped it cools down and the Important screen displays only the automatic heating data An exception to this is enabling the automatic heating feature using also the Last Welding feature If after setting the date and time of day for the heating element to heat up automatically you touch the Enabled Disabled button and additionally the Last Welding button the automatic heating feature is enabled and one more welding can be performed see sections 4 2 ff This means that in this case enabling automatic heating need not be the last action before leaving and the heating element does not cool down after auto matic heating was enabled In this way the welder can leave the worksite when the weld joint cools down after the last welding of the day When the appropriate cooling time is completed force to the the joined pipe is automatically canceled and the
18. e available in the welding parameter screens The manufacturer is in no circumstances Important liable for damage or consequential damage that occurs as a result of deviations from these pipe data or of modifications or attempted modifications to the control software Furthermore this will cancel any claims to warranty expressed for the ma chine To make a material available in this screen it has to be entered previously with all its technical welding parameters in the configuration menu Welding PFA pipes is subject to a valid license for this pipe ma terial Therefore when this material is selected either from the default materials or from the additional materials if defined a message to this effect is displayed The license key is disclosed either by the manufacturer or the distributor of the machine or when you purchase the PFA pipes and can then be entered in the machine parameters In all screens that allow changing the key data for the welding operation by touching the Additional Data button it is possible to access the ad ditional traceability data and change them as needed 4 5 Definition of Welding Parameters for Additional Materials The configuration menu see section 4 3 has an option Additional Materials which allows defining the key data the machine should use when welding pipes of a material that is not currently available in the machine If no additional operator defined pipe material has been saved to s
19. ed after touching the Face Ends button To face the butts once again in most cases the pipes have to be re adjusted in the clamps When pipe facing is successfully finished it is recommended not to touch the pipe butts with your bare hands To avoid fatty layers on the pipe use special pipe handling towels Info 4 6 2 Checking Pipe Alignment When the pipe butts are level to satisfaction it has to be checked if the pipes align properly to each other or if there is an offset Similar to facing the touchscreen tells the welder that this is the next step and the car riage can be closed in on the other pipe by the Start button When the pipe butts are next to each other two additional buttons appear besides Cancel the Face Ends button and the Alignment OK button If the pipes align properly confirm by touching the Alignment OK button and to start the welding process the machine will tell you to move the carriage apart and to close the pipe butts at the far end from the heating element with caps confirm this by Ok Without end caps the tempera ture difference between the welded and the open pipe butt may cause a suction effect to form which would then cool the bead thereby negatively affecting the quality of the welded joint A small offset between the pipes can be readjusted using the adjustment set screws located at the front of the machine If the alignment offset is too large or if there is too large or too uneve
20. ed welding parameters or non intended use Any such deviation or modification will cancel any and all warranties under which the product may be 3 2 Machine Description 3 24 Component Overview Heating Plate and Facing Tool Guard Pipe Clamps Support Console for Heating Plate and Facing Tool Fixed and Mobile Carriage of Machine Frame Emergency Stop Switch Scanning Pen Touchscreen Panel Confirmation Button for Two Hand Mode Steps Set Screws for Compensation of Small Horizontal or Vertical Alignment Gaps 8 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA Ball Guide Bushing of Support Console 4 in total Runner Blocks of Support Console 6 in total Power Supply Cord to Facing Tool Rail for Transport Lock and Transverse Guiding of Support Console Power Supply Cord from Mains Runner Blocks of Movable Carriage 4 in total Door of Equipment and Storage Cabinet Reducers Accessories Power Supply Cord to Heating Element Transport Lock Blocking Heating Element Movement Runner Blocks of Support Console 6 in total Ball Guide Bushings of Support Console 4 in total Installed Transport Lock Blocking Transverse Console and Longitudinal Facing Tool Movement 3 2 2 Touchscreen Control Panel g 3 AGRU SP 258 83 24 06 2016 14 23 Status Bar Title Band Hom Force CHI Multifunctional Area changes Actual Force CHI depending on context of display Display of
21. elder has the possibility Display 4 to e immediately start a welding process RGRU SP 258 S 24 06 2010 14 23 t 4 that will be performed with the same welding parameters as the previous welding touch the Ok button and move on to section 4 6 e enter new pipe related data for the next welding touch the New button and move on to section 4 4 Haters PUDF e change the machine settings in the Di te 258 configuration menu touch the Menu J s NM e un button e to read a new welder ID code using the scanning wand or e display the date for the next scheduled maintenance on the screeen by touch ing New button for some time Display 5 When the confirmation pushbutton on the front is touched si multaneously the three button in Display 5 have the following Info functions New Locking the machine so it will only be able to use it again by entering a valid welder identification code Menu Closing in the movable carriage of the machine toward the center closing the machine Ok Moving the movable carriage apart toward the edge opening the machine AGRU SP 118 5 24 85 2818 14 23 t The first five options of the configuration uz menu are immediately accessible the other options will be displayed only after an access code for the machine the so called selection code was entered see Display 6 The menu has the items listed in the following table To toggle between var
22. elding is not possible Distance Error The stroke of the carriage at facing change over or joining does not correspond to the expected distance it should travel welding has to be repeated Force Error The applied force is out of tolerance welding has to be repeated Power Supply Failure In the course of the last welding operation a power supply failure occurred welding has to be repeated Emergency Stop The welder has turned the machine off using the Emergency Stop switch If this was done because of a malfunction of the machine it must not be turned on again unless it is beyond doubt that it works properly Mirror Temperature Low The mirror heating element temperature is out of tolerance and cannot be adjusted as long as this error is not cleared welding or repeating a welding operation is not possible 5 Printing and Transferring Welding Reports The machine is equipped with USB A interface that gives you the op portunity to connect the tag printer or if permitted a USB stick and a USB B interface through which data can be E transferred to a PC e g with an installation RGRU SP 25875 24 06 2010 14 29 t Ee of the DataWork agru software 5 1 The Print Menu and Printing Transferring Reports When a data communication cable is con nected while the standard data screen see Display 5 is showing the machine displays the print menu According to the selection made on this menu data will be sent to the
23. er a valid welder identification code was entered AD J Enter the welder identification code by typing it on the touchscreen and saving it f to memory by touching the Ok button If a EIE U bar code for the welder code is available era you can also read it from the bar code using ei Getze the scanning pen All inputs for which a bar code is available can be entered from the bar code using a scanning Display 1 Ino EE AGRU SP 258 5 24 06 2010 14 23 t Entering data on the touchscreen must always be performed with the bare finger Using objects Important ballpoint pens screwdrivers etc may cause unrecoverable damage to the surface of the touchscreen 4 2 Entering Traceability Data for the Joint After the welder identification code was entered the traceability data for the joint have to be entered The machine displays the traceability data for the last joint that was welded see Display 3 which can be re used for the next welding operation by Display 2 simply touching the Ok button If traceability data are not the same as for AGRU SP 258 5 24 86 2818 14 23 the last joint change the data that are dif ferent by touching the appropriate Change button Depending on the kind of data you want to change the machine displays either a numeric keypad see Display 2 or an alphanumeric keyboard see Display 4 To confirm and save your data input to memory touch the Ok button Commis
24. ious possible settings or to open a sub menu for a given menu item touch the appropriate button Some of the buttons next to menu option change their color when they were pressed and are then displayed as though the button is held down In this case the held down button mean that this menu option is the selected option 14 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA Designation Setting Description Data to be entered Number of Tags Menu In a sub menu the number of tags to be printed for sticking them onto the welded pipes can be selected Show Reports Menu In a sub menu it is possible to select a job number in order to display the welding reports of this commission In report display mode it is also possible to print a label tag for this welding once again see section 5 2 E of Length Menu In a sub menu the unit of length used for displaying and saving mm inch welding data can be selected Temperature Unit Menu In a sub menu the temperature unit used for displaying and saving C F welding data can be selected New Page in Menu Automatic Heating Menu In a sub menu a time for instance on the following morning can be pre set when the heating element will start heating up automatically see sub section 6 2 Alarm Sound On Off By touching this button the alarm sound that the machine emits to validate the execution of a given step in the process can be enabled or dis
25. ken out of the clamps 20 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA AGRU SP 258 2 24 06 2010 Lr When the welding process is finished the machine displays an overview with the weld ing and traceability data that will be saved to the report the screen resembles the one in Display 20 and asks the welder to remove the pipes and visually check the quality of SA Kem Perea ERU the joint In case he finds that the joint is E Actual Force EM of poor quality although the machine did not alert him to any welding error he can 500 Mom Temp CACI manually classify the welding result as poor 488 actual Temp LOCI by touching the Error button This causes the machine to mark the joint as poor rather 188 7 non Tine E31 PUDF 250 14 2 than good in the the welding report 18 Actual Time Ls 4 7 Aborted Welding Process All welding relevant data are constantly monitored while the welding process is run ning If one or more of the parameters are out ORRU SP 250 5 24 86 2818 14 23 of tolerance and the machine cannot adjust them the welding process is aborted after a given period of time Display 16 The error that made the welding abort is displayed on the screen see Display 17 Additionally the LED icon in the welding diagram that belongs to the welding phase with the malfunction turns red i E The errors listed in the following table can Heze be displaye
26. n 4 3 it is possible BERU SP 250 9 24 66 2018 14 23 to display on the screen the welding reports saved to memory A screen like the one in Display 20 appears It is similar to the weld ing and traceability data overview shown at j Heat nominal the end of each successful welding opera LH tion The Error field reads Ok if no error i Heat actual occurred and contains the acronym PH mg for Pre Heat if the welding operation was d ickn Ambient Temp Distance performed with the pre heating feature Near the left edge of the Report Info screen you will find a list of all welding reports cur rently in memory Above this list the number of the selected report is given before the slash along with the total number of reports in memory after the slash Display 20 To move the selector bar through the list touch the scrollbar arrows to the right of the list The longer you touch them the faster the bar scrolls through the list To display the welding and traceability data of the selected report touch the Select button after having selected it in the list This will populate the fields in the right hand part of the screen with the values saved to the selected welding report To reprint an extra tag of this welding operation for sticking it onto the pipe touch the Tag button 5 3 Deleting Reports from Memory To delete the reports stored in memory use the appropriate option in the configuration me
27. n a distance between the pipe butts touch the Face Ends button to re adjust the pipes in the clamps and start the facing process again In both cases the machine moves the carriages apart to allow inserting either the heating plate or the facing tool 4 6 3 Pre heating the Pipe Butts and Inserting the Heating Element When pipe alignment was checked the machine tells the welder first to reposition the facing tool and heating element assembly to the right As all actions before this one has to be confirmed in two hand mode touching the appropriate button on the touchscreen and holding down the confirma tion push button on the front of the machine When the facing heating assembly is in the AGRU SP 250 S 24 06 2010 14 23 PERTY ready to heat position the machine shows In rt Heating lement the display asking the welder to insert the heating plate see Display 12 Then the welder can either start the stan dard welding process that will first launch the heat soaking phase or by pressing the Pre Heat button can pre heat the pipe butts before the welding process proper If he touches the Pre Heat button he has to decide on the next screen whether the left hand side the right hand side or both pipe butts are pre heated Touching Cancel will return the machine to the previous screen Display 12 If in the control software the pre heating time is set to 0 sec onds the machine will skip to the heat soaking phase
28. nu see sub section 4 3 Upon touching this button a safety warning asking if you really want to delete them appears on the screen and AGRU SP 258 5 24 06 2010 14 23 bek dk kk has to be confirmed to effectively delete the Gi reports currently in memory 6 System Data 6 1 Setting the Date and the Time of Day When the Date Time sub menu was selected in the configuration menu see Sub section 4 3 the screen shows what is reproduced in Display 21 The time of day and the date can be set using the keypad shown on the touchscreen panel Display 21 Version June 2010 agru SP 250 S User s Manual EN 23 ASAHI AMERICA 6 2 Enabling Automatic Heating When the Automatic Heating sub menu was selected in the configura tion menu see sub section 4 3 the screen shows what is reproduced in Display 22 This feature allows preprogramming a dateJAGRU SP 250 5 24 06 2010 14 23 and time of day when the heating element must start heating up This gives you the possibility e g to enter this evening a time for the following morning and then to start welding right after arriving at the worksite instead of waiting for the heating element to reach the appropriate temperature Diasbled For the automatic heating feature to work e the welding machine has to be connected to the power supply and be switched on all the Edi E time from preprogramming a time of day to E the start of heating Both power supply failur
29. o be repositioned or removed To do so loosen the locking bolts and either remove the clamp or re adjust it and secure it by tightening the locking bolts again If the diameter of the pieces to be welded is smaller than the clamp insert the reducer inserts This can be done with the enclosed Allen key i Pipe clamps and reducer inserts have to be clean or must be cleaned before welding starts To insert or remove the inserts Important do not use heavy tools hammer wrench They may damage the inserts The surfaces of the heating plate have to be free of grease and Important clean or they have to be cleaned ES ee sure all connectors are tight in their sockets and make sure that the machine is operated only if the conditions for safe Important 8nd intended use are met see also section 2 After preparing the machine for welding and connecting the power supply cord to the mains power supply the machine is turned on using the On Off switch The welcome screen as reproduced in Display 1 appears on the touchscreen panel Touch the appropriate button to select the display language that the machine will use 12 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA After the language was selected the ma chine takes the user to the welder code entry screen Without a valid welder identification code it is impossible to start welding pro cesses on the machine since the machine is unblocked for operation only aft
30. oduction Dear Customer Thank you very much for purchasing our product We are confident that it will meet your expectations The development manufacture and check of the infrared welding machine has been guided by our concern to offer a unit characterized by superior operation safety and user friendliness The unit was manufactured and checked according to state of the art technology and widely recognized safety regulations To ensure maximum operation safety please conform to the appropriate messages in this booklet and the regulations for the prevention of acci dents Carefully read the User s Manual to avoid damage to the machine or hardware in its environment as well as injury This manual is applicable to the following machines agru SP 250 S Thank you 2 Safety Messages This User s Manual contains important instructions for operating the in frared welding machine agru SP 250 S safely Every person who operates the machine will have to conform to the instructions of this manual The machine has been developed and checked with respect to welding AGRU materials For welding other makes no experiential data are avail able and or no liability or warranty can be assumed for the fitness and the reliable operation of the machine 2 1 The User s Manual The User s Manual is presented according to sections which explain the different functions of the machine All rights in particular the right to copy or reproduce in print
31. of it are accessible that may be under power The machine may be opened exclusively by an authorized service shop Pipe Facing Tool Start the pipe facing tool only when it is in its working position When facing pipes do not wear jewellery if needed wear a hair snood or net It is forbidden to remove shaving from the machine while the facing process is running Make sure nobody is present in this danger zone Heating Plate When working with the machine be extremely cautious while the heating plate is operating Since the heating plate and its guard present a very high temperature during the welding process it must not be operated if unobserved and sufficient distance has to be ensured to combustible materials in its surroundings Do not touch the heating plate or the heating plate guard Danger of Bruises and Injury Do not remain in the danger zone while the machine opens or closes and be sure not to have your hands between the moving and the fixed parts of the machine The forces exercised by the machine are so high that it will not be able to detect and recognize parts of the body 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 flammable liquids In regard of this acceptable work condi tions have to be ensured e g sufficient distance between the machine and other functional areas of the workshop Power Supply Only thr
32. ough Line with Protective Grounding Conductor The machine has to be operated exclusively with a power supply line equipped with a protective grounding conductor as a power supply without this safety element may cause severe machine damage If the machine is operated through a power supply without a grounding conductor this will void any and all warranty under which the product may be Power Only to Operational Machine Power must never be applied to the machine before it is com pletely installed and ready for operation No Foreign Bodies in Work Area The machine must never be used if there are foreign bodies or agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA objects in the work area in particular it must not be started if anything obstructs the smooth movement of any movable part or component of the machine 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 incomplete or illegible replace it without delay Feel free to contact us for assistance Info 2 4 Welder and Operator Obligations e The machine may be operated exclusively by persons who are famil iar with the applicable regulations the guidelines for the prevention of accidents and the User s Manual e The machine may be operated only when observed Welders must have been introduced properly to operating the machine or must have participated in a dedicated
33. sion Humber Helder Code Depending on the software version installed in your machine some Installing Company screens may differ slightly on your ABCD CORP machine from the reproductions in this manual Change 188231281828 Change Additional Oats Adresses ASTHM 4 4 4 4 4 4 4 444 Change Change When the traceability data were entered the machine displays the Display 3 first input screen of the welding process proper see Display 5 In this display it is possible to start the welding process and to customize the configuration of the machine When going on from traceability data input to the welding process proper or the input of characteristic welding parameters the machine performs a calibration of the points of reference for its movable parts Make sure this short process is not interrupted Version June 2010 agru SP 250 S Users Manual EN 13 ASAHI AMERICA ese quoe c on ees form all control actions on the touchscreen AGRU SP 250 5 24 06 2018 14 23 panel 4 3 Configuring the Machine pz MC CC In the first input screen of the welding pro cess proper Display 5 the key parameters of the last welding are shown material diameter and wall thickness of the welded pipe Furthermore the status bar at the top of the screen shows the date time of day and also either the current ambient tem perature or the power supply voltage or the welder s name or code In Display 5 the w
34. t box should also be used to store the machine The machine has to be stored in a dry location be clean or has to be cleaned and be locked against unwanted operation Infrarot StumpfschweiBmaschine Typ agru SP 250 S 2 7 Identifying the Machine Ni BOOS Netz 230V IP54 50 60Hz 1700W Each machine is identified by a name plate It shows the machine model Hersteller agru Kunststofftechnik Ap Ing Pesendorfer Str 31 Typ the serial number Nr and the manufacturer A 4540 Bad Hall CE Tel 43 7258 7900 Version June 2010 agru SP 250 S User s Manual EN 7 ASAHI AMERICA 3 Product Description and Principles of Operation 3 1 Intended Use The agru SP 250 8 Welding Machine is designed exclusively for weld ing plastic pipes and fittings using the infrared welding technique butt welding without contact Only the welding parameters shown on the touchscreen display prepro grammed by the manufacturer or defined by the user can be selected for a welding operation Any modification of the welding parameters contained in the control software is strictly prohibited It is also part of the intended use to conform to the instructions provided in the User s Manual S The manufacturer can in no circumstances be held liable for damage or consequential damage that occurs as a result of the non com Important Pliance with the procedures described in the User s Manual the modification of the manufacturer programm
35. tion in section 3 have to be lubricated regularly every 12 months The same holds for the ball bearing drive spindle ensuring longitudinal movement of the support console which is accessible in the equipment and storage cabinet However this spindle must only be lubricated by trained staff Damage due to inadequate improper or lack of lubrication are not eligible for warranty Lubricant and lubricant gun which both are fully matched to the lubrica tion the machine needs can be ordered with the manufacturer distributor It is unacceptable to use other lubricants than the dedicated product approved of by the manufacturer The application of common grease products or widely available general lubricants may cause serious damage to the machine and make it unfit for further use In the equipment and storage cabinet you will also find the fuses and the automatic safety switch for the heating element facing tool and facing tool motor We reserve the right to change technical specifications of the unit without prior notice Info P O Box 653 35 Green Street Malden MA 02148 Tel 800 343 3618 781 321 5409 ASAHI AMERICA Fax 800 426 7058 Website www asahi america com Email asahi asahi america com Version June 2010 agru SP 250 S User s Manual EN 25
36. touchscreen the machine can be customized to the application at hand see section 4 3 Configuring the Machine 3 24 Specifications agru SP 250 S Power Supply Characteristics Voltage 400 V AC 10 Frequency 50 60 Hz Total Rated Power 9 3 kW Heating Element Power 6 05 kW Facing Tool Power 0 75 kW Welding Operation Specs Welding Force 3500 N Speed of Facing Tool 23 3 rpm Ambient Temperature operation 0 C to 40 C 32 F to 104 F Ambient Temperature storage 5 C to 50 C 23 F to 122 F Operating Range 110 250 mm 4 3 4 12 1 2 Dimensions and Weight Dimensions W x D x H Machine in transport box w o support legs 940 x 1410 x 1400 mm 3 1 x 4 7 1 2 x 4 7 1 8 Machine only excluding printer 900 x 1370 x 1275 mm 2 11 1 2 x 4 8 x 4 2 bracket and support legs Weight approx 6200 kg Maximum Carriage Stroke 244 mm 9 5 8 10 EN agru SP 250 S User s Manual Version June 2010 CEE Power Outlet 32 A B db Tom than the other sockets 0 Contact Pin for Earth G the other pins S power supply connection is designed as a 3 phase plus earth ground connection No neutral conductor is needed The power supply connection should be rated at 32 amps and should be wired with an automatic safety switch of 32 amps medium slow blow The conductor section of the power supply connection should be minimum 4 sq mm s For the connection to mains power an approved CEE plus and outlet have to be
37. tts are worked by the facing tool which is inserted automati cally to obtain abutment along a fully parallel plane e Pipe alignment is checked and confirmed on the touchscreen e Automatic insertion of the heating element when inserting it the heating element has to be clean e After the heating element was inserted the pipes close in automati cally at the predefined force e When the carriages close in they also align the heating element exactly in between the pipe butts e At the same time the pipe butts are heated to the predefined tem perature e When the heat soaking phase is over the pipes are moved apart and the heating element is removed automatically e Once the heating element is removed the pipes close in again au tomatically Version June 2010 agru SP 250 S User s Manual 6 Contact Socket for Phase 1 L1 7 Contact Socket for Phase 2 L2 8 Contact Pin for Phase 3 L3 9 1 11 Contact Pin for Phase 1 L1 12 Contact Pin for Phase 2 L2 ASAHI AMERICA Contact Pin for Neutral not needed with SP 250 S CEE Power Plug 32 A with integrated phase inverter Contact Socket for Phase 3 L3 Contact Socket for Neutral not needed with SP 250 S Contact Socket for Earth Ground PE a little thicker round PE a little thicker than EN 11 ASAHI AMERICA e This is followed by a steady force increase until the fusion force is reached e The pipe then cools down at the predefined force e After the
38. ury because the carriage starts moving the operator must confirm the step on the touch screen and use the second hand to keep pressed the green confirmation push button on the machine front 4 6 1 Facing the Pipe Butts In the input screen reproduced in Display 5 when the OK button was touched the welding process proper starts by the insertion of the pipe facing tool The machine alerts the welder to this next step Facing requires three steps e Zeroing the facing tool position before clamping the pipes e Securing the pipes in the clamps und determining the facing road e Facing the butts First the machine asks the operator to insert the facing tool in Position 1 This is the position for zeroing the facing tool in relation to the movable carriage Confirm this screen and simultaneously hold down the green two hand operation confirmation button on the machine front This will cause the machine to bring the facing tool to the zeroing position While the machine automatically performs a zeroing calibra ES ion of the carriage position when it is switched on including when power is re applied after it was switched off using the emergency off button it is critical to zero the facing tool prior to the facing operation proper failing what it is not possible to ensure a joint of appropriate quality Important When the facing tool handle is located atjagGRU SP 258 5 24 86 2818 14 23 Position 1 the machine asks the operator to
39. used and wired according to the specifica Important tions quoted above Compare also the photograph as well as its legend and explanations below Prior to starting to first use the machine the power supply connection has to be verified Across any two phases L1 L2 L2 L3 L1 L3 a volt age of 400 V AC 10 has to be found If a neutral is wired to the same power supply socket across any of the three phases and the neutral a voltage of 230 V AC has to be found These measurement can be take with any common voltmeter for alternating current voltages Importan If connected appliances are equipped with a motor requiring 3 phase alternating current supply as is the case with the SP 250 8 the rotating field of the machine has to have the proper direction The SP 250 S checks this and if the rotation is incorrect a Power Supply Error message is displayed To change the direction of the rotation of the field the phase inverter in the plug can be used Two of its contact pins are placed on a grey turning disk A flathead scredriver can be used to turn this disk thereby inverting the positions of the two pins which in turn inverts the rotation of the field 3 8 Welding Process Overview The welding process is performed as follows e Pipes are clamped into the frame depending on the form of the component to be welded this may mean that the outer clamps have to be re adjusted or that reducer inserts have to be inserted e Pipe bu
40. ystem memory the unit displays an input screen that allows entering the name of the material for which the key data for welding it shall be defined Enter the name on the touchscreen keyboard see Display 4 and confirm it by touching the Ok button The machine moves on to the next input screen in which a pipe diameter for this material has to be entered on the numeric keypad see Display 2 After having confirmed this input by OK once more another screen allows entering the wall thickness for this material and size After the wall thickness the pressure level per SDR has to be entered in the next screen After this define the key welding parameters for the material just entered e g 250 mm PVDF pipe with a wall 14 2 mm thick To define them the unit guides the operator through a series of input screens in which the following can be entered joining force heat soaking time cooling time plate temperature force ramp facing force Confirm every entered value by touching Ok If parameters for welding additional user defined materials have al ready been entered and saved previously the unit shows a screen that resembles Display 8 Use the arrow keys in the upper area of the screen to switch back and forth between the various additional pipe materials 16 EN agru SP 250 S User s Manual Version June 2010 ASAHI AMERICA currently in memory For every pipe material up to three pipe diameters can be defined and for each di
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