AGRU SP 63-M User manual

User’s Manual
Mobile Infrared Butt-welding Machine
SP 63-M
Version October 2014
P.O. Box 1108 • 655 Andover St.,Lawrence, MA 01843 • Tel: [phone]
Fax: [phone]• Website: www.asahi-america.com • Email: [email protected]

Version October 2014 EN 3 agru SP 63-mobile User’s Manual
Contents
1 Introduction ...........................................................................................................5
2 Safety Messages...................................................................................................5
2.1 The User's Manual ................................................................................................5
2.2 Explaining Icons ....................................................................................................5
2.3 Safety Messages and Information on Remaining Risk .........................................6
2.4 User/Operator Obligations ....................................................................................7
2.5 Worksite Description .............................................................................................7
2.6 Warranty................................................................................................................7
2.7 Transport and Storage ..........................................................................................7
2.8 Identifying the Machine .........................................................................................8
3 Product Description and Principles of Operation ..................................................8
3.1 Intended Use.........................................................................................................8
3.2 Machine Description..............................................................................................8
3.2.1 Component Overview............................................................................................8
3.2.2 Control Panel and Connectors of the Control Unit ................................................9
3.2.3 Specifications ......................................................................................................10
3.3 Welding Process Overview .................................................................................10
4 Operation ............................................................................................................11
4.1 Check-out, Turning on, Selecting the Display Language ....................................11
Zeroing the Position of the Movable Carriage.....................................................13
4.2 Configuring the Machine .....................................................................................14
4.3 Changing Key Parameters of the Welding ..........................................................15
4.4 Entering Traceability Data for the Joint ...............................................................16
4.5 Definition of Welding Parameters for Additional Materials ..................................16
4.6 Fastening the Mechanical Structure of the Machine ...........................................17
4.7 Welding Process .................................................................................................18
4.7.1 Facing the Component Butts...............................................................................18
4.7.2 Checking Alignment ............................................................................................19
4.7.3 Inserting the Heating Element with or without Preheating ..................................20
4.7.4 Heating Stage .....................................................................................................20
4.7.5 Change-over Stage .............................................................................................20
4.7.6 Joining Stage ......................................................................................................21
4.7.7 Cooling Stage......................................................................................................21
4.7.8 End of Welding....................................................................................................21
5.12 Using ViewWeld to Manage Logged Welding Reports and Print Tags................21
4.9 Aborted Welding Process....................................................................................22
4.10 Indication of Joint Status and Possible Errors on the Tag...................................23
5 Printing Pipe Labels and Downloading Welding Reports....................................23
5.1 Downloading Welding Reports to a USB Stick....................................................24
5.2 Showing Reports in Memory, Printing Pipe Label Tags.......................................24
5.3 Deleting Reports from Memory ...........................................................................24
6 System Data........................................................................................................24
6.1 Setting the Date and the Time of Day .................................................................24
6.2 Data on the Machine and its Control Software....................................................25
6.3 Service and Repair..............................................................................................25
7 Service and Repair Contact ................................................................................25
7.1 Manufacturer Warranty........................................................................................25
7.2 Technical Documentation ....................................................................................25
7.3 Risk Assessment.................................................................................................25
P.O. Box 1108 • 655 Andover St.,Lawrence, MA 01843 • Tel: [phone]
Fax: [phone]• Website: www.asahi-america.com • Email: [email protected]

Version October 2014
4 EN agru SP 63-mobile User’s Manual
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.
P.O. Box 1108 • 655 Andover St.,Lawrence, MA 01843 • Tel: [phone]
Fax: [phone]• Website: www.asahi-america.com • Email: [email protected]

Version October 2014 EN 5 agru SP 63-mobile User’s Manual
1 Introduction
Dear Customer:
Thank you very much for purchasing our product. We are confident that
it will meet your expectations.
The development, manufacture, and check of the mobile, i. e., overhead-
welding-enabled, infrared butt-welding machine for thermoplastics 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 the most recent standards as they are applied, and
bearing ergonomic aspects in mind.
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 63-mobile
Thank you.
2 Safety Messages
This User’s Manual contains important instructions for operating the
infrared welding machine for thermoplastics agru SP 63-mobile 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 pipes and fittings. For welding other makes, no experiential data
are available and/or no liability or warranty can be assumed for the fit-
ness 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 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:
Caution
This icon indicates that non-compliance may result in a haz-
ardous situation that possibly causes bodily injury or material
damage.
Important
This icon indicates important messages related to the correct
use of the machine. Non-compliance may cause problems of
operation and damage to the machine.
Info
This icon indicates tips and useful information for using the
machine more efficiently and more economically.

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6 EN agru SP 63-mobile User’s Manual
2.3 Safety Messages and Information on Remaining Risk
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 230 V, 50/60 Hz power supply with
safety fuse or breaker of 16 A maximum. If power is connected through
a power line manifold, the power supply has to feature an earth-leakage
circuit breaker.
The length of the power supply cord must not exceed 10 m (30 feet) from
the circuit breaker.
Caution
Parts Under Power
After opening the machine or removing the cover, parts of it
are accessible that may be under power. The machine may be
opened exclusively by an authorized service shop and only
after it was disconnected from power.
Caution
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.
Caution
Heating Plate and Heating Plate Housing
When working with the machine, be extremely cautious while the
heating plate is operating. Since the plate and its housing guard
present a very high temperature during the welding process, it
must not be operated if unobserved, and sufficient distance to
combustible materials in its surroundings has to be ensured.
Do not touch the heating plate or the plate housing. The safety
alerts affixed to it have to be complied with strictly.
Caution
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.
Caution
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).
Overhead work is prohibited, unless:-
• the machine is safely and securely fastened and positioned;
• access to a large area around the worksite is controlled/limited
•(risk of falling objects); see also Sect. 2.5;
• a hardhat and safety goggles are worn (risk of falling objects and
•small blades of shaving during component facing)
Important
Power Supply Only through 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.

Version October 2014 EN 7 agru SP 63-mobile User’s Manual
Important
Power Only to Operational Machine
Power must never be applied to the machine before it is com-
pletely installed and ready for operation.
Info
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.
2.4 User/Operator Obligations
• The machine may be operated exclusively by persons who are fa-
miliar with the applicable rules, the guidelines for the prevention of
accidents, and the User’s Manual.
• The machine may be operated only when observed. Only persons
who were properly trained by agru or another, authorized organi-
zation and whose training was acknowledged by the appropriate
certificates are allowed to operate and observe the machine. Other
persons must neither operate nor observe it.
• The operating/owning organization engages to check at reasonable
intervals if the machine is operated by the users with the intended
use and under proper guidelines of safe work.
• The machine must never be operated if not in proper state of repair.
Before welding, the user is required to make sure that the state of
the machine is in order.
• The user has to make sure that only one person is present in the
zone where the machine is operating.
2.5 Worksite Description
• The conditions have to fully ensure that the machine cannot slide.
As well the segments of the base plate as the mechanical structure
and the base plate have to be securely connected to each other
before any components are clamped fast. In case of (overhead)
welding operations using the mechanical structure without the base
plate, the welding mechanics has to be securely fastened at the
components to be jointed with the supplied belts.
• Worksite access limitations have to be provided. Appropriate equip-
ment to achieve this can be requested from a service point or the
selling entity.
2.6 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.
Info
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.
2.7 Transport and Storage
During transport, the machine must be at all times in the transport box
it is shipped in.
Important
Ensure that the heating plate, the facing tool, and all movable/
removable parts of the machine are safely stowed away and,

Mobile Stumpfschweißmaschine
Typ agru SP 63-mobile
Geräte-Nr. 06310281
Netz 230V 50Hz 1700W IP54
Gewicht ca. 45 kg Baujahr: 2014
Lizenzhersteller
HÜRNER Schweißtechnik GmbH
Nieder-Ohmener Str. 26
D - 32325 Mücke
Typ agru SP 63-mobile
Exklusives Produkt der Fa.
agru Kunststofftechnik GmbH
Ing.-Pesendorfer-Str. 31
A - 4540 Bad Hall
Tel. [phone]
Fax [phone]
Version October 2014
8 EN agru SP 63-mobile User’s Manual
if applicable, secured with the transport lock during transport
at all times (see explanations and figures in Sect. 4.1).
The transport 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.
2.8 Identifying the Machine
Each machine is identified by a name plate. It shows the machine
model (“Typ”), its year of manufacture (“Baujahr”), the serial number
(“Geräte-Nr.”), the rated power (“Netz”), and the manufacturer (“Lizenz-
hersteller”).
3 Product Description and Principles of Operation
3.1 Intended Use
The agru SP 63-mobile Welding Machine is designed exclusively for
welding thermoplastic pipes and fittings using the butt-welding process
with plasticization by infrared beams.
Only the welding parameters shown on the screen display (prepro-
grammed by the manufacturer or defined by the user) can be selected
for a welding operation. If a modification of preinstalled parameters os
needed exeptionally, contact agru Kunststofftechnik.
It is also part of the intended use to conform to the instructions provided
in the User’s Manual.
Important
The manufacturer can in no circumstances be held liable for
damage or consequential damage that occurs as a result of the
non-compliance with the procedures described in the User’s
Manual, the modification of the manufacturer-programmed
welding parameters, or non-intended use. Any such deviation
or modification will void any and all warranties under which the
product may be.
3.2 Machine Description
The machine can be used as an in-shop installation, and with anodized
aluminum and stainless steel components, it is also suited for clean
room applications. The machine enables users to enter the data that are
relevant for the welding process and for the traceability of the welded
joint. From the entered welding parameters, it calculates automatically
the applicable forces, times, and temperatures and controls the semi-
automatic welding process.
All welding and traceability data are entered either directly at the ma-
chine, on the keypad of its front panel with display screen, or read from
a transponder card by the transponder reader. The welding process in
monitored in its entirety and saved to a welding report. All welding reports
can the be downloaded to a USB stick as an abstract, an extended report
or as a DataWork database file.
Using the menus displayed on the screen, the machine can be customized
to the application in hand (see section 4.3, Configuring the Machine).
3.2.1 Component Overview
(see figure on next page)

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3.2.2 Control Panel and Connectors of the Control Unit
Alphanumeric Keypad
MENU and Cursor Keys
Heating Element and Guard
Housing
Facing Tool
Clamps
Dedicated Base Plate for Fac-
ing Tool and Heating Element
Fixed and Mobile Carriage of
Machine Frame
Locking Ball Pin to Secure
Base Plates to Each Other
RFID Transponder Reader
Control Unit with Control Panel
Support Bracket für Facing
Tool and Heating Element
Thumb Screws for Locking
the Outer Clamp
(analogous on the other carriage)
Connector for Power Cord to
Label Tag Printer
Buzzer (at the front)
Heating Element Connector
(at the back)
USB Interface
(to connect USB stick or tag printer)
START/SET and STOP/
RESET Keys
Locking Ball Pin to Secure
Base Plates to Each Other
RFID Transponder Reader
Display Screen
Mains Socket & On/Off Switch
Emergency Stop Switch
Connector for Mechanical
Welding Chassis (control cable to
connector on back of control cabinet of
mechanics)

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3.2.3 Specifications
agru SP 63-mobile
Power Characteristics
Voltage
Frequency
Total Rated Power
Heating Element
Electrical Cordless Power Facing Tool
Charger for Power Facing Tool
Power Facing Tool with Cord (optional)
230 V
50/60 Hz
1.7 kW
1.38 kW
18 V, 5.2Ah (on battery, w/ 2 batteries)
220 - 240 V AC, 50/60 Hz, 0.085 kW
0.56 kW (facing tool as power tool connected to
mains socket provided on site, not on control unit)
Welding Operation Specs
Welding Force
Speed of Cordless Facing Tool
Speed of Facing Tool with Cord
Ambient Temperature (operation)
Ambient Temperature (storage)
Operating Range
Travel Stroke of Movable Carriage
10 - 500 N
approx. 66 rpm (in 2nd gear, speed set to max.)
approx. 73 rpm
+ 10°C to + 40°C (50°F to 104°F)
– 5°C to + 50°C (23°F to 122°F)
20 - 63 mm (3/4" - 2-1/2")
approx. 115.5 mm (4-1/2")
Dimensions and Weight
Dimensions (W x D x H)
Mechanical Assy (carriage moved apart)
Electronic Assembly
Mechan. & Electron. on Base Plate
Dedic'ed Base Pl. w/ Facer/H. Elem.
Transport Case
Weight
Mechanical Assembly
Electronic Assembly
Mechan. & Electron. on Base Plate
Facing Tool
Heating Element
Dedic'ed Base Pl. w/ Facer/H. Elem.
Transport Case (w/ mach., access.)
Transport Case, emptyx
460 x 174 x 311 mm (18-1/8" x 6-13/16" x 12-1/4")
279 x 245 x 219 mm (11" x 9-5/8" x 8-5/8")
550 x 376 x 348 mm (21-11/16" x 14-25/32" x 13-11/16")
260 x 350 x 294 mm (10-1/4" x 13-13/16" x 11-7/16")
800 x 600 x 608 mm (31-1/2" x 23-5/8" x 23-15/16")
14.2 kg (31.2 U.S. lbs)
6.6 kg (14.5 U.S. lbs; on base plate)
30 kg (66 U.S. lbs)
4.2 kg (9.2 U.S. lbs)
3.9 kg (8.6 U.S. lbs)
14.4 kg (31.7 U.S. lbs)
85 kg (187 U.S. lbs)
30 kg (66 U.S. lbs)
3.3 Welding Process Overview
The welding process is performed as follows:
Important
Prior to welding, the mechanical structure of the machine has
to be secured, either to the base plate or to the components
to be jointed (see Sect. 4.6).
• The facing tool is inserted between the carriages, into its position
for clamping the components in the machine, and the clamps them-
selves are adjusted to the spacer pins of the facing tool.
• The components are clamped and the facing distance is adjusted.
• The facing tool is moved to its position for facing.
• Pipe ends are worked using the pipe facing tool until a continuous
blade of shaving material forms.
• Pipe alignment is checked and confirmed by the welder.
• Insertion of the heating element; when inserting it, the heating ele-
ment has to be clean.
• After the heating element was inserted, closing in the movable car-
riage is confirmed, and the pipes close in at the predefined force.
• When the carriages close in, they also align the heating element
exactly in-between the pipe butts.
• The pipe butts are then heated to the predefined temperature.
• When the heating phase is over, the pipes are moved apart auto-
matically to allow for manually removing the heating element.

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• Once the heating element removal is confirmed, the pipes close in
on each other again.
• This is followed by a steady force increase until the fusion force is
reached.
• The pipe then cools down at the predefined force.
• After the cooling time is over, the force is automatically removed
from the carriages and the pipe or fitting can be taken out of it.
4 Operation
Before putting the machine into operation, review the transport locks and
safety auxiliaries as well as the way the machine is set into its transport
box. Whenever the machine is moved or shipped, it has to be set into this
box and all locks and auxiliaries have to be engaged. The photographs
below help with understanding the transport helpers.
Important
When the printer is moved or shipped, the roll of labels in the
printer has to be removed
Info
When installing the reducer inserts, place the narrower inserts
into the inner clamps, the broader inserts, into the outer clamps.
The insertion and the removal of the inserts is performed with-
out any tools. The reducers are secured to the clamps by the
force of the magnets only.
4.1 Check-out, Turning on, Selecting the Display Language
Place the machine on a level surface and ensure it cannot slide or secure
it safely at the components to be jointed. Sufficient 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. When starting the machine up,
remove the transport locks before applying power to the machine if it was
transported before start-up and the locks were engaged. Furthermore,
if the label tag printer ist planned to be used later on, connect it to the
machine and insert the roll of labels before the first welding operation.
Independently of the order of the explanations in this booklet, the steps
for setting the machine up and preparing everything for welding are
always performed in the following order (see the following figures for
reference):
1. Open the transport box.
2. Loosen the transport lock pole using the the star knob.
3. Take the dedicated plate for the facing tool and heating element out
of the box, set it on a level surface, making sure it will not slide, and
remove the transport lock of the heating element.
4. Take the base plate with the electronics and the mechanics out of
the box, set it on a level surface, making sure it will not slide, and
remove the transport lock of the movable carriages from in-between
the carriages (unlock the locking ball pin and remove it, then slide
the transport lock out of its seat in the opposite direction).
5. Take the facing tool out of the box and set it on its tabletop plate.
6. Take the battery charger out of the transport box.
7. Check the battery level and charge the batteries as needed.
8. Connect the mechanics and the heating element to the electronic
control unit.
9. Connect the V-lock power cable to its socket and the mains.
10. Switch the machine on and zero the movable carriage position.
11. Insert the reducers into the clamps.
Depending on the piece that is going to be welded, the outer clamps

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Inside view of the case for the
reducer inserts
Star knob securing the base
and tabletop plates, and
transport lock (self-locking
pin) of heating element
Transport lock of facing tool/
heating element carrier and
movable carriage (locking ball
pin on the back to unlock
locking bar)
may have to be repositioned or removed. To do so, loosen the locking
thumb screws and either remove the clamp or re-adjust it and secure it
by tightening the locking screws again.
If the diameter of the pieces to be welded is smaller than the clamp, insert
the reducer inserts. This can be done without using any tools since the
inserts are fastened in the clamps by magnetic attraction.
Important
Pipe clamps and reducer inserts have to be clean or must be
cleaned before welding starts. To insert or remove the inserts,
do not use heavy tools (hammer, wrench). They may damage
the inserts and the magnets.
Important
The surfaces of the heating plate have to be free of grease and
clean, or they have to be cleaned. Clean the heating element
only when it is cold. Refer to a service point for detailed infor-
mation on the procedures for cleaning the heating element.
Important
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 use are met (see also section 2).
Mechanics and
Electronics on Base
Plate
Tabletop Plate with
Heating Element in it
Guard
Case with
Reducer
Inserts
Second Battery
for Facing Tool
Box for
Accessories
Box for
Extension Cord
and User's
Manual
Facing Tool
Label Tag Printer
Charger for Fac-
ing Tool Battery

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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. It disappears after a couple of seconds or
when you press a key, and in the next screen you can select the display
language that the machine will use, using the cursor keys. The selected
language has to be confirmed by pressing the START/SET key.
After the language was selected, the machine takes the user to the
screen for setting the system clock and date, if this still needs to be
done or the auto-test determines they cannot be correct, and then to the
welder code input screen. Without a valid welder identification code, the
machine does not move on to the preparation of welding and the welding
process, since working with the machine without a welder identification
is prohibited.
Read the welder from a transponder card by RFID. If no card with the
welder identification code is available, it can also be typed on the keypad
and saved to memory by touching the START/SET key.
Info
All inputs for which a transponder card is available can be
entered by holding the card in front of the RFID reader.
Info
Depending on the software version installed in your machine,
some screens may differ slightly on your machine from the
reproductions in this manual.
When the welder code was entered, the movement position of the mov-
able carriage has to zeroed (see below). Then the machine displays the
so-called default screen (see Display 3). In this display, it is possible
to start the welding process and to customize the configuration of the
machine.
Zeroing the Position of the Movable Carriage
Wichtig
Without proper zeroing of the reference position of the movable
carriage, proper welding is impossible. Therefore, zeroing will
be skipped only when the machine remains at the same spot for
the next welding and no emergency stop was triggered. Zeroing
the carriage position is required and cannot be skipped after
the machine was switched on or the emergency stop switch
was pressed.
To zero the carriage position, the facing tool has to be removed from
in-between the carriages if it still is positioned between them, and the
START/SET key must then be pressed for confirmation (see Display 4).
If it hasn’t, press the STOP/RESET key. If the spacer pins of the facing
tool are placed in the recesses of the carriages, the movable carriage
can be moved apart by pressing the cursor key.
The same holds for the heating element. If it is still set on the carrier
between the two carriages of the machine, the user is requested to
remove it. Only after the removal was confirmed by START/SET, the
process continues.
The same query appears again for the pipes/components that might still
be in the clamps from the last welding operation. They, too, have to be
taken out of them, which has to be confirmed by START/SET.
When the welder confirms that there are no pipes in the clamps, the
machine asks that the movable carriage be closed in on the fixed one by
holding down the cursor keys, just as for facing, heating or joining, until
the message “Searching reference point” appear on the screen. When
Display 1
Display 2
********************
SP 63-mobile
ASP006_00_14003_01
********************
*** Welder Code ****
********************
***********
[RESET] [SET]
Display 3
Next Welding?
PVDF 40mm 2.27
22.10.14 15:24:58
[RESET] +0N [SET]
Display 4
Facing tool removed?
[RESET] [SET]

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14 EN agru SP 63-mobile User’s Manual
this message is showing, the machine determines the zero point of the
movable carriage as compared to the position of the fixed carriage, that
will apply for the next welding.
When this reference position/zero point was automatically zeroed and
saved to memory in the control unit, the machine asks the welder to
move the carriage apart, which indicated that the machine has now
been zeroed. To move the carriage apart, press the cursor key. The
machine returns to the default screen (see Display 3). Welding can now
be started or parameters can be edited.
4.2 Configuring the Machine
In the default screen (Display 3), the key parameters of the last welding
are shown (material, diameter, and wall thickness of the welded pipe)
along with the date and time. The last line of the display can be switched
to showing the current temperature and the current percentage of heat-
ing performance by pressing the number key 1 and to showing the ap-
plied force by pressing the key 2. Both keys are toggle switches, i.e. will
switch the fourth display line back to what is reproduced in Display 3
when pressed again.
In Display 3, the welder has the possibility to:
• immediately start a welding process that will be performed with
the same welding parameters as the previous welding (press the
START/SET key and move on to section 4.6);
• enter new traceability data, including another welder ID code, for
the next welding (press the STOP/RESET key and move on to sec-
tion 4.3);
• change the machine settings in the configuration menu (press the
MENU key);
Info
Other functionalities that are called when the default screen is
showing, are explained below in this booklet, including how to
call them from this screen.
After the MENU key was pressed, Display 4 appears and allows selecting
one of the various parts of the configuration menu. The options under
“Settings” of the configuration menu are immediately accessible, the op-
tions under “Advanced Settings” will be displayed only after an access
code was entered and confirmed by START/SET. The menu has the items
listed in the following table. The items under “Machine Data” are not listed,
as they are relevant for setting up and servicing the machine only, not
for normal operation, and, therefore, protected by another access code,
which will be disclosed to authorized personnel only.
To toggle from « On » to « Off » or vice versa for an option, press the
cursor key, to open a submenu or go to an additional screen for an
option, which is indicated by the letter – M –, press the MENU key.
Any changes in the configuration menu are saved to memory and will
be used by the machine in the future when the menu is quit by pressing
the START/SET key. By qutting it by pressing the STOP/RESET key, the
previous state is kept and no changes, if there were any, are saved.
Designation Setting Description / Data to be entered
—— “Settings” submenu ————————
Number of Tags Menu In a sub-menu, the number of tags to be printed after welding for
sticking them onto the welded pipes, can be selected.
Unit of Length
(mm / inch)
Menu In a sub-menu, the unit of length used for displaying and saving
welding data can be selected.
Display 5
**** Main Menu *****
>Settings -M-
Adv. Settings -M-
Machine Settings-M-

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Temperature Unit
(°C / °F)
Menu In a sub-menu, the temperature unit used for displaying and saving
welding data can be selected.
Buzzer ON / OFF if ON: The audible signal that validates certain steps in the process
is turned on;
if OFF: At the end of the respective steps no signal can be heard.
Buzzer Volume Menu In a sub-menu, the volume of the audible signal that the machine
emits to validate the execution of a given step in the process can be
set.
Language Menu In a sub-menu, the display language of the machine can be selected.
Info Menu In a sub-menu, information on the machine and the installed control
software version is displayed.
Contact Menu In a sub-menu, information on contact details for sales,
maintenance, and service is displayed.
—— “Advanced Settings” submenu ————————
Memory Control ON / OFF if ON: Machine refuses further welding operations when the memory
is full;
if OFF: Machine overwrites the oldest report when the memory is
full.
Date/Time Menu In a sub-menu, date and time can be set.
Delete Reports Menu 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;
the reports will be deleted only after another safety warning was
confirmed.
Set Additional
Materials
Menu Through a sub-menu, the key parameters for welding can be defined
for additional pipe materials that are not installed ex works (see
Sect. 4.5).
4.3 Changing Key Parameters of the Welding
In the default screen (see Display 3), it is possible to change the weld-
specific parameters for the joint to be welded. To do so, press the STOP/
RESET key. The screen that allows selecting the material of the compo-
nents that are going to be welded, is then displayed on the screen (see
Display 6). A selection can be made of default, or standard, (preinstalled)
or extra (user-defined) parameters or materials, using the , cursor
keys, and entering additional and traceability data for the welded joint
can also be selected. The selection has then to be confirmed by press-
ing the MENU key.
Additional (extra) parameters may be defined (see section 4.5) for a
maximum of four materials.
No matter whether default/standard or extra parameters were selected,
after pressing the MENU key, first the , cursor keys are used to select
the material of the components to be welded, the selection is confirmed
by pressing START/SET, and then, in the next screen, the component
diameter is selected in the same manner.
When you select an additional material, this has to be confirmed by en-
tering the access code for the configuration menu (see sub-section 4.2).
Default materials can be welded without entering this code.
Important
The machine must never be used to weld pipe materials, diam-
eters, and thicknesses other than those available in the welding
parameter screens. The manufacturer is in no circumstances
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-
Display 6
>Sel. Std. Para. -M-
Sel. Extra Para.-M-
Enter Welder -M-
Enter Comm. No. -M-

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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.
4.4 Entering Traceability Data for the Joint
After the welder identification code was entered, the traceability data for
the joint can be entered after the STOP/RESET key was pressed at the
default screen (see Sect. 4.3).If no traceability data are entered, those
currently saved to memory will be assigned to the next welding. This
means that no data input is needed if the data for the last joint that was
welded can be re-used for the next welding operation.
The input routine is identical for all additional/traceability data: selection
in the list reproduced in Display 6 using the , arrow keys (welder ID
code (but see Sect. 4.1 for this particular input), commission number,
additional data such as place or particularities of the joint, installing
company), confirmation in order to open the screen for entering that in-
formation using the MENU key, input of data with the keypad, and finally
confirmation of that input by pressing the START/SET key.
4.5 Definition of Welding Parameters for Additional Materials
The configuration menu (see section 4.2) has an option “Extra Param-
eters” in its “Advanced Parameters” submenu which allows defining
parameters the machine should use that are not yet preinstalled.
If no additional, operator-defined parameters have been saved to system
memory, the unit displays an input screen that allows entering the name
(max. 5 characters) of the material for which the parameters for weld-
ing it shall be defined. Enter the name on the keypad (see Display 8)
and confirm it by pressing START/SET. The machine moves on to the
next input screen, in which a pipe diameter for this material has to be
entered in the same way. 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 welding parameters for
the material just entered, e.g. 50 mm PE pipe with a wall 2.3 mm thick
(SDR 22). To define them, the unit walks the operator through a series
of input screens in which the following can be entered: joining force,
heating time, cooling time, heating element temperature, force ramp,
facing force, preheat time. All inputs are made using the keypad and
saved by pressing START/SET. The definition of an extra material can
be cancelled in any screen by pressing the STOP/RESET key. This will
delete all parameters that were already entered for the extra material
being defined.
If additional, user-defined welding parameters have already been entered
and saved previously, the unit shows a list of alle defined materials or
the entry “-----” wherever no material is saved to an existing slot (see
Display 9). As usual, with the , cursor keys, a line may be selected
and the selection, confirmed by the MENU key. (When the cursor key
is pressed at the last entry of a list, the cursor moves to the first entry
of that list.)
If an empty entry is selected, a new material with all its welding param-
eters can be entered for it, as described above. When a line with a mate-
rial is selected, pressing the MENU key will move you on to a screen of
the same kind with all diameters associated with the previously selected
material. On this screen, the material can be added a new diameter after
the selection of an empty entry, “- - mm,” and pressing the MENU key.
This launches the above-described input process, not for the material,
but for the size.
Display 9
Extra Material Menu
>1.MAT01 -M-
2.MAT02 -M-
----- -M-
Display 8
** Enter Material **
MAT01
[RESET] [SET]
Display 7
>Enter Welder -M-
Enter Comm. No. -M-
Enter Add. Data -M-
Enter Instal.Co.-M-

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When a line with a diameter entry is selected, another similar screen
shows, in which the same can then be done for the wall thickness/SDR.
When a wall thickness entry is selected in that screen and the MENU
key is pressed, a new selection menu appears with the options “Edit
Branch,” “Delete Branch,” and “Delete Tree.”
The “branch” meant by the menu options is the set of a user-defined
component material, its size, and its wall thickness or SDR value, e. g.
50 mm PE pipe with a 2.3 mm wall, that is, SDR 22. Selecting the “Edit
Branch” option, then, allows modifying the welding parameters applicable
to that material, size, and wall thickness in the same way as they are
entered for the first time, as described above.
The “Delete Branch” option can be selected to delete the “branch” of ma-
terial, diameter, wall thickness, along with its welding parameters, along
which the selection screen was accessed. Deleting has to be confirmed
in another safety screen. If this wall thickness or SDR is the only one
left for the pipe diameter in question, then the diameter is deleted from
the data “tree” too. And if the thus deleted diameter is the only one left
for this material, the entire material is deleted.
By selecting the “Delete Tree” option, it is possible to delete all addi-
tional, user-defined parameters. 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.
Info
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
The screen for selecting to edit or to delete a “branch” or the
entire “tree” of welding parameters is not accessible right away
and requires selecting the “branch” to be edited or deleted via
three selection screens (material, diameter, wall thickness/
SDR).
4.6 Fastening the Mechanical Structure of the Machine
The mechanical structure (chassis) of the machine is fastened to or
unfastened from the base plate using the lock frames that the black
anodized-aluminum legs of the structure plug into (see left-hand drawing
for reference). The leg is secured inside the frame by the fastening latch
at its back (seen only in the right-hand drawing), which, in turn, is kept
in place by the lock flap hooked into the fastening latch and then tilted
towards the back, along the leg. The traction excercised on the fasten-
ing latch by the flap can be adjusted by shortening or lengthening the
threaded pin that hooks into its mate at the edge of the latch.
The grooves in the base plate help slide the legs of the mechanical
structure into the lock frames into which the plug.

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Display 10
****** Facing ******
Insert facer pos. 1
147N 3.0mm
[RESET] [<->] [SET]
Prior to fastening or unfastening the mechanical structure, discon-
nect all electrical and control cables; reconnect only when done.
A second step of fastening the mechanical structure to the base plate,
when it is not planned to use it separate from the plate, is to lock the
plates to each other by sliding the one into the other and securing
it using the locking ball pins at the front right and back left corner
of the plate of the electronic control unit (see drawing to the right,
which only shows the locking ball pin at the rear). To unlock a
locked pin, push down the head of the pin inside the head.
To conclude the preparations of the welding process, connect the
two control cables: the one shown on the drawing to the right to the
connector at the back of the mechanical structure and the one from
the heating element to that on the right-hand side — when looking
at the keypad — of the electronic control (see Sect. 3.2.2).
Caution
When the mechanical structure is properly fastened to the base
plate, the fastening elements ensure a safe welding operation.
If the machine is used without the base plate, make sure that it
is positioned safely — including sufficiently far away from flam-
mable and combustible substances — at the components to be
jointed and that any needed means and auxiliaries of support
are indeed used.
Caution
When they are not being used and held by the support between
the carriages of the machine, the facing tool and the heating
element have to be inserted by their bars meant to hold them,
into the respective opening of the tabletop support (see draw-
ing to the right).
4.7 Welding Process
With or without calibrating/zeroing the carriage position (see at the end
of Sect. 4.1), the machine returns to the default screen (see Display 3).
If technical welding parameters or traceability data have to be changed
or entered and this has not been done before, it is still possible at this
point after pressing the STOP/RESET key (see Sect. 4.3 and 4.4). If it
is not needed, the welding process, with the current welding parameters
and traceability data, is started by pressing the START/SET key.
Info
Possibly the welder has to wait for the heating element to
reach the nominal temperature. This would then be indicated
on the screen. If the temperature difference between actual and
nominal is large, an additional delay may occur during which
the final temperature is adjusted.
4.7.1 Facing the Component Butts
The welding process starts by the insertion of the facing tool. The ma-
chine alerts the welder to this next step.
Important
Make sure that the plate carrying the facing tool and the heat-
ing element is set on a surface where it can sit safely and does
not slide throughout the entire welding process.
First, the machine asks the operator to insert the facing tool into position 1
(see Display 10). This is the position for clamping the components. In
this position the spacer pins of the facing tool do not sit in the recesses
of the clamp bodies in which they are during facing. Slide the facing tool
in-between the carriages of the machine in position 1 and confirm it is in
place by pressing the START/SET key.

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When the facing tool is located between the components, the machine
asks the operator to close in the carriage. This is done by pressing the
cursor key until the “<-” on the screen disappear. The process can
be aborted by pressing the STOP/RESET key.
When the mobile carriage has been moved in on the fixed one, clamp the
components to be jointed into the clamps. While the screen that requests
this of the welder can be seen, it is possible, using the , cursor keys,
to decrease or increase the distance the carriage will travel during facing
by 0.5 mm increments, from 3.0 mm through to 10.0 mm. When the facing
distance is as desired, confirm by pressing the START/SET key. The
machine moves the carriage apart for the next process item.
This next item of the facing process is to move the tool from position 1 to
position 2, the position for facing proper. Again, the screen requests this
of the welder. To move the facing tool, release its position lock. When it
sits in position 2, press the START/SET key.
Info
Prior to the facing process, checking the direction and the speed
of the rotation of the power facer is recommended.
The machine then asks the welder to start the facing tool. Do as you are
requested, using the On/Off switch of the power facer, and hold down
the cursor key until the machine moves the carriage apart automati-
cally. This indicates that the facing process is correct, considering the
previously set facing distance. Then switch the facing tool off at its On/
Off switch.
Info
If the key is released before the carriage moves apart, the
facing tool pauses to allow for removing shavings; when holding
down the cursor key again the machine resumes facing.
When the machine has moved the carriage apart, the facing tool can
be removed from in-between the pipes. Visually check the components
and, if they are o.k., confirm this by pressing the START/SET key (see
Display 11). If the result of facing is poor, the process can be repeated
after pressing the STOP/RESET key. To face the ends once again, in
most cases the pipes have to be re-adjusted in the clamps.
Info
If an error occurs during facing, the machine moves the mobile
carriage apart, displaying the corresponding error message.
The facing process can be aborted at any time by pressing the STOP/
RESET key.
4.7.2 Checking Alignment
When the component butts are level to satisfaction, it has to be checked if
they align properly to each other or if there is an offset. Similar to facing,
the screen tells the welder that this is the next step, and the carriage
can be closed in on the other by pressing the key until the machine
stops automatically.
If the pipes align properly, confirm by pressing START/SET again, in
order to move on in the welding process.
If the alignment offset is too large, or if there is too large or too uneven
a distance between the components, press the STOP/RESET key. The
machine then asks if facing should be repeated. For if the components
have to be re-adjusted in the clamps at this point, facing has to be re-
peated, too. That is, at the repeat-facing query press START/SET if you
want to repeat facing, STOP/RESET, if not. In both cases the machine
Display 11
****** Facing ******
Facing OK?
[RESET] [SET]
Display 12
Check offset
Move clamps together
[RESET] [<-]

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Display 12
Insert heating elem.
[RESET]
Display 13
Move clamps together
Move heat.el. right
[RESET]
Display 14
***** Heating ******
25°C Nom. 200N
25°C Act. 201N
[RESET] 50/ 5s
Display 15
*** Change-over ****
Remove heating elem.
25°C Act. 201N
[RESET] 3/ 1s
asks the operator to move the carriages apart in order to allow insert-
ing the heating plate, if facing is o.k., or the facing tool, if it is not and
facing should be repeated. To move the carriage apart, press the key.
If facing is not o.k. and the repeat-facing message is responded to by
pressing STOP/RESET, the process aborts.
4.7.3 Inserting the Heating Element with or without Preheating
After the alignment/offset check and before the heating element is in-
serted, the cover caps have to be installed to the far ends of the compo-
nents. This corresponding request shows on the screen. When the cover
caps are installed, confirm by pressing the START/SET key.
After that confirmation, use the , cursor keys on the next screen to
select if preheating the component should occur not at all, only at the
right-hand side or on both sides. The confirm this selection by pressing
START/SET. The rationale behind this is that in a pipe-to-fitting joint, the
fitting may have to be heated longer than the pipe end to plasticize.
Important
Preheating requires a preheating time ≠0 s to be defined in
system memory. Preheating would be ineffective if it were se-
lected now, but a preheating time of 0 s or none at all has been
defined in the material parameters. Therefore, the preheating
selection screen shows only if a preheating time is defined.
With or without preheating selected, the machine tells the welder to insert
the heating element in-between the components (see Display 12).As soon
as it is properly position, the machine recognizes this automatically and
asks the welder to move the mobile clamp/carriage towards the fixed on.
To do this, hold down the cursor key.
Info
The line “Move heating element (to the) right” shows only if
the option of preheating only the right-hand component was
selected. This requires the heating element to be moved slightly
to the right manually while the machine closes the mobile
carriage in on the fixed one. The machine stops this carriage
earlier to allow for preheating the component in the right-hand
clamp without closing in the other component too much yet on
the heating element. If the welding process was selected to
run without or with both-sides preheating, both components
close in on the heating element simultaneously. The switch
from preheating to the heating stage is automatic.
4.7.4 Heating Stage
In the first welding stage, the pipes close in on the heating element with
the defined welding force and are thereby warmed. The stage starts when
the mobile carriage is moved in on the fixed one (see Display 13).
During the entire duration of the heating stage, the components continue
to soak heat from the heating plate, in order to prepare jointing.
In case of malfunction, the welding process can be aborted by pressing
STOP/RESET. If the machine detects a malfunction, it aborts welding and
displays an error message as soon as the heating element is removed.
4.7.5 Change-over Stage
Info
10 sec prior to the switch to the change-over stage, the heating
stage screen shows the message “Prepare change-over” and
an audible signal sounds to alert the welder to the imminent
change-over for which he will have only a couple of seconds.
At the end of the heating stage the carriages are moved apart automati-

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cally. The heating element has to be removed manually from in-between
the components and the removal, confirmed by pressing START/SET as
soon as the [SET] option appears on the screen. It being confirmed, the
carriage closes in again at the defined jointing force (see Display 16).
The welder has to monitor the change-over and must abort welding by
pressing STOP/RESET, in case a malfunction occurs.
4.7.6 Joining Stage
In the joining stage (or, fusion stage) the machine increases the applied
force in accordance with the force ramp calculated for the joint. This
stage is also indicated on the screen.
4.7.7 Cooling Stage
When the full joining force is reached, the machine moves on automati-
cally to the cooling phase (see Display 17). The cooling time is displayed
as it progresses. During cooling, the applied joining force is constantly
monitored.
4.7.8 End of Welding
After a successful welding operation, the applied force is released, and
the pipes can be taken out of the clamps. The screen tells you so.
If no error was detected during the welding process, the machine allows
the welder to evaluate the joint by visual check (see Display 18).
When this prompt is responded to by pressing START/SET, the machine
displays the most important welding data. Then, the joint can be declared
sound by pressing START/SET or poor, by pressing STOP/RESET. Right
after this assessment, a label tag is printed off for the joint.
When the label tag has been printed, the machine shows all errors it
has registered since the heating element was removed for the change-
over stage, or, that no error occurred at all. This info message can be
acknowledged by pressing the START/SET key.
5.12 Using ViewWeld to Manage Logged Welding Reports and Print
Tags
The ViewWeld feature offers viewing an abstracted version of the welding
reports recorded during the welding processes and printing it as a label
tag to be affixed to the joint on the tag printer. The ViewWeld abstract
shows the report number, year of machine manufacture, and identifier for
the serial number, separated by the letter “m”, parameters of the welded
material, the date and time of the welding, along with an evaluation of
the quality of the joint/welding operation as o.k. or with errors (see Dis-
play 19; “PH” meaning “preheated”), where the first displayed abstract
is that of the last performed welding operation.
To call the ViewWeld abstract of a welding report, press the key in
the default screen (see Display 3). Browsing through the saved welding
reports is then possible by pressing the or cursor keys. The machine
will “jump” by 1, 10 or 100 reports depending on how long the key is
held down. To print a tag of the welding operation of which the abstract
is currently displayed, the label tag printer has to be connected to the
welder. Then press the START/SET key in the ViewWeld screen.
If a USB stick is inserted into the appropriate port while the ViewWeld
abstract is showing, the currently displayed report can be downloaded to
the stick. The desired file type still has to be selected (see at the begin-
ning of Sect. 5 for reference), and the download starts.
Display 16
***** Joining ******
25°C Nom. 9N
25°C Act. 10N
[RESET] 5/ 2s
Display 17
***** Cooling ******
25°C Nom. 96N
25°C Act. 96N
[RESET] 50/ 20s
Display 18
Remove pipes
for visual check
[SET]
Display 19
*** 00025m14.587 ***
PE-HD 63mm 5.3mm
28.10.2014 16:44
PH-WELDP. OK P