aquatherm 50336 User manual

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OPERATION AND MAINTENANCE MANUAL
aquatherm welding device Art.-No. 50336, 50337, 50341
Fusion for
aquatherm green pipe, aquatherm blue pipe, aquatherm lilac pipe, aquatherm red pipe and aquatherm ti
pipesystems from 16 up to 125 mm
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IMPORTANT!
Only use the original aquatherm welding devices and aquatherm wel-
ding tools, except devices and tools which are especially approved
by aquatherm.
2. Assemble and tighten the cold welding tools manually.
3. Before fusing the distribution block, in which two connections are
fused simultaneously, the welding tools have to be placed into the
respective holes as described in the adjoing table A and drawing B.
4. All welding tools must be free from impurities. Check if they are
clean before assembling. If necessary clean the welding tools with
a non fibrous, coarse tissue and with methylated spirit.
Place the welding tools on the welding device so that there is full
surface contact between the welding tool and the heating plate.
Welding tools over Ø 40 mm must always be fitted to the rear
position of the heating plate.
Electric supply:
The power supply must coincide with the data on the type plate of
the welding device and must be protected according to the local
regulations. To avoide high power loss, the conductor cross-section
of the used extension cables must be selected according to the
power input of the welding devices.
6. Plug in the welding device. Depending on the ambient temperature
it takes 10 - 30 minutes to heat up the heating plate.
PART A: MOUNTING OF THE TOOLS
Art.-No. Passage Hole Branch Hole
30115 Ø 25 mm A + E Ø 20 mm A + C
85123 Ø 20 mm A + B Ø 16 mm A + C
85124 Ø 20 mm A + B Ø 16 mm A + C
WRONG
RIGHT
A
B

Part A: Heating up phase
7. During the heating up phase tighten the welding tools carefully with
the Allan key.
Take care that the tools completely contact the heating plate. Never
use pliers or any other unsuitable tools, as this will damage the coating
of the welding tools.
8. The temperature of 260° C is required for the welding of aquatherm
PP-R pipes.
Acc. to DVS - Welding Guidelines the temperature of the welding
device has to be checked at its tool before starting the welding process.
This can be done with a fast indicating surface thermometer.
ATTENTION:
First welding - soonest 5 minutes after reaching of the welding
temperature. DVS 2207, Part 11.
Part A: Handling
9. A tool change on a heated device requires another check of the welding
temperature at the new tool (after its heating up).
10. If the device has been unplugged, e.g. during longer breaks, the heating
up process, has to be restarted (see item 6).
11. After use unplug the welding device and let it cool down. Water must
never be used to cool the welding device, as this would destroy the
heating resistances.
12. Protect aquatherm- welding devices and tools against impurities. Burnt
particles may lead to an incorrect fusion. The tools may be cleaned with
aquatherm cleaning cloths, Art.-No. 50193.
Always keep the welding tools dry.
13. After welding, do not lay the the device on the Teflon coated tool, but
put it down in the provided supporting stand.
14. For a perfect fusion, damaged or dirty welding tools must be replaced,
as only impeccable tools guarantee a perfect connection.
15. Never attempt to open or repair a defective device. Return the defective
device for repair.
16. Check the operating temperature of aquatherm- welding devices
regularly by means of suitable measuring instruments.
PART A: HEATING UP PHASE / HANDLING
Welding tools
Heating plate
Handle
Temperature pilot lamp (yellow)
glows constantly while the
heat-up phase and blinks, when the
welding temperature is achieved
Operating lamp (green)
glows constantly, as soon as
the device is conntected with
the power supply system

Part A: Guidelines
17. For the correct handling of welding machines the following must be
observed:
General Regulations for Protection of Labour and Prevention of Accidents
and particularly the Regulations of the Employers’ Liability Insurance Asso-
ciation of the Chemical Industry regarding Machines for the Processing of
Plastics, chapter: „Welding Machines and Welding Equipment“.
18. For the handling of aquatherm- welding machines, devices and tools
please observe General Regulations DVS 2208 Part 1 of the German
Association for Welding Engineering, Registered Society (Deutscher Ver-
band für Schweißtechnik e. V.).
Part B: Checking of devices and tools
1. Check, if the aquatherm- welding devices and tools comply with to the
guidelines “Fusion Part A”.
2. All used devices and tools must have reached the necessary operating
temperature of 260 °C. This requires acc. to “Fusion Part A, item 8” a
separate test, which is indispensable (DVS - Welding Guidelines):
Suitable measuring instruments have to measure a temperature of up to
350° C with a high accuracy.
NOTE:
aquatherm recommends the original aquatherm temperature measuring
device art.-no. 50188
PART B: PREPARATION FOR THE FUSION
3. Cut the pipe at right angles to the pipe axis. Only use aquatherm pipe
cutters or other suitable cutting pliers. Take care that the pipe axis is free
from burrs or cutting debris and remove where necessary.
4. Mark the welding depth at the end of the pipe with the enclosed pencil
and template.
5. Mark the desired position of the fitting on the pipe and / or fitting. The
markings on the fitting and the uninterrupted line on the pipe may be used
as a guide.
PART A: GUIDELINES
PART B: CHECKING OF DEVICES AND TOOLS
Measurement of temperature at the aquatherm butt-welding machine
Measurement of temperature at the aquatherm manual welding device (800W )
Measurement of temperature at the aquatherm welding machine
Cutting of the pipe
Marking of the welding depth

PART B: HEATING OF PIPE AND FITTING
Heating of pipe and fitting
6. Push the end of the pipe, without turning, up to the marked welding
depth into the welding tool.
It is essential to observe the above mentioned heating times.
Pipes and fittings of the dimensions Ø 75 to 125 mm can only be welded
with welding device Art.-No. 50141 (or with machine Art.-No. 50147).
On using the aquatherm- welding machine Art.-No. 50147 a separate
operating instruction has to be observed.
ATTENTION:
The heating time starts, when pipe and fitting have been pushed to the
correct welding depth on the welding tool. Not before!
PART B: SETTING AND ALIGNMENT
7. After the required heating time quickly remove pipe and fitting from the
welding tools. Joint them immediately, and without turning, until the
marked welding depth is covered by the PP- bead from the fitting.
ATTENTION:
Do not push the pipe too far into the fitting, as this would reduce the
bore and in an extreme case will close the pipe.
8. The joint elements have to be fixed during the specified assembly time.
Use this time to correct the connection. Correction is restricted to the
alignment of pipe and fitting. Never turn the elements or align the
connection after the processing time.
9. After the required cooling time the fused joint is ready for use.
The result of the fusion of pipe and fitting is a permanent material
joining of the system elements. Connection technique with security for
a life-time.
The fusion is subject to the following data
*heating times recommended by aquatherm at ambient
temperatures below + 5 °C
Dimension 160 - 630 mm:
The dimension 160 - 630 mm are joined by butt- welding.
Joining, fixing and…
…aligning
The result: a permanent connection!
Heating-up of pipe and fitting
Pipe
external- Ø
Welding
depth Heating time Welding time Cooling time
mm mm sec.
DVS
sec.
AQE* sec. min.
16 13,0 5 8 4 2
20 14,5 5 8 4 2
25 16,0 7 11 4 2
32 18,0 8 12 6 4
40 20,5 12 18 6 4
50 23,5 18 27 6 4
63 27,5 24 36 8 6
75 30,0 30 45 8 8
90 33,0 40 60 8 8
110 37,0 50 75 10 8
125 40,0 60 90 10 8

1.1
1.2
1.3
1.4
1.5
PART B: UNIVERSAL PEELING TOOLS
By using the aquatherm universal peeling tools the end pieces of the
aquatherm OT (oxygen tight), UV (UV-resistant) and MS (multilayer stabi)
pipes can be peeled. By the uniform removal of the outer layer of the
pipe any extension of the pipe system by electrofusion socket or fitting
is possible. The universal peeling tools are available in the sizes Ø 20-
Ø 125 mm (Art.-No. 50479 – 50488). The peeling process is done either
mechanically or manually. For the mechanical processing two attachment
plates for pipe sizes Ø20- Ø63 mm (Art.-No. 50499) and Ø75- Ø125 (Art.-
No. 50500) mm are available. For the mechanically processing of the
electrofusion sockets the peeler is extended by an attachment (Art.-No.
50489 – 50498). The power drill should have a high torque.
1. INSTRUCTIONS FOR THE MECHANICAL PEELING PROCESS
1.1. The attachment plate is clamped with the hexagon bolt in the power
drill.
1.2. The peeler is fixed with its screws in the slot matching the diameter
of the attachment plate and rotated clockwise so that the peeler adheres
to the attachment plate.
1.3. The peeling tool clamped on the chuck is set by the lead to the end
of the pipe.
1.4. The peeling process starts with rotation of the peeling tool upon slight
force in axial direction. The peeling operation is completed when the
attachment plate strikes against the pipe end.
1.5. The pipe now can be welded by socket welding method.
2. INSTRUCTIONS FOR THE MECHANICAL PEELING PROCESS FOR
ELECTROFUSION SOCKETS
2.1. The extension is centered with the peeler through the superimposed
chamfer fit and fastened with three Allen screws.
2.2. The attachment plate is clamped with the hexagon bolt in the power
drill and connected with the peeling tool (see photo 1.2.).
2.3. The peeling process starts with rotation of the peeling tool upon slight
force in axial direction. The peeling operation is completed when the
carrier plate strikes against the pipe end.
2.4. The peeling tool is withdrawn from the pipe and the E-socket welding
process can start.
3. PEELING INSTRUCTIONS FOR MANUAL PEELING
3.1. For the manual peeling two handles are mounted at the peeling tool.
3.2. The peeling tool is pushed onto the untreated pipe up to the stop.
3.3. The peeling tool is turned clockwise as long as the marked peeling
depth (see table) is reached.
3.4. If the specified/marked peeling depth (see table) is reached, the peel-
ing tool is removed and the socket welding process can start. If the electric
socket can be used as a sliding sleeve, the peeling depth for the electric
socket welding (see table) must be doubled.

2.1 3.1
2.2 3.2
2.3 3.3
2.4 3.4
TABLE OF PEELING DEPTH:
SOCKET AND ELECTRIC SOCKET WELDING
Diameter Peeling depth
Socket welding
Peeling depth
Electric socket
welding
ø 20 16 mm 39 mm
ø 25 20 mm 43 mm
ø 32 22 mm 45 mm
ø 40 25 mm 50 mm
ø 50 28 mm 56 mm
Diameter Peeling depth
Socket welding
Peeling depth
Electric socket
welding
ø 63 32 mm 65 mm
ø 75 34 mm 69 mm
ø 90 37 mm 77 mm
ø 110 42 mm 85 mm
ø 125 44 mm 90 mm
chamfer fit

PART C: WELD-IN SADDLES
aquatherm- weld-in saddles are available for pipe outer diameter of 40
- 630 mm.
Weld in saddles are used for
• branch connections in existing installations
• the substitution of a reduction-tee
• branch connections in risers
• sensor wells, etc.
1. Before starting the welding process, check whether the aquatherm-
welding devices and tools comply with the requirements of “Fusion Part A”.
2. The first step is to drill through the pipe wall at the intended outlet point
by using the aquatherm- drill (Art.-No. 50940-50956).
3. IMPORTANT!
Only the oxgen barrier layer of the aquatherm blue pipe OT Art.-No.
2170708-2170138 must be removed with the mentioned aquatherm
special peeling drills mentioned in the table beside.
For this the special peeling drill is inserted into the bore hole and
swaied 2-3 times with light pressure and low rotating speed between
the pipe walls until the oxygen barrier layer is completely peeled off.
Remove burrs, debris and other dirts with a chamfering tool or the
aquatherm cleaning wipes. Do not touch the peeled surface any more
and protect it from new pollution.
When using aquatherm green pipe - stabi composite pipes remove
the rest of the aluminium remaining at the bore hole with the
aquatherm- chamfering device.
4. The welding device / saddle welding tool must have reached the
required operating temperature of 260 °C (check with reference to
“Fusion Part B, item 2”).
5. The welding surfaces have to be clean and dry.
6. Insert the heating tool on the concave side of the weld in saddle tool
into the hole drilled in the pipe wall until the tool is completely in
contact with the outer wall of the pipe. Next the weld-in saddle tool is
inserted into the heating sleeve until the saddle surface is up against
the convex side of the welding tool. The heating time of the elements is
generally 30 seconds.
7. After the welding tool has been removed, the weld-in saddle tool is
immediately inserted into the heated, drilled hole. Then the weld-in
saddle should be pressed on the pipe for about 15 seconds. After being
allowed to cool for 10 minutes the connection can be exposed to its
full loading. The appropriate branch pipe is fitted into the sleeve on the
aquatherm- weld-in saddle using conventional fusion technology.
By fusing the weld-in saddle with the pipe outer surface and the
pipe inner wall the connection reaches highest stability.
Drilling through the pipe wall
The welding tool is inserted into the pipe wall …
…heating-up of the elements
Joining
Ready!
Removal of the oxgen barrier layer from the aquatherm blue OT-pipe
Art.-No. Dimension
50921 for weld-in saddles ø 20 & 25 mm
50922 for weld-in saddles ø 32 mm
50924 for weld-in saddles ø 40 mm
50926 for weld-in saddles ø 50 mm
50928 for weld-in saddles ø 63 mm
Art.-No. Dimension
50421 for weld-in saddles ø 20 & 25 mm
50422 for weld-in saddles ø 32 mm
50424 for weld-in saddles ø 40 mm
50426 for weld-in saddles ø 50 mm
50428 for weld-in saddles ø 63 mm
aquatherm saddle peeling tools
for aquatherm blue pipe ot
pipes ø 50-125 mm
aquatherm saddle peeling tools
for aquatherm blue pipe ot
pipes Ø 160-250 mm

SAFETY STANDARDS
1. This equipment must only be used in full compliance with the instructions
given in this manual. All other uses are to be considered improper and
forbidden. Improper use may cause injury to the machine operator or third
parties and/ or cause damage to the machine or other objects.
2. All standards concerning health and safety in the workplace must be
implemented at all times.
3. Before using the machine personnel must be properly trained in its
operation and in applicable accident-prevention regulations.
4. The components used in the construction of the machine and its
operating principles are such that special care should be taken to carry out
the following instructions:
4.1. Electric power supply:
Make sure the mains electricity supply is suitable for the machine. Do
not use an electricity supply which is subject to voltage surges or drops.
Use a guaranteed mains supply or power generators fitted with voltage
stabilizers. Make sure the machine’s power socket is protected with a high
sensitivity differential switch (IΔ=30 mA) and that the machine has an
earth connection.
4.2. Electricity:
Even if designed and manufactured in full accordance with applicable
standards and fitted with all the required safety devices, electrically
powered machinery nonetheless poses a risk to safety due to the nature of
this type of energy (i.e. risk of electric shock). Do not expose the machinery
and its electrical cables to the rain, to chemicals, to mechanical stress (e.g.
vehicles driving across the cables). Use perfectly dry pipes and connectors.
Do not use the machine if your hands are wet or the workplace is moist
or damp.
4.3. Avoiding burns:
Do not touch the heating element, metal components or plastic parts close
to the welding surface during heating, welding or cooling, since the plate
reaches very high temperatures. Operate the machine with the utmost
care. Wear heatproof gloves and protective clothing suitable for
preventing burns.
4.4. The workplace:
Make sure that unauthorized persons are unable to gain access to the
workplace. The workplace must be clean, tidy, properly ventilated and
well lit. There should not be any gases, fumes or flammable materials
present, such as solvents, oils, paints, etc. These may constitute a fire risk
if they come close to the heating element. Keep any objects or materials
susceptible to heat damage well away from the machine. When working
in tight, awkward places an external supervisor must be present to provide
assistance to the machine operator in case of need.
4.5. Checks and repairs:
Before using the machine check that no components are damaged.
Replace cables or components as soon as they become worn. Repairs
must be carried out only by an expert or specially trained technician using
exclusively original spare parts. Dismantling the machine involves a risk of
electric shock. No alterations may be made to the machine.
4.6. Presence of the operator at all times during operation:
The machine operator must not leave the machine while it is welding or
heating up.
4.7. Use pipes that are chemically inert: Do not carry out any welding
operations on pipes containing, or which may have contained, substances
which when heated generate explosive gases or other gases dangerous to
the human body.
4.8. Support: Position the welding machine using only the proper fork or
bench supports.
4.9. Take care with cables: Do not disconnect plugs, sockets or connectors
or move the machine by pulling on the electric cables.
4.10. Finally...: After work, remember to disconnect the welding machine
from the mains or supply socket.
4.11. The machine must not be used in areas where there is a risk of
explosion or fire. Only specially designed and manufactured machines must
be used in workplaces of this kind.
5. The manufacturer and dealer will not be liable for personal injury or
damage to property arising from the improper use of the machine.
6. WARNING
In the event of a fault of any kind during the guarantee period, send
the machine to the manufacturer or an authorized repair centre. Having
repair work carried out by personnel not authorized by aquatherm will
immediately invalidate the warranty
aquatherm GmbH • Biggen 5 • 57439 Attendorn • www.aquatherm.de