Asahi/America SP-110S User manual

Proweld Equipment
Owner & Maintenance
Manual
SP-110S
35 Green Street, PO Box 653, Malden, MA 02148
Tel: [phone] - Fax [phone] - Toll Free: [phone]
www.asahi-america.com - [email protected]
Direct Sales: East [phone] / Central [phone] / West [phone]

Contents
1Introduction..................................................................................................................................................3
2Safety Instructions and Messages..............................................................................................................3
2.1 The User’s Manual...............................................................................................................................3
2.2 Explaining Icons...................................................................................................................................4
2.3 Safety Messages..................................................................................................................................4
2.4 Warranty...............................................................................................................................................5
2.5 Service and Repair...............................................................................................................................5
2.6 Transport / Storage / Shipment............................................................................................................5
2.7 Identifying the Hydraulics / Welding Control Unit.................................................................................6
3Understanding the Machine ........................................................................................................................6
3.1 Machine Components..........................................................................................................................7
3.2 Technical Specs...................................................................................................................................8
3.3 Welding Pipes and Fittings...................................................................................................................9
4Operation.....................................................................................................................................................9
4.1 Check out, Turning on, Selecting the display language.....................................................................10
4.2 Entering traceability data for the joint.................................................................................................11
4.3 Configuring the machine...................................................................................................................11
4.4 Changing key data of the welding......................................................................................................12
4.5 Definition of the key data for additional materials..............................................................................13
4.6 Welding Process…………………………………………………………................................................15
5Printing Reporting Protocols......................................................................................................................19
5.1 Printing, the Print Menu......................................................................................................................19
6System Data..............................................................................................................................................21
7Service and Repair Contact ......................................................................................................................22
2 agru SP-110S User’s Manual Version December 2006

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 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 accidents.
Carefully read the User’s Manual to avoid damage to the machine or hard-
ware in its environment as well as injury.
This manual is applicable to the following machines:
agru SP-110S
Thank you.
2 Safety Messages
This User’s Manual contains important instructions for operating safely the
infrared welding machine agru SP-110S. 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 available
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 or electronic form) and distribute as well as to translate,
are reserved and subject to prior written authorization.
Version December 2006 agru SP 110-S User’s Manual 3

2.2 Explaining Icons
The following expressions and icons are used in this User’s Manual to refer
to safety-related issues:
This icon indicates that non-compliance may result in a
hazardous situation that possibly causes bodily injury or
material damage.
Caution
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.
Important
This icon indicates tips and useful information for using the
machine more efficiently and more economically.
Info
2.3 Safety Messages
Protect the power supply cord from cutting edges. Have an authorized ser-
vice 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.
Parts Under Power
After opening the machine or removing the cover, parts of it are
accessible that may be under power. The device may be opened
exclusively by an authorized service shop.
Caution
Pipe Facing Tool
Start the pipe facing tool only when it is in its working position.
When facing pipes, do not wear jewelry; 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
When working with the machine, be extremely cautious while the
heating plate is operating. Since the heating plate and its guard
presents 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 element or the heating element guard.
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
4 agru SP-110S User’s Manual Version December 2006

t may be.
Ensuring Acceptable Work Conditions
Caution
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 conditions
have to be ensured (e.g., sufficient distance from the machine to
other functional areas of the workshop).
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 produc
Important
Power Only to Operational Machine
Power must never be applied to the machine before it is
completely installed and ready for operation.
Important
User’s Manual
Info
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 Welder and Operator Obligations
• The machine may be operated exclusively by persons who are familiar
with the applicable regulations, the guidelines for the prevention of ac-
cidents, and the User’s Manual.
• 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 training. The operating/owning company en-
gages to check at reasonable intervals if the machine is operated by
the welders 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 welder is required to make sure that the state of the
machine is in order.
During transport, the heating element has to be secured with the
transport lock at all times. When installing the machine, remove
the transport lock before applying power to the machine.
Important
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. Further-
more, the provisions and instructions contained in the User’s Manual have to
have been respected.
2.6 Service and Repair
As the machine is used in applications that are sensitive to safety considera-
tions, it may be serviced and repaired only on our premises or by partners
who were specifically trained and authorized by us. Thus, constantly high
standards of operation quality and safety are maintained.
Version December 2006 agru SP 110-S User’s Manual 5

Non-compliance with this provision will dispense the
manufacturer from any warranty and liability claims for the unit
and any consequential damage.
Important
All machines that are new or newly programmed during maintenance or
upon request is wished are shipped with the most recent software version.
2.7 Transport and Storage
During transport, the machine must be at all times in the transport box it is
shipped in. Ensure that the heating element is locked during transport.
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”), the serial number (“Nr.”), and the manufacturer.
3 Product Description and Principles of Operation
3.1 Intended Use
The agru SP-110S Welding Machine is designed exclusively for welding
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.
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 cancel any and all warranties under which the
product may be.
Important
3.2 Machine Description
The machine can be used as an in-shop installation, and with anodized alu-
minum components, it is also suited for clean room applications. The ma-
chine 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 the applicable forces and temperatures and con-
trols the welding process automatically.
All welding and traceability data are entered either directly on a touchscreen
panel or read from a bar code using a scanning wand. 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 net-
work management software (such as DataWork agru).
6 agru SP-110S User’s Manual Version December 2006

Using the menus displayed on the touchscreen, the machine can be custo-
mized to the application in hand (see section 4.3, Configuring the Machine).
3.2.1 Component Overview Heating Element and Guard
Facing Tool
Position Handle of Facing Tool
Fixed and Mobile Carriage of
Machine Frame
Scanning Wand
Touchscreen Panel
Set Screws for Compensation of Small
Horizontal or Vertical Ali
g
nment Ga
p
s
Confirmation Button for Two-Hand Mode Steps
3.2.2 Touchscreen/Control Panel
Status Bar
Title Band
Multifunctional Area (changes
depending on context of display)
- Display of/data on welding
progress
- Parameter menus to configure
operation settings
- Input keyboards
- Error messages/Notes
Navigation Bar with User Inter-
face Buttons
Version December 2006 agru SP 110-S User’s Manual 7

3.2.3 Ports and Switches
Emergency Stop Switch
Scanning Wand
On/Off Switch
Buzzer
Power Supply Cord
Temperature Sensor
Serial Interface
Parallel Port
Printer Power Supply
Fuse
Nitrogen Rinse Port
230 V Power Outlet
3.2.4 Specifications
agru SP-110S
Power Characteristics
Voltage
Frequency
Total Rated Power
Heating Element
Facing Tool
230 V
50/60 Hz
1.58 kW, 6.8 A
1.35 kW
0.24 kW
Welding Operation Specs
Welding Force
Speed of Facing Tool
Ambient Temperature (operation)
Ambient Temperature (storage)
Operating Range
10 - 500 N
approx. 45 rpm
+0°C to +40°C (32°F to 104°F)
–5°C to +50°C (23°F to 122°F)
20 - 110 mm (3/4" - 4-1/3")
Dimensions
Dimensions (W x D x H)
Machine placed in the transport box
Machine only
Weight
Maximum Carriage Stroke
830 x 1080 x 730 mm (32-2/3" x 42-1/2" x 32-2/3")
675 x 900 x 630 mm (26-9/16" x 35-3/8" x 24-4/5")
approx. 90 kg (198 U.S. lbs.),
in box approx. 140 (308 U.S. lbs.)
145 mm (5-3/4")
8 agru SP-110S User’s Manual Version December 2006

3.3 Welding Process Overview
The welding process is performed as follows:
•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.
•Pipe ends are worked using the pipe facing tool until the machine
tells you that facing is successfully completed.
•Pipe alignment is checked and confirmed on the touchscreen.
•Semi-automatic insertion of the heating element; when inserting it,
the heating element has to be clean.
•After the heating element was inserted, the pipes close in
automatically at the predefined force.
•When the carriages close in, they also align the heating element ex-
actly in-between the pipe butts.
•At the same time, the pipe butts are heated to the predefined tem-
perature.
•When the heat-soaking phase is over, the pipes are moved apart
and the heating element is removed automatically.
•Once the heating element is removed, the pipes close in again au-
tomatically.
•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
4.1 Check-out, Turning on, Selecting the Display Language
Place the machine on a level surface and ensure it cannot slide. 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 tem-
perature 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 to 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 without using any tools since the
inserts are fastened in the clamps by magnetic attraction.
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
Important
The surfaces of the heating plate have to be free of grease and
clean, or they have to be cleaned.
Version December 2006 agru SP 110-S User’s Manual 9

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)
Important
Display 1
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 wel-
come screen, as reproduced in Display 1, ap-
pears on the touchscreen panel. Touch the
appropriate flag to select the display language
that the machine will use.
After the language was selected, the machine
takes the user to the welder code entry
screen. Without a valid welder identification
code, it is impossible to start welding processes
on the machine, since the heating element re-
fuses to heat up unless a valid code is entered.
Info
Enter the welder identification code by typing it
on the touchscreen and saving it to memory by
touching the “Ok” button. If a bar code for the
welder code is available, you can also read it
from the bar code using the scanning wand.
All inputs for which a bar code is
available can be entered from the
bar code using a scanning wand.
Entering data on the touchscreen
must always be performed with the
bare finger. Using objects (ballpoint
pens, screwdrivers, etc.) may cause
unrecoverable damage to the surface of the touchscreen.
Display
2
Info
Important
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 simply touching the “Ok” button.
If traceability data are not the same as for the
last joint, change the data that are different
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.
Depending on the software
version installed in your machine,
some screens may differ slightly
on your machine from the
reproductions in this manual.
10 agru SP-110S User’s Manual Version December 2006
Display
3