EM-Technik 3W Series User manual

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
1
Welding Adaptor 3W
Operating and Installation Instructions
EN

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
2
1 General information ............................................................................................................................................ 3
1.1 Introduction...................................................................................................................................................... 3
1.2 Warnings ......................................................................................................................................................... 3
1.3 Special Hazards .............................................................................................................................................. 3
1.4 General Safety Instructions ............................................................................................................................. 3
1.5 Designated Use............................................................................................................................................... 3
1.6 Reasonably Foreseeable Misuse .................................................................................................................... 3
2 Manufacturer’s Specification ............................................................................................................................. 4
2.1 Description ...................................................................................................................................................... 4
2.2 Transport and Storage..................................................................................................................................... 4
3 Technical Data ..................................................................................................................................................... 4
3.1 Dimensions...................................................................................................................................................... 4
3.2 Operating Medium........................................................................................................................................... 4
3.3 Pressure Guide ............................................................................................................................................... 4
3.4 Connect Welding Adaptor................................................................................................................................ 4
3.5 Connect Hose/Tube Side and Tube Thread .................................................................................................... 4
4 Assembly and Operation .................................................................................................................................... 4
4.1 Assembly Instructions...................................................................................................................................... 4
4.2 Tools Required ................................................................................................................................................ 5
4.3 Connect Thread Side ...................................................................................................................................... 5
4.4 Torque Chart.................................................................................................................................................... 5
4.5 Fastening Options ........................................................................................................................................... 5
5 Commissioning ................................................................................................................................................... 5
6 Maintenance......................................................................................................................................................... 5
7 Disposal ............................................................................................................................................................... 5
8 Return Delivery.................................................................................................................................................... 5
9 Troubleshooting / Fault Rectification ................................................................................................................ 5
10 Manufacturer‘s Declaration ................................................................................................................................ 6
11 Contact ................................................................................................................................................................. 6
Contents

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
3
1. General information
1.1 Introduction
• These instruction apply to the welding adapter of the
3W series, also referred to as connector.
• Read the instructions completely before using our pro-
ducts to prevent injuries, material damage and mal-
functions!
• Save the instructions for later reference.
• All rights including copyright and industrial property
rights are explicitly reserved.
1.2 Warnings
• Warnings are always identified by a signal word. The
following signal words or hazard levels are used:
Danger: Failure to follow instructions will
lead to serious injuries or death. High risk le-
vel of endangerment.
Warning: Failure to follow instructions may
lead to serious injuries or death. Moderate
risk level of endangerment.
Caution: May lead to slight or moderate inju-
ries. Low risk level of endangerment.
Note: Refers to an instruction that must ab-
solutely be followed.
Information: Gives useful tips and recom-
mendations..
1.3 Special Hazards
• It must be ensured that the connector is resistant for
the media and temperatures that will be used. The re-
sistance of the connector with aggressive media de-
pends in individual cases on many variables (such as
the temperature, concentration ratio of the medium,
material, environment, tube material etc.). The person
ordering the connector is responsible for checking for
the specific application. In case of doubt install the con-
nector on a trial basis.
• Always comply with the safety data sheets or the safety
requirements for the media you are using!
• Before removing the connector it must be ensured that
there is no more medium in the flexible tube system
and the pressure has completely dissipated. Exercise
caution for toxic, corrosive or hot media residue flowing
out of the line or remaining in dead spaces.
1.4 General Safety Instructions
• The connector must be properly connected to the
flexible tube system.
• Before installing the connector make certain that
external mechanical effects such as thrust and bending
forces are not acting on the flexible tube system.
• Installation, commissioning, operation, installation,
maintenance, troubleshooting and disassembly must
only be performed by qualified specialists with due con-
sideration of accident prevention regulations. Person-
nel must be capable based on their technical training
and experience of performing assembly tasks, follo-
wing technical specifications and recognizing possible
dangers.
• Personnel with deficient knowledge must be trained
and instructed.
• Areas of responsibility and responsibilities must be pre-
cisely regulated and personnel must be monitored.
These safety instructions do not take into consideration
any:
• Coincidences and events that could occur at the cus-
tomer location during assembly, operation and mainte-
nance.
• Local safety requirements, for which the operating
company is responsible to ensure compliance, inclu-
ding assembly personnel who are used.
1.5 Designated Use
• The connector must only be operated within the permit-
ted usage ranges for pressure and temperature.
• Only the operating media named in the documentation
are permitted to flow through the connector.
• The connector must only be operated if it is in flawless
technical condition.
• The connector must not be operated if it is in partially
assembled condition.
• If other operating modes are not named in the docu-
mentation, they must be approved with the manufac-
turer.
1.6 Reasonably Foreseeable Misuse
• Any usage other than designated use.
• Do not make any modifications to the product by your-
self!
• Components should only be retrofitted after consulta-
tion with the manufacturer.

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
4
2 Manufacturer’s Specification
2.1 Description
Wherever fixed connections are required, at process
transitions from rigid pipe to flexible hose lines or at pipe
ends, the 3W welding adaptor is used. It is suitable for
both butt and socket welding processes and thus offers
users a great deal of freedom during installation.
2.2 Transport and Storage
• The welding adaptor must be protected against me-
chanical damage, moisture, dirt and dust. The storage
temperature range is 10 – 40°C.
• Avoid UV radiation and direct sunlight.
• Leave the connector in its original packaging to ensure
the best possible protection.
• Dispose of the packaging material according to dispo-
sal requirements/environmental protection regulations.
3 Technical Data
3.1 Dimensions
The exact dimensions of the flexible tube connector
can be found on our homepage under the following link:
www.em-technik.com
Special sizes can be asked via [email protected]
3.2 Operating Medium
• Gaseous and liquid media that do not negatively affect
the physical and chemical properties of the relevant
housing and sealing material.
• If you have questions about resistance please contact
emtechnik.
• For the maximum permitted operating pressure/tempe-
rature see the pressure guide.
3.3 Pressure Guide
As the temperature rises, the effectiveness of the con-
nector falls, as shown by this table.
Material PP PVDF PFA
Pressure
Stage PN 10 PN 10 PN 10
-40°C 75% 75%
-20°C 100% 100%
5°C 100% 100% 100%
20°C 100% 100% 100%
30°C 80% 80% 90%
Material PP PVDF PFA
Pressure
Stage PN 10 PN 10 PN 10
40°C 70% 70% 85%
50°C 60% 60% 80%
60°C 50% 50% 70%
70°C 40% 45% 60%
80°C 30% 40% 50%
90°C 20% 35% 40%
100°C 35% 40%
110°C 30% 35%
120°C 25% 30%
130°C 25% 30%
140°C 10% 25%
150°C 20%
160°C 15%
170°C 10%
180°C 10%
3.4 Connect Welding Adaptor
The welding adaptor is attached to the pipe ends using
the butt or socket welding method.
3.5 Connect hose/tube side and male threa
• The welding adapter has a 1+, 1A, 1C or 1D series
hose connection.
• Also available with pipe connections for the 2N series.
• Alternatively, the welding adapter can be manufactured
with external thread.
• For the instructions of the hose or tube fitting, please
refer to the instructions corresponding to the connec-
tion principle under www.em-technik.com/en/technical-
information/assembly-guides
4 Assembly and Operation
4.1 Assembly Instructions
• Make certain the connector is suitable for the relevant
application. The connector must be suitable for the
operating conditions of the linesystem (medium, con-
centration, temperature and pressure) as well as the
relevant ambient conditions.

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
5
• Check the connector for transport damage before in-
stalling it. If the connector is damaged do not install it.
• The planner, the construction company or operating
company are responsible for the positioning and ins-
tallation of the connector. Planning and installation er-
rors can adversely affect the reliable functionality of the
connector and may represent a significant potential for
hazard.
• After the connector is installed perform a tightness and
function check.
4.2 Tools Required
The tools required for installation and assembly are not
included with delivery.
4.3 Connect Thread Side
• The connector must be connected so it is free of
mechanical stress.
• The connector can have a male thread (ISO, DIN,
ANSI) and can be connected with various connecting
elements of the emtechnik system.
Cylindrical thread Conical thread
Sealing is provided by a sealing collar for
Cylindrical threads (G, M or UNF).
A version with an O-ring is also possible.
Sealing is provided
by the thread itself
for Conical threads
(NPT).
Sealing Collar O-Ring Thread
• Each thread must always be connected with the same
thread type.
• If a plastic connector is used in combination with a
metallic male fitting, additional sealing with Teflon®
tape is recommended.
4.4 Torque Chart
Plastic Thread
G 1/8“ G 1/4“ G 3/8“ G 1/2“ G 3/4“
PP 1.0–1.5 2.5 5.0–6.0 5.0 10.0
PVDF 1.0–2.0 5.0 5.0–7.0 10.0 15.0
All data in Nm
4.5 Fastening Options
For the connectors are no fastening options intended.
5 Commissioning
5.1 Precondition for Commissioning
• Protect against leaks: Take protective measures
against exceeding the maximum permitted pressure
due to possible pressure surges.
• Check the tightness and function of the connector.
• In new systems and after repairs, flush the line system
to remove foreign materials.
6 Maintenance
• When used as designated, the connector is practically
wear-free and generally requires no maintenance.
• The operating company must perform regular visual in-
spections of the connector according to the operating
conditions to prevent leaks and damage.
7 Disposal
• When disposing of the connector and packaging,
comply with the relevant disposal requirements and
environmental protection regulations.
• When disposing of connector, pay careful attention to
any residues of toxic or corrosive media.
8 Return Delivery
Do not return before consulting with emtechnik.
1. Please consult with emtechnik.
2. Empty the connector properly.
3. Rinse and clean the connector thoroughly, especially
if the media is being conveyed are harmful, explosive,
hot, or hazardous in some other way.
4. For connectors that have been operated with aggres-
sive, corrosive, combustible, toxic or water polluting
media, a completely filled in clearance certificate must
always be included.
9 Troubleshooting / Fault
Rectification
Error Possible Cause Error
Rectification
Connection
between thread side
and system leaking
Sealing surface is
damaged
Use sealant, see 4.3

EM-Technik GmbH - Industriestraße 2 - 67133 Maxdorf - Germany
[email protected] www.em-technik.com
6
Error Possible Cause Error
Rectification
Flexible tube
connection is leaking
Flexible tube is not
correct mounted
Mount connector
correctly, see 4.5
No flow Connector is blocked Clean the connec-
tor or replace it if
necessary
10 Manufacturer‘s Declaration
• Our products do not fall under the scope of the Ma-
chinery Directive 2006/42/EC. However, they can be
incorporated in an installation that is considered as
machinery. In this case regard the following note: The
products may not be put into operation until it is made
sure that the final machinery into which our products
are incorporated complies with the provisions of the
Machinery Directive 2006/42/EC.
• Based on the fluid class, pressure and nominal diame-
ter, our products fall under diagram 8 of the Pressure
Equipment Directive PED 2014/68/EU. Because of the
ratio of nominal diameter, pressure and volume, they
fall only under article 4 paragraph 3 and are designed
and manufactured according to applicable good engi-
neering practice. They must not carry any CE marking.
• The warranty of armature expires in the following ca-
ses: Operating conditions which do not follow the in-
tended use or do not follow technical specifications.
Improper installation or assembly. Just as well as inap-
propriate use, dismantling or modification.
• Failure to observe information provided here may lead
to injuries, material damage, malfunctions and impuri-
ties due to escaping medium.
11 Contact
If you have questions or suggestions please contact us at:
EM-Technik GmbH
Industriestr. 2 Tel [phone]
67133 Maxdorf Fax [phone]
Germany [email protected]
Version 08/2021