HURNER CNC ECO 630 User manual

Version Februar 2018
Nieder-Ohmener Str. 26
35325 Mücke (Atzenhain)
HÜRNER SCHWEISSTECHNIK GmbH
Bedienungsanleitung•User’sManual•Руководство пользователя
User’sManual
CNC ECO 630
v. 2.0
The German version of the manual enclosed herein is the original copy, refl ected in the translations herein.
Inliegende deutsche Fassung der Anleitung ist der Urtext, welchen inliegende Übersetzungen wiedergeben.
The German version of the manual enclosed herein is the original copy, reflected in the translations herein.
La version allemande ci-après représente le texte original du manuel, rendu par les traductions ci-joint.
La versión alemana adjunta está el texto original de las instrucciones, que también representan las traducciones de esta.
Приложенная немецкая версия руководства является оригинальным текстом, с которого сделаны включенные переводы.
A versão em alemão desse manual anexo é a versão original, e foi a base para as traduções para as outras línguas.

Version February 2018 EN 3 HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
Contents
1 Introduction ........................................................................................................ 5
2 Safety Messages .................................................................................................. 5
2.1 The User's Manual............................................................................................... 5
2.2 Explaining Icons .................................................................................................. 5
2.3 Operating the Product Safely............................................................................. 5
2.4 Owner and Operator Obligations...................................................................... 6
2.5 Intended Use ....................................................................................................... 7
2.6 Required Worksite Conditions ........................................................................... 7
2.7 Warranty.............................................................................................................. 7
2.8 Transport and Storage........................................................................................ 7
2.9 Identifying the Product ...................................................................................... 7
3 Understanding the Machine .............................................................................. 7
3.1 Included Components......................................................................................... 8
3.2 Control Panel....................................................................................................... 8
3.3 Connectors........................................................................................................... 9
3.4 TechnicalSpecications ...................................................................................... 9
3.5 Overview of the Welding Process .................................................................... 10
4 Operation .......................................................................................................... 11
4.1 Start of Operation, Switching the Machine on............................................... 11
4.2 SettingtheDefaultCongurationoftheMachine........................................ 12
4.3 Entering Traceability Data................................................................................ 15
4.4 Entering Pipe or Fitting Parameters ................................................................ 15
4.5 Performing the Welding Process...................................................................... 16
4.5.1 Facing the Pipe Butts ........................................................................................ 16
4.5.2 Checking Pipe Alignment................................................................................. 16
4.5.3 Possibility to Change Welding Parameters...................................................... 17
4.5.4 Inserting and Monitoring the Heating Element ............................................. 17
4.5.5 Bead Build-up Stage ......................................................................................... 17
4.5.6 Heating Stage.................................................................................................... 18
4.5.7 Change-over Stage............................................................................................ 18
4.5.8 Joining and Cooling Stage ............................................................................... 18
4.5.9 End of Welding ................................................................................................. 18
4.5.10 Printing Label Tags............................................................................................ 19
4.6 Displaying Characteristics of the Welding System .......................................... 19
4.7 Using ViewWeld to Manage Logged Welding Reports and Print Tags ......... 19
4.8 Aborted Welding Process ................................................................................. 20
5 Downloading Welding Reports........................................................................ 21
5.1 Selecting the Reports to Download................................................................. 21
5.2 Saving the Reports to a Storage Media........................................................... 21
5.3 Deleting Data in Memory................................................................................. 22
5.4 Keeping Data in Memory ................................................................................. 22
6 Service and Repair............................................................................................. 22
7 Service and Repair Contact............................................................................... 22
8 Accessories/Parts for the Product..................................................................... 23

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4 EN HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
Caution
The success of the jointing operation de-
pends on consistent compliance with the
nominal pressures, times, and temperatures
of the welding. The correct pressure value
depends on the section of the cylinder of
the welding machine. Therefore, using the
hydraulics with another basic machine chas-
sis than the one it came with, will result in
a flawed and/or inconsistent welded joint.
If the hydraulic and control unit must ex-
ceptionally be used with another machine
chassis, core settings of the machine have
to be changed. Only the manufacturer and
authorized service points are able to make
this change. To this end, get in touch with
them.

Version February 2018 EN 5 HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
1 Introduction
Dear Customer:
Thank you very much for purchasing our product. We are confident
that it will bring you success and meet your expectations.
The development, manufacture, and check of the heating element
butt-welding machine HÜRNER CNC ECO 630 has been per-
formed with a view to superior operation safety and user-friendliness.
The machine was manufactured and checked according to state-of-
the-art technology and widely recognized safety regulations, as they
are applied.
To ensure maximum operation safety, please conform to the appropri-
ate messages in this booklet and the regulations for the prevention
of accidents.
Thank you.
2 Safety Messages
2.1 The User's Manual
This User’s Manual contains important instructions for the intended
and safe operation of the product. Every person who operates the
product has to conform to the instructions of this manual. 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 consent.
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 product. Non-compliance may cause problems of
operation and damage to the product.
Info
This icon indicates tips and useful information for using the
product more efficiently and more economically.
2.3 Operating the Product Safely
For your own safety, comply with the following instructions
• Protectthepowersupplycordandthehydraulicpressurelines
from cutting edges. Have an authorized service shop replace dam-
aged cables or lines immediately.
• Theproductmaybeoperatedandservicedexclusivelybyautho-
rized staff who were briefed on it.
• Theproductmaybeoperatedonlywhenobserved.
• Beforeoperatingtheproduct,alwayscheckfordamagedparts
and have them repaired or replaced by an authorized service shop
as needed.
• Thecovercapsofthehydrauliclinesandinterfaceporthaveto

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6 EN HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
be closed during transport in order to prevent contaminants and
humidity from entering the hydraulic and control unit.
• Mainssuppliers’wiringrules,VDEprovisions,DIN/CENstandards,
and applicable national legislation have to be respected.
• Withoutpriorauthorizationbythemanufacturer,modifications
to the product are unacceptable.
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.
Caution
Pipe Facing Tool
Start the pipe facing tool only after it was inserted into the
machine and carry it only by the handle, never by the disk
enclosure.
It is unacceptable to remove shavings from the machine while
the facing process is in progress. Make sure nobody is present
in this danger zone.
Caution
Heating Element
When working with the machine, be extremely cautious while
the heating element is used. Since the heating element pres-
ents a temperature of more than 200°C during the welding
process, it is absolutely indispensable that operators wear
suitable protective gloves. Bear in mind that the heating
element will remain hot for a while after it was turned off.
Caution
Danger of Bruises and Injury
Do not remain in the danger zone while the machine car-
riage moves apart or closes in, and be sure not to have your
arms or legs between the moving and the fixed carriage of
the machine.
Caution
Acceptable Work Conditions
The work zone has to be clean and has to have proper light-
ing. It is dangerous to operate while it is raining, in a humid
environment, or close to flammable liquids. In regard of this,
acceptable work conditions have to be ensured (tent, heat-
ing, etc.).
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 becomes
incomplete or unreadable, replace it without delay. Feel free
to contact us for assistance.
2.4 Owner and Operator Obligations
• Themachine may beoperated exclusively bypersons who are
familiar with the applicable regulations, the guidelines for the
prevention of accidents, and the User’s Manual. The owner/man-
ager shall provide the worker operating the machine with the
User’s Manual and shall make sure that the operator reads and
understands it.
• Themachinemaybeoperatedonlywhenobserved.Weldersmust
have been briefed properly on the operation of the machine or
must have participated in a dedicated training. The operating/
owning organization engages to check at reasonable intervals if
the machine is operated by the welders as intended and under
proper guidelines of occupational safety.

Stumpfschweißmaschine
Seriennr. 120007204
Hersteller
HÜRNER Schweißtechnik GmbH
Nieder-Ohmener Str. 26
D - 32325 Mücke
Nieder-Ohmener Str. 26
D - 32325 Mücke
Version February 2018 EN 7 HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
• Themachinemustbeoperatedonlywheninproperstateofrepair
and for one of the intended uses. Before welding, the welder 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
work zone where the machine is operating.
Important
During transport, the facing tool and the heating element
have to be placed into the provided carrying rack at all times.
2.5 Intended Use
The Butt-Welding Machine is intended exclusively for joining plastic
pipes and fittings according to the butt-welding process with heating
element. See Section 3 for an overview of the welding process enabled
by this machine.
The notion of intended use also includes:
• CompliancewiththeinstructionsintheUser’sManual
• Observationofallserviceandmaintenanceintervals
Important
All uses other than those mentioned above are not allowed
and will cancel any and all liability or warranty by the manu-
facturer. Unintended use may cause considerable hazards and
material damage.
2.6 Required Worksite Conditions
• Theconditionshavetofullyensurethatthemachinecannotslide.
• Worksite access limitationshave to be provided.Appropriate
equipment to achieve this can be ordered with the manufacturer.
• Themachinemustneverbeusedifthereareforeignbodiesor
objects in the work area; in particular, it must not be started if
anything obstructs the smooth movement of any movable part
or component of the machine.
2.7 Warranty
Warranty claims may be raised only if the conditions for warranty
given in the General Terms and Conditions of Sale and Delivery obtain.
2.8 Transport and Storage
2.9 Identifying the Product
Every product is identified by a name plate. It shows the model (“Typ”),
the serial number (“Seriennr.”), the most important specifications of
the hydraulic unit, and the manufacturer. The first two digits of the
serial number represent the year of manufacture.
3 Understanding the Machine
This butt-welding machine for plastics can be used both as an on-site
bei 160 bis 355:
The machine is shipped in a trans-
port box. Store the machine dry and
protected from humidity in this box.
Furthermore, the hydraulic tubing
Netz 400V 50Hz 1700W
Gewicht 43kg Baujahr: 2015
The box in which the product arrives should also be used for storage as a
protection against humidity. During transport or storage in the box, the hy-
draulic tubing should not be detached or squeezed. The pipe facing tool
and heating element have to be transported in the provided carrying rack.
Caution
Because of the heavy weight of the hydraulic unit and the
basic machine chassis of the butt welder, they have to be
transported or moved on site by two persons and/or using
appropriate hoisting tools as required.
Typ CNC 630 ECO

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HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
3.1 Included Components
• Machinechassis(“basicmachine”)tosecurethepartstobewelded
• Electricalheatingelementwithanti-stickcoating
• Electricalfacingtool
• Carryingandstoragerackforheatingelementandfacingtool
• Hydraulicandcontrolunitwithcontrolpanel
3.2 Control Panel
Emergency Stop Switch on the Control Unit
An Emergency Stop switch is provided on the control unit to abort
the welding process if needed in order to avoid hazardous situations.
If the Emergency Stop switch is pressed, it stops the power supply to
the facing tool, the heating element, the hydraulic circuit (discharge
of pressure, if applied), and the power supply socket. Power is fur-
ther supplied to the micro-controller board (the display screen keeps
working).
Important
When it was pressed, the Emergency Stop switch is locked.
When the hazard is cleared, the switch has to be unlocked
by turning the pushbutton clockwise. It is also possible to
move the carriage of the basic machine chassis manually.
and as a workshop installation, for jointing operations pipe-to-pipe, but
also for processing tees and elbows (see also the first paragraphs of Sect. 4.5
for more detailed information on this).
It has basically three functions:
• Controllingtheweldingprocess
• Monitoringalltherelevantparametersduringtheweldingprocess
• Generatingalogprotocol/reportoftheweldingprocess
Display Screen
INCREASE PRESSURE Key
REDUCE PRESSURE Key
Welding Progress Diagram
MENU and Cursor Keys
OPEN Key
(to move movable carriage apart)
STOP/RESET Key
START/SET Key
Alphanumeric Keypad
Emergency Stop Switch
Transponder Reader
The product ships with the following components:
• Reducerinsertsforclampsofmachinechassisforthefollowingnominalpipe
sizes: O.D. 315, 355, 400, 450, 500, 560 mm

Version February 2018 EN 9 HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
3.3 Connectors
3.43.4 TechnicalSpecications
HÜRNER CNC ECO 630
Power Specifications
Voltage
Frequency
Total Rated Powe
Heating Element
Facing Tool
Hydraulic & Control Unit
400 V 3 Ph * N
50 Hz
1.70 kW
Hydraulic Specifications
Operating Pressure max.
Cylinder
Ambient Temperature Range
Hydraulic Oil
160 bar
–5°C to +50°C
HF-E 15
Operating Range
Dimensions
Basic Machine Chassis
Facing Tool
Heating Element
Hydraulic & Control Unit
Carrying and Storage Rack
320 x 600 x 320 mm
Weights
Basic Machine Chassis
Facing Tool
Heating Element
Hydraulic & Control Unit
Carrying and Storage Rack
All Reducer Inserts
43 kg
Heating Element Connector
Ambient Temperature Sensor
Facing Tool Connector
On/Off Switch
USB A Interface Port
Power Supply Cord
Sensors Port
Hydraulic Tubing Connectors
Optional Handheld Scanner
Oil Refill Nipple with Level Probe
Buzzer
Power Supply to Label Tag Printer
Optional Scanning Pen Connector
 TechnicalSpecications
11.65 kW
8.10 kW
1.85 kW
31.40 cm²
315 through 630 mm
1200 x 900 x 900 mm
830 x 230 x 1000 mm
1050 x 60 x 800 mm
870 x 970 x 700 mm
173 kg
98 kg
38 kg
40 kg
250 kg

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HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
3.5 Overview of the Welding Process
After the thermoplastic material, the pipe diameter, and the wall
thickness were entered, the machine computes all parameters that
are critical for the welding process, taking into account the selected
welding standard (e.g., DVS, PIPA, NEN). The entire welding process
is automatically controlled, monitored, and its data logged and saved
to a welding report.
The saved welding data can subsequently be downloaded to a USB
mass storage media as a short or extended report in the PDF format
or the HÜRNER database format DataWork. Parameters applicable to
the welded joint and traceability data on the processed parts can be
entered either on the alphanumeric keypad on the front panel or read
from a transponder chip card. Reading bar codes with a scanning pen
or handheld scanner is available optionally.
For your convenience, the machine can be specifically costumized in
a Configuration Menu (see section 4.2).
The welder performs the welding process in the following manner:
• Pipesareclampedintotheframe.
If pipes with an outside diameter smaller than the maximum
dimension of the machine are welded, select the reducer set
needed. The 8 individual inserts of the set that matches the out-
side diameter of the pipe to be welded have to be attached to
the clamps of the machine chassis using the provided bolts.
• Themandatory and optionalcomponent traceability dataand
the data on the components are entered in the screen menus.
• Pipebuttsareworkedusingthepipefacingtool.
• Pipealignmentischeckedaccordingtotheinformationdisplayed
on the screen.
• Thetechnicaldataontheweldingprocessitselfareenteredorre-
used from the preceding welding operation, provided the manual
input of these data is enabled in the Configuration Menu.
• Theheatingelementisinsertedaftercleaningitandcheckingits
temperature.
• Aftertheheatingelementwasinserted,thepipescloseinauto-
matically on it at the predefined build-up pressure.
• Duringthebuild-upstagetheweldbeadbuildsup.Whenthe
bead size, as required under the selected standard, is achieved,
the welder has to confirm successful bead build-up. (If Automode
(see Section 4.2) is enabled, the successful bead build-up is de-
tected automatically; the machine computes the build-up time
depending on the parameters of the parts to be jointed.)
• Themachinethenmovesonautomaticallytotheheatingstage.
• Aftertheheatingstage,themachineautomaticallymovesthe
movable carriage apart and the welder has to remove the heat-
ing element from in-between the butts.
• Aftertheremovaloftheheatingelement,themachineautomati-
cally closes the pipes in on each other.

Version February 2018 EN 11 HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
• Thisisfollowedbyasteadypressureincreaseuntilthejoining
pressure is reached.
• Thenewjointthencoolsdownatthepredefinedpressure.Ifthe
selected weldind standard requires the pressure to be reduced in
the cooling stage, the machine performs this reduction automati-
cally, in line with the provisions in the standard.
• Afterthecoolingtimeisover,themachineshutsoffthepressure
automatically, and the joint can be taken out of the chassis.
• Iftheoptionaltagprinterisused,atagtolabelthenewjoint
can be printed off.
4 Operation
4.1 Start of Operation, Switching the Machine on
Important
Before the control unit is turned on, check the oil level of the
hydraulic and control unit and top up with HF-E 15 hydraulic
oil as needed.
Important
The surfaces of the heating element have to be free of grease
and clean, or they have to be cleaned.
Important
Make sure all connectors are tight in their sockets and note
that operation on a worksite is only acceptable if the power
supply has earth-leakage circuit breakers.
Place the machine on a level surface and ensure it cannot slide. After
connecting the power supply cord to the mains power supply or a
generator, the machine is turned on at the On/Off switch.
Caution
It has to be ensured that the voltage of the power source the
machine is connected to corresponds to the rated voltage of
the machine. Also the following has to be respected when
using extension cables:
After the machine was switched on, first Display 1 appears on the
screen, then a screen with the version of the used control software.
The machine will then automatically start an auto-test process (see
Display 2); this test, which includes three screens, can be canceled by
pressing the STOP/RESET key.
Important
If the input voltage is not within tolerance, from approx.
160 V to approx. 300 V, the machine switches itself off for
protection. This protective feature is provided by a switch
and will not result in an excess or insufficient voltage error
line (see Sect. 4.8).
If the machine is not in the “open” position (i.e., movable carriage as
far apart from the fixed one as possible), Display 3 shows. To move
it, press the OPEN key. The machine will then move it to the far end.
After that, Display 4 shows, with the data of the next welding, includ-
ing time of day, date, report number, and joint number, along with —in
the second-to-last line — the actual input voltage and the actual and
nominal heating element temperature before and after the slash.
** SYSTEM TEST **
Remaining Prot. 1500
17:23 21.06.09
Display 2
Open carriage
208°C ACT. 0.5bar
Next welding
15:44:52 29.05.12
235V 135C/220C
Rep. No. 00072/00002
Display 3
Display 4
********************
* HÜRNER *
********************
Display 1
bei ECO+ ist die Menüoption Naht-
nummer nicht da, weil die Funktion
stets eingeschaltet ist. Alle Texte zur
Nahtnummer müssen deshalb über-
prüft und ggf. angepasst werden.
For 400 V power: wire section 4.0 mm² = max. 75 m long
wire section 10.0 mm² = max. 100 m long
402V
320 V 485 V
*CNC 630 ECO 2.0 *

CODE: 415311
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12 EN HÜRNER CNC ECO 630 User’s Manual
HÜRNER Schweisstechnik GmbH
Nieder-Ohmener Str. 26
35325 Mücke, Germany
If the machine configuration requires the input of traceability data
for the joint that is going to be welded (commission number, welder
identification code, etc.), then input screens for these data are shown
before Display 4 appears.
The joint number, or weld number, is based on the job/commission
number. This means that it increments by 1 for every welding opera-
tion performed in the scope of the current commission (identified
previously by entering the appropriate job number). In the example in
Display 4, the next welding operation will be saved to welding report
number 72 while the joint itself is joint number 2 of the current job/
commission. For the joint number to be displayed, this option has to
be enabled in the Configuration Menu.
Info
The first joint of a commission for which no joint has been
saved to memory so far, always receives no. 1. If the memory
already holds joints for a commission, the machine finds the
highest number of the joints existing for that commission
and uses this number plus 1. The user is shown the number
thus found on the screen and can apply or change it. If the
user changes the joint number, it is his responsibility to make
sure that no number is assigned twice in one commission. If
a joint number appears twice in a commission, this will not
affect the welding process and the logging of its data in
any way. However, in that commission two joints will not be
distinguished by a unique number.
If user inputs leave some joint numbers unused (for instance,
for a given commission no. 1, 2, 3, 5, 6, 9), the gaps do not
get filled, and the automatically found number proposed for
the next welding operation will still be the highest existing
number plus 1 (that is, 10 in this example).
The joint number can also be entered after simultaneously pressing
the cursor keys and ðwhen Display 4 is showing on the screen.
Info
After it was turned on, the machine generally is in its “open”
position (see above). It is possible to bring the movable car-
riage to any desired position by pressing and holding down
the INCREASE PRESSURE key. The carriage can then be sent
back to the “open” position by pressing the OPEN key.
Info
Depending on the software version installed in your machine,
some screens may be slightly different on your display than
the reproductions in this manual.
4.2 SettingtheDefaultCongurationoftheMachine
The Configuration Menu is accessible by pressing the MENU key when
Display 4 is showing on the screen.
When the operator presses the MENU key, the screen asks to enter a
selection code (see Display 5). This is an access code that authorizes
the operator to select and change the default configuration that de-
termines how the machine behaves at every new welding operation.
The selection code can be entered by typing it on the keypad or by
reading it from a transponder card.
Important
After entering an incorrect code three times, the machine
returns to its “open” position (see Sect. 4.1 and Display 4). If
the entered menu selections code is correct, the Configura-
tion Menu shows on the screen, as in Display 6.
Settings -M-
>Report Generat. -M-
Sensor Params -M-
Machine Data -M-
Display 6
Enter Select Code
++++++
Display 5

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All screens of the Configuration Menu work in the same manner: use
the ñand òcursor keys to select a displayed configuration option. The
option can then be set to ON or OFF using the ðcursor key. The –M–
displayed at some configuration options indicates that a further screen
for that option can be accessed by pressing the MENU key.
Important
When you press the START/SET key, the displayed settings/
valeus are saved to memory and applied. Press the STOP/
RESET key to quit the currently displayed configuration screen
without saving any modifications you may have made.
The “Sensor Parameters” and “Machine Data” menu options enable
check and maintenance steps that are relevant only to technical service.
They are therefore protected by a second access code and will not be
addressed in this User’s Manual.
The “Settings” sub-menu allows the definition of settings related to
the machine itself and its operation during the welding process. In
the “Report Generation” sub-menu, the design of the welding reports
can be defined: which welding and traceability data to record, which
kind of data logging.
Info
The alphanumeric keypad is designed and works like the
keypad of a common mobile phone. If an input is numerical,
the keypress generates the number found on the respective
key. For an alphanumeric input, all characters found on a key
can be generated by pressing that key repeatedly in a row.
As soon as the desired character can be read on the screen,
wait a little longer until you press the next key to use the
displayed character.
In the ”Settings” sub-menu of the Configuration Menu, the following
parameters can be set:
Menu Item Setting Description / Possible Data
Automode ON / OFF
Memory Control ON / OFF if ON: when the system memory is full of reports, the system
will be blocked until the reports are printed or downloaded;
if OFF: it works but that the oldest report will be overwritten.
Ambient
Temperature
ON / OFF if ON: ambient temperature will be checked when machine is
turned on;
If the outside temperature is below 0°C, no welding process
should be started, or appropriate steps should be taken.
if OFF: no check of ambient temperature.
Manual Input ON / OFF if ON: it is possible to change the welding parameters manually;
if OFF: manual change of welding parameters is impossible.
Automatic Heating
Element
ON / OFF if ON: if an automatically removing ("jumping") heating
element is used, the system will remove it automatically from
in-between the components during change-over;
if OFF: no automatic removal is controlled by the system even
when an automatically removing heating element is used; the
welder will have to remove it manually at change-over.
if ON: the bead build-up stage is terminated automatically after
a duration computed from the parameters of the parts to be
welded, based on guideline values from experience (see also
Sect. 4.5.5);
if OFF: the bead build-up stage has to be terminated manually
by pressing the START/SET key.

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Menu Item Setting Description / Possible Data
Check Code Expiry ON / OFF if ON: identification number/code of the welder who will
perform the welding has to be current and not expired (default
period of validity 2 years from code issuance), or the welding
operation cannot be started;
if OFF: number/code validity is not checked at all.
Angle ON / OFF if ON: prior to the facing process, the angle for the jointing of
the components can be entered;
if OFF: the input of an angle—hence, an elbowed joint —is
impossible.
Welder Code
Options
— M — In a further screen, it can be determined when the welder code,
if it is enabled at “Recording,” has to be entered:always, i.e.
before evey single welding operation, only before the first
welding operation after switching the unit on or only after the
first welding operation of a new day/date.
Language — M — In a further screen, the language to use for the display screen
and the printed reports can be selected.
Time/Date — M — In a further screen, the time and the date of the system clock
can be set.
Buzzer Volume — M — In a further screen, the volume of the audible warning signal
can be set.
Temperature Unit — M — In a further screen, the measurement unit used for temperature
information can be set: Fahrenheit or Celsius.
Pressure Unit — M — In a further screen, the the measurement unit used for pressure
information can be set: bars or pounds per square inch.
Inventory Number — M — In a further screen, the number by which the machine/hydraulic
unit used to perform the welding is identified in the inventory
of the operating organization can be entered.
Number of Labels — M — In a further screen, the number of label tags to print out after a
welding operation can be selected (requires the optionally
available label tag printer).
Standard — M — In a further screen, the welding standard to be applied to the
welding can be selected.
In the ”Report Generation” sub-menu of the Configuration Menu, the
following parameters can be set:
Menu Item Setting Description / Possible Data
Welder Code ON / OFF if ON: number/code of the welder who will perform the
welding must be entered depending on the “Welder Code
Options” value under “Settings” (see above);
if OFF: the welder code is never requested by the machine.
Commission Number ON / OFF if ON: number/identifier of the commission to which the
welding belongs must be entered before every welding; input
of up to 32 alphanumeric characters.
Joint/Weld Number ON / OFF if ON: joint numbers related to a given job/commission can be
assigned, and the machine automatically increments to joint
numbers by 1 for that commission (see als at the end of
Sect. 4.1).
if OFF: the joint number management is not available.
Additional Data ON / OFF if ON: additional, user-defined data, e.g., address where the
welding is performed, can be entered before every welding;
input of up to 20 alphanumeric characters.
Fitting Code ON / OFF if ON: the code of a fitting to welded, in which the parameters
related to welding are contained, must be entered before
welding.
Pipe Codes ON / OFF if ON: the code of the pipes, in which the pipe parameters
related to welding are contained, must be entered before
welding.

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Menu Item Setting Description / Possible Data
Pipe Length ON / OFF if ON: the length of both pipes that are going to be welded has
to be entered before the welding;
if OFF: the length of the pipes cannot be entered.
Weather Conditions ON / OFF if ON: the weather conditions in which the welding takes place
have to be selected in a list prior to welding;
if OFF: the weather conditions will not be entered.
Installing Company — M — In a sub-menu, the name of the company carrying out the
piping and installation work can be entered.
Print Tags — M — In a sub-menu, a completed welding operation can be selected
to print off once more to label tag belonging to it.
Info
All data that are available in the chip of a transponder card
can be entered by placing the card in front of the card reader.
Optionally, if they are encoded in a bar code, they can be
read using a scanning pen or a handheld scanner.
4.3 Entering Traceability Data
If the machine is configured to request the input of traceability data
related to the welding, such as commission number and welder iden-
tification code, then the screens for entering these data are shown
before Display 4 appears (see Display 7). The same displays can be
accessed through a list that opens after the cursor key was pressed.
The input of these data uses either the alphanumeric keypad (see
also the Info message in Section 4.2) and then they are confirmed by
pressing the START/SET key, or they are read from a transponder card.
4.4 Entering Pipe or Fitting Parameters
From the “open” position of the machine (see Sect. 4.1 and Display 4),
possibly after traceability data were entered, the parameters for the
components to be jointed are shown (see Display 8), which can be
confirmed or changed.
To confirm that the parameters on the display should be used for the
next welding, press the START/SET key, to change them, press STOP/
RESET to select the material of the parts to be welded (see Display 9)
or the cursor key ñto enter the component diameter and wall thick-
ness (see Display 10). To select a material use the ñand òcursor
keys and confirm your selection by pressing the START/SET key. The
machine then moves on to pipe diameter/wall thickness input screen
(see Display 10) as well.
It is possible to switch back and forth between the pipe material and
the diameter/wall thickness screen without making any changes, by
pressing the ñkey.
The sub-menu that can be accessed at “Specialty Materials” allows the
selection of non-standard materials, which frequently are proprietary,
e.g., Wavin Safetech. As opposed to standard materials, specialties do
not allow the selection of all nominal pipe diameters or SDR values,
but only those that are actually available with that material. If a sep-
cialty material is selected, the diameter and the standard dimension
ratio (SDR) have to be entered in all cases, as they will not be applied
by the machine from the last completed welding operation.
Info
The specialty material screens include a menu option “Stan-
dard Material” to enable returning to the screen in which
they were selected, the screen reproduced in Display 9.
Enter Welder Code
++++++++++++++++++++
++++++++++
Display 7
bei ECO+ gilt für die Menüoption PT
100 Messung: Diese wird im Menü
zwar angezeigt, lässt sich aber nicht
ausschalten, d.h. es steht dauerhaft
auf „ein“.
SELECT PIPE MATERIAL
>PE80
PP
Specialty Mater.-M-
ENTER PIPE DIMENSION
Pipe Diameter:0250mm
Wallthickness:22.7mm
PE-HD
Pipe Diameter:0250mm
Wallthickness:22.7mm
ESC SDR 11.0 ENTER
Display 9
Display 10
Display 8

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In the screen for the diameter and the wall thickness of the pipes to
be jointed (see Display 10), the welder has to enter these data. Using
the entered data on material, diameter, and wall thickness or SDR ratio
of the parts, the machine computes the required pressures, welding
stage durations, and the heating element temperature.
Info
It is possible to switch back and forth between the wall thick-
ness and SDR value lines with the òkey (see Display 11).
When all data were entered, the parameters, along with the computed
SDR value or wall thickness, are displayed again for verification (see
Display 12). Any other change, if needed, can be started from here.
Confirm these values by pressing START/SET in order to go on to the
welding process proper.
4.5 Performing the Welding Process
When the welding parameters were confirmed or entered, pipe facing
starts.
4.5.1 Facing the Pipe Butts
To ensure that the pipe butts are level, insert the pipe facing tool be-
tween the machine carriages and turn it on. The machine then closes
the movable carriage in automatically in order to bring the pipes into
contact with the facing tool. Use the INCREASE PRESSURE and REDUCE
PRESSURE keys to adjust the pressure manually while the facing tool
is trimming the pipes.
If you discover after the facing process that the butts are still not level,
start over, insert the facing tool and repeat the process. It starts again
automatically When facing is properly done, pipe alignment has to be
checked (see Display 14).
4.5.2 Checking Pipe Alignment
Face Pipe Ends
230°C ACT. 0.5bar
Display 13
Check Pipe Alignment
Max. Gap :2.5mm
Display 14
PE-HD
Pipe Diameter:0250mm
Wallthickness:22.7mm
ESC SDR 11.0 ENTER
Display 12
ENTER PIPE DIMENSION
Pipe Diameter:0250mm
SDR :11.0
Display 11
When the pipes are properly faced, close in the movable carriage
completely by pressing the START/SET key, in order to check whether
a potential vertical and horizontal pipe misalignment is within the
tolerance allowed by the applicable welding standard. The maximum
acceptable gap between them is displayed (see Display 14). If the mis-
alignment is outside tolerance, the pipes must be readjusted in the
clamps and, if needed, facing has to be repeated. To repeat facing, press
the OPEN key, which will set the movable carriage back to the far end.
When pipe alignment is appropriate, move the carriage apart to the
far end for the welding proper, by pressing the START/SET key. If
needed, the welding process can be aborted by pressing the STOP/
RESET key.
Pipe facing should continue until shaving forms a continuous blade
that rolls twice or three times around the pipe ends, so the butts are
level. To stop facing, press the START/SET key. The machine then moves
the movable carriage apart.
To start welding, clamp the pipes into the machine chassis. Use the
appropriate reducers if the component size is smaller than the basic
machine chassis. When the third clamp of the machine is fastened to its
movablecarriage,tomovewiththerstandsecondpipeclamp,teesand
elbows can be clamped for processing into the fourth pipe clamp of the
machine. Then, to launch the welding process, press the START/SET key.

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4.5.3 Possibility to Change Welding Parameters
Subsequent to facing the pipe butts and checking the alignment of
the parts to be welded, Display 15 shows on the screen, provided that
manual data input is enabled in the Configuration Menu. In Display 15,
the welder can keep the parameters that define the welding process,
from the last welding by pressing the START/SET key, if there are such
parameters in memory already, or he can adjust them to the welding
at hand by pressing the STOP/RESET key (see Display 16).
The screens enabling manual input of welding parameters (Displays 16
and 17 plus one more line, not shown, for the heating element tem-
perature) allow the selection of a line using the ñand òcursor keys.
After selecting a line, its parameter value is changed by typing the
desired value on the alphanumeric keypad. The START/SET key serves
to confirm the inputs; then the control unit moves on from display to
display or from the last to the welding process.
Info
The parameters set manually are kept in memory when the
machine is turned off. If the pipe parameters change, all
parameters have to be set once again. The machine recog-
nizes the changed pipe parameters and brings the operator
directly to the menu that allows changing them.
4.5.4 Inserting and Monitoring the Heating Element
The machine controls and monitors constantly the temperature of
the heating element. If the temperature is not within the tolerance
thresholds, the machine shows an error message to this effect in the
first line of the display. Furthermore, the upper and lower thresholds
of the tolerance range are indicated in the fourth line along with the
current actual temperature (see Display 18).
As soon as the nominal temperature is reached, Display 19 shows.
4.5.5 Bead Build-up Stage
During the bead build-up stage, LED 1 flashes to indicate the progress
of the welding process. As soon as the build-up pressure is reached, as
shown in Display 20, both the computed maximum bead size and the
bead build-up time. If Automode is enabled the time is a countdown of
the remaining bead build-up time; if it is off, the time value increases
and shows the duration already used. During this stage, the build-up
pressure and the heating element temperature are monitored.
As long as the nominal pressure of the heating stage is not reached
yet, LED 2 flashes while LED 1 is lit. The machine reduces pressure
automatically.
Info
Do you want to use
data of previous
welding?
ESC <┘
Display 15
Buildup pr.:030.5bar
Heatsoakpr.:010.5bar
Heatsoaking:0120 s
Change-over:0005 s
Display 16
Cool. time t5:100 s
Cool. time t6:800 s
Cool. Pres.t6:012.2b
Press. ramp:010 s
Display 17
Plate temp. too low
222°C< 210°C < 232°C
Display 18
Put in heat. plate
222°C nom. 16.5bar
221°C act. 0.5bar
Display 19
Bead Height :2.0mm
Bead Build Time:68 s
230°C NOM. 16.5bar
229°C ACT. 12.5bar
Display 20
The so-called automode is a tool for monitoring the
duration of the bead build-up stage and moving on
automatically from the bead build-up to the heating
stage by decreasing the applied pressure. However, this
By inserting the heating element and pressing the START/SET key, you
make the machine move on to the bead build-up stage. At this time,
the pipes are placed together automatically and the computed pres-
sure during bead build-up is applied.
When the bead reaches the size indicated on the display, the operator
has to press the START/SET key to terminate the build-up stage, unless
the Automode (see below) is used. The machine then moves on to the
heating, or heat-soaking, stage.

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Important
Prior to the bead build-up of a welding process for which the
Automode can be used, the machine asks whether the bead
build-up time of the previous welding operation should be
re-used. Confirm this only if the ambient conditions, too,
(temperature, weather/rain tent etc.) are sufficiently similar.
If the application of the automode build-up time is denied,
the operator will have to confirm successful bead build-up
manually.
Important
If the welding parameters of the welding operation were
entered manually, the Automode is always disabled.
4.5.6 Heating Stage
The time for soaking heat in the heating stage is displayed as a
countdown showing the remaining seconds (see Display 21). A signal
is audible during the final 10 seconds of heat soaking, right before
the change-over stage. During the heating stage LED 3 flashes; LED 1
and LED 2 are lit.
During this stage, the pressure applied while the pipes soak heat,
and the heating element temperature are monitored and controlled.
4.5.7 Change-over Stage
After the full heating time, the carriage moves apart automatically.
The heating element has to be removed as fast as possible (see Dis-
play 22). On machines equipped with an optional automatic heating
element, it retracts automatically from in-between the pipes. During
the change-over stage LED 4 flashes; all previous LEDs are lit.
The machine then presses the pipes automatically together again.
4.5.8 Joining and Cooling Stage
In the joining stage the machine increases pressure in accordance with
the pressure ramp computed for the joint (see Display 23). During this
stage LED 5 flashes; all previous LEDs are lit.
When the full joining pressure is reached, the machine moves on to
the cooling stage (see Display 24). The cooling-down is represented
as a countdown of the remaining duration. During cooling, the join-
ing pressure applied in this stage is monitored. In the process, LED 6
flashes, all the previous LEDs are lit.
Info
Some standard, e.g., DVS, require the joining pressure to be
the same throughout cooling (t5). Others have it that the
initial joining pressure (t5) must be reduced after some time
into cooling (t6). If such a standard was selected, the machine
takes care of the pressure reduction required by the standard.
In that stage LED 7 flashes, all the other LEDs are lit.
4.5.9 End of Welding
A beep signals the end of the cooling time. Furthermore, the green
LED is lit to indicate a successful welding process. Confirm the end of
JOINING PHASE
230°C NOM. 16.5bar
229°C ACT. 14.5bar
COOLING PHASE
Cooling time :1234s
230°C NOM. 16.5bar
229°C ACT. 16.5bar
Display 23
Display 24
COOLING PHASE
Cooling time over
229°C ACT. 0.0bar
Display 25
Remove plate
Change-over : 8 s
230°C MAX 5.0bar
229°C ACT. 3.5bar
Display 22
HEAT SOAK PHASE
Heat Soak Time :148s
230°C MAX 5.0bar
229°C ACT. 3.5bar
Display 21
requires that the automode was enabled in the Configu-
ration Menu. If the welder sees that the bead has fully
formed although the bead build-up countdown has not
completed ended, he can end the bead build-up stage
early by pressing the START/SET key. The responsibility
for the proper joint of the components resides with the
welder entirely.

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welding by pressing the START/SET key. Pressure to the hydraulic lines
will then be shut off.
Info
Note in general that pursuant to DVS 2207-1 or other inter-
national standards, the cooling time has to be observed and
waited out for its entire length.
A reduction of the cooling time of up to 50%, i.e., joining
pressure release and removal of the welded part from the
welding system, is allowed in the following conditions:
• the welding is done in workshop conditions
• the removal from the welding equipment and the temporary
storage are causing only slight loads to the joint
• it concerns components with a wall thickness of ≥15 mm.
Under the welder‘s responsibility, the cooling time can be
reduced and the welding operation ended early, by pressing
the START/SET key if at least half of the cooling time is over.
A welding operation with reduced-duration cooling time is
identified in the welding report by the indicator -HC- ..
Report data (sample)
Material /
Welding Mode
PE 100 -C-HC-
Diameter [mm] 1200
Wall Thickness [mm] 109.1
SDR Value SDR 11.0
Angle [°] 0
4.5.10 Printing Label Tags
If the optional tag printer is connected to the USB port, tags used to
label the new joint can be printed from Display 25 after the welding.
To do so, press the START/SET key, and printing starts. The number of
tags is defined in the appropriate setting of the Configuration Menu,
under “Settings.” The screen indicates the end of printing. If printing
is impossible, the appropriate error message shows on the screen.
4.6 Displaying Characteristics of the Welding System
The key technical information on the welding system itself is displayed
by pressing the ðkey at the “Next Welding” screen (Display 4). They
are the software version, the serial number of the system, and the
number of currently available, unused reports. To quit this screen,
press the STOP/RESET key.
4.7 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 optionally avail-
able tag printer. The ViewWeld abstract shows the report number,
the date and time of the welding and the welding parameters along
with an evaluation of the quality of the joint/welding operation (see
Display 27), where the first displayed abstract is that of the last per-
formed welding operation.
To call the ViewWeld abstract of a welding report, press the ñkey
in the Next Welding screen (see Display 4). Browsing through the
saved welding reports is then possible by pressing the or ðcursor
WELDING ABORTED
Error Build-up Pres.
229°C ACT. 1.5bar
Display 26
00128 22.08.14 16:44
PE100 315mm
SDR11.0 / 28.6mm
Welding OK
Display 27

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keys. 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. The
printed label tag has a QR code (two-dimensional bar code), in which
information identifying the joint is encoded: date and time, report
number, welding system used, and joint status.
4.8 Aborted Welding Process
All parameters relevant to the welding are constantly monitored while
the welding process is running. If one or more of the parameters are
out of tolerance and the machine cannot adjust them within a speci-
fied delay, the welding process is aborted.
The error that made the welding abort is displayed on the screen (see
Display 26). Additionally, in the welding diagram the LED that belongs
to the welding stage with the malfunction starts flashing.
The errors listed in the following table can be displayed on the screen.
Type of Error Description
a. Data Input
Input Error Error while entering data on the keypad.
Code Error Error while reading data from a transponder card.
b. System
Clock Error The internal clock of the machine is defective; re-set the clock in the
Configuration Menu.
System Error Malfunction in the control system of the machine; power to the
machine has to be turned off and disconnected immediately, and the
machine has to be sent to the manufacturer or an authorized service
point for check and repair.
Pressure Sensor Defective The sensor indicated on the display (hydraulic pressure, heating
element temperature, ambient temperature) is defective; where
possible, check the connections/plug; have the machine inspected by
an authorized service shop if needed.
Heating Sensor Defective
Temperature Sensor
Defective
Printer not Ready
(only label tag printer)
The optional printer connected to the machine is not ready (possible
reasons: no communication or faulty cable).
c. Welding Process
Temperature low Heating element temperature will be increased automatically.
Temperature high Heating element temperature will be reduced automatically.
Insufficient Voltage The input voltage to the hydraulic and control unit is < 185 V; the
welding process is likely flawed, and repeating it is recommended.
Excessive Voltage The input voltage to the hydraulic and control unit is > 280 V; the
welding process is likely flawed, and repeating it is recommended.
Error Changeover It took too long to retract the heating plate and bring the pipes to
joining; welding will have to be repeated.
Ambient Temperature high Outside temperature outside the range from –5°C to +50°C.
Ambient Temperature low Outside temperature outside the range from –5°C to +50°C.
Error Drag Pressure Impossible to determine the drag pressure (pressure to “drag” the
pipes along by setting the movable carriage in motion); maybe pipes
will have to be clamped once again.
Error Build-up Pressure Computed maximum pressure that will be applied during welding is
too high; impossible to start welding; maybe pipes will have to be
clamped once again.
Error Heating Pressure Heat-soaking pressure too high, could not be re-adjusted.
Error Joining Pressure Joining pressure too high or too low, could not be re-adjusted.
< 320V
> 485V