STAUFF SPR-PRC-POC User manual

Operating instructions
Translation of the
original operating instructions
Machine for cutting ring
pre-assembly and final assembly
SPR-PRC-POC
R3.0, valid from firmware 3.6.x, 6010014620 22-10-2020
To avoid injuries and damage, read these operating instructions thoroughly
and attentively. Retain it for further reference.

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Additional operating instructions in other languages can be
downloaded at www.stauff.com.
Walter Stauffenberg GmbH & Co. KG
Im Ehrenfeld 4
58791 Werdohl, Germany
[phone]
[email protected]
www.stauff.com

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Table of contents
Table of contents
1
Information about the instructions ........................................................ 6
1.1 Target group of the operating manual ............................................6
1.2 Structure of warnings......................................................................6
1.3 Structure of instructions..................................................................7
1.4 Structure of additional information..................................................7
1.5
Structure of references ...................................................................7
2
For your safety .........................................................................................8
2.1 General safety instructions .............................................................8
2.2 Intended use...................................................................................9
2.3 Tasks and obligations of the operating company........................... 9
2.4 Personnel qualification .................................................................10
2.5 Personal protective equipment.....................................................10
2.6 Safety labels .................................................................................11
2.7 Safety devices ..............................................................................12
2.8
Securing the machine against reactivation...................................13
3
Machine description ..............................................................................14
3.1 Machine overview.........................................................................14
3.2 Technical data ..............................................................................15
3.3 Function ........................................................................................15
3.4 Tools and product.........................................................................15
3.5 Type plate .....................................................................................16
3.6
Spare parts and wear parts ..........................................................17
4
Transport and storage...........................................................................18
4.1 Safety............................................................................................18
4.2
Transport ......................................................................................18
5
Installation ..............................................................................................19
5.1 Safety............................................................................................19
5.2 Installing the machine...................................................................20
5.3 Attaching supply connections.......................................................20
5.4
Establishing readiness for operation ............................................20
6
Operation ................................................................................................21
6.1 Safety............................................................................................21
6.2 Switching on the machine.............................................................22
6.3 Establishing readiness for operation after emergency stop .........25
6.4 Warming up the machine..............................................................26
6.5
Setting up the machine.................................................................28
6.5.1
Language setup.................................................................28

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6.5.2 Setting up the system properties ...................................... 29
6.6
Setting up the tool ........................................................................ 33
6.7
Setting the operating mode .......................................................... 36
6.7.1
Setting automatic mode .................................................... 36
6.7.2
Setting button mode.......................................................... 36
6.7.3
Setting button mode with foot switch ................................ 38
6.8
Setting up the job ......................................................................... 41
6.8.1
Setting the assembly type................................................. 42
6.8.2
Setting the material ........................................................... 43
6.8.3
Setting the production quantity ......................................... 43
6.8.4
Setting the pressure for manual pressure......................... 44
6.9
Preparing the workpiece............................................................... 46
6.10
Assembling a cutting ring ............................................................. 48
6.10.1
Assembling a cutting ring in automatic mode ................... 48
6.10.2
Assembling a cutting ring in Manual Pressure mode........ 49
6.10.3 Assembling a cutting ring in button mode ......................... 50
6.10.4 Assembling a cutting ring in button mode with foot switch 52
6.11 Checking the product ................................................................... 53
6.12 Completing the job ....................................................................... 54
6.13 Final assembly in the fitting body ................................................. 55
6.14 Cleaning the machine................................................................... 55
6.15 Switching off the machine ............................................................ 56
7
Troubleshooting
............................................................................... 57
7.1
Safety ........................................................................................... 57
7.2
Troubleshooting............................................................................ 58
7.3
Malfunctions/error messages ....................................................... 59
7.3.1
Pressure: “Ultimate pressure out of limit” ......................... 59
7.3.2
Pressure:
“
Set pressure too high. Displayed value is
max. pressure. Confirm by entering new value.”.............. 60
7.3.3
Path: “Position detection”.................................................. 61
7.3.4
Light curtain: “Light curtain” .............................................. 62
7.3.5
Tube not pressed on ......................................................... 63
7.3.6
Piston not retracted........................................................... 63
7.3.7
Tool not detected .............................................................. 63
7.3.8
Reference run interrupted ................................................. 65
7.3.9
Wrong turning direction..................................................... 65
7.3.10
Other faults........................................................................ 66
8
Maintenance
...................................................................................... 67
8.1
Safety ........................................................................................... 67
8.2
Inspection and maintenance ........................................................ 67
8.3
Checking the emergency stop...................................................... 67
8.4
Checking the light curtain............................................................. 67

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Table of contents
9Decommissioning............................................................................. 68
9.1
Safety............................................................................................ 68
9.2
Dismantling................................................................................... 69
9.3
Disposal........................................................................................ 69
10
EC Declaration of Conformity...............................................................70
Index ...................................................................................................... 71

1 Information about
the instructions
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1 Information about the instructions
1.1 Target group of the operating manual
The operating personnel tasked with the following work has to read and
observe this operating manual:
• Installation
• Operation
• Malfunction
• Maintenance
See “Personnel qualifications” chapter 2.4, p. 10.
1.2 Structure of warnings
Coloured signal word boxes emphasise the warnings. Always read the full
warning text for effective protection against hazards!
The different colours and signal words of the following boxes designate
various hazard levels:
DANGER
Ignoring this warning results in serious or lethal injuries.
WARNING
Ignoring this warning can result in serious or lethal injuries.
CAUTION
Ignoring this warning can result in minor or moderate injuries.
ATTENTION
Ignoring this warning can result in damage.

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1 Information about
the instructions
Warnings always have the same structure. They include the signal word,
hazard type and source, consequences of ignoring them and steps to
avert/avoid hazards.
Example:
WARNING
Risk of shearing off and crushing fingers
►Ensure before start-up that all safety equipment is properly installed
and in working order.
►Ensure your fingers are not in the assembly area when
operating the machine!
1.3 Structure of instructions
Instructions are a direct request to carry out a task. They are structured in
line with the operation involved. Always carry out the operating steps in the
prescribed sequence.
The instructions are structured as follows and marked with the
appropriate symbols:
Objective of the instructions
1. Action step
Effect of the action step to check if the step has been
executed correctly.
2. Additional action step
Result of the overall instruction
1.4 Structure of additional information
Text marked with an information symbol provide
additional information and tips.
1.5 Structure of references
References are shown in this manual as follows:
Example:
“… only operate the machine as intended
chapter 2.2, p. 9.“

2 For your safety
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2 For your safety
To avoid accidents and injuries, …
• follow all safety instructions and warnings in these operating instructions
• observe hazard, prohibitory and instruction signs
• follow the accident prevention regulations and directives applicable at
the place of operation
• observe all inspection and maintenance intervals
• ensure to comply with the intended use
2.1 General safety instructions
Safety instructions help you in avoiding injuries and damage. Ensure
that you have read and understood all the safety instructions in these
operating instructions.
Safe working entails doing more that just reading the general safety
instructions in this chapter. Also read and follow the specific safety
instructions in each chapter affecting your work. Also observe
information in the referenced product documents.
The following general safety instructions apply to all work undertaken
on the machine:
• Observe the applicable national and international health and
safety regulations.
• Only operate the machine …
– in a technically satisfactory condition
– taking into account safety and hazards
– according to the intended use
– in compliance with this operating manual and
– with all safety devices unchanged, properly installed and
functional
• Wear the appropriate personal protective equipment for all work
on the machine chapter 2.5, p. 10.
• Observe all safety markings affixed to the
machine chapter 2.6, p. 11.
• Work on electrical equipment may only be carried out by
Walter Stauffenberg GmbH & Co. KG.
• Immediately eliminate any malfunctions which affect your safety
and/or reliable operation of the machine. Take the machine out
of service until the fault is rectified.
• Components – except tools – may only be replaced by
Walter Stauffenberg GmbH & Co. KG.

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2 For your safety
• Keep away from moving parts. Wear close-fitting clothes. Tie long hair
back to prevent it from being drawn into the machine. Remove any rings
and necklaces before the work.
• Be aware of the presence of residual energies in mechanical,
hydraulic and electrical components.
2.2 Intended use
The machine for cutting ring pre-assembly and final assembly is intended
exclusively for machine pre-assembly and final assembly of cutting rings on
tube ends in the Light and Heavy Series for outer tube diameters between
6 mm and 42 mm.
The machine is used together with assembly studs and counter
retaining plates specially designed for machine assembly.
The assembly parameters stored in the machine apply solely to the use of
an original STAUFF cutting ring FI-DS-.. in combination with the selected
tube material and the original STAUFF union nut. .
The machine may only be used within the specifications provided in the
chapter “Technical data” chapter 3.2, p. 15 and in compliance with the
maintenance instructions and other instructions in this manual and in the
referenced documents.
No changes, attachments or conversions may be carried out without
consulting the manufacturer. Such modifications could limit the operating
safety of the machine and are considered to be a violation of intended use.
Any use other than the intended use is not permitted.
2.3 Tasks and duties of the operating company
In addition to the instructions and information in these operating instructions,
the general, statutory and other mandatory regulations on accident
prevention and environmental protection also have to be observed.
To ensure safe machine operation, the operating company has to
at least …
• ensure that the machine is only operated as intended, in
proper condition, with all safety devices fully installed and
without damage
• establish the area of application and prepare the corresponding
operating instructions
• always keep the safety markings attached to the machined in a
complete and legible condition
• make the operating instructions available in a complete and legible
form at the operating location of the machine at all times
• instruct the personnel in safe working

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2 For your safety
• acquire the regulations applicable to the machine in their most recent
version and to familiarise personnel working on the machine with these
• provide personnel with the required personal protective equipment
• carry out a safety instruction
• ensure sufficient ventilation and lighting of the work areas
• collect any floor contamination using suitable means and dispose of
these observe the safety data sheet for the production equipment
used
2.4 Personnel qualification
Any work on the machine may only be carried out by qualified and
authorised personnel. Personnel instructed, trained or briefed in the work
involved is considered to be qualified. This has to be backed up by
appropriate certificates and records.
A distinction is made in this manual between the following groups
of persons:
• Operating personnel are those who have been verifiably briefed in
the operation and function of the machine. They input the data
required for the operation and carry out the required operating steps to
operate the machine. They are also responsible for simple
maintenance work and troubleshooting as specified in the inspection
and maintenance schedule and in the troubleshooting instructions.
• Personnel learning on the job may only work on the machine under
the constant supervision of personnel qualified for this work.
2.5 Personal protective equipment
The following personal protective equipment is mandatory for those
working on the machine:
Wear close-fitting work clothes!
Wear safety boots!

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2 For your safety
2.6 Safety markings
The following safety markings are attached to the machine in a clearly
visible and legible manner:
Warning – dangerous electrical voltage!
ISO 7010 – W012
Warning – hand injuries
ISO 7010 – W024

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2 For your safety
2.7 Safety devices
Safety devices protect operating personnel against hazards.
Before each startup of the machine, all safety devices have to be fitted
correctly and in working order.
Safety devices may only be removed when the machine has stopped and is
protected against being accidentally switched on again by means of a
padlock or a similarly suitable measure.
The following safety devices are attached to the machine or have to be
fitted by the operating company:
Electrical main switch
The electrical main switch is located at the
front of the machine. The electrical main
switch de-energizes the entire machine
(position: 0). The electrical main switch is
secured against reactivation chapter 2.8,
p. 13.
Light curtain
Light curtains prevent personnel from
reaching into the hazard area of the
machine. If anyone reaches into the hazard
area during operation, the respective light
curtain will trigger an emergency stop. This
stops all machine movements.
Emergency stop button
Pressing the emergency stop button
triggers an emergency stop resulting in all
machine movements being stopped.
To reactivate the machine, the triggered
emergency stop has to be unlocked
(Establishing readiness for operation after
emergency stop).
1
Light curtain
1
2 3
2
Electrical main switch
3
Emergency stop button
Fig. 1: Safety devices

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2 For your safety
2.8 Securing the machine against reactivation
Secure the machine against reactivation:
1. Ensure that …
a padlock is available for securing the machine against reactivation
(not included in the delivery).
2. Switch off the machine as described.
3. Secure the electrical main switch with a padlock.
Fig. 2: Electrical main switch protected with padlock
The machine is secured against reactivation

3 Machine description
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3 Machine description
3.1 Machine overview
Fig. 3: Overview
No. Designation Description
1Assembly area Machine workpiece
2Electrical main switch Switch on the machine
3“Ready/Process
runs” lamp
Machine ready for operation, machine running
4Operating panel Setting up the machine
5Enable Enable the machine
6Emergency stop button
Stop machine in an emergency
Optional foot switch Enable the machine
RJ45 interface PC connection;
At the rear of the machine
Power supply At the rear of the machine
Foot switch connection At the rear of the machine
Optional tool holder Tool holder offset to the top
1
2
3
4
5
6

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3.2 Technical data
General data
Dimensions (W x D x H) 780 mm x 650 mm x 305 mm
Weight incl. oil: 95 kg
Electrical power
Electrical connection: 400 V / AC3 / 50Hz
460 V / AC3 / 60Hz
Current consumption: 2.7 A
Hydraulic energy
Oil capacity: 4 litres
Max. operating pressure: 450 bar
Installation requirements
Ambient temperature: Dry between 15 °C and 35 °C
Position Horizontal
Sound pressure level
in acc. with EN ISO 11202:2009: 68 dB(A)
3.3 Function
The machine mechanically mounts cutting rings onto tube ends. Tubes
from the Light and Heavy Series with tube diameters between 6 mm and
42 mm can be used. Pre-assembly mode and final assembly mode are
available.
For more information on final assembly, please follow the detailed
instructions in the assembly instructions in the STAUFF Connect product
catalogue.
The machine is used together with assembly studs and counter-
retaining plates specially designed for mechanical mounting.
3.4 Tools and product
The machine for cutting ring pre-assembly and final assembly mounts
cutting rings onto tube ends. They form the basis for cutting ring fittings.
Fig. 4: Product

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1
Assembly stud
2Cutting ring
3Union nut
4Counter retaining
plate
Fig. 5: Components
The assembly stud and counter retaining plate are labelled with the
size:
• The number corresponds to the external tube diameter
• LL stands for the Extra-Light Series
• L stands for the Light Series
• S stands for the Heavy Series
Please refer to the STAUFF Connect product catalogue for additional
information on selecting the size.
3.5 Type plate
The type plate is located on the side of the machine.
Fig. 6: Type plate
The serial number is stamped into the frame at the front right.

3 Machine description
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3.6 Spare and wear parts
ATTENTION
Replacing components
Machine damage, malfunctions, faults
►Only Walter Stauffenberg GmbH & Co. KG may carry out work which
involves opening up the machine!
►Only authorised setup and maintenance personnel may carry
out maintenance work!
►Only use suitable tools in proper condition!
►Replace components only with genuine spares or those authorised
by the manufacturer.
Lists of authorised spare and wear parts can be obtained from
Walter Stauffenberg GmbH & Co. KG.

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4 Transport and storage
4.1 Safety
WARNING
Lifting loads
Serious or lethal injuries from falling/suspended loads
►Secure all moving components before raising the load.
►Only use undamaged lifting equipment which is approved for the weight
of the load to be lifted.
►Attach load attachment gear only at the indicated attachment points.
►Never leave loads suspended in the lifting devices without supervision.
►Never stand underneath suspended loads.
WARNING
Transporting the machine
Serious or lethal injuries from tilting or slipping loads
►Before transporting the machine, secure all its moving components.
►Secure the machine against overturning or slipping out of position
during transport.
►Only use transport vehicles which are suitable for the weight of the
machine.
4.2 Transport
Information on dimensions and weight can be found in
chapter 3.2, p. 15.
Note the following during transport:
• The attachment points are the side bars/grips of the machine.
• Keep the machine horizontal during all transport. Note that the centre of
gravity is in the installation area.
• Transport may only be carried out by an authorised specialist company
or by qualified personnel.
• Dispose of all packaging material in a proper and environmentally
compatible manner after transport.

5 Installation
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5 Installation
5.1 Safety
WARNING
Lifting loads
Serious or lethal injuries from falling/suspended loads
►Secure all moving components before raising the load.
►Only use undamaged lifting equipment which is approved for the weight
of the load to be lifted.
►Attach load attachment gear only at the indicated attachment points.
►Never leave loads suspended in the lifting devices without supervision.
►Never stand underneath suspended loads.
WARNING
Carrying out installation work
Serious or lethal injuries or machine damage due to incorrect installation
►Installation work may only be carried out by authorised specialist
personnel.
►Only use suitable tools in proper condition!
►Wear your personal protective equipment for all work.
WARNING
Connecting the machine to the power supply
Serious or lethal injuries from dangerous voltage
►Work on electrical equipment may only be carried out by qualified
electricians.
►Work on live parts is only permitted under supervision of a second
person.
WARNING
Risk of shearing off and crushing fingers
►Ensure before start-up that all safety equipment is properly installed and
in working order.
►Ensure your fingers are not in the assembly area when operating the
machine!

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CAUTION
Working on the hydraulic system
Eye injuries from ejected hydraulic oil
►Depressurise the machine!
►Only Walter Stauffenberg GmbH & Co. KG may carry out work
which involves opening up the machine!
►Wear your personal protective equipment including safety goggles
for all work undertaken on the hydraulic system!
5.2 Installing the machine
The machine is assembled ready for operation by the
manufacturer and delivered with the control unit set up.
Control unit updates can be requested from the
manufacturer. Note the following before the installation:
• Set up the machine on a sturdy base.
• Set up the machine so there is space to work around it.
• Inspect the machine for any signs of damage.
5.3 Attaching supply connections
Attach the machine to the following supply connections:
• Power supply
5.4 Establishing readiness for operation
A visual check and function test has to be carried out on the
machine before startup. Ensured that …
• all parts are mounted correctly, are undamaged and in full
working order
• all outer fittings are installed and fully tightened
• all safety devices are functioning chapter 8.3, p. 67 and
chapter 8.4, p. 67.