E50337_Bedienungsanleitung_1106_02

7/29/2019 E50337_Bedienungsanleitung_1106_02

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aquatherm

aquatherm - manual welding device

Art.-No.: 50336 / 50337 / 50341

for the processing of Fusiotherm

-, climatherm-and Firestop-pipe systems

ENGLISH


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Fusiotherm- manuel welding devices

Lieferumfang

1 piece Welding device

1 piece Base

1 piece Fixture for work bench

1 piece Allan key

2 piece Tool change clamp

1 piece Thermocolour pencil

2 piece Template

1 piece Transport case

1 piece Installation manual

1. Only use original Fusiotherm-welding devicesand Fusiotherm-welding tools.

2. Assemble and tighten the cold welding toolsmanually.

Technical Data

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3. Before fusioning the distribution block, in whichtwo connections are fused simultaneously (art.-no. 50337), the welding tools have to be placedinto the respective holes of the heating plate.

4. All welding tools must be free from impurities.Check, if they are clean before assembling.If necessary clean the welding tools with anon fibrous, coarse tissue and with spirit.

Art.-No. Passage Hole Branch Hole

30115 25 mm A + E 20 mm A + C

85123 20 mm A + B 16 mm A + C

85124 20 mm A + B 16 mm A + C

Heizbuchse

Operating lamp(green)

Temperature

pilot lamp(orange)

Heizdorn

Heating plate

Technical Data

Type: AQ 32 AQ 63 AQ 125

Art.-No.: 50336 50337 50341

Field of application: 16 - 32 mm 16 - 63 mm 50 - 125

Power supply: 230V 50-60 Hz. 230V 50-60 Hz. 230V 50-60 Hz.

Max. power: 500 W 800 W 1400 W


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Handling and Fusion

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5. Place the welding tools on the welding deviceso that there is full surface contact betweenthe welding tool and the heating surface. Wel-ding tools over 40 mm must always be fittedto the rear position of the heating plate.

Electric supply:The power supply must coincide with the dataon the type plate of the welding device andmust be protected according to the local regu-lations. To avoide high power loss, the conduc-tor cross-section of the used extension cablesmust be selected according to the power inputof the welding devices.

6. Plug in the welding device. Depending on theambient temperature it takes 10 - 30 minutesto heat up the heating plate.

The heat-up phase ends, if the temperaturepilot lamp blinks and a signal is audible.

7. During the heating up phase tighten the wel-ding tools carefully with the clamp. Take carethat the tools completely contact the heatingplate. Never use pliers or any other unsuitabletools, as this will damage the coating of thewelding tools.

8. The temperature of 260 C is required for thewelding of the Fusiotherm-system.

> Acc. to DVS-Welding Guidelines the tempe-rature of the welding device has to bechecked at its tool before starting the wel-

ding process.

Attention:First welding - soonest 10 minutes after reachingof the welding temperature. DVS 2207, Part 11.

9. A tool change on a heated device requires

another check of the welding temperatureat the new tool (after its heating up).

10. If the device has been switched off, i. e.during longer breaks, the heating up processhas to be restarted (from item 6).

11. After use turn the welding device off and letit cool down. Water must never be used tocool the welding device, as this woulddestroy the heating resistances.

12. Protect Fusiotherm-welding devices andtools against impurity. Burnt particles maylead to an incorrect fusion. Clean the wel-ding tools with non fibrous, coarse tissues andif necessary with spirit. Always keep the wel-ding tools dry. If necessary, dry them with aclean, non fibrous tissue.

13. For a perfect fusion, damaged or dirty wel-ding tools must be replaced.

14. Never attempt to open or repair a defectivedevice. Return the defective device for repair.

15. Check the operating temperature of Fusio-

therm

-welding devices regularly by meansof suitable measuring instruments.(see page 3)

16. For the correct handling of welding machi-nes the following must be observed:

> General Regulations for Protection of La-bour and Prevention of Accidents

and particularly the

> Regulations of the Employers LiabilityInsurance Association of the ChemicalIndustry regarding Machines for the Proces-sing of Plastics, chapter: "Welding Machinesand Welding Equipment".

17. For the handling of Fusiotherm-weldingmachines, devices and tools please observe

> General Regulations DVS 2208 Part 1 of theGerman Association for Welding Enginee-ring, Registered Society (Deutscher Verbandfr Schweitechnik e. V.)

RIGHT

WRONG


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Application:

As soon as the temperature pilot lamp of thewelding device indicates the end of the heat-upphase, put a firm chalk line on the heated exter-

nal surface of the welding tool. The colour mustchange within 1-2 seconds.

If the temperature is too high, the colour willchange immediately and if it is too low (below260 C) it will change after 3 or more seconds.

If the colour does not change within 1-2 se-conds another temperature test has to be car-ried out.

3. Cut the pipe at right angles to the pipe axis.Only use Fusiotherm-pipe cutters or othersuitable cutting pliers.

Take care that the pipe axis is free from burrsor cutting chips and remove if necessary.

Checking of devices and tools

1. Check, if the Fusiotherm-welding device andtool comply with to the guidelines.

2. All used devices and tools must have reachedthe necessary operating temperature of 260C. This requires acc. to Fusion Part A, item 9a separate test, which is indispensable (DVS-Welding Guidelines):

The DVS-Welding Guidelines allow the use of afast indicating surface temperature measu-ring instrument to check the welding tempe-rature required.

Suitable measuring instruments have to mea-sure a temperature of up to 350C with a highaccuracy.

Alternatively it is also possible to check the wel-ding temperature with the Fusiotherm-thermo-colour pencil. The application of the specialthermocolour chalk in the aluminium-pen hea-ted surfaces enables an exact reading with atolerance of 5 K.

It is possible, that the printed colour differs slightly from the original.

Handling and Fusion

afterbefore


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4. Mark the welding depth at the end of thepipe with the enclosed pencil and template.

5. Mark the desired position of the fitting on thepipe and / or fitting. (without picture)

The auxiliary markings on the fitting and theuninterrupted line on the pipe could be usedas a help.

6. Before fusing stabi composite pipe peel offthe aluminium-polypropylene layer comple-tely.

7. Only use original Fusiotherm-peeling toolswith undamaged peeling blades. Blunt pee-ling blades have to be replaced by originalones. It will be necessary to make trial pee-

lings to check the correct setting of the newblade. It should not be easier than usual topush the peeled stabi composite pipe or PP-stabi pipe into the welding tool.

8. Push the end of the stabi composite/PP-stabipipe into the guide of the peeling tool.

Peel the aluminium-PP-composite layer tothe stop of the peeling tool.

It is not necessary to mark the welding depthas the stop of the peeling tool indicates thecorrect welding depth.

9. Before starting the fusion, check if the alumi-nium-PP-composite layer has been complete-ly removed.

The General Guidelines for Heated Tool Socket

Welding acc. to DVS 2207 Part 11 are appliedhereupon.

The fusion is subject to the following datas

*Following DVS 2207 part 11: aquatherm recom-mends to increase the heat-up phase by 50%, if

the ambient temperature is below +5 C.

**These values exclusively concern aquathermsnew Firestop-sprinkler pipe system. For detailedinformation regarding Firestop, please requirethe prospect with order-no. E40000

10. Push the end of the pipe, without turning,up to the marked welding depth into thewelding tool. At the same time push the fit-ting, without turning, right down to the wel-ding tool.

It is essential to observe the above mentionedheating times.

Handling and Fusion

Pipeexter-nal-

Weldingdepth

Heat-up timeProcessing

timeCooling

time

mm mm sec. DVSsec.

AQE*sec. fs** sec. min.

16 13.0 5 8 - 4 2

20 14.0 5 8 5** 4 2

25 15.0 7 11 7** 4 2

32 16.5 8 12 8** 6 4

40 18.0 12 18 12** 6 4

50 20.0 18 27 18** 6 4

63 24.0 24 36 24** 8 6

75 26.0 30 45 30** 8 8

90 29.0 40 60 50** 8 8

110 32.5 50 75 60** 10 8

125 40.0 60 90 70** 10 8


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ADVICE:For ease of joining large diameter pipes and fit-tings, it is recommended to push them into thewelding tool in stages.

Pipes and fittings of the dimensions 75 + 125mm may only be welded with welding deviceArt.-No. 50341. On using the Fusiotherm-weldingmachine Art.-No. 50147 (with welding deviceArt.-No. 50341) the separate operating instruc-tion has to be observed.

ATTENTION:The heating time starts, when pipe and fittinghave been pushed to the correct weldingdepth on the welding tool.

11.After the heating time, quickly remove pipeand fitting from the welding tools. Join themimmediately, and without turning, until themarked welding depth is covered by thePP-bead from the fitting.

ATTENTION:Do not push the pipe too far into the fitting, asthis would reduce the bore and in an extremecase will close the pipe.

12.The joint elements have to be fixed during

the specified assembly time. Use this time tocorrect the connection.

Correction restricted to the alignment of pipeand fitting. Never turn the elements or align theconnection after the processing time.

13. After required the cooling time the fusedjoint is ready for use.

Installation ofFusiotherm-weld-in saddles

Fusiotherm-weld-in saddles are available forpipe outer diameters of 40, 50, 63, 75, 90, 110125, 160, 200 and 250 mm

weld-in saddles are used for

branch connections for manifold construction

the substitution of a tee

branch connections in risers

sensor wells, a.s.o.

The maximum sensor well diameter is specified

in the table on page 6.

Handling and Fusion


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Handling and Fusion

Art.-No. DimensionD d R h Sensorwels Borer Chamfering

Device*Tool

mm mm f mm mm Art.-No. Art.-No. Art.-No.

15156 40/20 mm 40 20 - 27.0 - 50940 50910 50614

15158 40/25 mm 40 25 - 28.0 - 50940 50910 50614

15160 50/20 mm 50 20 - 27.0 - 50940 50910 50616

15162 50/25 mm 50 25 - 28.0 - 50940 50910 50616

15164 63/20 mm 63 20 - 27.0 - 50940 50910 50619

15166 63/25 mm 63 25 - 28.0 - 50940 50910 50619

15168 63/32 mm 63 32 - 30.0 - 50942 50912 50620

15170 75/20 mm 75 20 - 27.0 - 50940 50910 50623

15172 75/25 mm 75 25 - 28.0 - 50940 50910 50623

15174 75/32 mm 75 32 - 30.0 - 50942 50912 50624

15175 75/40 mm 75 40 - 34.0 - 50944 50914 50625

15176 90/20 mm 90 20 - 27.0 - 50940 50910 50627

15178 90/25 mm 90 25 - 28.0 - 50940 50910 50627

15180 90/32 mm 90 32 - 30.0 - 50942 50912 50628

15181 90/40 mm 90 40 - 34.0 - 50944 50914 50629

15182 110/20 mm 110 20 - 27.0 - 50940 50910 5063115184 110/25 mm 110 25 - 28.0 - 50940 50910 50631

15186 110/32 mm 110 32 - 30.0 - 50942 50912 50632

15188 110/40 mm 110 40 - 34.0 - 50944 50914 50634

15189 110/50 mm 110 50 - 34.0 - 50946 - 50635

15190 125/20 mm 125 20 - 27.0 - 50940 - 50636

15192 125/25 mm 125 25 - 28.0 - 50940 - 50636

15194 125/32 mm 125 32 - 30.0 - 50942 - 50638

15196 125/40 mm 125 40 - 34.0 - 50944 - 50640

15197 125/50 mm 125 50 - 34.0 - 50946 - 50642

15198 125/63 mm 125 63 - 38.0 - 50948 - 50644

15206 160/20 mm 160 20 - 27.5 - 50940 - 50648

15208 160/25 mm 160 25 - 28.5 - 50940 - 50648

15210 160/32 mm 160 32 - 30.0 - 50942 - 50650

15212 160/40 mm 160 40 - 34.0 - 50944 - 50652

15214 160/50 mm 160 50 - 34.0 - 50946 - 50654

15216 160/63 mm 160 63 - 38.0 - 50948 - 50656

15228 200 -250 / 20 mm 200 - 250 20 - 27.5 - 50941 - 50660 / 50672

15229 200 - 250 / 25 mm 200 - 250 25 - 28.5 - 50941 - 50660 / 50672

15230 200 - 250 / 32 mm 200 - 250 32 - 30 - 50942 - 50662 / 50674

15231 200 / 40 mm 200 40 - 34 - 50944 - 50664

15232 200 / 50 mm 200 50 - 34 - 50946 - 50666

15233 200 / 63 mm 200 63 - 37.5 - 50948 - 50668

15251 250 / 40 mm 250 40 - 34 - 50944 - 50676

15252 250 / 50 mm 250 50 - 34 - 50946 - 50678

15253 250 / 63 mm 250 63 - 37.5 - 50948 - 50680

28214 40/25x1/2f 40 - 1/2 39.0 14 50940 50910 50614

28216 50/25x1/2f 50 - 1/2 39.0 14 50940 50910 50616

28218 63/25x1/2f 63 - 1/2 39.0 14 50940 50910 50619

28220 75/25x1/2f 75 - 1/2 39.0 14 50940 50910 5062328222 90/25x1/2f 90 - 1/2 39.0 14 50940 50910 50627

28224 110/25x1/2f 110 - 1/2 39.0 14 50940 50910 50631

28226 125/25x1/2f 125 - 1/2 39.0 14 50940 - 50636

28230 160/25x1/2f 160 - 1/2 39.0 14 50940 - 50648

28232 200 - 250 / 25 mm x1/2"f 200 - 250 - 1/2" 39.0 14 50941 - 50660 / 50672

28234 40/25x3/4f 40 - 3/4 39.0 16 50940 50910 50616

28236 50/25x3/4f 50 - 3/4 39.0 16 50940 50910 50619

28238 63/25x3/4f 63 - 3/4 39.0 16 50940 50910 50623

28240 75/25x3/4f 75 - 3/4 39.0 16 50940 50910 50627

28242 90/25x3/4f 90 - 3/4 39.0 16 50940 50910 50631

28244 110/25x3/4f 110 - 3/4 39.0 16 50940 50910 50636

28246 125/25x3/4f 125 - 3/4 39.0 16 50940 - 50648

28250 160/25x3/4f 160 - 3/4 39.0 16 50940 - 50624

28254 200 - 250 / 25 mm x 3/4"f 200 - 250 - 3/4" 39.0 16 50941 - 50660 / 5067228260 75/32x1f 75 - 1 43.0 20 50942 50912 50628

28262 90/32x1f 90 - 1 43.0 20 50942 50912 50632

28264 110/32x1f 110 - 1 43.0 20 50942 50912 50638

28266 125/32x1f 125 - 1 43.0 20 50942 - 50650

28270 160/32x 1f 160 - 1 43.0 20 50942 - 50660 / 50672

28274 200 - 250 / 32 mm x1f 200 - 250 - 1" 43.0 20 50942 - 50662 / 50674

*onlyforstabi-composite-pipesArt.-

No

.70806-70824

weld-in Saddles


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aquatherm GmbHKunststoff-Extrusions-

und Spritzgietechnik

www.aquatherm.de

Biggen 5D-57439 Attendorn

Phone: +49 (0) 2722 950-0Fax: +49 (0) 2722 950-100

E-mail: [email protected]

Wilhelm-Rnsch-Strae 4D-01454 Radeberg

Phone:+49 (0) 3528 4362-0Fax: +49 (0) 3528 4362-30

OrderNo.:E

50337

Edition12/06

1. Before starting the welding process, checkthat the Fusiotherm-welding devices and toolscomply with the requirements of page 3.

2. The first step is to drill through the pipe wallat the intended outlet point by using the Fusio-therm-drill.

branch 20/25 m: Art.-No. 50940/41 branch 32 mm: Art.-No. 50942 branch 40 mm: Art.-No. 50944 branch 50 mm: Art.-No. 50946 branch 63 mm: Art.-No. 50948

3.When using Fusiotherm-stabi composite pipesremove the rest of the aluminium remaining atthe bore hole with the Fusiotherm-chamfering

device.

20/25 mm outlet : Art.-No. 50910 32 mm outlet : Art.-Nr. 50912 40 mm outlet : Art.-Nr. 50914

4. The welding device/saddle welding tool musthave reached the required operating tempe-rature of 260 C

5. The welding surfaces have to be clean and dry.

6. Insert the heating tool on the concave side ofthe weld-in saddle tool into the hole drilled inuntil it is completely in contact with the outer

pipe-wall. At the same time the welding insaddle tool is inserted into the heating sleeveuntil the saddle surface is up against the con-vex side of the welding tool. The heating timeof the elements is generally 30 seconds.

7. After the welding tool has been removed, theweld-in saddle nozzle is immediately insertedinto the heated, drilled hole. weld-in saddleshould be pressed on the pipe for about 15seconds. After being allowed to cool for 10minutes the connection can be exposed to its

full loading. The appropriate branch pipe is fit-ted into the sleeve on the Fusiotherm-weld-insaddle using conventional fusion technology.

By fusing the weld-in saddle with the pipeouter surface and the pipe inner wall the con-nection achieves highest stability. The alterna-tive to reducing tees.

Handling and Fusion

Documents

E50337_Bedienungsanleitung_1106_02