HomeMy WebLinkAboutF15-0050_F15-0050 cut sheets 2_1438620540.pdf31
aquatherm TeMPeRATURe MeASURinG device
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50188 1 1
to check the correct welding temperature
aquatherm THeRMocoLoUR PenciL
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50190
50190 1 1
to check the correct welding temperature
aquatherm weLdinG TooL
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50208
50206 16 mm 1 1
50208 20 mm 1 1
50210 25 mm 1 1
50212 32 mm 1 1
50214 40 mm 1 1
50216 50 mm 1 1
50218 63 mm 1 1
50220 75 mm 1 1
50222 90 mm 1 1
50224 110 mm 1 1
50226 125 mm 1 1
aquatherm RePAiR kiT
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50307 7 mm 1 1
50311 11 mm 1 1
to close pipe holes up to 10 mm (pipe repair stick Art.-No. 60600)
aquatherm cLeAninG wiPeS
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50193 Box with 100 towels 1 1
for electrofusion sockets
bUTT weLdinG MAcHine RiTMo
Art.-no.for pipe dimensions Packing
unit
Price
m/pc Price eURo
50165 ø 160 - 250 mm 1
including wooden transport box.The butt welding machine can be obtained directly from Ritmo (www.ritmo.it)
PRodUcTS
aquatherm red pipe RePAiR STick
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
4160600 7/11 mm 10 1
Material: Fusiolen® PP-R FS to close pipe holes up to 10 mm.
Tool: aquatherm green pipe -repair kit (Art.-No. 50307 + 50311).
32
weLdinG TooLS & dRiLLS
aquatherm weLdinG TooL
for welding saddles of art.-no. 4115156-4115198 and 4128214-4128266
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50619
50614 40 x 20/25 mm 1 1
50616 50 x 20/25 mm 1 1
50619 63 x 20/25 mm 1 1
50620 63 x 32 mm 1 1
50623 75 x 20/25 mm 1 1
50624 75 x 32 mm 1 1
50625 75 x 40 mm 1 1
50627 90 x 20/25 mm 1 1
50628 90 x 32 mm 1 1
50629 90 x 40 mm 1 1
50631 110 x 20/25 mm 1 1
50632 110 x 32 mm 1 1
50634 110 x 40 mm 1 1
50635 110 x 50 mm 1 1
50636 125 x 20/25 mm 1 1
50638 125 x 32 mm 1 1
50640 125 x 40 mm 1 1
50642 125 x 50 mm 1 1
50644 125 x 63 mm 1 1
50648 160 x 20/25 mm 1 1
50650 160 x 32 mm 1 1
50652 160 x 40 mm 1 1
50654 160 x 50 mm 1 1
50656 160 x 63 mm 1 1
50657 160 x 75 mm 1 1
50658 160 x 90 mm 1 1
aquatherm red pipe exTRAcTion TooL
for sprinkler outlet Art- No.4114181-93
Art.-no.dimension Packing
unit
Price
m/pc Price eURo
50290 1 1
aquatherm dRiLL
for installation of weld-in saddles
Art.-no.dimension Packing
unit
Price
m/pc
Price
eURo
50940 20 & 25 mm (for pipes 40 - 160 mm)1 1
50942 32 mm 1 1
50944 40 mm 1 1
50946*50 mm 1 1
50948*63 mm 1 1
50950*/**75 mm 1
50952*/**90 mm 1
* may only be used in fixed drilling machines
PRodUcTS
* may only be used in fixed
drilling machines!
** tool holder MK4
33
1. important!
Only use original aquatherm welding devices and aquatherm welding
tools.
2. Assemble and tighten the cold welding tools manually.
3. All welding tools must be free from impurities. Check, if they are clean
before assembling. If necessary clean the welding tools with a non
fibrous, coarse tissue and with spirit.
4. Place the welding tools, so that there is full surface contact between
the welding tool and the welding plate. Welding tools over Ø 40 mm
must always be fitted to the rear position of the welding plate.
5. Plug in the welding device and check, if operating lamp is on. Depen-
ding on the ambient temperature it takes 10-30 minutes to heat-up the
welding plate.
The heat-up phase ends, when the temperature pilot lamp blinks
and a signal is audible.
electric power supply:
The power supply must coincide with the data on the type plate of the
welding device and must be protected according to the local regulations.
To avoide high power loss, the conductor cross-section of the used exten-
sion cables must be selected according to the power input of the welding
devices.
PART A:
Mounting of the welding tools
RiGHT
wRonG
FUSion
34
6. During the heat-up phase tighten the welding tools carefully with the
Allen Key. Take care that the tools fully contact the welding plate.
Never use pliers or any other unsuitable tools, as this will damage the
coating of the welding tools.
7. The required temperature to weld the aquatherm red pipe-system is
260 °C. Acc. to DVS-Welding Guidelines the temperature of the wel-
ding device has to be checked at its tool before starting the welding
process. This has to be done with a fast indicating thermometer or
alternatively with a aquatherm green pipe-thermocolour crayon. (see
“Fusion part B, item 2”)
ATTenTion:
First welding at the earliest 10 minutes after reaching the welding temperature
DVS 2207, Part 11.
8. A tool change on a heated device requires another check of the wel-
ding temperature at the new tool (after heat-up phase).
9. If the device has been unplugged, i. e. during longer breaks, the heat-
up process has to be restarted (from item 5).
10. After use unplug the welding device and cool down. Water must never
be used to cool the welding device, as this would destroy the heating
resistances.
PART A:
Heat-up phase
11. Protect aquatherm welding devices and tools against impurities.
Burnt-it particles may result in an incorrect fusion. The tools may be
cleaned with aquatherm cleaning wipes, Art.-No. 50193. Always keep
the burnt-in welding tools dry. If necessary, dry them with a clean, non
fibrous tissue.
12. For perfect fusion, damaged or dirty welding tools must be replaced,
as only undamaged tools ensure a perfect fusion welding.
13. Never attempt to open or repair a defective device. Return the defec-
tive device for repair.
14. Check the operating temperature of the aquatherm green pipe- wel-
ding devices regularly by means of suitable measuring instruments.
15. For the correct handling of welding machines the following must be
observed:
General Regulations for Protection of Labour and Prevention of Accidents
and particularly
the Regulations of the Employers’ Liability Insurance Association of
the Chemical Industry regarding Machines for the Processing of Plas-
tics, chapter: „Welding Machines and Welding Equipment“.
16. For the handling of the aquatherm welding machines, devices and
tools please observe
General Regulations DVS 2208 Part 1 of the German Association
for Welding Engineering, Registered Society (Deutscher Verband für
Schweißtechnik e. V.).
PART A:
Handling
PART A:
Guidelines
FUSion
welding tool
Heating plate
handle
Temperature pilot
lamp (yellow)
glows constantly while the heat-
up phase and blinks, when the
welding temperature is achieved
operating lamp (green)
glows constantly, as soon as the
device is conntected with the power
supply system.
35
1. Check, if the aquatherm welding device and tool correspond to the
guidelines “Fusion Part A”.
2. All devices and tools in use must have reached the required operating
temperature of 260° C in use. This needs a separate, compulsory test,
acc. to DVS-Welding Guideline. The control of the operating tempera-
ture can be made with fast indicating thermometers.
Suitable measuring instruments must offer a temperature measurement of
up to 350° C with a high accuracy.
Alternatively it is also possible to check the welding temperature with the
aquatherm-thermocolour crayon. The application of the special thermo-
colour chalk in the aluminium crayon enables an exact reading with a tole-
rance of +/- 5 K to heated surfaces.
Application:
After the temperature pilot lamp of the welding device has indicated the
end of the heat-up period, put a firm chalk line on the heated external
surface of the welding tool. The colour must change within 1 - 2 seconds.
If the temperature is too high, the colour will change immediately and if it
is too low (below 260° C) it will change after 3 or more seconds.
if the colour does not change within 1 - 2 seconds another tem-
perature test has to be carried out, respectively the control of the
welding device is required.
PART b:
checking of devices and tools
Temperature control with the aquatherm-thermocolour crayon
Temperature control - aquatherm welding device (1400 W)
Temperature control - aquatherm welding machine
FUSion
Measurement of temperature at the aquatherm butt-welding machine
Measurement of temperature at the aquatherm manual welding device (800W )
before after
36
3. Cut the pipe right-angled to the pipe axis.
Only use aquatherm green pipe-pipe cutters or other suitable cutting
tools. Take care that the pipe is free from burrs or cutting chips and
remove if necessary.
4. Mark the welding depth at the end of the pipe with the enclosed
pencil and template.
5. Mark the desired position of the fitting on the pipe and / or fitting.
The auxiliary markings on the fitting and the continued line on the
pipe may be used as a help.
The fusion is subject to the following data
The General Guidelines for Heated Socket welding acc. to dvS
2207 Part 11 apply.
PART b:
Preparation for the fusion
Pipe
external-Ø
welding
depth
Heat-up
time
welding
time
cooling
time
mm mm sec. DVS sec min.
20 14,5 5 4 2
25 16,0 7 4 2
32 18,0 8 6 4
40 20,5 12 6 4
50 23,5 18 6 4
63 27,5 24 8 6
75 30,0 30 8 8
90 33,0 40 8 8
110 37,0 50 10 8
125 40,0 60 10 8
Cutting of the pipe
Marking of the welding depth
FUSion
37
6. Push the end of the pipe, without turning, up to the marked welding
depth into the welding tool and at the same time the fitting, without
turning, as far as it will go on the tool. It is essential to observe the
above mentioned heating times.
Pipes and fittings of the dimensions Ø 75 to 125 mm may only be
welded with welding device Art.-No. 50341 (or with machine Art.-No.
50148). On using the aquatherm green pipe-welding machine Art.-No.
50148 a separate operating instruction has to be observed.
ATTenTion:
The heating time starts, when pipe and fitting have been pushed with
the correct welding depth on and in the welding tool. Not before!
7. After the stipulated heat-up time quickly remove pipe and fitting from
the welding tools. Join them immediately, without turning, until the
mark welding depth is covered by PP-bead of the fitting.
ATTenTion:
do not push the pipe too far into the fitting, as this would redu-
ce the bore and in an extreme case may close the pipe.
8. The joint elements have to be fixed during the specified processing
time. Use this time to correct the connection. Correction is restricted
to the alignment of pipe and fitting. Never turn the elements or align
the connection after the processing time.
9. After the cooling period the fused joint is ready for use.
The result of the fusion of pipe and fitting is a permanent material
joining of the system elements.
Unrivaled connection technique with security for a life-time!
PART b:
Setting and alignment
PART b:
Heat-up of pipe and fittings
Warming Joining, fixing and……aligning!
FUSion
38
Normally on fusioning a bead is formed around the entire circumference at the edge of the
socket. This bead is an indication of proper welding.
Incorrect shape of bead
Different shape of bead (b) or non-existent bead at one
or at both ends (a) (partial or total extent), resulting from:
• temperature of heating tool is too low (a)
• heat-up time too short (a)
• unacceptable tolerances (a and b)
• excessive temperature of heating tool (b)
• heat-up time too long (b)
Single shape of bead, resulting from:
• heat-up time too short
• temperature of heating tool is too low
• unacceptable tolerances
• heat-up of only one welding-part
Excessive melting, resulting from:
• temperature of heating tool is too high
• misaligned movement of welding-part, e.g. by inadequate fixing
• unacceptable tolerances
Elbow variance
Partially or double-sided inclined welded pipe into the socket without or with slight
bracing, resulting from:
• machinery defect
• false installation
Acceptable, if e ≤ 2 mm
Mistake of bonding by improper pipe insertion,
resulting from:
• heat-up time too short
• pipe ends not at 90° (right-angled)
• heating temperature too low
• axial movement during cooling time
• change-over time too long
Acceptable up to 0.1 x d and 0.15 x socket depth
viSUAL inSPecTion oF FUSion SeAM
1
2
3
4
5
FUSion
xd 300 ea b
39
1 2
3 4
5
viSUAL inSPecTion oF FUSion SeAM
The visual inspection may be only a first indication of the welding seam
quality.
but it is not a replacement for the leak test, which has to be carried out
after the completion of the installation.
correct fusion welding
Source:
DVS 2202-1, to purchase at DVS-publisher, Düsseldorf Copyright Publisher for fusion and related
procedures DVS-Verlag GmbH
FUSion
40
Art.-No.Dimension D d R h Sensorwells Drill Welding Tool
mm mm f mm ømm Art.-No.Art.-No.
4115156 40/20 mm 40 20 -27,0 -50940 50614
4115158 40/25 mm 40 25 -28,0 -50940 50614
4115160 50/20 mm 50 20 -27,0 -50940 50616
4115162 50/25 mm 50 25 -28,0 -50940 50616
4115164 63/20 mm 63 20 -27,0 -50940 50619
4115166 63/25 mm 63 25 -28,0 -50940 50619
4115168 63/32 mm 63 32 -30,0 -50942 50620
4115170 75/20 mm 75 20 -27,0 -50940 50623
4115172 75/25 mm 75 25 -28,0 -50940 50623
4115174 75/32 mm 75 32 -30,0 -50942 50624
4115175 75/40 mm 75 40 -34,0 -50944 50625
4115176 90/20 mm 90 20 -27,0 -50940 50627
4115178 90/25 mm 90 25 -28,0 -50940 50627
4115180 90/32 mm 90 32 -30,0 -50942 50628
4115181 90/40 mm 90 40 -34,0 -50944 50629
4115182 110/20 mm 110 20 -27,0 -50940 50631
4115184 110/25 mm 110 25 -28,0 -50940 50631
4115186 110/32 mm 110 32 -30,0 -50942 50632
4115188 110/40 mm 110 40 -34,0 -50944 50634
4115189 110/50 mm 110 50 -34,0 -50946 50635
4115190 125/20 mm 125 20 -27,0 -50940 50636
4115192 125/25 mm 125 25 -28,0 -50940 50636
4115194 125/32 mm 125 32 -30,0 -50942 50638
4115196 125/40 mm 125 40 -34,0 -50944 50640
4115197 125/50 mm 125 50 -34,0 -50946 50642
4115198 125/63 mm 125 63 -38,0 -50948 50644
4115218 160/75 mm 160 75 -42,0 -50950 50657
4115220 160/90 mm 160 90 -45,0 -50952 50658
4128214 40/25x1/2" f.40 1/2"39,0 14 50940 50614
4128216 50/25x1/2" f.50 1/2"39,0 14 50940 50616
4128218 63/25x1/2" f.63 1/2"39,0 14 50940 50619
4128220 75/25x1/2" f.75 1/2"39,0 14 50940 50623
4128222 90/25x1/2" f.90 1/2"39,0 14 50940 50627
4128224 110/25x1/2" f.110 1/2"39,0 14 50940 50631
4128226 125/25x1/2" f.125 1/2"39,0 14 50940 50636
4128234 40/25x3/4" f.40 3/4"39,0 16 50940 50614
4128236 50/25x3/4" f.50 3/4"39,0 16 50940 50616
4128238 63/25x3/4" f.63 3/4"39,0 16 50940 50619
4128240 75/25x3/4" f.75 3/4"39,0 16 50940 50623
4128242 90/25x3/4" f.90 3/4"39,0 16 50940 50627
4128244 110/25x3/4" f.110 3/4"39,0 16 50940 50631
4128246 125/25x3/4" f.125 3/4"39,0 16 50940 50636
4128260 75/32x1" f.75 1"43,0 20 50942 50624
4128262 90/32x1" f.90 1"43,0 20 50942 50628
4128264 110/32x1" f.110 1"43,0 20 50942 50632
4128266 125/32x1" f.125 1"43,0 20 50942 50638
PART c:
weld-in saddles
For pipe external diameters of 40, 50, 63, 75, 90, 110, 125, 160 mm
FUSion
41
1. Before starting the welding process, check if the aquatherm welding
devices and tools meet the requirements of “Fusion Part A”.
2. The first step is to drill through the wall of the pipe at the point inten-
ded for the outlet by using the aquatherm drill.
branch 20/25 mm: 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
branch 75 mm: Art.-No. 50950
branch 90 mm: Art.-No. 50952
3. The welding device/saddle welding tool must have reached the requi-
red operating temperature of 260 °C (check with reference to “Fusion
Part B, item 2”).
4. The welding surfaces have to be clean and dry.
5. Insert the heating tool on the concave side of the weld-in saddle tool
into the hole drilled in the side wall of the pipe until the tool is comple-
tely in contact with the outer wall of the pipe. Next the weld-in saddle
spigot is inserted into the heating sleeve until the saddle surface is up
against the convex side of the welding tool. The heating time of the
elements is generally 30 seconds.
6. After the welding tool has been removed, the weld-in saddle spigot is
immediately inserted into the heated, drilled hole. The weld-in saddle
should then be pressed on the pipe for about 15 seconds. After being
allowed to cool for 10 minutes the connection can be exposed to its
full loading. The appropriate branch pipe is fitted into the sleeve on the
aquatherm weld-in saddle using conventional fusion technology.
By fusing the weld-in saddle with the pipe outer surface and the pipe inner
wall the connection reaches highest stability.
PART c:
weld-in saddles
Drilling through the pipe wall
Heat-up of pipe…
...and fitting
Joining
FUSion
42
-One wooden transport box for the welding machine -aquatherm-welding tools diameter 50, 63, 75, 90, 110, 125 mm -One Allan key and tool change clamp -One aquatherm thermocolour crayon -One Installation manual -One roll stand
The aquatherm welding machine was especially developed for stationary
welding of pipe and fittings with an external diameter of 50 to 125 mm.
This machine is equipped with a hand crank to facilitate a precise pre-
assembly of complicated installation parts.
PART d:
aquatherm welding machine
Table to determine support intervals in conjunction with outside diameter.
PART d:
Support intervals
The fusion is subject to the following data
Pipe-
external-Ø
welding
depth
Heating
time
welding
time
cooling
time
mm mm sec. DVS sec min.
50 23,5 18 6 4
63 27,5 24 8 6
75 30,0 30 8 8
90 33,0 40 8 8
110 37,0 50 10 8
125 40,0 60 10 8
The General Guidelines for Heated Tool Socket Welding acc. to DVS 2207
Part 11 apply.
aquatherm red pipe SDR 7.4 SDR 11
Pipe diameter d [mm]
20 25 32 40 50 63 75 90 110 125 160
Support intervals in cm
120 140 160 180 205 230 245 260 290 320 285
FUSion
dimension 160 mm:
The dimension 160 mm is joined by butt- welding.
Detailed information on page 44 + 45.
43
-with heating plate without tools
-clamping fixture for fixing the prisma-light e. g. at the work bench
1. Check machine: temperature lamp blinks after reaching the welding
temperature (260° C), adjust clamping jaws 63 – 125 mm coarsely.
Mark welding depth with the template at the pipe.
2. Fix the fitting against the clamping jaws.
3. Place the pipe loose in the opposite clamping jaws.
4. Position the welding device centrically to the pipe-fitting axis and remo-
ve it.
5. Lock the front calibration knob and drive up the slide as far as it will
go.
6. In this position push the pipe against the fitting and fix it with the clamping
jaws.
7. Regulate the welding time according to the table on page 36 place the
welding device and push the fitting and pipe slowly as far as it will go up
to the marking.
8. The heating time starts when pipe and fitting are completely pushed
on the tool. When heating time is complete slide return the slide, re-
move the heating device quickly and join the pipe and fitting.
9. Consider cooling times from the table on page 36.
More detailed information can be taken from the enclosed operating ma-
nuals.
PART e:
welding machine prisma-light
Damaged pipes may be repaired - as already mentioned - by fusion
welding (see part B).
In addition the aquatherm red pipe-system offers the possibility of repair
by repair stick.
The suitable welding tool (Art.-No. 50307/11) and the repair stick
(Art.-No. 4160600) are described on pages 31+32.
The installation information is enclosed with the welding tool, but may
also be ordered separately.
PART F:
Repair
Heat-up
Pipe repair stick Cutting
FUSion
44
PART G:
bUTT-weLdinG oF PiPe diMenSion 160 mm
The following aquatherm red pipe series are available:
aquatherm red pipe SDR 11 MF (faser- composite pipe)
Pipes and fittings are fused, as explained below, by butt welding:
1. Protect your place of work from weather influences
2. Check, if welding machine works properly and heat it up
3. Cut pipes into required length
4. Plastic pipes are aligned and fixed by means of the clamping ele-
ments
5. Use the milling machine for planing the pipe end to be
plane-parallel
6. Remove the debris and clean the pipe ends with methylated spirit
7. Check if pipes match (tolerance: max. 0.1 x wall thickness)
8. Check width of gap between the two pipes to be welded (tolerance:
max. 0.5 mm)
9. Check the temperature of the heating element (210° C +/- 10° C)
10. Clean the heating element
FUSion
Before welding, pipes are cut into the required lengths
Check performance of the welding machine and heat it up
The parts to be welded are fixed and aligned respectively, the milling machine is used