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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