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OPERATION AND MAINTENANCE MANUAL

aquatherm welding device Art.-No. 50336, 50337, 50341

Fusion for

aquatherm green pipe, aquatherm blue pipe, aquatherm lilac pipe,  
aquatherm red pipe and aquatherm ti

pipesystems from 16 up to 125 mm

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SAFETY STANDARDS

1.

 This equipment must only be used in full compliance with the 

instructions given in this manual. All other uses are to be considered 

improper and forbidden. Improper use may cause injury to the machine 

operator or third parties and/ or cause damage to the machine or other 

objects.

2.

 All standards concerning health and safety in the workplace must be 

implemented at all times. The devices must not be used by children or 

persons with reduced physical, sensory or mental capabilities.

3. 

Before using the machine personnel must be properly trained in its 

operation and in applicable accident-prevention regulations.

4.

 The components used in the construction of the machine and its 

operating principles are such that special care should be taken to carry 

out the following instructions:

4.1.

 Electric power supply:

Make sure the mains electricity supply is suitable for the machine. 

Do not use an electricity supply which is subject to voltage surges 

or drops. Use a guaranteed mains supply or power generators fitted 

with voltage stabilizers. Make sure the machine’s power socket is 

protected with a high sensitivity differential switch (IΔ=30 mA) and 

that the machine has an earth connection.

4.2. 

Electricity:

Even if designed and manufactured in full accordance 

with applicable standards and fitted with all the 

required safety devices, electrically powered machinery 

nonetheless poses a risk to safety due to the nature 

of this type of energy (i.e. risk of electric shock). Do not expose 

the machinery and its electrical cables to the rain, to chemicals, 

to mechanical stress (e.g. vehicles driving across the cables). Use 

perfectly dry pipes and connectors. Do not use the machine if your 

hands are wet or the workplace is moist or damp.

4.3.

 Avoiding burns:

Do not touch the heating element, metal 

components or plastic parts close to the 

welding surface during heating, welding 

or cooling, since the plate reaches very 

high temperatures. Operate the machine with the utmost care. Wear 

heatproof gloves and protective clothing suitable for preventing burns.

4.4.

 The workplace:

Make sure that unauthorized persons are unable to gain access to the 

workplace. The workplace must be clean, tidy, properly ventilated and 

well lit. There should not be any gases, fumes or flammable materials 

present, such as solvents, oils, paints, etc. These may constitute a fire 

risk if they come close to the heating element. Keep any objects or 

materials susceptible to heat damage well away from the machine. 

When working in tight, awkward places an external supervisor must 

be present to provide assistance to the machine operator in case of 

need.

4.5.

 Checks and repairs:

Before using the machine check that no components are damaged. 

Replace cables or components as soon as they become worn. Repairs 

must be carried out only by an expert or specially trained technician 

using exclusively original spare parts. Dismantling the machine 

involves a risk of electric shock. No alterations may be made to the 

machine.

4.6. 

Presence of the operator at all times during operation:

The machine operator must not leave the machine while it is welding 

or heating up.

4.7.

 Use pipes that are chemically inert: Do not carry out any welding 

operations on pipes containing, or which may have contained, 

substances which when heated generate explosive gases or other 

gases dangerous to the human body.

4.8.

 Support: Position the welding machine using only the proper fork 

or bench supports.

4.9.

 Take care with cables: Do not disconnect plugs, sockets or 

connectors or move the machine by pulling on the electric cables.

4.10.

 Finally...: After work, remember to disconnect the welding 

machine from the mains or supply socket.

4.11.

 The machine must not be used in areas where there is a risk of 

explosion or fire. Only specially designed and manufactured machines 

must be used in workplaces of this kind.

5.1.

 Ensure that the power cord and all other heat-sensitive components 

do not come in contact with the welding device. After completion of 

the welding process and before the machine is put back into the case, 

make sure that all surfaces are cold enough so that fire can be avoided. 

5.

 The manufacturer and dealer will not be liable for personal injury 

or damage to property arising from the improper use of the machine.

6. WARNING

In the event of a fault of any kind during the guarantee period, send 

the machine to the manufacturer or an authorized repair centre. Having 

repair work carried out by personnel not authorized by aquatherm will 

immediately invalidate the warranty

aquatherm GmbH • Biggen 5 • 57439 Attendorn • www.aquatherm.de

Summary of Contents for 50336

Page 1: ...Beim Umgang mit der Maschine ist größte Vorsicht geboten Zur Vermeidung von Ver brennungen müssen stets Wärmeschutzhandschuhe und geeignete Arbeitskleidung getragen werden 4 4 Arbeitsplatz Der Arbeitsbereich muss für Unbefugte unzugänglich sein Er muss sauber ordentlich belüftet und gut beleuchtet sein Es dürfen keine Gase Dämpfe brennbaren Materialien wie Lösungsmittel Öl Lacke usw zugegen sein F...

Page 2: ...en groben Papiertuch und evtl mit Spiritus zu reinigen 5 Schweißwerkzeuge immer so montieren dass die Oberfläche nicht über den Rand des Heizschwerts ragt Schweißwerkzeuge ab Ø 40 mm sind immer an den hinteren Bohrungen des Heizschwertes zu befestigen 6 Schweißgerät an die Stromversorgung anschließen Die grüne Zu standsanzeige leuchtet konstant sobald das Gerät mit dem Strom netz verbunden ist Kon...

Page 3: ...h der Aufheizdauer erneut die Kontrolle der Einsatztemperatur an dem neuen Werkzeug erforderlich 10 Wenn das Gerät während längerer Pausen ausgeschaltet wird muss der Aufheizvorgang ab Punkt 6 erneut durchgeführt werden 11 Nach Beendigung der Schweißarbeiten Gerät ausschalten und ab kühlen lassen Das Schweißgerät niemals mit Wasser abkühlen da sonst die Thermowiderstände zerstört werden 12 aquathe...

Page 4: ...äß DVS Schweißrichtlinie darf die Kontrolle der benötigten Einsatztemperatur mit schnellanzeigenden Oberflächentemperatur Messgeräten durchgeführt werden Geeignete Messgeräte müssen eine Temperaturmesung bis 350 C ermöglichen und eine hohe Messgenauigkeit aufweisen HINWEIS aquatherm empfiehlt das original aquatherm Temperatur Messgerät Art Nr 50188 TEIL B VORBEREITUNG FÜR DIE FUSION 3 Rohr rechtwi...

Page 5: ...ete Einschweißtiefe durch die entstandene Wulst des Formteiles abgedeckt ist ACHTUNG Das Rohr darf nicht zu tief in das Formteil eingeschoben werden da dies sonst zu Verengungen im Extremfall zu Verschlüssen des Rohres führen kann 8 Die zusammengefügten Elemente sind während der Verarbeitungs zeit zu fixieren In dieser Zeit kann die Verbindung korrigiert werden Die Korrektur beschränkt sich ledigl...

Page 6: ...beginnt unter leichtem Druck Vorschub der Schälvorgang in Axialrichtung Der Schälvorgang ist abgeschlossen wenndieMit nehmerplatteamRohrendeanschlägt 1 5 DasRohrkannjetztperMuffenschweißverfahrenverschweißtwerden 2 ANLEITUNG MECHANISCHER SCHÄLVORGANG FÜR ELEKTRO SCHWEISSMUFFEN 2 1 Die Verlängerung wird mit dem Schäler durch die aufeinan derliegenden Passschrägen zentriert und mit drei Innensechs k...

Page 7: ...esser Schältiefe Muffenschweißen Schältiefe E Muffenschweißen ø 20 16 mm 39 mm ø 25 20 mm 43 mm ø 32 22 mm 45 mm ø 40 25 mm 50 mm ø 50 28 mm 56 mm Durchmesser Schältiefe Muffenschweißen Schältiefe E Muffenschweißen ø 63 32 mm 65 mm ø 75 34 mm 69 mm ø 90 37 mm 77 mm ø 110 42 mm 85 mm ø 125 44 mm 90 mm ...

Page 8: ... zu verschweißenden Flächen müssen sauber und trocken sein 6 Der Anwärmstutzen des Einschweißsattelwerkzeuges ist in die Bohrung der Rohrwandung zu stecken bis das Werkzeug die Rohr Außenwand komplett erreicht Anschließend wird der Stutzen des Sattels in die Heizbuchse eingeschoben bis die Sattelfläche die Werkzeugwölbung erreicht Die Anwärmzeit der Elemente beträgt bei allen Dimensionen 30 Sekund...

Page 9: ...burns 4 4 The workplace Make sure that unauthorized persons are unable to gain access to the workplace The workplace must be clean tidy properly ventilated and well lit There should not be any gases fumes or flammable materials present such as solvents oils paints etc These may constitute a fire risk if they come close to the heating element Keep any objects or materials susceptible to heat damage...

Page 10: ...g tools over Ø 40 mm must always be fitted to the rear position of the heating plate Electric 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 extension cables must be selected according to the power input of the welding devices 6 Plu...

Page 11: ... unplug the welding device and let it cool down Water must never be used to cool the welding device as this would destroy the heating resistances 12 Protect aquatherm welding devices and tools against impurities Burnt particles may lead to an incorrect fusion The tools may be cleaned with aquatherm cleaning cloths Art No 50193 Always keep the welding tools dry 13 After welding do not lay the the d...

Page 12: ...o Fusion Part A item 8 a separate test which is indispensable DVS Welding Guidelines Suitable measuring instruments have to measure a temperature of up to 350 C with a high accuracy NOTE aquatherm recommends the original aquatherm temperature measu ring device art no 50188 PART B PREPARATION FOR THE FUSION 3 Cut the pipe at right angles to the pipe axis Only use aquatherm pipe cutters or other sui...

Page 13: ...ce the bore and in an extreme case will close the pipe 8 The joint elements have to be fixed during the specified assembly 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 required cooling time the fused joint is ready for use The result of the fusion of p...

Page 14: ... process starts with rotation of the peeling tool upon slight force in axial direction The peeling operation is completed when the attachment plate strikes against the pipe end 1 5 The pipe now can be welded by socket welding method 2 INSTRUCTIONS FOR THE MECHANICAL PEELING PROCESS FOR ELECTROFUSION SOCKETS 2 1 The extension is centered with the peeler through the superimpo sed chamfer fit and fas...

Page 15: ... Socket welding Peeling depth Electric socket welding ø 20 16 mm 39 mm ø 25 20 mm 43 mm ø 32 22 mm 45 mm ø 40 25 mm 50 mm ø 50 28 mm 56 mm Diameter Peeling depth Socket welding Peeling depth Electric socket welding ø 63 32 mm 65 mm ø 75 34 mm 69 mm ø 90 37 mm 77 mm ø 110 42 mm 85 mm ø 125 44 mm 90 mm chamfer fit ...

Page 16: ... Insert the heating tool on the concave side of the weld in saddle tool into the hole drilled in the pipe wall until the tool is completely in contact with the outer wall of the pipe Next the weld in saddle tool 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 7 After the welding ...

Page 17: ...las fases de calentamiento soldadura y enfriamiento puesto que alcanzan temperaturas elevadas Prestar la máxima atención al manejar la máquina Llevar guantes atérmicos de protección y ropa de trabajo idónea para prevenir el peligro de quemaduras 4 4 Lugar de trabajo inhabilitar el lugar de trabajo a las personas no autorizadas Éste debe estar limpio ordenado ventilado y bien iluminado No debe habe...

Page 18: ...repase el borde de la placa calefactora Las matrices de soldar superiores a 40 mm de diámetro han de ser acopladas siempre en la parte trasera de la placa 6 Conectar el soldador y comprobar si está encendido el interruptor luminoso Interruptor luminoso verde ilumina cuando el soldador está conectado Piloto de control de temperatura amarillo ilumina durante el tiempo de calentamiento luce intermite...

Page 19: ...de calentado como se indica a partir del punto 6 n 11 Tras concluir los trabajos de soldar desconectar el aparato y dejarlo enfriar No enfriarlo nunca con agua puesto que entonces se deterioran las resistencias de calentamiento 12 Los soldadores y matrices aquatherm han de ser protegidos contra impurezas Las partículas quemadas pegadas a las matrices pueden conducir a una fusión deficiente Las mat...

Page 20: ... que es obligatoria y ha de ser acorde con las directrices de la DVS Según las mismas directrices el control de la temperatura de trabajo requerida puede realizarse con un aparato de medida de contacto Los aparatos de medida apro piados deben permitir medir la temperatura hasta 350 C y con alta precisión NOTA aquaterm recomienda el instrumento de medición de temperatura aquatherm original Art nº 5...

Page 21: ...sta que la profundidad de soldadura señalada sea cubierta por el anillo de polipropileno formado en la pieza ATENCIÓN No se debe introducir muy profundamente el tubo en la pieza pues éste podría estrecharse demasiado e incluso llegar a taponarse 8 Los elementos en cuestión han de ser unidos en el tiempo de soldadura indicado Durante este tiempo puede corregirse la unión Tal corrección se limita ex...

Page 22: ... Encajar la herramienta en el extremo del tubo a pelar 1 4 Iniciar el proceso de pelado aplicando una ligera fuerza en sentido axial del tubo La operación está completada cuando la placa de sujección alzanza la tubería 1 5 Ya se puede realizar la soldadura a enchufe del tubo 2 INSTRUCCIONES PARA EL PROCESO DE PELADO DE FORMA MECÁNICA SOLDADURA POR ELECTROFUSIÓN 2 1 Añadir la extensión de pelado pa...

Page 23: ...nchufe Distancia de pelado en soldadura por electrofusión ø 20 16 mm 39 mm ø 25 20 mm 43 mm ø 32 22 mm 45 mm ø 40 25 mm 50 mm ø 50 28 mm 56 mm Diámetro Distancia de pelado en soldadura a enchufe Distancia de pelado en soldadura por electrofusión ø 63 32 mm 65 mm ø 75 34 mm 69 mm ø 90 37 mm 77 mm ø 110 42 mm 85 mm ø 125 44 mm 90 mm chamfer fit ...

Page 24: ...n se inserta el asiento en la matriz calefactora hasta que la superficie del asiento alcance la curvatura de la herramienta El tiempo de calentamiento de los elementos es en general 30 segundos a partir de haber intro ducido la derivación en la matriz 7 Una vez retirado el equipo de soldar se introduce rápidamente el asiento soldable en la perforación calentada se presionará exactamente y sin gira...

Page 25: ... abbigliamento idoneo da lavoro per prevenire il pericolo di ustioni 4 4 Posto di lavoro deve essere pulito ordinato arieggiato e ben illuminato Non devono essere presenti gas vapori materiali infiammabili quali solventi oli vernici ecc Essi danno luogo a rischio di incendio se posti nel raggio d azione del termoelemento Tenere a debita distanza oggetti o materiali deperibili col calore Nel corso ...

Page 26: ...e sempre le matrici di saldatura in modo tale che le superfici non sporgano dal bordo della piastra Con il polifusore portatile le matrici con Ø 40 mm vanno sempre fissate nel foro posteriore della piastra 6 Collegare alla rete il polifusore controllando che le spie siano accese Spia della temperatura verde acceso quando il dispositivo per l alimentazione è collegato Spia di rete gialla illuminata...

Page 27: ... nuovamente la temperatura di esercizio della nuova matrice dopo la fase di riscaldamento 9 Se il polifusore viene spento per lunghe pause eseguire nuovamente la procedura al punto 5 10 Dopo il lavoro di saldatura spegnere il polifusore e lasciarlo raffreddare Non raffreddare mai il polifusore con l acqua perchè si danneggerebbero le resistenze elettriche 11 Proteggere dallo sporco il polifusore e...

Page 28: ... A punto 7 DVS Direttive della Saldatura Apparecchi di misura adatti devono permettere di rilevare temperature fino a 350 C con un elevato grado di precisione NOTA aquatherm raccomanda l originale dispositivo di misurazione della temperatura aquatherm Art No 50 188 PARTE B PREPARAZIONE ALLA FUSIONE 3 Tagliare il tubo ad angolo retto rispetto l asse del tubo Usare so lamente tagliatubi aquatherm op...

Page 29: ...amente e senza moto rotatorio inserirli in linea retta l uno nell altro fino al raggiungimento della profondità di saldatura contrassegnata dal rigonfiamento formatosi nel raccordo ATTENZIONE Non spingere troppo profondamente il tubo nel raccordo perchè questo può generare restringimenti e in casi estremi anche ostruzioni nel tubo 8 Gli elementi accoppiati devono essere fissati nella fase di lavor...

Page 30: ... raschiatura inizia con una leggera pressione avanzamento nella direzione assiale Il processo di raschiatura è terminato quando la piastra di accoppiamento appoggia contro l estremità del tubo 1 5 Il tubo ora può essere saldato con il procedimento di saldatura dei manicotti 2 ISTRUZIONI PER IL PROCESSO DI RASCHIATURA MECCANICA DEGLI ELETTROMANICOTTI 2 1 La prolunga viene centrata con lo spelatore ...

Page 31: ... Profondità di raschiatura per saldatura degli elettromanicotti ø 20 16 mm 39 mm ø 25 20 mm 43 mm ø 32 22 mm 45 mm ø 40 25 mm 50 mm ø 50 28 mm 56 mm Diametro Profondità di raschiatura per saldatura manicotti Profondità di raschiatura per saldatura degli elettromanicotti ø 63 32 mm 65 mm ø 75 34 mm 69 mm ø 90 37 mm 77 mm ø 110 42 mm 85 mm ø 125 44 mm 90 mm accoppiamento smussato ...

Page 32: ...e devono essere pulite ed asciutte 6 La parte concava della matrice deve essere inserita nel foro praticato nella tubazione fino al raggiungimento della parete esterna del tubo Contemporaneamente inserire il raccordo nella parte convessa della matrice Il tempo di riscaldamento è di 30 secondi per tutte le superfici 7 Dopo aver tolto il polifusore il raccordo a sella viene inserito nel foro riscald...

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