Operation and Maintenance
Manual
Version: 9912
SP 110
Welding Equipment
Power Requirements: 230VAC +10/-15%, 16A, 50/60
For Technical Service Contact:
Daten\Schweiss\SP\SP110\Operatin.doc
© by Agru/AWT/Gp/Rev.01 – 31.12.1999
Asahi/America
781-321-5409
35 Green Street
Malden, MA 02148
Table of contents:
1
General information on the manual ---------------------------------------------------------------------------- 4
2
Safety regulations -------------------------------------------------------------------------------------------------- 4
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
5.4
5.5
6
6.1
6.2
6.3
6.4
7
7.1
7.2
7.3
7.4
8
8.1
8.2
8.3
8.4
9
The user’s obligations ------------------------------------------------------------------------------------------------- 5
The personnel’s obligations ------------------------------------------------------------------------------------------ 5
Regulations for operation --------------------------------------------------------------------------------------------- 5
Safety devices ----------------------------------------------------------------------------------------------------------- 6
Maintenance, repair and inspection --------------------------------------------------------------------------------- 6
Product description ------------------------------------------------------------------------------------------------ 7
Field of application and predefined usage ------------------------------------------------------------------------- 7
Technical description and technical characteristics ------------------------------------------------------------- 7
Construction and initial operation ------------------------------------------------------------------------------ 8
Operating elements and components-------------------------------------------------------------------------------- 8
Installation of SP 110 ------------------------------------------------------------------------------------------------ 10
Connection and starting on of SP 110 ---------------------------------------------------------------------------- 10
Right of use ------------------------------------------------------------------------------------------------------------ 11
Operation and Welding ----------------------------------------------------------------------------------------- 12
Selection of welding method --------------------------------------------------------------------------------------- 12
Preparing SP 110------------------------------------------------------------------------------------------------------ 12
Program description -------------------------------------------------------------------------------------------------- 13
Working process ------------------------------------------------------------------------------------------------------ 16
Error and system message ------------------------------------------------------------------------------------------- 31
Weld quality and welding parameters ----------------------------------------------------------------------- 34
Welding bead ---------------------------------------------------------------------------------------------------------- 34
Weld failures----------------------------------------------------------------------------------------------------------- 34
Welding parameters -------------------------------------------------------------------------------------------------- 37
Weld labelling --------------------------------------------------------------------------------------------------------- 37
Maintenance ------------------------------------------------------------------------------------------------------ 38
Fuses--------------------------------------------------------------------------------------------------------------------- 38
Lubrication ------------------------------------------------------------------------------------------------------------- 38
Repair of failures ----------------------------------------------------------------------------------------------------- 39
Servicing ---------------------------------------------------------------------------------------------------------------- 39
Transportation and storage ------------------------------------------------------------------------------------ 40
General information -------------------------------------------------------------------------------------------------- 40
Unpacking of SP110 ------------------------------------------------------------------------------------------------- 40
Packing of SP 110 ---------------------------------------------------------------------------------------------------- 40
Storage ------------------------------------------------------------------------------------------------------------------ 40
Equipment and accessories ------------------------------------------------------------------------------------- 41
Operating instruction SP 110, Rev.01 - Version 9912
2
10
SUPPLEMENT --------------------------------------------------------------------------------------------------- 42
10.1
Spare parts and expendable material ------------------------------------------------------------------------------ 42
10.2
Installation guidelines for AGRU PURAD high-purity pipeline systems --------------------------------- 43
10.2.1
Design and pipe installation --------------------------------------------------------------------------------- 43
10.2.2
Admissible products ------------------------------------------------------------------------------------------- 43
10.2.3
Receiving inspection of products --------------------------------------------------------------------------- 43
10.2.4
Storage of material and components at the place of installation ------------------------------------- 44
10.2.5
Clean room clothing ------------------------------------------------------------------------------------------- 44
10.2.6
Welding and installation -------------------------------------------------------------------------------------- 44
11
Attestation of conformity --------------------------------------------------------------------------------------- 46
12
Guarantee Claims ------------------------------------------------------------------------------------------------ 47
Operating instruction SP 110, Rev.01 - Version 9912
3
1
General information on the manual
In this manual you will find the answers to all important questions about the construction and the
safe operation of your welding machine SP 110. You are obliged to study it carefully, in order to
avoid damages and injuries as well as to provide for the proper functioning.
At the same time we kindly ask you to inform us about faults, deficiencies and problems which
might occur during operation. This will help us to watch the steady improvement of our products
and the operating instructions.
Subject to changes without announcement.
Thank you.
Symbols
Below you find the explanations of the symbols used in this manual to ensure an easy understanding
and safe handling of the equipment.
Safety sign
The general hazard warning sign is marking texts, containing special safety rules. Ignorance
may be hazardous to the health of persons.
Important information
Marking of texts, containing important information.
2

Execution
Marking of texts, describing the execution of actions.

Enumeration’s
Marking of enumeration’s.
Safety regulations
The equipment has been designed for the welding of AGRU-products as to the best of our
knowledge. However, we are not liable for an improper welding seam quality or possible damages
arising thereof.
This state-of-the-art welding machine has been designed pursuant to the commonly accepted safety
regulations. Nevertheless, the machine might cause some danger to the operator or persons staying
next to it.
Operating instruction SP 110, Rev.01 - Version 9912
4
2.1 The user’s obligations
The user is obliged to...
 have the machine operated only by persons, familiar with the basic rules on working place safety,
who have been trained at the machine and proved by their signature that they have read and fully
understood the safety regulations and warning signs laid down in the operating instructions.
 have the machine operated only by persons, who have been trained by AGRU or a duly
authorised representative organisation, finally having obtained a valid welding certificate for SPwelding machines.
 have controlled the personnel’s safety concern at regular intervals.
 hand out the operating instructions, if the welding equipment should be passed over and owned
by another person/organisation or if it is leased, as well as to underline its importance.
 take care of observing the safe working conditions and the required perfect technical condition of
the machine.
 This machine has been designed for the welding of AGRU material. For welding of other brands
no experimental values are available and we are not able to warrant for any such suitability of the
welding machine whatsoever.
2.2 The personnel’s obligations
All persons directed to operate the machine are obliged to:
 observe the fundamental rules on safety and the prevention of accidents.
 read through the chapter on safety and warning signs in the operating instructions.
 get informed on the functioning of the machine before usage.
 operate the machine only when it is in a technically perfect condition and to report defects and
damages to the responsible user or operator.
 use the machine only for the specifically laid down purposes.
2.3 Regulations for operation
 The machine shall be connected to the mains supply only after completion of installation.
 In emergencies, where human beings and/or equipment are endangered, immediately press the
EMERGENCY-striking key of the operating control unit or turn off the main switch.
 After welding procedures and during breaks disconnect the machine and remove the access card.
Further, take care that only authorised personnel are admitted.
 According to the VDE 0100 the equipment may be operated only via current dividers equipped
with FI-protective switches.
 The SP 110 is designed as a single-operator welding set. Operation by more than one person is
not allowed. When the machine is switched on, only one responsible operator may stay in the
working place.
 Before the individual functional movements will be activated, the operator has to finish all
required preparing (see chapter 5: Operating and Welding) and provide for the perfect function
course.
 The planing tool rotates during operation and is equipped with sharp knives!
-
Wear tight clothes and possibly a hair-net, but no jewels or ornaments.
Do not reach into the running planing tool!
Operating instruction SP 110, Rev.01 - Version 9912
5
 Carriages work semiautomatically!
-
Do not reach into stationary and movable machine parts or the clamped pipe
ends!
Do not place objects on ways for shifting.
 The heating element is getting very hot during operation!
-
Do not touch the heating element and the protection cover.
Do not leave the heating element unattended.
Mind a sufficiently safe distance from inflammable materials.
 Do not clean the machine with compressed air, because dirt would be delivered into the guides
and planing chips blown onto the heating plate!
When PVDF, ECTFE and PFA-chips are heated-up, hydrofluoric acid may be generated!
Sufficient ventilation should be available!
 At butt welding the required teflon plates have to be mounted to the heating element; all welding
parameters have to be altered accordingly.
2.4 Safety devices
 Main switch with EMERGENCY function
In OFF-position the machine is currentless and idle.
 EMERGENCY-striking key at operating control unit.
If pressed (locked) all drives are currentless and idle.
 Position switch (proximity switch).
The individual functions are released only in the corresponding initial or working positions.
 Each critical control command activated over the touchscreen has to be simultaneously
acknowledged by the RELEASE-key.
 The lateral transport lock secures the planing tool and the heating element when the machine is
moved or transported.
 The crank geometry prevents the planing tool from uncontrolled swivelling during planing.
2.5 Maintenance, repair and inspection
 Only personnel and organisations authorised by AGRU are permitted to open the SP 110, to
adjust and repair it.
 Use only original spare parts and wearing parts.
 Perform maintenance and inspection work in due time.
 After finishing maintenance work control the functions of safety devices.
 Amendments, attachments and/or reconstruction work is allowed only by prior permission of the
manufacturer.
Operating instruction SP 110, Rev.01 - Version 9912
6
3
Product description
3.1 Field of application and predefined usage
The welding machine SP 110 is designed exclusively for InfraRed welding (non contact buttwelding) and heating element butt-welding of plastic pipes and plastic fittings. Only the welding
parameters which are shown on the display (pre-set values!) may be welded and stored respectively.
It is not allowed to alter the welding parameters given by AGRU!
Predefined usage first of all implies the observance of all regulations laid down in the operating
instructions.
Any usage going beyond it is not deemed predefined and appropriate. In such cases, the risk is borne
only by the operator. The manufacturer is not liable for any damages resulting thereof.
3.2 Technical description and technical characteristics
The welding machine SP 110 is designed as a semiautomatic device with an electronic joining
pressure control.
There is an external operating control unit with a touchscreen for the interactive operation and for
the input and output of welding parameters. All parameters relevant for the welding process are
stored and processed for the complete documentation by means of an optional PC-program. All
aluminium parts are anodised to enable operation under clean-room conditions.
General characteristics
Type of machine
Weldable materials
Weldable pipe dimensions
Welding pressure range
Dimensions (W x H x D)
Transport case (W x H x D)
Total weight
Weight of the machine
Connected loads
Electrical connection
Power input of heating element
Heating element temperature
Power input of planing tool
Planing tool speed
Storage temperature
Noise limit
Place of application
Ambient conditions
AGRU SP 110
PVDF, PP, ECTFE and optional PureBond® PFA
from OD 20 to 110 mm
from 10 to 500 N ±10%
approx. 580 x 625 x 670 mm
approx. 1075 x 740 x 715 mm
approx. 163 kg
approx. 98 kg
230VAC +10/-15%, 16A, 50/60Hz,
1-phase, 1/N/PE, min. 3x2,5mm², fuse protect. max.16A
max. 1600W
from 100°C to 500°C ±2% in pipe area
max. 300W
approx. 45rpm
0°C - 50°C
below 70dB(A)
workshops, industrial sites and clean-rooms
- according to DVS for welding areas
- Temperature: from +10°C to +35°C
- protection all elements from moisture
Table 3.1: Technical characteristics of SP 110
Operating instruction SP 110, Rev.01 - Version 9912
7
4
Construction and initial operation
4.1 Operating elements and components
14 5 6
9
11
Fig.4.1: Construction of SP 110
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Parts of SP 110
Machine panel
Operating control unit
Heating element
Planing tool
Inner clamping jaws
Outer clamping jaws
Stationary clamping unit
13
8
7
3
10
4 12
Notes
Fig. 4.2, Connections
Fig. 4.3, Operation of SP 110; detachable
Stationary
Movable and detachable, fixation by clamping lever
Height and lateral adjustment for offset compensation by means
of hand wheels
Clamping lever
Fixation of height and lateral adjustment
Movable clamping unit
Movements to right or left by means of electrical drive
Carriage for planing tool and Forward/backward movement by shifting lever
heating element
Movements to right or left by shifting lever
Transport lock
Fixation of planing tool and heating element during transport
Adjusting legs
Alignment of SP 110
Bubble level
Shows degree of alignment
Shifting levers
Movement of heating element and planing tool
Printing unit
Optional, for printing of weld tags; detachable
Nitrogen purging
Optional, not illustrated
Operating instruction SP 110, Rev.01 - Version 9912
8
23
19 20
Fig.4.2: Machine panel of SP110
No.
17
18
19
20
21
22
23
24
Parts of machine panel
Main switch
Shock-proof plug
Small plug connectors
Glass tube fuse
Safety cut-out
Mains cable
PC-cable
Temperature probe
28 25 29 26
Fig.4.3: Operating control unit
No.
25
26
27
28
29
30
31
32
33
34
Parts of operating c. unit
Touchscreen
EMERGENCY-striking key
RELEASE-key
PCMCIA-Slot
Buzzer
LED-signal
Keyboard interface
Serial interface
Parallel interface
Machine interface
18
17
22
21
Notes
Switching off the machine (with EMERGENCY-function)
Voltage supply to printer
Control of nitrogen purging
Protection of nitrogen purging
Protection of power elements
Connection to mains supply (network!)
Connection to operating control unit
Coverage of ambient temperature, not illustrated
27
34
30
31
33
32
Notes
Program operation and indication
Stopping engines in dangerous situation
Release of functions of movement
For entry card/memory card (keycard)
Acoustical indication during welding procedure
Lighting up green, if voltage supply is okay
Connection of a keyboard for servicing possible
Without function
Data transfer to printer (LPT)
Data transfer to control unit and supply of operating control unit
Operating instruction SP 110, Rev.01 - Version 9912
9
4.2 Installation of SP 110
General information
 Unpacking of SP 110 (see chapter 8, Transportation)
 Check delivery as to its completeness and possible shipping damages. Report shipping damages
and/or missing parts to AGRU. (Scope of delivery see chapter 9, Equipment and Accessories)
 Mount machine onto a solid, plane area and align it horizontally by means of the adjusting legs.
 Release the transport lock for planing tool and heating element.
 Swing out the rocker arm and tighten hand screw.
 Install the operating control unit and - if available - the printing unit to the rocker arm and fix it
by means of the clamping lever acc. to position shown in Fig.4.1.
Never touch the touchscreen with sharp or sharp-edged objects (such as screwdrivers, etc.).
4.3 Connection and starting on of SP 110
A 1-phase mains lead of the following characteristics is required for the machine operation:




230VAC +10/-15%, 50/60Hz
Protection is max. 16A
Minimum mains lead cross section is 3x2,5mm² (1/N/PE)
Maximum mains lead length is 10 m from the FI-switch
Before you plug in the mains lead and start the machine by the main switch it is required to:
Check and/or restore the electrical connections of heating element, operating control unit, printing
unit - if available - and nitrogen purging. If necessary, protect them by means of locking bows. The
most important plug connectors are marked in different colours. (Fig. 4.4).
SP 110 ->
Heating element
RED
Heating
element
Main supply -> SP 110
SP 110 -> Nitrogen purging
Nitrogen
purging
Printer transformer -> SP 110
SP 110
Operating control unit -> Printer
SP 110 ->
Operating control
unit
GREEN
Operating
control unit
Printer
optionally
y
Fig. 4.4: Plug connectors of SP 110
Operating instruction SP 110, Rev.01 - Version 9912
10
 Check position of safety cut-outs (inspection glass) - it has to be ON.
 Check position of EMERGENCY-striking key - it has to be unlocked (Fig. 4.5).
 Check position of main switch - it has to be OFF.
 Connect with mains lead and switch on SP 110 by main switch (position ON).
After a short time the starting image appears on the touchscreen with the AGRU logo (see
chapter 5.4, Working Process).
UNLOCKED
LOCKED
Fig.4.5: Functional description of EMERGENCY-striking key
4.4 Right of use
An access card is required for the purpose of the operator’s identification and external data storage
(keycard).
 Uncover PCMCIA-slots.
 Carefully insert the keycard with the printed side facing upward (until you reach point of
resistance) and cover slot (during operation the card always remains in the slot).
SP 110 can be operated only by means of a valid keycard.
Operating instruction SP 110, Rev.01 - Version 9912
11
5
Operation and Welding
5.1 Selection of welding method
By means of these selector keys you can choose the desired welding method. IR
stands for infrared or non-contact butt welding and CONTACT stands for the
conventional butt-welding method.
According to your selection the SP welding machine automatically sets the
required welding parameters and controls the temperature of the heating
element.
The conventional butt-welding (contact) method corresponds to the currently valid requirements of
the regulations of the DVS (German welding society). The parts to be joined are aligned under
pressure on the heating element (contact with the heating element), pre-heated without pressure and
joined at a specific pressure and time.
With non-contact welding no alignment time is required and heating may be started immediately.
This is done over a specifically defined gap between the heating element and the part to be welded.
Thus, a possible contamination of the welding surfaces can be minimised, leading to a substantially
higher purity of welding. After the pre-heating time you proceed the same way as with butt welding.
5.2 Preparing SP 110
General information
 Installation of reducing inserts
The reducing inserts for the different corresponding pipe dimensions are kept in the plastic kit.
 Open all four clamping jaws completely and place the inserts (4 x 3 pcs. of each dimension)
according to the constructional conditions (1 ½-insert and 2 ¼-insert per clamping jaw).
 Arrange remaining inserts in the plastic kit in proper order.
As the fixation of the inserts and the mechanical locking is carried out by magnetic force, no
instruments are needed to change the inserts. For removal of the inserts you only have to
surmount the magnetic force.
 Do not press the reducing inserts into the clamping jaws!
 Adjustment of outer clamping jaws
The position of the outer clamping jaws can be adjusted as required by the part to be welded.
 Release both clamping levers, position clamping jaw (or detach it) and reclamp it.
 Starting of printer
Refer to supplied original sample of operating instructions.
Operating instruction SP 110, Rev.01 - Version 9912
12
Butt welding (optinally)
 Installation of insert plates for butt welding
 Install the tefloncoated aluminium plates on either side of the cold heating plate.
 Fix them with the supplied countersunk head screws.
Never use insert plates in operating mode infrared welding, as the coating would be
destroyed in this case.
5.3 Program description
This program description is applicable to welding program SERVO 20, version no. 2.01.
Check first, whether this program version has been installed on your operating control unit (see
image LOGO)! If this is not the case, please contact the technical service of AGRU.
Operational procedures, setting and indication of welding parameters are performed via
touchscreen. The operator is guided through all of the welding procedures by the interactive
program flow.
In the first part of the welding program the operator has to carry out different inputs and settings. At
the same time according to these given values all necessary parameters are calculated or selected
automatically from the stored tables.
The particular welding is performed in the second part of the program. Here the operator’s task is to
perform preparing and activate the corresponding control functions.
After welding you may print out welding seam tags with a special printer (optional). All parameters,
relevant for the welding process, are stored in the operating control unit and available for further
processing.
 Operating levels
An access coding in form of 4 operating levels is provided to ensure the troublefree operation of the
machine. According to the code of the keycard only specific system accesses and system functions
are released (see Table 5.1) The first figure of the keycard serial number refers to the operating
level.
Operating level
1
2
3
4
Operator’s code
AGRU1
AGRU2
AGRU3
freely selectable 5digit character code
Table 5.1: Operating levels
Note
Manufacturer
AGRU
Operator, Distributor,
QC-personnel
Welder
Operating instruction SP 110, Rev.01 - Version 9912
Inhibited system access
N/A
Hardware set-ups
Hardware set-ups
Welding parameter set-ups
All, but welding control
13
 Program symbols and their functions
Depending on the active program position on the monitor you will see the corresponding status
images with input and output symbols. By pressing onto the input symbol the assigned function is
activated.
To release the control functions of movements, it is necessary to press the green RELEASE-key
simultaneously. If required, the operator is assisted both visually (information line) and
acoustically (by a horn).
Do not touch the touch panel surface with sharp or sharp-edged objects!
Turn image BACK:
Turn image FORWARD:
You can turn the page back by pressing this key.
You can turn the page forward by pressing this
key.
Selector keys:
Sliding button:
The keys with above characters serve for the
selection of conditions (heating element,
ON/OFF....), parameters (welding method,
material, wall thickness) and menu options. The
input keyboard has also been equipped with
selector keys.
Parameter adjustments are selected by changing
the sliding button position. (printer switch off or
number of tags to be printed after welding,..).
Dynamic pictures:
Dynamic pictures change depending on the actual condition (infrared welding or butt welding). This
is also true for select displays and diagrams.
Operating instruction SP 110, Rev.01 - Version 9912
14
Numerical displays:
Display lights:
These output fields serve for the display of
machine or welding characteristics in numerical
form.
These output fields serve for the display of
releases and activated functions (jaw closed,....).
Keys to control clamping jaws:
Multifunctional keys:
By these keys the movements (OPEN/CLOSE)
of the movable clamping jaws are controlled.
Various control functions may be released by
this input field (planing tool movements,
switching-on...). The graphics display and
functions alter depending on the actual function.
Stop key:
This special control key serves for switching off and interrupting
control functions (joining, putting planing tool into front position,...).
No EMERGENCY-function!
Information line, signalising and warning window:
Information on operational conditions of machine and control directions is given in an information
line in the upper screen section. Inquiries and system notes are indicated in windows with blue
background, warnings and disturbances in windows with red background.
If necessary, information outputs are accompanied by acoustic signals and must be acknowledged to
continue the program.
Operating instruction SP 110, Rev.01 - Version 9912
15
5.4 Working process
Fig. 5.1: Survey of program-backed welding procedure:
Fig. 5.1a: Flow chart of welding process
Operating instruction SP 110, Rev.01 - Version 9912
16
Fig. 5.1b: Flow chart of welding process
Operating instruction SP 110, Rev.01 - Version 9912
17
LOGO: Initial image
Information line
Program version
Operator card
information
Language
selection
Machine
characteristics
Change to
SYSTEM
Change to
INFO 1
After switching on the machine, the initial image LOGO appears.
It is possible to choose between the system level (image SYSTEM) or welding level
(image INFO 1). Hardware and software characteristics are illustrated for your information.
 SYSTEM: Select menu for system functions
Change to
LOGO
Operator code
Establish welding
table
Copy and delete
Data
Set system time
Test printer
Establish machine
settings
The select menu allows to enter system functions. Released functions are marked in green colour.
Authorised users will obtain information on the application of system functions from the technical
service of AGRU.
Only persons authorised by AGRU are allowed to make use of the system functions.
Operating instruction SP 110, Rev.01 - Version 9912
18
 INFO 1: Initial image of welding level
Change to
INFO 2
Change to
ADDRESS
Change to ROOM
Number of tag
printouts per
welding
Protocol
characteristics
Change to
LOGO
Change to
MATERIAL
Apart from the indication of welding characteristics this image includes several image changing
functions. The desired number of lag printouts can be chosen by the sliding button.
INFO 2: Selection and indication of stored welding characteristics.
Number of stored
data
Selected file
Pressure curve
Selection of file
Welding
characteristics
Take-over and
indication of
selected file
Change to
INFO 1
Open windows for
manual input of
file name
Selection of
memory medium
In this picture you can examine the characteristics of stored welding. You can read-in files from the
keycard or directly from the memory of the operating control unit. After selection of a file and its
transfer the welding data are indicated. As an alternative, you can perform a manual input of a file
name.
Operating instruction SP 110, Rev.01 - Version 9912
19
 ADDRESS: Input of address
Display of address
input
Keyboard for
address input
Change to
INFO 1
Confirmation of
input
The place of welding is entered over the keyboard block; it is automatically taken over at returning
to image INFO 1.
 ROOM: Input of room characteristics
Standard room
Clean room
Selection of
environment
Selection of clean
room class
Confirmation of
input
In this picture the environmental characteristics have to be entered. The selected room type is
marked by the signal lamp. On return to image INFO 1 the set characteristics are taken over
automatically. This settings are only for documentation and have no influence to the welding
parameters.
Operating instruction SP 110, Rev.01 - Version 9912
20
 MATERIAL: Input of material
Display of selected
material
Select menu
Change to
INFO 1
Change to
DIAMETER
You can select one of the given materials (e.g. PVDF) by the menu keys. When changing to image
DIAMETER, the setting is taken over automatically.
 DIAMETER: Input of diameter
Display of selected
diameter
Select menu
Change to
MATERIAL
Change to WALL
THICKNESS
You can select one of the given pipe diameters (e.g. 110 mm) by the menu keys. When changing to
image WALL THICKNESS the setting is taken over automatically.
Operating instruction SP 110, Rev.01 - Version 9912
21
 WALL THICKNESS: Input of wall thickness
Display of selected
wall thickness
Select menu
Change to image
DIAMETER
Change to
HEATING
ELEMENT
You can select one of the given pipe wall thickness (e.g. 5.3 mm) by the menu keys. When changing
to image HEATING ELEMENT, the setting is taken over automatically.
After setting the environmental and material characteristics in the first part of the program the
particular welding process is started now:
 HEATING ELEMENT: Setting of heating parameters
Display of active
method
Selection of
welding method
Heating element
characteristics
Release of heating
temperature
Indication of
ambient temp.
ON/OFF-key for
heating element
Indication of
power supply
Change to WALL
THICKNESS
Change to
INFO 3
After selection of the desired welding method the heating element parameters are loaded automatically and the machine is ready for welding.
Operating instruction SP 110, Rev.01 - Version 9912
22
Check your power supply.




230VAC +10/-15%, 50/60Hz
Protection is max. 16A
Minimum mains lead cross section is 3x2,5mm² (1/N/PE)
Maximum mains lead length is 10 m from the FI-switch
 Switching on of heating element (ON/OFF-button, button turns green).
The heating-up process is started and after the desired temperature is reached (release lamp turns
green) the count down of the REMAINING TIME begins (time to elapse until the heating
element reaches a constant temperature).
 After expiry of the remaining time turn to image INFO 3 (NEXT)
Changeover to INFO 3 is released only after expiry of the REMAINING TIME!
Time total needed for heating up is about 20 minutes.
If necessary, clean heating element with non frayed paper.
 Make non frayed paper available!
 Take care for safe current supply!
Consider the ambient conditions:
 The welding must not be carried out at direct sun irradiation and at draught.
 The ambient temperature must not be below +10°C and over +35°C.
Operating instruction SP 110, Rev.01 - Version 9912
23
 INFO 3: Display of welding parameters
Pipe
characteristics
Spec. welding
pressure
Desired pressure
curve
Pressure ramp
Joining pressure
Pre-heating
control pressure
Cooling time
Pre-heating time
Change to
HEATING
ELEMENT
Change to
PLANING TOOL
In this picture all relevant welding parameters are indicated that have been entered or calculated.
 After control of parameters change to image PLANING TOOL (NEXT).
On changing an inquiry window appears with the most important material data.
 After repeated control acknowledge by OK (image changing is concluded) or NOT OK and
repeat or correct setting of material (BACK)
The entered pipe characteristics must comply with the pipes to be welded!
 Always clean the machine, the planer blades and the planer knifes before each welding only with
non frayed paper!
Operating instruction SP 110, Rev.01 - Version 9912
24
 PLANING TOOL: Controlling
Shifting way
Planing tool
pressure
Planing tool
control
Clamping unit
CLOSED
Clamping unit
OPEN
Change to
INFO 3
Function stop
In this picture/program section the planing of the pipe ends is handled.
To provide a troublefree procedure, the different working positions have to be commenced
exactly. The touchscreen display is adapted automatically!
All control functions may be interrupted by function stop (STOP + RELEASE-key).
 Move planing tool to the left stop (Hand lever)
 Move movable clamping unit into position OPEN
(Clamping unit-OPEN + RELEASE-key)
1
These steps can be ignored, if the units already find
themselves in starting position.
When moving the clamping unit, the RELEASE-key has
to be kept pressed until the end position is reached,
otherwise a warning signal will appear. After arriving at
the end position the clamping unit is halted automatically!
 Move planing tool into position ALIGNING
(Hand lever)
 Move clamping unit into position PLANING
(Clamping unit-CLOSED + RELEASE-key).
 Place workpieces so that pipe ends touch the planing tool
plates and clamp them. The locking force of the individual
clamping jaws can be adjusted over the milled nut.
(Tighten the outside clamping jaws with more force to save
the pipe for moving up than the inside clamping jaws. These
are only used for Alignment).
Operating instruction SP 110, Rev.01 - Version 9912
2
25
When the locking force is too high, the workpiece and the clamping jaws can be damaged!
 Move movable clamping unit into position OPEN
(Clamping unit-OPEN + RELEASE-key)
 Move planing tool into position AHEAD (Hand lever)
 Switch on planing tool (Planing disc symbol +
RELEASE-key)
 Move clamping unit into position PLANING
(Clamping unit-CLOSED + RELEASE-key)
3
The work piece is guided automatically by the movable
clamping unit and maintains the planing pressure.
Take away chip material that accumulates behind the planing disc regularly. The chips can
cause that the planing tool engine will block or undergoes higher wear!
Do not put your hand into the stopped or rotating planing disc!
Danger of injury by sharp rotating knifes!
Danger! Clothing may be caught!
Wear tight-fitting clothes, if necessary wear a hairnet!
The process is ended, when no chips are left to be removed and the clamping units have come close
to the mechanical stops of the planing tool.
 Move movable clamping unit into position OPEN (Clamping unit-OPEN + RELEASE-key)
At the end position the planing tool is switched off automatically!
 Move planing tool into position BACK (Hand lever)
At the end position an inquiry window appears. Perform a visual control of the planing process.
 If acknowledged by OK, the image automatically turns to OFFSET CONTROL.
 If acknowledged by NOT OK, the planing process has to be repeated!
 See image planing (page 25)!
Operating instruction SP 110, Rev.01 - Version 9912
26
 OFFSET CONTROL: Alignment of pipes
Function stop
Clamping unit
CLOSED
Clamping unit
OPEN
Change to
PLANING TOOL
In this part of the program the work pieces are aligned to each other.
 Move movable clamping unit into position JOINING
(Clamping unit-CLOSED + RELEASE-key)
 Release lateral clamping lever under the stationary clamping
unit as well as hand wheel for height adjustment.
 Set height and lateral adjustment with both
hand wheels until work piece offset is compensated.
 Fix lateral clamping lever under the stationary clamping unit
and fix hand wheel for height adjustment.
 Place end caps onto pipe ends.
4
At the end position an inquiry window appears (see page 26):
 If you acknowledge by OK, open clamping unit and after reaching the end position,
automatically the image change to START WELDING.
5
 Move movable clamping unit into position
START WELDING
(Clamping unit-OPEN + RELEASE-key)
 If you acknowledge by NOT OK, you will have to repeat the offset compensation or, if required,
the planing (BACK)!
 Move movable clamping unit into position OPEN (Clamping unit-OPEN + RELEASE-key)
 See planing and/or offset control!
Operating instruction SP 110, Rev.01 - Version 9912
27
 JOINING: Pre-heating and joining
Track force
Joining pressure
nominal
Pressure curve
Joining pressure
actual
Pipe
characteristics
Fusion shrinkage
Error code
Total welding time
Heating element
temperature
Time counter
Function STOP
Change to
OFFSET
CONTROL
Function START
In this part of program the pre-heating and joining of the work piece are handled. This process is
carried out nearly fully automatically.
 Move tool unit till stop into position right (Hand lever)
 Starting of welding process (Function START +
RELEASE-key)
 Move heating element into position AHEAD till stop
(Hand lever + RELEASE-key), when reaching front stop,
the moveable clamping unit closes automatically into
position PRE-HEATING (after achieve control pressure
- green light turn off – depress release-key).
6
The time counter for pre-heating time begins to count down and a signal horn is sounded 10 sec.
before time runs out (to avoid signal horn press RELEASE-key). If you press release-key during
pre-heating and the pre-heating time runs out, the moveable clamping unit opens automatically.
 Move heating element into position BACK till stop
(Hand lever + RELEASE-key)
7
W
ir
The moveable clamping unit closes automatically and build up
d
the joining pressure. After achieving the joining pressure – see
d
indication on touchscreen – you can depress the release-key.
e
r
The whole adjustment process must be carried out rather
S
fast and exactly.
c
h
We recommend to press the RELEASE-key from the pre-heating time (10 sec. before time runs out)
w
till achieving the joining pressure (see touchscreen). The fusion process is fully automatic, the
e
movement of the tool unit (heating element/planer) have to be performed manually.
i
Take care, that nobody else is in the fusion area respectively clamping area to avoid any accidents.
ß
v
o
Operating instruction SP 110, Rev.01 - Version 9912
28r
g
a
The time counter for the cooling time begins to count down and after expiry of the time the image
turns to VISUAL automatically.
If the welding process is ended before joining or if the adjustment process lasts too long, then after
acknowledgement (OK) of the error signal the image is automatically turned to the next: PLANING
TOOL.
 Move movable clamping unit into position OPEN (RELEASE-key)
 Move heating element into position BACK (Hand lever)
 See planing tool sequence!
Plane only cooled down pipe ends!
If the welding process is ended during the cooling-down phase, then after acknowledgement (OK)
of the error signal the image is automatically turned to the next: VISUAL.
Operating instruction SP 110, Rev.01 - Version 9912
29
 VISUAL: Final image of data check
Error code
Welding
characteristics
Check inquiry
In this image the stored welding parameters are shown. It is required to carry out a welding seam
evaluation.
 Take out the welded work piece and check the weld.
As for the decisive criteria see chapter 6, Weld Quality.
 After acknowledgement (OK or NOT OK), the image is automatically turned to HEATING
ELEMENT; at the same time the weld tag is printed out (option).
If no printer is connected, it is necessary to acknowledge the inquiries, until the image turns to the
next: HEATING ELEMENT.
 Marking of weld
 The tag, printed by the optionally available printer, has to be fastened next to the weld. It
documents the proper execution of the welding.
 The pipe area to affix the tag shall be free from dust and grease
(if required, clean prior to sticking) to provide for proper and safe
adhesion (tag is destroyed on removal).
Place tag next to the weld for good visibility!
Tag
Operating instruction SP 110, Rev.01 - Version 9912
30
5.5 Error and system message
The tables 5.2a/b contain error messages, edited by the transmission window of warnings.
Error no. Message/Description
NO PLACE for DATA
01
The internal memory of the operating
control unit is full.
TOO MUCH FILES
02
The free target memory is insufficient
for the data to be copied.
NO MEMOcard plug in
03
No keycard in PCMCIA-slot.
ERROR FLASHcard
04
No access to internal memory of
operating control unit.
NO OPERATORcode
05
Operator code is invalid or file
unreadable.
ERROR TEMPERATURE
Heating element has still not been
released.
NO INPUT
07
Operator has tried to change to the
next image without input.
NO DATASAVE
08
No datasave possible!
NO PRINTER
09
Printer is not connected or switched
on, though in image INFO 1 the
printer has been activated.
TENSILE FORCE
10
The evaluated tensile force is too
high.
EMERGENCY STOP
11
EMERGENCY-striking key is locked.
ENDPOSITION
12
A control function has been activated
in spite of improper end positions of
carriages.
HARDWARE SOFTWARE
13
The hardware (machine) is not
compatible with the software
(operating control unit).
Table 5.2a: Error code
06
Clearance
Delete data of operating control unit on system
level. Before deletion the data should be stored on
a PCMCIA-card.
Reduction of selected files.
Insert keycard into PCMCIA-slot.
Contact technical service of AGRU!
(serious system failure)
Insert keycard with valid operator code into
PCMCIA-slot or newly encode the card on the
system level. Should the message appear again,
check the card.
Wait until desired temperature is reached and the
remaining time has expired.
Enter data.
Contact technical service of AGRU!
(Serious system error)
Connect printer or switch it on and acknowledge
error. The program tries four printing starts. In
case of another negative result, the program is
continued.
Decrease the tensile force of the pipe and repeat
the program cycle.
Unlock EMERGENCY-striking key.
Clear away positioning errors and activate the
function once more.
Contact technical service of AGRU!
Operating instruction SP 110, Rev.01 - Version 9912
31
Error no. Message/Description
NO DATAREAD
14
System files on internal memory not
available or unable to read.
SystemERROR
15
No access allowed to parallel
interface.
NO COMMUNICATION
16
Disturbance or interruption of data
transfer between operating control
unit and machine
WRONG OPERATORCODE
17
Operator tried to activate inaccessible
system functions.
MOTOR 1 TEMPERATURE
18
Motor temperature of movable
clamping unit is too high.
MOTOR 2 TEMPERATURE
19
Non applicable!
MOTOR 3 TEMPERATURE
20
Motor temperature of carriage for
planing tool and heating element is
too high.
MOTOR 4 TEMPERATURE
21
Motor temperature of planing tool
drive is too high.
MACHINE STOP
22
Welding procedure has been stopped
manually or after expiry of adjustment
time.
NO SAVE OLD DATA
23
No storage of historical data possible.
INADEQUATE POWER
24
Supply voltage is too low.
WRONG KEYCard
25
No access
WRONG CODE
26
Create a new operator code
NOT IN LIST
27
File not found
WRONG VERSION
28
Invalid format of file
POWER OFF
29
Heating element switched off
Table 5.2b: Error code
Clearance
Contact technical service of AGRU!
(New installation of system files required.)
Contact technical service of AGRU!
(Check operating control unit.)
Check plug-in connection and/or PC-cable.
See Chapter 5.3, Program Description
Acknowledge error and let motor cool down. If
the message appears again and again, have the
motor checked.
Acknowledge error and let motor cool down. If
the message appears repeatedly, have the motor
checked.
Acknowledge error and let motor cool down. If
the message appears again and again, have the
motor checked..
Acknowledge error message and end welding
procedure or repeat it.
Contact technical service of AGRU!
(Check operating control unit).
Check mains lead!
(Non-permissible line length or cross section)
Report, when trying to create a new operator card
with AGRU4
AGRU1 to AGRU3 are secured operator codes.
Only AGRU4 are recordable!
Input of correct file name
Contact technical service of AGRU!
Switch on heating element
Operating instruction SP 110, Rev.01 - Version 9912
32
Table 5.3 contains important messages, which are issued by the information line (red background).
Message/Description
Press Button
OPEN CLAMP
Table 5.3: Messages in information line
Clearance
Press the green RELEASE-key and
simultaneously activate the desired function over
the touchscreen.
Open movable clamping unit.
Operating instruction SP 110, Rev.01 - Version 9912
33
6
Weld quality and welding parameters
(valid for IR- and heating element-butt welding)
6.1 Welding bead
Ideally (normally) built-up welding bead
6.2 Weld failures
Below you find possible reasons for non-conform quality evaluated by the welder (by visual control
according DVS 2202 Part 1).
With all weld failures due to the mentioned causes it is required to repeat the welding.
Cracks
Cracks, parallel or cross to the weld
Cracks may occur:
 in the weld
 in the basic material
 in the heat affected zone
Cause: Material defect
Bead notches
Continuous or local notches in longitudinal direction of the weld
with the notch root in the basic material, for example caused:
 by insufficient joining pressure
 if pre-heating time is too short
 if cooling time is too short
Cause: Pipe dimension or type of material inadequately set, end caps not applied!
Notches and striae
Marginal notches in basic material, longitudinal or cross to the weld,
for example caused by:
 clamping tools
 inappropriate transportation
 faulty preparation of welding seam
Offset of joining areas > 10%
The joining surfaces are offset, differences in thickness are not
compensated.
Cause: Offset compensation not realised.
Operating instruction SP 110, Rev.01 - Version 9912
34
Angular deviation
for example by:
 machine malfunction
 faulty alignment
Cause: Pipe supports inadequate (e.g. at great distances)
Narrow, excessive welding bead
Excessive and sharp-edged welding bead locally or all along weld
length or weld circumference, caused by inadequate welding
parameters, in particular by:
 excessive joining pressure
Cause: Pipe dimension or type of material inadequately selected.
b
b
1
2
Non-uniform welding bead
Non-angular joining surfaces resulting in diversely built-up welding
beads locally or all along the weld length, caused for example by:
 faulty preparing of weld (improper planing)
 acceptable variation of the too beads b1  0,5 x b2
Bonding failure
No bonding or insufficient bonding on joining surfaces, locally or all
along the weld cross section, caused for example by:
 contaminated joining surfaces
 oxidised joining surfaces
Large Gaps
Voids on the joining surface, caused for example:
 if joining pressure is too low
 if cooling time is too short
Cause: Pipe dimension or type of material inadequately selected.
Pores caused by inclusions of foreign matters
Individual, largely distributed or locally frequent pores or inclusions,
caused for example by:
 vaporescence during welding (water, solvents,....)
 dirty heating element (heating element-butt welding)
(At higher wall thickness sporadic pores outside the joining area can occur.)
Operating instruction SP 110, Rev.01 - Version 9912
35
Bead Sizes
When inspecting completed welds on an SP tool, the following items should be evaluated
 The bead formation and uniformity. The previous ages provide this data on what factors to
look for when inspecting
 Weld label. On each label the words –WELDP.OK –need to be present on the label. This
indicates that all the Welding Paramters were conducted according to the procedure
 Weld label. If the weld label indicates an error, it will appear in a numeric sequence of zeros
and ones. The position of a one indicates the exact root cause of the error. See the chart and
explanation below of error checking
 Weld label. On each label, the material, diameter and wall thickness should be checked.
These items must match the pipe that the weld label is attached. Any difference indicates that
wrong paramters were enter into the touch panel and the pipe was welded at the incorrect
settings.
If errors do appear on the weld label, the actual weld production can be verified on the touch panel
by searching for the weld number. To conduct this information go to the Weld data screen located
on the first input screen (Same screen as where project name is entered)
By visually inspecting the weld and verifying the label accuracy a joint can be ceritified. While no
machine or system is full proof, combining the automation of the SP equipment with a solid
opearting and inspecting procedure should yield positive results.
In some cases, customers may want to inspect bead sizes. While measuring bead sizes is not
guarranty of weld quality, this is another option to look at to verify that the beads are in
specification. The measurement of bead size is not required, but the below chart has been made
available for PVDF per customer request.
SP110 Equipment
PVDF Only
Size
Pressure
Height
Height
Width
rating
Min
Max
Min
½” 20mm
230
0.0157
0.055
0.050
¾” 25mm
230
0.0157
0.060
0.050
1” 32mm
230
0.0157
0.067
0.060
1 ¼” 40mm
230
0.0276
0.070
0.075
1 ½” 50mm
230
0.0276
0.080
0.075
2” 63mm
230
0.0276
0.080
0.075
2 ½” 75mm
230
0.0315
0.085
0.085
3” 90mm
150
0.0315
0.092
0.075
4” 110mm
150
0.0315
0.092
0.075
Charts are for SP Equipment Only
Charts are for PVDF
Values are based on ambient welding temperatures of 20 to 25 C
Operating instruction SP 110, Rev.01 - Version 9912
Width
Max
0.120
0.130
0.135
0.160
0.170
0.170
0.175
0.190
0.190
36
6.3 Welding parameters
All welding parameters, such as pre-heating time, pre-heating temperature, joining distance, joining
pressure and cooling time are pre-set by the computer and correspond to the regulations of the DVS.
All of them are recorded completely and indicated on the touchscreen and/or stored to be retrieved
at any time. Additionally, they can be stored on a PCMCIA-card and evaluated by a PC-program.
6.4 Weld labelling
One part of quality assurance is the marking of the weld by a
safety tag. In addition to general data for identification the
quality code is printed on the tag.
After proper welding the code WELDP.OK is edited.
Weld No.
No.of tag
T
Date
Time
y
Machine number
p Pipe characteristics
e
Quality code
Failures or deviations are indicated by a eight-digit numerical code (0 = no failure, 1 = failure). In
Table 5.4 you find the explanations of the code functions.
Digit
Bit 0
Bit 1
Bit 2
Function
Joining pressure
Heating element temperature
Emergency stop (EMERGENCYkey)
Bit 3
Normal stop (STOP-function)
Table 5.4: Quality code
e.g. temperature failure:
Bit 0
0
Digit
Bit 4
Bit 5
Bit 6
Function
Joining path (pipes slipping through)
Data transfer
No function
Bit 7
Visual control
Bit 1
1
Bit 2
0
Bit 3
0
Bit 4
0
Bit 5
0
Bit 6
0
Bit 7
0
For each welding 0 to 3 tags can be selected and printed (see page 14).
Operating instruction SP 110, Rev.01 - Version 9912
37
7
Maintenance
At proper operation the welding machine SP 110 is nearly maintenance-free!
Pull out mains plug before you perform any kind of cleaning or maintenance work!
 Before starting work clean SP 110 by means of fluffiness paper and cleansing agent.
 Wipe touchpanel and heating element only by means of slightly moist fluffiness paper.
 Never apply compressed air at the machine.
7.1 Fuses
Basically, first it is required to define the cause and fix the fault before the safety cut-out is replaced and started up again (Table 7.1)!
Marking
Type/Notes
F1
B 6A, safety cut-out for planer
F2
B 10A, safety cut-out for heating mirror
F3
B 6A, safety cut-out for power pack and socket
F4
T 0,2A, glass tube fuse 5x20mm for nitrogen purging
Table 7.1: Fuses on machine panel
Additional fuses are contained within the machine (see service instructions). However, only persons
duly authorised by AGRU are allowed to open the machine.
7.2 Lubrication
Observe the following rules:
 The guides and threaded drives must always exhibit a visible grease film.
 Greasing again shall be performed at least every year!
 You should prefer repeated greasing in partial quantities to a single greasing again at the
specified time.
Lubricants
 All of the ball screw guides have to be lubricated by means of lithium base grease of consistence
class 2.
Manufacturer
Brand name
Mobil
Mobilex 2
Texaco
Multifak 2
Esso
Beacon 2
Klüber
Staburags NBU 12/300 KB
Table 7.2: Lubricants (examples)
Running distance/lubric interval
100km
100km
100km
200km
 All ball screws and fine pitch screws have to lubricated by means of roller bearing grease type
KP2K according to DIN51825.
Operating instruction SP 110, Rev.01 - Version 9912
38
7.3 Repair of failures
In the list below (Table 7.3) some disturbances are treated, their possible causes and clearance. In
case they cannot be cleared away or they are not mentioned below or if the machine components are
defective, please contact the technical service of AGRU.
Failure
Cause
Planing tool running tightly,
Planing tool knifes are dull.
planing surfaces won’t get plane
really, chatter marks.
Planing tool doesn’t work.
Safety cut-out turned off.
Heating plate surface has come
into contact with plastic.
Welding temperature not
reached.
No display shown after starting.
Printer does not react.
Control commands are not
executed.
Table 7.3: Failures of SP 110
Safety cut-out turned off.
Mains voltage too low.
Connection SP 110 =>
heating element is defectSafety cut-out turned off.
Connection SP 110 =>
operation control unit is
defect.
Connections are defect.
Position is incorrect.
Clearance
Replace planing tool knifes.
Switch on safety cut-out.
Clean cold heating element only
with paper (sharp objects would
damage the surface!)
Leave heating element switchedon. Plastic evaporates by itself
within a short period of time.
Switch on safety cut-out.
Check mains lead (dimensions).
Check plug connectors.
Switch on safety cut-out.
Check plug connector.
Check plug connection.
See chapter 5, working process.
7.4 Servicing
After 3000 welding operations and/or annual servicing intervals are required. For detailed
information please contact M/s. AGRU.
Operating instruction SP 110, Rev.01 - Version 9912
39
8
Transportation and storage
8.1 General information
 Transportation of complete SP 110 to be carried out only in original packing.
 Avoid pushes and concussions during packing and transportation.
 On transportation by a loading machine (forklift or stacker) the packed machine must be placed
on a wooden pallet.
 Transportation of SP 110 is also possible by plane.
 When shipped, the packing case must be additionally protected (from moisture).
Two men’s work is required for dismounting and mounting of the packing.
8.2 Unpacking of SP110
 Open the locks and remove the packing upper part. Take out all the accessories.
 Take SP 110 at carrying handles and lift it out of the packing lower part.
 Put on the packing upper part and fix it with locks.
 Plug in all connections correctly (see page 10).
The transport case may be used as a workbench!
8.3 Packing of SP 110
Before dismounting of SP 110:
 Move heating element and planing tool back into transport position.
 Move movable clamping unit outside to the right (zero position) in order to relieve load cell.
After switching off the SP110 wait for 1 hr. at least and let heating element cool down.
 Clean machine.
 Fasten heating element and planing tool in transport position by means of a locking screw.
 Disconnect all the electrical connections.
 Dismount operating control unit, printing unit (if applicable) and nitrogen purging unit.
 Roll up connection cables, coming directly from the SP 110 and lay them onto the machine.
 Fold down rocker arm and tighten hand screw.
 Close clamping jaws and clamp them.
 First put the SP 110 into the transport case and then stow away all the accessories at foreseen
positions.
 Put packing upper part in place and fasten it by locks.
8.4 Storage
 Store the SP 110 in the transport case in dry and weathering-resistant condition.
 Avoid high fluctuations of temperature - possible build-up of condensed water.
 As for the permissible storing temperature see chap. 3, technical description and characteristics.
Operating instruction SP 110, Rev.01 - Version 9912
40
9
Equipment and accessories
The scope of delivery comprises the parts mentioned below:
Welding machine SP 110
Quantity Description
1 pc.
Base frame with mounting and carriages
1 pc.
Heating element SP 110
1 pc.
Planing tool SP 110
1 pc.
Electronic unit
1 set
Clamping jaws SP 110 (4 pcs.)
1 pc.
Operating instructions
1 pc.
Operating control unit (Touchscreen)
1 set
Reducing inserts (4 rings, three-piece per ring) for the following pipe dimensions:
20, 25, 32, 40, 50, 63, 75 and 90 mm
1 set
Sealing caps (4 pcs. each) for the following pipe dimensions:
20, 25, 32, 40, 50, 63, 75, 90 and 110 mm
1 pc.
Plastic kit for reducing inserts
1 pc.
Entry/memory universal card (PCMCIA) mode level 3
1 pc.
Packing case
Options
Quantity
1pc.
1 roll
1 set
1 pc.
1 roll
1 pc.
1 pc.
Description
Printer with transformer installed, operating instructions and accessories
Special tags (1000 pcs.)
Reducing inserts for PureBond® PFA (½“, ¾“, 1“ and 2“) incl. PCMCIA-program
Enlargement of butt welding equipment
Thermoribbon
Nitrogen purging unit
PC-program for welding data documentation (SP-DATA)
Operating instruction SP 110, Rev.01 - Version 9912
41
10 SUPPLEMENT
10.1 Spare parts and expendable material
Quantity
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 set
1 pc.
1 pc.
1 pc
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 pc.
1 roll
1 roll
1 pc.
1 pc.
Description
Reducing inserts SP 110
Plane knife SP 110
Heating cartridge SP 110
Thermal probe SP 110
Heating element SP 110
Enlargement of butt welding
equipment SP 110
Operating control unit
PCMCIA-card
PCMCIA-card
Rocker arm, long
Transport case SP 110
Transformer for printer
Tags
Thermoribbon
Printer cable
Operating instructions SP 110
Type/Notes
OD 20
OD 25
OD 32
OD 40
OD 50
OD 63
OD 75
OD 90
hardened
10H7x155mm, 130mm heated
6H7x70mm, Pt100 special
coated
2x mounting plates, tefloncoated, incl. Screws
Touchscreen
S-RAM, 64K-Byte (AGRU4)
S-RAM, 1M-Byte (AGRU3)
600 mm, (for operating unit and printer)
230VAC/14VAC, 56VA
1000pcs., 25x40mm, narrow, polyacrylic sheet
33mmx91m, polyester resin
100 cm, parallel
Operating instruction SP 110, Rev.01 - Version 9912
42
10.2 Installation guidelines for AGRU PURAD high-purity pipeline systems
Material: PVDF-HP, PP-HP and ECTFE-HP
10.2.1
Design and pipe installation
 There should be only a minimum of welds and fittings. If possible, avoid expansion loops in overhead












pipelines. In unavoidably low pipeline sections install drain valves.
Unless otherwise agreed, install valves in all elevated or low pipeline sections. Ventilating valves and
drain valves should be furnished with a plug or cap on the discharge side.
Pipe clips must be installed in a way appropriate for plastic considering the installation guidelines acc. to
DVS 2210 part 1. In order to keep stresses low within in the system, only injection-moulded components
specifically dimensioned for the intended use shall be applied as fixed points.
The number of detachable connecting elements (flanges, screwed connections) shall be minimised. Prefer
welded connections to detachable connections.
Install flanged joins in stress-free condition. Apply cleaned sealing (e.g. Frank profiled flange sealing of
EPDM/PTFE-HP adequately cleaned and packed), realising an efficient sealing appropriate for plastic
with low starting torque’s.
Branches from the main line to a branch line with dimensions changing should possibly be performed
with zero dead-legs or the least possible by way of tees with reduced branches or by injection-moulded
instrumentation parts.
Dead-leg sections should be minimised directly by way of using bypass loops or installation of a
minimum-flow line with return function.
The inner system volume should be minimised by installing zero dead-leg valves, and highly-integrated
assembly/arrangement of component parts as well.
The ultra pure water system shall exhibit a continuous flow rate at a minimum speed of 0.5 m/s.
The system should be protected from backflow/back stroke.
Suitable component parts should be chosen at points for sampling and constitutional indication, which
also depend on the methods of analysing and testing. The components should not have dead spaces at all
or only the minimum admissible number and enable sampling directly in the volume flow
(instrumentation fitting, bacteria sampling fitting etc.).
Observe a vibration-reduced installation of pumps.
Provide devices for disinfection (e.g. zero dead-leg injection valves). Sensible components as ion
exchange resins must be secured before coming into contact with the corresponding reagents).
10.2.2
Admissible products
 The material specification comprises pipes, fittings, valves, and flow meters, which come into contact
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with super-clean/ultra-pure water.
Preferably, the raw material used for all the different systems/components should be made of identical
moulding materials.
Pipes, fitting and valves made of PVDF shall be in accordance with ISO 10931 parts 1,2,3 and 4. For
pipes and fittings made of PP DIN 8077/8078 shall be applicable.
Only pipes and fittings with the specific permission by DIBT are admitted for usage.
All components must be fabricated in clean rooms (min. class 1000) and cleaned by ultra pure water
before packaging. Packaging has to be carried out in clean rooms (min. class 100).
All extruded and injection-moulded components must have been furnished with a test certificate
according to DIN EN 10024 3.1 B.
10.2.3
Receiving inspection of products
 After cleaning all components must be packed and delivered to the place of installation.
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 The double packing should be opened only shortly before the pre-assembly or final assembly. This does
not apply to the incoming quality control (IQC), performed in a temporary clean room. After opening for
the purpose of incoming control or pre-assembly the machine must be packed again properly; the
components shall remain double-packed for further storage.
 Re-packing should correspond to the standard of the original packing, otherwise the material shall be
rejected or exposed to repeated cleaning.
 When pipes or fittings are brought into the temporary clean room, the outer packing is removed on
entering the clean area.
10.2.4
Storage of material and components at the place of installation
 Before pre-assembly or final assembly all the delivered material should be stored in a confined specific
area, adjacent to the clean room for processing.
 All incoming components for installation should be kept for intermediate storage in their original
packages in a dust-free place at room temperature, protected from sunlight. Pipe material shall be stored
horizontally - for this supports are necessary up to OD 63 mm at distances of at least 0.5 m. From OD 75
mm on supports should be at 1 m distances.
10.2.5
Clean room clothing
The clothing mentioned below must always be worn in the clean room and in the temporary clean room as
well. It must not be worn outside these areas. Damaged parts of clothes shall be replaced immediately.
 Clean room dress
 Helmet
 Plastic apron
 Protective shoes
 Protective mask
 Gloves with band
 Safety goggles or screen
10.2.6
Welding and installation
 Laying and installation may be performed only by authorised plastic welders (examination of welders
acc. to DVS 2212 part 1, subgroup 18).
 The certified plastic welder should possibly have got some experience in the installation of high-puritypiping systems in the semi-conductor industry. However, it is also possible to perform on-site welding
training of qualified specialists, who have not been experienced in HP-pipeline welding so far.
10.2.6.1 Pre-assembly
 Pre-assembly shall take place on site in a separate, temporary clean room of class 10.000.
 This room shall at any time be operated at an overpressure of 15 Pa.
 Although the components are handled in a clean room, they shall be kept closed, when they are not
processed. Sealing should be by means of PE-sheets or caps.
 Assembly and packing should be performed within the clean room on a clean workbench with a surface
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made of stainless steel or polypropylene.
Contamination of the inner surfaces of pipes and components should be avoided by careful handling.
If possible, pipe sections should be produced in the clean room, in order to minimise the amount of field
welding.
In the temporary clean room and in the entrance area no „particle-emitting“ material is admissible, such
as paper, cardboard or wood. If required, components should be stored in plastic containers.
Tacky mats should be placed at the entrance and exit, and replaced if necessary.
Packing have to be removed in the entrance area.
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10.2.6.2 Instruments and equipment
 Make available specifically selected clean-room instruments, which have to be stored separately and are
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allowed exclusively for the installation of HP-plastic piping systems.
Always consider that the heating areas must be clean and free from any material residues, which could
lead to discoloration and impure joining areas.
The instruments have to be cleaned at the beginning of each shift.
Only clean room wipers (clean and fluffiness) should be used.
All instruments, connecting equipment and heating elements, having direct contact, have to be
tefloncoated or made of stainless steel, in order to avoid contamination with metals or greases during the
joining process (this is non-applicable for IR-welding).
All instruments and areas in the clean room must be kept free from chips. It is left for the QSV to stop
any procedures which affect the quality of installation. Preparing and execution of welds.
10.2.6.3 General information on the welding technique
 The welding procedures and handling of the welding equipment, recommended by the manufacturer and
laid down in the operating instructions have to be observed.
 The procedure shall be agreed upon between the quality system manager (QSV) and the system
manufacturer well before installation.
 Also, on qualification of the welding process the acceptance criteria for the welds and test welding are
defined (coupons).
 Cutting into length should be performed by means of pipe cutters equipped with a cutting wheel. The
cutting tools should be especially suitable for this system and always kept clean.
 Cutting into length and working of the faces shall take place in clean rooms of class 1000.
10.2.6.4 General rules on installation
 The quality level of the materials should be maintained - from delivery up to the finished project.
 No smoking or eating is allowed during working time.
 Incoming control of material and marking of quality level according to the user’s standards of marking
and labelling.
 No use of gas-heated instruments is allowed.
 Pipe fitters and helpers, who are concerned with the manufacture and installation of the piping system,
must always wear clean room clothes and gloves.
 Clothes and gloves must be replaced during the shift, in case if they are worn out or damaged by
extraordinary contamination.
 Do not touch the inner surface of any kind of pipe component - neither in gloves.
 Valves and fittings must be further processed directly after unpacking and protected from contamination
at any single moment.
 Pipes and components shall be handled carefully to avoid damaging or scratching of the outer surfaces.
 The system should be purged by a filtered nitrogen stream, which is interrupted during welding. Mark
IR-welding joints by an adhesive clean tag, if possible, directly (with SP 110 an SP 250).
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11 Attestation of conformity
The manufacturer:
Ing. Wilfried HUFNAGL, Volkgasse 8, 1130 Wien
Confirms that the following described machine:
Welding machine SP 110
Corresponds to the requirements of the following European Standards:
89/392/EWG (Machine)
89/336/EWG (Electromagnetic compatibility)
73/23/EWG (Low voltage)
The following harmonised Standards have been used at the design and construction of the machine:
EN 50081-1: 1991; EN 50082-1: 1991
ÖNORM EN 292-1: 1992-03; ÖNORM EN 292-2: 1995-07
ÖVE EN 60204-1: 1993-02
Vienna, 15. 03. 1998
Ing. Wilfried Hufnagl
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12 Guarantee Claims
GUARANTEE CLAIMS AND COMPENSATION FOR AGRUWELDING EQUIPMENT SERIE SP
1. Guarantee
2. Compensation
1.1 AGRU is obliged to repair or change immediately all
parts, which are damaged or useless as a result of worse
material, incorrect construction or insufficient design.
The kind of performance and the place of repair are only
decided from us. The replaced parts will be our property.
1.2 Other guarantee claims of the buyer are excluded - also
special or tacitly promised properties of the delivery
(„dicta et promissa“).
1.3 If not agreed separately, we will only pay costs which
resulted from the repair or the replacement of the claimed
parts in our workshops.
1.4 The buyer is obliged at the loss of all guarantee claims to
inform us writtenly about the appeared damages.
1.5 The guarantee period is 6 months. It begins with the
dispatch of the shipment ex works.
1.6 The guarantee period acc. 1.5 will not be elongated by
the repair or acceptance, neither for the main delivery nor
for the new parts, also in case of the replacement of new
parts into the main delivery.
1.7 The buyer is obliged to return the claimed goods or the
claimed parts for the repair or replacement on request to
us or a from us determined third party; in that case, the
buyer takes the costs and danger of transport to us, as
well as the transport of the repaired or replaced parts
back to him.
1.8 The guarantee excludes damages as a result of natural
wear and tear, poor maintenance, disregard of working
instructions, excessive stressing, unsuitable working
supports, chemical or electrolytic influences, as well as
owing to other reasons, which are not based on our faults.
1.9 The guarantee expires if the buyer or a third party
perform changes or repairs on the delivery without our
written consent; moreover, if the buyer does not perform
suitable measures immediately in order to contain the
damage and if we can repair the fault.
1.10 From the begin of the guarantee, the vendor takes no
further liability than mentioned in this article, also not for
damages whose reason is before the danger transition.
1.11 This equipment is developed and designed for the
welding of AGRU-piping systems acc. to the best of our
knowledge and belief. AGRU takes no liability for faulty
welding joints and resulting damages, whatever it
concerns.
1.12 We have no experiences about the weldability of the
equipment with competitor products. According to this,
we cannot take over liabilities or other guarantees for the
suitability of the equipment with manifold products.
1.13 Basically, it is agreed that the operator of the machine
has to observe absolutely the corresponding operation
instructions, specially the welding guidelines and
directions from AGRU.
2.1 The compensation duty concerns us only if a gross
mistake can be proved. Compensation for an escaped
profit is excepted in any case. If the damage appears in
the from us delivered part, we are obliged to perform the
change only within the scope of the guarantee.
2.2 The purchased part offers only the security which can be
given on the basis of approval regulations, operation
instructions and regulations from our part about the
handling of the goods, specially with regard to possibly
prescribed checks and other given advises.
2.3 All compensation claims from faults on deliveries and/or
works have to be maintained legally within the
contractual decided guarantee period, otherwise expired if the fault is not accepted expressly.
3. Place of fulfilment and legal domicile
3.1 Place of contract and fulfilment is Bad Hall / Austria,
also in case that the transition is agreed for another place.
3.2 The buyer is not allowed to give his contract rights to a
third party without our consent.
3.3 The contract will be courteously in its conditions also in
case that some items will get ineffective.
3.4 The contact is subordinated to the Austrian Law.
3.5 For all indirect and direct disagreements resulting from
this contract, the factually responsible court of justice of
the company AGRU is responsible. The buyer could
also call another court of justice, which is responsible
for him.
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