PF Monomatic Manuel utilisateur

S c h w e i ß t e c h n o l o g i e G m b H

Karl-Bröger-Str.10 DE-36304 Alsfeld Tel:+49-6631-9652-0 Fax:+49-6631-9652-52

System Welding Device

PF – monomatic

PF-Schweißtechnologie GmbH –Karl-Bröger-Str. 10 –DE-36304 Alsfeld

Tel.: +49-(0)6631-9652-0 Fax.: +49-(0)6631-9652-52

Rev.: 2004-001-GB

Table of contents

1Introduction........................................................................................4

1.1

Maintenance periods.............................................................................................................. 4

2Scope of application and technical data..........................................4

2.1

Scope of application............................................................................................................... 4

2.2

Input of welding parameters ................................................................................................... 4

2.3

Range of fitting dimensions.................................................................................................... 5

2.4

Technical data........................................................................................................................ 5

3Important safeguards........................................................................7

4Controls and Plugs............................................................................8

5Power Connection .............................................................................9

5.1

Generator suitability ............................................................................................................. 10

6Starting a welding process.............................................................10

6.1

Preparation........................................................................................................................... 10

6.2

Welding with the FUSAMATIC

-Mode.................................................................................. 12

7Other Functions...............................................................................14

7.1

Function menu ..................................................................................................................... 14

7.2

Adjusting the display contrast...............................................................................................14

7.3

System configuration / Change language ............................................................................. 15

8Trouble shooting..............................................................................16

8.1

Replacing Welding Terminals............................................................................................... 16

8.2

Adapter ................................................................................................................................ 16

8.3

Start messages .................................................................................................................... 16

8.4

Error messages.................................................................................................................... 17

9Conformity Declaration ...................................................................19

Please note the safeguards in chapter 3

Rev.: 2004-001-GB

1 Introduction

Dear customer,

we thank you for the confidence in our product and wish you a contented work with it.

The present instructions manual includes, beside the description of the use of the devices, important

notes for your safety and the scope of application. Therefore, you should read carefully the present

instructions manual before the first use of the device. In case of failure or interruption of the workflow

read the appropriate chapter of this manual. Self-evidently we are ready to assist you at any time:

PF-Schweißtechnologie GmbH

Karl-Bröger-Str. 10

DE-36304 Alsfeld

Tel.: +49-6631-9652-0

Fax: +49-6631-9652-52

All notes and technical specification in this instructions manual were prepared with all necessary care.

The manufacturer keeps the right to make technical changes at the device, which are not directly

included into the present instructions manual.

1.1 Maintenance periods

Please note, that the bought product is a technically demanding machine for field application. In

accordance to the applicable standards like DVS 2208-1, BGV A2, ISO 12176-2 and most national and

international standards, these machines have to be subjected to a periodical maintenance. The

maintenance period is 12 month. When the machine is used quite often the maintenance should be

carried out more often.

During the maintenance the machine will be upgraded to the current technical state. Additionally you get

a 3-month function guarantee for the maintained device.

The maintenance and the related checks are important for you safety and the continuous working

reliability of the control unit. Therefore the maintenance and all necessary repairs, have to be carried out

by the manufacturer or a authorised service point.

2 Scope of application and technical data

2.1 Scope of application

The electro fusion control units of type Monomatic are exclusively for the electro fusion of thermoplastic

pipes (e.g. made of PE-HD, PE80. PE100 or PP) by use of electro fusion fittings with an welding voltage

lower than 48V . The control units are conform to the standard DVS 2208-1 as well as the ISO 12176-2,

which refer to the standards applicable for the electro fusion fittings to be used.

It is not allowed to use the electro fusion controllers, to which the present instruction manual refers to, for

an application not covered by the above stated terms. The manufacturer is not liable for the use of the

machine out of the scope of application.

2.2 Input of welding parameters

The electro fusion controllers of type Monomatic provides the following means for entering the welding

parameters:

FUSAMATIC-System:

By reading out the reference resistance in the connector pins of the FUSAMATIC-Fitting the control unit

automatically takes over the welding data of the fitting.

Rev.: 2004-001-GB

2.3 Range of fitting dimensions

For which range of fitting dimensions a electro fusion control unit can be used depends essentially on the

power consumption to the used fittings itself. Since the power consumption of the fittings are different for

different fitting manufacturers, a general statement concerning this point is hardly to make. In case of

doubt, each single case has to be checked separately. For electro fusion control units of the type

Monomatic the following general statement can be made, with the assumption, that all welding

processes were made one after the other, i.e. that the control unit is able to cool down during the

preparation time of the next fitting:

Note: The Monomatic control unit can be used for FUSAMATIC fittings only.

Use for dimension 20-355mm without any limit.

From a diameter for 400mm and higher there must be provided longer off-times to ensure a cooling

down of the control unit (Error message “Device too hot”). Before processing fittings in this dimension

range, you have to check that the welding current of the fitting does not exceed the maximum output

current of the control unit.

All above made statements refer to an ambient temperature of 20°C.

2.4 Technical data

Technical Data –Technische Daten Monomatic

ISO 12176-2 Class - Klassifizierung P23 U S1F A M

Input Voltage -Eingangsspannung 230V ~/AC, (185V-300V)

Input Current - Eingangsstrom 16A

Input Frequency - Eingangsfrequenz 50Hz (40-70Hz)

Output Voltage - Ausgangsspannung 40V

Output Current - Ausgangsstrom 60A (max.: 80A)

Power Consumption - Leistungsaufnahme 3200VA

Temperature Range -Arbeitstemperatur -10°C - +50°C

Protection Class - Gerätesicherheit IP54, Class 2

Weight incl. Cables - Gewicht inkl. Kabel 18kg

Main Supply Cable - Netzkabel 4,5 m (Euro-Plug –Euro-Stecker)

Welding Cable - Schweißkabel 5m (fixed –fest)

Welding Terminals - Anschlußkontakt 4,7mm (opt. 4,0mm)

Display - Display 4 x 20 Characters (alphanum.), background lighting

4 x 20 Zeichen (alphanumerisch), Hintergrundbeleuchtung

Dimension - Abmessungen 440mm x 380mm x 320mm

Monitoring Functions -

Überwachungsfunktionen

Input - Eingang Voltage / Current / Frequency

Spannung / Strom / Frequenz

Output - Ausgang Voltage / Resistance / Contact / Short circuit / Current Monitoring

Spannung / Widerstand / Kontakt / Kurzschluß /

Stromüberwachung

Other - Sonstige System / Working Temperature / Service

System / Arbeitstemperatur / Wartung

Error Messages - Fehlermeldung Plain Text / Acoustic Signal

Klartext im Display / Dauerwarnton

Enclosed Parts - Lieferumfang Control Box, Transport Box, Instructions Manual

Gerät, Transportbox, Bedienungsanleitung

Rev.: 2004-001-GB

Technical Data for 110V Control Units

Technical Data –Technische Daten Monomatic

Input Voltage -Eingangsspannung 110V ~/AC, (90V-150V)

Input Current - Eingangsstrom 40A

Input Frequency - Eingangsfrequenz 50Hz (40-70Hz)

3 Important safeguards

Before turning on the welding device, please, read this operating instructions as well as

the relevant safety and processing directions carefully.

Warning! With the use of electric tools you have to note the following basic safety

direction to protect against electric shock, injury and fire.

1. Keep your working area in order !

Disorder involves a certain danger.

2. Consider the influence of environment !

Do not expose electro tools to rain. Do not use electro tools in wet or damp surroundings or in the

neighbourhood of combustible liquids or gases.

3. Protect yourself against electric shock !

Avoid body contact with grounded components (e.g. radiators, metal pipes) or live cables. Do not carry

the device, with the finger on the power switch. Pull out the plug when you do not use the tool or when

changing the adapters and attachments.

4. Keep unauthorized people and children away !

Do not allow other people touch the device or cables –keep them away from your working place.

5. Store up your device safely !

Unused machines should be kept in a dry and locked room, inaccessible for children and unauthorized

people.

6. Use permitted accessories only!

Do only use accessories, especially current sources and lengthening cables, that are stated in the

operating instructions or recommended by us. The use of attachments, that are not stated in the

operating instructions, involves a certain danger for you. Do only use permitted and marked lengthening

cables outdoors.

7. Do not expose the cables to avoidable loads !

Do not carry the machine with the cable and do not use the cable to pull out the plug. Protect the cables

against heat, oil and sharp edges.

8. Lock after your tools carefully !

Keep your device clean. Follow the servicing instructions and the instructions for changing the tools.

Keep oil and grease away from the straps.

9. Check your device for damages !

Check your tools before every use for damages and function of the protection devices and machine

parts. All parts have to be mounted in the right way. They have to fulfil all conditions for a impeccable

running of the tool. Damaged protection devices and machine parts have to be repaired or replaced by

an authorized service point.

Rev.: 2004-001-GB

4 Controls and Plugs

(1) DISPLAY

(2) START

(3) STOP

(7)

(6)

(5)

(4)

(4) Power Switch

(5) Welding Cable

(6) Cable Holder

(7) Power Supply Cable

Rev.: 2004-001-GB

5 Power Connection

The connecting conditions of EVU, the VDE-directions, the accident prevention

regulations, DIN/CEN-regulations as well as national regulations have to be

considered.

Electro Fusion Control Units have to be used by operators, which are trained and authorised conform the

national and international standards and directives, only. The operator has to supervise the electro fusion

control box during the whole fusion process.

The electro fusion control unit has to be used within the following ranges:

Parameter 230V Control Units 110V Control Units

Input Voltage: 185V –300V (AC) 90V –150V (AC)

Input Frequency:: 40Hz –70Hz 40Hz –70Hz

Ambient Temperature: -10°C –+50°C -10°C –+50°C

Max. Output Power: 3600W 3600W

Caution: 110V Control Units shall not be used at 230V power supply and vice versa.

When operating on a electric distributor or the main power supply of nominal 230V, a min. 16 Amps slow

fuse comprising a residual current-operated protective device (RCCB) should be used (110V: min.

32Amps).

Extension Cables:

To extend the power supply cable you have to follow the following rules:

Cable length Cross Section (230V) Cross Section (110V)

Up to 20m 3 x 1.5mm² 3 x 4mm²

20 to 50m 3 x 2.5mm² 3 x 4mm²

50-100m 3 x 4mm² -

It is not allowed to extend the welding cable!

Important notes for the use of generators:

• First start generator, then plug in the device.

• No other machine or device shall be connected to the generator

• The idle running voltage should be regulated to 240V – 260V (AC) at nominal 230V

(nominal 110V: 120V –130V (AC)).

• Plug out welding device before turning off the generator.

• The usable generator power will decrease by 10% per 1000m height.

• Check the fuel level before starting the welding process.

Rev.: 2004-001-GB

5.1 Generator suitability

The Electro Fusion Controllers of type Monomatic provide the following means to increase the generator

suitability:

• Wide tolerance for input voltage and Input frequency.

• Display of current input voltage and frequency.

• Soft-Start for limitation of the generator load.

Despite this characteristics, the generators to be used have to fulfil the following requirements and

recommends, in order to avoid damaged of the control unit and to ensure that the internal monitoring

function of the control unit will not interrupt the welding process:

• suitable to drive inductive loads and phase cut systems

• no-load voltage adjustable to 240V –260V at nominal 230V (nominal 110V: 120V – 130V

(AC)).

• output current of 18 Amps at one phase at nominal 230V (nominal 110V: 36Amps).

• stable output voltage and engine speed, also at fast alternating loads

• synchronous generators with mechanical speed control preferred

• voltage peaks must no exceed 800V

Min. required generator output power 230V, 50Hz, 1-phase

Diameter Output Power

20-75 mm 2kW

90-160 mm 3,2kW

180-710mm 4.5kW (mechanically controlled)

5kW (electronically controlled)

For generators with insufficient control performance or voltage control it has to be selected 3-3.5 times

higher output power than the stated ones to achieve an undisturbed operation. Electronically controlled

generators tent to oscillate with the control of the welding process, which can lead to high output voltage

peaks. Please, test suitability before using that kind of generators.

Manufactures like HONDA, EISEMANN, GEKO, FISCHER, PANDA and KIRSCH provide generators

performed especially for this kind of application.

Caution: 110V Control Units shall not be used at 230V power supply and vice versa.

6 Starting a welding process

6.1 Preparation

Before starting you have to carry out the following steps in the given order:

1. Check the device, cables and adapters visually. If necessary you have to replace them.

2. Plug in Detachable welding cables.

3. Unroll welding, power and extension cables completely.

4. Switch of the Power Switch of the control unit.

5. Start the generator before you plug in the control unit. Wait until the generator output

voltage has stabilized.

6. Plug in the power cable of the control unit.

7. Switch on the power switch.

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