STAUFF SPR-PRC-POC Operating Instructions Manual
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STAUFF SPR-PRC-POC Operating Instructions Manual

Machine for cutting ring pre-assembly and final assembly
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Operating instructions
Translation of the
original operating instructions
Machine for cutting ring
pre-assembly and final assembly
SPR-PRC-POC
To avoid injuries and damage, read these operating instructions thoroughly
and attentively. Retain it for further reference.
R3.0, valid from firmware 3.6.x, 6010014620
22-10-2020

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Summary of Contents for STAUFF SPR-PRC-POC

  • Page 1 Operating instructions Translation of the original operating instructions Machine for cutting ring pre-assembly and final assembly SPR-PRC-POC To avoid injuries and damage, read these operating instructions thoroughly and attentively. Retain it for further reference. R3.0, valid from firmware 3.6.x, 6010014620 22-10-2020...
  • Page 2 Additional operating instructions in other languages can be downloaded at www.stauff.com. Walter Stauffenberg GmbH & Co. KG Im Ehrenfeld 4 58791 Werdohl, Germany +49 2392 916-0 sales@stauff.com www.stauff.com Machine for cutting ring pre-assembly and final assembly 2 / 72 www.stauff.com...

  • Page 3: Table Of Contents

    Safety .................... 21 Switching on the machine ............. 22 Establishing readiness for operation after emergency stop ..25 Warming up the machine .............. 26 Setting up the machine ..............28 6.5.1 Language setup ..............28 SPR-PRC-POC www.stauff.com 3 / 72...
  • Page 4 7.3.10 Other faults ................ 66 8 Maintenance ..................67 Safety ................... 67 Inspection and maintenance ............67 Checking the emergency stop ............67 Checking the light curtain ............. 67 Machine for cutting ring pre-assembly and final assembly 4 / 72 www.stauff.com...
  • Page 5 Table of contents 9 Decommissioning ................68 Safety .................... 68 Dismantling ................... 69 Disposal ..................69 10 EC Declaration of Conformity ............... 70 Index ...................... 71 SPR-PRC-POC www.stauff.com 5 / 72...

  • Page 6: Information About The Instructions

    Ignoring this warning can result in serious or lethal injuries. CAUTION Ignoring this warning can result in minor or moderate injuries. ATTENTION Ignoring this warning can result in damage. Machine for cutting ring pre-assembly and final assembly 6 / 72 www.stauff.com...

  • Page 7: Structure Of Instructions

    Text marked with an information symbol provide additional information and tips. 1.5 Structure of references References are shown in this manual as follows: Example: “… only operate the machine as intended chapter 2.2, p. 9.“ SPR-PRC-POC www.stauff.com 7 / 72...

  • Page 8: For Your Safety

    Take the machine out of service until the fault is rectified. • Components – except tools – only replaced Walter Stauffenberg GmbH & Co. KG. Machine for cutting ring pre-assembly and final assembly 8 / 72 www.stauff.com...

  • Page 9: Intended Use

    The assembly parameters stored in the machine apply solely to the use of an original STAUFF cutting ring FI-DS-.. in combination with the selected tube material and the original STAUFF union nut. .

  • Page 10: Personnel Qualification

    2.5 Personal protective equipment The following personal protective equipment is mandatory for those working on the machine: Wear close-fitting work clothes! Wear safety boots! Machine for cutting ring pre-assembly and final assembly 10 / 72 www.stauff.com...

  • Page 11: Safety Labels

    2.6 Safety markings The following safety markings are attached to the machine in a clearly visible and legible manner: Warning – dangerous electrical voltage! ISO 7010 – W012 Warning – hand injuries ISO 7010 – W024 SPR-PRC-POC www.stauff.com 11 / 72...

  • Page 12: Safety Devices

    To reactivate the machine, the triggered emergency stop has to be unlocked (Establishing readiness for operation after emergency stop). Light curtain Electrical main switch Emergency stop button Fig. 1: Safety devices Machine for cutting ring pre-assembly and final assembly 12 / 72 www.stauff.com...

  • Page 13: Securing The Machine Against Reactivation

    (not included in the delivery). 2. Switch off the machine as described. 3. Secure the electrical main switch with a padlock. Fig. 2: Electrical main switch protected with padlock  The machine is secured against reactivation SPR-PRC-POC www.stauff.com 13 / 72...

  • Page 14: Machine Description

    At the rear of the machine Power supply At the rear of the machine Foot switch connection At the rear of the machine Optional tool holder Tool holder offset to the top Machine for cutting ring pre-assembly and final assembly 14 / 72 www.stauff.com...

  • Page 15: Technical Data

    42 mm can be used. Pre-assembly mode and final assembly mode are available. For more information on final assembly, please follow the detailed instructions in the assembly instructions in the STAUFF Connect product catalogue. The machine is used together with assembly studs and counter- retaining plates specially designed for mechanical mounting.

  • Page 16: Type Plate

    • LL stands for the Extra-Light Series • L stands for the Light Series • S stands for the Heavy Series Please refer to the STAUFF Connect product catalogue for additional information on selecting the size. 3.5 Type plate The type plate is located on the side of the machine.

  • Page 17: Spare Parts And Wear Parts

    ► Only use suitable tools in proper condition! ► Replace components only with genuine spares or those authorised by the manufacturer. Lists of authorised spare and wear parts can be obtained from Walter Stauffenberg GmbH & Co. KG. SPR-PRC-POC www.stauff.com 17 / 72...

  • Page 18: Transport And Storage

    • Transport may only be carried out by an authorised specialist company or by qualified personnel. • Dispose of all packaging material in a proper and environmentally compatible manner after transport. Machine for cutting ring pre-assembly and final assembly 18 / 72 www.stauff.com...

  • Page 19: Installation

    Risk of shearing off and crushing fingers ► Ensure before start-up that all safety equipment is properly installed and in working order. ► Ensure your fingers are not in the assembly area when operating the machine! SPR-PRC-POC www.stauff.com 19 / 72...

  • Page 20: Installing The Machine

    • all parts are mounted correctly, are undamaged and in full working order • all outer fittings are installed and fully tightened • all safety devices are functioning chapter 8.3, p. 67 and chapter 8.4, p. 67. Machine for cutting ring pre-assembly and final assembly 20 / 72 www.stauff.com...

  • Page 21: Operation

    CAUTION Faulty safety devices Danger from the operator interfering with the safety equipment ► Before startup of the machine, ensure that all safety devices are installed correctly and are functioning. SPR-PRC-POC www.stauff.com 21 / 72...

  • Page 22: Switching On The Machine

    Fig. 8: Menu – Language settings 3. Press the button for the language to be set.  The language set appears at the top of the menu; this means the language is set. Machine for cutting ring pre-assembly and final assembly 22 / 72 www.stauff.com...
  • Page 23 7. If no tool is inserted, the message Insert tool pairwise! is shown.  Fig. 10: Start screen 8. If the message Insert tool pairwise! is shown, insert the tool. When the tool has been inserted, the Setup > order menu appears. SPR-PRC-POC www.stauff.com 23 / 72...
  • Page 24  The machine is ready for operation. The reference run is cancelled. Please refer to chapter 6.4, p. 26 if the machine cancels the reference run and the warm-up message appear. Machine for cutting ring pre-assembly and final assembly 24 / 72 www.stauff.com...

  • Page 25: Establishing Readiness For Operation After Emergency Stop

    1. Eliminate the fault as described in chapter 7, p. 57. Fig. 12: Menu – Setup > order 2. Release the Emergency stop button. 3. Press the Acknowledge button.  The Startup program runs message appears. Fig. 13: Menu – Setup > order SPR-PRC-POC www.stauff.com 25 / 72...

  • Page 26: Warming Up The Machine

    In this case, the machine has to be warmed up with the warm-up program. Machine for cutting ring pre-assembly and final assembly 26 / 72 www.stauff.com...
  • Page 27 5. When the warm-up program has been completed, a confirmation is shown on the screen. 6. Press the Home button to return to the Reference run menu. Reference run interrupted again Repeat the warm-up process for the machine. SPR-PRC-POC www.stauff.com 27 / 72...

  • Page 28: Setting Up The Machine

    2. Press the button for the language to be set.  The set language is shown at the top of the menu. 3. Press the Home button to exit the menu.  The language is now set. Machine for cutting ring pre-assembly and final assembly 28 / 72 www.stauff.com...

  • Page 29: Setting Up The System Properties

    Fig. 20: Menu – Setup > order  The Properties > level menu opens. 2. In the Properties > level menu, press the System button. Fig. 21: Menu – Properties > level  The System properties menu appears. SPR-PRC-POC www.stauff.com 29 / 72...
  • Page 30 1. Press the date/time display and enter the desired data. Fig. 23: Setting the time  How to see information on the quantity for each tool size: 1. Press the Tool counter button. Fig. 24: Tool counter Machine for cutting ring pre-assembly and final assembly 30 / 72 www.stauff.com...
  • Page 31 1. Press the Material counter button. Fig. 25: Material counter  How to access the Warm-up menu: 1. Press the Warm-up button. Fig. 26: Warming up Please refer to chapter 6.4, p. 26 if the Warm-up message is shown. SPR-PRC-POC www.stauff.com 31 / 72...
  • Page 32 Reset OK quantity button in the Quantity menu.  The OK quantity menu opens. Fig. 28: Menu – Reset quantity counter 2. Press the Reset button.  The actual production quantity number is reset. Machine for cutting ring pre-assembly and final assembly 32 / 72 www.stauff.com...

  • Page 33: Setting Up The Tool

    Damage to the machine caused by different sizes of the assembly stud and counter retaining plate ► Ensure that the same tool sizes are used. Using different tool sizes can result in damage to the tools! Correct cutting ring assembly is not possible. SPR-PRC-POC www.stauff.com 33 / 72...
  • Page 34 4. Place the assembly stud into the socket and attach with the split pin. Fig. 31: Attaching the assembly stud 5. Insert the counter retaining plate with the size label facing upwards. Machine for cutting ring pre-assembly and final assembly 34 / 72 www.stauff.com...
  • Page 35 6. Align tool size with the display in the Setup > order menu. Fig. 33: Menu – Setup > order 7. Press and hold the Reference run / push and hold button.  The reference run has been completed.  The machine is ready for operation. SPR-PRC-POC www.stauff.com 35 / 72...

  • Page 36: Setting The Operating Mode

     How to activate button mode: 1. In the Setup > order menu, press the Properties button.  The Properties > level menu appears. Fig. 34: Menu – Properties > level Machine for cutting ring pre-assembly and final assembly 36 / 72 www.stauff.com...
  • Page 37  The System properties menu appears. Fig. 35: Menu – System properties 4. Press the Light curtain <.> Button - Light curtain active button.  The PIN prompt opens. Request the PIN from Stauff. Fig. 36: Menu – System properties 5. Enter the PIN.

  • Page 38: Setting Button Mode With Foot Switch

    6.7.3 Setting button mode with foot switch The foot switch is not included in the delivery. The foot switch can be ordered from STAUFF. Button mode with foot switch is only possible is a foot switch is installed. Machine for cutting ring pre-assembly and final assembly 38 / 72 www.stauff.com...
  • Page 39 2. In the Properties > level menu, press the System button.  The System properties menu appears. Fig. 40: Menu – System properties 3. Press the Foot switch option – foot switch inactive button.  The PIN prompt opens. Request the PIN from Stauff. SPR-PRC-POC www.stauff.com 39 / 72...
  • Page 40 5. Press the Home button to exit the menu.  The Foot switch active message appears in the Setup > order menu.  The machine is in button mode with foot switch. Machine for cutting ring pre-assembly and final assembly 40 / 72 www.stauff.com...

  • Page 41: Setting Up The Job

    4. Set the assembly type chapter 6.8.1, p. 42. 5. Set the material chapter 6.8.2, p. 43. 6. Set the production quantity chapter 6.8.3, p. 43. 7. Tube size by selecting the tool chapter 6.6, p. 33. SPR-PRC-POC www.stauff.com 41 / 72...

  • Page 42: Setting The Assembly Type

    1. In the Setup > order menu, press the assembly type button.  The Setup > assembly menu opens. Fig. 45: Menu – Setup > assembly 2. Press the Automatic or Manual pressure input button. Machine for cutting ring pre-assembly and final assembly 42 / 72 www.stauff.com...

  • Page 43: Setting The Material

     The selected material and associated size are displayed. 6.8.3 Setting the production quantity  How to set up the production quantity: 1. In the Setup > order menu, press the production quantity button.  The input pad for entering the quantity opens. SPR-PRC-POC www.stauff.com 43 / 72...

  • Page 44: Setting The Pressure For Manual Pressure

    1. In Setup > order menu, press the Program button.  The window for program selection opens. 2. Select the Manual program.  The Remove tool message appears. Machine for cutting ring pre-assembly and final assembly 44 / 72 www.stauff.com...
  • Page 45 6. The Check movement range message appears. Fig. 50: Menu – Setup > order 7. Press and hold the Reference run / push and hold button. 8. Press the Set press. in bar button in the Processing order menu. SPR-PRC-POC www.stauff.com 45 / 72...

  • Page 46: Preparing The Workpiece

    If an error message is shown, refer to chapter 7.2, p. 58 6.9 Preparing the workpiece The assembly parameters stored in the machine apply solely to the use of an original STAUFF cutting ring FI-DS-.. in combination with the selected tube material and the original STAUFF union nut.
  • Page 47 Fig. 53: Inserting the workpiece 6. Insert the tube end into the assembly stud and ensure that the union nut is pushed onto the assembly stud. This stops any tilting of the union nut during assembly. SPR-PRC-POC www.stauff.com 47 / 72...

  • Page 48: Assembling A Cutting Ring

    4. Ensure that the workpiece has been prepared chapter 6.9, p. 46.  The Insert tube, push tube button is displayed in the Processing order menu. Fig. 55: Processing order Machine for cutting ring pre-assembly and final assembly 48 / 72 www.stauff.com...

  • Page 49: Assembling A Cutting Ring In Manual Pressure Mode

    This will invalidate the liability by Walter Stauffenberg GmbH & Co. KG. The data can be viewed after assembly. Please refer to chapter 6.11, p. 53 SPR-PRC-POC www.stauff.com 49 / 72...

  • Page 50: Assembling A Cutting Ring In Button Mode

    4. Ensure that the workpiece has been prepared chapter 6.9, p. 46.  The Insert + push tube, then press + hold Acknowledge button is displayed in the Processing order menu. Machine for cutting ring pre-assembly and final assembly 50 / 72 www.stauff.com...
  • Page 51 The cutting ring is assembled in line with the assembly type selected. 8. Checking the product chapter 6.11, p. 53 9. Continue assembly until the production quantity is 0.  The job has been processed. SPR-PRC-POC www.stauff.com 51 / 72...

  • Page 52: Assembling A Cutting Ring In Button Mode With Foot Switch

     The machine presses the assembly stud against the counter retaining plate, assembling the cutting ring. The cutting ring is assembled in line with the assembly type selected. 8. Checking the product chapter 6.11, p. 53 Machine for cutting ring pre-assembly and final assembly 52 / 72 www.stauff.com...

  • Page 53: Checking The Product

    3. The Actual data menu can be used for a quality assessment of the assembly process. To do this, press the Actual data button in the Processing order menu.  The Edit order > Actual data menu opens. SPR-PRC-POC www.stauff.com 53 / 72...

  • Page 54: Completing The Job

     The product has been checked. The machine is ready for operation. 6.12 Completing a job  How to set up a new job when the job is completed: 1. The Processing order main menu is open. Machine for cutting ring pre-assembly and final assembly 54 / 72 www.stauff.com...

  • Page 55: Final Assembly In The Fitting Body

    For final assembly in the fitting body, follow the detailed instructions – depending on the selected assembly type – in the assembly instructions in the STAUFF Connect product catalogue. 6.14 Cleaning the machine The machine and its components have to be cleaned after each use.

  • Page 56: Switching Off The Machine

    1. Ensure that …  the job is completed. Fig. 64: Job completed 2. Turn the main switch to “0 / OFF”. The machine is switched off.  Machine for cutting ring pre-assembly and final assembly 56 / 72 www.stauff.com...

  • Page 57: Troubleshooting

    ► Only Walter Stauffenberg GmbH & Co. KG may carry out work which involves opening up the machine! ► Wear your personal protective equipment including safety goggles for all work undertaken on the hydraulic system! SPR-PRC-POC www.stauff.com 57 / 72...

  • Page 58: Troubleshooting

    • appropriate personal protective equipment is worn for all troubleshooting work chapter 2.5, p. 10. Listed below are the faults which can be corrected by the operating personnel. Machine for cutting ring pre-assembly and final assembly 58 / 72 www.stauff.com...

  • Page 59: Malfunctions/Error Messages

    • Wrong diameter • The tube material and the entered parameters do not correspond • Strength too high • Strength too low Cutting ring • Oval cross section • Damaged • Strength (too hard/too soft) SPR-PRC-POC www.stauff.com 59 / 72...

  • Page 60: Pressure: " Set Pressure Too High. Displayed Value Is Max. Pressure. Confirm By Entering New Value

    Control • Manually entered pressure too high is max. pressure! Confirm by entering for the size, machine reduces the new value.” pressure. Press “Acknowledge” and eliminate the fault Machine for cutting ring pre-assembly and final assembly 60 / 72 www.stauff.com...

  • Page 61: Path: "Position Detection

    Error message on the machine Cause display: Position detection Cutting ring • Wrong size • Wrong alignment Press “Acknowledge” and eliminate • Oval the fault • Wrong geometry • Wrong size • Dirty surface • Wrong alignment • Tilted SPR-PRC-POC www.stauff.com 61 / 72...

  • Page 62: Light Curtain: "Light Curtain

    7.3.4 Light curtain: “Light curtain” Fig. 68: Light curtain activated Error message on the machine Cause display: Light curtain Light curtain • Is activated. Press “Acknowledge” and eliminate the fault Machine for cutting ring pre-assembly and final assembly 62 / 72 www.stauff.com...

  • Page 63: Tube Not Pressed On

    7.3.6 Piston not retracting Error message on the machine Cause display: Controller errors Control • Control fault. Contact the manufacturer. Press “Acknowledge” and eliminate the fault 7.3.7 Tool not detected Fig. 70: Inserting tools in pairs SPR-PRC-POC www.stauff.com 63 / 72...
  • Page 64 Insert tools in pairs, although tool has Tool • Tool sensor already been inserted • RFID chip missing at the counter retaining plate • Tool sensor defective • RFID chip not programmed Machine for cutting ring pre-assembly and final assembly 64 / 72 www.stauff.com...

  • Page 65: Reference Run Interrupted

    6.4, p. 26 7.3.9 Wrong turning direction Fig. 72: Wrong turning direction Error message on the machine Possible cause display: Power supply Wrong turning direction • Power supply connected correctly or phase reverser in wrong position. SPR-PRC-POC www.stauff.com 65 / 72...

  • Page 66: Other Faults

    Fault: Machine does not start • Power supply not switched on • Cable or connector damage • Screen defective Warm-up run • See chapter 6.4, p. 26 Machine for cutting ring pre-assembly and final assembly 66 / 72 www.stauff.com...

  • Page 67: Maintenance

    1. Switch on and start the machine. 2. Trigger the light curtain and check whether the machine stops. 3. Reset the emergency stop circuit with the Acknowledge button (Establishing readiness for operation after emergency stop).  The machine can be restarted. SPR-PRC-POC www.stauff.com 67 / 72...

  • Page 68: Decommissioning

    ► Only Walter Stauffenberg GmbH & Co. KG may carry out work which involves opening up the machine! ► Wear your personal protective equipment including safety goggles for all work undertaken on the hydraulic system! Machine for cutting ring pre-assembly and final assembly 68 / 72 www.stauff.com...

  • Page 69: Dismantling

    1. Use appropriate containers to collect, store, transport and dispose of substances with water toxicity. 2. Dispose of all parts separated by materials at the appropriate disposal points. 3. Always sort by materials for recycling. SPR-PRC-POC www.stauff.com 69 / 72...

  • Page 70: Ec Declaration Of Conformity

    10 EC Declaration of Conformity 10 EC Declaration of Conformity Machine for cutting ring pre-assembly and final assembly 70 / 72 www.stauff.com...

  • Page 71: Index

    Switching off Switching on Installation Tasks of the operating company Machine Technical data Installing Transport Switching off Troubleshooting Switching on Type plate Overview 12,16 Warnings Operating company Task Personal protective equipment Personnel Protective equipment Qualification References SPR-PRC-POC www.stauff.com 71 / 72...
  • Page 72 Let us know about any questions, suggestions or criticism you might have about your product or this documentation. 72 / 72...

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