+GF+ KL 630 Operating Instructions Manual

Butt fusion machine

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

KL 630

Butt Fusion Machine

Operating Instructions

Table of Contents

Need help?

Do you have a question about the KL 630 and is the answer not in the manual?

Questions and answers

Summary of Contents for +GF+ KL 630

Page 1 KL 630 Butt Fusion Machine Operating Instructions...
Page 2 TRADUZIONE DALL'ORIGINALE TRANSLATION FROM ORIGINAL COPY All rights reserved, in particular the rights of duplication and distribution as well as translation. Duplication and reproduction in any form (print, photocopy, microfilm or electronic) require the written permission of Georg Fischer Omicron S.r.l..
Page 3: Table Of Contents
Operating instructions KL 630 Table of contents Table of contents Page About this manual Warning notice Other symbols and notices Abbreviations Safety instructions Proper use General safety measures Working with safety in mind Disposal General Introduction Range of application Copyright...
Page 4 Table of contents Operating instructions KL 630 Failure analysis Maintenance Replacement of worn parts Hydraulic system Hydraulic unit 10 Customer Service...
Page 5: About This Manual
Operating instructions KL 630 0 About this manual About this manual The warning notices, symbols and their meanings as used in this manual are explained below to help you quickly understand the format of this instruction manual and how to use the machine safely.
Page 6: Other Symbols And Notices
0 About this manual Operating instructions KL 630 Other symbols and notices Symbol Meaning Attention Mandatory: you must observe this regulation Advise Suggest: This notice contains especially important information Abbreviations Abbr. Meaning KL 630 Butt fusion machine d 315–630 mm Electronic Remote Control (temperature regulator) Deutscher Verband für Schweisstechnik...
Page 7: Safety Instructions
Complete documentation should be kept in the vicinity of the machine. Proper use The KL 630 is to be used exclusively for the fusion of pipes and fittings made of PE, PP and PVDF. Any other use is not permitted. General safety measures •...
Page 8: Working With Safety In Mind
Always keep safety in mind while working. For your own personal safety as well as for the safe and optimal handling of the machine, the KL 630 must be installed correctly. Connect hydraulic hoses to and from the machine only when the hydraulic unit is shut off and not under pressure (observe manometer).
Page 9: Disposal
Operating instructions KL 630 1 Safety instructions Disposal Shavings and used hydraulic oil should be disposed of properly. Observe all the regulations, standards and guidelines applicable in your country. Separate collection of electronic and electrical waste (from the equipment) has to be ensured through appropriate systems.
Page 10: General
General Introduction This instruction manual was written for those persons responsible for the operation and care of the KL 630. It is expected and assumed that such persons have read, understood and will abide by the manual in its entirety.
Page 11: Copyright
Operating instructions KL 630 2 General Copyright The copyright for this instruction manual is held by Georg Fischer Omicron S.r.l.. This instruction manual is intended for assembly, operation and maintenance personnel. No part of the technical regulations or illustrations contained herein may be reproduced or distributed in any form, used illicitly for competitive purposes or passed on to others.
Page 12: Product Design, Equipment
3 Product design, equipment Operating instructions KL 630 Product design, equipment KL 630 Versions All KL 630 versions are included in this operating manual. In the following table are located all the components and technical features for each version. Descrizione...
Page 13: Standard Equipment
Operating instructions KL 630 3 Product design, equipment Standard equipment • Base machine (TOP1, TOP2) – Hardened and hard chrome-plated guide shafts – Third clamp is adjustable – Automatic detachment device for heating element – Tool and wrench set •...
Page 14 3 Product design, equipment Operating instructions KL 630 • Three phase Temperature remote control (TOP1, TOP2) – Metal case with Microprocessor assisted remote control – Digital display, status indicators, temperature and offset adjustments – Versions: only 400V 3~ • Hydraulic hose package (TOP1, TOP2) –...
Page 15: Technical Specifications
Operating instructions KL 630 4 Technical specifications Technical specifications Mod.: Voltage Power (max.) Weight packaging excluded KL 630 Top1 400V 3~ 11000 W – 26 A 486 kg KL 630 Top1 230V 3~ 11000 W – 36 A 490 kg...
Page 16: Transport And Assembly
Sensitivity Special care must be taken when transporting the KL 630 in order to prevent damage from impact or improper loading and unloading. All movable parts must be fixed in place.
Page 17: Fusion Preparation
For optimal use of the KL 630, operating personnel should be specially trained by Omicron. In-depth knowledge of the machine and it´s components and competence rule out handling errors thereby also preventing faulty fusion joints.
Page 18: Top1 Version Preparations
6 Fusion preparation Operating instructions KL 630 TOP1 version preparations 1. Connect hydraulic unit, planer and heater to the control box. 2. Connect control box to the power outlet. Check the voltage!! Caution 3. Main power (2) switch on. Control lamp (4) turns white.
Page 19: Functions Of The Temperature Regulator
Operating instructions KL 630 6 Fusion preparation 6.4.1 Functions of the temperature regulator The LED (1) is permanent ON when the power is connected and the display is showing the current heating element temperature. When flashing the temperature is regulated at the set point.
Page 20: Error Message Of The Temperature Regulator
6 Fusion preparation Operating instructions KL 630 By pressing the button (5) or (4) the value could be increased or decreased, the range is between +/- 25°C. Advise If the difference between the measured temperature on the heater plate surface and the displayed temperature on the temperature regulator is out of the range +/- 25°C, please contact your next service...
Page 21: Fusion
Operating instructions KL 630 7 Fusion Fusion The basics of butt fusion For butt fusion with a heating element, the parts to be joined (pipe/pipe, pipe/fitting fitting/fitting) heated fusion temperature in the fusion area and are fused under pressure without the use of additional materials.
Page 22: The Fusion Process
7 Fusion Operating instructions KL 630 The fusion process In order to weld pipes and/or fittings d < 630 mm, insert matching clamping half shells and fasten them with the screws. Clamp pipe/pipe, pipe/fitting or fitting/fitting in the clamping element.
Page 23: Calculating Drag Pressure
Operating instructions KL 630 7 Fusion 7.2.1 Calculating drag pressure Danger of crushing hands! Machine slide moves! Danger of injury in the moving machine slide! Pericolo When moving to the end positions do not reach into the machine. The machine drag pressure must be calculated before each new fusion! 1.
Page 24: Calculating Of The Fusion Pressure
7 Fusion Operating instructions KL 630 7.2.2 Calculating of the fusion pressure Attention The fusion pressure is the sum of the “table value + movement pressure” (e.g. 44 bar* 7 bar = 51 bar) * for HD–PE d 400 mm, SDR 11see Chapter 7.5, Time/Pressure diagram 7.2.3...
Page 25 Operating instructions KL 630 7 Fusion 4. Plane the facing surface of pipes/fittings until shavings are turned out in ribbons which are the same width as the pipe wall thickness. The max. planer pressure is 10 bar above the drag resistance.
Page 26: Fusion Process
7 Fusion Operating instructions KL 630 7.2.5 Fusion process The PTFE coating of the heating element must be protected from mechanical damage and/or dirt. Suggest Heating element with demaged PTFE -covering has to be replaced. Non- doservance affects the quality of the joining, see Chapter 9.1 Danger of burning! The heater is hot (220 °C)!
Page 27 Operating instructions KL 630 7 Fusion HEAT SOAK (of the fusion material) For PE: 10 x wall thickness in mm For PP: Interpolate the intermediate values. For PVDF: wall thickness plus sec. The heat soak pressure is kept constant by the hydraulic system while the heat soak time.
Page 28: Visual Check Of Welding Bead
7 Fusion Operating instructions KL 630 RELEASING (the hydraulic system) Danger of bruising! Release the pressure of the hydraulic system before opening the clamping stations. Warning Move control lever towards “open <>“ (lever position: halfway between neutral and fully open) until pressure on manometer shows nearly 0.
Page 29: Example
Operating instructions KL 630 7 Fusion Example Pipe/fitting PE100 Heater temperature 220 °C Pipe outer diameter 400 mm Drag resistance 7 bar Pressure rating SDR 11 Table value 44 bar Wall thickness 36.3 mm Adjustment value on 51 bar hydraulic unit Equalize with a pressure of 51 bar until a bead height of 3.0 mm...
Page 30 7 Fusion Operating instructions KL 630 Curve for standard values for heater temperatures in relation to pipe wall thickness HD-PE (PE 80) PE 100 °C °C T = 220°C = constant Pipe wall thickne ss / Rohrwanddicke /Spessore tu bo mm...
Page 31 Operating instructions KL 630 7 Fusion Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Time/Pressure tables according to DVS 2207/1 Pipe outer diameter Wall thickness 10.9...
Page 32 7 Fusion Operating instructions KL 630 Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Time/Pressure tables according to DVS 2207/1 Pipe outer diameter Wall thickness 17.9...
Page 33 Operating instructions KL 630 7 Fusion Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Heating element butt fusion of PE Time/Pressure tables according to DVS 2207/1 Pipe outer diameter Wall thickness 28.6...
Page 34 7 Fusion Operating instructions KL 630 Heating element butt fusion of PP Heating element butt fus ion of PP Heating element butt fus Heating element butt fus ion of PP ion of PP Fusion table/DVS 2207/11 guidelines Heating element temperature 210 °C ± 10 °C...
Page 35 Operating instructions KL 630 7 Fusion Heating element butt fusion of PP Heating element butt fusion of PP Heating element butt fusion of PP Heating element butt fusion of PP Time/Pressure tables according to DVS 2207/11 Pipe outer diameter Wall thickness 11.0...
Page 36 7 Fusion Operating instructions KL 630 Heating element butt fusion of PP Heating element butt fusion of PP Heating element butt fusion of PP Heating element butt fusion of PP Time/Pressure tables according to DVS 2207/11 Pipe outer diameter Wall thickness 28.6...
Page 37: Failure Analysis
Operating instructions KL 630 8 Failure analysis Failure analysis Feature Description Evaluation group External state of joint Cracks running length-wise or cross-wise to weld. They may Permissible Permissible Permissible be located: • In the weld • In base material •...
Page 38 8 Failure analysis Operating instructions KL 630 Feature Description Evaluation group External state of joint Welding flash too wide or too See pg.14 See pg.14 See pg.14 narrow over part or all of weld DVS 2202- DVS 2202- DVS 2202-...
Page 39: Maintenance
Operating instructions KL 630 9 Maintenance Maintenance The KL 630 should be checked and cleaned periodically. Normal care of the KL 630 is limited to periodic cleaning of the outside. Replacement of worn parts • PTFE coating of the heating element: Clots, cracks or other damage: –...
Page 40: Hydraulic Unit
9 Maintenance Operating instructions KL 630 Hydraulic unit • Oil level check Check the hydraulic oil level regularly. If necessary, refill the hydraulic oil according to Chapter 4.1. Oil tank ECO1, ECO2 • Changing the hydraulic oil After 3000 operating hours hydraulic oil need to be changed.
Page 41 Operating instructions KL 630 9 Maintenance We recommend having a service booklet to record maintenance work for each KL 630 machine. example: Date Service Repair Comments 15.09.2003 Georg Everything OK Fischer Omicron 25.10.2003 Georg Heating element Cable replaced Fischer Omicron...
Page 42: 10 Customer Service
10 Customer Service Operating instructions KL 630 10 Customer Service There is a separate spare parts list for ordering replacement parts. If repairs are necessary, please contact your local representative. Please indicate the following information: • Customer name. • Product description •...
Page 43 Operating instructions KL 630 10 Customer Service...
Page 46 KL630_english_rev05.doc Code no.: 790345103-4 Georg Fischer Omicron S.r.l. Via Enrico Fermi, 12 I 35030 Caselle di Selvazzano (Padova) – Italy...

This manual is also suitable for:

Kl 630 top1 Kl 630 top2