REMS SSM 160RS Instrucciones De Servicio página 15

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supply as soon as the leakage current to earth exceeds 30 mA for 200 ms. The
heating element butt welding unit (5) has its own connecting cable. It must
therefore be checked that the voltage specified on the rating plate of the heating
element butt welding unit matches the mains voltage. Only use sockets/exten-
sion leads with a functioning protected earth contact.
2.3. Positioning the welder and facing cutter
The welding unit (5) can be removed from every model in this series and used
as a hand-operated machine. In the case of the REMS SSM 160 RS and REMS
SSM 160 KS, it is installed the mounting (17) by the hand-grip (16), while in
the case of the REMS SSM 250 KS and REMS SSM 315 RF, it is secured with
an additional plug.
CAUTION
Only touch the heating element butt welding unit (5) on the handle (16)
or the grip (18) when it is plugged into an outlet. The heating element as
well as the metal parts between the heating element and the plastic handle
reach operating temperatures of up to 300°C. Touching these parts can cause
severe burns.
REMS SSM 160 RS
The heating element – butt welding unit (5) should not be centred after trans-
porting the machine, as this is already set when delivered.
REMS SSM 160 KS, 250 KS and REMS SSM 315 RF
After the machine has been transported, the welder (5) must be centred. For
this purpose, release clamping lever (22) and pull back the retainer (17) of the
welder (5) on the sliding block (21) as far as it will go. Now re-tighten the
clamping lever (22).
Swing out the heating element butt welding unit (5) and the facing cutter (6).
Always swing out the heating element butt welding unit (5) in the protective hood
(40) (Fig. 1). Before moving the welder (5) and facing cutter (6) sideways, slightly
raise the handle (18) or (20), otherwise the end-stop will apply a braking effect.
2.4. Electronic temperature control
DVS 2208 Part 1 prescribes that the temperature of the heating element must
be finely adjustable. The devices are equipped with a temperature control
(thermostat) to also ensure the required constant temperature on the heating
element. DVS 2208 Part 1 prescribes that the temperature difference in relation
to the control behaviour must be < 3°C. In practice, this degree of accuracy
cannot be achieved mechanically, but only by an electronic thermostat. For this
reason, therefore, welding machines operating at a fixed, preset temperature
or employing a mechanical thermostat may not be used for welding operations
as described in DVS 2207.
The temperature can be adjusted on all REMS welders. All models are supplied
with electronic thermostats. The butt welding unit is identified on the welder
rating plate by code letters, example of which is given below.
REMS SSG 180 EE: Adjustable temperature (E), electronic thermostat (E).
The preset temperature is adjusted to within ± 1°C.
2.5. Preheating the butt welding unit
The welder connecting lead is plugged into the socket (23) at the rear of the
facing cutter housing. As soon as this lead is connected to the mains, the
machine is ready to operate and the heating element will begin to heat up. The
red power-on indicator lamp (24) and green temperature indicator lamp (25)
light up. The machine requires about 10 minutes to heat up. Once the required
preset temperature is reached, the built-in thermostat cuts out the power supply
to the heating element. The red indicator lamp continues to glow. The green
temperature indicator lamp of the electronic thermostat (EE) will light up inter-
mittently, indicating the repeated switching on and off of the power supply. The
welding process can begin at the earliest after waiting another 10 minutes (DVS
2207 Part 1).
2.6. Selecting the correct welding temperature
The welder heating element is preadjusted to the average welding temperature
for PE-HD pipes (210°C). Depending on the pipe material and the gauge of
the pipe walls, it may be necessary to adjust this temperature. In this case,
observe the manufacturer's information on the pipes or mouldings without fail.
Fig. 5 contains a graph showing the guideline temperatures for heating elements
according to the gauge of the pipe walls. In principle, the higher temperature
should be used for thinner walls and the lower temperature for thick walls, as
far as possible (DVS 2207, Part 1). Ambient influences (Summer/Winter/wind/
humidity) may also necessitate temperature corrections. These are made for
example with a quick display temperature measuring instrument for surface
measurements with a contact surface of approx. 10 mm. The temperature can
be corrected if necessary by turning the temperature setting screw (26). If the
wrong temperature is set, please note that the heating element may only be
used 10 minutes after reaching the nominal temperature at the earliest.
3. Operation
The quality of the welded connections depends on the welder's qualification,
the suitability of the machines and devices used as well as the compliance with
welding regulations. The weld can be tested by non-destructive or destructive
methods. Welding work must be supervised. The type and scope of supervision
must be agreed between the contract parties. It is recommended to document
the procedure data in welding logs and on data media. Within the scope of
quality assurance, it is recommended to make and test sample welds under
the given working conditions before beginning and during the welding work.
Every welder must be trained and have valid proof of qualification. The intended
area of application may be decisive for the type of qualification.
3.1. Description of process
In heating element butt welding, the connecting faces of the parts to be welded
are aligned under pressure on the heating element, then heated up with reduced
pressure to welding temperature and joined (Fig. 6) and therefore welded under
pressure after removing the heating element.
3.2. Preparations of welding
If the machine is used in the open air, care must be taken to ensure that welding
will not be adversely affected by unfavourable environmental condi tions. In bad
weather or strong sunlight, the welding position should be covered, if necessary
with an awning. To prevent the uncontrolled cooling of the welding position by
draughts, the welded pipe ends should be enclosed. Out-of- round pipe ends
must be trued up before welding by e.g. carefully heating with a warm air heater.
Only pipes or pipes and mouldings of the same material and wall thickness
may be welded. The pipes are cut with the REMS RAS pipe cutter (accessory,
see 1.2.) or REMS Cento/REMS DueCento pipe cutting machine.
3.3. Clamping the pipes
According to the pipe diameter, the 4 clamp inserts (27) must be inserted into
the clamping devices (19) so that the chamfered side of the clamp inserts is
facing the welding point. The inserts are secured with hex screws (28) by
means of the wrench supplied. The two pipe support inserts (29) should be
similarly installed on the pipe supports (30) and secured with hex screws (28).
The pipes or pipe sections should be aligned in the clamping assembly before
being clamped. If necessary, long pipes should be supported with a REMS
Herkules 3B (accessory, see 1.2.). For short pipe sections, the pipe supports
(30) should be adjusted or turned through 180°. For this purpose, loosen
clamping knob (31) and reposition the pipe support or raise knob (32) and turn
the pipe support about the axis of the clamping knob (31). The pipe ends
should project 10-20 mm towards the centre beyond the clamping adapters
or clamps to permit planing.
Align the pipes or fittings in such a way that the faces are parallel to each other,
i.e. the pipe walls must be in alignment in the area of the joint. If necessary,
the clamps should be released and the pipes re-aligned and turned (check for
out-of-roundness). If adjustment proves unsuccessful after several attempts,
it will be necessary to readjust the clamping system (19). For this purpose, the
clamping screws (33) on both clamps should be released and a pipe clamped
in each of the two clamps. If the pipe is not resting in the clamps and on the
pipe supports, centre the clamps by tapping the sides. Then the clamping
screws (33) must be re-tightened with the pipe still clamped.
The clamps must enclose the pipe ends securely. If necessary, readjust the
clamping nut (34) under the clamping cam (35) until the clamping lever (36)
can only be closed with a certain amount of force.
3.4. Planing the pipe ends
Immediately before welding, the pipe ends must be planed flat. For this purpose,
the electric facing cutter (6) is swivelled into the working area and switched on
by means of the rocker switch in the handle (20). While the facing cutter is
running, the pipe ends must be slowly offered up to the planing discs by means
of the contact lever (7). Planing should be continued until an unbroken swarf
is formed on both sides. With the facing cutter still running, now slowly ease
off the contact lever (7) so that no swarf remains on the pipe ends. After the
facing cutter has been swivelled out, the planed pipe ends should be brought
together on a trial basis, so as to check that the faces are parallel and that the
pipes are not axially displaced. Under the application of adapting pressure, the
gap between the parallel faces must not exceed the width specified in Fig. 7
or the displacement on the outside of the pipe exceed 10 % of the wall thick-
ness. The planed faces must not be touched again before welding takes place.
If a pipe or moulding on one side can no longer be planed or must not be planed
at all, whereas further planing is required on the other side, the stop buffer on
the underside of the planer housing should be swivelled out on the side on
which no further planing should take place.
3.5. Butt welding process
In the welding process, the joint faces are heated to welding temperature by a
heating element, then welded together under pressure after the heating element
has been withdrawn. Before each welding process, the temperature of the
heating element in the welding area should be checked. If necessary, it must
be adjusted as described in 2.6. The heating element must also be cleaned
with lint-free paper or cloth and technical alcohol before every welding process.
In particular, no remnant of plastic must be left adhering to the coating on the
heating element. Also in the clean ing process, care must be taken to ensure
that the anti-adhesive coating of the heating element is not damaged by tools.
The process stages are shown in Fig. 8.
NOTICE
The use of white spirit to clean the heating element can lead to a diminished
quality of the weld due to the water that it contains.
3.5.1. Adapting
In the adapting process, the joint faces are pressed against the heating element
until a bulge forms around each circumference. During this process, a matching-
up pressure of e.g. 0.15 N/mm² should be applied for PE (DVS 2207, Part 1).
Depending on the diameter and wall thickness of the pipe, the requisite degree
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