Geberit ESG 3, Maintenance Manual

Page 1: ...Instandhaltungsanleitung Manuel d entretien Istruzioni per la manutenzione ESG 3 Maintenance Manual ...

Page 2: ...n 2 Safety 3 Inspection 4 Repair 5 Troubleshooting 13 Product This document contains all the information required for the professional maintenance of the following products 359 911 1P 1 Geberit electrofusion machine ESG 3 115 V 359 911 Px x Geberit electrofusion machine ESG 3 230 V ...

Page 3: ...trofusion sleeve couplings ø 40 160 mm with Geberit PE and Geberit Silent db20 pipes and fittings Geberit electrofusion tapes for anchor points ø 50 315 mm with Geberit PE pipes and fittings Any other use or use extending beyond the intended application is deemed to be improper Geberit will not accept any liability for any resulting damage Basic safety notes Before executing any maintenance tasks ...

Page 4: ...achine for visual defects cuts bumps excessive pollution Completeness Check the electrofusion machine for completeness electrofusion sleeve coupling cable connecting cable for electrofusion coupling with integrated thermal fuse connecting cable set operation manual snap cover carrying belt ...

Page 5: ...hree screws Start with the middle screw to center the cover Replacing the remote control cable 1 Disconnect the mains plug 2 Remove the electric pack entry cover 3 Disconnect the remote control cable connectors and remove the remote control cable 4 Mount the new remote control cable and connect the remote control cable connectors 5 Mount the electric pack entry cover Art no of new remote control c...

Page 6: ... new mains cable and connect the mains cable connector 5 Mount the electric pack entry cover Disassembling the housing 1 Remove the two lower screws on the upper tripods and all four screws M6 x 12 mm on the lower tripods 2 Untighten the eight screws on the inside of the upper housing section untight only do not remove Art no of new mains cable 242 948 P4 1 242 948 P0 1 242 948 P6 1 242 948 P5 1 2...

Page 7: ... upper section from the lower section 4 Remove the electric pack entry cover by removing the four screws M4 x 10 mm 5 Disconnect the mains cable connector 6 Disconnect the remote control cable connectors 7 Lift the rubber seal below the electric pack entry and pull out the electric pack from the upper housing section ...

Page 8: ...he housing clips do not fall off 9 Remove the seal from the electric pack entry 10 Disconnect the fan cable inside the electric pack entry and remove the tapes from the electric pack Replacing the electric pack seal 1 Remove the housing clips seven big and two small clips and carefully open the electric pack ...

Page 9: ...mble the housing Make sure that the seal fits tight on both sides of the cooling element Add the housing clips to fix the housing 4 Connect the fan cable and secure the cable with tape Replacing the fan 1 Remove the seal on the right and dismount the fan 2 Replace the fan 3 Hold the fan while mounting the seal right and left ...

Page 10: ...tioned 2 Add the housing clips to fix the housing seven big and two small clips 3 Connect the fan cable connector inside the electric pack Make sure the cable passes the provided recess in the electric pack entry seal Fix the fan cable with tape to the electric pack 4 Attach the right and the left protective bumper to the electric pack Make sure all housing clips are positioned correctly ...

Page 11: ...nector inside the electric pack entry 7 Snap in the remote control cable into the recess of the upper housing section 8 Connect the remote control cable connectors inside the electric pack entry 9 Mount the electric pack entry cover four screws M4 x 10 mm Make sure the seal is in the correctly positioned 10 Insert the upper housing section with the electric pack into the lower housing section ...

Page 12: ...Make sure the cover is placed as deep as possible while tighten the screws to allow best cover closing 13 Fasten the lower tripods with the four screws M6 x 12mm Use the two remaining screws to fasten the upper tripods 14 Test the electrofusion machine using the test procedures described later in this document If an electric pack needs to be replaced change the electric pack entry cover using a ne...

Page 13: ...or all types of electrofusion machines ESG 3 110 V and 230 V types Testing with electro sleeve coupling Execute the following steps If a test fails refer to the error list on page 14 Step Resistance Current Action Result test OK 1 7 Ω 5 A DC Press start stop button LED on after 80 seconds LED off LED on 2 36 Ω 5 A DC Press start stop button LED on after 80 seconds LED off LED on 3 36 Ω 5 A DC Pres...

Page 14: ...again after 10 seconds to interrupt the welding process After more than 10 seconds the resistor may overheat Welding process stops Step Action Result test OK 1 Connect the remote control unit to a 5 V power supply GND to pin 4 white 5 V to pin 3 violet of white 4 pole connector 2 Switch on the 5 V power supply All LEDs on after 3 seconds all LEDs flashing Bit Error description LED no 1 Relay test ...

Page 15: ...ivery The functional test is described earlier in this document 23 External watchdog flashing 24 Heat sink temperature too high on on 25 Ambient temperature too low on on 26 Welding aborted by user flashing 27 Maximum number of weldings reached flashing 28 Ambient temperature too high on on 30 General error flashing Bit Error description LED no ...

Page 16: ...e Plumber 3 242 966 00 1 Connecting cable for electrofusion coupling Plumber 4 242 947 00 1 Remote control with cable Electrically skilled person 5 242 948 P4 1 Mains cable 230 V SEV T12 Electrically skilled person 5 242 948 P0 1 Mains cable 230 V CEE 7 7 Electrically skilled person 5 242 948 P6 1 Mains cable 230 V AS NZS 3112 Electrically skilled person 5 242 948 P5 1 Mains cable 230 V BS 1363 A ...

Page 17: ...turer only 4 2 359 078 00 1 Electric housing with seal Service centre or manufacturer 4 2 1 359 079 00 1 Housing seal Service centre or manufacturer 4 3 359 077 00 1 Electric pack fall impact cushioning Service centre or manufacturer 5 359 086 00 1 Housing clip small 2 pieces Service centre or manufacturer 6 359 085 00 1 Housing clip large 2 pieces Service centre or manufacturer 7 359 090 00 1 Fan...

Page 18: ...r 11 359 075 00 1 Remote control protective cover Manufacturer only 12 359 073 00 1 Carrying belt Service centre or manufacturer Service spare parts may only be replaced by qualified service centres or by the manufacturer Grossenbacher Systeme AG Switzerland PCA repairs may only be carried out by the manufacturer Pos Art no Designation To be replaced by ...

Page 19: ...ine ESG 3 export parameters store service messages analyse errors The service software communicates with the electrofusion machine ESG 3 via a virtual COM port It works with all possible COM port settings baud rate parity stop bits etc During an active communication no weldings are possible Reading general information Open tab Aktuelle Werte Kalibrationswerte to show general information ...

Page 20: ...tion This allows for example to track the service history of the electric pack The messages are stored in the RAM of the electrofusion machine ESG 3 The length of a message is 32 characters To shorten the messages use the following service codes C1 electrofusion sleeve coupling cable C2 connecting cable for electrofusion coupling with integrated thermal fuse C3 remote control cable C4 mains cable ...

Page 21: ... of the electrofusion machine ESG 3 can store up to 400 data records index entries 0 199 show the last 100 successful 0 99 or unsuccessful 100 199 electrofusion sleeve weldings index entries 200 399 show the last 100 successful 200 299 or unsuccessful 300 399 thermofusion coupling weldings All data can be exported as csv file ...

Page 22: ...nload the package install it and start the DfuSe demo software 3 Disconnect the mains cable 4 Insert the jumper on the electric pack entry 5 Connect the mains cable to switch on the electrofusion machine ESG 3 6 Connect the PC via USB cable as shown above 7 The PC recognizes the new USB device as STM Device in DFU Mode The driver is located in the installation directory of the DfuSe demo software ...

Page 23: ...29 001 04 2014 966 653 00 0 00 10 Press Upgrade 11 Remove the jumper after the successful firmware upgrade 12 Disconnect the mains cable and connect it again to restart the electrofusion machine ESG 3 Step Action ...

Page 24: ...the electric packs with a problem description to the following address Grossenbacher Systeme AG Serviceabteilung Spinnereistrasse 10 9008 St Gallen Switzerland In case of questions contact the supplier via email telephone or fax service gesys ch Tel 41 0 71 243 2929 Fax 41 0 71 243 2930 Specification plate The Geberit electrofusion machine ESG 3 has a specification plate on the electric pack entry...

Page 25: ...EN 25 D68129 001 04 2014 966 653 00 0 00 ...

Page 26: ...EN 26 D68129 001 04 2014 966 653 00 0 00 ...

Page 27: ...EN 27 D68129 001 04 2014 966 653 00 0 00 ...

Page 28: ...Geberit International AG Schachenstrasse 77 CH 8645 Jona T 41 55 221 63 00 F 41 55 221 63 16 documentation geberit com www geberit com D68129 001 04 2014 966 653 00 0 00 ...