STAUFF SPR-PRC-POC, Operating Instructions Manual

Page 1: ...g instructions Machine for cutting ring pre assembly and final assembly SPR PRC POC R3 0 valid from firmware 3 6 x 6010014620 22 10 2020 To avoid injuries and damage read these operating instructions...

Page 2: ...d final assembly 2 72 www stauff com Additional operating instructions in other languages can be downloaded at www stauff com Walter Stauffenberg GmbH Co KG Im Ehrenfeld 4 58791 Werdohl Germany 49 239...

Page 3: ...t 10 2 6 Safety labels 11 2 7 Safety devices 12 2 8 Securing the machine against reactivation 13 3 Machine description 14 3 1 Machine overview 14 3 2 Technical data 15 3 3 Function 15 3 4 Tools and pr...

Page 4: ...cutting ring in button mode 50 6 10 4 Assembling a cutting ring in button mode with foot switch 52 6 11 Checking the product 53 6 12 Completing the job 54 6 13 Final assembly in the fitting body 55 6...

Page 5: ...SPR PRC POC www stauff com 5 72 Table of contents 9 Decommissioning 68 9 1 Safety 68 9 2 Dismantling 69 9 3 Disposal 69 10 EC Declaration of Conformity 70 Index 71...

Page 6: ...rsonnel qualifications chapter 2 4 p 10 1 2 Structure of warnings Coloured signal word boxes emphasise the warnings Always read the full warning text for effective protection against hazards The diffe...

Page 7: ...uctions are a direct request to carry out a task They are structured in line with the operation involved Always carry out the operating steps in the prescribed sequence The instructions are structured...

Page 8: ...each chapter affecting your work Also observe information in the referenced product documents The following general safety instructions apply to all work undertaken on the machine Observe the applicab...

Page 9: ...d in compliance with the maintenance instructions and other instructions in this manual and in the referenced documents No changes attachments or conversions may be carried out without consulting the...

Page 10: ...d in the work involved is considered to be qualified This has to be backed up by appropriate certificates and records A distinction is made in this manual between the following groups of persons Opera...

Page 11: ...1 72 2 For your safety 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...

Page 12: ...ain switch is located at the front of the machine The electrical main switch de energizes the entire machine position 0 The electrical main switch is secured against reactivation chapter 2 8 p 13 Ligh...

Page 13: ...gainst reactivation 1 Ensure that a padlock is available for securing the machine against reactivation not included in the delivery 2 Switch off the machine as described 3 Secure the electrical main s...

Page 14: ...the machine 3 Ready Process runs lamp Machine ready for operation machine running 4 Operating panel Setting up the machine 5 Enable Enable the machine 6 Emergency stop button Stop machine in an emerg...

Page 15: ...3 3 Function The machine mechanically mounts cutting rings onto tube ends Tubes from the Light and Heavy Series with tube diameters between 6 mm and 42 mm can be used Pre assembly mode and final assem...

Page 16: ...te are labelled with the size The number corresponds to the external tube diameter LL stands for the Extra Light Series L stands for the Light Series S stands for the Heavy Series Please refer to the...

Page 17: ...g GmbH Co KG may carry out work which involves opening up the machine Only authorised setup and maintenance personnel may carry out maintenance work Only use suitable tools in proper condition Replace...

Page 18: ...e Serious or lethal injuries from tilting or slipping loads Before transporting the machine secure all its moving components Secure the machine against overturning or slipping out of position during t...

Page 19: ...rious or lethal injuries or machine damage due to incorrect installation Installation work may only be carried out by authorised specialist personnel Only use suitable tools in proper condition Wear y...

Page 20: ...ed with the control unit set up Control unit updates can be requested from the manufacturer Note the following before the installation Set up the machine on a sturdy base Set up the machine so there i...

Page 21: ...e your fingers are not in the assembly area when operating the machine CAUTION Incorrect operation Hazard from incorrect operation and operator errors Operators must have read and understood the opera...

Page 22: ...switch to I ON The Unlocking menu appears after a few seconds The Ready Process runs lamp flashes The message Release emergency stop and confirm with Acknowledge appears Fig 7 Start screen The English...

Page 23: ...Press the Acknowledge button The messages Startup program runs and Please do not remove the tool are shown Fig 9 Start screen 7 If no tool is inserted the message Insert tool pairwise is shown Fig 10...

Page 24: ...Fig 11 Menu Setup order 10 Press and hold the Reference run push and hold button The reference run has been completed The machine is ready for operation The reference run is cancelled Please refer to...

Page 25: ...emergency stop How to return the machine to ready status after an 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 Pre...

Page 26: ...message is shown in the menu Fig 15 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 6 4 Warming up the...

Page 27: ...button It takes about 2 minutes to warm up the machine One action of the warm up program is to move the installation cylinders back and forth several times 4 WARNING Risk of shearing off and crushing...

Page 28: ...anguage How to set the language 1 In the Setup order menu press the Language globe button Fig 18 Menu Setup order The Language settings menu opens Fig 19 Menu Language settings 2 Press the button for...

Page 29: ...setup How to set the system properties 1 In the Setup order menu press the Properties button Fig 20 Menu Setup order The Properties level menu opens 2 In the Properties level menu press the System bu...

Page 30: ...bly 30 72 www stauff com Fig 22 Menu System properties How to set the time 1 Press the date time display and enter the desired data Fig 23 Setting the time How to see information on the quantity for e...

Page 31: ...to obtain information on the material quantity 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...

Page 32: ...n the function of the inputs and outputs 1 Press the PLC DI DO button Fig 27 Overview Function of the inputs and outputs The function of the inputs and outputs is displayed How to reset the actual pro...

Page 33: ...ly area and remove any dirt or objects Fig 29 Assembly area empty 2 In the Setup order menu on the control panel check the material and set up if necessary 3 Select the assembly stud and counter retai...

Page 34: ...y and final assembly 34 72 www stauff com Fig 30 Check the tool sizes 4 Place the assembly stud into the socket and attach with the split pin Fig 31 Attaching the assembly stud 5 Insert the counter re...

Page 35: ...2 Inserting the counter retaining plate 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...

Page 36: ...e In automatic mode assembly of the cutting ring is triggered by applying pressure in the assembly area The machine is automatically in automatic mode after a tool change restart emergency stop 6 7 2...

Page 37: ...nu 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 The light curtain is de...

Page 38: ...n inactive message appears in the Setup order menu Fig 38 Menu Setup order The machine is in button mode The light curtain is reactivated when the machine is restarted 6 7 3 Setting button mode with f...

Page 39: ...s the Properties button The Properties level menu appears Fig 39 Menu Properties level 2 In the Properties level menu press the System button The System properties menu appears Fig 40 Menu System prop...

Page 40: ...final assembly 40 72 www stauff com Fig 41 Menu System properties 4 Enter the PIN Foot switch is active 5 Press the Home button to exit the menu The Foot switch active message appears in the Setup ord...

Page 41: ...essing order menu press the Setup button Fig 42 Menu Processing order The Setup order menu opens Fig 43 Menu Processing order 3 Carry out the following steps in the order indicated 4 Set the assembly...

Page 42: ...72 www stauff com 6 8 1 Setting the assembly type How to set the assembly type Fig 44 Menu Setup order 1 In the Setup order menu press the assembly type button The Setup assembly menu opens Fig 45 Me...

Page 43: ...fter assembly Please refer to chapter 6 11 p 53 6 8 2 Setting the material How to set up the material 1 In the Setup order menu press the Material button The Setup material menu opens Fig 46 Menu Setu...

Page 44: ...e OK quantity to 0 6 8 4 Setting the pressure for manual pressure If the Manual pressure input assembly type is selected no assembly parameters which means there is no system check for assembly This w...

Page 45: ...the tool 4 The Insert tool pairwise message appears Fig 49 Menu Setup order 5 Insert tools 6 The Check movement range message appears Fig 50 Menu Setup order 7 Press and hold the Reference run push an...

Page 46: ...to the use of an original STAUFF cutting ring FI DS in combination with the selected tube material and the original STAUFF union nut Use reinforcing sleeves for thin walled tubes in accordance with t...

Page 47: ...to face towards the tube end 4 Insert the tube into the counter retaining plate from above 5 Note the correct position of the union nut Cutting ring and union nut are located between assembly stud an...

Page 48: ...a cutting ring in automatic mode How to assembly cutting rings in automatic mode 1 Ensure that the correct tool is set up chapter 6 6 p 33 2 Ensure that automatic mode is set up chapter 6 7 1 p 36 3...

Page 49: ...assembled in line with the assembly type selected 7 CAUTION Note Slightly more force is required for pressing in cutting rings of type WDDS due to the internal sealing ring 8 Checking the product chap...

Page 50: ...ounter retaining plate assembling the cutting ring The cutting ring is assembled in line with the assembly type selected 7 Check the product chapter 6 11 p 53 8 Continue assembly until the production...

Page 51: ...y stud Fig 58 Pressing on the workpiece 7 Press Acknowledge and hold during assembly The Ready Process runs lamp lights up continuously The machine presses the assembly stud against the counter retain...

Page 52: ...with foot switch is set chapter 6 7 3 p 38 3 Ensure that the job is set up chapter 6 8 p 41 4 Ensure that the workpiece has been prepared chapter 6 9 p 46 The Insert tube push tube button is displayed...

Page 53: ...mbly stud How to check the product 1 Remove the tube end from the assembly area 2 Check the cutting ring for correct seating and cutting edge overlap Fig 60 Overlap when final assembly is selected as...

Page 54: ...mode Fig 62 Actual data manual mode 4 Use the arrow buttons to view the last 10 assembly processes 5 Press the Home button to exit the menu The product has been checked The machine is ready for opera...

Page 55: ...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: ...tection Corrosion protection Apply a light oil film as corrosion protection to the moving machine parts after removing any stubborn dirt with a cleaning agent and after an extended downtime 6 15 Switc...

Page 57: ...ngerous voltage Only Walter Stauffenberg GmbH Co KG may carry out work which involves opening up the machine Work on electrical appliances may only be carried out by qualified electricians Switch off...

Page 58: ...of the fault and replace any defective components if necessary 4 If you cannot identify the reason for the fault contact the manufacturer 7 2 Troubleshooting For troubleshooting please note that the f...

Page 59: ...mit Press Acknowledge and eliminate the fault Tube end Not deburred Too much deburring Sawn off at an angle Tube Pressed in at an angle Oval cross section Diameter too small Diameter too large Wall no...

Page 60: ...ssure is max pressure Confirm by entering new value Fig 66 Set pressure too high Error message on the machine display Possible cause Set pressure too high displayed pressure is max pressure Confirm by...

Page 61: ...sition detection Fig 67 Position detection false Error message on the machine display Cause Position detection Press Acknowledge and eliminate the fault Cutting ring Wrong size Wrong alignment Oval Wr...

Page 62: ...pre assembly and final assembly 62 72 www stauff com 7 3 4 Light curtain Light curtain Fig 68 Light curtain activated Error message on the machine display Cause Light curtain Press Acknowledge and eli...

Page 63: ...ol Tube not pressed on from process start until end of assembly If this occurs repeatedly despite firm pressure a controller error is probably responsible Contact the manufacturer 7 3 6 Piston not ret...

Page 64: ...www stauff com Error message on the machine display Cause Insert tool pairwise Tool Insert tool no fault Insert tools in pairs although tool has already been inserted Tool Tool sensor RFID chip missi...

Page 65: ...pted Press Acknowledge and restart Operation Reference run not pressed until display changes Machine too cold Please execute warm up program chapter 6 4 p 26 7 3 9 Wrong turning direction Fig 72 Wrong...

Page 66: ...ube too flexible due to material or dimension ratio Pressing does not start Fault No reaction from the machine Machine Light curtain interrupted at start Control Contact sensor defective misaligned Op...

Page 67: ...be regularly checked for proper functioning This is the way to check the emergency stop 1 Switch on and start the machine 2 Actuate the emergency stop and check whether the machine stops 3 Release th...

Page 68: ...s Secure all moving components before raising the load Only use undamaged lifting equipment which is approved for the weight of the load to be lifted Attach load attachment gear only at the indicated...

Page 69: ...cants used Collect operating media and cleaning fluids containing solvents in appropriate containers to prevent substances with water toxicity from entering the ground or the sewage system 9 3 Disposa...

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

Page 71: ...company Task 9 End 56 P Personal protective equipment 10 Personnel 10 PPE 10 Protective equipment 10 Q Qualification 10 R References 7 S Safety devices 12 Safety features 12 Safety instructions 8 Saf...

Page 72: ...72 72 Let us know about any questions suggestions or criticism you might have about your product or this documentation...