E43362 - Welding machine IFM - Free user manual and instructions

USER MANUAL E43362 IFM

Installation instructions

Flushline pipe adapter for devices with G ^1/2 sealing cone

Contents

1 Preliminary note.... 3

1.1 Symbols used.... 3
1.2 Warnings.... 3

2 Safety instructions 4
3 Transport, handling and storage 5
4 Intended use 6

4.1 Basic notes 6

5 Installation.... 7

5.1 Basics 7
5.2 Adapter with leakage port.... 8
5.3 Marking of cable entry / display alignment 8
5.4 Using the welding aid 10
5.5 Forming.... 10
5.6 Tack welding 11
5.7 Welding operation 11
5.8 After welding 12
5.9 Post-processing 13
5.10 Installing the sensor with a G 1/2 sealing cone.... 13

6 Set-up 14
7 Disposal 15

1 Preliminary note

You will find instructions, technical data, approvals and further information using the QR code on the unit / packaging or at documentation.ifm.com.

1.1 Symbols used

√ Requirement
Instruction
Reaction, result

bold Designation of keys, buttons or indications

→ Cross-reference without link

→ Cross-reference with link

Important note

Non-compliance may result in malfunction or interference

Information

Supplementary note

1.2 Warnings

Warnings indicate the possibility of personal injury and damage to property. This enables safe product handling. Warnings are graded as follows:

WARNING

Warning of serious personal injury

▷ If the warning is not observed, fatal and serious injuries are possible.

CAUTION

Warning of minor to moderate personal injury

▷ If the warning is not observed, minor to moderate injuries are possible.

ATTENTION

Warning of damage to property

▷ If the warning is not observed, damage to property is possible.

2 Safety instructions

- The product described is a subcomponent for integration into a system.

• The system architect is responsible for the safety of the system.

• The system architect undertakes to perform a risk assessment and to create documentation in accordance with legal and normative requirements to be provided to the operator and user of the system. This documentation must contain all necessary information and safety instructions for the operator, the user and, if applicable, for any service personnel authorised by the architect of the system.

• Read this document before setting up the product and keep it during the entire service life.

• The product must be suitable for the corresponding applications and environmental conditions without any restrictions.
• Only use the product for its intended purpose (→ Intended use).
• Only use the product for permissible media (→ Technical data).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with the product or incorrect use by the operator.
• Installation, set-up, operation and maintenance of the product must be carried out by qualified personnel authorised by the machine operator.
• The welding operation must be carried out by authorised personnel.
• The welding operation must be carried out carefully and according to state-of-the-art technology.
• During the welding process, ensure sufficient fume extraction.
• Protect the product against damage.

CAUTION

During the welding operation, the adapter, the surrounding material and any welding aid used can increase in temperature to over 65\ °C ( 149\ °F ).

▷ Risk of burns.
▶ Allow all components to cool down.

3 Transport, handling and storage

▶ Store the product in its original packaging.
▶ Observe the permissible ambient conditions for the product during storage (→ Technical data).
▶ In case of return shipment, ensure that the product or components are cleaned especially from dangerous and toxic substances.

4 Intended use

The flushline pipe adapter (hereinafter referred to as adapter) is an inline housing for ifm sensors with different connection systems.

These instructions describe the connection version G ^1/2 sealing cone for all flush mount ifm sensors.

The use of the adapter ensures a hygienic integration of the sensor. At the same time the required welding operation is reduced to orbital welding at the two pipe ends.

The sensor to be mounted is flush with the inner wall of the pipe, which makes it fit for drainage. Vertical installation of the sensor into a horizontal pipe is possible. The medium flows directly across the sensor surface, which guarantees optimised cleaning conditions in accordance with standardised CIP conditions.

Installation of a pressure sensor: ➕ Operating instructions pressure sensor

Installation of sensors with probe: In order to prevent malfunction or damage, the probe must be shorter than the internal pipe diameter of the adapter!

The available pipe cross-section is restricted by the probe of the installed sensor.

Observe the minimum distances from probe tip to the opposite wall: ➞ Operating instructions of the installed device.

4.1 Basic notes

The adapter is a flush design inline housing, in accordance with international hygiene standards.

Observe the relevant international hygiene standards.

Ensure that the installation of the adapter in the system complies with international hygienic standards.

Observe the notes in the operating instructions of the sensor.

The welding operation must be carried out by authorised personnel.

The welding operation must be carried out carefully and according to state-of-the-art technology.

▶ During welding and the following cooling phase the sensor must not be in place.

The surfaces must be free from any contamination.

Welding materials must be suitable for the adapter and wall material.

The requirements in the specifications, of common practice, in regulations, norms, of intended use and the application must be applied.

They determine the welding procedure, the welding material, the connection category and connection type, including chamfer, welding penetration depth and demands on the surface.

Welding specifications according to EN13480-4, chapter 9 and AD2000, chapter HP5/2.

5 Installation

CAUTION

During installation, pressure or other fluids may escape from the plant.

▷ Risk of injury from pressure or other media.
▶ Ensure that no pressure is applied to the system during installation.
▶ Ensure that no fluids can leak out during installation.

Observe and adhere to state-of-the-art technology and applicable regulations during the welding process.

Carefully read and apply the operating instructions of all components used.

ATTENTION

Danger to the plant and the environment during welding operations and rework.

▶ Consider potential dangers and adhere to applicable regulations and guidelines.

CAUTION

During the welding operation, the adapter, the surrounding material and any welding aid used can increase in temperature to over 65\ °C ( 149\ °F ).

▷ Risk of burns.
▶ Allow all components to cool down.

WARNING

Dangers to persons during welding operations, rework and pressure tests.

▶ Consider potential dangers and adhere to applicable regulations and guidelines.

5.1 Basics

The adapter can be welded into pipes or provided with connection fittings.

During the installation or the welding process, the experience of qualified staff has priority. Procedures deviating from these instructions are permissible. (DIN EN ISO 3834-1 to -6 and DIN FB CEN ISO / TR3834-6).

The pipe must correspond with the wall thickness and the diameter of the two pipe connections on the inline adapter (DIN 11866).

The inline adapter must not warp.

Adapter with leakage ports according to EHEDG and 3-A:

For reliable draining: Align the adapter with only one leakage port so that the leakage port is located at the lowest possible point. Adapter with leakage port 8

Recommendation: Application of the TIG method in accordance with ➕ EHEDG DOC 35 "Hygienic welding of stainless steel tubing in the food processing industry".

Use a welding mandrel for optimum heat dissipation. G ^1/2 sealing cone = E43314

▶ Ensure correct alignment of the inline adapter.
▶ Prepare the pipe ends for orbital welding.
▶ Ensure rectangularity, freedom from burrs and chamfers.
▶ The inline adapter and its surfaces must be free from any kind of soiling and damage.
▶ Choose welding materials that are appropriate for the material of the adapter and the pipe.
▶ First, weld one side of the inline adapter, then weld the other side.

5.2 Adapter with leakage port

Für eine sichere Selbstentleerung bei einem Adapter mit mehreren Leckagebohrungen:

▶ Eine der Leckagebohrungen so ausrichten, dass sich diese am tiefsten Punkt befindet.

Für eine sichere Selbstentleerung bei einem Adapter mit einer Leckagebohrung:

▶ Align the leakage port so that it is located at the lowest possible point.

5.3 Marking of cable entry / display alignment

▷ The arrow (1) on the adapter serves as a guide for the cable entry of a 90° angled socket for a device without display, or the connector of a device with display if they are mounted in end position.

Device without display and 90° angled socket:

▶ When using a PEEK gasket.
▷ The arrow (1) on the adapter and the cable entry or the connector overlap.

Fig. 1: Device with PEEK gasket

▶ When using a metal seal (and PEEK gasket removed).
▷ The cable entry shifts clockwise by approx. 97° away from the arrow (1).

Fig. 2: Device with metal seal

Device with display and connector:

▶ When using a PEEK gasket.
The arrow (1) on the adapter and the connector overlap.

Fig. 3: Device with PEEK gasket

▶ When using a metal seal (and PEEK gasket removed).
▷ The connector shifts clockwise by approx. 97° away from the arrow (1).

Fig. 4: Device with metal seal

5.4 Using the welding aid

The sealing area of the adapter must not be damaged.

▶ Insert welding aid E43314 (for heat conduction and protection of the sealing edge) and tighten by hand.
▶ Carry out the welding operation.

After welding:

▶ Let the adapter and the welding aid cool down.
▶ Remove the welding aid.
▶ Remove deposits from the adapter thread.

▶ Screw in the sensor by hand in order to check for dimensional accuracy and functionality of the thread. If the tightening torque is too high, do not use any tool, but check the thread and replace the adapter, if necessary.

5.5 Forming

Welding with stainless steel: the welding material may not come into contact with oxygen during the welding process.

▶ Rinse the inside of the pipe with forming gas.

▶ Seal the pipe upstream and downstream of the weld seam using an end cap.
▶ Attach the supply line for the forming gas to the pipe.
▶ Bore holes into the opposite side (pipe seal), so that the gas can escape.
▶ Seal the adapter with the welding aid E43314 to prevent the forming gas from flowing off unintentionally.
▶ Ensure emission of gas with the required volume flow.

The forming gas may not produce any pressure inside the pipe.

The forming gas must be suitable for the applied welding method: TIG; MIG; MAG.

5.6 Tack welding

▶ Ensure plane-parallel alignment of the pipe end, perpendicular to the axis.
▶ Clamp the adapter and the pipe against each other using an appropriate mounting solution.
▶ During welding and the following cooling phase the sensor must not be in place.

Using forming gas is recommended during the tack welding process.

▶ Add weld tacks between the adapter and the pipe ends. Apply each new tack on the opposite side of the former, inside and outside of the pipe.
▷ Segments emerging evenly around the circumference of the pipe.

5.7 Welding operation

The power of the welding device must be adapted to the thickness of the wall.

In case of hygienic requirements take the appropriate measures to obtain a hygienic weld seam, in particular:

Choose the suitable welding method.

Choose the suitable welding parameters.

Align pipe ends accurately to avoid gaps or linear misalignment, etc.

Avoid overheating between the weld seams.

Avoid undercuts (hygienic areas) ➕ EHEDG DOC 35.

▶ During welding and the following cooling phase the sensor must not be in place.
▶ Apply weld seams between the weld tacks. Add each new seam on the opposite side of the former.

Recommendation: Start welding at the lowest point (A).

▶ The sealing edge of the adapter must not be damaged by weld spatter or similar.

1: Sealing edge

5.8 After welding

▶ Let the adapter cool down.
▶ Remove the welding aid.
▶ Check the quality of the weld seam: It must meet the applicable requirements for a hygienic weld seam, in particular:
• full weld penetration
• no gaps / cracks / porosity / tarnish
• no increased surface roughness
• no protruding outwards
- no sagging inwards
- no inclusions
▶ The thread and the sealing edge must be free from welding residues.

If the sealing edge of the adapter is damaged, the adapter can no longer be used.

▶ Replace the adapter.

5.9 Post-processing

If the pipe system is treated after the adapter has been welded in (e.g. grinding, pickling, sand-blasting, glass bead blasting or applying procedures such as powder coating, painting etc.):

▶ Make sure that the inside and sealing area of the adapter are clean and not damaged. Appropriate measure: ➕ Using the welding aid.

5.10 Installing the sensor with a G 1/2 sealing cone

General information for installing the sensor: ➞ Operating instructions of the sensor.

A lubricating paste is required to install the sensor. It must be suitable and approved for the given application and compatible with the elastomers used (e.g. seal).

During sensor installation, do not exert any axial leverage with the tool on the rotatable filter cover.

▶ Remove the protective packaging only just before mounting.
▶ Ensure cleanliness of the sealing areas.

In case of installation by means of a hexagon socket (1), make sure that the tool's spanner flat has an inner height of at least 30 mm. Align the rotatable filter cover (2) so that it is flush with one of the spanner flats.

▶ Use the lubricating paste sparingly.
▶ Screw the sensor into the inline adapter.
▶ Den Sensor anziehen. Recommended tightening torque: ➕ Operating instructions of the sensor.

Too much torque may impair the seal.

If the sealing area is damaged:

▶ Replace the inline adapter.

6 Set-up

▶ Before setting up the system: Check all components for ingress resistance.
Setting up the sensor: ➕ Operating instructions of the sensor.

7 Disposal

▶ After use dispose of the product or components in an environmentally friendly way in accordance with the applicable national regulations.