E30597 - Plumbing fittings IFM - Free user manual and instructions

USER MANUAL E30597 IFM

Operating instructions

Welding adapter with collar for necks and pipes

E30541

E30597

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 7

5 Installation.... 8

5.1 Welding aid 8
5.2 Cooling 8
5.3 Welding operation 9
5.4 Processing the weld seam 10

6 Set-up 12
7 Disposal 13

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
Instructions
Reaction, result

[...] Designation of keys, buttons or indications

→ Cross-reference

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 unit 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.

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

Fig. 1: Example welding adapter E30541
Dw: Wall thickness
Da: Outer diameter

Use on a T-piece:

The welding adapter with collar is suitable for a welded connection with an equally dimensioned pull-out on T-pieces ( → data sheet).

The inner diameter of the main line D_H must be at least the inner diameter of the welding adapter, it can also be larger.

Inner diameter welding adapter: Da – (2 x Dw).

Due to the transition to the sealing edge, the adapter is accessible for cleaning despite the small recess to the inner wall of the pipe in the T-piece.

The distance between the measuring cell surface (1) of the sensor and the inner wall of the main pipe should not exceed the diameter (2) of the pull-out in order to ensure cleaning in accordance with the applicable hygiene principles.

Fig. 2: Example welding adapter E30541 on a T-piece
1: Distance between sensor and inner wall of main pipe
2: Inner diameter of pull-out T-piece
D_H : Inner diameter of the main pipe

Use on a pipe:

The welding adapter with collar can also be welded to the end of a pipe of the same size.

4.1 Basic notes

If the pipe section is treated after the adapter has been welded in, for example grinding, pickling, sand-blasting, glass bead blasting or applying procedures such as powder coating, painting:

▶ Make sure that the inside and sealing area of the adapter are clean and not damaged.

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.

Welding aids or cooling devices must be used during welding.

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.

5 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

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

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

CAUTION

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

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

WARNING

Danger to persons during welding processes and rework.

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

5.1 Welding aid

The welding aid E30435 must be used.

The welding aid absorbs the thermal energy and helps to stabilise the adapter.

▶ Further information on the welding aid E30435 → Operating instructions.
▶ Screw the welding aid hand-tight into the adapter to be welded in.
▶ Carry out the welding process.
▶ After each welding, including the cooling phase, check the thread of the welding adapter for ease of movement. To do this, loosen the welding aid and tighten it again.
▶ After completion, remove the welding aid from the welding adapter.

5.2 Cooling

During the welding process, higher amounts of energy are introduced into the welding adapter in the area of the weld seam, which can only dissipate this energy into the welding aid to a limited extent.

To avoid overheating of the adapter:

▶ Ensure sufficient cooling times.
▶ Any specifications of a responsible welding specialist on targeted cooling devices must be applied.
▶ For cooling, water pockets can be introduced in a modified welding mandrel so that the adapter is permanently cooled from the inside.

5.3 Welding operation

The basic notes and guidelines must be adhered to:

▶ The welding method must be suitable for the welding task and the power of the welding equipment must be adapted to the material thickness.
▶ During welding, avoid overheating of the adapter and observe sufficient cooling phases.
▶ The sealing area of the adapter must not be damaged by weld spatter or similar. The sealing area should be sufficiently protected before starting the welding process.
▶ Use the welding aid E30435 or a cooling adapter to dissipate heat, stabilise and protect the sealing area. Welding aid ( → ☐ 8)

1: Welding aid E30435

2: Example welding adapter E30541

3: T-piece

▶ For an optimum welding result, apply a sufficient number of fixing points crosswise.

Fig. 3: Top view

1: Welding adapter
2: Welding aid E30435

▶ For an optimum welding result, apply the welding segments in the back-step method and crosswise.
▶ Ensure sufficient intervals between the individual sections to avoid overheating of the adapter.

Fig. 4: Top view

1: Welding adapter
2: Welding aid E30435

▶ After each welding, including the cooling phase, check the thread of the welding adapter for ease of movement. To do this, loosen the welding aid and tighten it again.
▶ After completion, remove all components from the welding adapter.
▶ Remove any residue from the thread of the adapter without damaging the sealing edge.
▶ Screw in the sensor by hand in order to check for functionality of the thread. If the tightening torque is too high during screwing in, do not use any tools but check the thread and replace the welding adapter, if damaged.

Carry out a leak check after the welding process.

5.4 Processing the weld seam

Prevent any damage to the sealing edge on the welding adapter if subsequent surface post-processing, for example grinding / polishing of the weld seam, is necessary.

▶ Carefully remove the material around the sealing edge in case of post-processing.
▶ The sealing edge for the sensor sealing on the welding adapter must remain unaffected.

Use protective devices and equipment according to the product specifications, installation conditions and ambient conditions.

Read and apply the operating instructions and safety instructions for the tools used.

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.