Virax VULCA D160 Manuel D'utilisation page 18

 Check whether the workpieces are tight in the clamping tool by moving the workpieces
together. Also check whether the heating element has reached operating temperature.
Heating is ended when the yellow pilot lamp on the temperature regulator flashes or the
correct ACTUAL value is adjusted.
To guarantee even distribution of heat over the entire surface of the heating plate, it
is required to wait a period of approx. 10 minutes after the lamp flashes (according
to DVS). You must check the temperature with an appropriate temperature
measurement device!
 Swing the trimmer (1) between the pieces of pipe until the ratchet pawl (7) snaps in and
turn on with the handle.
 With the grip bar (6) move the ends of the workpieces carefully against the rotating knives
of the trimmer disks.
For one-sided milling, turn the stop on the underside of the milling machine to the side that
is NOT to be worked on.
Risk of injury! Do not grasp into the running knife while the trimmer is put into
operation. Operate trimmer only in swivelled in state (work position) and swivel
back again afterwards. The operativeness of the safety switch in the trimmer
must be guaranteed at all times to prevent unintentional starting outside the
work position.
 After the front sides are trimmed flat, which can be recognized by a uniform and unbroken
chip, slowly move the pipes ends apart. Unlock the trimmer (1) by pulling out the ring (7)
and swivel it.
 Move workpieces together and check whether the welded surfaces are flat. If this is not
the case, trimming must be repeated.
The axial offset between the workpieces must not be greater than 10% of the wall
thickness and the gap between the flat surfaces must not be greater than 0.5 mm
(according to DVS). If this is not the case, adjust with the help of the clamping screws and
pipe supports and repeat trimming.
The trimmed surfaces prepared for welding must not be touched with the hands and
must be kept free of dirt.
3.2.3 Welding
Risk of crushing! Always maintain a safe distance from the machine when moving
clamping tools and pipes together! Never reach into the working area!
 Swivel the heating element (2) between the two workpieces.
 Bring the pipe ends together, put force to the grip bar (6) and stop the driveshaft by pulling
the clamping lever (5).
As soon as the required bead height is reached evenly over the entire circumference at
the pipe ends, disengage the clamping lever (5), reduce the force to the corresponding
preheating force (near 0) and screw up the clamping lever (5) tightly again. It must be
ensured that the workpiece ends abut evenly to the heating plate.
 After the preheating time is over, disengage clamping lever (5) move workpieces apart,
swivel out the heating element (2) and move the workpiece ends together again. While
doing this, increase the corresponding joining force as linearly as possible until the
nominal force is reached (see the accompanying book for welding parameters) and pull
the clamping lever (5). The joining force must be maintained during the entire cooling
period.
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