Geberit ESG 3 Maintenance Manual

ESG 3 Maintenance Manual

966.653.00.0 (00) Information Table of Contents Information.......................................................................................................................................................................................... 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]

966.653.00.0 (00) Safety Target group Maintenance and repair on this product may only be performed by skilled persons in accordance with EN IEC 62079:2001. Intended use The Geberit electrofusion machine ESG 3 may only be used for welding: • Geberit electrofusion 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, read the operating instructions and safety notes in document 966.475.00.0.

966.653.00.0 (00) Inspection Visual check Check the electrofusion machine 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

966.653.00.0 (00) Repair Replacing the snap cover 1 Remove the three screws on the inside of the upper housing. 2 Remove the damaged cover and mount the new one. 3 Fasten the new cover with the three 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 cable: • 242.947.00.1

966.653.00.0 (00) Replacing the mains cable 1 Disconnect the mains plug. 2 Remove the electric pack entry cover. 3 Disconnect the mains cable connector and remove the mains cable. 4 Mount the 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 • 242.948.1P.1

966.653.00.0 (00) 3 Hold down the lower housing section with the carrying belt and separate the 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.

966.653.00.0 (00) 8 Remove left and right protective bumpers to the sides. Make sure the 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.

966.653.00.0 (00) 2 Remove the seal and replace it. Ensure that the notch is at the top. 3 Carefully assemble 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.

966.653.00.0 (00) Assembling the electric pack and the housing 1 Attach the upper part of the housing to close the electric pack. Make sure the seal is correctly positioned. 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.

966.653.00.0 (00) 5 Pull the upper housing section over the electric pack. Make sure the rubber seal fits tight around the electric pack entry. 6 Connect the mains cable connector 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.

966.653.00.0 (00) 11 Make sure the bumper of the upper housing section slides over the lower housing section. Push down the upper housing until no gap is visible between the upper and lower housing parts. 12 Tighten all eight screws on the inside of the upper housing section. 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 new replacement nameplate. 15 Complete all necessary accessories including cables and operating manual.

966.653.00.0 (00) Troubleshooting Functional tests Functional tests can be carried out as follows: • simple tests: use commercially available electrofusion sleeve couplings d40–315 • detailed tests: follow the ESG 3 test setup below ESG 3 test setup Provide the following material for the test setup: • power supply, 230 V, fused with min. 10 A • electrofusion machine ESG 3 • connecting cable for electrofusion coupling • connecting cable for electrofusion coupling with integrated thermal fuse • multimeter with range 10 A DC and 10 A AC • double sliding resistor Culatti 2 x 38 Ω, 2 x 1200 W, 5.5 A, can be obtained via Grossenbacher Systeme AG (address see last page) Figure 1: Test setup This test setup can be used for 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 Press start/stop button and disconnect mains cable for 3 seconds to simulate a power failure The welding cycle restarts automatically. If the welding cycle does not restart, check the date settings or the battery contact 4 68 Ω 5 A DC Press start/stop button LED on, after 80 seconds: LED off, LED on 5 72–110 Ω 0.02 A DC Press start/stop button LED on, LED flashing, welding not possible 230 V ESG 3 ESG 3 Remote control Multi- meter E-coupling: DC T-coupling: AC Sliding resistor 2 x 38 ohms L N 4 m orange 4 m blue GND 5 V Rx Tx

966.653.00.0 (00) Testing with thermo fusion coupling Execute the following steps: If a test fails, refer to the error list on page 14. Testing the remote control unit Execute the following steps: If a test fails, refer to the error list on page 14. Error list Errors are displayed with the LEDs on the remote control unit. For a detailed error analysis use the service software. More than one error can be active at the same time. The errors are displayed according to their priority (important errors first). Step Resistance Current Action Result, test OK 1 46 Ω approx. 5 A AC Press start/stop button and press start/stop button again after 1–2 minutes to interrupt the welding process Welding process stops 2 31 Ω approx. 7 A AC Press start/stop button and press start/stop button again after 20 seconds to interrupt the welding process. After more than 20 seconds the resistor may overheat Welding process stops 3 22 Ω approx. 10.5 A AC Press start/stop button and press start/stop button 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: DC not loaded flashing on on on on 2 Relay test: DC relay error flashing on on on on 3 Relay test: discharge error flashing on on on on 4 Relay test: DO Drive_ESLEEEVE error flashing on on on on 5 Relay test: PWM_OFF output error flashing on on on on 6 Relay test: TSLEEVE relay error flashing on on on on 7 Relay test: AC relay error flashing on on on on 8 Coupling type has changed after the relay test flashing – – – – 10 E-coupling: input voltage out of tolerance on – on – – 11 E-coupling: no power or out of tolerance on – – – on 15 T-coupling: input voltage out of tolerance on – on – – 16 T-coupling: welding current not interrupted on – – – on 17 T-coupling: welding current stopped too early on – – – on 20 Disturbed communication to remote control flashing – – – 21 Earth leakage circuit breaker has triggered on on – – on 22 Self-test error flashing – – – –

966.653.00.0 (00) Functional check prior to delivery After a successful repair, execute a functional test prior to the delivery. 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.

966.653.00.0 (00) Available spare parts Spare parts have to be obtained from the respective Geberit sales company. The Geberit sales company orders the spare parts at the supplying factory in Pfullendorf, Germany. Pos. Art. no. Designation To be replaced by: 1 242.946.00.1 Connecting cable Plumber 2 242.945.00.1 Connecting cable for electrofusion coupling with integrated thermal fuse 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 Electrically skilled person 5 242.948.1P.1 Mains cable 115 V, CEE 17 Electrically skilled person Mains cable and remote control with cable may only be replaced by an electrically skilled person! 5 4 3 2 1

966.653.00.0 (00) Available service spare parts Service spare parts can only be obtained by the service centre directly from the manufacturer. Pos. Art. no. Designation To be replaced by: 1 359.087.00.1 Electric pack entry cover Service centre or manufacturer 1.1 359.088.00.1 Seal for electric pack entry cover Service centre or manufacturer 2 359.071.00.1 Upper housing section Service centre or manufacturer 3 359.072.00.1 Covering hood Service centre or manufacturer 4 359.076.00.1 Electric pack with fall impact cushioning Service centre or manufacturer 4.1 359.089.00.1 PCA Manufacturer 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 with seal Service centre or manufacturer 7.1 359.091.00.1 Fan seal (2 pieces) Service centre or manufacturer 8 359.074.00.1 Carrying belt fixture, left and right Service centre or manufacturer 9 359.069.00.1 Tripods, left and right Service centre or manufacturer 12 11 10 10 9 9 8 8 7.1 7.1 7 7 6 6 6 5 4.3 4.3 4.2.1 4.2 4.1 4 3 2 1.1 1 12 11 10 10 9 9 8 8 7.1 7.1 7 7 6 6 6 5 4.3 4.3 4.2.1 4.2 4.1 4 3 2 1.1 1

966.653.00.0 (00) 10 359.094.00.1 Lower housing section with carrying belt and carrying belt fixture Service centre or manufacturer 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:

966.653.00.0 (00) Operation with service software Function overview The service software can be used for the following tasks: • read parameters form electrofusion machine 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.

966.653.00.0 (00) Reading counter values and service messages Open tab Zähler / Servicemeldungen to show counter values and service messages. The field Zähler shows the welding history. The field Servicemeldungen allows to enter an individual comment for each service action. 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 • C5: electric pack • C6: fan • C7: housing cover • C8: upper housing section • C9: lower housing section

966.653.00.0 (00) Reading the welding history Open tab Logfile to show detailed history data. The EEPROM 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.

966.653.00.0 (00) Updating the firmware of the electric pack The firmware of the electric pack can be updated via the integrated USB bootloader. To update the firmware, execute the following steps: Step Action 1 Open www.st.com and search for um0412 2 Download 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 8 Select the update file with Choose 9 Check the option Verify after download

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

966.653.00.0 (00) Handling defective devices For repairs only entire ESG 3 electric packs and entire remote controls can be replaced. Both parts must not be opened for safety reasons. For transportation the default cardboard box of the ESG 3 can be used. Two electric packs including protection bumpers fit into one cardboard box. For repair send 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. [email protected] 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 cover. All information from the specification plate is also stored on the PCA. In this way, the Geberit electrofusion machine ESG 3 can be clearly identified at any time. +

Schachenstrasse 77 CH-8645 Jona T +41 55 221 63 00 F +41 55 221 63 16 [email protected] ➔www.geberit.com D68129-001 © 04-2014 966.653.00.0 (00)