GF Piping Systems ECOS 160 User manual

GF Piping Systems
Instruction manual
ECOS 160-315
Butt-Fusion Machine

All rights reserved,inparticular the rights ofduplication and distribution as wellas translation. Duplication and
reproductioninany form (print,photocopy,microfilm or electronic) requirethe writtenpermissionofGeorgFischer
Omicron S.r.l..

Operating instructions ECOS 160/250/315 Table of contents
I
Table of contents
Page
1
About this manual
1
1.1 Warning notice
1
1.2 Other symbols and notices
2
1.3 Abbreviations
2
2
Safety instructions
3
2.1 Proper use
3
2.2 General safety measures
3
2.3 Working with safety in mind
3
2.4 Disposal
5
3
General
6
3.1 Introduction
6
3.2 Range of application
6
3.3 Copyright
7
4
Product identification and description
8
4.1 Product identification
8
4.2 Product description
8
5
Technical specifications
10
6
Transport and assembly
11
6.1 Packaging
11
6.2 Sensitivity
11
6.3 Intermediate storage
11
6.4 Scope of delivery
11
7
Fusion preparation
12
7.1 General information
12
7.2 Preparations
12
7.3 Connection to mains
14
8
Fusion
15
8.1 The basics of butt fusion
15
8.2 The fusion process
16
8.2.1 Calculating drag pressure
16
8.2.2 Preparing the fusion surfaces
16
8.2.3 Calculating of the fusion pressure
18
8.2.4 Adjusting of the fusion pressure
18
8.2.5 Fusion process
19
8.3 Visual check of welding bead
21
8.4 Example ECOS 315/250
22
9
Failure analysis
23
10
Maintenance
25
10.1 Replacement ofworn parts
25
10.2 Hydraulic system
25
10.3 Hydraulic unit 25

Table of contents Operating instructions ECOS 160/250/315
II
11
Customer Service
28

Operating instructions ECOS 160/250/315 1 About this manual
1
1 About this manual
This manual is valid for ECOS 160, ECOS 250 and ECOS 315 butt-fusion machines
(hereinafter referred to as ECOS 160/250/315).
The warning notices, symbols and their meanings as used in this manual are explained
below to help you quickly understand the format of this instruction manual and how to
use the machine safely.
1.1 Warningnotice
Warning notices are used in this manual to inform you of possible injuries or damage
to property. Please read them and always abide by these warnings!
Symbol
Meaning
Danger
Imminent accute danger!
Failure to comply could result in death or extremely serious injury.
Warning
Possible accute danger!
Failure to comply could result in serious injury.
Caution
Dangerous situation!
Failure to comply could lead to injury or damage to property.

1 About this manual Operating instructions ECOS 160/250/315
2
1.2 Othersymbolsandnotices
Symbol
Meaning
Attention
Mandatory: you must observe this regulation
Advice
Suggest:This notice contains especially important information
1.3 Abbreviations
Abbr.
Meaning
ECOS 160
ECOS 250
ECOS 315
Butt fusion machine d 40–160 mm
Butt fusion machine d 75–250 mm
Butt fusion machine d 90–315 mm
DVS
Deutscher Verband für Schweisstechnik
(German Association of Fusion Technology)
PE
Polyethylene
PP
Polypropylene
PTFE
Polytetrafluorethylene
D
Pipe outer diameter

Operating instructions ECOS 160/250/315 2 Safety instructions
3
2 Safety instructions
The ECOS 160/250/315 Butt Fusion Machines are designed according to the latest
standards of technology. Using it for purposes other than those described in this
manual may cause injury to the operator or to others. It may also cause damage to the
machine or other equipment.
Any person in the company, who is involved in the assembly, disassembly,
reassembly, installation, operation or maintenance (inspection, maintenance work,
repair work) of the
ECOS 160/250/315, must have read and understood the complete instruction manual,
and in particular Section 1 on “Safety instructions”.
It is recommended that the user has this confirmed in writing.
Thus:
•The machine should only be used when in perfect working order.
•Always follow the safety instructions.
Complete documentation should be kept in the vicinity of the machine.
2.1 Proper use
The ECOS 160/250/315 are to be used exclusively for the fusion of pipes and fittings
made of PE, PP. Any other use is not permitted.
2.2 Generalsafetymeasures
•Use only the materials and dimensions specified in this manual. Other materials
may only be used after consulting Georg Fischer Omicron after-sales service.
•Use only original Georg Fischer Omicron spare parts and equipment.
•Inspect the ECOS 160/250/315 daily for visible signs of damageor defects. Have
damage or defects repaired immediately.
•Any work on the electricalequipment may only be done by a specialist.
•Observe all the regulations, standards and guidelines applicable in your country.
2.3 Workingwith safetyin mind
“Make your contribution to safety in the workplace."
•Report any deviations from normaloperation immediately to the person in charge.

2 Safety instructions Operating instructions ECOS 160/250/315
4
Always keep safety in mind while working.
For your own personal safety as well as for the safe and optimal handling of the
machine, the ECOS 160/250/315 must be installed correctly.
Connect hydraulic hoses to and from the machine only when the hydraulic unit is shut
off and not under pressure (observe manometer).
Danger of electric shock!
Inspect the electrical cords and devices!
Do not connect damaged cords or devices to the power supply.
Danger of burning!
The heater is hot (220 °C)!
Danger of burning hands on the hot heater.
Do not touch the heater when on.
Danger of burning!
Use the handles on the heater.
To move the heater, use the gloves! (EN 407 321XXX)
Danger of crushing hands!
The machine slide moves!
Danger of injury to hands in the moving machine slide!
Do not reach inside the machine when moving to the end positions.
Danger of cutting hands!
The planer blades are sharp!
Danger of cutting hands on the planer disk.
Do not touch the rotating planer disk.
Danger
Warning
EN 407 321XXX
Warning
Warning
Warning

Operating instructions ECOS 160/250/315 2 Safety instructions
5
Danger of injury due to high pressure oil leakages!
Inspect the outside wallof hydraulic hoses under pressure: make sure you wear safety
glasses before doing it!
Do not touch leaking oil with hands! Escaping high pressure oil can cause skin
penetration injuries!
Release the oil pressure to zero before replacing defective hoses.
Danger of bruising!
Machine components are heavy!
To move the components, use the gloves! (EN 388 2241)
2.4 Disposal
Shavings and used hydraulic oil should be disposed of properly.
Observe all the regulations, standards and guidelines applicable in your country.
Separate collection of electronic and electrical waste (from the equipment) has to be
ensured through appropriate systems.
note:
The here below symbol indicating separate collection for electrical and electronic
equipment according to 2002/96/CE WEEE directive (Waste Electrical and Electronic
Equipment).
EN 388 2241

3 General Operating instructions ECOS 160/250/315
6
3 General
3.1 Introduction
This instruction manualwas written for those persons responsible for the operation and
care of the ECOS 160/250/31. It is expected and assumed that such persons have read,
understood and will abide by the manualin its entirety.
Only with the knowledge contained in this manualcan faults on the ECOS
160/250/315 be prevented and trouble-free operation be ensured. It is therefore
imperative that the responsible persons are familiar with this manual.
We recommend that this manualbe read carefully prior to putting the machine in
operation, as we are not liable for any damage or interruptions in operation resulting
from failure to comply with this manual.
Should problems nevertheless arise, please contactdirectly Georg Fischer Omicron
s.r.l. or the nearest servicerepresentative.
This manual applies only to the ECOS 160, ECOS 250 and ECOS 315 butt-fusion
machines (hereinafter referred toas ECOS 160/250/315).
We reserve the right to make the technicalchanges necessary to improve the ECOS
160/250/315 which may result in deviations from the illustrations and information
contained in thismanual.
3.2 Range ofapplication
The ECOS 160/250/315 is designed exclusively for the fusion of thermoplastic plastic
pipes, fittings and valves according to the specified dimension range. Any other use is
not authorized. The manufacturer cannot be held liable for damages resulting from
unauthorized use; the user bears sole responsibility.