GF Piping Systems TM 160 ECO User manual

Instruction manual
GF Piping Systems
TM 160/250/315 ECO
Butt Fusion Machine

All rights reserved, in particular the rights of duplication and distribution as well as translation. Duplication and
reproduction in any form (print, photocopy, microfilm or electronic) require the written permission of Georg Fischer
Omicron S.r.l..

Operating instructions TM 160/250/315 ECO 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 4
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
7.2.1Heating Element Temperature Regulator 14
7.2.2Functions of the temperature regulator 14
7.2.3Heating element temperature adjustment 15
7.2.4Temperature offset adjustment 15
7.2.5Error messages 16
8Fusion 17
8.1The basics of butt fusion 17
8.2The fusion process 18
8.2.1Calculating drag pressure 18
8.2.2Preparing the fusion surfaces 18
8.2.3Calculating of the fusion pressure 20
8.2.4Adjusting of the fusion pressure 20
8.2.5Fusion process 21
8.3Visual check of welding bead 23
8.4Example TM 315/250 24
9Failure analysis 25
10Maintenance 27

Table of contents Operating instructions TM 160/250/315 ECO
II
10.1Replacement of worn parts 27
10.2Hydraulic system 27
10.3Hydraulic unit 28
11Customer Service 30

Operating instructions TM 160/250/315 ECO 1 About this manual
1
1 About this manual
This manual is valid for TM 160 ECO, TM 250 ECO and TM 315 ECO butt-
fusion machines (hereinafter referred to as TM 160/250/315 ECO).
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 Warning notice
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 TM 160/250/315 ECO
2
1.2 Other symbols and notices
Symbol Meaning
Attention
Mandatory: you must observe this regulation
Advice Suggest: This notice contains especially important
information
1.3 Abbreviations
Abbr. Meaning
TM 160
TM 250
TM 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)
HD-PE High Density Polyethylene
PE Polyethylene
PP Polypropylene
PTFE Polytetrafluorethylene
D Pipe outer diameter
ERC Electronic Remote Control

Operating instructions TM 160/250/315 ECO 2 Safety instructions
3
2 Safety instructions
The TM 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 theTM 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 TM 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 General safety measures
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 TM 160/250/315 daily for visible signs of damage or
defects. Have damage or defects repaired immediately.
Any work on the electrical equipment may only be done by a
specialist.
Observe all the regulations, standards and guidelines applicable in
your country.

2 Safety instructions Operating instructions TM 160/250/315 ECO
4
2.3 Working with safety in mind
“Make your contribution to safety in the workplace."
Report any deviations from normal operation immediately to the
person in charge.
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 TM 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 cutting hands!
The planer blades are sharp!
Danger of cutting hands on the planer disk.
Do not touch the rotating planer disk.
Danger of burning!
The heater is hot (220 °C)!
Danger of burning hands on the hot heater.
Do not touch the heater when on.
Use the handles on the heater.
Danger of crushing hands!
The machine slide moves!
Danger of injury to hands in the moving machine slide!
Do not reach into the machine when moving to the end positions.
Warning
Warning
Warning

Operating instructions TM 160/250/315 ECO 2 Safety instructions
5
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).

3 General Operating instructions TM 160/250/315 ECO
6
3 General
3.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the TM 160/250/315 ECO. It is expected and
assumed that such persons have read, understood and will abide by
the manual in its entirety.
Only with the knowledge contained in this manual can faults on the TM
160/250/315 ECO 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 manual be 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 contact directly Georg
Fischer Omicron s.r.l. or the nearest service representative.
This manual applies only to the TM 160 ECO, TM 250 ECO and TM 315
ECO butt-fusion machines (hereinafter referred to as TM 160/250/315
ECO).
We reserve the right to make the technical changes necessary to
improve the TM 160/250/315 ECO which may result in deviations from
the illustrations and information contained in this manual.
3.2 Range of application
The TM 160/250/315 ECO 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.