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.

Operating instructions TM 160/250/315 ECO 3 General
7
3.3 Copyright
The copyright for this instruction manual is held by Georg Fischer
Omicron S.r.l..
This instruction manual is intended for assembly, operation and
maintenance personnel. No part of the technical regulations or
illustrations contained herein may be reproduced or distributed in any
form, used illicitly for competitive purposes or passed on to others.
Georg Fischer Omicron S.r.l
Via E. Fermi, 12
I 35030 Caselle di Selvazzano
Padova (Italy)
Telephone [phone]
Fax [phone]

4 Product identification and description Operating instructions TM 160/250/315 ECO
8
4 Product identification and
description
4.1 Product identification
According the directives for machines an identification tag is added to
the base machine, showing the following information:
1. Manufacture
r
2. Type of machine
3. Serial number
4. Piston area
5. Pipes range
6. Year of manufacture
7. Wheight
8. Barcode
4.2 Product description
Base Machine
Hardened and hard chrome-
plated guide shafts (1)
Third clamp is adjustable (2)
Pull-Off mechanism for heating
element (3)
Hydraulic unit
Precision manometer Class 1,
scale 0–160 bar (0-100 bar TM 160),
diameter 100 mm (1)
Lightweight compact hydraulic
unit IP-33, steel protection frame,
control lever (2)
Freely adjustable pressure
regulator, equalization and fusion
pressure can be pre-set (3)
Integrated flexible hoses. Anti-drip,
rapid-action coupling with
2 3
4
8
5 6
1
7

Operating instructions TM 160/250/315 ECO 4 Product identification and description
9
protective caps .
Heating element
PTFE-coating
Power multi-cord (4 m) with
integrated temperature sensor
probe
Thermometer integrated
Electric planer
Torque transmission via robust
worm-gear device
Self locking device against
accidental unhooking (1)
Planer blades sharpened on both
sides (2)
Safety micro switch against
accidental starting (3)
Storage Case
Zinc-coated steel case for
transport and storage of both
heating element and pipe planer
Temperature Regulator
Metal case with microprocessor
assisted temperature control
Digital display of current heater
plate temperature
Indication of actual status,
adjustment of set temperature
and offset
2
1
3

5 Technical specifications Operating instructions TM 160/250/315 ECO
10
5 Technical specifications
Machine
description Butt-fusion machine to weld thermoplastic pipes PE, PP
Type TM 160 TM 250 TM 315
Serial No. ............ ............ ............
Total piston
area 353 mm2510 mm2510 mm2
Max.
pressure 100 bar 160 bar 160 bar
Type of
hydraulic oil LI 46 SHELL (viscosità 46)
LI 46 SHELL
(viscosità 46)
LI 46 SHELL
(viscosità 46)
Quantity of
hydraulic oil 2,0 l 2,0 l 2,0 l
Noise level 70 dB(A) 70 dB(A) 70 dB(A)
Tension 230 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz
Performance 1900 W 3070 W 3670 W
Dimension
(packaging) 105x68x68 cm 158x83x84 cm 158x83x84 cm

Operating instructions TM 160/250/315 ECO 6 Transport and assembly
11
6 Transport and assembly
6.1 Packaging
A decisive factor in the choice of packaging is the means of transport.
Usually the machine and all the accessories are delivered in a
cardboard box on a pallet or wooden case upon request.
6.2 Sensitivity
Special care must be taken when transporting the machine in order to
prevent damage from impact or improper loading and unloading.
All movable parts must be fixed in place.
Transport insurance should be provided for according to the type and
duration of transport. Condensation due to large temperature
fluctuations and sharp jolts during shipment should be avoided.
Please handle the machine with care.
6.3 Intermediate storage
If the machine is not used immediately upon delivery, the machine must
be stored in a safe place and properly covered.
6.4 Scope of delivery
The contents (number of transport crates, pallets, packages) and their
condition should be checked immediately upon receipt. Any damage
and/or missing parts should be noted right away on the bill of lading
and reported to Georg Fischer Omicron S.r.l. without delay.

7 Fusion preparation Operating instructions TM 160/250/315 ECO
12
7 Fusion preparation
7.1 General information
The Fusion Process described in the following chapters is based on the
instruction sheets and guidelines issued by the DVS 2207.
The fusion area should be protected against the influences of weather
(humidity, ambient temperature <+ 5 °C, extreme direct exposure to
sun) with such measures as pre-warming the fusion materials, tents,
heating.
For optimal use of the TM 160/250/315 the operating personnel should
be specially trained by Georg Fischer. In-depth knowledge of the
machine and it´s components and competence rule out handling errors
thereby also preventing faulty fusion joints.
7.2 Preparations
The standard configuration of the base machine is prepared to joint
pipe to pipe by using 2 clamps to fix each pipe in the base machine.
The planer and the heating element is inserted between the two central
clamps.
In order to clamp particular constructions or T-pieces or to use a flange
adapter, shift the clamping unit B to the required position. Therefore
remove the two spacers C (upper and lower on) from the original
position, position the clamping unit B and fix it with the two spacers C.
The pipe preparation and welding position is now changed, insert the
heating element into the pull-off mechanism between A and B.
Clean the couplings on the base machine and the hoses.
Connect the hydraulic hoses to the base machine and to the hydraulic
unit.
If the hydraulic hoses are not used, seal the couplings with the
protective caps. Clean the protective caps first.
Replace the heater if the PTFE -coating is damaged. Failure to comply
could impair the quality of the fusion weld.
Advice

Operating instructions TM 160/250/315 ECO 7 Fusion preparation
13
In order to weld pipes and/or fittings with an outer diameter smaller than
the clamp of the base machine, insert matching clamping half shells
and fasten them with the screws.
Clamp the components to be jointed in that way, that the pipe/fitting
ends reach out at least 30 mm from the clamps in order to perform a
proper weld. Make sure they are exactly aligned in the axial direction.
If necessary, the components can be turned or the clamping force
changed to achieve a better clamping position.
Adjustable roller supports or a floating suspension assist horizontal
movement of the pipes fixed in the carriage.
When pipes are positioned into the base machine, close the carriages till
the pipes are in contact with themselves. Control the position of the
stroke indicator in relation to the red mark (cylinder stroke end). If the
indicator is close to the red mark, during the welding procedure no
pressure could be transferred into the welding zone! The weld will not
perform !! Change the clamping position of the pipes! After planning the
pipe ends, the distance between the indicator and the mark has to grant
the movement during bead build up, heat soak phase and bead roll over!
Attention
Stroke indicato
r
Stroke end mark

7 Fusion preparation Operating instructions TM 160/250/315 ECO
14
7.2.1 Heating Element Temperature Regulator
1. Connect Heating element to the temperature regulator.
Check the voltage!
The generator has to be started before connecting the consumer and
must supply a constant output tension! Any sudden changes could
compromise the correct welding result and/or damage the control.
2. Connect temperature regulator to the power outlet or power
generator.
3. After the temperature regulator is connected to the power supply,
the current heating element temperature is shown on the display.
The LED (1) is ON and indicates the correct connection of the
heating element. If the temperature probe is damaged or the signal
is interrupted or the heating element is not connected properly, the
display will show the error “tc, E40”. In that case you have to
disconnect the power supply from the regulator and connect the
heating element.
4. Check the temperature of the heater plate surface with a quick-
indication temperature measurement according to the set
temperature.
7.2.2 Functions of the temperature regulator
The LED (1) is permanent ON when the power is connected and the
display is showing the current heating element temperature. When
flashing the temperature is regulated at the set point.
The LED (2) is ON when the set temperature is indicated on the display
Button (3) provides to switch ON and OFF the regulator, access to adjust
the set temperature and is used to confirm data.
Button (4) to decrease the value (set-point, offset)
Button (5) to increase the value (set-point, offset)
Button (5) and (3) together allows the adjustment of the offset
Before beginning with the first fusion, we recommend waiting approx. 10
minutes after the set fusion temperature has been reached, to allow even
heat distribution.
Caution
Advice
1
2
3 4 5

Operating instructions TM 160/250/315 ECO 7 Fusion preparation
15
7.2.3 Heating element temperature adjustment
After the heating element is connected and the temperature regulator
is supplied with power, push the button "ON SET" (3) for about 5-6
seconds. The LED 2 starts flashing, indicating that the programming
mode is activated, the display indicates the last adjusted set point.
To change the value of the set point use the buttons UP (5) and DOWN
(4), the value is changing immediately. To confirm the set point press
"ON SET" (3) or wait for approximately 10 seconds and the display will
change automatically to the indication of the current heating element
temperature.
After the connection to the power supply, the unit of measurement
(°C or F) is shown for few seconds. When it is shown, by pushing “ON SET”
(3) + DOWN (4) together, you can change the unit of measurement
(°C – F). Enter into the menu and change the unit of measurement using
the buttons UP (5) and DOWN (4). Press “ON SET” (3) to confirm.
The range of set temperature is from 100°C to 270°C
Any mistake occurred in the temperature set up can be corrected
repeating the set up procedure.
7.2.4 Temperature offset adjustment
Such adjustment is basically a calibration of the actual temperature
detected by the heating element probe (displayed on the temperature
regulator) in respect of the actual temperature measured on the
surface of the heater plate.
In order to set-up the temperature offset, the programming mode
should be activated by pressing together the buttons (5) and (3) for
about 5–6 sec. LED (1) and (2) starts flashing and the display shows the
value of the preset offset value.
By pressing the button (5) or (4) the value could be increased or
decreased, the range is between +/- 25°C.
If the difference between the measured temperature on the heater
plate surface and the displayed temperature on the temperature
regulator is out of the range +/- 25°C, please contact your next service
station.
With (5) the value of the offset will be confirmed.
Example: offset calibration.
Connect the temperature regulator to the heating element and to the power supply. Set up the
heating element temperature, i.e. 220 °C and wait until approximately 10 minutes for even
temperature distribution on the heater plate. Supposing that the measured actual temperature of
the heating element is 215°C. The difference with the set-up temperature (220°C) is therefore 5°C.
By setting-up an offset of 5°C the heat dissipations will be compensated.
Advice
Advice
Advice

7 Fusion preparation Operating instructions TM 160/250/315 ECO
16
7.2.5 Error messages
The temperature regulator controls different possible errors or difficulties
concerning the connections and the power supply. As soon as an error
occurs the ERC is providing the corresponding error message on the
display. To clear the message the ERC has to be switched OFF and ON.
Following the list of error messages with a description, possible causes
and solutions.
Error code Possible causes Solution
E40
Heater plate
missing
Heating element not
connected
Check if the heating
element is connected
correctly, switch Off and
On the unit again
Sensor circuit interrupted Contact service
E41
Resistance
interrupted
Circuit of resistance
interrupted Contact service
E90
Push button
pressed during
starting the
ERC
During the start up of the
ERC, one or more buttons
are activated
Check if one or more
buttons damaged or
active. Restart the ERC.
E98/E99
Error of
memory Contact service