GF TD-1 User manual

Georg Fischer Central Plastics
39605 Independence, Shawnee, OK 74804
Tel. [phone],Fax [phone] e-mail:
[email protected] www.gfcp.com
Manual No. 360045604
Revision November 2021
GEORG FISCHER PIPING SYSTEMS
GF Piping Systems

2
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
Safety Precautions....................................................3
Heaters are not Explosion Proof .................6
Electrical Safety ................................................8
Handling Hot Equipment ..............................8
Tools, Materials & Assy Specs............................3
Tools Required for Assembly & Repair ......6
High Temperature Protective Insulation ..8
Crimping Wire Connectors ...........................8
.
Wire Connections .............................................9
Sealants, Adhesives & Potting ......................6
Compounds ........................................................8
Heater Disassembly Procedure........................4
Heater Assembly Procedure...............................5
Pre-assembly Checks ......................................6
Handle Assembly .............................................8
Body Assembly .................................................8
Wiring ..................................................................9
Final Assembly .................................................6
Wiring Schematics & Diagrams...........................6
TD-1 Wiring Schematic ....................................6
TD-1 Wiring Diagram .........................................8
TD-3 & 14M Wiring Schematics.......................8
TD-3 & 14M Wiring Diagrams .........................9
Repairs ............................................................................11
Adjusting the Heater Temperature.................13
Troubleshooting Guide ...................................14
Parts List ................................................................15
Coated Heater Faces .........................................18
StatementofWarranty.......................................19
Table of Contents
Copy information listed on your Warranty Card for
your records:
Model No. _________________________________
Serial No. _________________________________
Date Received _____________________________
Distributor _________________________________

3
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
The purpose of this manual is to provide proce-
dures for using the TD-1, TD-3, & 14M Heaters. Use
these instructions in conjunction with instructions
provided by the pipe manufacturer. Additionally,
maintenance instructions are provided.
These heaters are also used with other Georg
Fischer equipment in sidewall fusion. Appropriate
sidewall fusion instructions are contained in the
Outrider manuals.
The TD-1, TD-3, and 14M electric heaters are fast
and efficient heater tools for use in the socket
and sidewall fusion of plastic pipe. Designed for
accurate temperature control, the heaters are
equipped with an adjustable thermoswitch and
an analog thermometer. Stick resistant coated
socket and saddle faces are available for a wide
variety of pipe sizes.
Power Requirements
120VAC, 60Hz (240VAC available)
TD-1 800 Watts
TD-3 1500Watts
14M
Weight
TD-1 3.1 lbs
TD-3 8.8 lbs
14M
Heater Body Size
TD-1 4 ½” X 5 1/2”
TD-3 7” x 6”
14M
Thermoswitch
Cartridge Type  Range º - 600º F.
Heaters
Cartridge Type
Thermometer
Stem type  Dial range º F
Accuracy +/- 1% around dial range. +/- 1/2 of
1% at mide range.
Temperature Control
+⁄ º
Description Specifications
1500Watts
11.52 lbs

4
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
Safety is important. Please use the proper per-
sonal protective equipment when using all hand
and power tools. Always wear OSHA approved or
government certied safety glasses when working
with power and hand tools. A full-face safety shield
may be needed for added protection when operat-
ing grinders or other high-speed equipment. Wear
hearing protection when operating loud equip-
ment. Use care when dealing with electricity and
handling hot heaters. Use heat resistant gloves to
handle hot heating irons. Always disconnect elec-
trical power before doing any work on equipment
wiring.
Heaters Are Not Explosion Proof
Heaters do not have sealed electrical contacts and
should never be plugged in and used in an area
that might contain ammable or explosive vapors
or dust. To be used in this type of environment,
the heater should be heated in a safe place and
unplugged before transfer to the location where
the fusion will occur.
Electrical Safety
An electrical shock can be deadly. Before plugging
a faulty or recently repaired heater into power use
a volt/ohmmeter to check for an electrical short in
the wiring or components. Be sure that your power
supply provides the correct voltage and is rated
for the power requirement of the equipment to be
tested. It is highly recommended that a Ground
Fault Interrupt circuit protection device be used for
testing heaters. Replace or repair a damaged or
frayed electrical cord or plug. After completing any
wiring always check the electrical circuit before
reassembly of the heater. Conrm that the elec-
trical safety ground is installed correctly. Use the
volt/ohmmeter to conrm that the safety ground is
electrically isolated from the power wires. Always
use extra care in a wet environment.
Handling Hot Equipment
Fusion heaters normally maintain a temperature
of 450Fº to 500ºF. They can cause severe burns if
not handled with care. Protective gloves capable
of withstanding these temperatures should be
worn. Never lay a hot heater on a surface that is
not heat resistant. Never leave a powered heater
unattended. A faulty thermoswitch or incorrect
thermoswitch setting can cause the heater to
reach temperatures above 700ºF. Only use a non-
synthetic cloth, like cotton, to wipe hot surfaces.
Tools,Materials,&AssySpecs
Please use the proper personal protective equip-
ment when using all hand and power tools. Use
care when dealing with electricity and handling
hot heaters.
Tools Required For Assembly and Repair
The following tools will be needed to properly as-
semble, service and repair the TD-1, TD-3 and
14M heaters.
• Crimping pliers capable of crimping
high temperature, non-insulated butt
connectors and parallel connectors for
14-16 gauge and 10-12 gauge wire
• Wire cutters and wire strippers
Safety Precautions

5
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
• Scissors or knife for cutting glass tape
• Screwdriver with a 3/16” round shank
and at blade at least ve inches long
(for thermal switch adjustment)
• 3/16” Hex wrench
• Adjustable open-end wrench capable of
1-1/8” size opening
• Flat punch
• Small hammer
• 3/16” diameter pin punch
• Volt/ohmmeter
High Temperature Protective Insulation
Protective sleeve material and insulation should
be capable of withstanding repeated exposure to
1,000ºF temperature (p/n: ).
Install the protective insulating sleeves before
crimping the wire connectors. Be sure that the
sleeve extends past the connector on each side
by ½” or more. Ensure that the sleeve cannot slip
from the connector by taping with the berglass
tape. A minimum of two layers of tape should al-
ways be applied. Alternate tape layers should be
wrapped with an opposite bias, i.e. with the angle
of the tape in the opposite direction.
Crimping Wire Connectors
Crimping tools should be kept in good working
conditions. Worn crimp jaws or pliers should be
replaced. Only use high temperature, nickel plated
butt and parallel crimp style connectors to con-
nect wires. Before crimping be sure that the seam
of the connector is oriented toward the female
side of the crimping jaws. Wire crimps should
be done with sucient force to securely trap all
of the wires. The connector should be deformed
completely. Each wire should be pulled rmly after
crimping to check the crimp.
Wire Connections
Use only high temperature wire connectors. DO
NOT USE INSULATED CONNECTORS.
Only strip the minimum amount of insulation from
the end of the wire to make a crimp connection.
This is normally about 3/16”.
Do not use lead-based solder to connect wiring.
This type of solder melts at a temperature well be-
low the operating temperature of the heating tool.
Wire ends, heater components and surfaces must
be kept clean and free of grease or oil. This in-
cludes oil from your hands. Wire ends should be
twisted prior to crimping.
Do not trim wire strands to reduce the size of the
wire. This will reduce the current carrying capacity
of the wire.
Do not twist multiple wire ends together before
crimping.
Do not allow sharp corners or loose wire strands.
Power cord wire insulation is not capable of with-
standing heater temperatures. If exposed to high
temperature, the rubber insulation will crack and
crumble leading to a short circuit in the wiring.
Sealants, Adhesives and Potting Compounds
Heater cartridges will reach temperatures higher
than the heater set temperature. Sealants or pot-
ting compounds can be used to secure and pro

6
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
tect wiring, wiring connectors and components.
The material used must be capable of withstand-
ing sustained temperature of 550ºF and a maxi-
mum temperature of 650ºF. If the material is close
to or contacts the heater cartridges, it should be
rated for a temperature of 900ºF.
Even sealants and adhesives rated for high tem-
perature have a tendency to degrade at high tem-
perature. Do not rely on them alone to provide
electrical insulation.
Heater Disassembly Proce-
dure
Be sure power is disconnected from the heater.
Remove butt plates or heater faces to prevent
damage to the coating. Exercise care when han-
dling the heater to prevent damage to the face of
the heater body. The heater body should be kept
at and smooth to allow good heat transfer to the
heater face during the fusion process.
Loosen the clamping nut on the cord strain relief.
This should allow the cord to slide through the cord
grip. Remove the screws that attach the handle to
the heater body. Carefully slide the handle out of
the body. Keep the handle aligned with the body
until the thermometer is clear of the body. At the
discretion of the operator, the thermometer may
be removed from the handle before the handle is
detached from the body.
Cut the wires that connect the black and white
power wires just below the crimp connectors. The
ground wire lug may be unscrewed from the body,
however the lug must be able to pass through
the cord grip. If the lug cannot be removed or slip
through the cord grip, cut the wire just below the
power cord crimp connector. The ground lug must
be removed on the TD-1 heater to allow removal
of the thermoswitch. Slide the wire out of the han-
dle.
To replace the wooden handle rst unscrew and
remove the cord grip. Unscrew and remove the
coupling that holds the wooden grip on the heater
handle. Slide the wooden grip o of the heater
handle. Do not twist the handle. It has an indexing
pin to keep it from turning. Repeated exposure to
heat can cause the wooden grip to stick to handle.
If necessary, use a pin punch and hammer to drive
the woodo of the handle.
Slide the thermoswitch and heater cartridges
from the heater body. Do not pull on the wires to
do this. During operation repeated heat cycles will
make the wire and wire insulation brittle. Use a pin
punch through the access holes in the bottom of
the heater body to push the components from the
heater body.
All insulation and berglass wrapping should be
replaced when reworking a used heater.
Heater Assembly Procedure
TD-1, TD-3 and 14M heaters are very similar in
construction. The following assembly procedure
will cover the three heaters with any differences
noted in the procedure. Check the parts lists to
determine dierences in the components used on
each heater.

7
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
Pre-assembly Checks
Use an ohmmeter to do a quick check of the circuit
continuity on the heater cartridges and the ther-
moswitch before starting. Also check for a short
to the heater bo on each component. This will
prevent installation of a faulty part. Make sure all
heater cartridge cavities and the thermoswitch cavity
are clean and free of oil, dirt or other debris. Wipe the
surfaces of the heater clean to remove dirt and
oil.
Handle Assembly
Slide the wooden handle over the shaft of the
heater handle weldment. Align the pin on the
handle weldment with the small hole in the end of
the wooden handle. Install the threaded coupling
onto the handle shaft. Each end of the coupling
has a dierent thread. Be sure the correct end is
threaded onto the shaft. Screw the coupling down
until it is ush with the end of the wooden handle.
Place the washer on the exible strain relief and
thread into the coupling. Tighten until the handle
is secure. Do not over-tighten. It will strip the plas-
tic threads. Feed the cord wire through the handle
assembly. After the wire passes through the han-
dle slip the gasket over the end of the wire. Pull 1
to 2 feet of wire through the handle. You will need
enough wire to work with the wire connections.
Body Assembly
Check the holes in the body to be sure they are
free of dirt and debris before inserting the two
heater cartridges and the thermoswitch. (The TD-
3 and 14M heaters will have three heater cartridg-
es.) The components should slide easily into the
body. If any interference is encountered, remove
the components and check the hole for debris
or damage. Slide the thermoswitch adjustment
screw shield over the adjustment screw shaft on
the end of the thermoswitch. The heater guide
shaft shown in the photo at the right hand end of
the heater body should not be installed until the
heater is to be used in eld operations.
Wiring
The following wiring schematic and wiring diagram
show the circuit connections for the TD-1 heater.
The picture to the left shows the heater after the
wiring has been completed prior to wrapping the
wire bundle with two wraps of ¾” high tempera-
ture berglass tape. The heater can operate at
temperatures in excess of 450ºF. CAUTION: Lead
solder should never be used to connect wiring. It
will soften at heater operating temperatures.
Before wiring the heater, each wire must be cut to
length and the insulation stripped to expose the
conductor. Remove from 3/16” to 7/32” of insula-
tion from the end of the wire.

8
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
Caution: The length of insulation removed
is important because excess exposed wire can
penetrate the insulation and cause an electrical
short.
The length of each wire should be measured af-
ter the wire is folded over into the body cavity and
bent up in the center of the body. The length of
each wire above the heater body is shown in the
following table. The length of the wire exposed on
the power cord is measured from the rubber cable
cover. When stripping the insulation be careful to
not cut the wire strands. The ground wire is made
from the longest piece of wire cut from the ther-
moswitch lead that connects to the heater car-
tridges.
Wire Length
Thermoswitch wire to the black power wire 3”
Heatercartridgeleadfurthestfromthethermoswitch 4”
All other wires including the ground wire 2.5”
Black power cord wire 1.25”
White power cord wire 2”
Green power cord wire (grounding wire) 2.5”
Crimp a grounding lug (p/n: ) to
the end of the longest piece of wire cut from the
thermoswitch. Pull on the lug to be sure it is se-
cure. Place the wire into the heater body and mea-
sure the length required; cut the wire and remove
the recommended amount of insulation. Attach
the grounding wire to the body with a screw and
lock washer.
Use a 10-12 ga parallel connector 360003390
to connect the two heater cartridges (three for
the TD-3 and 14M) to the short wire on the thermo-
switch. The longest heater cartridge lead should
be one of these wires. After crimping, pill on each
wire to be sure they are secure. Be sure there are
no exposed wire strands or sharp corners that could
penetrate the insulation. Slide an insulating sleeve
over the end of the crimped connection. Do no slip
the insulating sleeve all the way down. Let approxi-
mately ½” of the insulating sleeve extend past the
sleeve extend past the end of the connection. Cut
a 2.5” length of ¾” wide berglass tape. Fold the
end of the insulating sleeve over at the end and
lay the tape on the wire parallel to the wires with
the end of the tape extending past the end of the
connection about 1”. See the picture below. Wrap
the tape around wire and fold the end of the tape
over the end of the connection. Cut a 6” piece of
berglass tape and spiral wrap the end of the wire
with two layers of tape. Extend the over wrap past
the rst piece of tape.
Insulation of the Connector for the Thermoswitch to Heater
Cartridge Wiring
Note: Check to be sure the gasket is in place
over the power cord before making the rst pow-
er cord connection.
Parallel Crimp
Connector
Wires
¾” Wide Fiberglass
Tape
Insulating Sleeve
P/N: 28-8412-0100-10

9
Assembly & Repair Guide
TD-1, TD-3, & 14M Heaters
Slide an insulating sleeve over each of the re-
maining thermoswitch, ground wire and heater
cartridge leads. Use one 14-16 ga butt connector
(p/n: ) to connect the remain -
ing two heater cartridge wires to the white power
cord wire on the TD-1 and a 10-12 ga butt connec-
tor (p/n: ) to connect the three
heater cartridge wires to the white power cord wire
on the TD-3 and 14M. Pull on each wire to conrm
they are secure. Check for sharp corners or loose
wire strands. Slide the insulating sleeve over the
connector and be sure it is centered over the con-
nector.
Use a 14-16 ga butt connector 
to connect the remaining thermoswitch wire to
the black power cord wire and the ground wire
to the green power cord wire. Pull on each
wire to conrm they are secure. Check for sharp
corners or loose wire strands. Slide the insulating
sleeves over the connectors and be sure they are
centered over the connectors.
Final Assembly
Install the thermometer and tighten hand tight
only. The black, white and green power cord con-
nections should be positioned inside the heater
handle as far from the heater body as possible
without interfering with the cord strain relief. The
connections should be staggered to prevent rub-
bing against each other and causing an electrical
short circuit. After the wires are positioned togeth-
er with the connectors staggered, neatly fold and
position any excess length of wire into the cavity of
the heater body. Be sure to center the wire bundle
in the center of the heater body. Take care to pre-
vent insulation damage or interference with any
of the hardware. Cut a 12” length of ¾” wide -
berglass tape. Wrap the three-wire bundle with a
spiral wrapping from just above the heater body to
1” past the end of the rubber cable cover. The spi-
ral wrap should start at the power cord end, go to-
ward the heater body and come back to the power
cord to complete the two full layers of tape. Each
spiral wrap should overlap the previous wrap.
Use an ohmmeter to check the electrical circuit to
be sure there is no electrical short circuit before
installing the handle.
Slide the handle down the wire to the heater body
and position the gasket. Install the two mount-
ing screws. Tighten the cord-grip clamping nut to
rmly grip the wire. Do not over tighten the plastic
threads. They can strip easily.
The heater can now be powered for testing. The
completed heater shown in the picture has the
guide rod installed. This may be installed in the
eld prior to operation.

Assembly & Repair Guide
TD-1,TD-3, & 14M Heaters
Wiring Schematics & Diagrams
T
T
D-1 Wiring Schematic
TD-1 Wiring Diagram
Heater Cartrid
g
e
T
hermoswitch
Heater Cartrid
g
e
Green
Black
W
hite
Crimp Style Grounding Lug
Screwed to the Heater Body
Heater Cartridge
T
hermoswitch
Heater Cartridge
Black Wire
W
hite Wire
Green Wire
14-16 ga Butt Crimp Connector 3 Reqd
High Temperature Wire Lead Trimmed From Thermoswitch
10-12 ga Parallel Crimp Connecto
r
10