GF BCF Plus User manual

GF Piping Systems
Instruction Manual
BCF Plus
790.121.001 & 790.121.002

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 Piping Systems Ltd.

Instruction Manual BCF Plus Table of Contents
(11.15) BCF Plus_BA_04
I
Table of Contents
Page
1Introduction 1
2About these instructions 2
2.1Warning messages 2
2.2Further symbols and displays 3
2.3Abbreviations 3
3Button explanation 3
3.1Standby 3
4Safety information 4
4.1Other Related Documents 4
4.2Use according to instructions 5
4.3Working with safety in mind 5
4.4Safety devices and safety guards 6
5Technical Data 7
6Build-up of the BCF Plus 8
6.1Circuit points 8
7Fusion principles 9
8Features and Application 10
9Transport and Storage 11
9.1Transport 11
9.2Storage 11
10Fusion Machine Assembly 12
10.1Scope of Delivery 12
10.2Assembly of the machine and the HP-working table 12
10.3Power supply 14
11Perfect fusion joints 15
12Commissioning 16
12.1Commissioning without access code 16
12.2Commissioning with access code 16
13Menu structure and work sequence 17
13.1Setting the time, date and language 17
13.2Select pipe data 18
13.3Set values 20
13.4Cleaning the fusion zone, cutting the pipe and facing 21
13.5Clamping the pipes / fittings and positioning the bladder d
20 – 63 mm 23
13.6Correcting the bladder position 25
13.7Clamping the pipes / fittings and positioning the bladder d
75 – 110 mm 26
14Fusion 27

Table of Contents Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
II
15Visual weld bead inspection 30
16Creating stored fusion logs and labels 30
16.1Printout by date 31
16.2Printout by counter 32
16.3Output on USB stick 33
17Remote Welding Unit (RWU) 33
18Service and Maintenance 34
18.1Periodic maintenance 34
18.2Fuses and current supply 34
18.3Spare parts replaced by George Fischer 35
18.4General cleaning of the heating station 35
18.5Periodic maintenance 36
19Check for the service status 36
20Diagnostic 37
21Faults 39
22Info and error messages on the display 40
22.1Handling and machine errors 40
22.2Other error messages 41
22.3Informationsmeldungen 42
23Contrast adjustment 42
24Example of fusion log and label 43
24.1Directory of Service / Maintenance Centers 44
25Service form 44

Instruction Manual BCF Plus 1 Introduction
(11.15) BCF Plus_BA_04
1
1 Introduction
The BCF Plus- fusion machine has been developed for high-purity
applications, particularly in the semiconductor industry, the pharmaceutical and
food industries and for highest grade chemicals. The ability to ensure fusion
joints that are absolutely free of beads and crevices play a crucial role in
these ultra-clean applications.
A new welding technology, incorporated into the BCF Plus- fusion machine
makes this possible, unlike conventional welding machines (butt welding,
socket welding). This fusion machine can only be used in conjunction with
SYGEF or PROGEF Natural pipes, fittings and valves from Georg Fischer.
It is an automatic fusion machine. The fusion parameters, such as
temperature, fusion time and fusion pressure are permanently set for each
dimension. This is the only way to ensure a perfect fusion joint.
Then cleaner you work, then less time you will spend rinsing and cleaning.
Always work in clean-room conditions better than class 10.000 wherever
possible, or inside laminar flow boxes. Always wear gloves suitable for clean-
room conditions for all operations. The moisture from your hands contains ions,
bacteria, particles and organic impurities.

2 About these instructions Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
2
2 About these instructions
To allow a quick understanding of these instructions and safe handling of the
machine, all the warning messages, notes and symbols used in these
instructions are presented here along with their meaning.
2.1 Warning messages
In these instructions, warning messages are used to warn you about the
dangers of injury or material damage. Always read and observe these warning
messages!
Warning
symbol Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
WARNING
Possible danger!
Non-observance could result in serious injury.
ATTENTION
Dangerous situation!
Non-observance could result in minor injuries or material
damage.
Danger of burns
Danger of injury

Instruction Manual BCF Plus 3 Button explanation
(11.15) BCF Plus_BA_04
3
2.2 Further symbols and displays
Symbol Meaning
Important
Note Notes: Contain particularly important information for
comprehension.
1. Request for action in a sequence of actions: You have to do
something here.
Single request for action: You have to do something here.
2.3 Abbreviations
Abbr. Meaning
BCF Bead and Crevice Free
3 Button explanation
1Button
PRV / LFT
UP / MNU
NXT / EDT / RGT
DWN / MNU
2Stop / Stand-by button
3ENTER button
3.1 Standby
1. For Standby, the STOP button
must be pressed for 3 seconds.
2. For normal mode, the STOP
button must be pressed again for
3 seconds.
1 2 3

4 Safety information Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
4
4 Safety information
The BCF Plus fusion jointing machine is a state-of-the-art machine. The
machine may cause risks and danger if it is used improperly or not for its
intended purpose by untrained personal.
Consequently:
Every person working with the BCF Plus fusion jointing machine must
have read the complete Instruction Manual in particular have read and
understood this chapter and set up the BCF Plus fusion jointing machine
accordingly.
Keep the Instruction Manual ready at hand in the mobile working table of
the BCF Plus fusion jointing machine.
Use the machine only if it is in technically perfect condition. Faults and
malfunctions which could impair safety must be remedied immediately.
Ensure that only trained personnel work on the BCF Plus fusion jointing
machine.
Check, at regular intervals, that those working on the machine keep in mind
both safety and the risks involved.
Servicing and repairs
Only technical staff of George Fischer may
open the BCF Plus fusion jointing machine.
set the fusion parameters.
repair the BCF Plus fusion jointing machine.
Use only George Fischer spare parts and accessories.
We wish to explicitly point out that spare parts and accessories not delivered
by us have also not been tested and released by us. Installing and / or using
such pro-ducts, can under certain circumstances, change the constructive
standard characteristics of the BCF Plus fusion jointing machine. The result
can negatively influence active and / or passive safety features. In such cases,
George Fischer will not be held liable nor provide warranty coverage for any
injuries and damages resulting from such installation and use.
4.1 Other Related Documents
Safety Data Sheets for PVDF material
Declaration of Conformity
These documents are stored in the drawers of the machine or are available via
the agency of GF Piping Systems.
ATTENTION

Instruction Manual BCF Plus 4 Safety information
(11.15) BCF Plus_BA_04
5
4.2 Use according to instructions
The BCF Plus fusion jointing machine may only be used in accordance with the
information in these operating instructions. Use for other purposes may lead to
personal injury to either the user or other persons. In addition, the machine or
other property could be damaged.
Use the BCF Plus fusion jointing machine only to fuse pipes, fittings and valves
made of SYGEF or PROGEF Natural material. Any use beyond this is not
considered to be used as directed. The manufacturer will not be held liable for
any injuries and damages; these become the user’s full responsibility.
On no account may the fusion parameters preset by George Fischer be
changed. Please observe the raw material Safety Data Sheet according to
regulation (EC) when fusion-jointing is made of PVDF material.
Inspect the BCF Plus fusion jointing machine daily for outwardly visible signs of
damage and defects. Have any damages and defects immediately corrected
by the George Fischer Service Department.
4.3 Working with safety in mind
Always work with safety in mind.
The heating station becomes very hot during operation, so please:
Close the heating station and fix all mobile sections at the transport.
Do not store in the periphery of approx. 65 cm around the heating station
inflammable articles.
Do not touch the heating station while machine processing (Risk of burns).
Do not carry out fusion jointing in the vicinity of highly flammable liquids
and gases.
Do not cover the heating station.
Switch the BCF Plus off during long work breaks.
The facing tool has sharp blades, so please:
Keep your fingers well away from the facing tool.
The cooling fan is removable, so please:
Place the cooling fan in the mounting provided.

4 Safety information Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
6
Be careful not to incur injury from:
sharp edges
sudden closure of the heating station and / or clamping station
falling, improperly clamped piping components
unfastened machine base on the working table
accessories lying around in the safety area of the working table during the
fusion process
Disconnect from the mains before any cleaning or maintenance work.
Immediately report any inconsistencies in the operational condition of the
machine to the persons responsible.
4.4 Safety devices and safety guards
Operate the BCF Plus only if all safety devices and safety guards are fitted and
operable.
The ON/OFF switch is on the back of the machine on the left side.
Position 0: OFF Position 1: ON
The Safety lever is always to be removed after starting the fusion
process because of the danger of inadvertent opening of the heating
station, and the associated possible withdrawal from hot and melted plastic.
The locking mechanism on the drawer prevents the drawer from opening
during transport.
Recycling
Shavings and plastic remainders are to be recycled correctly.
During the disposal of the machine it is to be made certain that the inserted
storage battery is being disposed according to the local recycling regulations.
Further safety regulations
All current safety and accident prevention regulations.
National regulations, standards and directives.
George Fischer will assume no liability for damage and interruption to
operation resulting from non-observance of this Instruction Manual.
Note
WARNING
WARNING

Instruction Manual BCF Plus 5 Technical Data
(11.15) BCF Plus_BA_04
7
5 Technical Data
Manufacturer Georg Fischer Piping Sytems Ltd.
Machine type WNF® Plus
Weight 15-27 kg
(depending on configaration)
Weight of BCF Plus including
transport case and supplies 147-188 kg
(depending on configaration)
Dimensions (machine) 0,48 x 0,32 x 0,25 m
Dimensions (transport case) 0,80 x 0,60 x 1,20 m
Max. power consumption 1100 W
Voltage 115 / 230 VAC 10%
Permissible voltage fluctuations +10 % / -20 %
Electrical power supply 1-phasen alternating current
50/60 Hz (115 / 230 V) L/N/PE
The neutral wire must always be connected. Faults in the neutral wire may
cause damage to the machine.
Mains fuse 10 A
Protection rating IP 43
Working temperature range +10 °C to +40 °C
Storage temperature range +0 °C to +70 °C
< 70% relative humidity
2x USB A
(Host; 'bus powered hub') For “low power” devices (100mA):
USB-memory stick (up to 2GB;
FAT16), compatible for Windows
2000, XP, Linux (except U3),
dimensions: width 8 mm/ height 18,
'Self Powered', PCL-, IBM Proprinter-
and Epson FX compatible USB-
Printer, 'Self Powered' USB-HUB
This product uses GPL/LGPL software. The source code is available on a CD
at Brütsch Elektronik (Article Number 30.0003 645).
The CD also includes a document with information concerning the terms of the
corresponding GNU license. You will be charged CHF 50 for production and
shipping of the CD.
ATTENTION

6 Build-up of the BCF Plus Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
8
6 Build-up of the BCF Plus
6.1 Circuit points
* The locks are operated only by authorized George Fischer coworkers!
(Keys not included in the scope of delivery)!
Clamping Unit
Navigation panel
USB Fuses
Display
Machine housing Remote Welding UnitHeating station
Main switch
Fan Extension cable
Power cable
Service key *
Printer connection

Instruction Manual BCF Plus 7 Fusion principles
(11.15) BCF Plus_BA_04
9
7 Fusion principles
Welding of pipe-/ fitting- elements is done via heat introduction by halfshelled
heating elements to the pipe-/ fitting- exterior surfaces.
At the same time a flexible pressure hull (called “bladder”) supports the inside
of the welding zone for the avoidance of a welding bead. The bladder is
pressed to the tubing inner wall with compressed air, so that the necessary
welding pressure is produced when the plastic melts. So a completely smooth
welding area is developed.

8 Features and Application Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
10
8 Features and Application
The BCF Plus machine is a portable, electronically controlled plastic fusion
machine, which enables reproducible fusion results.
It is suitable for use in the workshop and on industrial sites.
Do not use the BCF Plus plastic fusion machine in trenches.
The BCF Plus fusion machines are suitable for use under clean room
conditions. George Fischer recommends working in class 10.000 clean-rooms
or better when fusion jointing SYGEF PVDF for clean and ultra-clean water
applications (e.g. in the semiconductor, pharmaceutical, biotechnology and
chemical industries). The cleaner the working environment is and the cleaner
you work, the less time you will spend cleaning and rinsing the finished system.
Clean-room gloves should always be used since moisture from your hands
contains ions, bacteria and particles.
The BCF Plus fusion machine can be operated with 115 / 230 VAC 10% in
contrast to its predecessor.
Furthermore, the BCF Plus machine was designed for fusion jointing of
SYGEF and PROGEF Natural. Two different types of bladders are
therefore required. These are either labeled or color-coded for identification
purposes.
SYGEF PVDF-
Bladder = silver head
PROGEF Natural -
Bladder = blue head
The Control System
records pipe data via keyboard
holds all the fusion data; it is no longer necessary to leaf through fusion
parameter tables
shows control questions on the display
monitors the entire fusion process
Pipe data which has been entered is saved even after the BCF Plus
machine has been shut off.
Only use the BCF Plus fusion machine to join those plastic components which
are indicated on the display with their data and dimensions.
ATTENTION

Instruction Manual BCF Plus 9 Transport and Storage
(11.15) BCF Plus_BA_04
11
9 Transport and Storage
9.1 Transport
Before packing the machine, let it cool
for 10 minutes after switching off.
Please transport the complete
machine in the HP-working table,
which also serves as a transport
wagon, and in the transport crate
designated for this purpose.
Avoid jolts and vibrations.
Check: Have all the moveable
parts been secured?
Always transport the machine in an
upright position.
9.2 Storage
Store the working table including the BCF Plus machine in a dry and
weatherproof place. Protect against large fluctuations in temperature which
may cause condensation.
For allowed storage temperatures, see Chapter 5, Technical Data.
The fusion machine, including all the equipment, must be stored and
transported in the original HP-working table.
George Fischer sales personnel will be glad to answer any questions you
might have concerning equipment maintenance.
IMPORTANT

10 Fusion Machine Assembly Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
12
10 Fusion Machine Assembly
10.1 Scope of Delivery
Check the shipment to make sure it is complete and that it hasn’t been
damaged during transport. Missing parts or transport damages should be
reported to George Fischer as soon as possible.
10.2 Assembly of the machine and the HP-working
table
Before using the machine, several components need to be assembled as
follows:
To align the BCF Plus horizontally, adjust the height of the machine feet
Insert the clamping units in the guide notches of the remote welding unit
–Fasten the clamping units with the screw on the back side
Assembly of the facing tool mounting plate and fixing of the facer
Insert the dimension-related components
–Heating station
–Clamping inserts
–Clamping inserts for the facing tool
Fixing of the hose box on the facing tool mounting plate
Link of the compressed air hose in the hose box to the machine
Connect the standard and / or label printer
Connect the machine to the power supply
Be careful when opening the transport crate:
–it could fall off the tailboard / loading ramp!
Be careful when moving the working table:
–It could tip!
ATTENTION

Instruction Manual BCF Plus 10 Fusion Machine Assembly
(11.15) BCF Plus_BA_04
13
In order to operate with the BCF Plus fusion machine, normally is this to set up
(if the conditions of work permit it), as is to be seen in fig:
1 Labelprinter
2 BCF Plus fusion machine
3 Heating stations d 20 – 110 mm
4 Inserts for the facing tool d 20 – 110 mm
5 Clamping Inserts d 20 – 110 mm
6 Hose box
7 Facing tool + Mounting plate
1 2 3 4 5 6 7

10 Fusion Machine Assembly Instruction Manual BCF Plus
(11.15) BCF Plus_BA_04
14
10.3 Power supply
The BCF Plus fusion machine will be connected directly via a 3-channel
115 V / 230 V- CE- shockproof plug to mains supply.
If the supplied mains plug needs to be exchanged because of the country-
specific electric power supply or connections, it is absolutely necessary that the
grounding is connected or the machine is grounded in some other way.
Wiring diagram 115 V / 230 V- CE:
L1: Connect phases
N: Connect neutral
PE: Connect grounding
For damages resulting from nonobservance of these instructions or from
negligence, the manufacturer assumes no liability. The operator of the fusion
machine bears sole responsibility.
For IT mains supply (IT= Isolated Terra) the customer must supervise the
isolation.
Excess voltage from the use of generators should be avoided.
Constant overvoltage and high voltage peaks can damage the electronic
system.
If using extension cables observe the following:
Cable cross-section: 115 V / 230 V min. 3 x 2.5 mm2
max. cable length: 50m
Always fully unwind cable drums.
black
blue
green / yellow
L1
N
PE
L1
N
PE
NOTE

Instruction Manual BCF Plus 11 Perfect fusion joints
(11.15) BCF Plus_BA_04
15
11 Perfect fusion joints
The most important prerequisites for perfect fusion joints are:
Trained personnel, instructed in the BCF Plus plastic fusion technology.
Only one person may operate the machine at the work place and oversee
the set pipe data.
The pipe data must agree with the pipe / fitting in the clamp.
Strictly follow the work steps shown on the display.
Maintain a working temperature between + 10 °C and + 40 °C.
Make sure the work environment is clean and dry.
Only join homogenous materials with the same nominal wall thickness
(max. permissible wall offset of 10%).
Use the prescribed cleaning agents on the pipe ends to be fusion jointed.
The use of the wrong cleaning agents can lead to faulty fusion results. It is
also important that the pipe ends to be fusion jointed and the bladder are
dry before starting the fusion process.

12 Commissioning Instruction Manual BCF Plus
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16
12 Commissioning
12.1 Commissioning without access code
1. Switch on the BCF Plus
2. Control date/time.
12.2 Commissioning with access code
In order to protect the BCF Plus machine from access by unauthorized third
parties, an access code can be supplied by Georg Fischer upon request from
the customer. Then only personnel who know the code can operate the
machine
1. Switch on the BCF Plus machine.
2. Enter the correct access code
with buttons.
3. Confirm with the ENTER
button.
4. If the access code is incorrect, an
alarm signal will sound and the
cursor jumps again to the first
number. The access code can
then be entered correctly.
5. Control date/time.
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2
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