GF GF 500 User manual

Operating Instructions GF 500
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 GF 500 Table of contents
I
Table of contents
Page
0About this manual 1
0.1 Warning notice 1
0.2 Other symbols and notices 2
0.3 Abbreviations 2
1Safety instructions 3
1.1 Proper use 3
1.2 General safety measures 3
1.3 Working with safety in mind 4
1.4 Disposal 5
1.5 Further safety guidelines 5
1.6 Other disposal 5
2General 6
2.1 Introduction 6
2.2 Range of application 6
2.3 Copyright 7
3Product design, equipment 8
3.1 Design 8
3.2 Standard equipment 9
4Technical specifications 10
4.1 Characteristic data 10
5Transport and assembly 11
5.1 Packaging 11
5.2 Sensitivity 11
5.3 Intermediate storage 11
5.4 Scope of delivery 11
6Fusion preparation 12
6.1 General information 12
6.2 Preparations 12
7Fusion 13
7.1 The basics of butt fusion 13
7.2 The fusion process 14
7.2.1 Calculating drag pressure 14
7.2.2 Calculating of the fusion pressure 14
7.2.3 Adjusting of the fusion pressure 15
7.2.4 Preparing the fusion surfaces 15
7.2.5 Fusion process 16
7.3 Visual check of welding bead 18
7.4 Example 19
7.5 Fusion data 19
8Failure analysis 27
9Maintenance 29

Table of contents Operating instructions GF 500
II
9.1 Replacement of worn parts 29
9.2 Hydraulic system 29
9.3 Hydraulic unit 30
10 Customer Service 31

Operating instructions GF 500 0 About this manual
1
0About this manual
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.
0.1 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
Warnings are always structured in the same manner:
•Warning symbol
•Type and source of danger
•Possible consequences, explanation of danger
•Prohibited (if applicable) (symbol: ;)
•Ways to prevent the danger (symbol: X)
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.

0 About this manual Operating instructions GF 500
2
0.2 Other symbols and notices
Symbol Meaning
Mandatory: you must observe this regulation.
1. Call for action in a particular sequence. You must do
something here.
XSingle call for action. You must do something here.
ZCall for action under certain circumstances. You must do
something here if the condition beforehand has been
fulfilled.
0.3 Abbreviations
Abbr. Meaning
GF 500 Butt fusion machine d 200–500 mm
DVS Deutscher Verband für Schweisstechnik
(German Association of Fusion Technology)
HD-PE High Density Polyethylene
PE Polyethylene
PP Polypropylene
PVDF Polyvinylidene fluoride
PTFE Polytetrafluorethylene
d Pipe outer diameter
Important
Attention
This notice contains especially important information.

Operating instructions GF 500 1 Safety instructions
3
1Safety instructions
The GF 500 Butt Fusion Machine (hereinafter referred to as GF 500) is
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 GF 500, 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.
1.1 Proper use
The GF 500 is to be used exclusively for the fusion of pipes and fittings
made of PE, PP and PVDF.
1.2 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 GF 500 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.

1 Safety instructions Operating instructions GF 500
4
1.3 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 GF 500 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 (210 °C)!
Danger of burning hands on the hot heater.
:Do not touch the heater when on.
XUse 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 GF 500 1 Safety instructions
5
1.4 Disposal
Shavings and used hydraulic oil should be disposed of properly.
1.5 Further safety guidelines
Observe all the regulations, standards and guidelines applicable in your
country.
1.6 Other disposal
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).

2 General Operating instructions GF 500
6
2General
2.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the GF 500. 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
GF 500 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 the nearest Georg
Fischer Omicron representative.
This manual applies only to the GF 500.
We reserve the right to make the technical changes necessary to
improve the GF 500 which may result in deviations from the illustrations
and information contained in this manual.
2.2 Range of application
The GF 500 is designed exclusively for the fusion of plastic pipes, fittings
and valves in the dimension range d 200–500 mm. 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 GF 500 2 General
7
2.3 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]

3 Product design, equipment Operating instructions GF 500
8
3Product design, equipment
3.1 Design
1 Storage case with heater and plane
r
2 Basic machine
3 Hydraulic unit
4
Power control box
1 2 3 4

Operating instructions GF 500 3 Product design, equipment
9
3.2 Standard equipment
•Base machine
–Hardened and hard chrome-plated guide shafts
–2. clamping element relocatable
–Heater release mechanism to optimize the changeover phase
–Tool and wrench set
•Hydraulic unit
–Precise hydraulic control unit for a consistent setting of the fusion
pressure
–Interface for SUVI 50 data recording device (optional)
•Storage case with heater and planer
•Heating element
–PTFE-coating
–Power cord 4 m
–Temperature gauge
–Electronic temperature controller
•Electric planer
–Worm drive
–Stop mechanism for safety
–Safety microswitch to prevent unintentional start-up
–Planer blades sharpened on both sides
•Power control box
–Made of sheet-steel and protected by a painted tubular frame
–All functional and safety components are contained inside:
electronic thermostat, relay and differential switch
•Hydraulic hose package
–With anti-drip, rapid-action couplings

4 Technical specifications Operating instructions GF 500
10
4Technical specifications
Planer
Power:
Voltage: Electromotor 760 W 400 V
Heater Power:
Voltage: 4000 W 400 V
Hydraulic unit Power:
Voltage:
Oil type:
1500 W
400 V
Viscosity 46
2 liters of hydraulic oil in canister,
Code No. 790 112 409
Power control box Voltage: 400 V
Machine complete Power:
Voltage: 5510 W 400 V
4.1 Characteristic data
Machine description:
Plastic butt fusion machine
Machine type GF 500
Machine no. ............
Total piston area 1413 mm2
Maximum pressure 160 bar
Weight of basic machine 172 kg
Weight of hydraulic unit 38 kg
Weight of planer 53 kg
Weight of heater 26 kg
Power control box 14 kg
Noise level 70 dB(A)

Operating instructions GF 500 5 Transport and assembly
11
5Transport and assembly
5.1 Packaging
A decisive factor in the choice of packaging is the means of transport.
Normally, the machine and all the accessories are delivered in a
cardboard box on a pallet.
5.2 Sensitivity
Special care must be taken when transporting the GF 500 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 GF 500 with care.
5.3 Intermediate storage
If the GF 500 is not used immediately upon delivery, the machine must
be stored in a safe place and properly covered.
5.4 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.

6 Fusion preparation Operating instructions GF 500
12
6Fusion preparation
6.1 General information
Chapter 6, Fusion Preparation, and Chapter 7, The Fusion Process, are
based on the instruction sheets and guidelines issued by the DVS.
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 GF 500, 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.
6.2 Preparations
1. Connect heater and planer to the power control box.
2. Connect power control box to the power.
Check the voltage!
ZMain power (3) switch on. Control lamp (1) turns white.
3. Set temperature controller (4) to the correct fusion temperature. For
guidelines, see the fusion tables in Chapter 7.5, from pg. 19.
4. Push heater switch (2). Switch turns green when heater on.
–Light on controller turns red during heating and starts blinking when
setting temperature is reached.
Before beginning with the first fusion, we recommend waiting approx. 10
minutes after the set fusion temperature has been reached to allow for
even heat distribution.
5. Check the fusion surfaces with a quick-indication temperature
measurement device for the set temperature.
6. Clean the couplings on the machine and the hoses.
7. Connect the hydraulic hoses to the machine and to the hydraulic
unit.
8. If the hydraulic hoses are not used, seal the couplings with the
protective caps. Clean the protective caps first.
Caution
Suggestion
1 2 3 4

Operating instructions GF 500 7 Fusion
13
7Fusion
7.1 The basics of butt fusion
For butt fusion with a heating element, the parts to be joined
(pipe/pipe, pipe/fitting or fitting/fitting) are heated to fusion
temperature in the fusion area and are fused under pressure without the
use of additional materials.
The heating element butt fusion joint must be done with a controllable
equalization pressure. See pressure/time tables
Only the same type of materials are to fuse.
The wall thicknesses in the fusion area need to be the same.
Correct Incorrect
Only the same wall thicknesses in the fusion area!
Equalization- and fusion pressure are identical. The heat soak pressure is
significant lower, but the contact between the pipe/fitting and the
heating element needs to be ensured.
Attention
1 2 3 4 5

7 Fusion Operating instructions GF 500
14
7.2 The fusion process
In order to weld pipes and/or fittings d < 500 mm, insert matching
clamping half shells and fasten them with the screws.
XClamp pipe/pipe, pipe/fitting or fitting/fitting in the clamping
element.
Pipe and/or fitting ends need to reach out at least 4 cm from the
pipe clamps in order to perform a proper weld. Make sure they are
exactly aligned in the axial direction.
If necessary, the pipes/fittings can be turned or the clamping force
changed with the clamping screw to achieve a better clamping
position.
Adjustable roller supports or a floating suspension assist horizontal
movement of the pipes clamped in the slide.
7.2.1 Calculating drag pressure
Danger of crushing hands!
Machine slide moves!
Danger of injury in the moving machine slide!
:When moving to the end positions do not reach into the machine.
The machine drag pressure must be calculated before each new fusion.
1. Open machine to stop.
2. Reduce pressure with the fine-adjustment pressure valve (turn
counter-clockwise).
3. Increase pressure with the fine-adjustment pressure valve while
simultaneously pulling control lever in the “close ><” direction (turn
clockwise).
4. Check the movement pressure on the manometer. As soon as the
machine slide moves evenly.
7.2.2 Calculating of the fusion pressure
The fusion pressure is the sum of the “table value + movement pressure”
(e.g. 44 bar* +7 bar = 51 bar)
* for HD–PE d 400 mm, SDR 11see Chapter 7.5, pg. 19, Time/Pressure
diagram
Warning
Attention
fine-
adjustment
4 cm 4 cm

Operating instructions GF 500 7 Fusion
15
7.2.3 Adjusting of the fusion pressure
1. Open the machine.
2. Reduce pressure with the fine-adjustment pressure valve (turn
counter-clockwise).
3. Move control lever towards “close ><” position and increase
pressure on the pressure valve (turn clockwise) until clamping
carriage moves smoothly.
4. Adjust fusion pressure with the fine adjustment pressure valve as soon
as both pipe ends are in contact (turn clockwise).
If the fusion pressure is set too high, re-adjust:
1. Open the machine.
2. Turn the fine-adjustment pressure valve approx. 3 revolutions to the
left.
3. Start fusion pressure again and set as described above.
7.2.4 Preparing the fusion surfaces
Danger of cutting hands!
Sharp planer blades!
Danger of injury to hands if the planer disk is touched.
:Do not touch the rotating planer disk.
XSnap in the safety lock.
"Emergency Stop" function!
By pressing the "Emergency Stop" button, power to the planer motor is
immediately interrupted. The planer motor can be started by pressing
the black toggle switch.
1. Open the machine.
2. Insert planer.
3. Snap in the safety lock.
This prevents the planer unit from jumping out of the machine during
planing.
Warning
Important

7 Fusion Operating instructions GF 500
16
Constant high pressure when facing, can cause damage on the drive and/or the
motor of the facer.
4. Plane the facing surface of pipes/fittings until shavings are turned out
in ribbons which are the same width as the pipe wall thickness. The
max. planer pressure is 10 bar above the drag resistance.
To make sure the gap and the wall offset are in order, both sides must always
be planed!
5. Switch facer off.
ZRemove facer of the machine and place in the case.
6. Close machine until pipes/fittings. Touch each other. Maximum
tolerance of the gap is 0.5 mm.
7. Check the alignment at the same time.
8. The wall offset on the outside may not exceed 10 % of the wall
thickness.
9. If it is larger, the pipe/fitting can be turned or the clamping force
on the inner clamping units can be changed to achieve a better
clamping position.
10. In this case, the fusion surfaces need to be remachined.
11. Remove shavings which have fallen into the pipe e.g with a brush.
Before each fusion, the fusion surfaces must be cleaned with lint-free
paper and grease-free cleaner, e.g. industrial alcohol (Tangit KS).
Never touch the fusion surfaces with your hand after cleaning!
7.2.5 Fusion process
The PTFE coating of the heating element must be protected from
mechanical damage and/or dirt. Heating element with demaged PTFE -
covering has to be replaced. Non-observance affects the quality of the
joining, see Chapter 9.1, from pg. 29.
Danger of burning!
The heater is hot (210 °C)!
Danger of burning hands on the hot heater.
:Do not touch the heater when on.
XUse the handles on the heater.
Caution
A
ttention
Warning
10 % s
s
0.5 mm