GF MD 160 User manual

Instruction manual
GF Piping Systems
MD 160 / JIG 125
Butt / Socket 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 MD160 / JIG125 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 description, equipment 8
4.1Butt Fusion Machine MD 160 8
4.2Socket Fusion Machine JIG 125 9
5Technical specifications 10
5.1Voltage / Power 10
5.2Characteristic data 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 for Butt Fusion with MD160 12
7.3Preparation for Socket Fusion with JIG 125 15
8Fusion 18
8.1Butt fusion 18
8.1.1Fusion process 19
8.1.2Visual inspection of the fused joint 25
8.1.3Fusion data 26
8.2Socket Fusion 35
8.2.1Fusion process 35
8.2.2Fusion data 38
9Maintenance 40
9.1Replacement of worn parts 40
10Customer service 41

Operating instructions MD160 / JIG125 1 About this manual
1
1 About 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.
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 acute danger!
Failure to comply could result in death or extremely
serious injury.
Warning
Possible acute 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 MD160 / JIG125
2
1.2 Other symbols and notices
Symbol Meaning
1.1. Action request in a sequence of actions
 Stand-alone request for action
1.3 Abbreviations
Abbr. Meaning
Midicron160
(MD160)
JIG125
DVS
Butt fusion machine d 50–160 mm
Socket fusion machine d 63–125 mm
Deutscher Verband für Schweisstechnik
(German Association of Fusion Technology)
PE Polyethylen
PP Polypropylen
PTFE Polytetrafluorethylen
d Pipe outer diameter
Attention
Suggestion: this notice contains especially important
information

Operating instructions MD160 / JIG125 2 Safety instructions
3
2 Safety instructions
The Midicron 160 (hereinafter referred to as MD160) and JIG125 fusion
machines were 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. The machine or
other equipment may also be damaged.
Any person in the company, who is involved in the assembly,
disassembly, re-assembly, installation, operation or maintenance
(inspection, maintenance work, repair work) of the MD160 and JIG125,
must have read and understood the complete instruction manual, and
in particular Section 1 of “Safety instructions”.
It is recommended that the user has this confirmed in writing.
Thus:
 The machine should only be used when in perfect working condition.
 Always follow the safety instructions.
The complete documentation should be kept in the vicinity of the
machine.
2.1 Proper use
The MD160 and JIG125 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 should be used only after consulting the Georg Fischer
Omicron after-sales service.
 Use only original Georg Fischer Omicron spare parts and equipment.
 Inspect the MD160 and JIG125 daily for visible signs of damage or
defects. Have any damages 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 MD160 / JIG125
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 safe and optimal handling of
the machine, the MD160 and JIG125 must be installed correctly.
Danger of electric shock!
Inspect the electrical cords and devices!
Do not connect damaged cords or devices to the power supply.
Danger of burning!
The heater is hot (210 - 270 °C)!
Danger of burning hands on the hot heater.
Do not touch the heater when on.
Danger of burning!
Use the handles on the heater.
To move the heater, use the gloves! (EN 407 321XXX)
Danger of crushing hands!
The machine slide moves!
Danger of injury to hands in the moving machine slide!
Do not reach inside the machine when moving to the end positions.
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 bruising!
Machine components are heavy!
To move the components, use the gloves! (EN 388 2241)
Danger
Warning
EN 407 321XXX
Warning
Warning
EN 388 2241

Operating instructions MD160 / JIG125 2 Safety instructions
5
2.4 Disposal
Remaining pipe sections, shavings from calibration, etc. 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 MD160 / JIG125
6
3 General
3.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the MD160 and JIG125. 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 it is possible to
prevent faults on the MD160 and JIG125 and to ensure trouble-free
operation. 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 (see back of this manual).
This manual applies only to the MD160 and JIG125.
We reserve the right to make technical changes necessary to improve
the MD160 and JIG125, which may result in deviations from the
illustrations and information contained in this manual.
3.2 Range of application
The MD160 and JIG125 are designed exclusively for the fusion jointing of
plastic pipes, fittings and valves in the dimension range d 50–160 mm
(MD160 - Butt Fusion) and d 63–125 mm (JIG125 - Socket Fusion). 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 MD160 / JIG125 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 the assembly, operating 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 description, equipment Operating instructions MD160 / JIG125
8
4 Product description, equipment
4.1 Butt Fusion Machine MD 160
Base Machine MD160
 Fast-locking handle (1) to
maintain the fusion force
 Hand wheel for slide
movement / force build-up (2)
 Base clamping plates (3):
- for mounting the reduction
inserts for clamping the
pipes / fittings
- freely adjustable up to 15°
each
 Lock / unlock screw (4) to
switch base machine from
JIG125 to MD160 configuration
and viceversa.
 Fusion force scale (5)
 Locking handles (6), for
clamping units adjustment
perpendicularly to the
longitudinal axis
Heating element
 Non-stick PTFE -coated
 Integrated electronic
temperature controller
 Support included
Electric planer
 Planer blades sharpened on
both sides
 For single or double – sided
facing of pipe ends
3
1
2
4 5
6

Operating instructions MD160 / JIG125 4 Product description, equipment
9
Additional standard equipment
 Reduction clamping inserts
d 50 – 140 mm
 Reduction inserts for pipe
supports d 50 - 140 mm
 Specific tool set
 Base machine table support
 Wooden transport crate
4.2 Socket Fusion Machine JIG 125
Base Machine JIG125
 Fast-locking lever (1)
 Hand wheel for easy moving of
machine carriage (2)
 Back-stop to enhance clamping
action with fittings (3)
 Lock / unlock screw to switch
base machine from JIG125 to
MD160 configuration and
viceversa (4)
 Lifting handle (5)
 Prismatic pipe clamping unit (6)
 Prismatic fitting clamping unit (7)
Heating element
 Non-stick PTFE -coated
 Integrated electronic
temperature controller
 Support included
Additional standard equipment
 Metal case for heating element
transportation, including a
complete set of heating spigots
& bushes (type A) d 63 – 125 mm
 Specific tool set
 Special bag for base machine
transportation
3
1
2
4
5
7
6

5 Technical specifications Operating instructions MD160 / JIG125
10
5 Technical specifications
5.1 Voltage / Power
MD160
JIG125
230V 115V 230V 115V
Heating element 800 W 800 W 1500 W 1500 W
Electric planer 850 W 750 W --- ---
Machine Complete 1650 W 1550 W 1500 W 1500 W
5.2 Characteristic data
Machine description:
Butt fusion machine
Machine type MD160
Max Force 115 daN
Weight of basic machine 13.8 kg
Weight of electric planer 8.4 kg
Weight of heating element 3.5 kg
Dimensions (wooden crate) (mm)
Weight of machine complete with
standard equipment
620 x 425 x 660
57 kg
Socket fusion machine
Machine type JIG125
Weight of basic machine 10.3 kg
Weight of heating element 3.4 Kg
Dimensions (bag) (mm) 510 x 350 x 400
Weight of metal case kit with 18 kg
complete set of heating spigots
and bushes type A

Operating instructions MD160 / JIG125 6 Transport and assembly
11
6 Transport and assembly
6.1 Packaging
The machine MD160 and all the accessories are delivered in a wooden
crate, while JIG125 is delivered on a pallet with a bag and metal case
kit. The combined MD160 / JIG125 full package version is delivered in a
wooden crate as well.
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 MD160 or JIG125 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 delivery
and reported to Georg Fischer Omicron s.r.l. without delay.

7 Fusion preparation Operating instructions MD160 / JIG125
12
7 Fusion preparation
7.1 General information
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, using tents,
heating. For optimal use of the MD160 and JIG 125, operating personnel
should be specially trained by Georg Fischer Omicron. 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 for Butt Fusion with MD160
1. Mount the heating element on the support
Danger of electric shock!
Inspect the electrical cords and devices!
Do not connect damaged cords or devices to the power supply.
Check the voltage!
2. Connect the heating element to the electric mains.
3. Set the correct fusing temperature at the heater using the
temperature-control knob (A).
Function of the control lamps:
Red and green lamps are lit during heat-up. Once the fusing
temperature is reached, the red lamp will start blinking.
Before starting the first fusion process, we recommend waiting approx.
10 minutes after the set fusing temperature has been reached to allow
of even heat distribution.
4. Check the fusion surfaces for the set temperature using a quick-
indication temperature measuring device.
Danger of burning!
The heater is hot (210 - 240 °C)!
Danger of burning hands when touching the hot heater.
Do not touch the heater when on.
Use the handles on the heater.
Danger
Caution
Suggestion
Warning
A

Operating instructions MD160 / JIG125 7 Fusion preparation
13
5. Assemble the specific clamping units for butt fusion on the base
machine: slide the clamping units into the supports, then fix them
in the working position by means of the locking levers.
6. Switch the base machine into MD160 configuration: loosen the
screw (B) carefully until it stops. Fusion force is now built up via
spring tension.
B

7 Fusion preparation Operating instructions MD160 / JIG125
14
To use the machine on a workbench, screw the machine support (C) on
it, then fix the base machine in the support (C) by means of the two
bolts (D)
or clamp the base machine into a commercially available vice.
C
D

Operating instructions MD160 / JIG125 7 Fusion preparation
15
7.3 Preparation for Socket Fusion with JIG 125
1. Assemble the heating plate extension bracket by means of the two
M8 screws.
2. Mount the heating element on the support
3. Mount the appropriate heating bushes and spigots. The heating tools
may not be scratched or damaged in any way. The welding surfaces
must be clean
Take care the bushes and spigots are placed at the correct sides of the
heating plate, as shown below:
The screws should be tightened only after the fusion temperature has
been reached.
Attention
Bushes
Spigots
Larger side of
heater handle

7 Fusion preparation Operating instructions MD160 / JIG125
16
Danger of burning!
Heater is hot (260 °C)!
Danger of burning hands on the hot heater.
Do not touch heater when on.
Use the handles on the heater.
4. Use heating spigots and bushes with L1 and L2 according to the
table below.
Danger of electric shock!
Inspect the electrical cords and devices!
Do not connect damaged cords or devices to the power supply.
Check the voltage!
5. Connect the heating element to the electric mains
6. Set the correct fusing temperature at the heater using the
temperature-control knob (A).
 Function of the control lamps:
 Red and green lamps are lit during heat-up. Once the fusing
temperature is reached, the red lamp will start blinking.
Before starting the first fusion process, we recommend waiting approx.
10 minutes after the set fusing temperature has been reached to allow
of even heat distribution.
Check the outer heating bush with a tempil stick or a quick-indication
temperature measurement device for the set temperature.
Warning
 d L1
heating bushes
mm
L2
heating spigots
mm
Code
63 40.0 36.0 790 310 269
75 43.0 39.0 790 310 270
90 46.0 43.0 790 310 271
110 51.5 47.0 790 310 272
125 53.0 49.0 790 310 273
Danger
Caution
Suggestion
A