GF SG 125 User manual

Instruction manual
GF Piping Systems
SG 125
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 instruction SG 125 Table of contents
I
Table of contents
Seite
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 design, equipment 8
4.1Design 8
4.2Standard equipment 9
5Technical specifications 10
5.1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 12
8Fusion 15
8.1The basics of socket fusion 15
8.2The fusion process 15
8.3Fusion data 17
9Failure analysis 20
10Service 21
11Customer service 22

Table of contents Operating instruction SG 125
II

Operating instruction SG 125 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
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: )
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 instruction SG 125
2
1.2 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.
 Single call for action. You must do something here.
 Call for action under certain circumstances. You must do
something here if the condition beforehand has been
fulfilled.
1.3 Abbreviations
Abbr. Meaning
SG 125 Socket fusion machine d 16–125 mm
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 instruction SG 125 2 Safety instructions
3
2 Safety instructions
The SG 125 Socket Fusion Machine (hereinafter referred to as SG 125 ) 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 SG 125, 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 SG 125 is to be used exclusively for the fusion of thermoplastic
components.
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 SG 125 daily for visible signs of damage or defects. Have
damage or defects repaired immediately.
 Work on the electrical equipment may only be done by a specialist.

2 Safety instructions Operating instruction SG 125
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 SG 125 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 (260 °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.
Danger
Warning
Warning

Operating instruction SG 125 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 symbol below indicates separate collection for electrical and
electronic equipment according to 2002/96/CE WEEE directive (Waste
Electrical and Electronic Equipment).

3 General Operating instruction SG 125
6
3 General
3.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the SG 125. 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 SG
125 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 SG 125.
We reserve the right to make the technical changes necessary to
improve the SG 125 which may result in deviations from the illustrations
and information contained in this manual.
3.2 Range of application
The SG 125 is designed exclusively for the socket fusion of plastic pipes,
fittings and valves in the dimension range d 16–125 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 instruction SG 125 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 design, equipment Operating instruction SG 125
8
4 Product design, equipment
4.1 Design
1
V
-
s
haped pipe supports
2 Handwheel to move slide togethe
r
3 Handwheel for clamping the pipe on the left slide
4
M
achine frame
5 Left prismatic clamping unit with clamping devices and clamping
jaws
6 Stop screw to position the pipe and fitting correctly during the heat
soak phase
7 Heating element with heating spigots and bushes
8 Positioning ring/stop with graduation for joining phase
9 Stop for pipe/fitting
10 Right prismatic clamping unit with clamping devices and clamping
jaws
11
Handwheel for clamping the fitting on the right slide
12
Back stop
13
Swivel handle for heating element
14 Optional: Universal outer prismatic clamping unit, complete
3
1 2 5 6 7
8 10 11
12
4
9 13
14

Operating instruction SG 125 4 Product design, equipment
9
4.2 Standard equipment
 Basic machine
– Compact, sturdy design, distortion-free machine bed
– Handwheel to move the machine slide via rack
 Heating element
– With electronic temperature control (or thermostatic control)
– High temperature accuracy of 4 °C
 Additional basic equipment
– Universal, left and right prismatic clamping unit, complete, for
clamping pipe and fitting
– Depth stop
– V-shaped pipe supports d 20–125 mm
– Back stop
– Machine-specific tool set
– Timer to clock fusion time
– 3 Allen wrenches with T-handle SW 5, SW 6 and SW 8
– 1 combination wrench SW 19
– 3 cap screws M8 x 40
– 1 cap screw M6 x 40
– 1 positioning pin 4 mm for heating spigot and bushes
– Instruction manual

5 Technical specifications Operating instruction SG 125
10
5 Technical specifications
Heating element Power (Voltage 230V):
Power (Voltage 115V):
Temperature
accuracy:
1500 W; 6.5 A
1500 W/13 A
4 °C
5.1 Characteristic data
Machine description:
Plastic socket fusion machine
Machine type SG 125
Machine number ............
Weight of standard equipment 52 kg

Operating instruction SG 125 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.
Normally, the machine and the accessories are shipped in a wooden
crate.
6.2 Sensitivity
When transporting the SG 125, special care must be taken in order to
prevent damage from impact or improper loading and unloading.
All movable parts must be fixed in place prior to transport.
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.
The SG 125 should be handled with care.
6.3 Intermediate storage
If theSG 125 is not used immediately upon delivery, the machine must
be stored in a safe place and covered properly.
6.4 Scope of delivery
The contents (number of tranport crates, pallets, packages) and their
condition should be checked immediately following 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 instruction SG 125
12
7 Fusion Preparation
7.1 General information
For optimal use of the SG 125, operating personnel must be specially
trained by Georg Fischer Omicron. In-depth knowledge of the machine
and the related components rule out handling errors, thereby also
preventing faulty fusion joints.
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.
 Generally, only similar types of materials can be fused.
7.2 Preparations
2. Mount the appropriate heating spigots and bushes. The heating
tools may not be scratched or damaged in any way. The fusion
surfaces must be clean.
3. Use heating spigots and bushes with L1 and L2 according to the
table below.
 d L1
heating bushes
mm
L2
heating spigots
mm
Code
16 27,0 23,0 799 300 155
20 28.0 24.0 799 300 156
25 30.0 26.0 799 300 157
32 32.5 28.0 799 300 158
40 34.5 30.0 799 300 159
50 37.5 33.0 799 300 160
63 42.0 37.0 799 300 161
75 46.0 41.0 799 300 162
90 50.0 45.0 799 300 163
110 56.0 51.0 799 300 164
125 63.0 54.0 799 300 165
Warning

Operating instruction SG 125 7 Fusion Preparation
13
4. Tighten the fastening screws only after the desired fusion
temperature has been reached.
5. Set the correct fusion temperature on the heating element with the
temperature control dial (260 °C 10 °C for PE, PP and PVDF).
Check the voltage!
6. Connect to mains.
 Functions of control lights:
– Electronic heater:
Red and green lights are on during heating up.
When the fusion temperature is reached, the red light blinks.
– Thermostatic heater:
Red and green lights are on during heating up.
When the fusion temperature is reached, the green light goes out.
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.
7. Check the outer heating bush with a tempil stick or a quick-
indication temperature measurement device for the set
temperature.
 Standard settings of the stop screws for the heat soak phase:
Length of stop screw
A 76.5 mm
B 13.5 mm
8. Place the clamping jaws in the clamping position corresponding to
the diameter to be fused.
 Dimension ranges:
16 / 20-26 / 26-38 / 38-54 / 54-82 / 82-134
Caution
Suggestion

7 Fusion Preparation Operating instruction SG 125
14
9. Fasten the clamping jaws with the Allen wrench.
Note the two positioning pins!
 Use the V-shaped pipe supports for additional support.
 Secure the components to be fused with the back stop to prevent
axial movement.
 When joining long pipe sections, it is advisable to use also the outer
prismatic clamping units.
10. Calibrate the pipe ends with the corresponding manual pipe
peeling tools.
 d (mm) Chamfering tool
code
Peeling length
l (mm)
Peeling diameter
ds (mm)
16 - 13 15,85–15,95
20 799 300 260 14 19.85–19.95
25 799 300 270 16 24.85–24.95
32 799 300 280 18 31.85–31.95
40 799 300 290 20 39.75–39.95
50 799 300 300 23 49.75–49.95
63 799 300 310 27 62.65–62.95
75 799 300 320 31 74.65–74.95
90 799 300 330 35 89.65–89.95
110 799 300 340 41 109.55–109.95
125 - 46 124,55–124,95

Operating instruction SG 125 8 Fusion
15
8 Fusion
8.1 The basics of socket fusion
For socket fusion with a heating element, the pipe ends and fitting
sockets are heated to fusion temperature in the heating bush or the
heating spigot respectively and fused overlapping, without the use of
additional materials.
The calibrated pipe ends, heating tools and fitting sockets are
coordinated in size so that a fusion pressure is built up and a
homogenous joint occurs.
Only similar types of materials can be fused.
8.2 The fusion process
11. Adjust the positioning ring/stop with graduation (8) to the
appropriate pipe dimension for the joining phase.
12. Position the V-shaped pipe supports to the correct height.
13. Swivel in the stop for pipe/fitting (9).
14. Place the pipe on the left slide in the prismatic clamping unit and on
the V-shaped pipe supports.
Secure the pipe loosely with the handwheel.
Slide together up to the stop for pipe/fitting (9) and clamp pipe in
the prismatic clamping unit. Do not fasten the prismatic clamping
unit too tightly on the fitting side! Danger of deforming the fitting
fusion socket!
In the same position, clamp the fitting, support with the back stop
(12).
Open the slide, swivel down the stop for pipe/fitting (9).
Attention
8 9 12 9

8 Fusion Operating instruction SG 125
16
15. Clean the heating spigots and bushes prior to each fusion with dry,
clean, lint-free paper.
16. Clean the calibrated pipe and fitting with lint-free paper and
grease-free cleaner, e.g. trichloroethylene or industrial alcohol
(Tangit KS).
17. Swivel in the heater with heating spigots and bushes when the fusion
temperature has been reached and the waiting time has elapsed.
18. Set the heat soak time for the corresponding pipe and the
respective materials on the timer. For fusion parameters (heat soak,
changeover and cooling times), see Chapter 7.3, from page 16.
19. Insert the pipe and fitting to the stop in the heating bush or spigot by
sliding the carriage together using the handwheel. Watch the heat
soak time! (Fig. 1)
20. When the heat soak time has elapsed, open the slide, swivel out the
heater and join together the pipe/fitting up to the stop. Observe the
cooling time! The use of cooling agents is not permitted! (Fig. 2)
21. Unclamp the pipe and fitting from the SG 125.
22. Wait at least 1 hour after the last fusion before doing a pressure test.
Fig. 1
Fig. 2