GF CNC 4.0 400 User manual

Instruction manual
GF Piping Systems
CNC 4.0 400/500/630
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..
COPIA ORIGINALE
ORIGINAL COPY

Operating instructions CNC 4.0 400/500/630 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 General safety measures 3
2.2 Working with safety in mind 4
2.3 Disposal 5
3 General 6
3.1 Introduction 6
3.2 Range of application 6
3.3 Copyright 7
4 Product identification and description 8
4.1 Product identification 8
4.2 Product description 8
5 Technical specifications 10
5.1 Available pipe dimensions 11
6 Transport and assembly 14
6.1 Packaging 14
6.2 Sensitivity 14
6.3 Intermediate storage 14
6.4 Scope of delivery 14
7 Fusion preparation 15
7.1 General information 15
7.2 Preparations 15
7.2.1 Connection to the power supply 17
7.3 Touch screen interface 19
7.3.1 Settings of Touch Screen 19
7.3.2 System error 20
7.4 Hoist Lifting Cylinder (only CNC 4.0 630) 20
8 WELDING 22
8.1 Welding according given standards 22
8.1.1 Selection of the welding standard 22
8.1.2 Selection of the pipe diameter 23
8.1.3 Selection of the wall thickness (SDR) 23
8.1.4 Summarization of selected parameters 24
8.2 Preparation 25
8.2.1 Clamp the pipe 25
8.2.2 Position and clamp pipes. 26
8.2.3 Contact position 27
8.2.4 Drag pressure 28
8.2.5 Pipe planing 29
8.2.6 Sliding and Alignment control 33
8.2.7 Clean pipes 35

Table of contents Operating instructions CNC 4.0 400/500/630
II
8.2.8
Insert the heating element
36
8.3 Fusion process 36
8.3.1 Bead build up 37
8.3.2 Heat soak time 39
8.3.3 Change over 40
8.3.4 Cooling time 41
8.3.5 Welding conclusion 43
8.3.6 Mark joint 44
8.3.7 Save protocol 44
8.4 Visual check of welding bead 46
9 Machine Set-up 47
9.1 View Configuration 47
9.2 Language selection 48
9.3 Calibration 48
9.4 Machine settings 50
9.4.2 Machine 52
9.4.3 Welding standard 53
9.4.4 Reset internal memory 53
9.4.5 Service 54
9.5 Configuration 54
9.5.1 Repeat Bead 54
9.5.2 CTC Process 55
9.5.3 Traceability 57
9.5.4 Operator code 60
9.5.5 Job code 62
9.5.6 Password management 63
10 Data 65
10.1 Optional data 65
10.2 Memory 66
10.2.1 Protocols transfer 66
10.2.2 USB Memory status 67
10.2.3 View Internal Memory 67
10.3 GPS 68
10.4 Connection with label printer 69
10.5 Bluetooth connection with WeldinAir version 70
10.5.1 Start WeldinAir on Android 70
10.5.2 Start WeldinAir on iOS 71
11 FREE welding standard 73
11.1 Name of the welding cycle 73
11.2 Input of welding parameters 74
12 Error/Warning messages 76
13 Maintenance 83
13.1 Replacement of worn parts 83
13.2 Hydraulic system 83
13.3 Hydraulic unit 84
14 Customer Service 86

Operating instructions CNC 4.0 400/500/630 Table of contents
III

Table of contents Operating instructions CNC 4.0 400/500/630
IV

Operating instructions CNC 4.0 400/500/630 1 About this manual
1
1 About this manual
This manual is valid for CNC 4.0 400,500 and CNC 4.0 630 butt-fusion
machines (hereinafter referred to as CNC 4.0 400/500/630).
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 CNC 4.0 400/500/630
2
1.2 Other symbols and notices
Symbol
Meaning
Attention
Mandatory: you must observe this regulation
Advice
1.
►
Suggestion: this notice contains especially important
information
Action request in a sequence of actions
Stand-alone request for action
1.3 Abbreviations
Abbr.
Meaning
CNC 4.0 400
CNC 4.0 500
CNC 4.0 630
Automatic butt fusion machine d 125–400 mm
Automatic butt fusion machine d 200–500 mm
Automatic butt fusion machine d 315–630 mm
DVS Deutscher Verband für Schweisstechnik
(German Association of Fusion Technology)
PE Polyethylene
PP Polypropylene
PTFE Polytetrafluorethylene
d Pipe outer diameter

Operating instructions CNC 4.0 400/500/630 2 Safety instructions
3
2 Safety instructions
The CNC 4.0 400/500/630 Butt Fusion Machines are 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 CNC 4.0
400/500/630, 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 General safety measures
Use only the materials and dimensions specified in this manual. Other
materials may only be used after consulting Georg Fischer after-sales
service.
Use only original Georg Fischer Omicron spare parts and equipment.
Inspect the CNC 4.0 400/500/630 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.
Observe all the regulations, standards and guidelines applicable in
your country.

2 Safety instructions Operating instructions CNC 4.0 400/500/630
4
2.2 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 CNC 4.0 400/500/630 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 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 (220 °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
Warning
EN 407 321XXX
Warning
Warning

Operating instructions CNC 4.0 400/500/630 2 Safety instructions
5
Danger of injury due to high pressure oil leakages!
Inspect the outside wall of hydraulic hoses under pressure: make sure
you wear safety glasses before doing it!
Do not touch leaking oil with hands! Escaping high pressure oil can
cause skin penetration injuries!
Release the oil pressure to zero before replacing defective hoses.
Danger of bruising!
Machine components are heavy!
To move the components, use the gloves! (EN 388 2241)
Danger of injury!
The base machine is high!
It is strictly forbidden to go onto the base machine!
Accidental fall could result in death or extremely serious injury!
2.3 Disposal
Shavings and used hydraulic oil 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. Observe all
the regulations, standards and guidelines applicable in your country.
note:
The symbol below indicates separate collection for electrical and
electronic equipment according to 2002/96/CE WEEE directive (Waste
Electrical and Electronic Equipment).
Warning
EN 388 2241
Danger

3 General Operating instructions CNC 4.0 400/500/630
6
3 General
3.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the CNC 4.0 400/500/630. 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
CNC 4.0 400/500/630 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 into 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 Georg Fischer
Omicron s.r.l. directly or the nearest service representative.
This manual applies only to the CNC 4.0 400/500/630 butt-fusion
machines.
We reserve the right to make technical changes necessary to improve
the CNC 4.0 400/500/630 which may result in deviations from the
illustrations and information contained in this manual.
3.2 Range of application
The CNC 400/500/630 4.0 are designed exclusively for the fusion of pipes
and fittings made of thermoplastics (PE, PP, PB) according to the
specified dimension range. Any other use is not authorized. The
manufacturer cannot be held liable for damages resulting from
unauthorized use; the user bears sole responsibility.
CNC 4.0 400: Ø125 – Ø400 mm;
CNC 4.0 500: Ø200 – Ø500 mm;
CNC 4.0 500: Ø315 – Ø630 mm;

Operating instructions CNC 4.0 400/500/630 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 identification and description Operating instructions CNC 4.0 400/500/630
8
4 Product identification and
description
4.1 Product identification
In accordance with the directives for machines, an identification label is
attached to the base machine, showing the following information:
1.
Manufacturer
2. Type of machine
3. Serial number
4. Piston area
5. Pipe range
6. Year of manufacture
7. Weight
8. Barcode
4.2 Product description
Base Machin
e
Hardened and hard chrome-
plated guide shafts (1)
Adjustable third clamp (2)
Pull-Off mechanism for
heating element (3)
1
2
3
6
4
1
5
5
3
2
7

Operating instructions CNC 4.0 400/500/630 4 Product identification and description
9
Hydraulic unit
USB port (1)
Oil level gauge (2)
Touch Screen (3)
Socket for potentiometer (4)
Socket for planer (5)
Socket for heating element (6)
Main switch (7)
Printer socket (8)
Quick action couplings (9)
Mains cable (10)
GPS receiver (11)
Storage Case
Zinc-coated steel case for transport
and storage of both heating element
and pipe planer
Heating element
PTFE-coating
Power multi-cord with wire
probe integrated (4 m)
Temperature gauge integrated
in the handle
Electric planer
Stop mechanism for safety
Safety microswitch to prevent
unintentional start-up
Planer blades sharpened on
both sides
2 3
1
9
6
8 11 7
4
5 10

5 Technical specifications Operating instructions CNC 4.0 400/500/630
10
5 Technical specifications
CNC 4.0 400 CNC 4.0 500 CNC 4.0 630
Base
machine Total piston
area: 904 mm21413 mm21413 mm2
Facer Power:
1100 W
760 W (*) 1500 W
Voltage:
230 V
1 Phase (2 wires)
400 V
3 Phase (4 wires)
400 V
3 Phase (4 wires)
Heater Power:
3500 W
4000 W
8000 W
Voltage:
230 V
1 Phase (2 wires)
400 V
3 Phase (4 wires)
400 V
3 Phase (4 wires)
Hydraulic
unit
Power:
1500 W
1500 W
1500 W
Voltage:
400 V
3 Phase (4 wires)
400 V
3 Phase (4 wires)
400 V
3 Phase (4 wires)
Max pressure:
160 bar
Oil type
Viscosity
46
2 liters of hydraulic oil in canister
Machine
complete
Power: 5,7 kW
6,3 kW
10,5 kW
Voltage:
400 V
±
10%
3 Phase (4 wires)
400 V
±
10%
3 Phase (4 wires)
400 V
±
10%
3 Phase (4 wires)
Noise level:
70 dBA
(*) : 1500 W with PP version
Attention:power generator output must satisfy the following connections
L1 - L2 = 400 Vac
L2 - L3 = 400 Vac
L1 - L3 = 400 Vac

Operating instructions CNC 4.0 400/500/630 5 Technical specifications
11
5.1 Available pipe dimensions
Tables below show the available selections, depending on diameter,
thickness and material (PE and PP) of the pipes, with reference to DVS
2207 welding standards.
L1 - L2 = 400 Vac
L2 - L3 = 400 Vac
L1 - L3 = 400 Vac

5 Technical specifications Operating instructions CNC 4.0 400/500/630
12
(*) : only with PP version

Operating instructions CNC 4.0 400/500/630 5 Technical specifications
13

6 Transport and assembly Operating instructions CNC 4.0 400/500/630
14
6 Transport and assembly
6.1 Packaging
A decisive factor in the choice of packaging is the means of transport.
Usually the machine and all the accessories are delivered in a wooden
case.
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 machine 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 lading
and reported to Georg Fischer Omicron S.r.l. without delay.