GF SG 160 User manual

Instruction manual
GF Piping Systems
SG 160
Combination Butt and
Socket Fusion Machine
for Processing Plastic Pipes

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.

Operating instructions SG 160 Table of contents
I
Table of contents
Page
0 About this manual 1
0.1 Warning messages 1
0.2 Other symbols and notes 2
0.3 Abbreviations 2
1 Safety 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
2 General 6
2.1 Introduction 6
2.2 Range of application 6
2.3 Copyright 7
3 Product design, equipment 8
3.1 Standard equipment 8
4 Technical specifications 9
4.1 Characteristic data 9
5 Transport and assembly 10
5.1 Packaging 10
5.2 Sensitivity 10
5.3 Intermediate storage 10
5.4 Scope of delivery 10
6 Design and Mode of Operation 11
6.1 Installation 12
7 Fusion Preparation 13
7.1 General information 13
7.2 Heating element settings 13
7.2.1 Temperature setpoint adjustment 13
7.3 Butt fusion preparation 14
7.4 Socket fusion preparations 16
8 Fusion 21
8.1 Butt fusion 21
8.1.1 Preparing for butt fusion 22
8.1.2 Adjusting the fusion Force 24
8.1.3 Fusion process 25
8.1.4 Visual check of welding bead 28
8.1.5 Failure analysis 29
8.2 Socket Fusion 31
8.2.1 Preparing for socket fusion 31
8.2.2 Fusion process 33
8.2.3 Failure Analysis in Socket Fusion 36

Table of contents Operating instructions SG 160
II
9 Fusion data 38
10 Maintenance 50
10.1 Replacement of worn parts 50
11 Customer service 51

Operating instructions SG 160 0 About this manual
1
0 About this manual
To allow quick understanding of these instructions and safe handling of the
machine, all the warning messages, notes and symbols used in this manual
are presented here along with their meaning.
0.1 Warning messages
Warning messages are used in this manual to warn you against possible
injuries or damage to property. Always read and abide by these warning
messages!
Warning
symbol
Meaning
DANGER
Direct imminent danger!
Non-observance could result in death or extremely serious
injuries.
WARNING
Possible imminent danger!
Non-observance could result in serious injuries.
CAUTION
Dangerous situation! Non-observance could result in minor injuries or damage to
property.
Warning messages are always structured according to a set pattern:
•Warning symbol
•Type and source of danger
•Possible consequences, explanation of the danger
•Prohibitions (if applicable) (symbol: )
•Measures to prevent danger (symbol: )

0 About this manual Operating instructions SG 160
2
0.2 Other symbols and notes
Symbol
Meanin
g
Important
Attention
Notes which contain information particularly important for
comprehension.
Mandatory instruction: You must take notice of this symbol.
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.

Conditional request for action: You have to do something here
if the condition specified before is met.
0.3 Abbreviations
Abbr.
Meaning
SG 160 Butt / Socket Fusion Machine d 32–160 mm / d 16–110 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

Operating instructions SG 160 1 Safety instructions
3
1 Safety instructions
The Butt and Socket Fusion Machine (hereinafter referred to as SG 160) 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 160, 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 SG 160 is to be used exclusively for the fusion of thermoplastic
components.
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 after-sales
service.
•Use only original Georg Fischer spare parts and equipment.
•Inspect the SG 160 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.

1 Safety instructions Operating instructions SG 160
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 SG 160 must be installed correctly.
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/240 °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.
WARNING
WARNING
WARNING

Operating instructions SG 160 1 Safety instructions
5
1.4 Disposal
•Shavings 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).
1.5 Further safety guidelines
Observe all the regulations, standards and guidelines applicable in your
country.

2 General Operating instructions SG 160
6
2 General
2.1 Introduction
This instruction manual was written for those persons responsible for the
operation and care of the SG 160. 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 160 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
representative (see back of this manual).
This manual applies only to the SG 160.
We reserve the right to make the technical changes necessary to improve the
SG 160 which may result in deviations from the illustrations and information
contained in this manual.
2.2 Range of application
The SG 160 is designed exclusively for the fusion of plastic pipes, fittings and
valves in the dimension range d 32–160 mm (Butt fusion) and d 16–110 mm
(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 SG 160 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 the assembly, operating and
maintenance personnel. No part of the technical descriptions, 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 SG 160
8
3 Product design, equipment
3.1 Standard equipment
•Base machine
– High-precision, distortion-free and robust machine bed
– Hand wheel for easy moving of machine carriage
– Fusion pressure is maintained whith a user-friendly torque limiter
– Handle for safe transport of the machine
•Planer
– Optimized cutting geometry for even and chatter-free planing
– Powerful parallel planer, swivels in and out for single or double-sided
facing of pipe ends
– For your personal safety, a safety switch has been integrated to prevent
unintentional start-up in the working position
•Heater
– With electronic temperature control
– High temperature accuracy of ±4 °C
– High quality, non stick PTFE coating
•Additional basic equipment
– V-shaped pipe supports d 16 – 160 mm for support of fittings
– Timer to clock fusion times
– Tool set specified to machine

Operating instructions SG 160 4 Technical specifications
9
4 Technical specifications
Planer
Power:
Voltage: 700 W 230 V/50 Hz 115 V/60 Hz
Heater
Power:
Voltage: 1500 W 230 V/50 Hz 115 V/60 Hz
4.1 Characteristic data
Machine description:
Combined butt – and socket fusion machine
Machine type SG 160
Machine no. ............
Weight of standard equipment 45 kg

5 Transport and assembly Operating instructions SG 160
10
5 Transport and assembly
5.1 Packaging
A decisive factor in the choice of packaging is the means of transport.
Normally, the machine and the accessories are shipped in a carton crate.
5.2 Sensitivity
When transporting the SG 160, 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 crushes
during shipment should be avoided.
The SG 160 should be handled with care.
5.3 Intermediate storage
If the SG 160 is not used immediately upon delivery, the machine must be
stored in a safe place and covered properly.
5.4 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.

Operating instructions SG 160 6 Design and Mode of Operation
11
6 Design and Mode of Operation
The SG 160 is designed as a combination fusion machine, equipped for both
butt and/or socket fusion. The design is based on the modular principle. With
the accessory parts, user-specific needs can be easily met. The SG 160 is
operated manually.
Butt Fusion Version
Socket Fusion Version

6 Design and Mode of Operation Operating instructions SG 160
12
6.1 Installation
The installation of the SG 160 should be done according to specifications in
order to ensure safe and optimal operation.
The transport crate is designed as a work bench.
The machine can be lifted out when the clamps are released. When the lid is
closed, please see that the machine is placed in the provided mounting slots.
Check the voltage!
The generator has to be started before connecting the consumers and must
supply a constant output voltage!
CAUTION

Operating instructions SG 160 7 Fusion Preparation
13
7 Fusion Preparation
7.1 General information
This manual is based according to 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 SG 160, operating personnel must be specially trained
by Georg Fischer. In-depth knowledge of the machine and the related
components rule out handling errors, thereby also preventing faulty fusion
joints.
7.2 Heating element settings
7.2.1 Temperature setpoint adjustment
To set the welding temperature, press the button Pshortly < 3 sec.
The LED OUT 1 will switch ON, the actual temperature set point for the
welding temperature is displayed.
By pressing UP or DOWN the desired temperature set point can be selected.
Press shortly UP or DOWN to change one unit only, by pressing continuosly
the UP or DOWN button the digits will change fast.
To confirm the new setting press the button Pshortly < 3 sec or wait
approximately 15 seconds to change automatically in the operation mode.
The current measured temperature will be displayed. When the temperature is
at the set point the green LED will be on, if the temperature is below the set
point the LED OUT 1 will be on!
2 1 0
2 1 02 1 0
2 1 0 P
U
▼
▲
2 6 0
2 6 02 6 0
2 6 0 P
U
▼
▲

7 Fusion Preparation Operating instructions SG 160
14
If you entered uncontrolled in the programming operation, it is sufficient to wait
20 second without pressing any key. The controller will switch back itself and
shows the actual temperature.
7.3 Butt fusion preparation
The machine can be prepared for butt fusion in only a few steps.
Loosen the knurled-head screw. Pressure is now built up via spring tension.
The groove in both eccentric screws (in front and at the back) should be
horizontal and secured with the safety screw. The heating plate can be moved
axially
Attention
Attention
Eccentric screw

Operating instructions SG 160 7 Fusion Preparation
15
Adjust the rotation direction of the planer as displayed in the picture below. The
rotation direction of the planer, as seen from the motor side, is clockwise.
Mount the inner basic clamping plates left and right. Install the inserts and the
left and right clamping brackets for the corresponding dimensions.
For additional support, Y-supports are available.
When joining long pipe pieces, use the outer basic clamping plates!
Suggestion

7 Fusion Preparation Operating instructions SG 160
16
7.4 Socket fusion preparations
Usually on the SG 160, the fitting is clamped on the right and the pipe on the
left, as seen from the user’s side. If necessary, the machine can be prepared
or rebuilt at a later time for the opposite clamping version. The following
instructions refer to the fitting being clamped on the right side.
Mount the disengaging device on the fitting side (in our example on the right).
Mount the depth stop in such a way that the locking fork points toward the
fitting side.
The stops on the depth stop must be set according to the following
standards: