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Operating Instructions

GF 500

Butt Fusion Machine

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Summary of Contents for GF 500

Page 1: ...Operating Instructions GF 500 Butt Fusion Machine ...

Page 2: ...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 ...

Page 3: ...3 1 Design 8 3 2 Standard equipment 9 4 Technical specifications 10 4 1 Characteristic data 10 5 Transport and assembly 11 5 1 Packaging 11 5 2 Sensitivity 11 5 3 Intermediate storage 11 5 4 Scope of delivery 11 6 Fusion preparation 12 6 1 General information 12 6 2 Preparations 12 7 Fusion 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 Calcu...

Page 4: ...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 ...

Page 5: ... 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 P...

Page 6: ...tion 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 diame...

Page 7: ...rticular 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 Genera...

Page 8: ... 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 X Use the handles on the hea...

Page 9: ...gulations 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 ...

Page 10: ...ting 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 fr...

Page 11: ...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 39 049 8971411 Fax 39 049 633324 ...

Page 12: ...3 Product design equipment Operating instructions GF 500 8 3 Product design equipment 3 1 Design 1 Storage case with heater and planer 2 Basic machine 3 Hydraulic unit 4 Power control box 1 2 3 4 ...

Page 13: ...I 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 funct...

Page 14: ...ters 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 c...

Page 15: ...ransport 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 content...

Page 16: ...box 2 Connect power control box to the power Check the voltage Z Main 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...

Page 17: ... 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 ...

Page 18: ...s 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 ...

Page 19: ...st 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 X Snap in the safety lock Emergency Stop function By pressing the Emerge...

Page 20: ... 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...

Page 21: ...ence check fusion chart chapter 7 5 move control lever towards open lever position halfway between neutral and fully open until pressure on manometer shows nearly 0 Do not open the machine pipes have to keep contact with the heating element 2 Start timer with preset heat soak time Heat soak of the fusion material For PE 10 x wall thickness in mm For PP Interpolate the intermediate values For PVDF ...

Page 22: ...ng the hydraulic system Danger of bruising X Release the pressure of the hydraulic system before opening the clamping stations 1 Move control lever towards open lever position halfway between neutral and fully open until pressure on manometer shows nearly 0 Do not open machine slides 2 Open clamping station before removing welded pipes fittings All fusion joints must have cooled completely before ...

Page 23: ...utt fusion of HD PE Fusion table DVS 2207 1 guidelines Heating element temperature 210 C 10 C 1 2 3 4 5 Nominal wall thickness Equalize Bead height on heating element after equalization equalization at 0 15N mm2 Heat soak Heat soak time 10 x wall thickness heat soak at 0 02 N mm2 Change over Join Time until max pressure reached Cooling Cooling time at fusion pressure p 0 15 N mm2 0 01 mm mm min va...

Page 24: ...8 Pressure build up time sec 5 5 6 6 6 6 7 8 8 Cooling time min 7 8 9 10 11 12 13 15 16 S 16 SDR 33 Pipe outer diameter 200 225 250 280 315 355 400 450 500 Wall thickness mm 6 2 6 9 7 7 8 6 9 7 10 9 12 3 13 8 15 3 Fusion surface mm 3775 4728 5861 7333 9304 11783 14981 18911 23298 Equalization fusion pressure bar 4 5 6 8 10 13 16 20 25 Bead height mm 1 0 1 0 1 5 1 5 1 5 1 5 2 0 2 0 2 0 Heating pres...

Page 25: ...4 4 16 2 18 2 20 5 22 8 Fusion surface mm 5458 6947 8545 10745 13599 17243 21830 27661 34181 Equalization fusion pressure bar 6 7 9 11 14 18 23 29 36 Bead height mm 1 5 1 5 1 5 2 0 2 0 2 0 2 0 2 5 2 5 Heating pressure bar 1 1 1 1 2 2 3 4 5 Heat soak time sec 91 103 114 128 144 162 182 205 228 Change over time sec 7 7 8 8 9 9 9 10 11 Pressure build up time sec 7 7 8 8 9 10 11 12 13 Cooling time min...

Page 26: ...1 1 23 7 26 7 29 7 Fusion surface mm 7032 8908 10936 13736 17407 22133 28018 35507 43881 Equalization fusion pressure bar 7 9 12 15 18 23 30 38 47 Bead height mm 1 5 2 0 2 0 2 0 2 0 2 5 2 5 3 0 3 0 Heating pressure bar 1 1 2 2 2 3 4 5 6 Heat soak time sec 119 134 148 166 187 211 237 267 297 Change over time sec 8 8 8 9 10 10 11 12 13 Pressure build up time sec 8 8 9 10 11 12 13 14 15 Cooling time ...

Page 27: ... 7 50 3 55 8 Fusion surface mm 12498 15818 19467 24455 30941 39325 49894 63161 77869 Equalization fusion pressure bar 13 17 21 26 33 42 53 67 83 Bead height mm 2 5 2 5 3 0 3 0 3 0 3 5 3 5 4 0 4 0 Heating pressure bar 2 2 3 3 4 6 7 9 11 Heat soak time sec 224 252 279 313 352 397 447 503 558 Change over time sec 11 12 13 14 15 17 18 20 22 Pressure build up time sec 13 14 15 16 18 20 23 25 28 Cooling...

Page 28: ...hange over Join Time until max pressure reached Cooling Cooling time at fusion pressure p 0 10 N mm 0 01 mm mm min value s s max time s min min value up to 4 5 0 5 up to 135 5 6 6 4 5 7 0 0 5 135 175 5 6 6 7 6 12 7 0 12 0 1 0 175 245 6 7 7 11 12 20 12 0 19 0 1 0 245 330 7 9 11 17 20 30 19 0 26 0 1 5 330 400 9 11 17 22 30 40 26 0 37 0 2 0 400 485 11 14 22 32 40 55 37 0 50 0 2 5 485 560 14 17 32 43 ...

Page 29: ... 249 267 285 Change over time sec 6 6 6 7 7 7 7 7 8 Pressure build up time sec 7 7 8 8 9 10 11 13 14 Cooling time min 10 12 13 15 16 18 20 23 25 S 12 5 SDR 26 PN 4 Pipe outer diameter 200 225 250 280 315 355 400 450 500 Wall thickness mm 7 7 8 6 9 6 10 7 12 1 13 6 15 3 17 2 19 1 Fusion surface mm 4652 5847 7250 9053 11514 14587 18491 23387 28856 Equalization fusion pressure bar 3 4 5 6 8 10 13 17 ...

Page 30: ...Cooling time min 29 32 35 39 44 48 54 60 65 S 3 2 SDR 7 4 PN 16 Pipe outer diameter 200 225 250 280 315 355 400 450 500 Wall thickness mm 27 4 30 8 34 2 38 3 43 1 48 5 Fusion surface mm 14857 18791 23186 29082 36816 46701 Equalization fusion pressure bar 11 13 16 21 26 33 Bead height mm 2 0 2 0 2 0 2 5 2 5 2 5 Heating pressure bar 1 1 2 2 3 3 Heat soak time sec 411 437 463 493 520 555 Change over ...

Page 31: ...to clamping tools improper transport faulty fusion preparation 4 Displaced fusion surfaces due to oval shaped pipe ends improper storage of pipes improper fastening in the clamps 5 Angular deflection of fused components due to machine error adjustment error 6 Fusion bead is narrow raised sharp edged over the entire or part of the joint circumference due to incorrect fusion parameters 7 Fusion bead...

Page 32: ...rence due to dirty and or oxidized fusion surfaces change over time too long heater temperature too high too low 10 Cavities in the fusion surfaces due to insufficient fusion pressure cooling time too short 11 Single very widespread or local concentrations of pores due to soiled heating element vapors formed during fusion water solvents ...

Page 33: ... to the nearest service center or to the manufacturer see the back of this manual Danger of injury Sharp planer blades Danger of cutting if the planer blades which are sharp on both sides are touched The planer blades on the planer should be replaced periodically For order number see spare parts list 9 2 Hydraulic system The hydraulic connections on the machine and on the hydraulic unit need regul...

Page 34: ...3000 operating hours hydraulic oil need to be changed 1 Let off the old hydraulic oil 2 Pour in 2 liters of new hydraulic oil Dispose of used dirty oil properly We recommend having a service booklet to record maintenance work for each GF 500 machine Date Service Repair Comments 15 09 2000 B Muster Everything OK 25 10 2000 E Service Heater Cable replaced Maintenance Attention Service booklet Exampl...

Page 35: ...ice 31 10 Customer Service There is a separate spare part list for ordering replacement parts If repairs are necessary please contact your local representative Please indicate the following information Machine type GF 500 Machine no see type plate ...

Page 36: ...GF 500_english_rev01 doc Code no ALIBR74201 A Georg Fischer Omicron S r l Via Enrico Fermi 12 I 35030 Caselle di Selvazzano Padova Italy ...

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