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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

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Summary of Contents for SG 160

Page 1: ...Instruction manual GF Piping Systems SG 160 Combination Butt and Socket Fusion Machine for Processing Plastic Pipes...

Page 2: ...articular 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 Fis...

Page 3: ...ristic 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 Prepar...

Page 4: ...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...

Page 5: ...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 immine...

Page 6: ...ave 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...

Page 7: ...on 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 fol...

Page 8: ...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 bu...

Page 9: ...llection 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 equ...

Page 10: ...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 represe...

Page 11: ...or 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...

Page 12: ...laner 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 h...

Page 13: ...l 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 mach...

Page 14: ...sport 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 shoul...

Page 15: ...ration 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...

Page 16: ...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 plac...

Page 17: ...nts 7 2 Heating element settings 7 2 1 Temperature setpoint adjustment To set the welding temperature press the button P shortly 3 sec The LED OUT 1 will switch ON the actual temperature set point for...

Page 18: ...ck 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...

Page 19: ...ion 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 correspon...

Page 20: ...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...

Page 21: ...nurled head screw The spring will become disengaged and a direct pressure buildup is possible The groove in both eccentric screws in front and at the back should be vertical The heating plate can now...

Page 22: ...crews should be tightened only after the fusion temperature has been reached Adjust the rotation direction of the planer as displayed in the picture below The rotation direction of the planer as seen...

Page 23: ...op screws and tighten with the special wrench Mount clamping jaws These are marked with the respective dimension ranges Type 1 30 50 50 90 Type 2 16 30 90 125 For additional support Y supports are ava...

Page 24: ...key uncontrolled in the programming operation of the heating element The fusion set temperature should be checked on the fusion tools with tempil sticks or an appropriate fast responding temperature...

Page 25: ...ng element butt fusion joint must be done with a controllable equalization pressure See pressure time tables Chapter 8 1 5 from pg 29 Only the same type of materials are to fuse The wall thicknesses i...

Page 26: ...e axial directlon Swing in planer and hold with left hand It is important that the safety hook is fastened on the guide shaft Plane by pushing together until both surfaces to be joined show no unmachi...

Page 27: ...better alignment In this case a new machining of the surfaces to be fused is required Shavings which fall into the pipe must be removed for example with a brush Before fusing the machined surfaces mus...

Page 28: ...rce The fusion process requires different contact pressures in the fusion are on the one hand for equalization and fusion and on the other for heating The pressure of the fusion area is transferred in...

Page 29: ...qualization heat soak and fusion can be found in the respective tables see chapter 9 Equalization phase fusion bead creation on both sides 1 Swing heating element into position 2 By turning the hand w...

Page 30: ...the fusion table of the joint material Keep the left hand on the hand wheel to secure the position and open the locking screw than turn the hand wheel carefully clock wise When reducing the force turn...

Page 31: ...ide apart Immediately swing the heating element out of the machine Joining and cooling phase fusion process Turn the hand wheel counterclockwise and quickly build up the required fusion force F5 F1 Se...

Page 32: ...ully the wheel counterclockwise 2 Open the clamps and remove the fused pipes fittings All fusion joints must have cooled completely before the pressure test is performed This is generally the case app...

Page 33: ...weld caused by for example Clamping tools Incorrect transport Fault in edge preparation Locally permissible if ending flat and s 0 1s but max 0 5mm Locally permissible if ending flat and s 0 1s but ma...

Page 34: ...b1 0 6 x b2 Permissible if b1 0 5 x b2 Feature Description Evaluation group I II III Internal state of joint No fusion or incomplete fusion on joint faces over part or the whole of weld cross section...

Page 35: ...inated in such a way that a fusion pressure is built up during jointing and an even joint is created In general only uniform materials must be fused In order to obtain optimal fusion results only corr...

Page 36: ...without removing the pipe Open the clamping jaws slightly move the carriage to the right until the clamping jaws come in contact with the peeling tool Tighten the clamping jaws again The present posi...

Page 37: ...ling device to the back and remove shavings 8 2 2 Fusion process The heating bushes and spigots must be cleaned with a dry clean lint free paper before each jointing The pipe fitting parts to be joint...

Page 38: ...hand wheel slowly push pipe and fitting into onto the heating bush resp spigot approx 2 3 sec until to the end stop The heating time begins when the pieces are in the final position When the heating...

Page 39: ...empil sticks or an appropriate fast responding temperature measurement device It is prohibited to use any coolant The joint may only be stressed by further installing after the cooling period has expi...

Page 40: ...ible cause heating time too short heating element temperature too low inadmissible tolerances Different bead formation or no bead on one or both sides over the entire joint length or only a part Possi...

Page 41: ...cking Local axially on surface or circular formation of channel Possible cause notches in the pipe surface diameter tolerance of pipe or fitting exceeded incorrect mechanical working pipe not aligned...

Page 42: ...min min value up to 4 5 0 5 45 5 5 6 4 5 7 0 1 0 45 70 5 6 5 6 6 10 7 0 12 0 1 5 70 120 6 8 6 8 10 16 12 0 19 0 2 0 120 190 8 10 8 11 16 24 19 0 26 0 2 5 190 260 10 12 11 14 24 32 26 0 37 0 3 0 260 3...

Page 43: ...ing force daN 1 1 1 1 1 2 2 t2 heating time sec 18 19 22 27 31 35 40 t3 change over time sec 5 5 5 5 5 5 5 t4 Pressure buildup time sec 5 5 5 5 5 5 5 t5 Cooling time min 6 6 6 6 6 6 6 S 16 SDR 33 mm 3...

Page 44: ...5 5 5 5 5 6 6 t4 Pressure buildup time sec 5 5 5 5 5 5 6 6 t5 Cooling time min 6 6 6 6 7 8 9 10 S 10 SDR 21 32 40 50 63 75 90 110 125 140 160 e wall thickness mm 2 4 3 0 3 6 4 3 5 3 6 0 6 7 7 7 A Fusi...

Page 45: ...5 5 5 5 6 6 6 7 8 t4 Pressure buildup time sec 5 5 5 5 5 6 6 6 7 8 t5 Cooling time min 6 6 6 6 8 10 11 13 14 16 S 5 SDR 11 32 40 50 63 75 90 110 125 140 160 e wall thickness mm 2 9 3 7 4 6 5 8 6 8 8 2...

Page 46: ...time sec 5 5 6 7 7 8 9 10 11 t5 Cooling time min 6 8 10 12 14 16 20 22 24 Guidelines for heating element socket fusion of pipes and piping components in PE HD at an ambient temperature of 20 C and mod...

Page 47: ...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...

Page 48: ...ll thickness mm 2 0 2 3 2 8 3 4 3 9 4 3 4 9 A Fusion surface mm 383 525 767 1138 1484 1833 2387 F1 F5 fusion force daN 4 5 8 11 15 18 24 Bead Wulst Bordino mm 0 5 0 5 0 5 0 5 0 5 0 5 0 5 F2 heating fo...

Page 49: ...F1 F5 fusion force daN 3 4 7 10 15 21 31 41 51 67 Bead Wulst Bordino mm 0 5 0 5 0 5 0 5 0 5 1 0 1 0 1 0 1 0 1 0 F2 heating force daN 1 1 1 1 1 2 3 4 5 7 t2 heating time sec 135 111 135 156 172 192 217...

Page 50: ...1 2 3 4 5 Pipe outer diameter Heat soak Changeover Cooling for PN 10 SDR 112 s for PN 6 SDR 17 6662 s Maximum time s fixed s total min d in mm 16 5 4 6 2 20 5 4 6 2 25 7 1 4 10 2 32 8 1 6 10 4 40 12...

Page 51: ...ion pressure build up time Cooling Cooling time at fusion pressure p 0 10 N mm 0 01 Cooling time 1 2 x wall thickness 2 min mm mm min value s s max time s min min value 1 9 3 5 0 5 59 75 3 3 4 5 0 6 3...

Page 52: ...8 9 10 11 PN 10 32 40 50 63 75 90 110 125 140 160 e wall thickness mm 2 0 2 3 2 8 3 4 3 9 4 3 4 9 A Fusion surface mm 383 525 767 1139 1484 1833 2388 F1 F5 fusion force daN 4 5 8 11 15 18 24 Bead Wuls...

Page 53: ...ambient temperature of 20 C and moderate air movement Heater temperature 260 C 10 C 1 2 3 4 5 6 Pipe outer diameter min Heat soak Changeover Cooling wall thickness mm s Maximum time s fixed s total m...

Page 54: ...other damage heating element needs to be recoated send the heating element to the nearest service center or to the manufacturer see the back of this manual Danger of injury Sharp planer blades Danger...

Page 55: ...e is a separate spare part list for ordering replacement parts If repairs are necessary please contact your local representative See back of this manual for a list of addresses Please indicate at leas...

Page 56: ...11 Customer service Operating instructions SG 160 52...

Page 57: ...Operating instructions SG 160 11 Customer service 53...

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Page 60: ...r com www gfps com mx Middle East Georg Fischer Piping Systems Switzerland Ltd Dubai United Arab Emirates Phone 971 4 289 49 60 gss ps georgfischer com www gfps com int Netherlands Georg Fischer N V 8...

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