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GEORGE FISCHER SG 160 Instruction Manual

Combination butt and socket fusion machine for processing plastic pipes
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Instruction Manual
Combination Butt and Socket Fusion
Machine SG 160
for Processing Plastic Pipes.

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Summary of Contents for GEORGE FISCHER SG 160

  • Page 1 Instruction Manual Combination Butt and Socket Fusion Machine SG 160 for Processing Plastic Pipes.
  • Page 2 Notice:...
  • Page 3 Dear customer, ask your sales and service centre to explain and to show all functions of the welding machine. Before putting the unit into operation you have to read and understand the operating manual and in particular the safety instructions. By this operating manual you will be instructed of the correct use and informed about the safety rules of this welding machine.

  • Page 4: Table Of Contents

    Page Table of Contents 1. Safety 1.1 Safety definition 1.2 Workshop safety 2. Technical Data 2.1 Characteristic Data 2.2 Range of Applications 2.3 Type Description 2.4 Subassemblies - Overview 3. General 3.1 Introduction 3.2 Range of Applications 4. Transport 4.1 Packaging 4.2 Disassembly 4.3 Sensitivity 4.4 Intermediate Storage...
  • Page 5 7.5 Failure Analysis in Butt Fusion 7.6 Basics of Socket Fusion 7.7 Preparing for Socket Fusion 7.8 Fusion Tables/Fusion Process 7.9 Special Cases in Socket Fusion 7.10 Failure Analysis in Socket Fusion Maintenance 8.1 Periodic Maintenance 8.2 Replacement of Worn Parts 8.3 Setting the parameter 8.4 Calibrating and programming 8.5 Basic adjustment...

  • Page 6: Safety

    1.2 Workshop safety Give special attention to the following safety rules! The welding machine for plastic pipes SG 160 is built on todays technology and corresponds to the general workshop safety if it is used as prescribed. Using the machine by...
  • Page 7 – A daily visual check up of the SG 160 has to be done. Damages and defects have to be repaired. Repairs of the electronics have to be done through the official supplier.
  • Page 8 Especially dangerous are the heating element and the planing element. The heating element and the planing element may only be operated by the special handles. Never touch the planing element at the surface. It contains two shaving blades. The heating element is heated up to 210° C (410°...

  • Page 9: Technical Data

    January 1, 1997. 2.2 Range of Applications and Authorized Usage The SG 160 is made exclusively for the fusion jointing of plastic pipes, fittings and valves. Any other use is not authorized. The manufacturer is not liable for any damage resulting thereof;...

  • Page 10: Subassemblies - Overview

    2.4 Subassemblies - Overview The following subassemblies are contained in the basic package. 2.4.1 Machine Base with Slide Machine base of steel sections welded with four handles on the side. Two tempered, chrome-plated guide shafts for the slide. Tempered, chrome-plated guide shafts for the heating plate and the planer.

  • Page 11: General

    The complete technical documentation should be kept in the vicinity of the SG 160. Especially important details for the use of the SG 160 are noted in this Manual. This Manual must be observed if failure-free operation of the SG 160 is to be warranted.

  • Page 12: Transport

    Condensation due to large fluctuations in temperature as well as sharp jolts during transport should be prevented. The SG 160 is to be handled with proper care. 4.4 Intermediate Storage If the SG 160 is not installed immediately upon receipt, it must be stored in a protected place.

  • Page 13: Design And Mode Of Operation

    – 1 pan head screw M8 x 70 5. Design and Mode of Operation 5.1 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.

  • Page 14: Butt Fusion Version/Accessory Parts

    5.3 Butt Fusion Version Clamping bracket LEFT Accessory Parts Planer with pick-up Heating plate for peeling and chamfering tools Clamping bracket RIGHT Insert Basic clamping plate RIGHT Basic clamping plate LEFT Handweel for moving the slide 5.4 Socket Fusion Version/ Accessory Parts Peeling tool Planer with pick-up...

  • Page 15: Installation

    Fig. 5 For other methods of installation, for example on a stationary work bench, it is recommended that the SG 160 is fastened to the bench with a clamp in order to prevent it from moving during the fusion process.

  • Page 16: Starting Operation

    6. Starting Operation 6.1 General Information Proper training of the operating personnel has a great influence on the optimal functioning of the SG 160. 6.2 Preparing for Butt Fusion The machine can be prepared for butt fusion in only a few steps.
  • Page 17 The set temperature can be read by pushing the P-key. Fig. 11 Fig. 11 In case of operation problems please check chapter 8.3, page 45. Do not press any key uncontrolled in the Attention! programming operation. Now the SG 160 is ready for butt fusion.

  • Page 18: Preparing For Socket Fusion

    6.3 Preparing for Socket Fusion 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.
  • Page 19 The groove in both eccentric screws (in front and at the back) should be vertical and secured with a safety screw. The heating plate can now be moved radially. Fig. 16 Fig. 16 Attention! Mount heating bushes and spigots. The heating bushes may not be scratched or damaged in any way.
  • Page 20 Do not press any key uncontrolled in the pro- gramming operation. The fusion set temperature should be checked on the fusion tools with tempil sticks or an appropriate, fast responding, temperature measurement device. Fig. 24 The SG 160 is now ready for socket fusion. Fig. 24...

  • Page 21: Operation

    7. Operation 7.1 Basics of Butt Fusion For butt fusion with heating element, the parts to be joined (pipe/fitting or fitting/fitting) are warmed to the fusion temperature within the fusion range and fused under pressure without the use of additional materials.

  • Page 22: Preparing For Butt Fusion

    7.2 Preparing for Butt Fusion Heating element butt fusion joints may only be done by carefully trained personnel. Place pipe/pipe, fitting/fitting or pipe/fitting in the clamping device. The pipes/fittings must be correctly aligned in the axial directlon. Fig. 25 Fig.25 Swing in planer and hold with left hand.
  • Page 23 After swinging out the planer, the pieces should be checked by pushing them together until they touch. If there is a space between the two pieces, it may be no larger than max. 0.5 mm. At the same time, the alignment should be checked. Maximum allowable misalignment on the outside may not exceed 10% of the wall thickness.

  • Page 24: Fusion Tables/Fusion Process

    (See pressure/time diagram below). For the SG 160 the pressure can be read on the Fig.27 daN-scale of the feed shaft. Fig. 27 Pressure/Time Diagram...
  • Page 25 Heating Element Butt fusion of PE Fusion Table / Guidelines ( DVS 2207) Heating Element Temperature 210° C +/- 10° C Wall thickness Fusion Heating element Equalization p = Heating p = Change-over Cooling under temperature 0,15 N/mm 0,02 N/mm fusion pressure p = 0,15 N/mm Time for...
  • Page 27 Heating Element Butt Fusion of PP Fusion Table/Guidelines (DVS 2207) Heating Element Temperature 200° C +/- 10° C Heating Wall Heating Equalization Changeover Fusion Cooling under thickness element p = 0,01 N/mm fusion pressure p =0,10 N/mm temperature = 0,10 N/mm Heating time Bead height Max.
  • Page 29 Fusion pressure max. = (d + off size allowance - s incl. off-size allowance) x s incl. x p x π Heating Element Butt Fusion of PVDF Fusion Force Table SG 160 Fusion Force Table at PVDF 0.10 N/mm Fusion Pressure...
  • Page 30 7.3.2 Butt Fusion Process Swivel heating element between pipe/fitting. Fig. 28 Equalization (Fusion Table Col. 2) Equalization of pipe/fitting to heating element until Fig.28 an even bead is formed around the complete circumference. Equalization pressure = Fusion pressure Fig. 29 Release Then reduce the pressure to approx.
  • Page 31 Secure the slide with the fixing lever. Fig. 32 Cooling (Fusion Table, Col. 6) The cooling time must be strictly observed. For high ambient temperatures, the upper table value must be used, for lower temperatures, the lower value suffices. Fig.32 Attention! It is prohibit to use any coolant! All fusion joints must have cooled completely...

  • Page 32: Special Cases In Butt Fusion

    7.4 Special cases in Butt Fusion • Segment fusion • Thin-walled pipes • Reinforced fiber pipe Segment fusion By standing the Y-supports on end, fittings can be clamped at an angle. Thin-walled pipes Due to the circular clamping, thin-walled pipes (liner pipes, drains) can also be fused on the SG 160.
  • Page 33 7.5 Failure Analysis in Butt Fusion 1 Cracks Cracks running parallel to or across the joint. Possible cause: - in the joint - in the basic materials - in the heat flow zone. 2 Bead notches Traversing or local notches parallel to the welding joint with root in basic material.
  • Page 34 7 Insufficient fusion bead Fusion bead too wide or too narrow over a part or the entire joint length. Possible cause: - wrong heating time - wrong heating element temperature - wrong fusion pressure 8 Uneven fusion bead Non-angular fusion surface due to differing beads over a part or the entire joint length.
  • Page 35 7.6 Basics of Socket Fusion For socket fusion with heating element, the pipes and pipe parts are fused overlapping without the use of additional materials. The pipe ends and fitting sockets are heated on a socket- or spigotshaped heating element to the required fusion temperature and then joined in one another.
  • Page 36 Before starting up the peeling unit, feed 10-15 mm of the pipe into the peeling tool. The peeling tool will not be ejected if the rotation direction is wrong. The pipe end is worked until the front end of the pipe lightly touches the plate of the peeling tool.
  • Page 37 Loosen the stop and remove the pipe from the peeling tool. Swing the peeling device to the back. Remove shavings. 7.8 Fusion Tables and Fusion Process The heating bushes and heating spigots must be cleaned with a dry, clean, lint-free paper before Attention! each jointing.
  • Page 38 Heating Times for Socket Fusion Joints of PE at 20° C ambient temperature (DVS 2207, part 1). Heating Element Temperature 260° C +/- 10° C pipe Heating Chang-over Cooling outer PN 10 PN 6 time (max. diameter SDR 11 SDR 17,666 allowable) fixed total...
  • Page 39 Heating Times for Socket Fusion Joints of PVDF at 20° C ambient temperature (DVS 2207, part 15). Heating Element Temperature 260° C +/- 10° C pipe min wall Heating Change- Cooling outer thickness over time diameter max. allo- fixed total d in mm in mm wable s...
  • Page 40 By turning the handwheel, slowly push pipe and fitting into/onto the heating bush, resp. heating spigot (approx. 2-3 sec). It is pushed together to the end stop. The heating time begins when the pieces are in the final position. Fig. 40 Fig.40 When the heating time is over, pull the pieces quickly apart, swing out heating element and then...
  • Page 41 7.9 Special Cases in Socket Fusion • Difficult Fitting Combinations • Secondary Containement Piping Difficult fitting combinations By moving the clamping devices, unusual combinations can be easily joined. Secondary Containement Piping Only a few changes and a different set of clamps and the machine can be used with the Georg Fischer Secondary Containement System.
  • Page 42 7.10 Failure Analysis in Socket Fusion 1 Different bead formation or no bead on one or both sides (over the entire joint length or only a part). Possible cause: - heating element temperature too high - heating time too long - inadmissible tolerances 2 Different bead formation or no bead on one or both sides (over the entire joint length or only a...
  • Page 43 7 Jointing error with insufficient form-locking 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 with fitting 8 Compressed pipe cross-section during heating or fusion.
  • Page 44 8. Maintenance 8.1 Periodic maintenance The SG 160 is easy to maintain, given it is used correctly. Normal care of the SG 160 is limited to periodic cleaning of the outside. The motor for the planer is completely encapsulated, thus requiring no maintenance.
  • Page 45 8.3 Setting the parameter for the welding temperature on the heating element (Operating modus) Press P shortly < 3 sec. (Fig. 44) Fig.44 The led OUT will flash, the actual parameter for the welding temperature is displayed. By pressing UP or DOWN the desired temperature can be selected.
  • Page 46 Hold the P-key and the UP-key (or DOWN-key) at the same time to change the value. Example: The heating element is on a temperature of 205° C and the Digital Heat Controller shows 210° C, please correct CAL by -5°, from -5°...
  • Page 47 8.5 Basic adjustment Parameter: Unit: Description: Default: °C / °F Differential switching point °C / °F Low / minimum set °C / °F High / maximum set sec. Output delay °C / °F range to dynamic output value °C / °F time to dynamic output value sec.
  • Page 48 8.6 Change from programming to operation mode Do not press any key during 20 seconds. The Controller will switch back itself to the operating mode. The display switches back to the actual temperature. The instrument is not to be switched off before exiting from the programming phase because Attention! otherwise the data inserted in the last session...
  • Page 49 9. Wiring Diagram SG 160...
  • Page 50 Georg Fischer Rohrleitungssysteme GmbH, Sandgasse 16, 3130 Herzogenburg, Tel. +43(0)2782/8 56 43-0, Fax +43(0)2782/8 51 56, e-mail: georgfischer@via.at George Fischer Pty. Ltd., 4 Jacks Road, South Oakleigh, Victoria 3167, Tel. +61(0)3/95 63 88 99, Fax +61(0)3/95 63 89 66, e-mail: sales@georgefischer.com.au Georg Fischer NV/SA, Digue du Canal 109-111 –...

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