1. Manuals
  2. Brands
  3. +GF+ Manuals
  4. Measuring Instruments
  5. SG 160
  6. Instruction manual

+GF+ SG 160 Instruction Manual

Combination butt and socket fusion machine for processing plastic pipes
Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SG 160 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for +GF+ SG 160

Summary of Contents for +GF+ SG 160

  • Page 1 GF Piping Systems Instruction manual SG 160 Combination Butt and Socket Fusion Machine for Processing Plastic Pipes...
  • Page 2 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.

  • Page 3: Table Of Contents

    Operating instructions SG 160 Table of contents Table of contents Page About this manual Warning messages Other symbols and notes Abbreviations Safety instructions Proper use General safety measures Working with safety in mind Disposal Further safety guidelines General Introduction Range of application...
  • Page 4 Table of contents Operating instructions SG 160 Fusion data 10 Maintenance 10.1 Replacement of worn parts 11 Customer service...

  • Page 5: About This Manual

    Operating instructions SG 160 0 About this manual 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.

  • Page 6: Other Symbols And Notes

    0 About this manual Operating instructions SG 160 Other symbols and notes Symbol Meaning Important Notes which contain information particularly important for comprehension. Attention Mandatory instruction: You must take notice of this symbol. Request for action in a sequence of actions: You have to do something here.

  • Page 7: Safety Instructions

    1 Safety instructions 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.

  • Page 8: Working With Safety In Mind

    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.

  • Page 9: Disposal

    Operating instructions SG 160 1 Safety instructions 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.

  • Page 10: General

    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.

  • Page 11: Copyright

    Operating instructions SG 160 2 General 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.

  • Page 12: Product Design, Equipment

    3 Product design, equipment Operating instructions SG 160 Product design, equipment 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 –...

  • Page 13: Technical Specifications

    Operating instructions SG 160 4 Technical specifications Technical specifications Planer Power: 700 W Voltage: 230 V/50 Hz 115 V/60 Hz Heater Power: 1500 W Voltage: 230 V/50 Hz 115 V/60 Hz Characteristic data Machine description: Combined butt – and socket fusion machine...

  • Page 14: Transport And Assembly

    Normally, the machine and the accessories are shipped in a carton crate. 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.

  • Page 15: Design And Mode Of Operation

    6 Design and Mode of Operation 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.

  • Page 16: Installation

    6 Design and Mode of Operation Operating instructions SG 160 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.

  • Page 17: Fusion Preparation

    (humidity, ambient temperature <+ 5 ° C, extreme dir ect 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.

  • Page 18: Butt Fusion Preparation

    7 Fusion Preparation Operating instructions SG 160 Attention 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. Butt fusion preparation The machine can be prepared for butt fusion in only a few steps.
  • Page 19 Operating instructions SG 160 7 Fusion Preparation 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.

  • Page 20: Socket Fusion Preparations

    Operating instructions SG 160 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.
  • Page 21 Operating instructions SG 160 7 Fusion Preparation The aluminum stop must always be in the shown position. Screw in the knurled-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.
  • Page 22 7 Fusion Preparation Operating instructions SG 160 The fusion surfaces must be clean. The screws 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 from the motor side, is counterclockwise.
  • Page 23 Operating instructions SG 160 7 Fusion Preparation Move the clamping device on the slide to the stop 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 available.
  • Page 24 Do not press any 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 measurement device. The SG 160 is now ready for socket fusion...

  • Page 25: Fusion

    Operating instructions SG 160 8 Fusion Fusion Butt fusion For butt fusion with a heating element, the parts to be joined (pipe/pipe, pipe/fitting or fitting/fitting) are heated to fusion temperature in the fusion area and are fused under pressure without the use of additional materials.

  • Page 26: Preparing For Butt Fusion

    8 Fusion Operating instructions SG 160 8.1.1 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.
  • Page 27 Operating instructions SG 160 8 Fusion 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.

  • Page 28: Adjusting The Fusion Force

    8 Fusion Operating instructions SG 160 8.1.2 Adjusting the fusion Force 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 a force of the spring, which is...

  • Page 29: Fusion Process

    Operating instructions SG 160 8 Fusion 8.1.3 Fusion process The PTFE coating of the heating element must be protected from mechanical damage and/or dirt. Heating element with damaged PTFE -covering has to be replaced. Non- observance affects the quality of the joining, see chapter 10.1, from pg. 50.
  • Page 30 8 Fusion Operating instructions SG 160 Heating phase (reduction of equalization force after formation of the fusion bead) 1. When an even fusion bead has been formed along the entire circumference of the pipe (according to the Fusion Tables, chapter 9), the force is reduced to the heating force (F2) according the fusion table of the joint material.
  • Page 31 Operating instructions SG 160 8 Fusion Change-over phase (removing the heating element) The change-over time should be as short as possible. When the heat soak has ended Turn the hand wheel clockwise and move the slide apart. Immediately swing the heating element out of the machine.

  • Page 32: Visual Check Of Welding Bead

    8 Fusion Operating instructions SG 160 Releasing Attention Do not move the machine carriages! 1. Reduce the fusion force to 0 via the hand wheel, therefore secure the position of the hand wheel with the left hand, open the locking screw and turn carefully the wheel counterclockwise.

  • Page 33: Failure Analysis

    Operating instructions SG 160 8 Fusion 8.1.5 Failure analysis Feature Description Evaluation group External state of joint Cracks running length-wise or cross-wise to weld. They may Permissible Permissible Permissible be located: • In the weld • In base material •...
  • Page 34 8 Fusion Operating instructions SG 160 Feature Description Evaluation group External state of joint Welding flash too wide or too pg.14 pg.14 pg.14 narrow over part or all of weld DVS 2202-1 DVS 2202-1 DVS 2202-1 length, caused by, for example:...

  • Page 35: Socket Fusion

    Operating instructions SG 160 8 Fusion 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 bushes and spigots to the required fusion temperature and then joined together.
  • Page 36 8 Fusion Operating instructions SG 160 Attention The pipe end has to be machined until the cross-sectional area of the pipe contacts the base plate of the peeling tool. Stop the motor 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.

  • Page 37: Fusion Process

    Operating instructions SG 160 8 Fusion Mount the fitting, the planer disc serves as a stop. Open the locking screw and move the pipe out of the peeling tool. Swing the peeling device to the back and remove shavings. 8.2.2...
  • Page 38 8 Fusion Operating instructions SG 160 The parts must be jointed according to the time indications in the socket fusion table in chapter 9. By turning the hand wheel, slowly push pipe and fitting into/onto the heating bush, resp. spigot (approx. 2-3 sec) until to the end stop.
  • Page 39 Operating instructions SG 160 8 Fusion After the cooling time (cooling time = heating time) loose the fixing lever and remove the piece. Attention The fusion set temperature should be checked periodically on the fusion tools with tempil sticks or an appropriate, fast responding, temperature measurement device.

  • Page 40: Failure Analysis In Socket Fusion

    8 Fusion Operating instructions SG 160 8.2.3 Failure Analysis in Socket Fusion Feature Description Internal state of joint Different bead formation or no bead on one or both sides (over the entire joint length or only a part). Possible cause: •...
  • Page 41 Operating instructions SG 160 8 Fusion Feature Description Internal state of joint Insufficient fusion joint length with completely or only partially melted fusion surface. Possible cause: • heating time too short • pipe ends not right-angled • heating element temperature too low •...
  • Page 42 9 Fusion data Operating instructions SG 160 Fusion data Heating element butt fusion of PE Fusion chart according to DVS 2207-1 Nominal wall Equalize Heat soak Change-over Join Cooling thickness Bead height on Heat soak time = 10 x Time until max...
  • Page 43 Operating instructions SG 160 9 Fusion data Process steps for heating element butt fusion Ø Outside pipe diameter Wall thickness Fusion surface Equalization force Heating force Fusion force Ø e: wall thickness – – – A: Fusion surface mm² –...
  • Page 44 9 Fusion data Operating instructions SG 160 Ø e: wall thickness – – A: Fusion surface mm² – – 1396 1812 2283 2995 F1&F5 : fusion force – – S 12.5 Bead – – F2: heating force – – SDR 26 t2: heating time –...
  • Page 45 Operating instructions SG 160 9 Fusion data Ø e: wall thickness A: Fusion surface mm² 1435 2144 2734 3434 4491 F1&F5 : fusion force Bead F2: heating force SDR 17 t2: heating time t3: change over time t4: Pressure buildup time t5: Cooling time Ø...
  • Page 46 9 Fusion data Operating instructions SG 160 Ø e: wall thickness 10.3 12.3 15.1 17.1 19.2 – A: Fusion surface mm² 1470 2093 3002 4502 5796 7286 – F1&F5 : fusion force – S 3.2 Bead – F2: heating force –...
  • Page 47 Operating instructions SG 160 9 Fusion data Heating element butt fusion of PP Fusion chart according to DVS 2207-11 Heating element temperature 210 °C ± 10 °C Nominal wall Equalize Heat soak Change-over Join Cooling thickness Bead height on the...
  • Page 48 9 Fusion data Operating instructions SG 160 Ø Outside pipe diameter Wall thickness Fusion surface Equalization force Heating force Fusion force Ø e: wall thickness – – – – A: Fusion surface mm² – – – – 1187 1500 1960 F1&F5 : fusion force...
  • Page 49 Operating instructions SG 160 9 Fusion data Ø e: wall thickness – – A: Fusion surface mm² – – 1360 2052 2629 3317 4314 S 8.3 F1&F5 : fusion force – – Bead / Wulst / Bordino – – SDR 17.6 F2: heating force –...
  • Page 50 9 Fusion data Operating instructions SG 160 Guidelines for heating element socket fusion of pipes and piping components of PP at an ambient temperature of 20 °C and moderate air movement. Heater temperature 260 ° C ± ± ± ± 10 ° C...
  • Page 51 Operating instructions SG 160 9 Fusion data Heating element butt fusion of PVDF Fusion chart according to DVS 2207-15 Heating element temperature 240 °C ± 8 °C Nominal wall Equalize Heat soak Change-over Join Cooling thickness Bead height on the...
  • Page 52 9 Fusion data Operating instructions SG 160 Ø Outside pipe diameter Wall thickness Fusion surface Equalization force Heating force Fusion force Ø e: wall thickness – – A: Fusion surface mm² – – 1158 1743 2243 2806 3684 F1&F5 : fusion force –...
  • Page 53 Operating instructions SG 160 9 Fusion data Guidelines for heating element socket fusion of pipes and piping components of PVDF at an ambient temperature of 20 °C and moderate air movement. Heater temperature 260 ° C ± ± ± ± 10 ° C Pipe outer min.
  • Page 54 10 Maintenance The SG 160should be checked and cleaned periodically. Standard care of the SG 160 is limited to periodic cleaning of the outside. If the planer chain needs to be tightened or replaced, the motor can be turned eccentrically by loosening the socket head screws.
  • Page 55 Operating instructions SG 160 11 Customer service 11 Customer service There 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.
  • Page 56 11 Customer service Operating instructions SG 160...
  • Page 57 Operating instructions SG 160 11 Customer service...
  • Page 60 GF Piping Systems Worldwide at home Our sales companies and representatives ensure local customer support in over 100 countries www.gfps.com Argentina / Southern South America Finland Mexico / Northern Latin America Singapore Georg Fischer Central Plastics Georg Fischer AB Georg Fischer S.A. de C.V. George Fischer Pte Ltd Sudamérica S.R.L.

Table of Contents