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+GF+ IR-110 A Instruction Manual

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GF Piping Systems
Instruction Manual
GF Piping Systems
GF Piping Systems
IR-110 A
790.164.001
GF Piping Systems

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Summary of Contents for +GF+ IR-110 A

  • Page 1 GF Piping Systems Instruction Manual GF Piping Systems GF Piping Systems IR-110 A 790.164.001 GF Piping Systems...
  • Page 2 Original instructions Disclaimer The technical data are not binding. They neither constitute expressly warranted characteristics nor guaranteed properties nor a guaranteed durability. They are subject to modification. Our General Terms of Sale apply. Observe instruction manual The instruction manual is part of the product and an important element within the safety concept.
  • Page 3 Abbreviations Safety and Responsibility Working with Safety in Mind Safety Devices and Safety Guards Product Design, Equipment Machine Design IR-110 A IR-110 A – Front View 5.1.1 IR-110 A – Back View 5.1.2 IR-110 A – Side View 5.1.3 IR-110 A – Circuit Breaker 5.1.4...
  • Page 4 Table of Contents Instruction Manual IR-110 A 13.1 Select PIPE DATA 13.2 Clean and Insert Components 13.3 Facing 13.4 Check the Facing Quality 13.5 Gap and wall offset check 13.6 Close components 13.7 Start Fusion 13.8 Jointing & Cooling 14 Fusion Data Management 14.1 Printout and Export Protocol/ Label/ Video...
  • Page 5 With the IR-110 A fusion machine from GF Piping Systems, the fusion time can be reduced by 30% on average compared to conventional butt fusion.
  • Page 6 The following materials/systems are released: PVDF SYGEF, PP grey PROGEF, PE100 ecoFIT, PP-n PROGEF Natural Use the IR-110 A only to fuse pipes, fittings and valves made of plastic. The pipes shall be round another geometric form as named is prohibited. Any use beyond this is not authorized.
  • Page 7 Instruction Manual IR-110 A 2 Use of the Machine Unintended Use On no account may the IR-110 A be used to solder or weld electrically conductive materials (e.g. metal pipes). The infrared fusion machine is not intended for use on construction site trenches.
  • Page 8 This document contains all necessary information for the installation, operation and service of the product. To allow a quick understanding of these instructions and safe handling of the IR-110 A machine, all the warning messages, notes and symbols used in these instructions are presented here along with their meaning.
  • Page 9 Instruction Manual IR-110 A 3 About these Instructions Hot surface danger of burns! CAUTION Hazard of rotating tools, danger of cutting injuries! CAUTION Keep Hands Clear Danger of crushing injuries! CAUTION 3.1.2 Further Symbols Symbol Meaning Important Contain particularly important information for comprehension.
  • Page 10 Other Related Documents  Safety Data Sheets for PVDF material  Declaration of Conformity These documents are stored in the drawers of the IR-110 A machine or are available via the agency of GF Piping Systems. Abbreviations Abbr. Meaning Graphical User Interface...
  • Page 11 4 Safety and Responsibility Safety and Responsibility The IR-110 A infrared fusion machine is constructed according to the essential safety and health requirements for the EU market. The machine may pose risks and danger if it is used improperly or not within its intended purpose by untrained persons.
  • Page 12  Do not cover the heating plate/cage  Do not place objects on the cage and do not cover the cage  Switch the IR-110 A off during long work breaks The facer has sharp blades. CAUTION Consequently:  Keep your fingers and hands well away from the facer when it is operating.
  • Page 13 Instruction Manual IR-110 A 4 Safety and Responsibility Safety Devices and Safety Guards Operate the IR-110 A only if all safety devices and safety guards are available and fully functional.  The facer is switched on only if it has been enabled by the control.
  • Page 14 Instruction Manual IR-110 A 5 Product Design, Equipment Product Design, Equipment The IR-110 A is an automated welding machine for plastic piping systems of the dimension range of d20 - d110mm. Delivery content (Details see chapter 21) Fusin machine complete with work...
  • Page 15 Instruction Manual IR-110 A 5 Product Design, Equipment Machine Design IR-110 A IR-110 A – Front View 5.1.1 IR-110 A fusion machine Emergency stop (red button) Outer clamping device (fixed to clamping slide, adjustable with hand lever) Inner clamping device...
  • Page 16 Instruction Manual IR-110 A 5 Product Design, Equipment IR-110 A – Back View 5.1.2 Clamping slide lock 10 Shavings collection tray (removable) 11 Manual adjustment for the facer 12 Manual adjustment for the heater IR-110 A – Side View 5.1.3...
  • Page 17 22 Main switch 23 Power cable connector 230V 24 Environment temperature sensor 25 Fine wire fuse (10 A) 26 Circuit breakers 27 Two-hand button IR-110 A – Circuit Breaker 5.1.4 1 230V Output (e.g. for Printer) 2 Heater 3 Facer CAUTION Closed circuit: Red color, ...
  • Page 18 Instruction Manual IR-110 A 5 Product Design, Equipment IR-110 A – Top View 5.1.5 28 Bubble level 29 Movable clamping slide 30 Heater 31 Facer IR-110 A – Detail View 5.1.6 32 IR temperature sensor 33 Video camera...
  • Page 19 Instruction Manual IR-110 A 5 Product Design, Equipment Accessories 5.2.1 Clamping Inserts / End Caps Clamping inserts d20 - d90 mm End caps d20 - d110 mm (4x each dimension) 5.2.2 Drawers 1 Clamping inserts & End caps 2 Printer, Documents, Brush, Tools 3 Free space 5.2.3...
  • Page 20 Instruction Manual IR-110 A 6 Transport to Worksite Transport to Worksite Transport the IR-110 A always in the intended transport box.  Always transport the machine upright  Avoid vibration and shock  Use a pallet truck for movement ...
  • Page 21 Instruction Manual IR-110 A 7 Description of Icons Description of Icons Home Fusion process Manual operations Settings Fusion data Video management Favorites Confirm Cancel Delete Export protocols Printout Return Refacing Fusion number 2 Emergency stop Heater is hot Heater warms up...
  • Page 22 Monitors and records the entire work process  Quality control and assurance with sensors and protocols NOTICE Use only GF plastic piping materials for welding with the IR-110 A machine which are defined in the graphical user interface of the machine.
  • Page 23 The different steps of the infrared fusion method are explained briefly below. Welding Parameters All relevant parameters are pre-defined in the software of the IR-110 A machine. The appropriate parameters are activated by selecting the respective material and dimension of the components to be welded.
  • Page 24 Joints The essential conditions for perfect fusion joints are:  Only Persons who are trained and certified on the IR-110 A and in the infrared fusion technology are allowed to use the machine  Only ONE person may operate the IR-110 A at the workplace, and this...
  • Page 25 11 Machine Set-up 11.1 Machine Preparation Transport the IR-110 A to its destination ideally by using a fork lift. Manual transport of the machine only requires four people. Ambient temperature range +5°C to +40°C. The workplace lightening should be at a minimum level of 300 lux.
  • Page 26 Instruction Manual IR-110 A 11 Machine Set-up 3. Unlock the clamping slide by turning the lock towards the ‘unlock symbol’ 4. Open safety belt of the heater cage 5. Move the heater cage in the upper position. Ensure that heating cage lock is properly...
  • Page 27 Instruction Manual IR-110 A 11 Machine Set-up 7. Turn the manual adjustment button of the heater to the left until heater has moved down to parking position 8. Remove heater transportation device 9. Move the moveable clamping slide to the right hand side 10.
  • Page 28 Instruction Manual IR-110 A 11 Machine Set-up If machine is not levelled properly adjustment is to be done. 13. Loosen the screw and the adjusting knob of the mounting plate and turn plate to the side 14. Open counter nuts for levelling 15.
  • Page 29 Instruction Manual IR-110 A 11 Machine Set-up 11.2 Cleaning Clean the facer surfaces with Tangit special cleaner PE/PP/PVDF (Code No. 799298023) or >90% Isopropyl-alcohol (semiconductor grade IPA) and a lint-free cleaning cloth. For cleaning of the facer blades special attention is required!
  • Page 30 Instruction Manual IR-110 A 12 Menu Structure and Work Sequence 12 Menu Structure and Work Sequence 12.1 Graphical User Interface Home Favorites, Basic information Fusion Process Selection of pipe data Start fusion process Manual Operations Diagnostic, Clean heater Settings Date/ Time/ Language/...
  • Page 31 Instruction Manual IR-110 A 12 Menu Structure and Work Sequence 12.3 Settings 1. Press SETTINGS 2. Press DATE/ TIME: - define Time, Date, Date …format, Time format 3. Press LANGUAGE: - select the language for xGUI and protocol English French...
  • Page 32 Instruction Manual IR-110 A 12 Menu Structure and Work Sequence 5. Press PRINTER - If printer (protocol or label) is connected you can choose printer (automatic printouts) or no printouts (protocol and label) 6. Define number of automatically printed out...
  • Page 33 Instruction Manual IR-110 A 12 Menu Structure and Work Sequence 9. Press UNITS 10. Select between Celsius (°C) and Fahrenheit (°F) Confirm all settings with:...
  • Page 34 Instruction Manual IR-110 A 13 Fusion Process 13 Fusion Process 13.1 Select PIPE DATA 1. Enter FUSION PROCESS menu or select a favorite in the home menu Important When starting the machine, initialization runs after pressing the two- hand buttons. Therefore, remove welding components from the clamping slides.
  • Page 35 Instruction Manual IR-110 A 13 Fusion Process 8. Keep the two-hand buttons pressed until the facer has reached facing position Important With the selection of material, dimension and pressure rate the appropriate welding parameters are activated. Selecting the correct pipe data is compulsory for a successful fusion joint.
  • Page 36 Instruction Manual IR-110 A 13 Fusion Process 3. Close the inner clamping devices first NOTICE Support pipes which are longer than 1.0 m or when there is a significant weight. 4. Adjust the clamping pressure with the screw on the lever...
  • Page 37 Instruction Manual IR-110 A 13 Fusion Process 13.3 Facing 1. Press two-hand buttons until facer has moved to the facing position and facing process has started  For safety reasons, the facer will only run when in the correct position.
  • Page 38 Instruction Manual IR-110 A 13 Fusion Process 3. Remove plastic shavings in the work area with a brush NOTICE Do not touch the faced pipe ends with a brush! 4. Dry clean the faced pipe ends with a lint-free cloth...
  • Page 39 Instruction Manual IR-110 A 13 Fusion Process 13.4 Check the Facing Quality Check if zero point deviation is in the tolerance ( 0.15) Confirm it NOTICE If the zero point deviation is not in the tolerance ( 0.15) the welding...
  • Page 40 Instruction Manual IR-110 A 13 Fusion Process 13.6 Close components Close the component endings with end caps in order to prevent air flow NOTICE Air circulation above 0.2 m/sec (0.6 feet / sec) can have a negative effect on the fusion results.
  • Page 41 Instruction Manual IR-110 A 13 Fusion Process 13.7 Start Fusion 1. Control data and change worksite if needed 2. Confirm with two-hand buttons The temperature difference between the welding parts and the machine environment should not be more than 10°C; otherwise fusion process will not start.
  • Page 42 Instruction Manual IR-110 A 13 Fusion Process The heating process begins and is, visually illustrated Shortly before the heating- up time ends a repetitive beep tone sounds Clamping slide opens and the heater moves back to the parking position (repetitive beep tone) The machine records the welding parameters.
  • Page 43 Instruction Manual IR-110 A 13 Fusion Process In order to assign the actual fusion weld clearly and unequivocally to the piping system plan (isometric drawing); it is also possible to give the weld a variable second number (No2). First welding number is on-going over the machine life time.
  • Page 44 Instruction Manual IR-110 A 13 Fusion Process  The welder has the option to overwrite an OK Welding as a NOK welding (e.g. contamination) NOTICE  Second fusion number (No.2) can be changed or activated here too 2. Place label on top next to the weld bead 3.
  • Page 45 This makes it necessary to clearly identify every fusion weld in a system in order to warrant unequivocal traceability. The IR-110 A fusion machine from GF Piping Systems makes it possible to connect a label printer and a protocol printer via USB. One protocol and two labels are printed simultaneously for each fusion to place one directly next to the weld (top) and another one on the piping system plan.
  • Page 46 Instruction Manual IR-110 A 14 Fusion Data Management 1. Press Export on USB-Stick (Protocol/ Video) 2. Select Format Document or complete (pdf + xml + video) xml: Only for GF NOTICE analysations 3. Confirm Export with: 1. Press the video button to start the video of the fusion 2.
  • Page 47 Instruction Manual IR-110 A 14 Fusion Data Management Multiple fusion In the overview multiple printouts (Protocol/ Label) or export (Protocol/ Video) on an USB-Stick can be done. Press the printer widget  Filter by Fusion No.: 1. Choose ‘Format’ (Protocol or...
  • Page 48 Instruction Manual IR-110 A 14 Fusion Data Management Press Export on USB- Stick (Protocol/ Video)  Export all fusions 1. Select Format Document or complete (pdf + xml + video) 2. Select “not filtered” 3. Confirm Export with:  Filter by Fusion No.: 1.
  • Page 49 Instruction Manual IR-110 A 14 Fusion Data Management  Filter by Welder: 1. Select Format Document or complete (pdf + xml + video) 2. Filter by Welder 3. Select Welder 4. Confirm Export with: 14.2 Label For every completed weld two identical labels are printed (factory setting) that clearly identify the weld.
  • Page 50 Instruction Manual IR-110 A 14 Fusion Data Management 14.3 Fusion Protocol An “OK” fusion protocol is no guarantee for a correct joint. A visual weld NOTICE inspection is required to confirm the weld joint quality.
  • Page 51 Instruction Manual IR-110 A 15 Weld Bead Inspection 15 Weld Bead Inspection Every fusion joint must be checked visually by the welder after the machine gives out the message “fusion process completed”. 15.1 Weld Bead Inspection Use a dark background to evaluate better the „silhouette” of the fusion bead.
  • Page 52 Instruction Manual IR-110 A 15 Weld Bead Inspection 15.3 Bead Shapes For a visual inspection, bead constitution, wall offset, K-value and possible bead contamination are examined. Depending on the material (PVDF, PP), the pipe dimension and the combination of components (pipe - pipe, pipe - fitting, fitting - fitting), there are typical IR bead shapes, which can be used as guidelines in evaluating a weld.
  • Page 53 Instruction Manual IR-110 A 15 Weld Bead Inspection 15.4 Wall Offset The offset of the jointing surfaces to one another may not be more than 10% of the pipe wall thickness, eo  0.1 * e (eo = wall offset; e = wall thickness) If the wall offset “eo”...
  • Page 54 Instruction Manual IR-110 A 15 Weld Bead Inspection 15.6 Bead Contamination Bead contamination of any kind, which is in the weld, can significantly reduce the stability of the joint depending on the location of the contamination. Apart from diminishing the joint strength, there is the danger of contaminating the medium conveyed in the piping system.
  • Page 55 Instruction Manual IR-110 A 15 Weld Bead Inspection 15.7 Weld Bead Inspection Process Due to the high reproducibility of IR welds, GF developed a tailored testing procedure for weld bead inspections (WBI) as explained in detail below. It is always advantageous to use a reference sample of a weld at the same dimension of the same material.
  • Page 56 Instruction Manual IR-110 A 16 Preparation Transport and Storage 16 Preparation Transport and Storage 16.1 Transporting  Before packing the machine make sure that the heater temperature is below 80°C; this can be checked via the home screen. The cooling time depends on the ambient temperature and can take several hours.
  • Page 57 Instruction Manual IR-110 A 16 Preparation Transport and Storage After waiting period: Heating element is below 80°C 7. Shut down the machine and disconnect all cables 8. Move the outer clamping devices close to the inner ones and tighten them 9.
  • Page 58 Instruction Manual IR-110 A 16 Preparation Transport and Storage 12. Slide heater transportation device into the guiding groove 13. Turn the manual adjustment button of the heater on the right until heater has moved up to transport position 14. Ensure that the transport...
  • Page 59 Instruction Manual IR-110 A 16 Preparation Transport and Storage 17. Unlock the heater cage and move it to the lower position 18. Fasten safety belt of the heater cage 19. Clean the machine and empty the shavings collection tray 20. Lift up the safety bar to the...
  • Page 60 16 Preparation Transport and Storage 21. Close the front cover 22. Place and close the top cover of the machine and lock it Transport the complete IR-110 A in its own transport case.  Transport the transport case always upright ...
  • Page 61 Instruction Manual IR-110 A 16 Preparation Transport and Storage 16.2 Storage Store the machine in its transport case, under dry conditions and weatherproof. Avoid excessive temperature fluctuations. This could result in condensation, which would effect the electronic systems. See chapter 17. Technical data for permitted storage temperature.
  • Page 62 Instruction Manual IR-110 A 17 Technical Data 17 Technical Data 17.1 Data Sheet Manufacturer GF Piping Systems Ltd. Machine type IR-110 A Weight machine / working table 130 kg / 120 kg Total weight 250 kg Dimensions (machine) 0,91 x 0,91 x 0,55 m...
  • Page 63 Instruction Manual IR-110 A 17 Technical Data 17.2 Power Supply The IR-110 A fusion machine will be connected directly via a 3-channel 230 V shockproof plug to mains supply. Wiring diagram 230 V. black blue green / yellow Connect phases Phase L must be 10 A protected or be able to supply 10 A.
  • Page 64 Instruction Manual IR-110 A 18 Manual Operations 18 Manual Operations 18.1 Clean heater The ceramic-coated heater body is self-cleaning; the melted plastic shavings will burn off. In order to prevent corrosion of the ceramic-coated heater body by PVDF shavings (which contain fluoride), they must be removed immediately by using a wooden spatula.
  • Page 65 Instruction Manual IR-110 A 18 Manual Operations 4. When the heater temperature is reached the cleaning process starts automatically 5. After the cleaning process the machine is ready for use Do not inhale the gases released during the cleaning process! (Could result in...
  • Page 66 Instruction Manual IR-110 A 18 Manual Operations 18.2 Diagnostic 1. Enter DIAGNOSTIC 2. Press General Switch on/off Heater 3. Press Camera Control camera function 4. Press CREATE SYSTEM DUMP Only if requested by GF Service 5. Press EXPORT SYSTEM DUMP...
  • Page 67 Instruction Manual IR-110 A 19 Service and Maintenance 19 Service and Maintenance 19.1 Replacing of facer blades Each facer blade has four cutting edges. It can be turned three times before it needs to be replaced. When turning or replacing the blade, make certain that there are neither dirt nor shavings on the facer blade support, otherwise the facing measure will be negative, i.e.
  • Page 68 Instruction Manual IR-110 A 19 Service and Maintenance 19.3 Periodic Maintenance / Mending / Service Level Georg Fischer Piping systems police is that all IR fusion machines should have basic maintenance and calibration check every 2500 fusions or after a period of 18 months.
  • Page 69 This form should be used to systematically find and eliminate previously known defects. The faults are categorized by machinery parts what makes it easier to find the source of the problem. Faults which occur when the IR-110 A fusion machine is not handled or used correctly are not listed here. Defect...
  • Page 70 Instruction Manual IR-110 A 20 Troubleshooting Defect Cause Remedy Comments Heater    “Clean heater” in Heater surface Shavings from If necessary repeat the menu “Manual (ceramic) came in facing cleaning process Operations” contact with plastic  See Chapter 18 ...
  • Page 71 Instruction Manual IR-110 A 20 Troubleshooting Defect Cause Remedy Comments Clamping Slide    Zero point Shavings trapped in Use a sharp tool to Stop screw must be measurement failure drilling for facer clean drill hole and visible guiding pins at the...
  • Page 72 Instruction Manual IR-110 A 21 Scope of Delivery and Accessories 21 Scope of Delivery and Accessories Content of the complete Quantity Description Dim. (mm) Code machine: IR-110 A complete 20-110 790164001 Clamping insert (one piece) 790164022 Clamping insert (one piece)
  • Page 73 Instruction Manual IR-110 A 22 IR-Welding and Maintenance Trainings 22 IR-Welding and Maintenance Trainings GF Piping Systems is a system provider in the piping systems market. This includes, in addition to the core products (fittings, valves, pipes and fusion machines) service and customer training, such as certified welding and maintenance courses.
  • Page 74 Instruction Manual IR-110 A 22 IR-Welding and Maintenance Trainings Training IR-Weld Bead Inspection (IR-A / IR-Plus) This course should transmit basic knowledge about weld bead inspection, so that the participant is able to judge the quality of IR weld beads in terms of weld bead characteristics.
  • Page 75 Instruction Manual IR-110 A 23 Annex 23 Annex 23.1 Checklist for Weld Bead Inspection The following table shows possible fusion errors, their causes as well as remedies. Fusion error Causes Remedies Reduced bead   Air currents > 0.2 m/sec due to:...
  • Page 76 Instruction Manual IR-110 A 23 Annex Fusion error Causes Remedies   Fusion parameters not correctly Check the fusion protocol set, e.g.: PP instead of PVDF Overlap distance too small Pipe dimension too small (20 mm instead of 32 mm) ...
  • Page 77 Instruction Manual IR-110 A 23 Annex Fusion error Causes Remedies Partially   Air currents greater than 0.2 m Reduce air currents missing or /sec directly on the interface of  Seal gap with tape reduced bead the clamping elements (gap at the 9 o’clock...
  • Page 78 Instruction Manual IR-110 A 23 Annex Fusion error Causes Remedies Bead relatively   Overheating of the pipe Try to have ideal fusion conditions, large (large components due to high material i.e. material and ambient melting or ambient temperature (>40 °C) temperature at approx.
  • Page 79 Instruction Manual IR-110 A 23 Annex 23.2 Service Form This form enables the quick processing of repair orders. You should describe the defect(s) as precisely as possible so that it is easier and faster for the Service Center to identify the cause and complete the repair.
  • Page 80 Instruction Manual IR-110 A 23 Annex 23.3 Service Form Please fill in the form with block letters! Sender: (Address) Contact person: Phone: Fax: E-mail: Estimated date of arrival at Service Center: Pick up of goods: No / Yes, Datum: Service order for: Machine type: Machine No.:...
  • Page 81 Instruction Manual IR-110 A 23 Annex 23.4 Directory of Service / Maintenance Centers In addition to the Level 2 - Service Centers, GF Piping Systems offers Level 1 – interval service at most of their sales companies. To remedy any defects, please contact our representative.
  • Page 82 Instruction Manual IR-110 A 23 Annex 23.5 Declaration of Conformity...
  • Page 83 Instruction Manual IR-110 A 23 Annex...
  • Page 84 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 France Mexico / Northern Latin America Singapore Georg Fischer Central Plastics Sudamérica Georg Fischer SAS Georg Fischer S.A.

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790.164.001