+GF+ IR-63 M Instruction Manual

Infrared fusion machine

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GF Piping Systems

IR-63 M

Infrared Fusion Machine

Instruction manual

790180199 IR-63 M Infrared Fusion Machine

MA_00161/ EN / 01 (02.2025)

CH-8201 Schaffhausen/Switzerland

+41 52 631 30 26/info.ps@georgfischer.com

www.gfps.com

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Page 1 GF Piping Systems IR-63 M Infrared Fusion Machine Instruction manual 790180199 IR-63 M Infrared Fusion Machine MA_00161/ EN / 01 (02.2025) © Georg Fischer Piping Systems Ltd CH-8201 Schaffhausen/Switzerland +41 52 631 30 26/info.ps@georgfischer.com www.gfps.com...
Page 2 GF Piping Systems Translation of the original instruction manual Disclaimer The technical data are not binding. They neither constitute expressly warranted characteristics nor guaranteed properties nor a guaran- teed durability. It is subject to modification. Our General Terms of Sale apply.
Page 3: Table Of Contents
GF Piping Systems Contents About this document Safety information Meaning of the signal words Observe instruction manual Safety and responsibility EC and UKCA declaration of conformity Product description Intended use Technical specifications Machine overview Fusion process sequence description Machine set-up Transport and unpack Connections Startup procedure...
Page 4 GF Piping Systems Set overlap Clean and position components Facing Welding End of welding Remote welding 6.10 Reassemble heater handle Fusion data management Print/export single fusion Print multiple fusions Export Example fusion label and fusion protocol CONNECT Welding Data Weld bead inspection Process Review machine fusion protocol Visual weld bead inspection...
Page 5 GF Piping Systems 10.3 Service Desk 10.4 Directory of Service/Maintenance Centers 10.5 Repairs Troubleshooting Scope of delivery and accessories 12.1 Scope of delivery 12.2 Accessories (not in scope of delivery) Disposal Training courses...
Page 6: About This Document
IR-63 M Infrared Fusion Machine Instruction manual About this document Other applicable documents Document Safety Data Sheets for PVC-U, PVDF, PFA and ECTFE material • Declaration of Conformity • Control data sheet • These documents are stored in the machine control interface, or are available via the agency of GF Piping Systems.
Page 7: Observe Instruction Manual
Training required for operation! Only persons who are trained and certified on the IR-63 M infrared fusion machine and in infrared welding technology are allowed to operate the fusion machine. Incorrect installation, putting into operation or service can cause personal injury and damage to prop- erty, as well as endanger the environment.
Page 8 IR-63 M Infrared Fusion Machine Instruction manual ► Set up the fusion unit on a stable, level surface (Exception: remote welding). ► Secure the fusion machine at the workplace. ► Protect the fusion machine from falling down. ► Protect the fusion machine from water.
Page 9: Ec And Ukca Declaration Of Conformity
Instruction manual IR-63 M Infrared Fusion Machine EC and UKCA declaration of conformity The manufacturer Georg Fischer Piping Systems AG, 8201 Schaffhausen (Switzerland) declares that the subsequently listed ma- chines are machines according to the listed unifying design standard in terms of the EC Machine Directive 2006/42/EC and comply with the requirements of this directive that apply to machines.
Page 10: Product Description
The IR-63 M is a manual, electronically controlled infrared fusion machine for plastic piping systems from GF Piping Systems. The IR-63 M infrared fusion machine may only be used for welding approved round pipes, fittings and valves in the dimensions d20 - d63 mm (1/2"...
Page 11: Technical Specifications
Instruction manual IR-63 M Infrared Fusion Machine Technical specifications 3.2.1 Specifications Specifications IR-63 M infrared fusion machine Manufacturer Georg Fischer Piping Systems Ltd. Machine type IR-63 M Operation mode Manual Materials PVDF SYGEF, PP-H PROGEF, PE100 ecoFIT, PP-n PROGEF Natural, ECTFE SYGEF, IR PVC-U metric,...
Page 12: Machine Overview
IR-63 M Infrared Fusion Machine Instruction manual Machine overview Pos. Designation Machine housing Touchscreen display with GUI for machine control Fixation options Lever left (fixed) Clamping slide lever (movable) Movable clamping slide Clamping device Facer Heater Ambient temperature sensor Type plate...
Page 13: Label Printer
Instruction manual IR-63 M Infrared Fusion Machine 3.3.1 Label printer Label printer Brother PT-P900W (See separate operating instructions) Pos. Designation Printer Power cable 230V USB cable Ribbon white 24mm 3.3.2 Box for accessories Pos. Designation End caps d20-63mm Brush & set of wrenches...
Page 14: Fusion Process Sequence Description
Jointing process The fusion pressure of the IR-63 M infrared fusion machine is defined by the overlap distance. The melted material only needs to be moved to the stop. By using the stop to generate fusion pressure, reproducibility of the welding results is increased.
Page 15: Machine Set-Up
IR-63 M Infrared Fusion Machine Machine set-up Transport and unpack 4.1.1 Transport Description Transport the IR-63 M always in the intended transport box. Always store heater and facer in transport box when not • in use. Always transport the machine upright. •...
Page 16: Connections
Carefully swing the heater onto the guide rail from above (1 & 2) tighten the screw (3). Connections 4.2.1 Connect plugs Attach the cables for power supply, clamping slide, facer and heater firmly to the IR-63 M infrared fusion machine. Pos. Designation Power cable Clamping slide Facer...
Page 17 IR-63 M Infrared Fusion Machine 4.2.2 Connect power supply The IR-63 M infrared fusion machine is connected to the main supply via the 230 V power cable. DANGER! Danger to life due to electric shock! Touching live conductors can result in death or serious injury from electric shock.
Page 18: Startup Procedure
IR-63 M Infrared Fusion Machine Instruction manual Startup procedure Step Procedure Start the fusion machine using the main switch. The green light indicates that the machine has power. The display turns on and the GUI starts. Enter welder name. The worksite is taken from the last login but it can be changed.
Page 19: Graphical User Interface (Gui)
Instruction manual IR-63 M Infrared Fusion Machine Graphical user interface (GUI) Icon Description Home Favorites • Basic information • Login / Change welder / CONNECT Welding Data • Fusion Process Selection of pipe data • Start fusion process • Save favorites •...
Page 20: Home Screen
IR-63 M Infrared Fusion Machine Instruction manual Home screen Pos. Designation Home Fusion process Manual operations Settings Fusion data management Date and time Status automatic heat up Status CONNECT Welding Data Status heater Login / Change welder / CONNECT Welding Data Home 5.2.1...
Page 21: System Dump
5.3.5 Automatic heat up Description The IR-63 M infrared fusion machine can be programmed to automatically heat up at a specific date and time. Select automatic heat up. Select date & time. The machine can be programmed up to 3 days in advance.
Page 22: Standby Mode
IR-63 M Infrared Fusion Machine Instruction manual 5.3.6 Standby Mode Description If standby mode is activated, the heater switches off. Select Standby Mode. Standby Mode is accesible in manual operations if automatic heat up is activated. Confirm Machine goes into Standby Mode and heater turns off.
Page 23: Icons
Instruction manual IR-63 M Infrared Fusion Machine Icons Description Home Fusion process Manual operations Settings Fusion data Automatic management heat up CONNECT Welding Create favorite Confirm Cancel Delete Printout Data Export Change welder Refacing Return Standby mode Alarm...
Page 24: Fusion Process
IR-63 M Infrared Fusion Machine Instruction manual Fusion process Pre-conditions for good infrared fusion joints The essential conditions for perfect fusion joints are: Environment ► Ensure an ambient temperature of +5°C to +40°C for the welding machine and the components.
Page 25: Select Pipe Data
Instruction manual IR-63 M Infrared Fusion Machine Select pipe data Step Procedure Select material Select diameter Select PN or SDR Option: save selection to favorites by selecting the star widget and selecting saving spot Option: enter Isometric drawing number under Isometric or additional information, under Info 1 &...
Page 26 IR-63 M Infrared Fusion Machine Instruction manual Open clamping devices. Close the clamping slide as far as possible (1). Position components in clamping device, and slide them carefully against pipe stop (2). Close the clamping devices from the inside (1), to the outside (2).
Page 27: Facing
Instruction manual IR-63 M Infrared Fusion Machine Facing 6.6.1 Procedure Step Procedure Face the clamped components by carefully moving the clamping slide lever all the way to the stop on the left. The facer starts automatically. Note: the facer only works if it is positioned correctly.
Page 28 IR-63 M Infrared Fusion Machine Instruction manual 6.6.3 Check the facing quality Step Procedure Check wall offset between components. Max. 10% wall offset is allowed on average depending on the pipe wall thickness. Check gap between components. Max. gap 0.2 mm is allowed ►...
Page 29: Welding
Instruction manual IR-63 M Infrared Fusion Machine Welding Step Procedure Use your right hand to insert the heater by the handle (1). Within the displayed insert time, use the clamping slide lever to move the clamping slide to the stop. Do not lock the clamping slide lever.
Page 30: End Of Welding
IR-63 M Infrared Fusion Machine Instruction manual Remove welded components from the clamping slide and visually inspect the weld bead, see chapter „8 Weld bead inspection“ on page 39. End of welding Step Procedure 27.11.2024 13:14 Confirm IR-63 M 27K3HEQ5D5P Optional: place fusion label on the right side of the weld bead at the 12 No.
Page 31: Reassemble Heater Handle
Instruction manual IR-63 M Infrared Fusion Machine 6.10 Reassemble heater handle In certain cases it is beneficial to move the heater handle to a different position to free up more space for the installation. Step Procedure Disconnect heater from machine housing. Heater must be cold.
Page 32 IR-63 M Infrared Fusion Machine Instruction manual Step Procedure Turn around lever and tighten the four cylinder head screws. Note: Use the four middle borings, not the long holes. Turn around heater and assemble heater handle with the two T20 torx plastic screws.
Page 33: Fusion Data Management
The IR-63 M infrared fusion machine makes it possible to connect a label and protocol printer via USB. Furthermore, the protocol can be exported digitally via USB-stick or wireless to CONNECT Welding Data.
Page 34: Example Fusion Label And Fusion Protocol
IR-63 M Infrared Fusion Machine Instruction manual Example fusion label and fusion protocol NOTICE! An ‚OK‘ fusion protocol / label is no guarantee for a correct joint. A visual weld inspection is required to confirm the weld joint quality. 7.4.1 Example Fusion Label Pos.
Page 35: Connect Welding Data
Instruction manual IR-63 M Infrared Fusion Machine CONNECT Welding Data 1. Establishing an Internet connection Fix the CONNECT Welding Data box (Code No: 790180019) to the side of the machine The Internet connection can be established via WLAN, cell phone hotspot or Ethernet connection.
Page 36 IR-63 M Infrared Fusion Machine Instruction manual 1. Establishing an Internet connection Select WLAN and enter the password if necessary. 2. Login with CONNECT Hub account Enter e-mail address and password. Choose organisation Define settings Project selection Select the project in which the protocols are to be saved in •...
Page 37: Weld Bead Inspection
Instruction manual IR-63 M Infrared Fusion Machine 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. Review Machine Fusion Protocol •...
Page 38: Review Machine Fusion Protocol
During the visual inspection of individual fusion welds, it is necessary to check the correspondence of the data of the weld protocol with the actual weld bead and the label placed on the pipe component: Pipe data/material/dimension/wall thickness/pressure rate • Confirmation of date/time • IR-63 M infrared fusion machine number • Comparison of parameters (set/actual) • Fusion number •...
Page 39 Instruction manual IR-63 M Infrared Fusion Machine 8.3.2 Beads Bead shape Depending on the material (PVDF, PP, ect.), 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 40: Wbi-Tool
IR-63 M Infrared Fusion Machine Instruction manual K-value The K-value describes the distance between the lowest point of the bead groove (base of the bead) and the pipe crown (outer surface of the pipe in mm). K-value The examination of the K-value must be done over the entire pipe circumference.
Page 41 Instruction manual IR-63 M Infrared Fusion Machine 8.4.1 Checklist for weld bead inspection NOTICE! The listed fusion errors indicate a faulty fusion result. Fusion error Causes Remedies ► Prevent/minimize air currents Reduced bead or not a Air currents > 0.2 m/sec due to: complete bead or half ►...
Page 42 IR-63 M Infrared Fusion Machine Instruction manual Fusion error Causes Remedies ► Prevent/minimize air currents Partially reduced or Air currents > 0.2 m/sec due to: missing bead ► Place machine in a protected area HEPA filter in clean rooms •...
Page 43 Instruction manual IR-63 M Infrared Fusion Machine Fusion error Causes Remedies ► Try to have ideal fusion conditions, i.e. Bead relatively large Overheating of the components due to high (large melting volume) material or ambient temperature (>40 °C) material and ambient temperature at approx.
Page 44: Transport And Storage
IR-63 M Infrared Fusion Machine Instruction manual Transport and storage NOTICE! Incorrect lifting can damage the fusion machine. ► Before lifting, switch off the fusion machine and disconnect the power plug. ► Only lift the fusion machine on the underside.
Page 45 Check, if all moving parts have been secured. Put the heater and the facer into the transport case. Place the IR-63 M infrared fusion machine and the box for the accessories into the transport case. Place the cover on the transport case and close it.
Page 46: Storage
IR-63 M Infrared Fusion Machine Instruction manual Storage Store the machine in its transport case, under dry conditions and weatherproof. • Avoid excessive temperature fluctuations. This could result in condensation, which would affect the electronic systems. • See Chapter „3.2.1 Specifications“ on page 13 for permitted storage temperature.
Page 47: General Maintenance
Instruction manual IR-63 M Infrared Fusion Machine 10.2 General maintenance 10.2.1 Cleaning the heater surface The ceramic-coated heater body is self-cleaning. Go to manual operations and select “clean heater”. The heater will heat up to 540°C and hold the temperature for three hours, the plastic resedue will burn off.
Page 48: Service Desk
IR-63 M Infrared Fusion Machine Instruction manual 10.3 Service Desk Please fill out the service form below and contact your responsible Georg Fischer representative to schedule a machine service. The machine has to be sent to your nearest GF Service & Maintenance Center. Before shipping, check if all four serial numbers (heater, machine housing, facer &...
Page 49: Directory Of Service/Maintenance Centers
Instruction manual IR-63 M Infrared Fusion Machine 10.4 Directory of Service/Maintenance Centers In addition to the level 2 Service Centers listed below, GF Piping Systems maintains additional repair centers in most of their sales companies. For troubleshooting, please contact your local GF Piping Systems office directly.
Page 50: Troubleshooting
IR-63 M Infrared Fusion Machine Instruction manual Troubleshooting The fusion machine has an error message system which indicates operating errors to the operator and which provides the operator with information on machine errors and faults. This form makes it possible to systematically search for and correct faults in response to the faults known to us so far. The problem areas are structured as self-contained units and can thus be tackled in a targeted manner.
Page 51 Instruction manual IR-63 M Infrared Fusion Machine Defect Causes Remedies Comments Message “Temperature Temperature sensor(s) Contact service center Start diagnostics pro- • • • sensor defect” are defective gram, see chapter „5.3.1 Diagnostic“ on page 22 Heater surface (ceramic Mechanical damage of the...
Page 52: Scope Of Delivery And Accessories
IR-63 M Infrared Fusion Machine Instruction manual Scope of delivery and accessories 12.1 Scope of delivery There are two versions of the IR-63 M infrared fusion machines with different scopes of delivery: IR-63 M standard 790180001 • IR-63 M complete 790180003 •...
Page 53: Accessories (Not In Scope Of Delivery)
Instruction manual IR-63 M Infrared Fusion Machine 12.2 Accessories (not in scope of delivery) Quantity Description Dimension (mm/inch) Code No. Allen key 5mm 790180079 Extension cable set 6m 790180013 CONNECT Welding Data box 790180019 Cleaning tissues KO-TON-R (100 pieces) 790122085...
Page 54: Training Courses
IR-63 M Infrared Fusion Machine Instruction manual Training courses 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. The correct installa- tion of our products is just as important as the quality of the products itself.
Page 55 Instruction manual IR-63 M Infrared Fusion Machine...
Page 56 GF Piping Systems Local support around the world Visit our webpage to get in touch with your local specialist: www.gfps.com/our-locations The information and technical data (altogether “Data”) herein are not binding, unless explicitly confirmed in writing. The Data neither constitutes any expressed, implied or warranted characteristics, nor guaranteed properties or a guaranteed durability.