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Important:It should be noted that electrofusionand socket fusion fittings are notalways compatible. The length of thespigot does not permit a joint to bemade.

ToolsElectrofusion control unit is a fullyautomatic unit for fusing pipe andelectrofusion fittings together, it canoperate at either 240 volts or 110volts. This is suitable for fusing allelectrofusion joints from 16mm110mm.

Welding cable this has a plug ateach end, one end is screwed ontothe top socket of the electrofusioncontrol unit, the other in is pluggedinto an electrofusion fitting to makejoints.

Primary cable 110v This has a plugat each end. One end is screwedonto the bottom socket of theelectrofusion control unit, the otherend is plugged into a 110 voltbuilding site power transformer, toprovide power to the electrofusioncontrol unit.

Primary cable 240v. This has a plugat each end. One end is screwedonto the bottom socket of theelectrofusion control unit, the otherend is plugged into a 240v socket toprovide power to the electrofusioncontrol unit.

Pipe shears for snipping throughpipes 16 to 25mm o.d.

Pipe roller cutters for cutting thepipe at right angle.One size for 25-63mm pipes.One size for 75-110mm pipes.The pipe must not be cut with a sawor serrated blade since this will leaveunacceptable burrs.

Cleaning fluid for cleaning the pipe

Lint free cloth Apply the cleaningfluid to the cloth to clean the pipe.

Electrofusion Jointing

welding cable

This section covers the tools requiredfor electrofusion jointing, setting upthe tools for use, preparing the pipesand fittings for jointing. Fusing thepipes and fitting together with theelectrofusion machine.

Primary cable 240v

Primary cable 110v

Cleaning fluid and cloth

Pipe shears

Pipe roller cutters

Electrofusion control unit

GEORGE FISCHER ‡8.50

Note:Only the cables come as standardwith the electrofusion control unit.The other tools can be obtainedseparately or are available asstandard tools with INSTAFLEX socketfusion machinery. Cleaning fluid andlint free cloth must be purchasedseparately.

Preparing the electrofusioncontrol unit for useThe electrofusion control is small andrelatively light weight device and isdesigned for ease of transportationaround site.Internally it is a complicatedelectrical device and can easily bebroken or develop a fault if dropped.Care must be taken when in use toalways place it on a flat and levelsurface where it is unlikely to beknocked off or damaged.

To operate select whether you will beusing a 240 volt domestic powersupply or a 110 volt building sitepower source and select the leadwith the appropriate plug.

Attach the primary power cable tothe control unit by plugging it into thesocket at the bottom of the box, thenrotating the outer plastic ring on theplug clockwise. The thread will securethe cable to the control unit.

Attach the welding cable to thecontrol unit by plugging it into thesocket at the top of the box, thenrotating the outer plastic ringclockwise the thread will secure thecable to the control unit.

The electrofusion control unitis portable

Attach the welding cable

Attach the power cable(110v Primary cable shown)

Note:The newelectrofusion controlunit is now suppliedwith 3 outputs.

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Plug the control unit primary cableinto a power source. All the lights onthe front of the control panel shouldilluminate briefly while the control unitconducts a self diagnostic test.

When this is completed the "power"light in the bottom right hand cornershould remain illuminated, thisindicates the control unit is ready tobegin welding.

If the alarm light comes on, there maybe a fault with the unit and GeorgeFischer Sales Ltd. should becontacted Tel: 01203 535535.

The electrofusion control unit willoperate satisfactorily within theconditions listed below.

110v 240vMin Max Min Max

Mains voltage 88v 127v 185v 264vMains frequency 47Hz 65Hz 47Hz 65HzTemperature 15°C 40°C 15°C 40°C

Preparing the fittingsClean the polybutylene fittingsinternally with Tangit KS. Reiniger,cleaning fluid.Apply the cleaning fluid to a clean,dry, lint free cloth.

Rub the moist cloth firmly around theinside of the fitting, on all faces to bejoined

Place the cleaned fitting carefully onthe working surface. Avoid anymoisture or dirt getting inside thefitting.

NoteDo not handle the inside of thefitting after cleaning it as yourhand will dirty the fitting and itwill need to be cleaned again.

Several fittings can be pre-cleaned atone time, so long as the cloth is stillmoist with cleaning fluid and theassembly area is not dusty or wet.

Plug in and check that alllights come on

Ready light on

Moisten cloth with cleaningfluid

Clean the fitting

Note:The newelectrofusion controlunit is now suppliedwith 3 outputs.

GEORGE FISCHER ‡8.52

Preparing the pipe.The pipe must be cut at right angles,using the appropriate pipe cutters.Shears for pipe 16 up to 25mm androller cutter for pipes above 25mm.

The pipe should not be cut with ahacksaw or similar serrated blade asthis will leave unacceptable burrs,and probably result in a cut which isnot at right angles to the pipe, whichis very important.

The pipe must be free from deepscratches and burrs.

NoteThe pipes in all sizes must NOT bechamfered

Apply the cleaning fluid to a cleandry, lint free cloth.

Rub the moist cloth firmly around theoutside of the pipe about 100mm upthe pipe for fittings below 63mm andabout 200mm up the pipe for fittingsabove 63mm. (It is necessary to cleanthe pipe this far, because whenmaking electrofusion joints it isstandard practice to slip the fittingfully onto one end of the pipe).

This should remove any dirt and theprinted marks on the pipe (If it doesnot you may be using the wrongcleaning fluid)

NoteRemember not to handle theoutside of the cleaned pipe withyour hand as this will make itdirty, and it will need to becleaned again.If you have to put the pipe downensure the clean end does notcome into contact with anysurfaces.

Keep cleaned pipe offsurfaces

Clean the pipe

Moisten cloth with cleaningfluid

Cutting pipe sizes 25mmand above.

Snip the pipe sizes 25mmand below.

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Mark the insertion depth on the pipeafter it has been cleaned.Do not use a wax pencil to markthe insertion depth.

Pipe o.d. Insertion depth16mm 27mm20mm 30mm25mm 34mm32mm 37mm40mm 40mm50mm 44mm63mm 50mm75mm 67mm90mm 73.5mm

110mm 80mm

The insertion depths shown aboveare the distance from the centre tothe edge of the electrofusion fitting,so a fitting of the appropriate sizewhich has a mark showing its centrecan be used as an aid for markingthe insertion depth.

NoteIt is important to mark both endsof pipe which will be inserted intothe electrofusion fittings, to avoiderrors.

The pipe is now ready forelectrofusion jointing.

Mark insertion depth with atape measure...

...or mark insertion depthfrom centre mark on fitting

GEORGE FISCHER ‡8.54

Electrofusing the pipe andfittings together

All the pipes have a line down oneside and the fittings have externalmarks every 45° these enableinstallers to keep prefabricated pipesand fittings in the correct alignmentwhen doing electrofusion joints onsite.

The pipes will touch in the centre ofthe electrofusion sockets, the otherfittings have a “Z” dimension shownin the product guide, to helpcalculate what lengths to cut pipesto. So it is easy to calculate thelengths of the pipes required forelectrofusion installations. The “Z”dimension method is describedelsewhere.

The electrofusion fittings are usuallyused to join pre-fabricated pipeworksub-assembled together on site.

Electrofusion spigots, elbows, teesand reducersThe electrofusion spigots sizes from16 to 63mm o.d. are usually fusedwith socket fusion into the end of afitting, typically an elbow or tee.

When jointing in situ the preparedpipe end is then inserted its fulldistance into the spigot, elbows, teesor reducers and the 2 screws oneither side of the fitting are firmlytightened to prevent the pipe fromslipping out.

The electrofusion fitting will now beready for jointing.

Electrofusion socketThe electrofusion sockets areavailable in all sizes from 16 to110mm. They normally have the fulllength of the socket slipped onto onepipe end.

Alignment line on pipe

Marks at 45° intervals to aidalignment

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The other pipe end is brought upflush to the pipe end with theelectrofusion socket.

The socket is slipped over both pipeends, so the insertion marks on bothpipe ends are just disappearing thisconfirms the pipe ends are positionedexactly in the centre of theelectrofusion fitting.

The 4 screws around the electrofusionsocket are tightened to hold thepipes firmly in place.

The electrofusion socket is now readyfor jointing

Jointing electrofusionfittings to the pipeThe fusion joint occurs between theoutside wall of the pipe and theinside surface of the electrofusionfitting.

As a result the electrofusion fittingswill be a permanent part of the pipework system.

The screws on the fittings only holdthe pipe and fittings together whenprior to and during electrofusionjointing process. They do not addmechanical strength or extended lifeexpectancy.

Cross section through anelectrofusion joint

Note: Electrofusion fittings now use an allen key fixing and not screwdriver fixingas illustrated in these examples.

GEORGE FISCHER ‡8.56

To make an electrofusion joint simplyplug the welding cable from theelectrofusion control unit, into theelectrofusion fitting.

You will hear a beep as the cable isplugged in and the ready light, onthe electrofusion control unit shouldcome on.

If the alarm comes on, do not use thisfitting and return it George Fischer forexamination/replacement.

NoteWith 75, 90 and 110mmelectrofusion sockets and allelectrofusion tees and elbows eachend is joined separately. It isimportant to plug the weldingcable into all ends of the fittingbefore starting any joints. So theelectrofusion control unit canperform its diagnostics on thefitting to check that no faults exist.(If you do not do this you couldfind you have fused one end. Butthe other end has a fault and youneed to cut the half fusedelectrofusion fitting out andreplace a length of pipe).

If the fitting does not have a fault,simply press the start button.

No timer has to be set.

The electrofusion process is fullyautomatic, it will recognise the fittingbeing fused and automatically fuse itfor the correct time, but the fusiontimes are listed below for reference.

Pipe o.d. Total fusion timemm seconds

16mm 4520mm 5025mm 6532mm 7540mm 8550mm 10563mm 12075mm 105 each end90mm 110 each end

110mm 120 each end

Plug in welding cable

The ‘Ready’ light shouldbe on

Press ‘Start’

Note:The newelectrofusion controlunit is now suppliedwith 3 outputs.

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As the electrofusion control unit isfusing the pipe and fitting together, alittle indicator pip will rise from withinthe fitting to indicate a joint has beensuccessfully made.

Although the electrofusion fitting getswarm during the electrofusionprocess, it is never unsafe, or too hotto handle.

If for any reason the indication pipdoes not rise or you are uncertain thejoint had been made (someone mayhave switched off the power) or afault develops during the fusionprocess. Leave the fitting for aminimum of 1 hour, then you can goback and re-make the joint safely.

When the joint has been completeda beeper will sound and the end lightwill come on. This indicates that asuccessful joint should have beenmade.

During electrofusion jointing the pipeand fitting should not be moved, orsubjected to unnecessary stresses.The pipe and fitting should beallowed to cool for a few minutesafter each joint has been made,before being moved or subjected tostress.

Pipe o.d. Minimum cooling time

16mm 4 mins20mm 4 mins25mm 4 mins32mm 4 mins40mm 4 mins50mm 6 mins63mm 6 mins75mm 6 mins90mm 6 mins

110mm 6 mins

Minimum cooling times beforemoving pipe and fittings

Wait one hour after the last joint hasbeen made before filling the systemwith water and pressure testing, up to15 bar pressure.

Joint indicator starts to show

Joint indicator fully showing

Hold the joint in place

‘End’ light will show whenthe joint is complete

Remove the welding cable

Note:The newelectrofusion controlunit is now suppliedwith 3 outputs.