Manual - Electrofusion Welder 2011 · Electrofusion Welder 26/07/2011 Pg 2 INDEX 03. Important Notice 04. Specifications 05. PAT Record 06. Calibration & Warranty

Electrofusion Welder


26/07/2011

www.LaboratoryDrainage.co.uk

Pg 2

INDEX

03. Important Notice

04. Specifications

05. PAT Record

06. Calibration & Warranty

06. Certificate of Conformity

07. Waste Electrical Electronic Equipment

07. Restriction of Hazardous Substances

08. Instructions For Use

08. General Operation

09. Quick Start Guide

10. Multiple connections

11. Data Logging

11. Data Log Memory

11. Downloading the weld memory

12. Options

12. Passwords

14. Fault Codes

17. Welding Unit Repair Information

17. Testing the Completed System

18. Jointing Guide

Visit www.plasticpipewelding.com to register your product and receive

notifications about software and product updates.

Visit www.cpv.co.uk to view CPV-Zurn product information


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IMPORTANT NOTICE

• RISK OF EXPLOSION! This unit must not be used in a gaseous atmosphere.

• RISK OF ELECTRIC SHOCK! Do not open. No user serviceable parts inside.

• To avoid damaging the welding unit, do not interrupt the supply voltage or disconnect the output lead, while the unit is welding a

fitting.

• This welding unit is Class 1, and must be used with an earthed supply (grounded).

• This welding unit has been designed for use with electrofusion fittings from the CPV-Zurn Fusion Lock system.


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SPECIFICATIONS

Operating Mode: CPV-Zurn Fusion Lock

Operating Language: English (others on request)

Operating Temperature: -20 to +40 degrees Celsius

Data entry system: Integrated alpha-numeric keypad

Data log memory: 2048 welds

Data memory download: USB flash memory drive

Input voltage: 110 V ac

88 V to 132 V +/- 20%

Input current: 1 A to 8 A

Input frequency: 50 Hz (40 to 70 Hz)

Input power: 100 VA to 880 VA

Output current (fixed) 15,5 A ac true rms

Output stability: +/- 1,5 %

Output voltage (varies in range

shown according to fitting) 4 V to 50 V range

Output power: 60 W to 775 W

Welding time: Automatic: temperature compensated

Weight (with leads): 15 kgs

Size: 46 cm x 35.5 cm x 20.3 cm

Environmental protection: IP65

Input lead length: 5 m

Output lead length: 5 m

Plug 16 amp plug fitted

Advance Welding has a policy of continuously improving product design,

and as such reserve the right to change specification of its products

without prior notice and with impunity.

The CPV-Zurn Fusion Lock Welder is designed for jointing CPV-Zurn

components ONLY. Conversely, NO other welding equipment may be

used for jointing CPV-Zurn components

.


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PAT RECORD

PORTABLE APPLIANCE TEST RECORD

Make

Advance

Welding

Serial

Number

Voltage

110 v

Power

Output

775 W max

Current

15 amps

Fuse

16 amps

Visual Inspection & Test

Date Environ-

ment

Sock-

et

Plug Flex Body Earth

ohms

Insulati

on

m ohms

OK /

not

OK

Signa-

ture

N/A


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CALIBRATION & WARRANTY

This welding unit has been manufactured, inspected and tested in

accordance with the quality control systems in place at Advance Welding.

This welding unit has been calibrated using equipment that is traceable to

national and international standards, through a NAMAS accredited

laboratory.

NAMAS (National Accreditation of Measurement and Sampling) is a

service of UKAS (United Kingdom Accreditation Service).

This welding unit has a TWELVE month calibration and warranty period,

active from the first use of the unit by the end user customer. (This date is

logged by the welding unit and can be seen by entering the password

SFWD in the more options screen.)

Full warranty information is available on our web site.

CERTIFICATE OF CONFORMITY

This welding unit has been designed to comply

with the harmonised standards under the "New

Approach" directives, and has been CE marked

accordingly.

The applicable standards are:

89/336/EEC Electromagnetic compatibility

73/23/EEC Low voltage equipment

98/37/EC Machinery safety

On behalf of Advance Welding: K.M.Wilkinson.


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WASTE ELECTRICAL ELECTRONIC EQUIPMENT DIRECTIVE (WEEE)

Within the European union, this symbol

indicates that this product should not be

disposed of with household waste. It should be

taken to an appropriate recycling facility.

For information on how to recycle this product

responsibly please visit our web site.

Advance Welding has registered with a WEEE compliance scheme, details

are available on request.

RESTRICTION OF HAZARDOUS SUBSTANCES DIRECTIVE (RoHS)

This Directive bans the placing on the EU

market of new electrical and electronic

equipment containing more than agreed levels

of lead, cadmium, mercury, hexavalent

chromium, polybrominated biphenyl (PBB) and

polybrominated diphenyl ether (PBDE) flame

retardants.

This product is RoHS compliant.

RoHS CompliantDirective 2005/ 95/ EC

Pb


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INSTRUCTIONS FOR USE

Connect the welding unit to the correct supply voltage and switch it on.

The screen will show a welcome message along with the software version

and date.

The owner information is now shown on the display. (For information on

how to program this into the unit, see the Calibration manual.)

The main menu is now shown:

A Welding

D Options

During operation, except when welding, pressing the (STAR) key will

jump back to this menu.

Note:

The operation of the unit can be customised by turning features on and

off, such as data logging. This manual details all available modes and

features. For information on how to customise the welding unit see the

“Passwords” section later on in this manual.

GENERAL OPERATION

The welding unit is fitted with an alpha-numeric keypad, which is used by

the operator to input data. There are four Quick-Keys, acting as shortcut

keys, as follows:

A Accept the data entry

B Backspace one position

C Clear the input

D Options


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The function of the Quick Keys is prompted on the screen.

When entering data, letters and numbers can be selected by repeatedly

pressing the same key, e.g. A B C 2 A B C 2 . After a short pause the cursor

will move to the next position.

Special characters and spaces can be selected by pressing the 1 or 0 keys.

(This is the same method used for text with mobile phones.)

QUICK START WELDING

From the main menu 2 selections are possible, A (Welding) and D

(Options) To select welding press the A Accept Quick-Key. Then select A

for data logging off or B for data logging on. If data logging on is selected,

one can then optionally enter Operator’s Name, Location and Job

Reference by entering data and repeatedly pressing the A Accept key

If not already connected, the display will then carry the instruction to

connect the lead and fittings.

Then select a preheat or fusion mode option (Select key)

Fusion 1.5”- 4”

Fusion 6”

Preheat 12 secs

Confirm the option required by pressing the A Accept Quick-Key

Note: 1.5” – 4” fittings have a set time of 120 seconds fusion and 120

seconds cooling (240 seconds shown) 6” fittings have a set time of 150

seconds fusion and 120 seconds cooling (270 seconds shown)


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If the data log is enabled the display will display an Abraded/Tight? query

(green for yes, red for no) This acts as a memory jogger to confirm that

this operation has been done. Press the START button and the

temperature and temperature compensated time selected will be shown.

Press START again to begin welding.

During the weld, the display will show the combined welding and cooling

time counting down to zero, and the weld number. The unit will monitor

the welding to make sure it does not go out of limits. Any faults that are

detected will terminate the welding and cause an error message to be

displayed. These are listed later on in this manual.

The fittings must not be touched or disconnected during the cooling

period; doing so will cause a fault to be recorded on the data log and a

faulty joint may result.

At the end of the cooling period the display will ask for the output lead to

be disconnected from the fitting. Doing this will reset the unit back to the

‘connect lead and fittings’ option, ie; in readiness for the next weld to be

progressed.

MULTIPLE CONNECTIONS

The unit can weld multiple joints in series.

Do not exceed the numbers shown in the table below.

Do not mix size 1.5”-4” fittings with size 6” fittings in the same fusion

weld cycle.

Joints can be connected in series using the link cables provided.


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DO NOT MIX 1.5”-4” FITTINGS WITH 6” FITTINGS IN THE

SAME FUSION WELD CYCLE

7


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DATA LOGGING

If Data Logging is ON at the start of welding, then the parameters of

welding will be recorded. These can subsequently be down loaded into a

portable memory stick for transfer to a computer and subsequent

analysis.

DATA LOG MEMORY

It is possible to enter three pieces of information to identify the weld. The

first is the Operator’s Name, the second is the Location where the weld is

being done, and the third is an Information field for more details.

The display will show all three pieces of information in turn: Enter the

required information and press the A key to accept it.

Note:

This information will be saved when the weld has been completed, and

will be prompted the next time a new weld is carried out.

The display will also ask if the pipe/fitting has been abraded and

tightened. Select yes or no using the Start or Stop buttons. This

information will be saved on the data log memory.

DOWNLOADING THE WELD MEMORY

The data log memory is downloaded by using an ‘industry standard’ USB

flash memory device. The data can be encrypted for protection, to stop

unauthorised alteration of the information.

A download program is supplied that un-encrypts the data and allows it

to be viewed, filtered, graphed and printed. This software is supplied on

the USB memory pen. Run the Install file and follow the instructions.


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Plug the USB flash memory drive into the USB connector on the side of

the welding unit.

From the main menu:

Press the D Quick-Key to select options.

Press the A Quick-Key to select download data.

Confirm that you want to download the data. The display will show that it

is “Enumerating the device”. While this is showing, the unit is initialising

the memory drive. The data will now be downloaded.

The display will ask if you want to reset the data log memory. Select yes

or no then disconnect the memory drive when prompted to do so.

OPTIONS

From the main menu:

Press the D Quick-Key to select options.

Press the B Quick-Key to select other options.

From here the time and date can be set, along with supervisor and

calibration options. These are password protected.

Use the following passwords in order to select the facility required.


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PASSWORDS

The following passwords are available:

AWOM Set operating modes.

The available modes of operation are displayed next to a letter key, A B C

D. To configure a mode press the corresponding key, e.g. A = Manual

mode. Next the options for that mode are displayed, for example Data

Logging. Pressing the letter key (e.g. A) will toggle that option on and off.

Set the options as required then press the (star) key. Set other modes of

operation as required, then press the (star) key to save them and return

to the password menu.

JFMA Set the date.

The data can be set in the format dd/mm/yyyy.

ATOZ Set the operating language.

The available languages are displayed. Press the letter shown to select

the language.

AINF Show unit information.

The serial number, part number, calibration date and calibration period

are shown. Press any key and the weld counters are shown.

SFWD Show date of first weld.

The date that the first weld was carried out is shown. This is used to set

the start of the warranty period.

AWKL Clear data log memory.

The data log memory is erased.


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SWUD Update the software.

The internal software can be upgraded. Copy the new software (supplied

by Advance Welding) onto a USB memory pen and plug it into the USB

connector on the side of the box. Enter the password. When prompted

press the A key to accept. The software will now be updated. When

completed the screen will show “Success!”. Unplug the welding unit from

the power supply to complete the process.

DLEN Set download to plain text.

The data download will be a Common Separated Variable (csv) file, with a

.xls extension. This can either be viewed in the Advance Welding Data

Download Manager or in Microsoft Excel.

DLEY Set download to encrypted.

The data download will be an encrypted file, with a .pfd extension. This

can only be viewed in the Advance Welding Data Download Manager.

AWHD Download all welds, including non-logged.

This password will download all welds, including those done when the

unit was not set to data logging mode. All visible and hidden welds are

downloaded. The hidden, non-logged welds, will show blank in the

operator input fields.

Other passwords are available for authorised repair centres. These

include calibration, changing owner details and setting/showing the

distributor selling data.


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FAULT CODES

During operation, the welding unit monitors all aspects of its operation. If

a fault occurs then an error message will be shown.

0: Weld OK

No Fault, weld completed OK.

1: Stuck button on start up

This fault shows when the power is first switched on. Either the Stop,

Start, or a keypad button is stuck in. Free the button to clear the fault.

2: Output fault before weld start

This fault shows when the power is first switched on. The unit will check

the output terminals to make sure no voltage is present when first

switched on. If this fault happens then the internal power relays have

stuck in the closed position. The unit will need to be returned for service.

4: No calibration

This fault happens when the unit has no calibration. This will normally not

show, and if the unit has been calibrated, would be caused by a fault with

the internal memory. Return the unit for service.

5: Case temperature sensor fault (if fitted)

Some units have a case temperature sensor fitted to switch the unit off if

the electronics become too hot. This fault will show if the sensor is faulty.

Return the unit for service.


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6: Case temperature out of limits (if fitted)

Some units have a case temperature sensor fitted to switch the unit off if

the electronics become too hot. This fault will show if the temperature is

too hot. Let the unit cool down.

10: Low supply frequency 70Hz

The unit has detected that the supply frequency is above 70 Hz. This will

normally be caused by a poor quality generator. If this fault happens then

check the supply or change the generator.

12: High supply voltage >140v

The unit has detected that the supply voltage is more than 140 volts.

Check the supply voltage and if necessary use a different generator.

13: Low supply voltage


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It could be caused by the use of long extension leads. If a large fitting is

welded then a high current will be taken from the supply. If extension

leads are used, there will be a volts drop down the lead making the unit

sense a low supply voltage. Try not to use extension leads with the unit. If

you have to then use just 30 feet of cable, the same size fitted to the unit.

14: Relay failed to latch on weld start

This fault could happen when the start button is pressed. If the main

power relays do not operate correctly then this fault will be shown. The

unit needs to be returned for service.

20: Welding current Excessive (>150%)

This fault will happen if the welding current is more than 50% high for

more than 0.3 seconds. This fault is normally caused by a fault within the

unit, a short circuit triac. The unit must be returned for service.

21: Welding current High (>125%)

This fault will happen if the welding current is more than 25% high for

more than 1 second. This fault is normally caused by a fault within the

unit, a short circuit triac. The unit must be returned for service.


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22: Welding current High (>112.5%)

This fault will happen if the welding current is more than 12.5% high for

more than 1.5 seconds. This fault can be caused by a fault within the unit,

a short circuit triac. It can also be caused by a poor quality generator with

the supply voltage fluctuating. Try a different generator.



more than 2 seconds. This fault will normally be caused by a poor quality

generator with the supply voltage fluctuating. Try a different generator.



more than 3 seconds. This fault will normally be caused by a poor quality

generator with the supply voltage fluctuating. Try a different generator.

25: User stop button pressed

The operator has pressed the stop button.

26: Relay unlatched

During welding, if the main power relay disconnects then this fault will be

shown. It could be caused by the unit being knocked or a temporary dip in

the power supply. If the fault persists then the unit should be returned for

repair.


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27: Fitting open circuit

This fault is shown if the output lead disconnects from the fitting while

welding. Follow the guidelines from the fitting manufacturer, reconnect

the lead and try welding again.

28: Welding current Low (


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WELDING UNIT REPAIR INFORMATION

There are no user serviceable parts inside the welding unit. If an internal

fault happens with the unit then it must be returned to Advance Welding

or one of its authorised service agents for repair.

TESTING THE COMPLETED SYSTEM

The completed system should be tested for leaks in accordance with BS

EN 12056-2:2000. An air test should be completed in one operation but

for large multi-storey systems testing in sections may be necessary. Air

should be pumped into the system until a pressure of 38mm water gauge

is obtained and remains constant for a period of no less than 3 minutes


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JOINTING GUIDE

STEP 1

Tools Required:

Pipe Cutters – cut the pipe square and deburr ends.

Solvent Wipes – clean the pipe ends with the solvent wipes provided.

STEP 2

Dissemble Fittings - remove locking nuts from fittings. Ensure sockets are

clean and free from oily deposits.


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STEP 3

Insertion of Fusion Lock seals – insert seals fully into the sockets after

ensuring that the terminals are in the desired position relative to the pipe

circumference (operator choice)

Reapply the locking nuts, hand tight - bend the terminal connectors

inward first.


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After Hand Tightening Locking Nuts - bend the Fusion Seal terminals

slightly outwards.

STEP 4

Ring Depth Gauge – insert the pipe fully into the depth gauge and mark

the pipe circumferentially as shown.

Joint depths –

1½” = 26mm

2” = 31mm

3”, 4”, & 6” = 53mm


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STEP 5

Pipe Insertion – insert pipe into the joint assembly, until depth mark

disappears and the pipe ‘bottoms out’.

STEP 6

Tighten Locking Nut - use the CPV-Zurn spanner and/or strap wrenches.

The depth mark should be just visible.

THE PIPES SHOULD BE A SNUG FIT Do not proceed if they are loose

Straighten up the Fusion Seal Terminals

IMPORTANT CHECK (BEFORE FUSION): Where necessary, support

horizontal runs to prevent sagging and clamp vertical runs to prevent

joint movement


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STEP 7

Connection Cable – connect the shrouded clips of the output cable to the

fusion seals.

STEP 8

Velcro Tape - Support the connection cable with Velcro tape to the pipe

and/or fittings to minimise the weight on the fusion seals

Fusion Cycle:Three options are available

i) 1.5”-4” fittings

ii) 6” fittings

iii) Preheat 12 secs

Multiple Connections - Use the shrouded jumper leads provided.

For Example – the maximum number of multiple joints of the same size

that can be made is as follows:-

1½” - ten,

2”- seven

3”- four

4”- three

6”- two

IMPORTANT: DO NOT MIX 1.5”-4” FITTINGS WITH 6” FITTINGS IN THE

SAME FUSION WELD


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Welding Machine Maximum Wattage is 750 watts – do not exceed this.

Individual fittings are rated as follows:

38 (1½”) – 72w

51 (2”) – 90w

76 ( 3”) – 180w

102 (4”) – 240w

152(6”) – 336w.

STEP 9

Welding Procedure– P7-9 for full detail

Press START on the CPV-Zurn Fusion Lock Welder.

The welder will indicate successful completion of the electrofusion joint

process (welding plus cooling time) by a discontinuous bleep.

If fusion cycle is aborted for any reason, cool joint completely before

restart

Carefully remove the connection cables from the fusion seal terminals.

Proceed to the next joint (s).

Cool fused joints for a minimum of ½ hour before testing.

Documents

Manual - Electrofusion Welder 2011 · Electrofusion Welder 26/07/2011 Pg 2 INDEX 03. Important Notice 04. Specifications 05. PAT Record 06. Calibration & Warranty