CPV Act1 Manuel utilisateur
Act1 Electrofusion Welder
Act1 Electrofusion Welder
06/06/2011 www.ProcessPipes.co.uk Pg 2
Index
Operating ontrols................................................................................3
Safety Notes ..........................................................................................4
Product Specification ............................................................................5
Intended Use .........................................................................................6
Introduction ..........................................................................................6
Delivered Items .....................................................................................6
Electrical Safety .....................................................................................7
Using the Equipment.............................................................................8
Manual Welding ....................................................................................9
Extreme Low Temperature Operation................................................10
Set Up Options ....................................................................................11
Information .........................................................................................12
Fault Finding........................................................................................13
Maintenance .......................................................................................16
Disposal ...............................................................................................17
alibration and Warranty....................................................................17
Declaration of onformity...................................................................20
Service and Repair...............................................................................21
Quick Start Guide ................................................................................22
Jointing Guide…………………………………………………………………………………23
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Operating ontrols
1. Welding able (can be provided with optional right angle plug)
2. Welding able Socket
3. Protective Lid
4. Display
5. Buttons
6. Protective Frame
7. Ratings Plate
8. Supply able
1. Welding Cable
8
. Supply Cable
6
. Protective Frame
7
. Ratings Plate
2
.
Welding Cable Soc et
5
.
Bu
ttons
4
.
Display
3
.
Protective Lid
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Safety Notes
•RISK OF EXPLOSION! This welding unit must not be used in a gaseous atmosphere.
•RISK OF ELECTRIC SHOCK! Do not open. No user serviceable parts inside.
•Before using, always visually inspect the unit to see that the cables and connectors are not
worn or damaged. Replace the damaged part before welding.
•Switch off and remove the plug from the mains before adjusting, cleaning, or if the cables
are entangled and before leaving the equipment unattended for any period.
•To avoid damaging the unit, do not interrupt the supply voltage or disconnect the welding
cable, while the unit is welding a fitting.
•Do not lift or pull the equipment by its cables.
•Do not disconnect the welding cables by pulling on them, always pull off the connectors
from the fitting.
•Do not start a weld without the pipe correctly inserted into the fitting.
•Do not touch the fitting while welding.
•Do not weld in the rain or leave the equipment outdoors whilst it is raining.
•Weld only in daylight or in good artificial light.
•The operator is responsible for accidents or hazards occurring to other people or their
property while using this equipment. Keep the work area safe!
•Keep bystanders a safe distance away from the machine while welding.
•Never allow people unfamiliar with these instructions to use the welding unit.
!
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Product Specification
Operating Type: ontrolled voltage.
Operating Modes: Manual
Operating Languages: English, French, Dutch, Polish, Russian. (others on
request)
Operating Temperature: -10
o
to +40
o
#1
Welding Voltage: 8 to 48 V ac (39,5 V)
Welding urrent: 1 to 65 A ac (true rms)
(100 A short term)
Welding Power: 8 VA to 3120 VA
Welding Time: 1 to 3600 seconds
Apparent Power Factor: 0.15 to 0.92
Supply Voltage:
#2
110 V ac (+/- 20%) 40 to 60 Hz
Supply urrent:
#2
1 to 30 A ac (true rms)
Supply Power:
#2
3,500 W (peak at 0.15 APF)
Supply Voltage:
#3
230 V ac (+/- 20%) 40 to 60 Hz
Supply urrent:
#3
1 to 15 A ac (true rms)
Supply Power:
#3
3,500 W (peak at 0.15 APF)
Supply Protection: lass 1 – Earthed
Data log memory: Not available
Data download/upload: Not available
Weight: 28 kg
Size: 38 cm x 38 cm x 39 cm
Protection Level: IP65
#1
An extended temperature unit is available with limits -40
o
to +50
o
.
#2 #3
The unit is available in either 110v or 230v operation.
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.
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Intended Use
This equipment is intended to weld constant voltage electrofusion fittings suitable for low,
medium and high pressure pipe work systems.
This welding unit has been approved in the UK by Transco to the standard T/SP/E E/1 2005
‘Specification for Electrofusion ontrol Boxes’, and is approved for use on all UK gas distribution
networks.
This welding unit complies with the UK Water Industry Specification WIS 04-32-08 ‘Specifications
for the fusion jointing of polyethylene pressure pipeline systems using PE80 and PE100 materials’,
and is suitable for use on all UK water distribution networks.
This welding unit has been designed to comply with the International Organization for
Standardization standard ISO12176-2:2000 "Plastic pipes and fittings, equipment for fusion
jointing polyethylene systems , part 2, electrofusion".
Introduction
This manual gives instructions on the correct assembly and safe use of your welding unit. It is
important that you read these instructions carefully, and keep these instructions for the life of the
unit.
This manual does not detail the specific welding procedure for the fittings: scraping, clamping and
assembly of joints. For this information you must contact the manufacturer of the fittings.
Delivered Items
arefully remove the welding unit from its packaging and check that you have the following items:
•Welding unit.
•Welding cable.
When parts are missing or damaged, please contact your dealer.
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Electrical Safety
WARNING! Switch off and remove the plug from the mains before adjusting, cleaning or if the
cable is cut, damaged or entangled.
This welding unit is lass 1 and requires an earthed (grounded) connection. An earth spike must be
used with generators.
This unit is supplied in either 110 volt or 230 volt operation. heck the rating plate on the side of
the unit for the correct supply voltage.
The power source must be capable of providing 3500 Watts.
Extension cables should only be used if they comply with the H07RNF harmonized standard. They
must be fitted with connectors to the BS EN 60309-2 standard. All cables must be unwound from
the reel to stop inductive heating effects. The cable dimensions should be as follows:
110 Volt operation 230 Volt operation
Up to 63mm diameter Up to 63mm diameter
2.5mm
2
cable = 30m 1.5mm
2
cable = 40m
Up to 180mm diameter Up to 180mm diameter
2.5mm
2
cable = 20m 1.5mm
2
cable = 25m
Over 180mm diameter Over 180mm diameter
4.0mm
2
cable = 10m 2.5mm
2
cable = 20m
It is recommended for increased electrical safety to use a Residual urrent Device (R D) with a
tripping current of not more than 30 mA. Always check your R D every time you use it. The supply
cable must be inspected for signs of damage before each use and the equipment may only be used
if in perfect condition. Damaged cables must be replaced by an approved service agent. This
equipment is classified as “Portable for use on industrial applications”, and must undergo a formal
electrical safety check (Portable Appliance Test) as per local regulations.
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Using the equipment
Prepare and clamp the pipe and fittings inline with the manufacturers recommendations.
onnect the welding cable to the unit and the fitting to be welded. onnect the supply cable to
the correct supply voltage and switch the unit on.
The screen will show a welcome message along with the software version and date. The owner
details are then shown
The main menu is now shown on the display. During operation, except while welding, pressing the
star key on the keypad will jump back to this menu.
Notes:
The operation of the unit can be customised by turning welding modes on and off, along with
some features like the cooling time. This manual details all available modes and features. For
information on how to customise the welding unit see the “Set Up” section later on in this manual.
The welding unit is fitted with an alpha-numeric keypad, which is used by the operator to input
data. Down the right hand side there are four Quick-Keys, A B D. These act as quick shortcut
keys, their function being prompted on the screen.
When entering data, letters and numbers can be selected by repeatedly pressing the same key,
e.g. A B 2 A B 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 cell phones.) Pressing the B Quick-Key will step Back one position. Pressing
the Quick-Key will lear the input field.
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Manual Welding
This mode of operation is designed to weld all fittings in manual mode.
From the main menu:
Press the A Quick-Key to select manual welding, then:
The display will ask for the welding cable to be connected to the fitting.
The display will now prompt for the welding time and voltage to be entered. Press the Quick-key
to select the welding time. Enter this from the numbered keypad, e.g. 100. This can be between 1
second and 3600 seconds. Press the A Quick-key to accept the new time.
(Optional voltage select) Press the D Quick-key to select the welding voltage. Enter this from the
numbered keypad, e.g. 26. This can be between 8 volts and 48 volts. A default option of 39,5 is
available. Press the A Quick-key to accept the new voltage.
When the correct time and voltage have been selected, press the A Quick-key to accept them. The
display will now ask for the START button to be pressed. Press Start to begin welding.
During the weld, the display will show the set welding time, the remaining welding time, the set
welding voltage and the welding power generated in the fitting. The unit will also 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.
(Optional cooling time) At the end of the weld the cooling time will be shown. This counts upwards
from zero and will continue until stopped by the operator. This is shown as an aid to the operator
to allow them to know how long it was since the weld finished. Press any key to continue.
The display will ask for the welding cable to be disconnected from the fitting. Doing this will reset
the unit back to the welding menu.
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Extreme Low Temperature Operation (Optional)
The welding unit has an extended temperature range option, which allows it to work down to -
40
o
. This unit has special supply and welding cables that remain flexible at extremely low
temperatures. It also has an internal case heater to warm the electronics to an acceptable working
temperature.
When the temperature inside the unit is below -15
o
, the following operation will apply:
Plug the welding unit into the correct supply voltage and switch it on.
The internal case heater will switch on and an indicator light will show on the lid next to the
display.
When the internal temperature warms to the correct level, the case heater will switch off, the
indicator light will switch off and the electronics will switch on.
The operation of the unit is now as previously described.
Extended temperature range facility is a factory-fitted option and must be requested when
ordering the product from you supplier.
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