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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

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to view CPV-Zurn product information

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Summary of Contents for Zurn

Page 1: ...Electrofusion Welder ...

Page 2: ...s 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...

Page 3: ...OCK 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 ...

Page 4: ... 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 prod...

Page 5: ... 5 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 ...

Page 6: ...m 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...

Page 7: ...e 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...

Page 8: ... 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 wi...

Page 9: ...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 fusi...

Page 10: ...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 Do...

Page 11: ...Electrofusion Welder 26 07 2011 www LaboratoryDrainage co uk Pg 11 DO NOT MIX 1 5 4 FITTINGS WITH 6 FITTINGS IN THE SAME FUSION WELD CYCLE 7 ...

Page 12: ...nter 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...

Page 13: ...ating 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 ...

Page 14: ...ress 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 per...

Page 15: ... 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...

Page 16: ...rst 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 ...

Page 17: ... 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 95v This fault can be caused by a few problems It could be that the generator is running slo...

Page 18: ...eld 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 un...

Page 19: ...econds This fault will normally be caused by a poor quality generator with the supply voltage fluctuating Try a different generator 24 Welding current High 101 5 This fault will happen if the welding current is more than 1 5 high for 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 p...

Page 20: ...by using long extension leads with the unit It is recommended that only 30 feet of extension are used and the cable should be the same thickness as the input lead on the unit 29 Welding current Low 50 This fault will happen if the welding current is more than 50 low for more than 1 second It can be caused by a faulty fitting Try another fitting If this doesn t clear the fault then there is a probl...

Page 21: ...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 constan...

Page 22: ...2 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 ...

Page 23: ...3 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 ...

Page 24: ...inage co uk Pg 24 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 1 26mm 2 31mm 3 4 6 53mm ...

Page 25: ... 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 ...

Page 26: ...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 1 ten 2 seven 3 four 4 three 6 two IMPORTANT DO NOT MIX 1 5 4 FITTINGS WITH 6 FITT...

Page 27: ...ocedure 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 joi...

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