Kerotest Shannon Portafuse III Operator'S Manual Download Page 9

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Kerotest Manufacturing

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SHANNON & PAF III OPERATORS MANUAL - REV 3

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Processor Overview

Shannon

The

Shannon

is a full-featured, transformer-based Electrofusion Processor

designed to meet all of your

electrofusion needs in one convenient package. The internal transformer ensures access to the full output
capability of the processor every time you take it to a job site.

Portafuse III

The

Portafuse III

is a full featured, battery-powered Electrofusion Processor designed to meet all of your small

diameter electrofusion needs in one convenient package. When powered by the 48V 9ah SLA battery pack,
the

Portafuse III

can fuse any fitting with a current requirement of 30 amps or less without the use of an AC

power source. If your job requires more than 30 amps, the

Portafuse III

can

connected to an optional external

transformer to increase the output capability to a level equal to that of the

Shannon

Summary of Contents for Shannon Portafuse III

Page 1: ......

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Page 3: ...must be located out of the trench For protection against the risk of electric shock connect Shannon Electrofusion Processors to properly grounded outlets only When operating a Portafuse III Electrofusion Processor remember to regularly inspect the battery pack and charger for damage The charger does not contain any serviceable components If the charger gets damaged it will need to be replaced Only...

Page 4: ...Options 16 Customer Responsibilities 17 Service Recommendations 18 Customer Maintenance 18 Calibration Recommendations 18 Service Contact Information 19 General Operation 20 Modes of Operation 20 Primary Fusion Mode 20 Alternate Fusion Modes 20 Power Up 21 Shannon 21 Portafuse III 22 Boot Sequence 23 Barcode Fusions 24 Alternate Fusion Methods 26 Manual Barcode Entry 26 Manual Data Entry 27 Monito...

Page 5: ... Drive USB models only 46 Downloading Wirelessly Bluetooth models only 47 GPS 47 Trouble 47 Position Accuracy 48 Position Error Indicator 48 General Maintenance 49 Changing the Fuse AC Processors Only 49 AC Power Sources 49 Utility Power 49 Generators 50 Inverters 50 Sizing a Power Supply 50 Battery Care Maintenance 51 Battery Pack 51 Charger Charging 51 Battery Storage 51 Battery Installation and...

Page 6: ...used b The Processor has been maintained calibrated serviced and used in full compliance with this Manual and other technical information or literature provided by EF TECHNOLOGIES INC from time to time c the Processor has not been altered or modified after leaving EF TECHNOLOGIES INC S premises shows no evidence of disassembly or tampering is not and has not been subjected to abnormal operating co...

Page 7: ...NTERRUPTION OR ANY OTHER CLAIM FOR INCIDENTAL CONSEQUENTIAL SPECIAL OR PUNITIVE DAMAGES 6 THE ABOVE MENTIONED WARRANTIES ARE THE SOLE AND EXCLUSIVE WARRANTIES TO ANY PURCHASER CUSTOMER OR USER OF THE PROCESSOR OR SERVICES THERE IS NO WARRANTY CONDITION OR REPRESENTATION OF ANY NATURE WHATSOEVER EXPRESSED OR IMPLIED BY STATUTE OR OTHERWISE EXCEPT AS HEREIN CONTAINED AND EF TECHNOLOGIES INC DISCLAIM...

Page 8: ...eatures Kerotest Electrofusion Processors are reliable easy to use rugged tools designed to withstand conditions found at typical construction sites throughout the world Kerotest Electrofusion Processors are splash proof and highly shock resistant Kerotest Electrofusion Processors can fuse all manufacturers fittings requiring outputs that are within the voltage and current values listed in the Spe...

Page 9: ... take it to a job site Portafuse III The Portafuse III is a full featured battery powered Electrofusion Processor designed to meet all of your small diameter electrofusion needs in one convenient package When powered by the 48V 9ah SLA battery pack the Portafuse III can fuse any fitting with a current requirement of 30 amps or less without the use of an AC power source If your job requires more th...

Page 10: ...o 104 F Batteries Operating Temperature Range 0 F to 140 F Operating Modes Barcode Manual Barcode Manual Output Cable Length 12 feet Fitting Adapters Field replaceable 90 degree 4 7 4 0mm Input Cable Length 12 feet N A Fusion Information Storage 1000 Fusions Downloading USB Models have a USB A type connector for connecting a USB flash drive to download fusion data Bluetooth Models have an Internal...

Page 11: ...ay mean START CONTINUE OK or SAVE depending upon the context of the operation being performed at the time 3 The STOP button may mean STOP RESET or CANCEL depending upon the context of the operation being performed at the time 4 The UP button and DOWN button are used to scroll through the various menus These buttons should be used when the processor menu displays selection options UP button for DOW...

Page 12: ...Manufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 10 of 60 Faceplate View Shannon USB AutoCal Port Download Port Replaceable Display Shield 4X20 LCD Display START button STOP button UP button DOWN button ...

Page 13: ... Manufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 11 of 60 Faceplate View Shannon Bluetooth 4X20 LCD Display START button STOP button DOWN button Replaceable Display Shield Bluetooth Antenna UP button ...

Page 14: ...anufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 12 of 60 Faceplate View Portafuse III UP button AutoCal Port Download Port 4X20 LCD Display Replaceable Display Shield STOP button START button DOWN button ...

Page 15: ...Kerotest Manufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 13 of 60 Left Side View Shannon Portafuse III Output Cable Power Switch Battery Pigtail Connector Output Cable Buzzer ...

Page 16: ...Kerotest Manufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 14 of 60 Right Side View Shannon Back Side View Portafuse III Power Switch Fuse Input Cable External Transformer Connector ...

Page 17: ...uring SHANNON PAF III OPERATORS MANUAL REV 3 Page 15 of 60 Output Cable Options Fitting Adapters Output Cable Barcode Wand SMART Scanner Output Lead Ends Temperature Sensor 4 0mm 90 degree 4 7mm 90 degree Adapter Wrench ...

Page 18: ...Kerotest Manufacturing SHANNON PAF III OPERATORS MANUAL REV 3 Page 16 of 60 Scanner Options SMART Scanner Barcode Wand ...

Page 19: ...er each day s use N A When not in use recharge the battery pack at least once per month It is recommended that the battery pack be left on charge when not in use N A Turn the processor OFF after each use to prevent the batteries from discharging It is recommended that the battery pigtail be disconnected after use to ensure the unit is not accidentally turned ON LEAVING THE PROCESSOR ON WHILE IN ST...

Page 20: ...ity of the fusion may be compromised 2 Make sure the fitting adapters are clean and properly attached to the Output Lead Ends Failure to do so may result in an improper output applied to the fitting 3 Pull the Output Lead Ends straight off the fitting when disconnecting and avoid side loads 4 Make sure that power sources are appropriately rated and operating at the manufacturer s specified capacit...

Page 21: ...ystems and perform as many calibrations as you would like at your facility and at your convenience Call 302 451 1088 to make arrangements for service and to obtain an RMA number for the return Every effort will be made to return processors within two 2 business days Consult your carrier for the proper method of packaging the unit for return shipments Always insure the package for the full replacem...

Page 22: ...tments based on ambient temperature Pre fusion resistance checks against manufacturer specified tolerances These features help ensure that the proper fusion parameters are entered However it is important to understand that no amount of machine checks will ever negate the requirement for a well trained observant operator to make a final GO NO GO decision regardless of which Mode of Operation is bei...

Page 23: ...wer up sequence This feature will not protect the processor from voltage spikes after initial power up When the processor is first turned ON each day you may need to press and hold the green button for approximately one 1 second until the unit powers up DO NOT UNDER ANY CIRCUMSTANCES PRESS AND HOLD THE POWER SWITCH IN THE ON POSITION WHILE STARTING A GENERATOR THAT THE PROCESSOR IS PLUGGED INTO DO...

Page 24: ...al transformer to the generator in connector on the back of the Portafuse III Electrofusion Processor see picture on page 14 2 Plug the battery pack pigtail into the receptacle located on the left side of the processor The connectors are color coded and should mate easily with little force DO NOT FORCE THE CONNECTORS TOGETHER 2 Start the generator Make sure the generator is running smoothly in hig...

Page 25: ...rs Battery Powered Processors CONNECT FITTING CONNECT FITTING Temperature 75 F Temperature 75 F Gen 120V 60 0Hz Batt 52 0V OK The second line indicates the ambient temperature the processor is measuring and will be used to modify the fusion time if required by the fitting manufacturer Check to make sure the temperature reading is accurate If the processor has been in direct sunlight or has been mo...

Page 26: ...sor will be due for calibration In this case May 11 2021 Release the UP button to return to the CONNECT FITTING screen To begin the fusion process follow the instructions in the following section that corresponds to the fusion method that you wish to perform Barcode Fusions The Barcode Fusion Method is always preferred and should be used whenever possible When beginning a Barcode Fusion start from...

Page 27: ...s that detail how to gather this data VERIFY SETUP INNO 2 COUPL 40 0V 60 sec PRESS START The VERIFY SETUP screen shows the following information The fitting type Innogaz 2 Coupler The requested output 40 0 Volts The total temperature compensated fusion time in seconds In this case 60 seconds The VERIFY SETUP screen allows the operator a final opportunity to verify that the fusion parameters displa...

Page 28: ... provided by the fitting s manufacturer The Alternate Fusion selection screen can be accessed by pressing the UP button and the DOWN button at the same time when the processor is displaying the SCAN BARCODE screen The Alternate Fusion selection screen looks like the following SELECT METHOD 1 Manual Barcode 2 Manual Select the desired method by using the UP button and the DOWN button When the desir...

Page 29: ... barcode number that was manually entered you will receive an Error Message and will be forced to check the number and reenter it FAILURE TO VERIFY THAT THE FUSION INFORMATION IS CORRECT BEFORE STARTING A FUSION COULD RESULT IN SIGNIFICANT DAMAGE TO PROPERTY PERSONAL INJURY AND OR DEATH NOTE If Calculated Resistance is enabled and the operator receives a Warning Code 55 refer to the appropriate se...

Page 30: ...d the numbers will continue to scroll slowly at first and then faster as time passes When the desired number of seconds are displayed press the START button Once the data has been successfully entered the Kerotest Electrofusion Processor will display a screen similar to the following VERIFY SETUP Manual Fusion Data 40 0V 60 sec PRESS START The VERIFY SETUP screen allows the operator a final opport...

Page 31: ...TERS When operating in Barcode Fusion Mode this resistance check is to make sure that the actual fitting connected matches the resistance of the fitting described in the fusion parameters When operating in an Alternate Fusion Mode this resistance check is used to verify that the fitting is still attached Although many fittings have similar resistance measurements and this check is NOT fool proof i...

Page 32: ...he total energy expended during this fusion in amp hours In this case 0 085 amp hours This number increases during the fusion process as energy is expended The present measured voltage of the generator or battery In this case 120 0 volts and 51 0 volts The current generator frequency In AC powered processors This number should remain relatively constant throughout the fusion When the fusion is com...

Page 33: ...Error Codes and the following screen will be displayed after the error message screen DISCONNECT OUTPUT LEADS FUSION NOT COMPLETE Errors Encountered After the Output Lead Ends are disconnected the Kerotest Electrofusion Processor will return to the CONNECT FITTING screen and will be ready to accept information for the next fusion NOTE If Operator Traceability is enabled remember that the Operator ...

Page 34: ...rmal operation Setting the Date and Time When Option 1 is highlighted press the START button to select it The following screen will be displayed SET THE DATE TIME 05 11 2018 15 30 With the keypad see page 40 enter the correct date using the MM DD YYYY format and the correct time using the 24 hour military format Press the START button to save the information entered and return to the Basic User Me...

Page 35: ... MENU SHOULD BE ADJUSTED WITHOUT SPECIFIC INSTRUCTIONS FROM THE FACTORY OR THE FITTING MANUFACTURER The Advanced User Menu is accessed by holding the DOWN button when the processor is first powered up Keep holding the DOWN button through the INTERNAL SELF TEST screen until you are prompted for a passcode that must be entered before proceeding Contact an authorized representative see page 19 to obt...

Page 36: ...lways measures resistance using a lab quality 4 wire measurement This is the processor s primary method of resistance measurement and is frequently used during Quality Control testing by fitting manufacturers ON If a processor displays Warning Code 55 see page 53 an operator has the option to perform a secondary Calculated Resistance check During this secondary check the unit calculates a resistan...

Page 37: ...ty functions Values are OFF ON or OPT OFF disables the Pipe Fitting Traceability function ON enables the Pipe Fitting Traceability function The machine WILL NOT allow a fusion to proceed unless at least one 1 traceability barcode is scanned OPT Optional enables the Pipe Fitting Traceability function but will allow a fusion to proceed if the operator decides not to scan a traceability barcode When ...

Page 38: ...Scan Mode set the SMART SCANNER option in the Basic User Menu to YES In Smart Scan Mode additional features not available in Scan Mode can be used Smart Scan Mode allows you to View fitting data on the SMART Scanner screen before beginning a fusion START and STOP a fusion using the SMART Scanner button Scan Pipe Fitting Traceability barcodes When operating in Smart Scan Mode the SMART Scanner will...

Page 39: ... error code and take appropriate corrective action based on the information displayed GPS Mode Operating the SMART Scanner in GPS Mode is the same as operating the SMART Scanner in Smart Scan Mode with the addition of GPS data For this reason only the differences are highlighted in this section When the SMART Scanner prompts the operator to connect the fitting the current GPS position will be disp...

Page 40: ...fter a few minutes the SMART Scanner still has not acquired 5 satellites you may try to follow some of the suggestions in the GPS section on page 47 or you can bypass the GPS data by simply connecting the fitting The SMART Scanner will show you a message similar to the following WAIT FOR GPS SIGNAL PRESS TO IGNORE IF YOU CHOOSE TO PRESS THE BUTTON YOU WILL BE ABLE TO SCAN THE BARCODE AND COMPLETE ...

Page 41: ...e is recognized release the button The following pictures illustrate a few simple tips that will improve scanning reliability YES For best results hold the SMART Scanner perpendicular to the barcode to be scanned YES The aiming light should be centered and evenly spaced over the barcode to be scanned NO Do not hold the SMART Scanner so that the beveled scanning end is parallel to the barcode to be...

Page 42: ...Keypad To enter data in any field manually press the UP button or the DOWN button to scroll through the list of valid characters When you find the one you wish to use press the START button to move to the next character If an invalid character is entered press the STOP button to back the cursor up to the previous character and change it If the STOP button is pressed while on the first character th...

Page 43: ... to the pipe and or the fitting This data will not affect the fusion however it will be associated with the fusion in the download If the Pipe Fitting Traceability option is set to ON or OPT the operator will be prompted to scan the barcodes immediately after the fitting barcode is scanned The screen will look similar to the following SCAN TRACEABILITY BARCODE 1 Press START if done You can scan on...

Page 44: ...or details on how to enter data with the keypad Manually entered Operator ID codes can contain up to 10 characters and include letters and or numbers When the START button is pressed after the last character the processor will advance to the CONNECT FITTING screen See page 20 for details on how to perform a fusion If the Operator ID function is set to SCAN use a barcode wand or SMART Scanner to sc...

Page 45: ...Max 1 78 Hold START to clear Press the START button to clear the warning code The processor will display a screen similar to the following 4 wire res is out of range Ignore and do secondary check START Yes STOP No At this time the operator has two options 1 Cancel the fusion 2 Perform the secondary check and attempt to continue fusing the fitting To CANCEL THE FUSION 1 Press the STOP button to can...

Page 46: ...PERTY PERSONAL INJURY AND OR DEATH 2 If the Calculated Resistance check is successful the fusion will proceed normally When the fusion is complete a screen similar to the following will be displayed COOLING TIME 5 min Actual Fusion Time 60 sec PRESS START Press the START button to continue 3 If the Calculated Resistance check fails the processor will display a screen similar to the following ERROR...

Page 47: ...ured resistance of the fitting before the fusion Mea Res Post The actual measured resistance of the fitting after the fusion Cooling time The cooling time of the fitting specified in the barcode ID Res The measured value of the ID Resistor for ID Resistance fusions Input Volts The measured generator voltage taken before the fusion High Volts The highest measured generator voltage during the fusion...

Page 48: ...to the drive 4 A progress screen similar to the following will be displayed as the download proceeds DOWNLOADING DATA 48 5 After the download is complete the processor will return to the CONNECT FITTING screen You may now disconnect the USB flash drive from the USB Host Port to resume normal operation ONLY NEW FUSIONS PERFORMED SINCE THE LAST DOWNLOAD WILL BE WRITTEN TO THE DRIVE THE USB FLASH DRI...

Page 49: ...T Scanner can be used to record the latitude and longitude of the processor where the fusion is done The GPS coordinates are accurate to within 10 15 meters The latitude and the longitude as well as the number of satellites used when generating the fix are stored with each fusion and output during the download Once downloaded the coordinates can be input into many commercially available mapping pr...

Page 50: ...st possible confidence level to be used for applications demanding the highest possible precision at all times 1 2 Excellent At this confidence level positional measurements are considered accurate enough to meet all but the most sensitive applications 2 5 Good Represents a level that marks the minimum appropriate for making business decisions Positional measurements could be used to make reliable...

Page 51: ...n remove the cap The fuse should come out when the cap is removed 2 Remove the old fuse and replace it with the new one 3 Replace the fuse cap by pushing down and turning it clockwise AC Power Sources When installing electrofusion fittings in field applications it is necessary to have a reliable source of AC power for the electrofusion processor This AC power source should be well maintained and s...

Page 52: ...fferently For example a 5 000 watt generator from one company may or may not be equivalent to a 5 000 watt generator from another company When determining the correct generator size the operator must 1 Determine the maximum current required to fuse a particular fitting The information can be obtained from the fitting manufacturer Please note the largest fitting does not necessarily require the mos...

Page 53: ...nvironment As a general rule it is recommended that you completely charge the batteries after each day that the unit is used If the batteries are not used make sure that they are charged at least once per month It is recommended that the batteries are left on charge until they are needed Battery Storage The battery pack should always be stored fully charged in a cool dry place to maintain maximum ...

Page 54: ... larger couplers A pigtail converts a 30 amp twist lock to a 15 amp straight blade plug It is designed to power the processor when a NEMA L5 socket is not available especially while downloading Its use is not recommended in field applications with electrofusion fittings Temperature Measurements The processor s temperature sensor is located near the end of the output cable in the barcode wand SMART...

Page 55: ...ing occurs if the average output current during a fusion exceeds the maximum current rating of the batteries used to power the processor This is a post fusion warning and only applies to battery powered processors Discontinue the use of the fitting that was fused when the warning was generated The fusion parameters of the particular fitting exceed the operating specifications of the processor FAIL...

Page 56: ...persists there is more than likely a calibration or output cable malfunction 103 Shorted Coil in Fitting Check for a short stab or a sorted coil 105 Can t maintain output voltage Verify the Output Lead ends are clean the power supply is sized correctly for the fitting you are fusing and that the power supply is operating correctly 108 The power supply was shut off during the previous fusion This c...

Page 57: ...ed This is more than likely a temperature measurement problem Verify the temperature displayed in the CONNECT FITTING screen is reasonable and within the range specified in the Specification Table See page 8 If the temperature displayed differs significantly from the actual temperature then there is a processor problem and it must be returned for service 121 Invalid Operator ID card scanned Verify...

Page 58: ...en the processor will need to be returned for service 141 The ambient temperature is too low to fuse fittings of this type Same as error 101 142 The processor believes that the same fitting was fused twice Do not fuse a fitting more than two 2 times unless directed so by the fitting manufacturer 143 The fitting was disconnected before the specified heat soak time was observed Do not disconnect the...

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Page 64: ...KEROTEST MANUFACTURING CORP 5500 Second Avenue Pittsburg PA 15207 www kerotest com 412 521 5942 K 1499 Rev B EAN S 1632 ...

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