Electrofusion socket welding

Preparation

Follow carefully the order of working steps! Preparation is one of the most important steps of the electro fusion process!

1. Cut the ends of the pipes rectangularly and burr them thoroughly.
   
   
2. Clean and dry the ends of the pipes at the necessary length.
   
   
3. Mark the depth of fusiotherm®-electro socket on the end of each pipe.
   
   
4. Peel the surface of both pipes within the marks thoroughly with a peeling apparatus or a lame by min. 0.1 mm , max. 0.2 mm (use fusiotherm®-peeling tool).
   
   
5. Clean again thoroughly.

Without complete peeling of the surface in the fusion area, you will not achieve a homogeneous and tight welding connection.

Injuries of the surface like axial grooves and scratches are not accepted in the fusion zone.

Do not touch peeled surfaces and protect them against dirt and grease. Start the fusion process within 30 mins after peeling!

Electro fusion

The fusiotherm®-electro-fusion device was especially developed for electrofusion sockets from Ø 20 - 160 mm.

Technical information:

• supply voltage: 230 V (nominal voltage)
• nominal capacity: 2.800 VA, 80 % ED
• rated frequency: 50 Hz - 60 Hz
• moisture-proof class:moisture-proof class II
  (earthed wire)

General and checkpoints

Cleanliness is - besides correct workmanship - the most important precondition for fusions. To assure the cleanliness of the fittings do not unwrap these before processing!

1. Correct oval pipes by pressing clamps, never by peeling!
   
   
2. Use permissible and functioning electro fusion equipment only!
   
   
3. All parts of the system to be fused as well as the temperature sensors shall have the same temperature (e.g. sun radiation or non-suitable stocking may create differences in temperature!) within the acceptable range of temperature (i.e. +5 °C to 40 °C according to DVS 2207).

Assembling of fusiotherm®-electro sockets

Principle: Avoid contamination carefully and fix all parts securely!

1. Open protective foil of the fusiotherm®-electro socket (cut with knife along the edge of the bore), leave the rest of the foil intact. Clean the inside of the fitting carefully with aquatherm®-cleansing clothes. Assemble the fitting within 30 mins after opening of the protective foil.
   
   
2. Push the fusiotherm®-electro socket on the clean and dry end of the pipe (up to the marked depth). Use pressing clamps if necessary.
   
   
3. Now remove the protective foil completely and push the second prepared pipe end into the fusiotherm®-electro socket as far as it will go.

Pipes must leave, free from tension or own weight, within the fusiotherm®-electro socket.The socket has to be movable at both pipe ends after assembling. The air gap has to be even around the circumference. A not stress free resp. displaced connection can effect an unacceptable melt-flow and a defective connection. Suitable measurements have to ensure that during the complete fusionprocess (including cooling) the pipes are aligned correctly, no outer forces may effect on the welding and that the pipes cannot move. The pipe ends and the electro sockets have to be dry on assembling. If there are any doubts referring the cleanliness and dryness of the fusiotherm®-electro socket, the inner surface has to be cleaned and dried: aquatherm®-cleansing clothes are well suitable.

Fusion process

1. Position the fitting with even air gap around the circumference.
2. Regulate fusion equipment for the right fusion parameter.
3. Compare the indications on the display of the fusion equipment with the parameters of the label.
4. Start and monitor the fusion process.

Do not move or stress pipe and fitting during the whole fusion process including cooling time.

Cooling time and pressure test

A fused pipe-joint shall not be moved, stressed or loosed before complete cooling. The minimum cooling time is marked on each fusiotherm®-electro socket. Environmental temperatures of more than 25 °C or strong sun-radiation need longer cooling times.

Pressure tests shall be made only after complete cooling, i.e. one hour after the end of the cooling time of the last fusion-joint. If temperature is more than 25° C, please wait for 1.5 to 2 hours.

Working pressure

fusiotherm®-electrofusion sockets correspond to the pressure of PN 20. The relation between working temperature, pressure load and service life is given in the tables "Permissible working pressure."

For further information concerning the electrofusion socket and details about the fusiotherm®-electrofusion device please ask for operating instructions.

Kind of stress
Compressive stress
Minimum waiting period
Tension, bend, torsion of
non-pressurized pipes

20 minutes
test- or working pressure of pipes under pressure
to 0,1 bar
0.1 to 1 bar
over 1 bar
20 minutes
60 minutes
120 minutes
Repeating of the welding process

60minutes