Heating element socket welding

The fusiotherm pipe system other than 160mm is all joined by socket fusion.

It is essential that all installations are undertaken by certified, trained aquatherm registered installers. Aquatherm NZ Ltd offer regular training courses to certify trades people in the application of the fusiotherm® system. Contact us.

Only use original fusiotherm®-welding devices and fusiotherm®-welding tools.

Preparation for fusion

1. Cut the pipe at right angles to the pipe. Only use fusiotherm®-pipe cutters or other suitable cutting pliers. Take care that the pipe axis is free from burrs or cutting debris and remove where necessary.
   
   
2. Mark the welding depth at the end of the pipe with the enclosed pencil and template.
   
   
3. Mark the desired position of the fitting on the pipe and / or fitting.

The markings on the fitting and the uninterrupted line on the pipe could be used as a guide.

Heating up the elements

1. Push the end of the pipe, without turning, up to the marked welding depth into the welding tool.

It is essential to observe the above mentioned heating times.

Pipes and fittings of the dimensions Ø 75 to 125 mm can only be welded with welding device Art.-No. 50141 (or with machine Art.-No. 50147). On using the Fusiotherm®-welding machine Art.-No. 50147 a separate operating instruction has to be observed.

ATTENTION:
The heating time starts, when pipe and fitting have been pushed to the correct welding depth on the welding tool. Not before!

Setting and Alignment

2. After the heating time quickly remove pipe and fitting from the welding tools. Join them immediately, and without turning, until the marked welding depth is covered by the bead of PP from the fitting.

ATTENTION:
Do not push the pipe too far into the fitting, as this would reduce the bore and in an extreme case close the pipe.

3. The joint elements have to be fixed during the specified assembly time. Use this time to correct the connection. The correction is only restricted to the alignment of pipe and fitting. Never turn the elements or align the connection after the processing time.
   
   
4. After the cooling period the fused joint is ready for use.

The result of the fusion of pipe and fitting is an inseparable material joining of the system elements.

Connection technique with security for a life-time!

The fusion is subject to the following data

sec-AQT = heating times recommended by temperatures under +5°C by aquatherm

Dimension 160:

The dimension 160 mm is joined by butt-welding.
Click here for detailed information.

Weld-in saddles

An advanced fusion method for branch connections in existing installations and the replacement or substitution of a reducing tee for rises, ring mains and manifolds.

Weld-in saddles are available for pipe dimensions 40mm to 160mm.

By fusing the weld in saddle with the pipe outer surface and the pipe inner wall the connection reaches highest stability.

1. Before commencing the welding process, check whether the Fusiotherm®-welding devices and tools meet the requirements of "Fusion Part A".
   
   
2. The first step is to drill through the wall of the pipe at the point intended for the outlet using the Fusiotherm®-drill.

• branch 20/25 mm: Art.-No. 50940
• branch 32 mm: Art.-No. 50942
• branch 40 mm: Art.-No. 50944
• branch 50 mm: Art.-No. 50946
• branch 63 mm: Art.-No. 50948

3. When using Fusiotherm®-stabi composite pipes remove the rest of the aluminium remaining at the bore hole with the Fusiotherm®-chamfering device.

• branch 20/25 mm: Art.-No. 50910
• branch 32 mm: Art.-No. 50912
• branch 40 mm: Art.-No. 50914

4. The welding device/saddle welding tool must have reached the required operating temperature of 260 °C (check with reference to "Fusion Part B, item 2").
   
   
5. The welding surfaces have to be clean and dry.
   
   
6. Insert the heating nozzle on the concave side of the weld in saddle tool into the hole drilled in the side wall of the pipe until the tool is completely in contact with the outer wall of the pipe. Next the weld in saddle nozzle is inserted into the heating sleeve until the saddle surface is up against the convex side of the welding tool. The heating time of the elements is generally 30 seconds.
   
   
7. After the welding tool has been removed, the weld in saddle nozzle is immediately inserted into the heated, drilled hole. The weld in saddle should then be pressed on the pipe for about 15 seconds. After being allowed to cool for 10 minutes the connection can be exposed to its full loading. The appropriate branch pipe is fitted into the sleeve on the Fusiotherm®-weld in saddle using conventional fusion technology.