Advance welding Act 2 User manual

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

ACT 2

(Data logging 40v welding unit)

Operating manual

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Index

Operating Controls.....................................................4

Safety Notes...............................................................5

Product Specification..................................................6

Intended Use..............................................................7

Introduction ................................................................8

Delivered Items ..........................................................9

Electrical Safety........................................................10

Using the Equipment................................................11

Data Log Memory.....................................................12

Manual Welding........................................................13

Fusamatic Welding...................................................14

Extreme Low Temperature Operation.......................15

Downloading the Weld Memory................................16

Upgrading the Operating Software...........................17

Set Up Options.........................................................18

Information...............................................................20

Fault Finding ............................................................21

Maintenance.............................................................25

Disposal ...................................................................26

Calibration and Warranty..........................................27

Declaration of Conformity.........................................29

Service and Repair...................................................30

Quick Start Guide.....................................................32

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Operating Controls

1. Welding Cable (can be provided with optional right angle plug)

2. USB Memory Drive

3. USB Socket

4. Welding Cable Socket

5. Protective Lid

6. Display

7. Buttons

8. Protective Frame

9. Ratings Plate

10. Supply Cable

1. Welding Cable

2. USB Memory

10. Supply Cable

8. Protective Frame

9. Ratings Plate

3. USB Socket

4. Welding Cable Socket

7. Buttons

6. Display

5. Protective Lid

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

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.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Product Specification

Operating Type: Controlled voltage.

Operating Modes: Manual, Fusamatic#1

Operating Languages: English, French, Dutch, Polish, Russian.

(others on request)

Operating Temperature: -10oC to +40oC #2

Welding Voltage: 8 to 48 V ac (39,5 V)

Welding Current: 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: #3 110 V ac (+/- 20%) 40 to 60 Hz

Supply Current: #3 1 to 30 A ac (true rms)

Supply Power: #3 3,500 W (peak at 0.15 APF)

Supply Voltage: #4 230 V ac (+/- 20%) 40 to 60 Hz

Supply Current: #4 1 to 15 A ac (true rms)

Supply Power: #4 3,500 W (peak at 0.15 APF)

Supply Protection: Class 1 –Earthed

Data log memory: 2048 welds

Data download/upload: USB flash memory drive

Weight: 28 kg

Size: 38 cm x 38 cm x 39 cm

Protection Level: IP65

#1 Fusamatic is a welding system owned by The Fusion Group PLC.

#2 An extended temperature unit is available with limits -40oC to +50oC.

#3 #4 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.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

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/ECE/1 2005 ‘Specification for Electrofusion Control 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".

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

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.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Delivered Items

Carefully remove the welding unit from its packaging and check that you have

the following items:

Welding unit.

Welding cable.

USB flash memory drive.

When parts are missing or damaged, please contact your dealer.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

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 Class 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. Check 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

2.5mm2 cable = 30m 1.5mm2 cable = 40m

Up to 180mm diameter Up to 180mm diameter

2.5mm2 cable = 20m 1.5mm2 cable = 25m

Over 180mm diameter Over 180mm diameter

4.0mm2 cable = 10m 2.5mm2 cable = 20m

It is recommended for increased electrical safety to use a Residual Current

Device (RCD) with a tripping current of not more than 30 mA. Always check

your RCD 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.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Using the equipment

This welding unit takes the ambient temperature into account when

calculating the energy required to weld the fitting. It must therefore be allowed

to reach ambient temperature before use and must be at the same

temperature as the fitting to be welded.

Prepare and clamp the pipe and fittings inline with the manufacturers

recommendations.

Connect the welding cable to the unit and the fitting to be welded. Connect

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 and data logging. 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 C 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 C 2 A B C 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 C Quick-Key will Clear the input field.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Data Log Memory (Optional)

The unit can record information about the weld, along with the date and time,

and additional operator entered information.

It is possible to enter three pieces of information to identify the weld. The first

is the Operator’s Name, the second is the Location where the weld is being

done, and the third is an Information field for more details.

The display will show all three pieces of information:

Pressing the B Quick-key will select the ‘Operator Name’ and allow changes

to be made. Enter the required information and press the A Quick-key to

accept it.

Pressing the C Quick-key will select the ‘Location’ and allow changes to be

made. Enter the required information and press the A Quick-key to accept it.

Pressing the D Quick-key will select the ‘Information Field’ and allow changes

to be made. Enter the required information and press the A Quick-key to

accept it.

When all the information has been entered, press the A Quick-key to accept

it.

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 scraped and clamped.

Select yes or no using the Quick-Keys. This information will be saved on the

data log memory.

The unit can save 2048 welds in memory. When the memory is full, it will be

overwritten from the beginning in blocks of 24 welds. This will allow the last

2000 welds to be held in memory.

An optional “lifetime weld memory” feature is available. This uses an SD

memory card fitted internally that records every weld carried out by the unit.

This is designed as a backup device and can only be downloaded by an

approved service agent.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Manual Welding (Optional)

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:

Press the A Quick-Key to weld with data logging OFF.

Press the B Quick-Key to weld with data logging ON.

The display will ask for the welding cable to be connected to the fitting. When

this has been done it will show the data logging options (if selected). Enter

the information as required.

The display will now prompt for the welding time and voltage to be entered.

Press the C 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.

ACT2 Electrofusion Welding Unit –Operator Manual –Rev: 2.4.a

Fusamatic Welding (Optional)

This mode of operation is designed to weld the fully automatic “Fusamatic”

fittings, manufactured and sold by The Fusion Group.

From the main menu:

Press the B Quick-Key to select automatic welding.

Press the A Quick-Key to select Fusamatic welding.

Press the A Quick-Key to weld with data logging OFF.

Press the B Quick-Key to weld with data logging ON.

The display will ask for the welding cable to be connected to the fitting. Make

sure that the red lead end is attached to the red terminal on the Fusamatic

fitting and the black lead end to the other.

When this has been done it will show the data logging options (if selected).

Enter the information as required. The unit will now read the fitting and set the

welding time accordingly. This will be displayed.

Press Start to begin welding.