CPV Act1 User manual

Act1 Electrofusion Welder

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Index
Operating ontrols................................................................................3
Safety Notes ..........................................................................................4
Product Specification ............................................................................5
Intended Use .........................................................................................6
Introduction ..........................................................................................6
Delivered Items .....................................................................................6
Electrical Safety .....................................................................................7
Using the Equipment.............................................................................8
Manual Welding ....................................................................................9
Extreme Low Temperature Operation................................................10
Set Up Options ....................................................................................11
Information .........................................................................................12
Fault Finding........................................................................................13
Maintenance .......................................................................................16
Disposal ...............................................................................................17
alibration and Warranty....................................................................17
Declaration of onformity...................................................................20
Service and Repair...............................................................................21
Quick Start Guide ................................................................................22
Jointing Guide…………………………………………………………………………………23

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Operating ontrols
1. Welding able (can be provided with optional right angle plug)
2. Welding able Socket
3. Protective Lid
4. Display
5. Buttons
6. Protective Frame
7. Ratings Plate
8. Supply able
1. Welding Cable
8
. Supply Cable
6
. Protective Frame
7
. Ratings Plate
2
.
Welding Cable Soc et
5
.
Bu
ttons
4
.
Display
3
.
Protective Lid

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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.
!

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Product Specification
Operating Type: ontrolled voltage.
Operating Modes: Manual
Operating Languages: English, French, Dutch, Polish, Russian. (others on
request)
Operating Temperature: -10
o
to +40
o #1
Welding Voltage: 8 to 48 V ac (39,5 V)
Welding urrent: 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:
#2
110 V ac (+/- 20%) 40 to 60 Hz
Supply urrent:
#2
1 to 30 A ac (true rms)
Supply Power:
#2
3,500 W (peak at 0.15 APF)
Supply Voltage:
#3
230 V ac (+/- 20%) 40 to 60 Hz
Supply urrent:
#3
1 to 15 A ac (true rms)
Supply Power:
#3
3,500 W (peak at 0.15 APF)
Supply Protection: lass 1 – Earthed
Data log memory: Not available
Data download/upload: Not available
Weight: 28 kg
Size: 38 cm x 38 cm x 39 cm
Protection Level: IP65
#1
An extended temperature unit is available with limits -40
o
to +50
o
.
#2 #3
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.

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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/E E/1 2005
‘Specification for Electrofusion ontrol 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".
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.
Delivered Items
arefully remove the welding unit from its packaging and check that you have the following items:
•Welding unit.
•Welding cable.
When parts are missing or damaged, please contact your dealer.

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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 lass 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. heck 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
2.5mm
2
cable = 30m 1.5mm
2
cable = 40m
Up to 180mm diameter Up to 180mm diameter
2.5mm
2
cable = 20m 1.5mm
2
cable = 25m
Over 180mm diameter Over 180mm diameter
4.0mm
2
cable = 10m 2.5mm
2
cable = 20m
It is recommended for increased electrical safety to use a Residual urrent Device (R D) with a
tripping current of not more than 30 mA. Always check your R D 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.

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Using the equipment
Prepare and clamp the pipe and fittings inline with the manufacturers recommendations.
onnect the welding cable to the unit and the fitting to be welded. onnect 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. 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 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 2 A B 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 Quick-Key will lear the input field.

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Manual Welding
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:
The display will ask for the welding cable to be connected to the fitting.
The display will now prompt for the welding time and voltage to be entered. Press the 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.

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Extreme Low Temperature Operation (Optional)
The welding unit has an extended temperature range option, which allows it to work down to -
40
o
. This unit has special supply and welding cables that remain flexible at extremely low
temperatures. It also has an internal case heater to warm the electronics to an acceptable working
temperature.
When the temperature inside the unit is below -15
o
, the following operation will apply:
Plug the welding unit into the correct supply voltage and switch it on.
The internal case heater will switch on and an indicator light will show on the lid next to the
display.
When the internal temperature warms to the correct level, the case heater will switch off, the
indicator light will switch off and the electronics will switch on.
The operation of the unit is now as previously described.
Extended temperature range facility is a factory-fitted option and must be requested when
ordering the product from you supplier.

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Set Up Options
From the main menu: Press the D Quick-Key to select options.
From here the time can be set by the operator. Other changes can be made, however, these are
password protected and must be carried out by an approved service agent.
The following options are available:
Date.
The date can be set.
Display Language.
Available languages can be selected and set.
Modes of Operation.
Manual: On/Off, ooling time On/Off, Variable voltage On/Off.
alibration Period.
The calibration period can be set between 1 month and 99 months (or turned off). For 28 days
prior to the calibration expiry date, the unit will prompt that the calibration is due and will count
down the remaining days. When the calibration has expired, it can be set to warn the operator or
lock the unit.
Owner Details.
The owner details, shown when the unit is first switched on, can be entered or changed.
Download Format.
The format of the data log download can be changed from protected PFD to plain text XLS.
Purchase Date.
The date the unit was sold to the customer can be set and viewed. This allows more accurate
record keeping.
Warranty Period.
The date the unit was first used can be viewed. This allows accurate control of the warranty
period.

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Information
Information about the welding unit can be viewed from the options menu. Select more options
and then enter the password A I N F followed by the A Quick-Key.
The serial number and part number of the unit are shown. The calibration date and calibration
period are also shown. Press the A Quick-Key and the following weld counters are shown: Total
weld count, weld count at last calibration, welds done since last calibration.

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Fault Finding
During operation, the welding unit monitors all aspects of its operation. If a fault occurs then an
error message will be shown.
0: Weld OK
No Fault, weld completed OK.
1: Stuck button on start up
This fault shows when the power is first switched on. Either the Stop, Start, or a keypad button is
stuck in. Free the button to clear the fault.
2: Output fault before weld start
This fault shows when the power is first 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.
3: Toroid thermal switch tripped
This fault happens when the toroidal transformer becomes too hot. This will happen if the unit is
used for a long period of time on large fittings. Let the unit cool down and the fault will clear. If
this happens when the unit is cold, then there could be a bad connection on one of the internal
plugs. In this case, the unit will need to be returned for repair.
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 a fault with the internal memory. Return the unit for
service.
5: ase temperature sensor fault (if fitted)
Some units have a case temperature sensor fitted to switch the unit off if the electronics become
too hot. This fault will show if the sensor is faulty. Return the unit for service.
6: ase temperature out of limits (if fitted)
Some units have a case temperature sensor fitted to switch the unit off if the electronics become
too hot. This fault will show if the temperature is too hot. Let the unit cool down.
7: Ambient temperature less than -40
o
.
The unit has detected that the ambient temperature is very cold or the sensor has broken. If the
temperature is not below -40
o
then the unit will need to be returned to a service agent for repair.
!

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8: Ambient temperature more than +600
o
.
The unit has detected that the ambient temperature sensor has broken or a wire has gone open
circuit. The unit must be returned to a service agent for repair.
10: Low supply frequency <40Hz
The unit has detected that the supply frequency is below 40 Hz. This will normally be caused by a
poor quality generator. If this fault happens then check the supply or change the generator.
11: High supply frequency >70Hz
The unit has detected that the supply frequency is above 70 Hz. This 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 (or 280v with a 220v supply)
The unit has detected that the supply voltage is more than 140 volts (280 volts with a nominal
220v supply). heck the supply voltage and if necessary use a different generator.
13: Low supply voltage <95v (or 190v with a 220v supply)
This fault can be caused by a few problems. It could be that the generator is running slowly and so
the supply voltage is low. Try speeding the generator up or use a different generator.
It could also be caused by a generator that is too small. If a large fitting is welded, then a large
amount of power will be needed from the generator. If it can not supply this power then it will
stall and the voltage will drop away. heck that the generator is the correct size, if needs be try
another generator.
It could be caused by the use of long extension leads. If a large fitting is welded then a high current
will be taken from the supply. If extension leads are used, there will be a volts drop down the lead
making the unit sense a low supply voltage. Try not to use extension leads with the unit. If you
have to then use just 10 meters of 4.0mm
2
cable, the same size fitted to the unit.
14: Relay failed to latch on weld 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: Low output volts (-1.25%)
This fault will happen if the output voltage is 1.25% lower than the set point for more than 3
seconds. This can be caused by a generator that is not big enough to supply the required power to
the fitting. heck the size of the generator and if needs be try another generator. It can also be
caused by using long extension leads with the unit. It is recommended that only 10 meters of
extension are used, and the cable should be the same thickness as the input lead on the unit
(4.0mm
2
).

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21: High output volts (+1.25%)
This fault will happen if the output voltage is 1.25% higher than the set point for more than 3
seconds. It will normally be caused by a poor quality generator with the supply voltage fluctuating.
Try a different generator.
22: Excess output volts (+6.25%)
This fault will happen if the welding voltage is 6.25% more than the set point for more than 2
seconds. This fault is normally caused by a fault within the unit, a short circuit triac. The unit must
be returned for service.
23: Low output current (<2.5A)
This fault will happen if the welding current is below 2.5 amps for more than 3 seconds. It can be
caused by a faulty fitting. Try another fitting. If this doesn’t clear the fault then there is a problem
inside the unit and it must be returned for repair.
24: Shorted turn detected in fitting.
While welding, the unit has detected a sharp increase in welding current. This is normally caused
by a shorted turn happening in the fitting. (An increase OF 10%). If this happens then it is most
likely a faulty fitting. This must be replaced. If the fault persists then it could be a fault within the
unit.
25: User stop button pressed
The operator has pressed the stop button.
26: Relay unlatched
During welding, if the main power relay disconnects then this fault will be shown. It could be
caused by the unit being knocked or a temporary dip in the power supply. If the fault persists then
the unit should be returned for repair.
27: Fitting open circuit
This fault is shown if the output lead disconnects from the fitting while welding. Follow the
guidelines from the fitting manufacturer, reconnect the lead and try welding again.
127: Power off failure.
If the power is turned off while the unit is welding, this fault will be recorded to the datalog.

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Maintenance
Regularly check for obvious defects such as loose or damaged cables and connectors. Look for
warn components and broken covers or housings.
There are no user serviceable parts inside the unit. It should be returned to an approved service
agent for repair and calibration.
It is recommended that the unit is calibrated every twelve months.
After use, clean the outside of the unit with a soft brush or cloth. arefully wind up and store the
cables around the frame in the location provided.

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Disposal
The equipment and packaging should be sorted for environmentally friendly recycling.
DO NOT DISPOSE OF THIS EQUIPMENT INTO HOUSEHOLD WASTE !
According to the European Directive 2002/96/E Waste Electrical
and Electronic Equipment (WEEE), when no longer suitable for
use, this equipment must be separately collected and sent for
recycling.
According to the European Directive 2005/95/E Restriction of
Hazardous Substances (RoHS), this equipment does not contain
more than the agreed levels of lead, cadmium, mercury,
hexavalent chromium, polybrominated biphenyl (PBB) and
polybrominated diphenyl ether (PBDE) flame retardants.
RoHSCompliant
Directive 2005/ 95/ EC
Pb

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alibration and Warranty
This welding unit has been manufactured, inspected and tested in accordance with the quality
control systems in place at Advance Welding.
This welding unit has been calibrated using equipment that is traceable to national and
international standards, through a NAMAS accredited laboratory. NAMAS (National Accreditation
of Measurement and Sampling) is a service of UKAS (United Kingdom 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.
onditions of Warranty:
This warranty covers only those defects to the product which arise from normal use of the
product, and will become invalid if any of the following apply:
•Failure to follow the operating instructions.
•Improper or inadequate maintenance.
•Unauthorised modification.
•Misuse or any use not in accordance with the operating manual or good industry practice.
•Physical abuse of the product.
•Operation outside the products specifications.
•Improper site preparation or site maintenance.
•Faulty pipe or fitting.
Extent of Warranty:
Subject to the conditions and limitations of warranty; Advance Welding warrants that its electrical
products will be free from defects in materials and workmanship for a period of twelve months,
and its mechanical products for six months, from the date of purchase by the end-user customer.
If during this period, notice of a defect which is covered by this warranty is received, then Advance
Welding will either repair or replace the product at its option. Any replacement product will have
functionality at least equal to that of the product being replaced, and will in our opinion, perform
consistently with its age and usage.
Unless otherwise agreed, all warranty work will be carried out by Advance Welding or an
authorised and approved service facility.
ustomers will prepay all shipping charges for products returned under warranty, and Advance
Welding will charge for return of the products back to the customer.
This warranty statement gives the customer specific legal rights. The customer may also have
other rights which vary from country to country in the world.

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Limitations of Warranty:
Advance Welding does not warrant the operation of any product to be uninterrupted or error free.
Advance Welding specifically disclaims the implied warranties of satisfactory quality and fitness for
a particular purpose.
Advance Welding makes no other warranty of any kind, whether express or implied, with respect
to its products.
To the extent that this warranty statement is inconsistent with the law of the locality where the
customer uses the product, this warranty statement shall be deemed modified by the minimum
necessary to be consistent with such local law.
To the extent allowed by local law, the remedies provided in this warranty statement are the
customer’s sole and exclusive remedies.
This equipment has been designed for use with the range of fittings and pipe available at the time
of its design and development. Advance Welding can accept NO liability for the equipments ability
or otherwise to be used with new or different fittings or pipe that subsequently appear in the
market place.
This equipment is not intrinsically safe and must not be used in a gaseous or explosive
atmosphere. Advance Welding can accept NO liability if the equipment is used in these
circumstances.

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Declaration of onformity
This welding unit has been designed to comply with the
harmonised standards under the "New Approach" directives, and
has been E marked accordingly.
The applicable standards are:
89/336/EE Electromagnetic compatibility
73/23/EE Low voltage equipment
98/37/E Machinery safety
More detailed information is available on our web site at www.ElectrofusionWelding.com
On behalf of
Advance Welding:
K.M.Wilkinson
.