Franklin Electric EF1-110V-10 Manual

FUELING SYSTEMS
GRID SOLUTIONS
EV SYSTEMS
CASE-MOUNTED WELDER
OPERATOR GUIDE
408001008 r5
MODEL
EF1-110V-10
EF1-110V-10-A

The information in this publication is provided for reference only. While every eort has been made to ensure the reliability and accuracy of the
information contained in this manual at the time of printing, we recommend that you refer to “franklinfueling.com” for the most current version of
this manual. All product specifications, as well as the information contained in this publication, are subject to change without notice. Franklin Fueling
Systems does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way connected with,
installation, operation, use, or maintenance by using this manual. Franklin Fueling Systems assumes no responsibility for any infringement of patents
or other rights of third parties that may result from use of this manual or the products. We make no warranty of any kind with regard to this material,
including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.
Copyright © 2022 Franklin Fueling Systems, LLC, Madison, WI 53718. All world rights reserved. No part of this publication may be stored in a retrieval
system, transmitted, or reproduced in any way, including, but not limited to, photocopy, photograph, magnetic, or other record, without the prior
written permission of Franklin Fueling Systems.
For technical assistance, please contact:
Franklin Fueling Systems
3760 Marsh Rd.
Madison, WI 53718
USA
Web: franklinfueling.com
Tel: [phone] • Fax: [phone]
Tel: USA & Canada [phone] • Tel: UK [phone]
Tel: Mex 001 800 738 7610 • Tel: DE [phone] • Tel: CN [phone]
UPP and Gemini are registered trademark of Franklin Electric Company, Inc.
408001008 r5
Conventions used in this manual
This manual includes safety precautions and other important information presented in the following format:
NOTE: This provides helpful supplementary information.
IMPORTANT: This provides instructions to avoid damaging hardware or a potential hazard to the environment, for example: fuel leakage from
equipment that could harm the environment.
CAUTION: This indicates a potentially hazardous situation that could result in minor or moderate injury if not avoided. This may also be used to
alert against unsafe practices.
WARNING: This indicates a potentially hazardous situation that could result in severe injury or death if not avoided.
DANGER: This indicates an imminently hazardous situation that will result in death if not avoided.
Operating precautions
Franklin Fueling Systems (FFS) equipment is designed to be installed in areas where volatile liquids such as gasoline and diesel fuel are present.
Working in such a hazardous environment presents a risk of severe injury or death if you do not follow standard industry practices and the instructions
in this manual. Before you work with or install the equipment covered in this manual, or any related equipment, read this entire manual, particularly
the following precautions:
IMPORTANT: To help prevent spillage from an underground storage tank, make sure the delivery equipment is well-maintained, that there is a proper
connection, and that the fill adaptor is tight. Delivery personnel should inspect delivery elbows and hoses for damage and missing parts.
CAUTION: Use only original FFS parts. Substituting non-FFS parts could cause the device to fail, which could create a hazardous condition and/or
harm the environment.
WARNING: Follow all codes that govern how you install and service this product and the entire system. Always lock out and tag electrical circuit
breakers while installing or servicing this equipment and related equipment. A potentially lethal electrical shock hazard and the possibility of an
explosion or fire from a spark can result if the electrical circuit breakers are accidentally turned on while you are installing or servicing this product.
Refer to this manual (and documentation for related equipment) for complete installation and safety information.
WARNING: Before you enter a containment sump, check for the presence of hydrocarbon vapors. Inhaling these vapors can make you dizzy or
unconscious, and if ignited, they can explode and cause serious injury or death. Containment sumps are designed to trap hazardous liquid spills
and prevent environmental contamination, so they can accumulate dangerous amounts of hydrocarbon vapors. Check the atmosphere in the sump
regularly while you are working in it. If vapors reach unsafe levels, exit the sump and ventilate it with fresh air before you resume working. Always have
another person standing by for assistance.
WARNING: Follow all federal, state, and local laws governing the installation of this product and its associated systems. When no other regulations
apply, follow NFPA codes 30, 30A, and 70 from the National Fire Protection Association. Failure to follow these codes could result in severe injury,
death, serious property damage, and/or environmental contamination.
WARNING: Always secure the work area from moving vehicles. The equipment in this manual is usually mounted underground, so reduced
visibility puts service personnel working on it in danger from moving vehicles that enter the work area. To help prevent this safety hazard, secure the
area by using a service truck (or some other vehicle) to block access to the work area.
DANGER: Make sure you check the installation location for potential ignition sources such as flames, sparks, radio waves, ionizing radiation, and
ultrasound sonic waves. If you identify any potential ignition sources, you must make sure safety measure are implemented.

Contents
1 Introduction.......................................................................................................................1
1.1 Documentation..........................................................................................................1
1.1.1 Symbol Legend ...............................................................................................1
2 Safety/Security ..................................................................................................................2
2.1 General Safety Information.........................................................................................2
2.2 Welder Safety Information..........................................................................................2
2.3 Liability Restrictions...................................................................................................3
2.4 Hazard Assessment ...................................................................................................3
2.5 Required Personal Protective Equipment (PPEs) ........................................................3
3 Overview ...........................................................................................................................4
3.1 Component / Feature Identification & Location ...........................................................4
3.2 Technical Specifications ............................................................................................5
4 Application ........................................................................................................................6
4.1 Using the Welder .......................................................................................................6
4.2 Multiple Welds...........................................................................................................7
4.3 Other Important Tips..................................................................................................7
5 Appendix...........................................................................................................................8
5.1 Maintenance .............................................................................................................8
5.2 Display Indicators ......................................................................................................8
5.2.1 Successful Operation Indicators ......................................................................8
5.2.2 Fault Indicators .............................................................................................10
5.3 Disposal ..................................................................................................................12
5.4 Declaration of Conformity ........................................................................................12

Intentionally Blank

1
1 Introduction
The EF1-110V-10 electrofusion welder from Franklin Fueling Systems works with all
UPP® electrofusion fittings and products. The EF1-110V-10 features state-of-the-art
electronics which allowing for a compact, user-friendly design. Features include:
• Robust construction, dust proof / water resistant (IP65 rated) features with
enhanced graphic feed-back of the electrofusion progress.
• Diagnostic capabilities ensuring increased reliability and tolerance in a variety of
climatic conditions.
• Automatically recognizes the fitting when connected with the correct welding
cable. It also checks the ambient temperature and adjusts the energy level to
balance with the local environment, applying the correct amount of energy for a
successful weld.
1.1 Documentation
• This document is intended for qualified and certified installation persons.
• Instructions in this document are in English. All other language versions are
translations of this original document.
• Illustrations in this document show a typical setup and are for instruction and
description purposes only.
• Information given in this document is given as a guide only. It is the installer's
responsibility to ensure that correct and safe procedures are always followed.
• This document and related documents are available from:
Franklin Electric at www.franklinfueling.com.
1.1.1 Symbol Legend
Wear Protective Headwear Wear Eye Protection
Wear Protective Clothing Wear High-Visibility Clothing
Wear Protective Gloves Wear Safety Footwear
Refer to instruction guide. Connect an earth terminal to the ground
General Warning Warning: Electricity
Warning: Flammable Material
No open flame; Fire, open ignition source and smoking prohibited

2
2 Safety/Security
2.1 General Safety Information
• Only perform procedures in this document you are qualified and certified to perform.
• Personnel working on or with energized equipment must be authorized by
relevant regulatory bodies to carry out such work and must have the appropriate
training. Check with your employer and relevant regulatory body’s rules for
working with energized equipment.
• In case of inconsistency or contradiction between information contained in this
document and any laws, rules and regulations, obey the stricter of the two.
• Keep unqualified personnel at a safe distance during installation.
• Always wear all required PPE on-site and during installation.
• If it is necessary to remove safety/security devices, immediately reinstall the
safety / security devices after completing the work.
2.2 Welder Safety Information
NOTE: Hazardous area definitions are from European Directive 1999/92/EC.
Further guidelines can be found in the APEA Blue Book 2nd Edition and IEC 60079-10-1,
“Explosive atmospheres - Part 10-1: Classification of areas - Explosive gas atmospheres”.
• The EF1-110V-10-10 is designed for use on construction sites and meets
applicable European and International safety standards. The machine should
be handled with the care usually given to electrical equipment, especially during
transport.
• The machine must only be used outside of hazardous areas (Zones 0, 1 and 2).
• Before each use:
• Check the condition of the machine, particularly the main power cables. If any
damage is discovered, contact the supplier immediately and do not use the
machine.
• Inspect the welding cables and replace if there is any doubt about their
condition.
• Check that the power source is within the parameters shown below before using.
• Protect the welder from moisture.
• Never lift or pull the machine by its power cable or the welding cables.
• Never disconnect welding cables by pulling on the cable itself; always
disconnect by grasping the connectors and pulling.
WARNING: Never re-weld a fitting that is still warm. Serious fire or burn damage can
occur and hot material may be ejected from the weld zone.
WARNING: Power conducting elements may become exposed creating a potential
electrical shock hazard.
WARNING: UPP® welding units must never be operated in Zones 0, 1 or 2.

3
2.3 Liability Restrictions
NOTE: All liabilities of the supplier are invalidated in the following cases.
• The EF1-110V-10 is used outside the indicated application area.
• Non-UPP® fittings or pipe are used.
• The operator has not been trained to use the EF1-110V-10 or the UPP® system.
• Operating instructions have not been observed.
• Unauthorized repairs, maintenance or modifications have occurred.
• The EF1-110V-10 has been used outside of its technical specification.
• Safety instructions have not been observed.
• Improper or inadequate maintenance.
• Misuse, physical abuse or any use not in accordance with the operating manual
or good industry practice.
• Improper site preparation or site maintenance.
2.4 Hazard Assessment
Prior to beginning work and prior to recommencing work after leaving and returning
to the worksite, a worksite, pre-job hazard assessment must be performed to identify
safety and environmental needs. At a minimum, this hazard assessment should:
• Identify possible hazards and risks.
• Identify the safety needs of the job.
• Identify the correct procedures, practices and equipment.
• Eliminate unsafe conditions and actions from the worksite.
• Identify the need for personal protective equipment.
• Inspect equipment before use.
• Confirm sheaths of all cables are secured and undamaged.
• Confirm plugs and connectors are properly connected and serviceable.
• Perform ongoing risk assessment during the project.
2.5 Required Personal Protective Equipment (PPEs)
These PPEs are required during all phases of installation.
Wear Protective Clothing Wear Eye Protection
Wear High-Visibility Clothing Wear Protective Gloves
Wear Protective Headwear Wear Safety Footwear

4
3 Overview
UPP® electrofusion fittings are welded by the EF1-110V-10 case-mounted welder
utilizing a constant, standard alternating current, provided by either a main connection
or a generator. Generators must have a rated output of at least 2.8 kW (3.5 kVa) and
power input must be between 93 and 127 volts at 40 to 70 Hz. The EF1-110V-10
automatically recognizes the fitting when connected and applies the correct amount of
energy for a successful weld.
The EF1-110V-10 case-mounted welder takes the ambient temperature into account
when calculating the energy required to weld correctly. It must be allowed to reach
ambient temperature before use and must be at the same temperature as the fitting to
be welded. The temperature sensor is located on the back of the case (see Figure 2).
The EF1-110V-10 case-mounted welder has a power (on/o) switch, a weld start
button and a LED display (to show weld progress). The LEDs can also indicate any fault
conditions that may aect the weld (see Figure 2).
3.1 Component / Feature Identification & Location
Figure 1 – EF1-110V-10 Electrofusion Welder Component Overview.
Instructions
7 pin Welding Cable Connector
Bridging Cables (red x2; blue x1)
7 pin Secondary Welding Cable Connector
7 pin Primary and Gemini Secondary Welding Cable
Power Cable
7 pin Fusion Chamber Welding Cable Connector
7 pin Primary (blue) Welding Cable
Figure 2 – EF1-110V-10 Main Features Overview.
Power (On/O) Switch
Power On Indicator
Temperature Sensor
Fault Indicator
Weld Progres LEDs
START / STOP Button

5
3.2 Technical Specifications
Table 1 – Specifications.
Description Value
Stock Code Number EF1-110V-10
Supply voltage 110 V +/- 15% (93 V to 127 V)
Supply frequency 50/60 Hz (40 Hz to 70 Hz)
Supply power 2.8 kW / 3.5 kVa
Supply protection Class 1 earthed (grounded)
Environmental protection IP65
Operating temperature -15° C (5° F) to +45° C (113° F)
Shipping dimensions 420 mm (16.5") wide x 340 mm (13.4") deep x 180 mm (7") high
Shipping weight 18.7 kg (41 lb)
Power Supply Requirements
An earth-spike (grounding rod) must be used with generators.
1. Welder must be powered with:
• A quality 110 VAC, power supply with maximum tolerance of ± 15%.
• A quality generator capable of supplying a minimum of 2.8 kW (3.5 kVa),
5000W (5kW) recommended.
2. If used with a 110 V transformer follow these specifications:
• Safety Isolating transformer: 3.3 kVa minimum.
• Auto transformer: 3.3 kVa minimum.
Extension Cords / Cables
Extension cables must comply with or be equivalent to H07RN-F specifications. Cable
use must comply with the following table.
Table 2 – Wire size/run.
Wire Size AWG (Metric) Maximum Run SAE (Metric)
15 (1.5 mm) 82' (25 m)
13 (2.5 mm) 164' (50 m)
11 (4.0 mm) 246' (75 m)
NOTE: All cable must be unwound from reel to prevent inductive heating eects.

6
4 Application
The EF1-110V-10 is designed to automatically weld UPP® Primary and Secondary
Containment electrofusion fittings and Electrofusion Chambers. This is done by using
color-coded welding leads as shown in Table 3.
Table 3 – Weld and fitting/lead information.
Fitting Type
Welding Cable
Color
Size of Welding
Pim (mm)
Current
(Amps)
Weld Time @ 20° C
(Seconds)
Primary and Gemini® Secondary Fittings Red 4.0 4 184
Secondary Green 2.0 5 80
Fusion Chamber White 2.3 7 360
Riser Fittings Blue 2.0 10 360
The EF1-110V-10 can be used in ambient temperatures between -15° C (5° F) and
+45° C (113° F). Only personnel fully trained and certified in the use and installation of
the UPP® system should use this equipment.
4.1 Using the Welder
• Ensure that the machine is positioned outside hazardous zones ATEX 0, 1 and 2.
• Allow the machine and fittings to reach the ambient temperature of the site.
• Keep the machine out of direct sunlight and free of any obstruction.
• Make sure fittings and pipe have been prepared in accordance with UPP®
Installation instructions.
Follow the steps below to weld Electrofusion fittings.
1. Connect the required welding lead to the EF1-110V-10:
• PRIMARY and GEMINI® SECONDARY fittings = RED (ORANGE) cable.
• SECONDARY fittings = GREEN cable.
• FUSION CHAMBER = WHITE cable.
• RISER fittings = BLUE cable.
2. Connect the welding lead to the UPP® Fusion fitting(s), making sure connectors
are firmly pushed onto the pins.
3. Connect the EF1-110V-10 to a suitable 110V power supply.
4. Turn the unit ON. All LEDs light in sequence, then green Power LED remains on.
5. Momentarily depress the orange START button until first weld light illuminates.
The first weld light comes on, then successive LEDs light up until green 100%
LED is lit, showing weld is complete.
6. Disconnect welding lead from fitting. The 100% LED and Power LED remains on.
7. ALWAYS Reset for the next weld by holding START button for 3 seconds. All LEDs
will light in sequence, then the green power LED remains on.

7
4.2 Multiple Welds
In Primary mode, the EF1-110V-10 can simultaneously weld up to three UPP® fittings,
provided that:
• The sum of the resistance values (circled number on UPP® fittings) does not
exceed 10.
• The UPP® fittings are connected to the EF1-110V-10 in series using the bridging
leads provided (see photos A & B).
BBAA
You can ensure that you have connected the fittings correctly and that the welds are
successful by checking that all of the connected fittings get warm and that all of the
indicator pins are exposed at the end of the welding time. Fusion fittings with X or no
marking may NOT be welded in series. You may also simultaneously weld up to two
RISER fittings at once.
NOTE: Gemini® fitting must complete center weld before multiple welds to pipe can be
completed.
NOTE: Welder must be power cycled or reset by holding the Start / Stop button until
weld progress LEDs go dark, and the welder recalibrates before the next weld can be
initiated.
4.3 Other Important Tips
• Switch o the machine during breaks and at the end of the job.
• The weld cycle can be stopped at any time by pressing the START/STOP button.
This will generate an error code and you must wait for the fitting to cool before
attempting to continue.
• If you have any doubt about a welded joint, UPP® fittings can be welded again
provided they are left to cool at ambient temperature for a minimum of one hour.
WARNING: Never re-weld a fitting that is still warm. Serious fire damage can occur
and hot material may be ejected from the weld zone creating a burning hazard.
WARNING: Power conducting elements may become exposed creating an electrical
shock hazard.

8
5 Appendix
5.1 Maintenance
• There are no user serviceable parts inside the EF1-110V-10 welding unit.
• Damaged or defective products should be returned to an approved service agent
for repair or calibration.
• Welding unit and cables should be checked for damage or defects and parts
repaired or replaced prior to each use.
• The welding unit can be cleaned using a soft brush or cloth.
• After use, carefully coil cables and store in the case.
• Electrical Safety Testing “Portable Appliance Test” (PAT) should be carried out in
accordance with local legislation.
• It is recommended that the welder is returned to Franklin Fueling Systems on a
regular basis (3 years or less) for checking and recalibrating.
5.2 Display Indicators
5.2.1 Successful Operation Indicators
A successful weld cycle is actively indicated by successive lighting of yellow LEDs on
the right side of the display until the electrical warning LED and 100% LED are lit green.
TABLE 4 – Successful Operating Codes.
Step LED Indicator Meaning
1 – 7 Yellow Successful progression of the welding process.
8Green Successful completion of the welding cycle.

9
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress

10
5.2.2 Fault Indicators
When an error has occurred during the weld cycle that will have an eect on the
success of the joint, the red warning LED on the right side of the display will light up.
Also one of the “weld progress” lights will light up at the same time to show what type
of fault has occurred.
TABLE 5 – Troubleshooting Codes.
Error LED Fault Indicated Meaning Action for Solution
1 Power supply failure
during weld.
Power was o at
sometime during
the weld.
• Check and repair power supply.
• Check plug connection.
• Check cables are not damaged or broken.
• Re-weld fitting only after it is allowed to cool to ambient
temperature for 60 minutes.
2 Stop button pressed
during weld.
Stop button was
pressed.
• Re-weld fitting only after it is allowed to cool to ambient
temperature for 60 minutes.
3 Power supply out of
limits.
Supply voltage
93 V to 127 V and
frequency is not
between 40 and
70 Hz.
• Check and rectify generator output.
• Check main supply.
• Make sure supply is to required specification.
4 Ambient temperature
out of range.
Temperature of the
EF1-110V-10 is
not between -15° C
(5º F) and +45° C
(113º F)
• Allow EF1-110V-10 and fitting to cool in the shade.
• Wait for ambient temperature to return to range.
5 No output current
(open circuit).
Loose connection to
terminal pin.
Loose contact in the
welding circuit.
Faulty fitting.
Start button not
depressed for long
enough.
• Make sure connectors are pushed firmly onto terminal
pins.
• Check welding cable connection and continuity.
• Move generator closer and use shorter extension cord.
• Replace fitting.
• See operating sequence (step 5).
6 Low output current. Resistance value of
fitting is too high.
Too many fittings
connected in series
(Primary mode
only).
Input voltage too
low.
• Use only UPP® Electrofusion fittings and correct
welding cable.
• Check resistance codes on fittings - do not exceed a
sum total of 10.
• Check supply voltage.
• Check extension leads being used are to specification.
7 High output current. Regulation error in
electronics.
• Switch o machine and switch on again after 10
seconds.
• Ensure welder is within temperature range.
• If problem persists, return EF1-110V-10 to supplier.
NOTE: The EF1-110V-10 can be reset after a fault has been remedied by pressing and
holding the START / STOP button for 3 seconds.

11
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress
1
2
34567
0%
100%
50%
Weld Progress

12
5.3 Disposal
The equipment and packaging should be sorted for environmentally friendly recycling.
IMPORTANT: Do not dispose of this equipment into household waste!
When no longer suitable for use, this equipment must be separately collected and
sent for recycling.
EEA UK
European Directive 2012/19/EU:
Waste Electrical and Electronic
Equipment (WEEE).
The Waste Electrical and Electronic
Equipment Regulations 2013.
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.
EEA UK
European Directive 2011/65/EU:
Restriction of Hazardous Substances
(RoHS).
The Restriction of the Use of Certain
Hazardous Substance in Electrical and
Electronic Equipment Regulations 2012.
5.4 Declaration of Conformity
This equipment has been
designed to comply with the
harmonised standards under
“New Approach” directives
and has been CE Marked
accordingly:
This equipment is in conformity
with the relevant UK Statutory
Instruments and their
amendments:
This equipment conforms to the
basic requirements according
to the applicable technical
regulations:
2014/30/EU: Electromagnetic
compatibility.
Electromagnetic Compatibility
Regulations 2016.
TR CU 020/2011 On
electromagnetic compatibility of
technical means.
2014/35/EU: Low Voltage
Equipment.
Electrical Equipment
(Safety) Regulations 2016.
TR CU 004/2011 On Safety of
low voltage equipment.
2006/42/EU: Machinery Safety. Supply of Machinery
(Safety) Regulations 2008.

13
Intentionally Blank

408001008 r5
FUELING SYSTEMS
GRID SOLUTIONS
EV SYSTEMS