Franklin Fueling Systems EF1-230V User manual

EF1-230V HAND-HELD WELDER
OPERATION GUIDE

The information in this publication is provided for reference only. While every effort 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 © 2021 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:
franklinfueling.com
3760 Marsh Rd. • Madison, WI 53718 • USA
Tel: USA & Canada [phone] • Fax: [phone]
Tel: UK [phone] • Tel: Mex 001 800 738 7610
Tel: DE [phone] • Tel: CN [phone]
UPP and GEMINI are registered trademarks of Franklin Electric Company, Inc.
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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
CONTENTS.........................................................................................................................................3
INTRODUCTION..............................................................................................................................1
SAFETY ........................................................................................................................................1
LIABILITY RESTRICTIONS .............................................................................................................1
TECHNICAL SPECIFICATIONS.......................................................................................................2
POWER SUPPLY ...........................................................................................................................2
EXTENSION CORDS / CABLES.......................................................................................................2
PARTS ..........................................................................................................................................2
APPLICATION..................................................................................................................................3
MAIN FEATURES..........................................................................................................................3
USING THE EF1...............................................................................................................................4
TIPS ...........................................................................................................................................4
MULTIPLE WELDS........................................................................................................................5
MAINTENANCE ..............................................................................................................................6
FAULT INDICATORS......................................................................................................................6
DISPOSAL........................................................................................................................................7
DECLARATION OF CONFORMITY ................................................................................................7

Intentionally Blank

1
INTRODUCTION
SAFETY
• UPP® welding units must only be used outside hazardous areas (zones 0, 1 and2).
Hazardous area denions are from European Direcve 1999/92/EC (further guidelines can
be found in the APEA Blue Book 2nd Edion).Further guidelines are found in IEC 60079-10-
1, “Explosive atmospheres - Part 10-1: Classicaon of areas - Explosive gas atmospheres”
• The EF1 is designed for usage on construcon sites and meets applicable European and
Internaonal safety standards. The machine should be handled with the care usually given
to electrical equipment, especially during transport.
• Each me it is used, check the condion of the machine, parcularly the mains power cable.
If any damage is discovered, contact the supplier immediately and do not use the machine.
• Check the state of the welding cables before use and replace them if there is any doubt
about their condion.
• Protect the welder from geng wet.
• Always check that the power source is within the parameters below before using the EF1.
• Never li or pull the machine by its power cable or the welding cables. Never disconnect
welding cables by pulling the cable; always pull o the connectors.
• Never re-weld a ng that is sll warm. Serious re or burn damage can occur and hot
material may be ejected from the weld zone. Power conducng elements may become
exposed creang an electrical shock hazard.
LIABILITY RESTRICTIONS
All liabilities of the supplier are invalidated in the following cases:
• The EF1 is used outside the indicated applicaon area.
• Non-UPP® ngs or pipe are used.
• The operator has not been trained to use the EF1 or the UPP® system.
• Operang instrucons have not been observed.
• Unauthorised repairs, maintenance or modicaons have been carried out.
• The EF1 has been used outside of its technical specicaon.
• Safety instrucons have not been observed.
• Improper or inadequate maintenance.
• Misuse, physical abuse or any use not in accordance with the operang manual or good
industry pracce.
• Improper site preparaon or site maintenance.

2
TECHNICAL SPECIFICATIONS
• Stock code: EF1-230V
• Supply voltage: 230 V +/- 15% (194 V to 264 V)
• Supply frequency: 50/60 Hz (40 Hz to 70 Hz)
• Supply power: 2.8 kW / 3.5 kVA
• Supply protecon: Class 1 earthed (grounded)
• Environmental protecon: IP65
• Operang temperature: -15 ºC (5 ºF) to +45 ºC (113 ºF)
• Shipping dimensions: 460 mm (18") wide x 210 mm (8.3") deep x 210 mm (8.3”) high
• Shipping weight: 3.6 kg (8 lb)
POWER SUPPLY
Welder must be powered with:
• A quality 230 VAC, 50 Hz power supply with maximum tolerance of ±15%.
• A quality generator capable of supplying a minimum of 2.8 kW (3.5 kVA). Note that an earth-
spike (grounding rod) must be used with generators.
• If used with a 110v to 230v step-up transformer follow these specicaons:
• Safety Isolang 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:
WIRE SIZE AWG WIRE SIZE MAXIMUM LENGTH
1.5 mm 15 82 ft (25 m)
2.5 mm 13 164 ft (50 m)
4.0 mm 11 246 ft (75 m)
NOTE: All cable must be unwound from reel to prevent inductive heating effects.
NOTE: EF1 welding cables use special 7- pin connectors.
PARTS
Bridging cables (x2)
EF1Electrofusion Welder
7pin Secondary
welding cable
Power cable
7 Pin Fusion chamber welding cable

3
APPLICATION
The EF1 is designed to automatically weld UPP® Primary and Secondary Containment
electrofusion fittings, Electrofusion Chambers and Large diameter 10 amp fittings. This is done by
using color-coded welding leads as shown below.
TYPE OF FITTING WELDING CABLE COLOR WELDING PIN SIZE CURRENT WELD TIME @ 20° C
Primary and GEMINI®
Secondary ttings Red 4 mm 4 A 184 s
Secondary Green 2 mm 5 A 80 s
Fusion Chamber White 2.3 mm 7 A 360 s
Large Diameter (10 A) Black 2 mm 10 A 365 s
The EF1 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.
MAIN FEATURES
UPP® electrofusion fittings are welded using a constant current. The EF1 automatically recognizes
the fitting when connected and applies the correct amount of energy for a successful weld.
7 pin Weld cable
connector
Fault
indicator
Weld progress
LED’s
Temperature sensor
Power on Indicator
ON / OFF Switch (on
side of unit)
START/ STOP button
• The EF1 takes the ambient temperature into account when calculang the energy required
to weld correctly. It must therefore be allowed to reach ambient temperature before use
and must be at the same temperature as the ng to be welded. The temperature sensor
is located adjacent to the power cable entry gland.
• The EF1 works on standard alternang current and either a mains connecon or a generator
can be used. Generators must have a rated output of at least 3.5 k VA and power input must
be between 194 and 264V at 40 to 70 Hz.
• The EF1 has an on / o buon, a weld start buon and an LED display showing the weld
progress. The LEDs can also show any fault condions that may aect the weld.

4
USING THE EF1
• Ensure that the machine is posioned outside hazardous zones
ATEX 0, 1 and 2.
• Allow the machine and ngs to reach the ambient temperature of the site.
• Keep the machine out of direct sunlight and free of any obstrucon.
• Make sure ngs and pipe have been prepared in accordance with UPP® Installaon
instrucons.
Follow the steps below to weld electrofusion fittings:
1. Connect the required welding lead to the EF1 Welder:
• PRIMARY and GEMINI® SECONDARY ngs = RED (ORANGE) cable
• SECONDARY ngs = GREEN cable
• FUSION CHAMBER = WHITE cable
• 10 AMP ngs = BLACK 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 Welder to suitable 230V 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 rst weld light comes on, then successive LEDs light up unl 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 next weld by holding START button for 3 seconds. All LEDs will light in
sequence, then the green power LED remains on.
TIPS
• Switch o the machine during breaks and at the end of the job.
• The weld cycle can be stopped at any me by pressing the START/STOP buon. This will
generate an error code and you must wait for the ng to cool before aempng to
connue.
• If you have any doubt about a welded joint, UPP® ngs can be welded again provided they
are le to cool at ambient temperature for a minimum of one hour.
WARNING: Never re-weld a ng that is sll warm. Serious re damage can occur and
hot material may be ejected from the weld zone creang a burning hazard.
WARNING: Power conducng elements may become exposed creang an electrical
shock hazard.

5
MULTIPLE WELDS
In Primary mode the EF1 can simultaneously weld up to three UPP® fittings, provided that:
• The sum of the resistance values (circled number on UPP® ngs) does not exceed 10.
• The UPP® ngs are connected to the EF1 in series using the bridging leads provided.
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.

6
MAINTENANCE
• There are no user serviceable parts inside the EF1 welding unit.
• Damaged or defecve products should be returned to an approved service agent for repair
or calibraon.
• 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 so brush or cloth.
• Aer use, carefully coil cables and store in the compartments provided in the carry case.
• Electrical Safety Tesng “Portable Appliance Test” (PAT) should be carried out in accordance
with local legislaon.
• It is recommended that the welder is returned to Franklin Fueling Systems on a regular
basis, at around 3 year intervals, for checking and recalibrang.
FAULT INDICATORS
When an error has occurred during the weld cycle that will have an effect 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. To reset
the welder, after you correct a fault, press and hold the START/STOP button for three seconds
LED Fault Meaning Solution
1Power supply failure
during weld
The power supply was off at sometime
during the weld
• Check and repair power supply
• Check plug connection
• Check cables are not damaged or broken
• Re-weld tting only after it is allowed to cool
to ambient temperature
2Stop button pressed
during weld Stop button was pressed • Re-weld tting only after it is allowed to cool to ambient temperature
3Power supply out of
limits
Supply frequency not between 40 and 70
Hz, or Voltage not between 194 & 264V
• Check and rectify generator output
• Check mains supply
• Make sure supply is to required specication
4Ambient temperature
out of range
Temperature of the EF1 is not between
-15° C (5º F) and +45° C (113º F)
• Allow EF1 and tting to cool in the shade
• Wait for ambient temperature to return to
range
5No output current
(open circuit)
Loose connection to terminal pin
Loose contact in the welding circuit
Faulty tting
Start button not depressed for long
enough
• Make sure connectors are pushed rmly on to
terminal pins
• Check welding cable connection and
continuity
• Move generator closer and use shorter
extension cord
• Replace tting
• See operating sequence, step 5
6 Low output current
Resistance value of tting is too high
Too many ttings connected in series
(Primary mode only)
Input voltage too low
• Use only UPP® electrofusion ttings and
correct welding cable
• Check resistance codes on ttings - do not
exceed a sum total of 10
• Check supply voltage
• Check extension leads being used are to
specication
7 High output current Regulation error in electronics
• Switch off machine and switch on again after
10 seconds.
• Ensure welder is within temperature range
• If problem persists, return EF1 to supplier

7
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 Substances in Electrical
and Electronic Equipment Regulations
2012
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/EC: Machinery safety Supply of Machinery
(Safety) Regulations 2008

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