Highland Supercell User manual

Lithium-ion powered electrofusion processor
TM
Operations Manual

3
TABLE OF CONTENTS
Operang Controls .................................................................4
Delivered Items ......................................................................5
Intended Use ..........................................................................5
Introducon............................................................................5
Product Specicaon ..............................................................6
Safety Notes ...........................................................................7
Electrical Safety ......................................................................8
Transport of Dangerous Goods ...............................................9
Capacity ................................................................................10
Baery Charging ...................................................................10
Using the Equipment – Screen Symbols ...............................12
Using the Equipment – On / O ...........................................13
Using the Equipment – Barcode Welding .............................14
Using the Equipment – Manual Welding ..............................17
Using the Equipment – Checking Baery Capacity ..............20
Using the Equipment – Main Menu .....................................20
Using the Equipment – Downloading Data Log ....................21
Using the Equipment – View Logs ........................................22
Using the Equipment – View Details ....................................23
Service and Calibraon .........................................................24
Fault Finding .........................................................................24
Hardware Reset ....................................................................29
Disposal – End of Life ...........................................................30
Warranty ..............................................................................31
Repair ...................................................................................33
8 Helpful Tips ........................................................................34

4
OPERATING CONTROLS

5
DELIVERED ITEMS
Carefully remove the welding processor from its packaging and check that you have the follow-
ing items:
• Welding processor.
• Wireless bar code scanner.
• Mains powered baery charger.
• +12V dc car charging lead.
• USB memory drive.
Note: to download a copy of this manual, visit www.supercellef.com
INTENDED USE
This equipment is intended to fuse constant voltage electrofusion ngs suitable for low, me-
dium, and high-pressure pipe work systems, up to a maximum diameter of 14 inch (355mm).
This welding processor has been designed to comply with the Internaonal Organizaon for
Standardizaon standard ISO12176-2:2000 “Plasc pipes and ngs, equipment for fusion
joinng polyethylene systems, part 2, electrofusion”.
INTRODUCTION
This manual gives instrucons on the correct assembly and safe use of your electrofusion pro-
cessor. It is important that you read these instrucons and always keep these instrucons with
the unit.
This manual does not detail the specic welding procedure for the ngs: peeling, clamping
and assembly of joints. For this informaon, please contact the ngs manufacturer or refer
to your organizaon’s internal procedures.

6
PRODUCT SPECIFICATION
Operang Type: Controlled voltage.
Operang Modes: Manual, Bar Code
Operang Languages: English, French, Spanish
(Others on request)
Operang Temperature: -4oF to 113oF #1
Welding Voltage: 8 to 48 V (39,5 V) (true rms)
Welding Current: 1 to 65 A (true rms)
Welding Power: 8 VA to 2600 VA
Welding Time: 1 to 3000 seconds
Data log memory: >10,000 welds (solid state internal storage)
Data download/upload: USB ash memory drive
Protecon Level: IP54
Weight: 30.8 lb
Size: 17.5” x 11.5” x 12”
Supply voltage: Lithium-Ion rechargeable baeries.
Baery charger.
Supply voltage: 100V to 240V
Supply Power: 550W (@ 240V)
#1 The baeries can only be charged between 32oF to 113oF.
Highland has a policy of connuously improving product design, and as such reserve the right
to change specicaon of its products without prior noce and with impunity.

7
SAFETY NOTES
• WARNING: RISK OF ELECTRIC SHOCK! Do not open. No user serviceable parts inside.
Only to be opened by an approved service agent.
• WARNING: RISK OF EXPLOSION! This electrofusion processor is NOT intrinsically safe
and must NOT be used in a gaseous atmosphere. Do not use this equipment in the
trench.
• WARNING: This product can expose you to chemicals which are known to the state of
California to cause cancer. For more informaon, visit www.p65warnings.ca.gov
• Before use, always visually inspect the unit to see that the cords and connectors are not
worn or damaged. Replace any damaged parts before use.
• Switch o before adjusng, cleaning, or if the cords are entangled and before leaving the
unit unaended for any period.
• To avoid damaging the unit, do not disconnect the output cables, while the unit is fusing.
• Do not li or pull the unit by its cords.
• Do not disconnect the output cables by pulling on them, always carefully pull o the
connectors from the ng using the integrated grips.
• Do not start a fusion without the pipe correctly inserted into the ng.
• Do not touch the ng while fusing.
• Do not operate the unit or leave the unit outdoors in precipitaon (rain, snow, hail,
etc…).
• Operate the unit in daylight or in good arcial 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 instrucons to use the electrofusion processor.

8
ELECTRICAL SAFETY
Supercell is baery powered and there is no requirement to carry out in-service electrical
tesng. However, baeries in equipment can potenally fail and cause res. Supercell must be
visually inspected for damage before each use.
The operator should carry out a visual inspecon of Supercell every me it is used. If the case
is split or broken, or any connectors are damaged, then the equipment must not be used, and
it should be returned to your distributor for immediate repair.
The wall powered charger requires addional tesng and is subject to both a visual inspecon
and an in-service electrical test.
The operator should carry out a visual inspecon on the charger every me it is used.

9
TRANSPORT OF DANGEROUS GOODS
Supercell contains a baery pack made from Lithium-ion baeries. These have been classied
by the United Naons as hazardous materials and been assigned to Class 9 - Miscellaneous
Hazard Classicaon.
Addionally, the United Naons Commiee of Experts on the Transport of Dangerous Goods
have classied them under UN 3481 Lithium-ion baeries contained in equipment.
The equipment has passed all relevant tests to allow it to be transported.
There is a requirement under UN3481 that the product is packaged and labeled correctly for
transport. Please save the original packaging in case the machine needs to be transported. It is
mandatory that the following label is aached to the outside of the packaging and the carrier
is informed that it contains Lithium-ion baeries.
If you do not have the original packaging, then please contact your distributor, or visit www.
supercellef.com/baeries for informaon on how to ship Supercell.

10
CAPACITY
Due to dierences in ng type and ng manufacturing, each ng will have dierent ener-
gy requirements for fusion. As such, capacity cannot be explicitly given. However, in tesng the
energy requirements of various ng types from various manufacturers, the expected capaci-
ty on a full baery charge is as follows:
1” ngs: 195 on a full charge
2” ngs: 74 on a full charge
3” ngs: 21 on a full charge
4” ngs: 8 on a full charge
6” ngs: 5 on a full charge
14” ngs: 1 on a full charge
Note: This is given as a guide only, and exact capacity will depend on a range of factors.
BATTERY CHARGING
IMPORTANT. Supercell can only be charged at temperatures between 32°and 113°Fahren-
heit. If the baery pack is above 113F then you must allow it to cool before charging.
An exclamaon mark will be shown on the baery to signify it is too hot.
Keep the charger dry at all mes. Do not charge in the rain.
Do not use the charger if it is damaged.
Supercell will only charge when it is turned o.
The charger will become hot with prolonged use.

11
Supercell can be charged using two methods:
• using the wall charger connected to the 120V/240V wall power, or a 120V/240V vehicle
mounted inverter.
• using the +12V dc charger cord, connected to a 12V vehicle auxiliary socket.
Wall Charger
1. Make sure Supercell is turned o, (hold the red stop buon in for 3 seconds to power o
the machine).
2. Plug the charger into the wall and power it on. The green light will ash once per sec-
ond.
3. Plug the charger output into the charging socket of Supercell.
4. The charger’s indicator light will turn solid red, and the baery pack will start to charge.
5. The baery pack will charge from 0% to 100% in approximately 90 minutes (on 120V).
When charging is complete, the charger’s indicator light will turn solid green.
6. Power o the charger and unplug it. CAUTION: the charger will become hot with extend-
ed use.
7. If the charger’s indicator light ashes red while charging, then there is a fault with either
the charger or Supercell. Contact your distributor for help.
8. If the baery pack exceeds 113°F while charging, Supercell will detect this and halt
charging, and the light will go solid green. This will happen even if the baery pack is not
completely charged. Turn Supercell on and check the charge percentage to make sure
the charge completed.
+12V Auxiliary charger.
1. Make sure Supercell is turned o, (hold the red stop buon in for 3 seconds to power o
the machine).
2. Plug the charger cord into the 12V auxiliary socket of the vehicle.
3. Plug the charger into the charging socket of Supercell.
4. The baery pack will start to charge. There is no indicaon of charge.
5. The baery pack will charge from 0% to 100% in approximately six hours.
6. To check the state of charge of the baery pack, turn Supercell on and check the baery
percentage. If it is not fully charged turn Supercell o to resume charging.

12
USING THE EQUIPMENT – SCREEN SYMBOLS
The le-hand side of the screen shows prompts to the operator for the next steps that need to
be taken, in this example, connect the welding cord to the ng or press the star key for the
menu. The right-hand side shows informaon icons. In this example the baery is at 98%, the
me is 13:00, the GSM radio is disconnected (if ed) and the Blue Tooth is disconnected.
The right-hand side can also show symbols such as press the Start buon:
In this example buons A, B or C can be pressed:
This shows the ng welding icon:

13
USING THE EQUIPMENT – ON / OFF
Turning the machine ON.
To turn the machine on, press and hold in the green START buon for three seconds. The dis-
play will show:
The manufacturer logo.
The product name.
The owner details.
The main screen.
Turning the machine OFF.
To turn the machine on, press and hold in the red STOP buon for three seconds. The display
will turn o.
The machine will auto power o aer ve minutes of inacvity.

14
TEMPERATURE MEASUREMENT
The processor’s temperature sensor is located on the side of the enclosure. The temperature
sensor does not respond immediately to thermal changes. To assure accurate ambient tem-
perature measurements, the output cable end should be le in the ng environment for
at least 15 minutes. Direct exposure to sun light and other heat sources will adversely aect
accuracy.
TEMPERATURE COMPENSATION
When using the Highland Electrofusion Processors in Barcode Fusion Mode or Manual Barcode
Mode, to fuse ngs that require temperature compensaon it is essenal that care be given
to ensure that the correct inial fusion temperature is measured. The processor will automat-
ically adjust the fusion me per the measured temperature as specied by the fusion parame-
ters.
THE PROCESSOR WILL NOT AUTOMATICALLY COMPENSATE FUSION TIME IN MANUAL MODE
USING THE EQUIPMENT – BARCODE WELDING
Make sure that a barcode scanner/dongle is aached to the USB port.
Connect the output leads to the ng.
Scan the barcode on the ng. If this doesn’t read, then the numbers can be entered by press-
ing the A key.
When the barcode is read correctly this screen is shown.

15
The capacity of the baery is checked and the number of this type of ng that can be fused
is shown.
The resistance of the ng is checked with the barcode to make sure the right code has been
scanned.
Scan the traceability code on the ng or press the A key to move on.
The ng details are shown. Press the green START buon to begin fusion.
A couple of seconds aer the start, the calibraon is checked. This is the smart-calibraon
check.

16
As fusion progresses, the welding voltage and current are shown.
The me counts down to zero and the clock on the graphic lls up to show the fusion progress.
When fusion is complete the cooling me is shown. Allow to complete or press the A key to
skip.
At the end of the cooling me, the fusion number is shown.
Disconnect the output leads from the ng to reset the machine.

17
USING THE EQUIPMENT – MANUAL WELDING
Make sure that a barcode scanner/dongle is NOT aached to the USB port or, during the bar-
code fusion opon, press the B key when the scan ng message is shown.
Connect the output leads to the ng.
Enter the fusion me and press the A key.
Enter the fusion voltage. Press the D key to select 39.5 volts.
When the voltage is entered, press the A key.

18
The capacity of the baery is checked and the number of this type of ng that can be fused
is shown.
The ng details are shown. Press the green START buon to begin fusion.
A couple of seconds aer the start, the calibraon is checked. This is the smart-calibraon
check.
As fusion progresses, the welding voltage and current are shown.
The me counts down to zero and the clock on the graphic lls up to show the fusion progress.

19
When fusion is complete the cooling me is shown. This will count upwards, press the A key to
stop.
At the end of the cooling me, the fusion number is shown.
Disconnect the output leads from the ng to reset the machine.

20
USING THE EQUIPMENT – CHECKING BATTERY CAPACITY
If you want to know what capacity the baery has or if you can fuse a specic ng, scan the
ng barcode and the required energy will be checked from a lookup table held in memory.
When the screen shows connect ng, with no ng aached to the output leads, scan the
ng barcode.
The capacity for this type of ng is shown.
USING THE EQUIPMENT – MAIN MENU
When the screen shows, press the star key to enter the main menu.
Three opons are shown on the screen. Use the B and C keys to select the required opon
then press A.

21
USING THE EQUIPMENT – DOWNLOAD DATA LOG
Select data download from the menu.
Select the data download type. The default is 1: Encrypted. This requires supporng soware
to view. Visit www.supercellef.com for more informaon
Opon 2 is an unencrypted XML which can be viewed using most spreadsheet soware.
Insert a USB memory drive into the USB port on the machine. You may have to remove the
barcode dongle rst.
The data log will start to download.
I