HSS Hire Hire-Weld HW888 Troubleshooting guide

When not in use, store the equipment somewhere
clean, dry and safe from thieves and unauthorised users.
Switch OFF the power supply and unplug the unit.
Disconnect all leads and coil them up neatly ready
for return to your local HSS Hire Weld Depot.
Code 55021
Manual
Electrofusion
Pipe Welder
A manually set welding unit for fusing
pipes up to 400mm in diameter
Operating & Safety Guide HW888
HW888/01
©HSS Hire Service Group Plc 2003 No. HW888/01
Group Office: 25 Willow Lane, Mitcham, Surrey CR4 4TS
Web Site: http://www.hss.com/hireweld
...any comments?
If you have any suggestions to enable us to improve
the information within this guide please fax your
comments or write to the Product Manager at the
address below
Fax: [phone]
FINISHING OFF
The green button to the right of the unit is the START
button. Press this to begin the electro-fusion process and
timer.
The arrow (up and down) buttons are used to alter the
welding time displayed on the LCD display.
The LCD display will show various information
including the time selected and when welding, the time as
it counts down.
Plug the unit into its power supply and switch the
supply ON.
The LCD will prompt the user to connect the output
leads to the fitting. Connect the leads ensuring a firm
positive connection is achieved.
The unit will then ask for the electrofusion time for
the particular joint. The time information will be found on
the joint, enter the value using the arrow buttons.
Finally, press the green START button to activate the
weld, the LCD will display elapsed time.
Once the weld is complete, allow the joint time to
cool correctly, based upon the information from the joint
manufacturer before disconnecting the output leads
and proceeding to the next joint.
Never push the equipment beyond its design limits.
If it will not do what you want with reasonable ease and
speed, assume you have the wrong type or size of welder
for the job. Ask at your local HSS Hire Weld Depot for
advice.
Keep the equipment clean. You will find this less of a
chore if you clean it up regularly rather than wait until the
end of the hire period.
BASIC TECHNIQUES
Fitting
Connection
Socket
Output
Leads
Pipe
Fitting
Joint Information Box
EQUIPMENT CARE

For advice on the safety and suitability of this equipment
contact your local HSS Hire Weld Depot.
There is a serious risk of personal injury if you do not
follow all instructions laid down in this guide.
The hirer has a responsibility to ensure that all necessary
risk assessments have been completed prior to the use
of this equipment.
Most welding tasks may be considered as hot work in
site situations and may be subject to specific permits to
work.
This equipment should only be used by an operator
who has been deemed competent to do so by
his/her employer.
This equipment should be used by an able bodied,
competent adult who has read and understood these
instructions. Anyone with either a temporary or permanent
disability, should seek expert advice before using it.
Keep children, animals and bystanders away from
the work area. Cordon off a NO GO area using cones,
barriers or tape, available for hire from your local HSS Hire
Weld Depot.
Never use this equipment if you are ill,
feeling tired, or under the influence of
alcohol or drugs.
Wear practical, protective clothing, gloves and
footwear. Avoid loose garments and jewellery that
could get in the way. Tie back long hair.
This equipment is heavy (28kg), never attempt to lift
it on your own, always get help.
Always transport, store and operate the machine in
an upright position.
Always switch equipment OFF before making any
adjustments to it. Never leave it switched ON and
unattended.
Ensure the work area is well lit and ventilated, a fume
extractor or smoke eliminator should be used. If in doubt,
ask about lighting and ventilation equipment at your local
HSS Hire Weld Depot.
Do not work near flammable gases or liquids, petrol
or paint thinner fumes for example. Keep combustible
materials at a safe distance - at least 5m.
Make sure you know how to stop the machine
operating in case you get into difficulty.
Check the condition of the equipment before use. If
it shows signs of damage or excessive wear, return it to
your local HSS Hire Weld Depot.
The HSS Manual Electrofusion Pipe Welder must only
be powered from a 32amp 110V supply, either from a
5 kVA + generator or a suitable transformer.
If the equipment fails, or if its power supply cable or
plug becomes damaged, return it. Never try to repair
it yourself.
Keep cables out of harm’s way, and clear of the work
area.
Extension leads should be avoided however, if
unavoidable they should be fully unwound and
loosely coiled, away from the equipment. Never run
them through water, over sharp edges or where they could
trip someone.
Keep the equipment dry, using electrical equipment in
very damp or wet conditions can be dangerous.
To reduce the risk of electric shock, always use
a suitable RCD (Residual Current-Operated Device)
available from your local HSS Hire Weld Depot. Or
power the equipment from a mains circuit with a built in
RCD.
Ensure the Manual Electrofusion Pipe Welder and
the power socket are switched OFF before plugging
into the power supply.
GENERAL SAFETY GETTING STARTED
ELECTRICAL SAFETY
Output Lead
Connection
Socket
Output Lead
Warning!
During electric/electronic welding/cutting
operations, intense magnetic & electrical fields are
produced and these may interfere with other
electronically sensitive equipment.
All personnel wearing Heart Pacemakers or other
electronically controlled medical devices must be
kept away from any electric/electronic
welding/cutting operations.
The welding/cutting equipment should be installed
at least 5 metres away from any computer
equipment to minimise any possible interaction.
Cables carrying signals between electronic devices
are capable of picking up interference from
electric/electronic welding/cutting operations. This
interference may prejudice the way in which these
devices function and therefore all signal-carrying
cables should also be sited outside the 5metre
zone.
Do not place objects that are sensitive to
magnetism (wristwatches, credit cards, computer
discs etc.) near the welding or cutting zone. They
may be rendered useless.
The welding/cutting equipment is itself
electronically sensitive and its position relative to
other radiation emitting equipment (mobile
phones, remote controls, motor speed controllers
etc.) must be considered.
Let It Cool
Handle welding equipment and work with care –
it will be hot. Leave equipment to cool before
changing welding rods, moving earth clamps, and
so on.
This guide is designed to help the user to safely set
up, operate and dismantle the welder. It is not
intended as a guide to pipe fabrication or welding
techniques as it is assumed that the user already has the
necessary training/knowledge and experience.
Position the main unit close to the power supply and
the pipe joint.
Connect the output leads 5-pin plug to the
connection socket on the side of the main unit (see
illustration). Push the plug in then lock in place by turning
the lock collar clockwise until the red dot on the plug lines
up with the red dot on the socket.
It is essential to familiarise yourself with all the
controls before starting.
The HSS Manual Electrofusion Pipe Welder is not
fitted with an ON/OFF switch. The unit will run
whenever plugged into a live power supply.
There is a red STOP button, if you get into difficulty
at any time, press the STOP button to stop any welding
process.
Main Unit
LCD Display
Red Stop
Button
Green Start
Button
Up & Down Buttons