Watts ORION RF-3000LE User manual

Installation Instructions
Rionfuse CF
Rionfuser™ 3000LE Bluetooth®
Rionfuser™ 3000LE LT
Rionfuser™ 3000LE USB
Polypropylene and PVDF Chemical Waste
Systems
Read this Manual BEFORE using this equipment.
Failure to read and follow all safety and use information can result in death,
serious personal injury, property damage, or damage to the equipment.
Keep this Manual for future reference.
WARNING
!
Local building or plumbing codes
may require modifications to
the information provided. You
are required to consult the local
building and plumbing codes prior
to installation. If the information
provided here is not consistent
with local building or plumbing
codes, the local codes should be
followed. This product must be
installed by a licensed contractor
in accordance with local codes
and ordinances.
WARNING
!
NOTICE
Follow the guidelines listed here for
proper installation, operation, and
maintenance.
RF 3000LE
DANGER
!
Electricity, electrocution
and shock hazards.

2
Calibration Recommendations
It is strongly recommended that each processor be calibrated at least once every two (2) years. This
will help ensure that the Rionfuser™ Electrofusion Processor is in proper calibration and should
enable any potential problems to be identified early.
RF-3000LE
When the calibration period has expired the processor will display the message, "Error 113: Calibra-
tion Required," informing the operator that the calibration date has passed. When this occurs, the
processor will stop performing fusions until it has been recalibrated.
Rionfuser™ LT
When the calibration period has expired the processor will display the message "Error 113: Calibra-
tion Required," informing the operator that the calibration date has passed. This will not prevent the
processor from performing fusions; however, the processor should be calibrated as soon as possible.
Service Contact Information
Calibrating your Rionfuser™ Electrofusion Processor:
1. Send the processor to a WATTS service center and let our technicians do it.
Call [phone] to make arrangements for service and to obtain an RMA number for the return.
Every effort will be made to return processors within 2 business days.
The correct output voltage cannot be assured
if the processor is not calibrated at least once
every two (2) years.
Consult your carrier for the proper method of
packaging the processor for return shipments.
Always insure the package for the full replace-
ment value. Keep in mind that most carriers will
not honor insurance claims if the product is not
shipped in accordance with their guidelines.
WATTS is not responsible for damage caused in
shipping.
NOTICE
NOTICE

3
RF-3000LE Product Overview
Rionfuser™ Electrofusion Processor
Connection Sizes: 1.5" – 12" (38mm to 305mm)
The Rionfuser™ RF-3000LE electrofusion processor is a reliable, easy-to-use, rugged tool designed to
withstand conditions found at typical construction sites. It comes with an integral splash-proof and shock
resistant outer suitcase-style enclosure. The Rionfuser™ RF-3000LE is used to thermally fuse Orion
Rionfuse RFCF couplings to Orion pipe and fittings, and can be used with Orion PP, FRPP or PVDF prod-
ucts. The RF-3000LE can be operated from any AC power source meeting the listed input power require-
ments, and comes with an intuitive user interface. The Rionfuser™ RF-3000LE cannot be used with other
manufacturers’ electrofusion couplings. The RF-3000LE supports Bluetooth®wireless technology that can
be viewed instantly via your mobile device using Apple®iOS and Android™ operating systems. A free app
can be downloaded from the App Store®online store or Google Play™ store.
Features
• Size-dependent multiple joint fusion capability
• Field calibration capability
• Downloadable internal memory for data storage
• Bluetooth wireless connection to mobile devices
• 4X20 LCD display with replaceable shield
• Compact and lightweight
• Field-replaceable output cable ends
• User-accessible fuse
• Emergency stop switch
• Can store fusion information for 1,000 fusions
Specification
Hermetically sealed joints conforming to ASTM F1290, Technique 1 are to be produced for the Orion chem-
ical piping system using the Orion Rionfuser™ machine model RF-3000LE, an electrofusion processor
designed to be used exclusively with Orion RFCF electrofusion couplings in either FRPP or PVDF material.
The RF-3000LE shall have an integral splash-proof and shock resistant outer suitcase-style enclosure,
intuitive LCD display user interface, size dependent multiple joint fusion capability, field calibration capabil-
ity, and downloadable internal memory. The fusion machine shall have user-accessible fuse, emergency
stop switch, Bluetooth® wireless communication, and will operate from any AC power source meeting
listed input power requirements.
Model RF-3000LE
Operating Parameters
Supply Voltage – 97 VAC to 150 VAC
Supply Frequency – 47 Hz to 70 Hz
Supply Waveform – Sine Wave or Square Wave
Output Current – 20 Amps AC
Output Voltage – 95 VAC at 120 Volts Input
Operating Temp. Range – 0°F to 120°F (-18°C to 49°C)
Operating Modes – CF FRPP, PVDF, Manual
Input Cable Length – 12ft (3.66m)
Output Cable Length – 24ft (7.315m)
Fusion Information Storage – 1,000 Fusions
Languages – English
Environmental Protection – IP54 Splash-Proof
Calibration Interval – 2 Years
Dimensions – 19in x 14in x 7in (47mm x 36mm x 18mm)
Weight – 17lbs (7.7kg)

Installation Instructions
Step 1
Confirming RF-3000LE is Calibrated
Start up your Rionfuser™ RF-3000LE and it will perform a Self Test. If the Cal
Due date has passed or is within the life of your project, then STOP, and con-
tact your Orion Representative for instructions on how to get your machine
recalibrated. Watts disclaims all liability for installations performed with a
Rionfuser past its calibration date.
For additional information reference the RF-3000LE Instruction Manual
included in the carrying case.
Step 2
Preparing the Pipe
Material preparation is essential to achieving satisfactory fusion results. Deburr all
field-cut pipe ends. Following the coupling insertion depth chart, mark the coupling
insertion depth from the end of the pipe/fitting to insure that the coupling is properly
positioned during the fusion cycle. Then, using 60 grit emery cloth, abrade the
marked ends of the pipe and fitting to remove the natural “sheen” of the plastic. After
abrading, clean all joint surfaces thoroughly with isopropyl alcohol to remove any dirt,
grease and the contaminants left from the sandpaper and any other foreign matter
from the surface. We suggest using a spray bottle with 90% or higher isopropyl
alcohol to soak a lint resistant cloth to thoroughly wipe the joint surface clean.
COUPLING INSERTION DEPTH MARKING
Pipe Diameter Mark Distance from Pipe End
in. in.
1
1⁄2
1
2 1
31
3⁄8
41
3⁄8
6 2
82
5⁄8
10 2
5⁄8
12 2
5⁄8
Abrade surfaceMark coupling depth
From table

5
Step 3
Joint Assembly
Insert the prepared ends of the pipe/fitting into both hubs of the Rionfuse CF
coupling. Double check the markings to verify proper seating of the pipe.
Step 4
Connecting Lead Cables
The installer must make sure the joint is properly supported during the fusion cycle
and afterwards as the joint cools to ambient. For underground installation the
joint must be protected from soil falling into the fusion assembly area. If ambient
temperature has dropped below 60F in the last 24 hrs, we recommend the use of
warming blankets to support, wrap, and protect the pipe during the fusion process.
With the Rionfuser unit connected to a dedicated power source and powered ON,
connect the lead cables to the coupling.
Step 5
Selecting Fitting Style
The unit will now prompt the installer to “SELECT FITTING STYLE”. Scroll UP or
DOWN to highlight the proper fitting style being fused, then press START to select
the fitting style.
Insert into coupling and
verify proper seating
Connect lead cables
Fitting style selection screen

6
Step 6
Selecting Pipe Size
Next the unit will prompt the installer to select the size of the joint being fused.
Scroll UP or DOWN to highlight the correct size, then press START to select size.
Step 7
Selecting Heat Cycle
The unit will ask if a pre-heat cycle is needed for the joint. If fusion will be performed
where pipe temperatures are outside the range of 60 - 90 degrees F, please consult
Orion Fittings Technical department at [phone] before proceeding. All other
fusions should be performed using the STANDARD cycle, which is selected by
pressing the START button.
Step 8
Verifying Welding Parameters
The screen will display “VERIFY WELDING PARAMETERS” and an audible beep
will sound to indicate the fusion unit is ready to begin welding. Verify the welding
data displayed on the screen matches the joint being fused. If the information is
incorrect, press the STOP/BACK button to return to any of the menu options to
correct the fusion parameters. Once the parameters have been verified, press
START to begin the fusion weld.
Fitting size selection screen
Fusion cycle type selection screen
Fusion cycle type selection screen

7
Step 9
Successful Weld Completion
After pressing START, the Rionfuser™ will begin the weld. After the welding cycle
has completed, another audible beep will sound to indicate that the fusion weld
is complete. If the beeping pattern is an equal, consistent beeping, the joint was
successful. If the beeping pattern is irregular, it indicates that an error has occurred
during the fusion cycle (if an error code is received during fusion, please contact
your local Orion rep for troubleshooting information). Once the joint is completed,
the lead cables can be removed and the process repeated for the next joint.
To download completed fusion data, please see our IOM-OR-RIONFUSE 2128 for
instructions.
Successful weld
completion screen
NOTICE
Do not stress newly-fused joints until fully cooled to ambient, typ-
ically 10-20 minutes depending on size. Successful weld comple-
tion screen does not eliminate need for system leak testing.
POLYPROPYLENE RIONFUSE CF COUPLING
Pipe Size Fusion Time Fusion Current
in. min. amps
1 -
1⁄2
2:00 8.25
22:00 8.25
33:00 14.25
43:00 14.25
64:30 19.00
84:45 19.00
10 7:20 17.00
12 8:00 16:50
MULTIPLE JOINTING RIONFUSE CF
Pipe Size Maximum number of couplings
in. num.
1 -
1⁄2
4
2 3
3 3
4 2
6 1
8 1
10 1
12 1
PVDF RIONFUSE CF COUPLING
Pipe Size Fusion Time Fusion Current
in. min. amps
1 -
1⁄2
2:00 8.25
22:00 8.25
33:00 14.25
43:00 14.25
64:45 18.00

8
Downloading to a USB Flash Drive
Fusion data from an RF-3000LE USB or Rionfuser™ LT Electrofusion Processor is downloaded onto an
external USB flash drive. The data is output in a binary format that is compatible with a free macro-en-
abled Excel Spreadsheet available from Orion Engineering Department.
To download fusion data from the processor to a USB flash drive, perform the following steps:
1. Turn On the processor and allow it to proceed through the INTERNAL SELF TEST until it reaches
the CONNECT LEADS screen.
2. Plug a formatted USB flash drive into the USB host connector on the face of the processor.
3. The USB flash drive will be detected automatically, and the fusion data will be written to the
drive.
4. A progress screen similar to the following will be displayed as the download proceeds:
5. After the download is complete, the processor will return to the CONNECT FITTING screen. You
may now disconnect the USB flash drive from the USB Host Port to resume normal operation.
NOTE:
Only new fusions performed since the last download will be written to the drive.
The USB flash drive must be formatted using FAT or FAT32 with a sector size of 512 bytes.
Rionfuser™ LT
The Rionfuser™ LT Electrofusion Processor has a 9 pin D-sub connector instead of a USB host
connector. To download fusion data from a Rionfuser™ LT Electrofusion Processor onto a USB
flash drive, you will need a USB to Serial Port adapter. This adapter is available for purchase from
WATTS. One adapter may be used with multiple processors.
The pictures below show a 9 pin D-sub connector and the installed adapter for your reference.
DOWNLOADING DATA
48%
9 Pin D-Sub
Connector
USB Host
Adapter
Installed

9
Downloading Wirelessly
Fusion data from an RF-3000LE Bluetooth®Electrofusion Processor is downloaded wirelessly
through the EF Utilities app. Once data has been downloaded, it can be viewed at any time with a
smart phone, tablet, or computer.
To download fusion data from the processor to the EF Utilities app, perform the following steps:
1. Turn ON the processor and allow it to proceed through the INTERNAL SELF TEST until it
reaches the CONNECT LEADS screen.
2. Open the EF Utilities app on your smart phone or tablet and select, "Connect to EF Machine."
3. Follow the download instructions in the app.
All progress indications and user feedback are communicated through the EF Utilities app which is
available on iOS and Android app stores. To set up an account and register your EF processor(s),
contact EF Technologies.
POWER SOURCES
When installing electrofusion fittings in field applications, it is necessary to have a reliable source of
AC power for the processor. This AC power source should:
• be well maintained and subjected to a periodic maintenance schedule.
• provide output voltage within the specified operating range.
• contain a matching outlet, which is required to connect with the plug equipped on the
processor.
Utility Power
Utility power is a reliable and ideal power source for the Rionfuser™ Electrofusion Processor.
However, it is not practical to gain access to this kind of power source in field applications. When
fusing with utility power, a dedicated connection to the service panel is recommended because the
potential amperage draw is very high.
Generators
Fuel powered generators are also a good source of electrical power for the Rionfuser™ Electrofu-
sion Processor. Always make a note of the minimum fitting power requirements. Additional power
capacity is recommended for intangibles (i.e. powering other accessories, wear & tear, etc.). Before
starting a fusion, it is important to make sure:
• the generator has enough fuel to complete the electrofusion cycle.
• the auto-throttle is disengaged (in anticipation of immediate power draw).
Inverters
Inverters are an acceptable AC power source for the Riofuser™ Electrofusion Processor, though
some produce output waveforms that are troublesome with specific fittings. We recommend perform-
ing compatibility tests using the lightest and heaviest anticipated loads before approving an inverter
system. Feel free to contact us to discuss issues regarding the use of inverters.
Power Specifications
Extension Cords
Because electrofusion fittings produce a high amperage draw, the use of an extension cord is not
encouraged. In the event such usage is necessary, the following lengths and wire gauges are recom-
mended:
Extension cords should not be used when fusing multiple fittings at the same time.
Cord Length Wire Gauge
Less than 25 feet 12/3
Less than 50 feet 10/3
Less than 100 feet 8.3
Supply Voltage 97 VAC to 150 VAC
Supply Frequency 47 Hz to 70 Hz
Supply Waveform Sine Wave or Square Wave
Output Current 20 Amps AC
Output Voltage 95 volts AC at 120 Volts Input

10
Calibration Warnings
**This section applies to the RF-3000LE Electrofusion Processor only.
Rionfuser™ Electrofusion Processors are programmed to provide operators with plenty of time to
schedule a calibration. However, if the RF-3000LE Electrofusion Processor reaches its calibration
due date, it will stop fusing until it has been calibrated.
When the calibration due date is within 90 days or less, the processor will display reminders whenev-
er the machine is powered on. The calibration reminder will look similar to this:
The processor will countdown the number of days until calibration is due. The text mm/dd/yyyy
shows the month, day, and year that the calibration is due.
To avoid being locked out of the processor, WATTS recommends scheduling a calibration
as soon as it starts to display this reminder message.
On the date that calibration is due, the processor will display, "Error 113: Calibration Required," and
stop fusing until it is calibrated.
When the RF-3000LE Electrofusion Processor displays Error 113, it will not fuse until it has
been calibrated.
To schedule a calibration, please see page 2 for instructions and contact information.
90 DAY REMINDER
Calibration Due On
mm/dd/yyy
PRESS START
General Maintenance
Changing the Fuse
** This section applies to the RF-3000LE Electrofusion Processor only. The Rionfuser™ LT Elec-
trofusion Processor has no external fuse that can be changed.
Important Notes
• The fuse protects the internal electronic circuitry. If the display lights up when power is
turned on, you DO NOT need to replace the fuse.
• This procedure should be performed in a "shop" environment, never a "field" environment.
• The most probable cause of fuse failure is a defective or inappropriately sized generator. If
you have a fuse problem, check your generator first.
Tools Required
• 1/8" Flat Blade Screwdriver
• 5 x 20mm, 250V, 2 Amp Slow Blow Fuse.
Use a Cooper Bussman Fuse Part Number BK1/S506-2-R or equivalent.
Procedure
1. Insert a screwdriver into the slot in the fuse holder cap. Press in slightly while turning count
er-clockwise, then remove the cap. The fuse should come out when the cap is removed.
2. Remove the old fuse and replace it with the new one.
3. Replace the fuse cap by pushing down and turning it clockwise.

IS-OR-Rionfuse CF 2141 EDP# 1915462 © 2021 Watts
Warranty: Our products are carefully inspected for manufacturing defects. However, it is not always possible to detect
hidden defects. Our products are warranted only to the extent that we will replace them without charge if they are proved
to have manufacturing defects within one year of the date of delivery to the site where they are to be used, or installed,
and provided we have been given an opportunity to inspect any product alleged to be defective and the installation or
use thereof.
NO WARRANTY IS INCLUDED AGAINST ANY EXPENSE FOR REMOVAL, REINSTALLATION OR OTHER CONSEQUENTIAL
DAMAGES ARISING FROM ANY DEFECT. THE WARRANTIES SET OUT ABOVE ARE THE ONLY WARRANTIES MADE AND
ARE EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
USA: T: [phone] • OrionFittings.com
Canada: T: [phone] • F: [phone] • OrionFitting.ca
Latin America: Tel: [phone] • OrionFittings.com
NOTICE
Inquire with governing authorities for local installation
requirements.