User Manual Welder
Contents
1. BH PetroTechnik Australia 61 3 95 50 18 74 EH Headquarters 3 EJ PetroTechnik do Brasil 55 II 3159 0909 Petis Technic Lid 3 KU PetroTechnik France 33 I 69 21 41 41 PetroTechnik House z fu PetroTeknik AB 46 8 767 86 34 Olympus Close Whitehouse Industrial Estate 2 ES PetroTechnik Inc 1 201 871 7300 Ipswich Suffolk IPI 5LN Le PAD Japan 81 3 3297 7870 pd LA tel 44 0 1473 243300 fax 44 0 1473 243301 email info petrotechnik com www petrotechnik com Petrolechnik protecting your liquid assets Welder EW8 10V User Manual UPP SYSTEMS NOTE EWG welding cables use special 7 pin connectors 7 Pin Fusion welding cable Power cable NOT regular 4 pin connectors EWS Electrofusion Welder chamber 7 pin Primary welding cable Power on Indicator EW8110V MAN 03 10 06 N 7 pin Secondary welding cable Technical Details UPP Stock Code Number Operating Voltage Operating Frequency Power Rating 7 pin Weld cable Protection Class connector Operating Temperature Shipping Dimensions Sia Bridging cables Shipping Weight x2 Temperature Sensor Fault indicator Weld progress LED s START STOP button EW8 1 10V IOVolts 10 45 to 65Hz I50vA IP65 15 C to 45 C 420 x 340 x 180mm 1 3kg EW8110V MAN 03 10 06 Fault Indicators When an error has occurred during the weld cycle that will have an effect on the succ2. EW has an on off button a weld start button and an LED display showing the weld progress The LEDs can also show any fault conditions that may affect the weld Safety The EWS is designed for usage 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 and 2 Each time it is used check the condition of the machine particularly 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 condition Always check that the power source is within the parameters shown above before using the EW8 Never lift or pull the machine by its power cable or the welding cables Never disconnect welding cables by pulling the cable always pull off the connectors EW8110V MAN 03 10 06 Liability Restrictions All liabilities of the supplier are invalidated in the following cases The EW8 is used outside the indicated application area Non UPP fittings or pipe are used The operator has not been trained to use the EW8 or the UPP system Operating instructions have not been observed Unauthorised repairs or maintenance have been carried out The EW8 has been used outside of its technical
3. fitting See operating sequence step 5 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 Switch off machine and switch on again after 10 seconds If problem persists return EW8 to supplier Application The EW8 is designed to automatically weld UPP Primary and Secondary Containment electrofusion fittings Also using the white 7A welding leads the EW8 can be used to weld the UPP Fusion chamber riser to the chamber base It can be used in ambient temperatures between 15 C and 45 C Only personnel fully trained 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 EW8 automatically recognises the fitting when connected and applies the correct amount of energy for a successful weld The EW8 takes the ambient temperature into account when calculating the energy required to weld correctly lt must therefore 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 at the rear of the unit on the right hand side The EW8 works on standard alternating current and either a mains connection or a generator can be used Generators must have a rated output of at least 4kW and power input must be between 98 and I2lvolts at 45 to 65Hz The
4. photos below 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 It is not possible to do multiple welds on Secondary fittings These can be identified by their smaller terminal pins and require the use of the green welding cables Other Useful Tips Switch off 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 to ambient temperature NEVER RE WELD A FITTING THAT IS STILL WARM EW8110V MAN 03 10 06
5. ess 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 Fault Indicated Power supply failure during weld Stop button pressed during weld Power supply out of limits Ambient temperature out of range No output current open circuit Low output current High output current Meaning The power supply was off at sometime during the weld Supply frequency not between 45 and 65 Hz or Voltage not between 98 amp 21 Volts Temperature of the EW8 is not between 15 c and 45 c Loose connection to terminal pin Loose contact in the welding circuit Faulty fitting Start button not depressed for long enough Resistance value of fitting is too high Too many fittings connected in series Primary mode only Input voltage too low Regulation error in electronics EW8110V MAN 03 10 06 Solution Check and rectify power supply Check plug connection Re weld fitting only after it is allowed to cool to ambient temperature Re weld fitting only after it is allowed to cool to ambient temperature Check and rectify generator output Check mains supply Allow EWS and fitting to cool in the shade Wait for ambient temperature to return to range Make sure connectors are pushed firmly on to terminal pins Check welding cable connection and continuity Replace
6. specification Safety instructions have not been observed Using the EW8 Ensure that the machine is positioned outside hazardous zones 0 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 Action Information on Display Connect the required welding lead to the EW8 Welder PRIMARY fittings RED lead None SECONDARY fittings GREEN Connect welding lead to the UPP fusion fitting s making sure con None nectors are firmly pushed onto Connect the EW8 Welder to a None IODy power supply Switch ON All LEDs light in sequence then green Power LED remains on First weld light comes on then Press orange START button until successive LEDs light up until first weld light illuminates green 100 LED is lit showing weld is complete Disconnect welding lead from 100 LED and Power LED fitting remains on ALWAYS Reset for next weld by holding START button for 3 seconds All LEDs light in sequence then green power LED remains on EW8110V MAN 03 10 06 Multiple Welds In Primary mode the EW68 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 EVV8 in series using the bridging leads provided see
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