UPP Piping Systems - Franklin Fueling Systems
Contents
1. small end first Cut Secondary Pipe 2 Trim or slide the secondary pipe back 40 mm En Slide Reducer on Secondary 8 Ensure elbow or tee primary spigots measure 30 mm 1 346 and cut to length if required Trim or Slide Secondary 3 Prepare primary and secondary pipe using hand scraper 4 Secondary pipe must be scraped all the way up to 150mm 6 0 from its end Measure Primary Spigots Scrape Secondary 10 9 Prepare Primary and Secondary spigots of 15 Before welding check that the secondary tee elbow with hand scraper containment reducer is fitted in correct location over scraped zone of secondary pipe 16 Weld Primary couplers 17 Once weld is complete allow to cool for at least 30 minutes 18 If needed do not weld the secondary until the primary piping has been inspected 19 Clean inside of reducer spigot and outside of the Tee Elbow spigots with acetone Scrape Primary and Secondary 10 Clean Primary spigots of tee elbow with acetone 11 Clean Secondary spigots of tee elbow with acetone Clean Inside of Secondary 20 Slide reducers into place ensure full insertion 21 Weld secondary 22 Allow to cool for at least 30 minutes before putting any stress on the joint Clean with Acetone 12 Clean primary welding coupler using acetone 13 Fit couplers to primary Tee Elbow spigots Assembled Secondary Fittings Clean Weld Coupler with Acetone 142. 5 Electrofusion Preparation Detalls aaaaaaaaaaaaaannna nunnunnununnnunuunnnnnunnnnnunnunnnnnunnunnunnna 6 CUINA PILLE c 6 A e A US 6 E ln e EE 7 Mark Merton Depas dr P 7 Marking Insertion Depth by Prettingen 7 EE ln Tue s s a 8 Welding a ak AN ii 8 very Weld Complicado dni 9 Welding Secondary Containment Pipe And Fittings 10 Overview The polyethylene construction of UPP pipe allows all connections to be joined using an electrofusion welding process This provides a joint which is stronger than the pipe itself and with no leak paths Electrofusion is carried out quickly and simply using specialist tools available from FranklinFueling A large variety of electrofusion fittings are available from simple couplers for making in line pipework joints to welded terminations for terminating double wall secondary containment pipework and entry seals Installation Guidelines Follow the guidelines below to insure a successful installation All pipe must be cut square All pipes must be scraped to remove the oxidation area before Electrofusion All Spigot fittings supplied un bagged must be scraped to remove the oxidation area before electrofusion Pipes fittings and sockets must be cleaned with acetone where they join All joints should have the pipe inserted into the electrofusion fitting ensuring that th
3. Insert Primary pipe into welding couplers ensure pipe is fully inserted Insert Primary Pipe into Coupler 11 OFFS 2011 408001007 Rev1 Franklin Fueling Systems www franklinfueling com 3760 Marsh Road Madison WI 53718 U S A Tel 1 608 838 8786 Fax 1 608 838 6433 Tel USA 8 Canada 1 800 225 9787 e Tel M xico 001 800 738 7610 Franklin Fueling Systems GmbH Rudolf Diesel Strasse 20 e 54516 Wittlich GERMANY Tel 49 6571 105 380 e Fax 49 6571 105 510 Franklin Fueling Systems LTD 8 Olympus Close Whitehouse Industrial Estate Ipswich Suffolk IP1 5LN United Kingdom Tel 44 1473 243300 Fax 44 1473 243301
4. 0 ElF 7 Electrofusion elbow 90 03 110 ElF 9 Electrofusion elbow 45 04 063 ElF 4 Electrofusion elbow 45 04 090 EIF 7 Electrofusion elbow 45 04 110 EIF 9 Electrofusion equal tee 08 050 EIF 4 Electrofusion equal tee 08 063 EIF 4 Electrofusion equal tee 08 090 EIF 7 Electrofusion equal tee 08 110 EIF 9 Electrofusion reducer 09 090 063 EIF 5 Electrofusion reducer 09 110 090 EIF 7 Electrofusion entry seal 302 Flange Electrofusion entry seal 303 Flange 2 Straight Clamp Installed Electrofusion entry seal 305 Flange 3 Electrofusion entry seal 308 Flange 3 Welding Cables Chart Size of Welding Current Pim mm Weld Time 20C Seconds Type Welding of Cable Fitting Colour Primary Re 4 Note Aresistance value of X means that there is no marked resistance value on the fittings and these should be treated as having values of 10 Secondary Fusion Chamber Large Diameter IOamp Connect the leads from the welding unit to the fittings per the chart above The leads should fit firmly It is very important to use the correct cable Welding Process After the welder is turned on press the start button to begin the welding process The weld time is determined by the welder and no further input is required Note Before pushing the start button the welder must show a green ready light Hold the start button down momentarily and then release it The welder display will show welding progress Once comple
5. 03 090 EIF 03 110 EIF 2 7 16 45 Elbow 04 063 EIF Electro 04 090 EIF 2 7 16 fusion 04 110 EIF 2 3 4 Marking Insertion Depth by Pre Fitting The insertion depth can also be marked by inserting the cleaned pipe fully into the fitting and marking around the fitting Marking Insertion Depth Inscribe a line around the junction of the pipe and fitting Note When using this method make sure the pipe is fully inserted Visually check if possible or listen feel for the pipe positively contacting the stop Clamping Check for correct alignment of the assembly both vertically and horizontally and ensure that it is not subjected to any bending load or weight that could deform to the joint while it is in a molten state Use UPP clamps to keep the assembly in the correct alignment position preventing any movement during the welding and subsequent cooling process If a clamp cannot be used for example in a small tank chamber precautions need to be taken to ensure that the assembly is not under any stress Welding Overview UPP 230 volt and 115 volt intelligent Welding Units supply the precise electrical energy to fuse two UPP products together safely on site The heat causes the pipe and joint surfaces to melt and fuse After electrofusion the assembly is left to cool while the polyethylene solidifies to form a homogenous union stronger than either pipe or fittings Note UPP welders use a constant current outp
6. T use these welders with other manufacturer s piping or fittings Chemical Safety Where using chemicals such as Acetone during the installation of UPP systems products be sure to follow all safety guidelines given on the chemical containers themselves or on any accompanying literature Confined Space e Some installation of UPP products may occur in confined spaces where a lack of oxygen and a concentration of toxic vapors is likely to be experienced Such working conditions are dangerous and all local health and safety guidelines for working in such environments should be followed Material Handling Protective Equipment Ensure the correct personal protective equipment PPE is used at all times in line with local health and safety requirements Material Safety Data Ensure all safety data is accessed and used while installing UPP Systems Material Safety Data Sheets are available in the download area of the UPP website Transport amp Storage UPP products should be transported and stored in accordance with the guidelines contained in Section 1 Heavy items Heavy items should be handled using suitable lifting equipment operated by authorised personnel Contents Sal Vi aa k aaa tas A l anes S NI II LIC M I II 2 OVETVICW iiai 4 installation Gurdellli8S osa 4 Electrofusion InstFile Ori serca co cena sebo e dodo 4 Electrofusion Procedure OvervieWw aaaaaaaaaaaaazaananunnnnnnunnnnnnnnnunnnnnnnnnnnnnnnnnnununnnnnnnnnna
7. d i Franklin Fueling Systems UPP Piping Systems Electrofusion Welding Instructions Franklin Fueling Systems 3760 Marsh Rd Madison WI 53718 USA Tel 1 608 838 8786 800 225 9787 Fax 1 608 838 6433 www franklinfueling com Safety Important UPP Systems must only be installed by fully trained and certified installers Failure to follow installation instructions will invalidate warranty and installer certification Electrofusion Safety e UPP Welding Units must never be operated in Zone 1 or Zone 0 areas Hazardous area definitions are from European Directive 1999 92 EC and guidelines can be found in the APEA Blue Book 2nd Edition Ensure Welding Units are connected to a power supply that meets the requirements detailed in the user manual and are within the requirements of any local authority or regional legislation e An important requirement of any type of piping system is to safely connect all metallic components to ground Metallic components and more general conductive materials due to their high capacitance can have the potential to store a high amount of electrostatic energy sparks discharge can only be observed over conductive elements All exposed metal parts used in UPP System installations should be adequately grounded to a dedicated earth ground electrode and brought to a potential equal to that of other metal parts in the close proximity Use ONLY FFS EF1 110 or EF1 230 welders with UPP Piping Do NO
8. e marked insertion depth is reached Joints must not be under any stress during welding or until ambient temperature is reached after welding Electrofusion Instruction Organise all necessary tools and equipment on the job site prior to commencing the installation of pipe and fittings The basic installation tool set should always include UPP Electrofusion welder Pipe cutter Pipe Scraper Cleaning Solvent e Straight and angled clamps Permanent marker or Chinagraph pencil white yellow or red e Tape measure Refer to the following sections for more detailed information on the above tooling Electrofusion Procedure Overview Measure and cut pipe to required length Use one of the scraping tools provided in the allowing for correct insertion depth into UPP installation box to prepare the pipes and welding coupler fittings for welding Clean scraped areas of pipe fitting using a Measure and mark pipe to indicate correct lint free cloth moistened with Acetone insertion depth into fusion fitting Clean bore of the welding coupler with Acetone Assemble the joint and hold in place with clamp Check that insertion is up to the marked depth indication Connect welder to clamped assembly and e Check insertion depth mark for movement follow welding unit instructions Ensure e Check that welding completion indicators are out appropriate welding cables are used e Allow joint to cool to ambient
9. ilt into them these do not require scraping before being used but must be cleaned with a solvent See below Cleaning To ensure that there is no grease moisture or dirt in the electrofusion zone during welding it is important to clean all the pieces of the assembly prior to welding The following solvents may be used Acetone preferred sopropyl alcohol e richloroethane po Using An Acetone Soaked Cloth To Clean A Welding Socket and Seal Spigot Do NOT USE solvents that leave an oily film on the joining surface such as turpentine petrol or synthetic dilutents The surfaces to be cleaned include All scraped areas of pipes and fittings The inside of electrofusion fittings and welding couplers Once the areas of pipes and fittings to be welded have been wiped clean avoid touching the cleaned areas or allowing contact with any sources of grease dirt Note In wet weather protect the fittings from water Water in the fittings can contaminate the welds and cause failures Mark Insertion Depth Mark the insertion depth on pipe ends using a permanent marker or China graph pencil and a ruler Using a Ruler to Mark Insertion Depth The following table shows the correct insertion depth into UPP primary electrofusion fittings Insertion Length Inches Product Description Code mm Welding Coupler 90 Elbow 03 050 EIF Electro 03 063 EIF fusion
10. ted it is good practice to write the time on the fitting to determine when clamps can be removed Wait 20 minutes for the weld to cool before removing clamps Resetting the welder Always reset the welder between welds by depressing and holding the start button for 3 seconds Verify Weld Completion The first indication of a successful weld is that the welder s green 100 LED is lit Most fittings have a weld indicator built in After the weld the center of the indicator should protrude above the surrounding area eld Indicator Before welding Weld Indicator After welding SE EE Ec Weld Indicator Completed Look in the Tightness Testing Section for complete inspection procedure Troubleshooting Refer to the welder documentation for complete welder operation and error codes f power is lost during the weld allow the fitting to cool in place for at least an hour and then restart the weld process Welding Secondary Containment Pipe And 5 Clean primary pipe end with acetone Fittings Green welding cables should be used for welding secondary containment pipe e Some welding unit displays will read Secondary Mode and after five seconds Connect welding element Procedure 1 Cut Co axial pipes to required length using the pipe cutter as shown Clean Secondary with Acetone 6 Pre clean secondary pipe 200 mm 8 0 from end 7 Clean reducer with acetone and slide it along secondary pipe
11. temperature Wait at Note Case mounted EF1 110 shown EF1 230 least 20 minutes before any stresses are exerted Handheld welder can also be used upon the assembly Electrofusion Preparation Details Cutting pipe Primary pipe single wall pipe Cut primary pipe only by using the appropriate UPP pipe cutter tool and never using a hand saw The UPP cutting tool gives 100 straight cuts every time and no burring ensuring that the cut ends fit flush into any welding couplers or fittings A paa Cutting primary pipe using UPP cutting tool There are two different pipe cutters available for varying pipe diameters Pipe Diameter Pipe Diameter 199 mm inches PCUT 50 110 1 2 4 PCUT MED 110 160 4 6 Secondary containment pipe double wall pipe e Cut secondary containment pipe in exactly the same way as primary pipe using the UPP pipe cutting tools When cutting coaxial pipe it is possible to cut through both pipe layers in one go Be careful of this if you want your primary pipe length longer than the secondary sheath inside sumps and chambers etc H i d a Cutting Secondary Pipe Using UPP Cutting Tool Duct pipe e tis not possible to cut UPP corrugated duct pipe using the UPP pipe cutting tools A hand saw should be used to cut the duct using the corrugations as guides to help create a clean straight cut Scraping It is imperative that the scraping of pipes and fittings is carried o
12. ut UPP components must never be welded with other brands of welding unit Both types of welder can be used from the mains supply or from a generator The welding machine measures the ambient temperature and the welding coupler electrofusion fittings resistance values The welder must be close to the same temperature as the joint it is welding Bridging A maximum of three primary couplers or primary electrofusion fittings may be welded at the same time by using bridging leads Most electrofusion couplers and fittings have a resistance index number marked onto them inside a circle i e The total value of the index number of the three items to be welded must not exceed 10 If the fitting lacks a resistance index number then it must be treated as having an index number of 10 A list of resistance numbers can be seen in the following table Screw Clamps The screw clamps on some fittings are used to hold the pipe in place for clamping The piping may have a pre load force that could pull the pipe out slightly before clamping Tighten the screws to hold the piping in place while the clamps are installed Description Part number a Primary welding socket 02 50 2 Primary welding socket 02 63 2 Primary welding socket 02 90 4 Primary welding socket 02 110 6 Primary welding socket 02 160 10 Primary welding socket 02 200 10 Electrofusion elbow 90 03 050 EIF 4 Electrofusion elbow 90 03 063 EIF 4 Electrofusion elbow 90 03 09
13. ut exactly as described here to remove the layer of oxidised material that builds up on the pipe when it is exposed to air This oxidised layer hinders the quality of the weld and must be removed Note NEVER under any circumstance use sand paper on primary or secondary pipe Primary pipe single wall pipe Primary pipe must be scraped using the UPP scraping tool These tools remove a controlled outer layer of oxidised polyethylene over the length of the pipe which is inserted into a coupler or electrofusion fitting Scraping UPP Primary Pipe Using Scraping Tool Secondary containment pipe double wall pipe e Secondary containment pipe has to be scraped using the UPP hand scraper SCR HAR A layer of plastic must be removed all along the length of pipe to be inserted into the welding coupler or electrofusion fitting Scraping UPP Secondary Pipe Using Hand Scraper Non Electrofusion Fittings Non electrofusion fittings i e those that need an electrofusion coupler to be welded if supplied Un bagged must be scraped with the UPP hand scraper before welding Scraping UPP Non Electrofusion Fitting with Hand Scraper The polyethylene area of these fittings must be scraped using the UPP hand scraper to remove a layer of oxidised polyethylene along the whole length that is to be inserted into the welding coupler Electrofusion Fittings Welding Couplers Electrofusion fittings are those with welding elements bu
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