EW8 User manual V5.indd
Contents
1. Petrolechnik protecting your liquid assets Hand held Welder EW8 230V User Manual E PetroTechnik Australia 61 3 95 50 18 74 EE Headquarters E PetroTechnik do Brasil 55 11 3159 0909 PetroTechnik Ltd g WE PetroTechnik France 33 69 21 41 41 Petro Technik House fam PetroTeknik AB 46 8 767 86 34 Olympus Close Whitehouse Industrial Estate ES PetroTechnik Inc I 201 871 7300 Ipswich Suffolk IPI SLN z SJ P amp D Japan 81 3 3297 7870 enc UPP SYSTEMS tel 44 0 1473 243300 fax 44 0 1473 243301 email info petrotechnik com www petrotechnik com NOTE EWS welding cables use special 7 pin connectors NOT regular 4 pin connectors 7 pin Secondary welding cable Tu I x 7 Pin Fusion chamber welding cable EVVY8 Electrofusion Welder Power on Indicator ON OFF Switch on side of unit aye jJ EW8 MAN 04 09 06 Bridging cables 7 pin Primary welding cable lt Power cable 7 pin Weld cable connector Fault indicator Weld progress LED s START STOP button Temperature sensor Technical Details UPP Stock Code Number EW8 230V TR Operating Voltage 230v 15 194 to 264v Operating Frequency 45 to 65Hz Power Rating 150vA Protection Class IP65 Operating Temperature 15 C to 45 C Shipping Dimensions 410mm wide x 230mm deep x 200mm high Shipping Weight 3 25kg Operating Requirements WARNING This machine is2. illuminates green 100 LED is lit showing weld is complete Disconnect welding lead from fitting Power LED ALWAYS Reset for next weld by All LEDs light in sequence then holding START button for 3 seconds green power LED remains on EW8 MAN 04 09 06 Multiple Welds In Primary mode the EW8 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 EW8 in series using the bridging leads provided see 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 EW8 MAN 04 09 06
3. ccessful 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 in the mains cable clamp close to the unit 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 4k VW and power input must be between 195 and 264volts at 45 to 65Hz The EW68 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 EW 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 machin
4. e by its power cable or the welding cables Never disconnect welding cables by pulling the cable always pull off the connectors EW8 MAN 04 09 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 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 reguired welding lead to the EW8 Welder PRIMARY fittings RED lead SECONDARY fittings GREEN lead Connect welding lead to the UPP fusion fitting s making sure connec None tors are firmly pushed onto pins Connect the EW8 Welder to a 230v Nore None power supply None All LEDs light in sequence then Switch ON green Power LED remains on First weld light comes on then Press orange START button until first successive LEDs light up until weld light
5. for the electrofusion welding of UPP Systems products only Power Supply This machine must be powered with A good quality 230V AC 50Hz power supply with maximum tolerance of 15 A good quality generator 1500 VA minimum power rating Extension Leads The maximum input lead lengths are as follows 5mm Cable 25m 2 5mm Cable 50m 4 0mm Cable 75m Note All cable must be unwound from the reel to stop inductive heating effects EW8 MAN 04 09 06 Fault Indicators When an error has occurred during the weld cycle that will have an effect on the success 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 freguency not between 45 and 65 Hz or Voltage not between 194 amp 264V 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 I
6. nput voltage too low Regulation error in electronics EW8 MAN 04 09 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 EW8 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 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 su
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