EHF350

OPERATOR’S
MANUAL

DIXON INDUSTRIES PTY LTD

ABN 89 008 171 855
17 Frederick Road, Royal Park, South Australia, 5014.Tel: +61 8 8240 1555. Fax: +61 8 8240 5588
Email: sales@dixonind.com.au,
 EHF350 electric hydraulic butt welder
Simply Better.

1. Safety considerations ...............................................................................................................................3

2. Machine Description.................................................................................................................................4
2.1. General Specification ...........................................................................................................................4
2.2. Hydraulic System .................................................................................................................................5
2.3. Heater Plate .........................................................................................................................................5
2.4. Facer ....................................................................................................................................................5
2.5. Reducing Liners ....................................................................................................................................5
2.6. Accessory Case.....................................................................................................................................5
2.7. Fittings Attachment .............................................................................................................................6
2.8. High Pressure Welding .........................................................................................................................6
3. Using the EHF350 – single pressure low pressure method.......................................................................7
3.1. Preparation ..........................................................................................................................................7
1.2. Pipe Alignment ....................................................................................................................................7
3.2. Drag Pressure.......................................................................................................................................7
3.3. Facing ...................................................................................................................................................7
3.4. Re-Check Pipe Alignment .....................................................................................................................8
3.5. Bead Up ...............................................................................................................................................8
3.6. Heat Soak .............................................................................................................................................8
3.7. Fusion Cycle .........................................................................................................................................8
3.8. Weld Quality Check..............................................................................................................................8
4. EHF350 Maintenance - Daily.....................................................................................................................9
4.1. Maintenance - Daily Check List ............................................................................................................9
5. Maintenance - Periodic.............................................................................................................................9
5.1. General/Drag .......................................................................................................................................9
5.2. Heater Plate .........................................................................................................................................9
5.3. Heater Temperature Adjustment ........................................................................................................9
5.4. Temperature Calibration ...................................................................................................................10
5.5. Heater Non-Stick Cloth Replacement ................................................................................................10
5.6. Heater failure .....................................................................................................................................10
5.7. Jammed Sensor Bulb..........................................................................................................................11
5.8. Operating Pressure ............................................................................................................................11
5.9. Pressure Gauge Calibration ...............................................................................................................11
5.10. Synchronising The Carriage Cylinders ................................................................................................11
5.11. Hydraulics Bleeding Method ..............................................................................................................11
5.12. Facer Drive .........................................................................................................................................12
5.13. Facer Bronze Roller Replacement ......................................................................................................12
5.14. Cutter Blade Sharpening ....................................................................................................................13
5.15. Eccentric Alignment Mechanism Repairs...........................................................................................13
5.16. Damaged Eccentric Toggle Stud Thread ............................................................................................13
5.17. Seized (Front Or Bottom) Eccentric Assembly ...................................................................................13
5.18. Seized (Rear Or Top) Eccentric Assembly ..........................................................................................14
6. Notes About Heater Plates And Temperature ........................................................................................15
6.1. PE Welding Temperatures .................................................................................................................15
6.2. Heater Plate Temperature .................................................................................................................15
6.3. Measuring Surface Temperature .......................................................................................................15
7. Butt Welding Guidelines .........................................................................................................................16
8. Weld Failure Trouble Shooting ...............................................................................................................16
9. Warranty.................................................................................................................................................17
10. Machine Assembly Drawings .............................................................................................................18
11. Butt Welding Tables (single pressure, low pressure) .........................................................................27
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1. Safety considerations
Know the machine
This machine should only be used by an operator fully trained in its use.
Read these operating instructions carefully. Learn the operation, limitations and potential
hazards of using your butt fusion machine.
Avoid dangerous environments
The equipment is not explosion proof. Never carry out butt fusion in a gaseous or combustible
atmosphere.
Electrical safety
Use only a qualified electrician to carry out electrical maintenance work.
Connect electrical components only to a voltage source that corresponds to that marked on the
components.
Do not operate the electrical equipment in damp or wet locations.
Prevent electric shock by correctly grounding electrical components. The green (or green/yellow)
conductor in the electric cable is the grounding wire and should never be connected to a live
terminal. The use of earth leakage protection with portable electric tools is essential and must be
provided by the user.
Heater
The heater operates at over 200°C and contact can cause serious burns. Always wear gloves
when handling the hot plate.
The heater is supplied with a short extension cord that has a high melting point outer sheath.
This will delay, but will not prevent, the inevitable life threatening situation which could occur if
the cord is allowed to contact the hot plate and melt through.
Never use a standard appliance cord with low melting point PVC sheath.
Facer
The facing machine is powerful and the cutting blades are sharp. To prevent injury the facer
should only be operated when it is securely located in the pipe cutting position.
The nature of the machine and welding process makes it impractical to guard the operational
area. Do not attempt to remove shavings from the cutting area while the facer is running.
Remove loose clothing or jewelry to prevent these items being dragged into moving parts.
Hydraulic pressure
A sudden hydraulic oil leak can cause serious injury or even death if the pressure is high enough.
Do not search for oil leaks with the fingers because a fine jet of pressurised oil could penetrate
the skin causing serious injury. Use a piece of cardboard to test for leaks under pressure.
Avoid spraying oil into eyes when bleeding air from the system by wearing safety glasses and
keeping the face clear of the area.
Keep fingers and limbs well clear of moving clamps, facer or heater to avoid crush injuries.
Maintain equipment carefully
The machine has moving parts and/or parts that may deteriorate with age and require
maintenance. Regular inspection is recommended. For best results keep all machine components
clean and properly maintained. Always disconnect the power when adjusting, servicing or
changing accessories. Repair or replace damaged electric cables.
Transporting the machine
Dixon equipment mounted on wheels is not designed for on-road towing. Any attempt to do so
could result in machine damage and/or personal injury. Transportation should be by truck or
similar, with the machine well secured. Do not allow the heater plate to contact the facer.

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2. Machine Description
The FUSIONMASTER® EHF350 is designed for
“single pressure – low pressure” butt welding
of pipe from 355mm down to 110mm. It is a
compact and manoeuvrable butt welding
machine, ideally suited to joining PE pipe to
pipe in the field.
The EHF350 machine strength is derived from
its rigid steel main frame, hard chromed steel
guide shafts, and high strength cast
aluminium alloy clamps.
Two double ended hydraulic cylinders
mounted along the axial centre line provide
inherent rigidity and a balanced application
of welding pressure.
The clamps are designed for side loading of pipe, which facilitates the removal of the machine
from a completed pipe joint and especially from trench work. Pipe alignment is simply achieved
by adjusting the unique eccentric cam mechanisms attached to the fixed clamps.
Four pneumatic tyred wheels positioned close to the centre of the machine make it very
manoeuvrable. The wheel assemblies are easily removed for trench work or transportation. Two
lifting holes in the main frame end plates enable overhead lifting.

2.1. General Specification

Machine dimensions
Main clamp bore 355 mm
Length overall 1,230 mm
Width overall 690 mm
Height overall (wheels attached) 1,030 mm
Component Weights
Butt machine with facer 150kg
Heater plate 12kg
Facer 11kg
Fittings chuck 8kg
Heater/Facer stand 8kg
Reducing liner sets 5kg (min.) to 13kg (max.)
Liner carry case (empty) 11kg
Liner carry case (loaded) 45kg
Hydraulic Specifications
Cylinder area for weld calculation 1,233 mm²
Power pack 0.37kW, 240V, single phase, 26kg
Relief valve setting 9,500kPa
Pressure gauge 0 - 10,000kPa
System oil capacity 3 litre
Recommended hydraulic oil Any brand with viscosity ISO 46
Heater plate 1400W, 240V, single phase
Recommended genset for field operation. 5kva, 240V, single phase
Recommended grease for facer drive Shell Alvania EP/LF2

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2.2. Hydraulic System

A portable electric hydraulic power pack applies pressure to the hydraulic cylinders to transport
the moving clamps.
The maximum machine pressure is factory set by adjusting a pressure
relief valve located inside the oil tank.
Three pressure regulators control the Carriage Cylinder Pressure
during the fusion process. The regulators allow the operator to
independently preset facing pressure, bead-up and/or welding-
cooling pressure or drag pressure, depending on how the operator
prefers to work. During travel in the reverse direction (clamp
opening), the regulators do not control pressure, nor does the gauge register pressure.
A 3-way selector allows the operator to easily choose one of the pre-set pressures during the
weld process.
Carriage motion direction is controlled by pushing the directional control valve lever in the
required direction of travel.

2.3. Heater Plate

The 2400 watt, 240v, single phase aluminium heater plate has a cast in circular element to ensure
uniform heat distribution. Temperature is controlled by an adjustable thermo-mechanical
controller, and a LED indicates when power is flowing to the element. A dial thermometer
indicates internal plate temperature. (Refer section on heater technology.) It takes less than 18
minutes to heat up to working temperature.
Replaceable non-stick cloths are fitted to the heater surfaces to eliminate hot plastic adhesion.
They are secured by snap rings enabling quick and easy field repair if the surface is damaged.
The detachable 1.8m electric cord has a high melting point outer sheath for protection against
short periods of accidental contact with the heater.
During welding the heater is stored in a floor stand, which is attached to the machine frame for
transportation.

2.4. Facer
The facer is integrally mounted on the machine frame, providing effortless machining of pipe
faces. The facer is driven by a 2 speed, high torque electric drill (1150W, 240V, 50hz). It has a
single blade on each cutting face and can cut pipe from 355mm outside dia. to 75mm inside dia.

2.5. Reducing Liners

Each reducing liner size consists of 2 plain rings and 2 narrow rings.
When welding pipe to pipe the plain rings are usually mounted in the
inner two clamps, with the narrow rings in the two outer clamps. The
narrow rings are for clamping short leg moulded fittings and must be
placed in the inner clamps when welding elbows.
The wide liners from 110mm to 180mm nest inside 200mm liners. All
the narrow liner sizes fit directly into the main 355mm clamp.
Reducing liners can be manufactured to suit any pipe size from 324mm
(12” imperial) to 110mm, in either metric or imperial dimensions.
Note: The EHF350 is not able to hold 355mm short leg moulded
elbows or most short leg moulded Tees. Such fittings should
be purchased with long leg lengths to enable the Tee or elbow
section to protrude beyond the end clamp.

2.6. Accessory Case

Steel carry cases are available for storing reducing liners. Each case holds up to three sizes.

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2.7. Fittings Attachment

The fittings attachment tool is used when butt welding stub flanges or shouldered end fittings to
pipe. It is usually held in the inner 355mm main clamp on the hydraulic cylinder side. The tool
centrally locates flanges or shouldered ends quickly and accurately. It will securely hold the fitting
either by the outside or inside diameter depending on the fitting size.

2.8. High Pressure Welding

The EHF350 is not designed for high pressure welding. However the high pressure method may
be used providing the combined welding + drag pressure for a particular job falls within the range
of the fitted pressure gauge.

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 EHF350 electric hydraulic butt welder
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3. Using the EHF350 – single pressure low pressure method

3.1. Preparation
1. Connect only to a 240v, 50Hz power source. Ensure the output of any portable
generator used is 240v ± 20v.
2. Check for air in the hydraulic system and bleed if necessary (see maintenance
section).
3. Clean and/or replace the non-stick cloths. Clean the heater plate before every
weld with clean dry paper or cotton cloth - never use synthetic materials that may
melt.
4. Check, and if necessary adjust the heater surface temperature.
5. Install the correct reducing liners for the pipe to be welded.
6. Check the facer cutting action (the shaving thickness should be 0.30-0.40mm).
7. Before facing, clean inside and outside of each pipe end, and the cutter blades.
8. Record the drag pressure from the pressure gauge before every weld.
9. Add the drag pressure to the calculated pressure to determine the appropriate
bead up and fusion gauge pressures.

1.2. Pipe Alignment

Place the pipes in the clamp jaws with about 30mm of pipe extending past the clamps into the
TIP
weld zone. Tighten the clamp toggle bolts securely using a shifter to prevent the pipe from
Put the top clamp
moving when under hydraulic pressure. The outer ends of the pipe should be supported such
over the pipe, then
that any external bending loads on the machine are eliminated and drag pressure is minimised
engage the bottom
toggle bolt and Move the pipe ends together until they are almost touching, then check for misalignment
hold it in place, (maximum allowable misalignment is 10% of wall thickness). Reduce any misalignment to an
then engage the acceptable amount by adjusting the top and bottom fixed clamp eccentric adjusters.
upper toggle bolt,
(Adjustment will not be possible if the pipe ends are in contact and under pressure.)
then tighten the
toggle nuts. Move the pipe end clear of the weld zone and record the drag pressure. Add this value to the
fusion pressure required to join the pipe (refer welding table).

3.2. Drag Pressure

"DRAG" is the amount of pressure required to overcome carriage friction plus the effort required
to move the pipe. As drag pressure is a variable, it must be measured before every weld.
To determine the drag pressure, open the directional control valve and observe the pressure at
which the carriage just begins to move. The EHF350 drag pressure without pipe loaded should be
in the range 200-800kPa.
If drag pressure is excessive it may adversely affect the weld. Drag may be reduced by one or
more of the following actions:
1. Use a low friction pipe support/roller system.
2. Ensure the pipe support/roller system maintains the whole length of the pipe level
with the machine base to prevent bending forces acting on the machine frame.
3. Minimise the amount of pipe being pulled. Welding machines are not designed to
pull multiple lengths of pipe.
4. Ensure the heater/facer rest bar does not obstruct carriage movement
All of these techniques are always important, but become critical when working near the limits of
machine capacity.

3.3. Facing
Move the pipe ends apart and insert the facer. Ensure the facer retaining hook latches on to the
rest bar to prevent the facer from jumping out of the machine during the facing operation.

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Start the facer rotating. Move the pipe ends into contact with the facer and apply the minimum
pressure necessary to achieve cutting until a continuous shaving of plastic is simultaneously
produced from both sides of the facer.
Caution: To maximise drill and facer drive life, operate the drill at low speed (for maximum
torque), and do not apply excessive carriage pressure – e.g. never exceed 2,000 kPa
more than drag.
On completion of facing, reverse the pipe carriage away from the facer then stop facer rotation.
This prevents a step being produced in the faced ends. Raise the facer up and fully out of the
machine.

3.4. Re-Check Pipe Alignment

Clear away all plastic cuttings without contaminating the pipe ends. Do not touch the cut surface
or re-clean it. Move the pipe ends together and re-check pipe alignment (maximum allowable
misalignment is 10% of wall thickness).
Always re-face the pipe ends if it becomes necessary to rotate the pipe in the clamps after initial
facing.

3.5. Bead Up
Check the heater plate temperature before commencing each joint in case there has been any
failure of the power supply or temperature controller.
Place the heater plate between the pipe faces.
Move the carriage to bring the pipe faces into contact with the heater plate. Increase pressure to
the predetermined “bead-up” pressure.
Maintain pressure until an initial bead has formed completely around the pipe circumference on
both sides of the heater plate. The bead up time is variable, and is influenced by weather
conditions and pipe dimensions.

3.6. Heat Soak

After bead up, reduce the pressure down to the drag pressure to maintain a slight positive
pressure between the pipe and the heater for the heat soak period. Failing to reduce pressure
forces hot plastic out of the joint zone and could lead to a weld failure.
On completion of heat soak time, reverse the carriage direction to “crack” the heater plate away
from the melted pipe, then move the heater plate out of the weld zone as quickly as possible.
(Refer to parameters table for allowable changeover time).
The unique non-stick cloths allow a "peeling off" action as the pipe is cracked away, minimising
adhesion of the melted pipe to the heater.
Caution: Do not allow the heater plate to slide across the pipe ends and distort the melted
surface. Do not contaminate the melted surface in any way.

3.7. Fusion Cycle

Bring the melted pipe faces into contact with each other immediately to minimise heat loss from
the weld zone. Smoothly build up to the required fusion pressure to avoid squeezing out too
much hot plastic.
Unless hydraulic pressure is maintained while the weld is cooling, shrinkage will occur and voids
may form in the weld zone. It is essential to run the pump and maintain the pipe under pressure
in the clamps until the weld/cooling time is complete.

3.8. Weld Quality Check

Inspect the uniformity of the bead size inside and out, top and bottom of the pipe. It is advisable
to monitor and record times, temperatures and pressures at each phase of every joint for future
reference. (See section on trouble-shooting weld failures.)

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 EHF350 electric hydraulic butt welder
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4. EHF350 Maintenance - Daily

4.1. Maintenance - Daily Check List
1. Keep the machine and accessories clean and free of dust and grease. Do not
lubricate any HF350 components except for the facer drive (see later).
2. Inspect hydraulic components for leaks from connections and seals. Overhaul
seals and fittings as necessary.
3. Check for air in the carriage cylinders (as evidenced by shuddering, and/or
“springing back” of the cylinders). Air in the hydraulics will adversely affect weld
quality and must be removed by bleeding (see later).
4. Check the pressure gauge needle returns to zero and does not stick.
5. Check the temperature of a number of points on the surface of both sides of the
heater plate. The reading at any point on either side of the heater plate surface
should not be more than ±10°C from the desired welding temperature. (Refer
later section on heater plates.)
1. Do electrical safety checks.
2. Replace non-stick cloths if damaged in way of the weld area.
3. Facing blades should be sharp and have defect free cutting edges to provide
continuous shaving thickness of 0.30-0.40mm. Shim worn blades if necessary;
sharpen cutter blades if blunt; replace cutter blades if chipped.
4. Ensure the facer drill is securely fixed into the facer body casting, if not the drive
gears may not mesh properly causing extensive damage.
5. Feel for “sloppy” movement of the cutter plates. This indicates the need to adjust
the facer drive internally.
6. If using a portable generator, ensure its output is 240v ± 20v and 50hz, to protect
electronic equipment from permanent damage.

5. Maintenance - Periodic
In addition to the daily checks, more detailed inspections of the key machine components should
be carried out before commencing each new project, or after 250 operating hours. Any faults
found should be corrected as described in this section.

5.1. General/Drag
Check the hydraulic cylinder shafts for cuts or dents likely to damage the hydraulic seals.
Check the machine frame, main carriage guide shafts, hydraulic shafts and heater rest bars are
not damaged or bent such that excessive drag pressure results. Without pipe in the machine,
drag pressure should not exceed 1200kPa

5.2. Heater Plate

Heater surfaces should be flat, smooth and free of dents or gouges. Dress as necessary.
FUSIONMASTER® heater plates have a vent machined in the edge of the casting to allow
entrapped air to escape from under the non-stick cloth. Clean out any build-up of foreign
material from the air vent to prevent any adverse temperature effect.
Caution: Ensure heater plate non-stick surfaces are protected from damage during transport.

5.3. Heater Temperature Adjustment

The temperature setting of the EHF350 heater is controlled by turning the adjusting screw on the
top of the heater handle, clockwise for higher temperature, and anticlockwise for lower
temperature.

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5.4. Temperature Calibration

The thermometer in the heater plate indicates the internal plate temperature not the surface
temperature, although the difference will not be great.
It is essential to check and record the surface temperature of the heater plate before every weld.
This is best measured with either a contact pyrometer or a non-contact infrared pyrometer. The
outer circumference of the heater should not be measured as this is too far from the weld area.
The pyrometer used to measure surface temperature will itself require calibration to a procedure
as recommended by the pyrometer manufacturer.
Caution: Be aware that an insulating air gap can form between the Teflon cloth and the hot
plate. Always ensure the cloth is forced into contact with the hot metal surface when
using an infrared or non-contact pyrometer or a false reading is likely to occur. Never
use an infrared pyrometer on a shiny surface as a false reading will occur.

5.5. Heater Non-Stick Cloth Replacement

The non-stick cloths should be replaced if they are torn, contaminated, or badly discoloured (due
to overheating) or lose their non-stick ability.. Use the following procedure.
1. Use a screw driver to lever the snap rings out of their securing grooves. This takes
very little force. Do not attempt to remove the snap rings if the plate temperature
is more than 40°C because they will not release.
2. With the plate flat, place a new cloth into position and reposition the snap ring
over the cloth.
3. Push the snap ring into the groove around an arc of the plate. Hold in position
with one hand. With the free hand, use a piece of wood or plastic to force the
snap ring completely into its groove. (This may take several attempts until some
experience is developed.) Never use metallic objects to force the snap rings back
into position as this may result in accidental damage to the cloth.

5.6. Heater failure

If the heater does not power up, check for damage to leads or connectors, or failure of the
temperature controller (thermo-switch), or failure of the element pad. Refer to heater drawing.
1. Always first test the power supply and the power cord on some other appliance to
ensure those items are not at fault.
2. Use an electrician to test the heater element and the thermo-switch. The element
resistance should be 24 ohms ± 10%. If there is a short circuit, or open circuit, the
element pad must be replaced. If the element, leads and connectors are OK, check
the thermo-switch.
3. To check the thermo-switch turn the adjusting screw and listen for an audible click
as it switches. Placing a meter across the terminals will also show a change in
resistance as it switches. If this doesn’t happen the switch is faulty. Replace as
necessary.
4. To remove the thermo-switch:
• Remove the four screws securing the Bakelite handle to the heater bracket.
• Disconnect the 4 conductors (2 quick connect, 2 screw lugs) and remove
the earthing connectors.
• Remove the four socket head cap screws which secure the heater bracket
to the heater plate.
• Remove the two 3/16" hex drive countersunk screws that retain the
thermo-switch. Turn the thermo-switch adjustment screw fully counter-
clockwise to enable its removal from the rubber grommet in the handle
case. Extract the thermo-switch from the heater bracket and carefully
withdraw the element leads, copper capillary tube and sensor bulb from
the casting. Do not damage the capillary tube.
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• Inspect insulation, wiring and connectors for damage. Repair as necessary.

5. Before refitting the thermo-switch, apply some silicon heat sink compound
sparingly to the sensor bulb for improved thermal sensitivity.
6. To refit the thermo-switch, reverse the removal procedure taking care not to
pinch or damage the capillary tube, sensor bulb, or electrical insulations. Ensure
the earthing conductors are reconnected.
7. Plug the power cord into the handle and switch on. The neon should light
immediately, indicating power on. When first fitted, allow 20 minutes for the
heater to reach temperature and to stabilise, before making any adjustments.
Always allow several minutes for the plate temperature to stabilise after making
any adjustment.

5.7. Jammed Sensor Bulb

If the sensor bulb becomes jammed in the heater casting, it will need to be drilled out using a
9.8mm long series drill. Drilling depth is 160mm below the top face of the heater casting.
Caution: Use exactly a 9.8mm drill or the bulb will be too loose to allow good heat transfer
from the casting. This will adversely affect temperature control. Drilling deeper
than 160mm could damage the electric element.

5.8. Operating Pressure

Start the hydraulic pump and note the gauge readings for each pressure regulator. The operating
pressure of the EHF350 is limited to 9,500kPa by a relief valve that is located inside the oil tank
adjacent to the pump. Should it be necessary to adjust the relief pressure contact the
manufacturer for advice. Care should be taken if increasing the pressure above this setting as the
pressure gauge may be damaged.
(Older models were fitted with a 0-8000kPa gauge with operating pressure limited to 7,500kPa.)
During normal operation the hydraulic oil temperature will reach up to 80°C, and the electric
motor up to 70°C. Handle with care.
5.9. Pressure Gauge Calibration
Pressure gauges are easily damaged and may lose their accuracy. Periodically either
1. Remove the pressure gauge and check it against a known standard test gauge, or
2. Replace the pressure gauge with a certified gauge from time to time.

5.10. Synchronising The Carriage Cylinders

If air enters the cylinders, the carriage motion will eventually become out of phase or jerky. This
will adversely affect the welding operation and air should be bled from the cylinders (see below).
The presence of air in the system could result from loose hydraulic fittings, damaged hydraulic
cylinder shafts or seals. These should all be inspected and repaired if necessary before bleeding
the system.
Caution: The clamp cylinders are series connected to ensure both cylinders apply equal
pressure. Do not change this configuration without consulting the manufacturer.
The cylinder balance valve in the line between the clamp cylinders must remain closed
during normal operation. This valve is only used when bleeding air from the system.

5.11. Hydraulics Bleeding Method

The following method is recommended for recharging the hydraulic system with oil, or when
bleeding air from the cylinders.
1. Check that all fittings are tight. Remove the filler nut from the oil tank and insert a
filling funnel.
2. Fill the tank 3/4 full and keep adding oil to maintain this level as it is taken up by
the system. Operate the pump and the directional control lever alternately in each
direction such that the cylinders begin to fill with oil, adding oil to the tank as

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required until the cylinders start to move. Use any brand of oil with a viscosity of
ISO 46.
3. Entrapped air will rise to the top of the cylinders. To
ensure all air is able to escape from the cylinders, rock
the machine over on 2 wheels (as shown right) such
that the cylinder ports are pointing skywards during
bleeding. Ensure the machine is safely supported when
in this position.
Do not omit this step or air will remain in the system.
4. Shut the cylinder balance valve (in the line between the 2 cylinders) and pump the
cylinders fully open.
5. Open the cylinder balance valve before reversing the directional control valve to
ensure air exhausts to the tank rather than escaping back into the cylinders.
Reverse the directional control valve slowly so as not to damage the pressure
gauge. Maintain the oil tank level at 3/4 full. (If motion stops, the oil level is
probably too low.)
6. Repeat this cycle in each direction until any change of the directional control
lever, and the resultant motion of the carriage, is immediate and exactly in
sequence. There should also be no clamp spring back at the end of the cylinder
stroke (either end) on changing the directional control valve.
7. At this point all air should be fully expelled from the system. Top up the oil tank as
necessary.
8. At the end of this process ensure the cylinder balance valve is closed to lock the
cylinders in phase.

5.12. Facer Drive

Refer to Facer drawing.
1. Inspect the drill for mounting and alignment. Contact your local Bosch supplier
with specific drill service enquiries.
2. Remove the drill and access the facer drive assembly by removing the securing
screws from the idler cutter plate and removing the plate.
3. Clean out any dirt or plastic cuttings that could either damage the drive
components, and/or significantly reduce facing efficiency.
4. Inspect the bevel gear assembly for wear. If replacement is deemed necessary,
replace both the bevel bear and pinion as a set.
5. Check that the 119 tooth main drive sprocket is in contact with all four bronze
rollers. Two rollers are concentrically bushed and two are eccentrically bushed.
This design enables bronze roller or sprocket wear to be taken up by adjusting the
two eccentric guide rollers. These are adjusted by loosening the holding bolts and
rotating the bush in the direction of chain rotation, until the sprocket is supported
by all 4 rollers.
6. Tension the chain by adjusting the eccentrically bushed idler sprocket as described
above.
7. Once the rollers wear beyond the point of any further adjustment, the guide roller
& bearing assemblies must be replaced.

5.13. Facer Bronze Roller Replacement

Refer to Facer drawing.
1. Remove the screws holding the idler cutter plate and remove the cutter plate.
2. Detach the driven cutter plate from the main sprocket by removing the 12
sprocket screws and carefully knocking the plate away from the sprocket. (The
cutter plate locates in a groove machined into the sprocket face.)

FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 12
 EHF350 electric hydraulic butt welder
Simply Better.

3. Carefully note the location of the eccentric and concentric bronze roller
assemblies and remove them.
4. Refit new concentric roller assemblies.
5. Hang main sprocket.
6. Refit new eccentric roller assemblies.
7. Adjust the eccentric rollers in the direction of chain rotation, so that all four
bronze rollers support the main sprocket and the sprocket and rollers all turn
freely.
8. Fit the chain and idler sprocket. Tension the chain by adjusting the eccentric bush
in the idler sprocket.
9. Lubricate sparingly, and only with a high pressure grease e.g. Shell Alvania EP2.
Do not use graphite grease, molybdenumdisulphide or similar, as they may run
and leak out of the facer, providing a potential weld contamination problem.
10. Refit the driven cutter plate to the main sprocket, and test rotation before
replacing the idler cutter plate.

5.14. Cutter Blade Sharpening

If chipped or damaged, the blades should be replaced.
If blunt, the high grade tool steel blades may be sharpened with a tool&cutter grinder. Shim the
cutter blades if they are sharp, but shavings are too thin.

5.15. Eccentric Alignment Mechanism Repairs

See drawing “eccentric assembly” for part numbers referenced in the next three sections.

5.16. Damaged Eccentric Toggle Stud Thread

1. Should the ½" stud (BF350055) be broken off or the threaded hole damaged, it
may be able to be repaired in situ using a ½" BSW 'heli-coil'.
2. Apply Loctite 290 to the stud when refitting and do up finger tight.

5.17. Seized (Front Or Bottom) Eccentric Assembly

1. Unscrew and remove the eccentric shaft pivot-long (BF350044).
2. Remove four shaft nut mounting screws (BF000231) from shaft nut-long
(BF350030).
3. Unscrew the shaft nut – long (BF350030).
4. Remove the toggle screw (BF350055) from the bronze bush to enable the internal
eccentric assembly to be pushed out of the steel tube.
5. If the assembly is seized, use a press to push the bronze eccentric assembly out of
the outer steel tube.
6. Clean up any corrosion inside the steel casing.
7. Observe that there are no cracks in the silver solder joints between the bronze
bushes and both ends of the stainless steel connector tube. If the solder is broken,
the complete eccentric must be returned to the manufacturer for proper
alignment and re-soldering, or a new part fitted.
8. Check for free rotation of the shaft pivot-long inside the bronze bushes. Ream
Bushes if required.
9. Lightly grease the bronze bushes before reassembling.
10. Reassemble components in reverse order.
11. Replace the shaft nut (BF350030) and do it up tightly, then back off just enough to
align the shaft nut mounting screw holes with the nearest hole in the frame plate.

FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 13
 EHF350 electric hydraulic butt welder
Simply Better.

5.18. Seized (Rear Or Top) Eccentric Assembly

1. Remove two pivot bolts (BF350053) from the left and right hand hinge plates
(BF350042).
2. Rotate the upper eccentric assembly with the clamps attached clear of the side
frame plates to allow access to the end of the eccentric adjuster.
3. Remove Toggle Nut (BF050028) and Washer (BF000272). (Use Anti-Seize on toggle
nut when re-assembling.)
4. Remove stud (BF350055). (Use Loctite290 on screw when re-assembling. NOTE:
do not tighten Set Screw.)
5. Push Connector Tube Assembly (BF350054) out of Tube (BF350006). (Apply
Grease when reassembling.)
6. Remove Shaft pivot-short (BF350043) from top eccentric tube-bushed (BF350006)
and check for free rotation, ream Bushes if required.

FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 14
 EHF350 electric hydraulic butt welder
Simply Better.

6. Notes About Heater Plates And Temperature

6.1. PE Welding Temperatures
Polyethylene pipe is weldable at temperatures ranging from 180°C to 260°C. However butt fusion
parameters typically specify 220 ±15°C which is the required surface temperature of the heater
plate.
Temperatures greater than 240°C when coupled with long heat soak times may result in
diminution of the anti-oxidants in the pipe.
Cold joints will result if the weld temperature is too low, or the heat soak time is too short, or the
time between removal of the heater and butting the pipes together is too long.
Caution: Either situation may lead to premature joint failure.

6.2. Heater Plate Temperature

Heater plate temperature displays generally indicate the internal heater temperature. Actual
surface temperature may vary from the display, and will also fluctuate, for the following reasons.
7. The rate of heat loss from the heater surface depends on the design of the heater
plate and temperature controller. The surface temperature could be significantly
different to the thermometer indication. This variation will be greatest on cold,
windy days. Always use a shelter when welding in these conditions.
8. As power input cycles on and off the temperature will be highest just after the
power cycles off and lowest just as it cycles back on.
9. The temperature is unlikely to be exactly the same at every point on the heater
surface due to manufacturing tolerances.
10. As heat is transferred into the pipe during heat soak, the heater temperature
initially falls but eventually returns to the set point.

6.3. Measuring Surface Temperature

11. Always wait 5 minutes after the heater has first reached set temperature for the
Note: temperature to stabilize before recording measurements.
It is not physically 12. Take readings at several points (at 3, 6, 9, 12 o’clock) on both sides of the heater,
possible for heater at the diameter of the pipe being welded.
surface temperatures to 13. FUSIONMASTER heater plates are fitted with non-stick replaceable cloth. It is
vary significantly from
essential to use a contact probe to force the cloth into intimate contact with the
one point to another. If
such a variation is
plate. (Incorrect readings will result when the cloth system traps an insulating air
observed, it is most layer between the cloth and the heater surface.)
likely to result from 14. If a contact probe is used it should be held in position for several seconds before
using an incorrect the reading is taken.
temperature measuring 15. If an infra red pyrometer is used incorrect reading are likely to result unless:
technique.
• the emissivity is set at 0.95 for use on the non-stick cloth;
• the device is held square to the surface being measured;
• the non-stick cloth is forced into intimate contact with the heater plate (see
suggestion below).
16. Never use an infra-red pyrometer to take a reading from a shiny aluminium
surface (such as a FUSIONMASTER heater without cloths, or the outer rim of
a heater plate) or an error will result.

6.4. Suggestion
Use a "spot control adapter" fitted to an Infra-red pyrometer for consistently
accurate measurements. When pressed squarely against the heater surface the
infra-red beam is correctly focused every time, and intimate contact between
the heater plate and non-stick cloth is assured.
FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 15
 EHF350 electric hydraulic butt welder
Simply Better.

7. Butt Welding Guidelines

It is recommended that the following guidelines be downloaded from Plastics Industry Pipe
Association of Australia Ltd web site (www.pipa.com.au)
1. POP003 Butt Fusion Jointing of PE Pipes and Fittings - Recommended Parameters.
2. TP003 Specifying Butt Welding of Polyethylene Pipe Systems.
FUSIONMASTER® welders are designed for the “single pressure – low pressure” fusion
method described in POP003.
The welding tables appended to the EHF350 operating manual are based on POP003-SP-LP.
Operators should take care to determine the compatibility of materials for butt welding and only
attempt to weld pipes and fittings made of the same polymer, eg PE to PE, PP to PP, PVDF to
PVDF, etc.
The joint area must always be protected from adverse weather conditions, eg strong winds,
excessive cold or heat, or rain, which could lead to the pipe wall developing non-uniformly
heated zones and consequent failure issues.
The weld zone should be free of bending stress, free of notches or similar damage, and be free of
contamination.

8. Weld Failure Trouble Shooting

(Bead shapes are exaggerated for effect.)
Uniform bead correct welding.
NB the external bead is always more uniform than the internal bead.
Crack down centre of bead.
"Cold weld" signified by clean break through the middle of the weld
with a smooth appearance.
Could be due to insufficient heat soak time or temperature, or
changeover time too long, or excessive soak pressure, or insufficient
fusion pressure, or no allowance for drag pressure, or drag pressure
too great eg due to pulling pipe up a gradient.
Misalignment - maximum allowable 10% of wall thickness.
Care should also be taken to ensure pipes or fittings being joined
have the same diameter and wall thickness or the probability of weld
failure is significantly increased.
Insufficient bead roll over.
Could be due to insufficient heat soak time or temperature, or
changeover time too long, or insufficient fusion pressure, or no
allowance for drag pressure,
Unequal bead size.
Look for temperature gradients e.g. pipe surface in the hot sun vs
pipe in the shade, or heater plate hot spots.
Look for unequal application of pressure.
If unequal uniformly around the whole circumference, look for
physical difference in materials being joined eg melt flow index.

FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 16
 EHF350 electric hydraulic butt welder
Simply Better.

9. Warranty

FUSIONMASTER Butt Fusion Equipment

1. Subject to the terms below, Dixon Industries Pty Ltd (“The Company”) warrants to
repair or replace at its option ex-works Adelaide any product manufactured or
repaired by it within 2 years from the date of shipment which are found to be
defective due to either faulty workmanship or use of faulty materials, provided
that such defective product is returned to the Company’s works at the customer’s
expense, unless otherwise agreed.
2. This warranty is limited solely to products manufactured or repaired by the
Company. Products not manufactured by the Company (such as pumps, gauges,
motors, switches, etc.) are not covered by this warranty. In relation to a repair,
this warranty is limited to the Company’s cost of parts and labour to remedy a
defective repair.
3. This warranty does not apply to any product that has been damaged by accident,
misuse, neglect, use of an electrical power supply that is incompatible with the
design specifications of the product or repair or alteration of the product by
anyone other than the Company.
4. A warranty claim must be made to the Company in writing within 14 days of the
first occurrence of the event or condition on which the claim is based. The claim
must include proof of purchase and a detailed statement of the manner in which
the product has been used and the event or condition occurred. The Company’s
decision to admit or refuse any warranty claim shall be binding.
5. Replacement parts provided to the customer before the right to a warranty claim
is accepted by the Company will be invoiced at the full cost of the parts, including
applicable taxes and freight charges. If a warranty claim is accepted, the cost of
any replacement parts covered by the warranty claim which have been so
invoiced will be credited to the customer.
6. All costs of returning product to the customer shall be paid by the customer.
7. Other than provided in this warranty, the Company excludes any other
responsibility or liability whatever to the maximum extent permitted by law
including liability for breach of contract, negligence or incidental, consequential,
indirect or special damages including without limitation, interruption to use of the
product or any other plant or equipment.

Disclaimer
As the conditions of use of welding equipment are outside the control of Dixon Industries, no
warranties are expressed or implied and no liability is assumed in connection with the use of butt
welding equipment or the butt welding guidelines or parameters.

The manufacturer reserves the right to vary specifications without notice.

FUSIONMASTER® and DIXON® are registered trademarks of Dixon Industries Pty. Ltd. ©August 2002 Revised August 2013 Page 17
 P.No.BF000239

37 29 27 33 41 40 39 7 6 5 4 3 1
38 26 25 32

2
41 BF000219 Cover Plate Mtg. Screw 4
8 40 BF000218 Cover Plate Mtg. Washer 4
39 BF350228 Cover Plate 1
9 38 BF350244 Bosch Drill 1
37 BF350214 Bevel Pinion 1
BF350234 36 BF000260 Drill Mount Mtg. Washer 4
10 Drill Mount A.,
supplied as 35 BF000265 Drill Mount Mtg. Nut 4
Assembly
34 BF350234W Drill Mount Weldment 1
11
33 BF000239 Set Screws 2
12 32 BF350208 Drill Adaptor & 2 Set Screws 1
31 BF000337 Handle Lock Pin 1

23 30 BF350233 Handle Lock 1

BF350212
29 BF000217 Blade Mtg. Screw 6
Cutter Blades
& Screws, 28 BF350212B Driver Cutter Blade 1
21 supplied as kit
27 BF350212A Idler Cutter Blade 1

22 26 BF000255 Cutter Plate Mtg. Screws 2

25 BF350220 Cutter Plate, Idler 1
24 BF350202 Cutter Plate, Driven 1
23 BF350219 Drive Chain & Link 1
22 BF350203 Main Sprocket 114T- 3/8"Pitch 1
21 BF000226 Main Sprocket Mtg. Screws 12
20 BF000133 Mtg. Nut, Guide Roller Assy 4
19 BF350210 Concentric Bush 2
18 BF350209 Eccentric Bush 2
17 BF350231 Guide Roller Bearing Spacer 4
BF350206 4
16 BF000082 Circlip
Guide Roller/
Bearing A., 15 BF000022 Bearing 8
supplied as
Assembly 14 BF350226 Guide Roller 4
13 BF350221 Mtg. Bolt, Guide Roller Assy 4
12 BF000338 Idler Screw 1
11 BF000268 Spring Washer 1
10 BF350218 Idler Eccentric Bush 1
BF350216 9 BF000021 Bearing 1
Idler Spr./Brg.A
suppl.as Assy 8 BF350205 Idler Sprocket 1
7 BF350217 Idler Spacer 1
BF350211 6 BF000319 Bearing 2
34 35 36 31 30 Bevel Gear/
24 Sprocket/ 5 BF350207 Outer Spacer Ring 1
Bearing A.
4 BF350215 Inner Spacer Ring 1
supplied as Kit
29 3 BF350204 Bevel Gear & Sprocket 1
2 BF000074 Glycodur Bush 2

20 19 17 18 16 15 14 13 28 1 BF350201 Facer Body 1

Item Part No. Part Name QTY
typ. 4 places, except Item 18 & 19, Drawing Name: Copyright . No part of this drawing
Scale: not to scale
- locate Ecc. Bush (Item 18) closest to Idler Sprocket and Bevel Gear may be reproduced in whole or in
HF350 Facer Assembly Drawn: SR part without the written permission
OPERATORS MANUAL ONLY Update: 5/12/2014 of Dixon Industries Pty. Ltd.

UNCONTROLLED DOCUMENT CAD File: U:\Inventor\HF350\BF350200\BF3502A0.idw A.B.N. 89 008 171 855 www.dixonind.com.au
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 355 355 355 355 355 355 355 355 355 315 315 315 315 315 315 315 315 315
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 9.2 10.3 12.8 15.8 19.7 27.5 33.9 41.7 51.0 8.2 10.3 12.8 15.8 19.7 24.5 30.1 37.1 45.2
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.9 1.0 1.3 1.6 2.0 2.8 3.4 4.2 5.1 0.8 1.0 1.3 1.6 2.0 2.4 3.0 3.7 4.5

bead up pressure P1 170+/-20 kPa 1378 1531 1898 2322 2862 3902 4715 5654 6716 1084 1354 1676 2048 2520 3078 3715 4461 5283
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 101 113 141 174 217 303 373 458 561 90 113 141 174 217 269 331 408 497

heater out T3 0.1t + 4 second 5 5 5 6 6 7 7 8 9 5 5 5 6 6 6 7 8 9

pressure up T4 0.4t + 2 second 6 6 7 8 10 13 16 19 22 5 6 7 8 10 12 14 17 20

welding & cooling pressure P3 170+/-20 kPa 1378 1531 1898 2322 2862 3902 4715 5654 6716 1084 1354 1676 2048 2520 3078 3715 4461 5283
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 12 13 16 19 23 31 37 45 54 11 13 16 19 23 27 33 40 48

cooling time out of clamps before rough handling T6 t+3 minute 12 13 16 19 23 31 37 45 54 11 13 16 19 23 27 33 40 48

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 1/6
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 280 280 280 280 280 280 280 280 280 250 250 250 250 250 250 250 250 250
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 7.3 9.1 11.3 14.2 17.5 21.7 26.8 33.0 40.3 6.6 8.2 10.2 12.6 15.6 19.4 23.9 29.4 36.0
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.7 0.9 1.1 1.4 1.8 2.2 2.7 3.3 4.0 0.7 0.8 1.0 1.3 1.6 1.9 2.4 2.9 3.6

bead up pressure P1 170+/-20 kPa 863 1068 1316 1630 1990 2428 2935 3526 4185 696 854 1055 1291 1584 1938 2341 2806 3337
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 80 100 124 156 193 239 294 362 443 73 90 112 138 172 213 263 323 396

heater out T3 0.1t + 4 second 5 5 5 5 6 6 7 7 8 5 5 5 5 6 6 6 7 8

pressure up T4 0.4t + 2 second 5 6 7 8 9 11 13 15 18 5 5 6 7 8 10 12 14 16

welding & cooling pressure P3 170+/-20 kPa 863 1068 1316 1630 1990 2428 2935 3526 4185 696 854 1055 1291 1584 1938 2341 2806 3337
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 10 12 14 17 21 25 30 36 43 10 11 13 16 19 22 27 32 39

cooling time out of clamps before rough handling T6 t+3 minute 10 12 14 17 21 25 30 36 43 10 11 13 16 19 22 27 32 39

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 2/6
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 225 225 225 225 225 225 225 225 225 200 200 200 200 200 200 200 200 200
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 5.9 7.3 9.1 11.4 14.2 17.5 21.6 26.5 32.4 5.2 6.6 8.2 10.2 12.6 15.5 19.2 23.6 28.8
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.6 0.7 0.9 1.1 1.4 1.8 2.2 2.6 3.2 0.5 0.7 0.8 1.0 1.3 1.6 1.9 2.4 2.9

bead up pressure P1 170+/-20 kPa 556 689 852 1055 1293 1573 1904 2275 2703 439 553 678 835 1019 1239 1504 1804 2133
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 64 80 100 125 156 193 238 291 356 57 73 90 112 138 171 211 260 316

heater out T3 0.1t + 4 second 5 5 5 5 5 6 6 7 7 5 5 5 5 5 6 6 6 7

pressure up T4 0.4t + 2 second 4 5 6 7 8 9 11 13 15 4 5 5 6 7 8 10 11 14

welding & cooling pressure P3 170+/-20 kPa 556 689 852 1055 1293 1573 1904 2275 2703 439 553 678 835 1019 1239 1504 1804 2133
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 9 10 12 14 17 21 25 29 35 8 10 11 13 16 19 22 27 32

cooling time out of clamps before rough handling T6 t+3 minute 9 10 12 14 17 21 25 29 35 8 10 11 13 16 19 22 27 32

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 3/6
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 180 180 180 180 180 180 180 180 180 160 160 160 160 160 160 160 160 160
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 4.7 5.9 7.3 9.1 11.3 14.1 17.3 21.2 25.9 4.3 5.2 6.6 8.2 10.1 12.5 15.4 18.9 23.1
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.5 0.6 0.7 0.9 1.1 1.4 1.7 2.1 2.6 0.4 0.5 0.7 0.8 1.0 1.2 1.5 1.9 2.3

bead up pressure P1 170+/-20 kPa 357 445 547 674 826 1010 1220 1459 1729 287 349 439 537 653 796 965 1153 1368
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 52 65 80 100 124 155 190 233 285 47 57 73 90 111 137 169 207 254

heater out T3 0.1t + 4 second 4 5 5 5 5 5 6 6 7 4 5 5 5 5 5 6 6 6

pressure up T4 0.4t + 2 second 4 4 5 6 7 8 9 10 12 4 4 5 5 6 7 8 10 11

welding & cooling pressure P3 170+/-20 kPa 357 445 547 674 826 1010 1220 1459 1729 287 349 439 537 653 796 965 1153 1368
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 8 9 10 12 14 17 20 24 29 7 8 10 11 13 15 18 22 26

cooling time out of clamps before rough handling T6 t+3 minute 8 9 10 12 14 17 20 24 29 7 8 10 11 13 15 18 22 26

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 4/6
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 140 140 140 140 140 140 140 140 140 125 125 125 125 125 125 125 125 125
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 3.8 4.6 5.8 7.1 8.8 10.9 13.4 16.6 20.3 3.3 4.2 5.1 6.4 7.9 9.8 12.1 14.8 18.1
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.4 0.5 0.6 0.7 0.9 1.1 1.3 1.7 2.0 0.3 0.4 0.5 0.6 0.8 1.0 1.2 1.5 1.8

bead up pressure P1 170+/-20 kPa 222 270 335 409 501 610 735 885 1051 174 218 265 327 399 487 590 705 837
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 41 51 63 78 97 120 147 182 223 36 46 56 70 86 107 133 162 199

heater out T3 0.1t + 4 second 4 4 5 5 5 5 5 6 6 4 4 5 5 5 5 5 5 6

pressure up T4 0.4t + 2 second 4 4 4 5 6 6 7 9 10 3 4 4 5 5 6 7 8 9

welding & cooling pressure P3 170+/-20 kPa 222 270 335 409 501 610 735 885 1051 174 218 265 327 399 487 590 705 837
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 7 8 9 10 12 14 16 20 23 6 7 8 9 11 13 15 18 21

cooling time out of clamps before rough handling T6 t+3 minute 7 8 9 10 12 14 16 20 23 6 7 8 9 11 13 15 18 21

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 5/6
 Parameters based on PIPA Guideline POP003: 6.1 issued Sept 2011 350 hydraulic cylinder area 1233mm²

nominal pipe od D mm 110 110 110 110 110 110 110 110 110 90 90 90 90 90 90 90 90 90
SDR 41 33 26 21 17 13.6 11 9 7.4 41 33 26 21 17 13.6 11 9 7.4
PE80 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN3.2 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20
PE100 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25 PN4 PN6.3 PN8 PN10 PN12.5 PN16 PN20 PN25
mean wall thickness t mm 2.9 3.7 4.6 5.7 7.0 8.6 10.6 13.0 16.0 2.4 3.0 3.8 4.6 5.8 7.0 8.7 10.7 13.0
Parameter
mean heater surface temp 220+/-15 °C 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220

allowable axial misalignment 0.1t mm 0.3 0.4 0.5 0.6 0.7 0.9 1.1 1.3 1.6 0.2 0.3 0.4 0.5 0.6 0.7 0.9 1.1 1.3

bead up pressure P1 170+/-20 kPa 135 169 211 256 313 378 457 547 650 92 114 141 171 210 252 307 368 434
+ measured drag P3 +drag kPa

total bead up pressure P3 kPa

soak pressure P2 drag kPa drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag drag
soak time T2 (11±1)t second 32 40 51 62 77 95 117 143 175 26 33 41 51 63 77 96 118 143

heater out T3 0.1t + 4 second 4 4 4 5 5 5 5 5 6 4 4 4 4 5 5 5 5 5

pressure up T4 0.4t + 2 second 3 3 4 4 5 5 6 7 8 3 3 4 4 4 5 5 6 7

welding & cooling pressure P3 170+/-20 kPa 135 169 211 256 313 378 457 547 650 92 114 141 171 210 252 307 368 434
+ measured drag P3 +drag kPa

total welding & cooling pressure P3 kPa

minimum welding & cooling time in the clamps T5 t+3 minute 6 7 8 9 10 12 14 16 19 5 6 7 8 9 10 12 14 16

cooling time out of clamps before rough handling T6 t+3 minute 6 7 8 9 10 12 14 16 19 5 6 7 8 9 10 12 14 16

PE welding parameters POP003.6.1 SPLP.xls FUSIONMASTER350 NB the drag pressure must be re-measured and added to the calculated weld pressure for each new joint . appendix 6/6
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