HW825 Fusion Welder

HW825 Fusion Welder
the numerical keypads then press enter. If the joint
is a 39.5Vac.rms. joint you can weld in this mode by
entering a voltage of 99.
Finally, press the green START button to activate the
weld, the LCD will display remaining time. Once the weld
is complete, the buzzer will sound and the LCD will
display a joint reference number for your records.
You should now switch the main unit OFF before
disconnecting the output leads and proceed to the
next joint.
It is recommended that you turn OFF the
generator if you have some distance to move the trolley
to the next location.
When you have finished the work session turn
OFF the generator at the engine ON/OFF switch.
Barcode Set Up…
With the unit switched OFF, press and hold the No
5 keypad and switch the main unit ON.
The LCD will display ‘BARCODE MODE’, you can
now release the No 5 key and proceed with the set-up.
The LCD will then display ‘VERSION 5.0’ then
‘ENT.OP-CODE 000’. The latter is asking you to input
your operator code and should NOT be used unless the
unit is to be used by more than one person. If you input
a new three-digit code, make sure you don’t forget it.
The LCD will prompt the user to connect the output leads
to the fitting. Connect the leads ensuring a firm
positive connection is achieved.
The unit will ask for the barcode for the particular
joint. The barcode will be
Connections found on the joint, simply
hold the scanner over the
Output
barcode and depress the
Leads
trigger until the LCD displays
the 24 bit code read.
If the barcode cannot be
read the LCD will display a
fault and you will have to
enter the code manually.
Enter the code using the
Joint
Joint
Information numerical keypads then
press enter.
You will then be prompted to press the green START
button to activate the weld, the LCD will display
remaining time. Once the weld is complete, the
buzzer will sound and the LCD will display a joint
reference number for your records.
You should now switch the main unit OFF before
disconnecting the output leads and proceed to the
next joint.
It is recommended that you turn OFF the
generator if you have some distance to move the trolley
to the next location.
When you have finished the work session turn
OFF the generator at the engine ON/OFF switch.
EQUIPMENT CARE
Operating & Safety Guide HW825
Never push the equipment beyond its design
limits. If it will not do what you want with
reasonable ease and speed, assume you have the
wrong type or size of welder for the job. Ask at
your local HSS Hire Weld Depot for advice.
Regularly check the fuel level and top as required
using the correct fuel: unleaded petrol.
Check the engine oil level daily. Let the engine cool,
stand it on level ground, withdraw the dipstick and wipe
it clean. Now, replace the dipstick, withdraw it a second
time and verify that the oil level is between MIN and
MAX. Top up as required.
Keep the equipment clean. You will find this less of a
chore if you clean it up regularly rather than wait until
the end of the hire period.
When not in use, store the equipment somewhere
clean, dry and safe from thieves.
FINISHING OFF
Switch OFF the electro fusion unit. Switch OFF the
generators engine and close the fuel tap
Disconnect all leads and coil them up neatly ready
for return, to your local HSS Hire Weld Depot.
Electro-Fusion
Pipe Welder &
Generator
…any comments?
A pipe-welding device completed
with own generator for use with
specialist polyethylene pipe systems.
If you have any suggestions to enable us to improve
the information within this guide please fax your
comments or write to the Product Manager at the
address below
Fax: 020 8687 5001
©HSS Hire Service Group Plc 2002 No. HW825/01
Group Office: 25 Willow Lane, Mitcham, Surrey CR4 4TS
Web Site: http://www.hireweld.com
Code 55026
HW825/01
Manual Set up…
The manual set up allows for two operation
modes.
With output voltage set at 39.5Vac.rms (where
each process would be fixed at that setting and no fusion
voltage would be required).
With output voltage selected by the user (between
8 and 44Vac.rms. the user would also need to input
fusion time and voltage information).
Manual 39.5Vac.rms. setting…
With the unit switched OFF, press and hold the No
3 keypad and switch the main unit ON.
The LCD will display ‘MANUAL MODE 39.5’, you
can now release the No 3 key and proceed with the
set-up.
The LCD will then display ‘VERSION 5.0’ then
‘ENT.OP-CODE 000’. The latter is asking you to input
your operator code and should NOT be used unless the
unit is to be used by more than one person. If you input
a new three-digit code, make sure you don’t forget it.
The LCD will prompt the user to connect the output leads
to the fitting. Connect the leads ensuring a firm
positive connection is achieved.
The unit will then ask for the electro-fusion time
for the particular joint. The time information will
be found on the joint, enter the value using the
numerical keypads then press enter.
Finally, press the green START button to activate the
weld, the LCD will display remaining time. Once the
weld is complete, the buzzer will sound and the LCD
will display a joint reference number for your records.
You should now switch the main unit OFF before
disconnecting the output leads and proceed to the
next joint.
Manual Variable 8 – 44Vac.rms. setting…
With the unit switched OFF, press and hold the No
4 keypad and switch the main unit ON.
The LCD will display ‘MANUAL MODE 8/44’, you
can now release the No 4 key and proceed with the
set-up.
The LCD will then display ‘VERSION 5.0’ then
‘ENT.OP-CODE 000’. The latter is asking you to input
your operator code and should NOT be used unless the
unit is to be used by more than one person. If you input
a new three-digit code, make sure you don’t forget it.
The LCD will prompt the user to connect the output leads
to the fitting. Connect the leads ensuring a firm
positive connection is achieved.
The unit will ask for the electro-fusion time for the
particular joint. The time information will be found
on the joint, enter the value using the numerical
keypads then press enter.
The unit will then ask for the fusion set voltage for
the particular joint. Again, the voltage information
will be found on the joint, enter the value using
GENERAL SAFETY
For advice on the safety and suitability of this equipment
contact your local HSS Hire Weld Depot.
There is a serious risk of personal injury if you do
not follow all instructions laid down in this guide.
The hirer has a responsibility to ensure that all
necessary risk assessments have been completed
prior to the use of this equipment.
Most welding tasks may be considered as hot work
in site situations and may be subject to specific
permits to work.
This equipment should only be used by an operator
who has been deemed competent to do so by
his/her employer.
This equipment should be used by an able bodied,
competent adult who has read and understood these
instructions. Anyone with either a temporary or permanent
disability, should seek expert advice before using it.
Keep children, animals and bystanders away from
the work area. Cordon off a NO GO area using
cones and either barriers or tape, available for hire
from your local HSS Hire Weld Depot.
Warning!
During electric/electronic welding/cutting
operations, intense magnetic & electrical fields
are produced and these may interfere with
other electronically sensitive equipment.
All personnel wearing Heart Pacemakers or
other electronically controlled medical devices
must be kept away from any electric/electronic
welding/cutting operations.
The welding/cutting equipment should be
installed at least 5metres away from any computer
equipment to minimise any possible interaction.
Cables carrying signals between electronic
devices are capable of picking up interference
from electric/electronic welding/cutting
operations. This interference may prejudice the
way in which these devices function and
therefore all signal carrying cables should also
be sited outside the 5metre zone.
Do not place objects that are sensitive to
magnetism (wristwatches, credit cards,
computer discs etc) near the welding or cutting
zone. They may be rendered useless.
The welding/cutting equipment is itself
electronically sensitive and its position relative
to other radiation emitting equipment (mobile
phones, remote controls, motor speed
controllers etc.) must be considered.
Never use this equipment if you are ill,
feeling tired, or under the influence of
alcohol or drugs.
Wear practical, protective clothing,
gloves and footwear. Avoid loose
garments and jewellery that could catch in moving parts,
tie back long hair.
This equipment is heavy never attempt to lift
it on your own, always get help.
Take all necessary precautions to protect yourself
and others against the possibility of contracting
infectious diseases in your work environment.
Always switch OFF and unplug the equipment
when not in use.
Never use welding equipment near computers or
any sensitive electronic equipment.
Exhaust Danger
NEVER operate petrol engines indoors or in a
confined space.
The exhaust contains gases that can Kill.
Ensure the work area is well lit and ventilated, a
fume extractor or smoke eliminator should be used. If in
doubt, ask about lighting and ventilation equipment at
your local HSS Hire Weld Depot.
Do not work near flammable gases or liquids, petrol
or paint thinner fumes for example. Keep combustible
materials at a safe distance – at least 5m.
Make sure you know how to switch this machine
OFF before you switch it ON in case you get into
difficulty.
FUEL SAFETY
NEVER refuel while the engine is hot or running.
Never smoke or allow naked lights into the area
while refuelling.
Never inhale fuel vapour.
ALWAYS mop up spillage’s as quickly as possible,
and change your clothes if you get fuel on yourself.
ALWAYS store fuel in a purpose-made sealed
container, in a cool, safe place well away from
the work area.
Always switch OFF the equipment before moving
it to another site or servicing it.
Engines, especially the exhausts, get very hot so
switch off and allow to cool before touching them.
Keep flammable materials well away from engine
and exhaust.
Never leave the engine running and unattended.
Check the condition of the equipment before use.
If it shows signs of damage or excessive wear, return it to
your local HSS Hire Weld Depot.
ELECTRICAL SAFETY
The HSS Electro-Fusion Pipe Welder is powered by
its own generator.
Generator
Control Box & Scanner
Connection 5 Pin
Socket
Socket
Scanner
Close
Trigger
RS232
Plug
Scanner
Connection
Red
STOP Numeric
Button Keypad
Choke
RS232
Socket
Green
START Button
Open
Fuel
Tap
Pull
Start
Yellow Dot
Pipe Welder
Control Box
Lock
Collar
Generator
If the equipment fails, or if the welding supply
cable or plug becomes damaged, return it. Never
try to repair it yourself.
Keep the equipment dry, using electrical
equipment in very damp or wet conditions can be
dangerous.
GETTING STARTED
This guide is designed to help the user to safely set
up and dismantle the welder and start and stop
the generator. It is not intended as a guide to
welding techniques as it is assumed that the user
already has the necessary training/knowledge and
experience.
Position the main unit close to the pipe joint.
Connect the output lead 5-pin plug to the
connection socket on the side of the welder control
box (see illustration). Push the plug in then lock in place
by turning the lock collar clockwise until the yellow dot on
the plug lines up with the yellow dot on the socket.
If using the barcode system, connect the readers’
RS232 plug to the RS232 socket marked ‘BAR CODE’.
It is essential to familiarise yourself with all the
controls before starting.
Starting The Generator Engine: Move to the rear of
the trolley and check the engine and fuel levels,
and refill as required.
Close the choke (if starting from cold), turn on the
fuel, and switch the engine ON at the engine
ON/OFF switch. Grasp the trolley with one hand
and give two or three pulls on the starter with the
other. If the engine does not start adjust choke setting.
When the engine runs, open choke and let the
engine tick over for a few moments to warm up.
Once the engine has warmed up then the unit is ready
to use. Note that the unit will automatically set the
throttle as power demand varies.
Move to the front of the unit.
On the control panel there is a red emergency STOP
button which also acts as the ON/OFF master
switch for the pipe welder control box. To switch the
Trolley
Fuel
Tank
Engine ON/OFF
Switch
Dipstick
welder ON, turn the STOP button anticlockwise
until it pops out.
If you get into difficulty at any time, press the
STOP button to switch the pipe welder OFF and
stop any welding process.
The green button to the right of the unit is the
START button. Press this to begin the electro-fusion
process and timer.
The key buttons marked 0 through to 9 are used
to input values where required and are also used
to select different functions (as described in BASIC
TECHNIQUES).
The LCD display will show various information,
depending on the situation.
BASIC TECHNIQUES
The Electro-Fusion Pipe Welder can be set up in
either manual or barcode mode depending on the
type of fittings you are using.
Start the engine as described in GETTING
STARTED.
If no barcode is available, follow the ‘manual set
up’ instructions. If a barcode is available, follow
the ‘barcode set up’ instructions.
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