Mounting Instructions for

HA-WELD Electrofusion Saddles for PE Pipes Order No. 526 1. Intended use and product description
The fusion saddle of polyethylene (PE 100) is fused and welded at the contact surfaces (pipe outside surface and inside surface of resistance welding saddle) by means of the resistance wires (invisible heating spirals) integrated in the top half. The metal connections integrated in the top part of the saddle serve the purpose of accommodating valves and/or drilling saddles and/or pipelines or drilling tees.

2. Installation
Warning! Please use only welding devices that have been approved by the manufacturer as to their function for processing HA-WELD electrofusion saddles (see DVS 2207, part 1, 5.2). The described sequence of the working steps must be absolutely complied with. General: The welding quality will be determined to a great extent by careful preparation. Electrofusion joints may be established only by trained personnel. Only material of the same kind can be welded. In this context PE 80 and PE 100 are regarded as being of the same kind and can therefore be welded together. Alignment: Align the top part of the fusion saddle on the pipeline and mark the fusion zone (the pipe surface covered by the saddle) by means of an appropriate marker. Cleaning of fusion zone: Immediately prior to mounting the marked area of the pipe surface must be completely and absolutely cleaned from the oxide layer by means of a hand scraper or spokeshave. Depending on the condition of the surface this layer may be 0.2 to 0.7 mm in thickness. Warning! If the oxide layer is not completely removed, the weld joint may be leaking or defective. At least 0.2 mm must be removed completely. The created surface should be even and free from dimples and scratches at the pipe surface. Sandpapering, filing or cleaning with solvent will not be sufficient and is not admissible. The surfaces thus processed shall be protected from dirt and grease (such as handcream, oily rags, etc.) running water as well as rainwater and frozen fog. The pipe surfaces to be welded and the inside surfaces of the fusion saddles must be absolutely clean, dry and free from grease. Immediately prior to mounting (after scraping) the welding surfaces shall be cleaned by means of ethanol 99.9% (or Tangit KS / Tangit KS cleaning tissues), using only absorbent, lintfree and undyed paper. Make sure not to carry any dirt from the edges to the welding surface. The cleaning agent must be completely vaporized before welding. Mounting of drilling saddle: Put the top half with the outlet onto the cleaned pipe surface, align it and engage the clamps of the bottom half into the top half. Take the screws out of the holders and push them into the bores provided for this purpose. Tighten all 4 screws regularly by hand. Check the mounting position again and tighten the screws to approx. 5-10 Nm by means of a socket spanner or a screwdriver. Check the contact surface between the saddle and the pipe visually. In the crest area the top half must rest snugly on the pipe. Warning! When mounting from the side make sure that the bar code for welding is visible at the top side. During mounting make sure not to damage the inside surface of the fusion saddle. Welding of drilling saddle: Connect contacts (designed acc. to EN 1555-3 type B) to the welding unit. Make sure that the contacts are clean and dry, clean them, if necessary. The welding parameters are contained in a bar code applied laterally to the fusion saddle. The parameters are read into the welding unit via a reading wand. (Observe mounting instructions of welding unit).
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Start fusion. Compare the data shown in the display of the welding unit with those on the fusion saddle (see table T.1) If the bar code is not legible the parameters can be input manually. Warning! For general safety reasons during welding keep a distance of 1 m to the welding point. Never weld with medium emerging. Do not interrupt the welding procedure. Fusion with other materials than PE 80/100 is not possible. Welding may take place only at ambient temperatures between 0C and +45C. Warning! If the cooling-down period is not observed, the fusion saddle may be isolated from the pipe at fusion level. During this time the bottom half must not be dismantled or released. Examination: After finishing the fusion process check if welding has been performed properly: - No fault indication at the welding unit display (observe operating instructions of welding unit) Indicator PIN: The indicator PIN only indicates the fact that fusion has been performed. It does not tell anything about the quality achieved. Depending on the gap conditions between the fusion saddle and the pipe the movement and appearance of the indicator pin may vary. The successful performance of the welding process is indicated only by the welding unit. indicator pin

before fusion

after fusion

Marking: By means of proper marking (e.g. inscription with SNOWMAN SILVER MARKER) the welding point shall be permanently provided with the position from the installation drawing. Welding must be substantiated by the record of the welding unit. Welding defect: If a welding defect (interwinding fault) is indicated at the welding unit, welding has to be discarded. If the pipe has not yet been penetrated (drilled), the saddle may be left on the pipe. However, it must be permanently marked as defective welding. Mounting and welding shall be repeated at another place. T.1 Fusion parameters Pipe Welding voltage 63 mm 0V 90 mm 18V 110 mm 18V 125 mm 18V 160 mm 18V 225 mm 18V Resistance 0.00 0.95 0.95 0.95 0.95 0.95 Welding time 0 sec 190 sec 190 sec 190 sec 190 sec 190 sec Cooling-down period 30 min 30 min 30 min 30 min 30 min 30 min

If you have any further questions or if you need more information please contact: Hawle Armaturen GmbH Anwendungstechnik Liegnitzer Str. 6 83395, Freilassing Phone: +49 (0)8654-6303-0 Fax: +49 (0)8654-6303-222 E-Mail: anwendungstechnik@hawle.de Internet: www.hawle.de

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Subject to alteration