Advance Welding ACT40 Manual de usuario
ACT40 Electrofusion Welding Unit - Operator Manual
Operating Controls
ACT 40
© 2019. Advance Welding 1
Operating Controls ........................................................................................................................
Safety Notes .....................................................................................................................................
Product Specication ...................................................................................................................
Intended Use ....................................................................................................................................
Introduction ......................................................................................................................................
Delivered Items ................................................................................................................................
Electrical Safety ................................................................................................................................
Using the Equipment .....................................................................................................................
Data Log Memory ............................................................................................................................
Manual Welding .............................................................................................................................
Fusamatic Welding .......................................................................................................................
Bar Code Welding .........................................................................................................................
Fusion Operator Badge ..............................................................................................................
GPS Location .................................................................................................................................
Extreme Low Temperature Operation .................................................................................
Downloading the Weld Memory .............................................................................................
Upgrading the Operating Soware .......................................................................................
Set Up Options ..............................................................................................................................
Information .....................................................................................................................................
Fault Finding ...................................................................................................................................
Maintenance ..................................................................................................................................
Disposal ............................................................................................................................................
Calibration and Warranty ...........................................................................................................
Declaration of Conformity ........................................................................................................
Service and Repair.........................................................................................................................
Quick Start Guide ..........................................................................................................................
ACT 40V
(Automatic 40v welding unit)
Operating manual
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 2
Operating Controls ........................................................................................................................
Safety Notes .....................................................................................................................................
Product Specication ...................................................................................................................
Intended Use ....................................................................................................................................
Introduction ......................................................................................................................................
Delivered Items ................................................................................................................................
Electrical Safety ................................................................................................................................
Using the Equipment .....................................................................................................................
Data Log Memory ............................................................................................................................
Manual Welding .............................................................................................................................
Fusamatic Welding .......................................................................................................................
Bar Code Welding .........................................................................................................................
Fusion Operator Badge ..............................................................................................................
GPS Location .................................................................................................................................
Extreme Low Temperature Operation .................................................................................
Downloading the Weld Memory .............................................................................................
Upgrading the Operating Soware .......................................................................................
Set Up Options ..............................................................................................................................
Information .....................................................................................................................................
Fault Finding ...................................................................................................................................
Maintenance ..................................................................................................................................
Disposal ............................................................................................................................................
Calibration and Warranty ...........................................................................................................
Declaration of Conformity ........................................................................................................
Service and Repair.........................................................................................................................
Quick Start Guide ..........................................................................................................................
Index
3
4
5
6
6
6
7
8
9
10
11
12
13
14
14
15
15
16
17
18
22
23
23
26
27
28
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 3
1. Welding Cable (can be provided with optional right angle plug)
2. USB Memory Drive
3. Bar Code Scanner (Optional)
4. Bar Code Pen (Standard)
5. USB Socket
6. Welding Cable Socket
7. Protective Lid
8. Display
9. Buttons
10. Protective Frame
11. Ratings Plate
12. Supply Cable
1. Welding Cable (can be provided with optional right angle plug)
2. USB Memory Drive
3. Bar Code Scanner (Optional)
4. Bar Code Pen (Standard)
5. USB Socket
6. Welding Cable Socket
7. Protective Lid
8. Display
9. Buttons
10. Protective Frame
11. Ratings Plate
12. Supply Cable
Operating Controls
1. Welding Cable
2. USB Memory Drive
3. Bar Code Scanner
4. Bar Code Pen (Standard)
5. USB Socket
6. Welding Cable Socket
7. Protective Lid 8. Display
9. Buttons
10. Protective Frame
11. Ratings Plate 12. Supply Cable
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 4
• RISK OF EXPLOSION! This welding unit must not be used in a gaseous
atmosphere.
• RISK OF ELECTRIC SHOCK! Do not open. No user serviceable parts
inside.
• Before using, always visually inspect the unit to see that the cables and
connectors are not worn or damaged. Replace the damaged part before
welding.
• Switch o and remove the plug from the mains before adjusting, cleaning, or
if the cables are entangled and before leaving the equipment unattended for
any period.
• To avoid damaging the unit, do not interrupt the supply voltage or disconnect
the welding cable, while the unit is welding a tting.
• Do not li or pull the equipment by its cables.
• Do not disconnect the welding cables by pulling on them, always pull o the
connectors from the tting.
• Do not start a weld without the pipe correctly inserted into the tting.
• Do not touch the tting while welding.
• Do not weld in the rain or leave the equipment outdoors whilst it is raining.
• Weld only in daylight or in good articial light.
• The operator is responsible for accidents or hazards occurring to other people
or their property while using this equipment. Keep the work area safe!
• Keep bystanders a safe distance away from the machine while welding.
• Never allow people unfamiliar with these instructions to use the welding unit.
Safety Notes
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 5
Product Specication
Input Power Connections
for this model:
•110V version
• 120V version
ONLY AVAILABLE IN 110/120V SUPPLY AREAS
Input plug for your region or
country are available
Contact us for more information
Bespoke OEM
As a bespoke OEM Original Manufacturer we can
produce this product as an OEM to suit your business
Contact us to discuss your requirements
Specication details - ACT 40/80V
Operating Modes Manual, EasiGrip,
Barcode
Welding Voltage 39.5V (8 to 48V)
& 79V
Welding Current 1-65A
(100A Peak)
Welding Time 1-6000 seconds
Supply Voltage 115V ± 15%
(40-60Hz)
Supply Current 1-63A
Supply Power 7500 W
Weight 13 kg
Size 39 x 36 x 25cm
Operating Temp. -15ºC to +50ºC
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 6
This equipment is intended to weld constant voltage electrofusion ttings suitable for low,
medium and high pressure pipe work systems.
This welding unit has been approved in the UK by Transco to the standard T/SP/ECE/1
2005 ‘Specication for Electrofusion Control Boxes’, and is approved for use on all UK gas
distribution networks.
This welding unit complies with the UK Water Industry Specication WIS 04-32-08
‘Specications for the fusion jointing of polyethylene pressure pipeline systems using PE80
and PE100 materials’, and is suitable for use on all UK water distribution networks.
This welding unit has been designed to comply with the International Organization for
Standardization standard ISO12176-2:2000 “Plastic pipes and ttings, equipment for fusion
jointing polyethylene systems , part 2, electrofusion”, and can weld all bar coded ttings
including extended traceability codes.
This manual gives instructions on the correct assembly and safe use of your welding unit. It
is important that you read these instructions carefully, and keep these instructions for the
life of the unit.
This manual does not detail the specic welding procedure for the ttings: scraping,
clamping and assembly of joints. For this information you must contact the manufacturer of
the ttings.
Carefully remove the welding unit from its packaging and check that you have the following
items:
• Welding unit.
• Welding cable.
• USB ash memory drive.
• Bar code pen reader.
When parts are missing or damaged, please contact your dealer.
Intended Use
Introduction
Delivered Items
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 7
Electrical Safety
WARNING! Switch o and remove the plug from the mains before adjusting,
cleaning or if the cable is cut, damaged or entangled.
This welding unit is Class 1 and requires an earthed (grounded) connection. An earth
spike must be used with generators.
This unit is supplied in either 110 volt or 230 volt operation. Check the rating plate
on the side of the unit for the correct supply voltage.
The power source must be capable of providing 3500 Watts.
Extension cables should only be used if they comply with the H07RNF harmonized
standard. They must be tted with connectors to the BS EN 60309-2 standard. All
cables must be unwound from the reel to stop inductive heating eects. The cable
dimensions should be as follows:
It is recommended for increased electrical safety to use a Residual Current Device
(RCD) with a tripping current of not more than 30 mA. Always check your RCD every
time you use it.
The supply cable must be inspected for signs of damage before each use and the
equipment may only be used if in perfect condition. Damaged cables must be
replaced by an approved service agent.
This equipment is classied as “Portable for use on industrial applications”, and
must undergo a formal electrical safety check (Portable Appliance Test) as per local
regulations.
110V Volt operation
Up to 63mm diameter
2.5mm2 cable = 30m
Up to 180mm diameter
2.5mm2 cable = 20m
Over 180mm diameter
4.0mm2 cable = 10m
230 Volt operation
Up to 63mm diameter
1.5mm2 cable = 40m
Up to 180mm diameter
1.5mm2 cable = 25m
Over 180mm diameter
2.5mm2 cable = 20m
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 8
This welding unit takes the ambient temperature into account when calculating the
energy required to weld the tting. It must therefore be allowed to reach ambient
temperature before use and must be at the same temperature as the tting to be
welded.
Prepare and clamp the pipe and ttings inline with the manufacturers
recommendations.
Connect the welding cable to the unit and the tting to be welded. Connect the
supply cable to the correct supply voltage and switch the unit on.
The screen will show a welcome message along with the soware version and date.
The owner details are then shown
The main menu is now shown on the display. During operation, except while welding,
pressing the star key on the keypad will jump back to this menu.
Notes:
The operation of the unit can be customised by turning welding modes on
and o, along with some features like the cooling time and data logging. This
manual details all available modes and features. For information on how to
customise the welding unit see the “Set Up” section later on in this manual.
The welding unit is tted with an alpha-numeric keypad, which is used by the operator
to input data. Down the right hand side there are four Quick-Keys, A B C D. These act
as quick shortcut keys, their function being prompted on the screen.
When entering data, letters and numbers can be selected by repeatedly pressing the
same key, e.g. A B C 2 A B C 2 . Aer a short pause the cursor will move to the next
position. Special characters and spaces can be selected by pressing the 1 or 0 keys.
(This is the same method used for text with mobile cell phones.) Pressing the B Quick-
Key will step Back one position. Pressing the C Quick-Key will Clear the input eld.
Using the equipment
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 9
The unit can record information about the weld, along with the date and time, and
additional operator entered information.
It is possible to enter three pieces of information to identify the weld. The rst is the
Operator’s Name, the second is the Location where the weld is being done, and the
third is an Information eld for more details.
The display will show all three pieces of information:
Pressing the B Quick-key will select the ‘Operator Name’ and allow changes to be
made. Enter the required information and press the A Quick-key to accept it.
Pressing the C Quick-key will select the ‘Location’ and allow changes to be made.
Enter the required information and press the A Quick-key to accept it.
Pressing the D Quick-key will select the ‘Information Field’ and allow changes to be
made. Enter the required information and press the A Quick-key to accept it.
When all the information has been entered, press the A Quick-key to accept it.
This information will be saved when the weld has been completed, and will be
prompted the next time a new weld is carried out.
The display will also ask if the pipe/tting has been scraped and clamped. Select yes
or no using the Quick-Keys. This information will be saved on the data log memory.
The unit can save 2048 welds in memory. When the memory is full, it will be
overwritten from the beginning in blocks of 24 welds. This will allow the last 2000
welds to be held in memory.
An optional “lifetime weld memory” feature is available. This uses an SD memory card
tted internally that records every weld carried out by the unit. This is designed as a
backup device and can only be downloaded by an approved service agent.
Data Log Memory (Optional)
ACT40 Electrofusion Welding Unit - Operator Manual
ACT 40
© 2019. Advance Welding 10
This mode of operation is designed to weld all ttings in manual mode.
From the main menu:
Press the AQuick-Key to select manual welding, then:
Press the AQuick-Key to weld with data logging OFF.
Press the BQuick-Key to weld with data logging ON.
The display will ask for the welding cable to be connected to the tting. When this has
been done it will show the data logging options (if selected). Enter the information as
required.
The display will now prompt for the welding time and voltage to be entered. Press
the CQuick-key to select the welding time. Enter this from the numbered keypad,
e.g. 100. This can be between 1 second and 3600 seconds. Press the AQuick-key to
accept the new time.
(Optional voltage select) Press the DQuick-key to select the welding voltage. Enter
this from the numbered keypad, e.g. 26. This can be between 8 volts and 48 volts. A
default option of 39,5 is available. Press the AQuick-key to accept the new voltage.
When the correct time and voltage have been selected, press the AQuick-key to
accept them. The display will now ask for the START button to be pressed. Press Start
to begin welding.
During the weld, the display will show the set welding time, the remaining welding
time, the set welding voltage and the welding power generated in the tting. The unit
will also monitor the welding to make sure it does not go out of limits. Any faults that
are detected will terminate the welding and cause an error message to be displayed.
These are listed later on in this manual.
(Optional cooling time) At the end of the weld the cooling time will be shown. This
counts upwards from zero and will continue until stopped by the operator. This is
shown as an aid to the operator to allow them to know how long it was since the weld
nished. Press any key to continue.
The display will ask for the welding cable to be disconnected from the tting. Doing
this will reset the unit back to the welding menu.
Manual Welding (Optional)
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