Dixon Industries

Dixon Industries for FUSIONMASTER® PE butt welding equipment, and Teflon® coating services

FAQ

Q. Butt Welding General Procedure:

A. View the Butt welding - general Procedure PDF

Q. Australian Industry Butt Welding Guidelines

A. View the Australian Industry Butt Welding Guidelines

Q: Can FUSIONMASTER® butt welders do 'high pressure' welding as in ISO 21307.

A: FUSIONMASTER® butt welders are designed to apply pressure according to 'single pressure – low pressure' and 'single pressure – dual pressure' butt welding parameters. They are not generally capable of safely delivering sufficient pressure to meet 'single pressure – high pressure' parameters. It is not practical to modify the equipment to for 'high pressure' welding.

Q. What is the cylinder area of FUSIONMASTER® welders for weld calculations?

A.

Model - Cylinder area
225 - 753mm2
350 - 1233mm2
450 - 2027mm2
630 - 2027mm2
1000 - 4940mm2
1200 - 6428mm2

Q. What hydraulic oil should be used in FUSIONMASTER® welders?

A. Any hydraulic oil with a viscosity that matches the ISO viscosity grade 46.

Q. What power is drawn by FUSIONMASTER® welders?

A.

Model: Power used continuously operating all electrical components.
110 or MV70: 240 volt - 1 phase – 2.0 kva
225: 240 volt - 1 phase – 3.5 kva
350: 240 volt - 1 phase – 5.0 kva
450: 415 volt - 3 phase – 13.0 kva
630: 415 volt - 3 phase – 15.0 kva
1000: 415 volt - 3 phase – 25.0 kva
1200: 415 volt - 3 phase – 30.0 kva

Q. I am getting a big temperature difference on either side of the heater plate. What's wrong?

A. FUSIONMASTER® heaters are tested before they leave the factory to ensure that the maximum temperature variation anywhere on the surface is less than 20°C. The variance is usually less than 10°C.

If your temperature readings differ by more than 20°C, it will probably be caused by the way temperature is being measured. The cause of large variations from side to side is usually entrapment of an insulating air bubble between the plate and the PTFE cloth. Make sure that the cloth is in contact with the hot plate surface before measuring the temperature. Check that the air escape slot cut in the heater plate circumference is unobstructed.

Q. Notes about heater plates and temperature

A. View the Notes about heater plates and temperature PDF

Q. Why aren't FUSIONMASTER® heater plates PTFE coated?

A. The appropriate PTFE material for coating of heater plates can only be applied to a thickness of about 0.050mm. Such coatings do not have good abrasion resistance and are easily damaged allowing plastic to stick to the aluminium hot plate. As the non-stick surface degrades (either coating or cloth system) it becomes a source of contamination that can lead to weld failure. Recoating is essential, but as PTFE coaters are few and far between, the contaminated heater is often left in service to keep the job going. This is a dangerous practice. The FUSIONMASTER® cloth system can be easily changed in the field so lost time is minimised and weld quality is assured.

Q. Is PTFE cloth as good as a PTFE coating?

A. The PTFE cloth is actually a fibreglass material impregnated with PTFE. The non-stick characteristic of the cloth system is only slightly less than that of a PTFE coating. However the cloth is 0.132mm thick and has better resistance to damage than a PTFE coated heater.

Q. How is air bled from the hydraulics of FUSIONMASTER® welders?

A. Please download and refer to the maintenance section of the relevant operator manual.

Q. What is the recommended cleaning process for heaters and facers?

A. The cleaning regime used will depend on the amount and type of contamination. 

First remove any mud/dirt on the pipe with a wet cloth to prevent it falling into the weld zone. Remove any residual moisture with a dry paper towel or cotton cloth. 

Assuming the heater non-stick surface is in good condition, our cleaning recommendation is to wipe the facer and heater with a dry paper towel or cotton cloth before every weld. Do not use synthetic cloth material as this is likely to melt causing additional contamination. 

The pipe end will never be cleaner than just after it has been faced. Never touch the pipe face with anything after facing. 

We recommend against using solvents as they may simply dissolve contaminants and spread them around. When the solvent evaporates the contaminant remains. If for some reason a solvent is used during cleaning, the solvent should be washed away with water, and then moisture removed with a dry cloth. 

Any non-stick heater surface will slowly break down and eventually lose its non-stick characteristic. The non-stick surface must then be replaced. The rate at which it breaks down will depend on the welding temperature, the number of hours at temperature, and the abrasiveness of the cleaning process. The use of some solvents will hasten this process.

Q. Why don't FUSIONMASTER® butt welders have a removable clamp for T welding?

A. FUSIONMASTER® welders (model 350 and larger) have a pipe alignment mechanism instead of a removable clamp. It is not physically possible to have both features!

Our research has shown that aligning pipe ends is a much bigger problem in the field than welding T's. Overcoming alignment problems adds large amounts to set up times, and these times increase as the pipe diameter increases. Make sure you order T's and elbows with sufficient leg length to enable them to be clamped in the welder.

Q. Can PE80 be welded to PE100?

A. Yes, but because the materials are different, the bead size will not be equal. Talk to your pipe or fittings supplier for more information.

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