Butt welding general procedure
view the Butt welding - general Procedure PDF.

 

Australian Industry Butt Welding Guidelines
view the Australian Industry Butt Welding Guidelines. (link opens in external window)

 

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

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

 

What hydraulic oil should be used in FUSIONMASTER® welders?
Any hydraulic oil with a viscosity that matches the ISO viscosity grade 46.

 

What power is drawn by FUSIONMASTER welders?

Model	Power used continuously operating all electrical components
110 or MV70 225 350 450 630 1000 1200	240 volt - 1 phase – 2.0 kva 240 volt - 1 phase – 3.5 kva 240 volt - 1 phase – 5.0 kva 415 volt - 3 phase – 7.5 kva 415 volt - 3 phase – 10.0 kva 415 volt - 3 phase – 30.0 kva 415 volt - 3 phase – 35.0 kva

 

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

 

Notes about heater plates and temperature
view the Notes about heater plates and temperature PDF.

 

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

 

Is PTFE cloth as good as a PTFE coating?
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.

 

How is air bled from the hydraulics of FUSIONMASTER® welders?
Please download and refer to the maintenance section of the relevant operator manual.

 

What is the recommended cleaning process for heaters and facers?
The cleaning regime used will depend on the amount and type of contamination. But there is a right way and a wrong way.

Most contamination is likely to stem from the heater. Any PTFE heater surface will slowly break down and eventually lose its non-stick characteristic. The PTFE surface should then be replaced. The rate of PTFE breakdown depends on the welding temperature, the number of hours at temperature, and the abrasiveness of the cleaning process, e.g. use of some solvents reduces the PTFE life.

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

If mud/dirt on the pipe could fall into the weld zone, remove it with a wet cloth, and remove any moisture with a dry paper towel or cotton cloth.

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 is still there. 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.

 

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

 

What is 'dual pressure' welding?
'Dual pressure' is a technique used predominantly in the UK for welding PE100 pipe. This method differs form the commonly used procedure in that the weld pressure is maintained for only 10 seconds and then the pressure is reduced to just above drag pressure for the remainder of the welding+cooling time. This method is not supported by Australian pipe makers..

 

Can PE80 be welded to PE100?
Yes, but because the materials are different, the bead size will not be equal. Talk to your pipe or fittings supplier for more information.