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Table of Contents
Summary of Contents for Raptor RAPPACT3110
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Page 1: Installation Instructions
Electrofusion Welding Unit Installation Instructions RAPPACT3110... -
Page 2: Table Of Contents
OPERATIng MAnUAl COnTEnTs Operating Controls Safety Notes Product Specification Intended Use Introduction Delivered Items Electrical Safety Quick Start Guide 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 Software Set Up Options Information Fault Codes Maintenance Disposal Calibration and Warranty Declaration of Conformity Service and Repair... -
Page 3: Operating Controls
Operating Controls 1 Welding Cable (can be provided with optional right angle plug) USB Memory Drive Bar Code Scanner (Optional) 3 Bar Code Pen and Cord (Standard) 4 USB Socket 5 Welding Cable Socket 6 Protective Lid 7 Display 8 Buttons 9 Protective Frame 10 Ratings Plate 11 Supply Cable 12 Fuse Holder... -
Page 4: Safety Notes
safety notes 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 off 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 fitting. • Do not lift or pull the equipment by its cables. • Do not disconnect the welding cables by pulling on them; always pull off the connectors from the fitting. • Do not start a weld without the pipe correctly inserted into the fitting. • Do not touch the fitting while welding. • Do not weld in the rain or leave the equipment outdoors while it is raining. • Weld only in daylight or in good artificial light • The operator is responsible for accidents or hazards occurring to other people or their property while using this equipment. • Keep your work area safe! •... -
Page 5: Product Specification
RAPTOR Electrofusion Welding Unit — Operator Manual — Rev: 3.4.g PRODUCT sPECIFICATIOn Operating Type: Controlled voltage. Operating Modes: Manual, Fusamatic#1, Bar Code Operating Languages: English, French, Dutch, Polish, Russian. (others on request) Operating Temperature: 14oF to 104oF #2 Welding Voltage: 8 to 48 V ac (39,5 V) Welding Current: 1 to 65 A ac (true rms) (100 A short term) Welding Power: 8 VA to 3120 VA Welding Time: 1 to 3600 seconds Apparent Power Factor: 0.15 to 0.92 Supply Voltage: #3 110 V ac (+/- 20%) 40 to 60 Hz Supply Current: #3 1 to 30 A ac (true rms) Supply Power: #3 3,500 W (peak at 0.15 APF) Supply Voltage: #4 230 V ac (+/- 20%) 40 to 60 Hz Supply Current: #4 1 to 15 A ac (true rms) Supply Power: #4 3,500 W (peak at 0.15 APF) Supply Protection: Class 1 – Earthed Data log memory: 2048 welds Data download/upload: USB flash memory drive Weight: 60 lb Size: 15 inch x 15 inch x 15.5 inch Protection Level: IP65 #1 Fusamatic is a welding system owned by The Fusion Group PLC. #2 An extended temperature unit is available with limits -40oF to +122oF. #3 #4 The unit is available in either 110v or 230v operation. Advance Welding has a policy of continuously improving product design, and as such reserve the right to change specification of its products without prior notice and with impunity. InTEnDED UsE This equipment is intended to weld constant voltage electrofusion fittings suitable for low, medium and high pressure pipe work systems. This welding unit has been approved in the U K by Transco to the standard T/SP/ECE/1 2005 ‘Specification for Electrofusion Control Boxes’, and is approved for use on all U K gas distribution networks. -
Page 6: Delivered Items
DElIvERED ITEMs Carefully remove the welding unit from its packaging and check that you have the following items: • Welding unit • Welding cable • USB flash memory drive • Bar code pen reader When parts are missing or damaged, please contact your dealer. 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. ElECTRICAl sAFETY Extension cables should only be used if they comply with the HO7RNF harmonized standard. They must be fitted with connectors to the BS EN 60309-2 standard. All cables must be unwound from the reel to stop inductive heating effects. The cable dimensions should be as follows: 110 Volt operation 230 Volt operations Up to 63mm diameter Up to 63mm diameter 2.5mm2 cable = 30m 1.5mm2 cable = 40m Up to 180mm diameter Up to 180mm diameter 2.5mm2 cable = 20m 1.5mm2 cable = 25m Over 180mm diameter Over 180mm diameter 4.0mm2 cable = l0m 2.5mm2 cable = 20m 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. -
Page 7: Quick Start Guide
QUICK sTART gUIDE • Prepare the pipe and fitting according to the manufacturer’s specification. • Unwind all cables from the welding unit. • Connect the welding cable to the fitting. • Connect the supply cable to the correct voltage and switch it on. • The unit will power up and go to the main menu. • Press the B Quick-key to select Automatic welding. • Press the D Quick key to select Bar Code welding. • If the unit is set to data log, enter the details as shown on the screen. • Read the bar code on the fitting with the pen/scanner. • Press the Start button. • The time will count down to zero as the fitting is being welded. Any faults will be indicated on the display. • At the end of the weld, disconnect the welding cable to reset the unit. • Press the Star key to return to the main menu if required. -
Page 8: Using The Equipment
UsIng THE EQUIPMEnT This welding unit takes the ambient temperature into account when calculating the energy required to weld the fitting. It must therefore be allowed to reach ambient temperature before use and must be at the same temperature as the fitting to be welded. Prepare and clamp the pipe and fittings inline with the manufacturer’s recommendations. Connect the welding cable to the unit and the fitting 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 software 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 customized by turning welding modes on and off, along with some features like the cooling time and data logging. This manual details all available modes and features. For information on how to customize the welding unit see the “Set Up” section later on in this manual. The welding unit is fitted 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. After 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 field. 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 first is the Operator’s Name, the second is the Location where the weld is being done, and the third is an Information Field 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/fitting 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 fitted 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. -
Page 9: Manual Welding
MAnUAl WElDIng This mode of operation is designed to weld all fittings in manual mode. From the main menu: Press the A Quick-Key to select manual welding, then: Press the A Quick-Key to weld with data logging OFF. Press the B Quick-Key to weld with data logging ON. The display will ask for the welding cable to be connected to the fitting. 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 C Quick-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 A Quick-key to accept the new time. (Optional voltage select)Press the D Quick-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 A Quick-key to accept the new voltage. When the correct time and voltage have been selected, press the A Quick-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 fitting. 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 finished. Press any key to continue. The display will ask for the welding cable to be disconnected from the fitting. Doing this will reset the unit back to the welding menu. FUsAMATIC WElDIng This mode of operation is designed to weld the fully automatic “Fusamatic” fittings, manufactured and sold by The Fusion Group. From the main menu: Press the B Quick-Key to select automatic welding. Press the A Quick-Key to select Fusamatic welding. Press the A Quick-Key to weld with data logging OFF. Press the B Quick-Key to weld with data logging ON. The display will ask for the welding cable to be connected to the fitting. Make sure that the red lead end is attached to the red terminal on the Fusamatic fitting and the black lead end to the other. When this has been done it will show the data logging options (if selected). Enter the information as required. The unit will now read the fitting and set the welding time accordingly. This will be displayed. 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 fitting. 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 finished. Press any key to continue. -
Page 10: Fusion Operator Badge
The display will ask for the welding cable to be connected to the fitting. When this has been done it will show the data logging options (if selected). Enter the information as required. (Optional extended traceabililty) If selected, the unit will prompt for the extended traceability codes to be read from the fitting. Up to five codes can be read from fittings, pipes and accessories. When complete, press the A Quick-Key to continue. The display will ask for the fusion bar code to be read. When this has been done the display will show the set welding parameters. 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 fitting. 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 finished. Press any key to continue. The display will ask for the welding cable to be disconnected from the fitting. Doing this will reset the unit back to the welding menu. FUsIOn OPERATOR bADgE To allow full traceability of the operator, and stop untrained people using the equipment, an Operator Badge system is available. Using an approved training centre, the operator is trained on the correct use of the equipment and then issued with an operator badge that has his details encoded on it. When the welding unit is switched on, the operator badge must be read with the bar code pen (or scanner) to unlock the unit and allow welding to take place. Details from the operator badge are recorded in the data log memory. Three standard modes of operation are available: 1. Every Day. The first time the welding unit is used every day, the operator badge must be read. This will unlock the unit for use all day and will then automatically relock at midnight (even if the unit is not powered on). It can also be relocked by reading the operator badge again. 2. Every Power. Every time the welding unit is switched on, the operator badge must be read to unlock the unit. It will remain unlocked until switched off. 3. Every Weld. Every time a weld is carried out, the operator badge must be read to unlock the unit This is required even if the unit is not powered off. To activate these modes of operation, please contact your approved service agent. Friatec Fittings. This unit is approved to weld the Friatec Large Diameter couplers, manufactured by Friatec, only when used with the Friatec Operator Badge system. To maintain the Friatec warranty, the installer must be trained by an authorized agent and be issued with a Friatec Operator Badge. Only trained operators should install these fittings. gPs lOCATIOn The welding unit has the ability to record the GPS satellite location of the weld. This is stored as Northing’s and Easting’s and entered into the data log along with an optional depth. Using a hand held GPS device, the location of the weld can be found, and then this is entered into the data log memory along with the operator name, location and information To activate these modes of operation, please contact your approved service agent. lOW TEMPERATURE OPERATIOn The welding unit has an extended temperature range option, which allows it to work down to -40°F. This unit has special supply and welding cables that remain flexible at extremely low temperatures. It also has an internal case heater to warm the electronics to an acceptable... -
Page 11: Downloading The Weld Memory
Plug the welding unit into the correct supply voltage and switch it on. The internal case heater will switch on and an indicator light will show on the lid next to the display. When the internal temperature warms to the correct level, the case heater will switch off, the indicator light will switch off and the electronics will switch on. The operation of the unit is now as previously described. Extended temperature range facility is a factory-fitted option and must be requested when ordering the product from you supplier. DOWnlOADIng WElD MEMORY The data log memory is downloaded by using an ‘industry standard’ USB flash memory device. The data can be encrypted for protection, to stop unauthorized alteration of the information. A data download manager is available free of charge and is supplied on the USB memory device with the welding unit This allows the encrypted data to be read, filtered, printed and saved. It also allows the data to be saved as an encrypted file or as a Microsoft Excel spreadsheet. Plug the USB flash memory drive into the USB connector on the side of the welding unit From the main menu: Press the D Quick-Key to select options. Press the A Quick-Key to select download data. Confirm that you want to download the data. The display will show that it is “Enumerating the device”. While this is showing, the unit is initializing the memory drive. The data will now be downloaded. The display will ask if you want to reset the data log memory. Select yes or no then disconnect the memory drive when prompted to do so. The data can be download as either an encrypted PFD file, or as a plain text XLS file. To change the settings please contact your approved service centre. UPgRADIng THE sOFTWARE The operating software can be upgraded through the external USB connector. New software is loaded onto a USB memory drive then flashed into the welding unit using a password code. This allows the software to be upgraded without opening up the unit or changing the memory chip. Software upgrade must be carried out by an approved service agent, and are email led from the manufacturer. sET UP OPTIOns From the main menu: Press the D Quick-Key to select options. From here the time can be set by the operator. Other changes can be made, however, these are password protected and must be carried out by an approved service agent. The following options are available: Date. The date can be set. Display Language. -
Page 12: Fault Codes
Owner Details The owner details, shown when the unit is first switched on, can be entered or changed. Download Format The format of the data log download can be changed from protected PFD to plain text XLS. Hidden Data Download Even when data logging is not selected for a weld, details are still recorded but then hidden from the normal data download, and not selected when the data is downloaded to a USB memory disk. To aid fault finding, all welds carried out including those “not logged” can be downloaded. Lifetime Weld Memory (Optional hardware) The entire weld memory for the lifetime of the welding unit is stored in an internal SD memory card. This can be downloaded as an archive of all welds carried out. - Page 13 7: Ambient temperature less than -40°C. The unit has detected that the ambient temperature is very cold or the sensor has broken. If the temperature is not below -40°C then the unit will need to be returned to a service agent for repair. 8: Ambient temperature more than +600°C. The unit has detected that the ambient temperature sensor has broken or a wire has gone open circuit. The unit must be returned to a service agent for repair. 10: Low supply frequency <40Hz The unit has detected that the supply frequency is below 40 Hz. This will normally be caused by a poor quality generator. If this fault happens then check the supply or change the generator. 11: High supply frequency >70Hz The unit has detected that the supply frequency is above 70 Hz. This will normally be caused by a poor quality generator. If this fault happens then check the supply or change the generator. 12: High supply voltage >140v (or 280v with a 220v supply) The unit has detected that the supply voltage is more than 140 volts (280 volts with a nominal 220v supply). Check the supply voltage and if necessary use a different generator. 13: Low supply voltage c95v (or 190v with a 220v supply) This fault can be caused by a few problems. It could be that the generator is running slowly and so the supply voltage is low. Try speeding the generator up or use a different generator. It could also be caused by a generator that is too small. If a large fitting is welded, then a large amount of power will be needed from the generator. If it can not supply this power then it will stall and the voltage will drop away. Check that the generator is the correct size, if needs be try another generator. It could be caused by the use of long extension leads. If a large fitting is welded then a high current will be taken from the supply. If extension leads are used, there will be a volts drop down the lead making the unit sense a low supply voltage. Try not to use extension leads with the unit. If you have to then use just 10 meters of 4.0mm2 cable, the same size fitted to the unit. 14: Relay failed to latch on weld start This fault could happen when the start button is pressed. If the main power relays do not operate correctly then this fault will be shown. The unit needs to be returned for service. 20: Low output volts (-1.25%) This fault will happen if the output voltage is 1.25% lower than the set point for more than 3 seconds. This can be caused by a generator that is not big enough to supply the required power to the fitting. Check the size of the generator and if needs be try another generator. It can also be caused by using long extension leads with the unit. It is recommended that only 10 meters of extension are used, and the cable should be the same thickness as the input lead on the unit (4.0mm2). 21: High output volts (+1.25%) This fault will happen if the output voltage is 1.25% higher than the set point for more than 3 seconds. It will normally be caused by a poor quality generator with the supply voltage fluctuating. Try a different generator. 22: Excess output volts (+6.25%) This fault will happen if the welding voltage is 6.25% more than the set point for more than 2 seconds. This fault is normally caused by a fault within the unit, a short circuit triac. The unit must be returned for service. 23: Low output current (c2.5A) This fault will happen if the welding current is below 2.5 amps for more than 3 seconds. It can be caused by a faulty fitting. Try another fitting. If this doesn’t clear the fault then there is a problem inside the unit and it must be returned for repair.
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Page 14: Maintenance
30: Bar Code Mode: No fitting connected This fault is shown if the output lead is not connected to a fitting when a bar code is read. Connect the fitting. 31: Bar Code Mode: Ohms error This fault is shown if the connected fitting resistance is different from that coded into the bar code. Try another fitting. 40: Bar Code Invalid: Temperature Compensation. Digits 22 and 23 of the bar code have been decoded incorrectly. 41: Bar Code Invalid: Resistance Coefficient. Digit 18 of the bar code has been decoded incorrectly. 42: Bar Code Invalid: Welding Voltage. Digits 13 and 14 of the bar code have been decoded incorrectly. 43: Bar Code Invalid: Regulation Mode. Digit 12 of the bar code has been decoded incorrectly. 44: Bar Code Invalid: Fitting Size. Digits 9, 10 and 11 of the bar code have been decoded incorrectly. 45: Bar Code Invalid: Cooling Time. Digit 7 of the bar code has been decoded incorrectly. 46: Bar Code Invalid: Fusion Cycle Type. Digit 5 of the bar code has been decoded incorrectly. 47: Bar Code Invalid: Energy Correction. Digit 3 of the bar code has been decoded incorrectly. 48: Bar Code Invalid: Component Type. Digits 1 and 2 of the bar code have been decoded incorrectly. 49: Bar Code Invalid: Check Digit. Digit 24 of the bar code has been decoded incorrectly. 50. USB Memory: Disc full. This fault will happen if the USB flash memory pen is full. Delete some from the device. 51: USB Memory: File allocation table full. This will happen if the USB flash memory pen’s file structure becomes fragmented. Follow the instructions with Windows to de-fragment the memory pen. 52: USB Memory: File not found. When performing a software upgrade, the required file was not found on the memory drive. Reload the upgrade files onto the memory drive. 127: Power off failure. If the power is turned off while the unit is welding, this fault will be recorded to the data log. MAInTEnAnCE Regularly check for obvious defects such as loose or damaged cables and connectors. Look for worn components and broken covers or housings. There are no user serviceable parts inside the unit It should be returned to an approved service agent for repair and calibration. It is recommended that the unit is calibrated every twelve months. After use, clean the outside of the unit with a soft brush or cloth. Carefully wind up and store the cables around the frame in the location provided. DIsPOsAl The equipment and packaging should be sorted for environmentally friendly recycling. -
Page 15: Calibration And Warranty
According to the European Directive 2005/95/EC Restriction of Hazardous Substances (RoHS), this equipment does not contain more than the agreed levels of lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyl (PB B) and polybrominated diphenyl ether (PBDE) flame retardants. This welding unit has been manufactured, inspected and tested in accordance with the quality control systems in place at Advance Welding. This welding unit has been calibrated using equipment that is traceable to national and international standards, through a NAMAS accredited laboratory. NAMAS (National Accreditation of Measurement and Sampling) is a service of U KAS (United Kingdom Accreditation Service). This welding unit has a TWELVE month calibration and warranty period, active from the first use of the unit by the end user customer. CAlIbRATIOn & WARRAnTY Conditions of Warranty: This warranty covers only those defects to the product which arise from normal use of the product, and will become invalid if any of the following apply: • Failure to follow the operating instructions. • Improper or inadequate maintenance. • Unauthorized modification. • Misuse or any use not in accordance with the operating manual or good industry practice. -
Page 16: Declaration Of Conformity
DEClARATIOn OF COnFORMITY The applicable standards are: with the harmonized standards under the New Approach directives, and has been CE marked accordingly. Electromagnetic compatibility Low voltage equipment Machinery safety More detailed information is available on our web site at www.ElectrofusionWelding.com On behalf of Advance Welding: This welding unit has been designed to comply Unit B Orchard Works Spen Vale Street Heckmondwike West yorkshire WF16 ONQ United Kingdom www.ElectrofusionWelding.com FOR sAlEs, sERvICE AnD REPAIR: Area 3 UTAH Area 1 WASHINGTON 1055 West 650 North, Centerville, UT 84014-0668. 740 South 28tb Street, Washougal, WA 98671. Phone 801-295-4373 Phone 800-634-5082 Area 4 INDIANA Area 2 ARIZONA 2702 North Tibbs Avenue, Indianapolis, IN 46222-2131. 1215 East Warehouse Avenue, Tucson, AZ 85719-6755 Phone 866-620-4373 Phone 866-930-4373 Area 5 FLORIDA 1995 Lasso Lane, Lakeland, FL 33801.
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