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Kerotest Shannon Portafuse III Operator's Manual

Electrofusion processor
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Summary of Contents for Kerotest Shannon Portafuse III

  • Page 3: Safety

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 SAFETY • Please read and understand this instruction manual before using Shannon or Portafuse III Electrofusion Processors. • Gas company safety standards and precautions should be followed at all times.

  • Page 4: Table Of Contents

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 TABLE OF CONTENTS Safety ..................................1 Warranty And Limitation Of Liability ........................4 Introduction ................................6 Preface ................................6 Features ................................6 Processor Overview ............................7 Shannon ..............................7 Portafuse III ..............................
  • Page 5 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Appendix ................................36 Scanning Barcodes ............................36 Barcode Wand ............................36 SMART Scanner™ ............................36 Using an External Transformer ........................40 Entering Data with the Keypad ........................40 Traceability ..............................

  • Page 6: Warranty And Limitation Of Liability

    EF TECHNOLOGIES, INC. does not warrant that the operation of Kerotest Electrofusion Processors will be uninterrupted or error free.
  • Page 7 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 EF TECHNOLOGIES, INC.’S LIABILITY IN RESPECT TO THE SALE IS STRICTLY LIMITED TO THE REPLACEMENT OF PROCESSORS OR SERVICES AS HEREINBEFORE SPECIFIED AND EF TECHNOLOGIES, INC. SHALL NOT, IN ANY EVENT, BE LIABLE FOR ANY DAMAGES WHETHER FOR THE LOSS OF USE OR BUSINESS INTERRUPTION OR ANY OTHER CLAIM FOR INCIDENTAL, CONSEQUENTIAL, SPECIAL OR PUNITIVE DAMAGES.

  • Page 8: Introduction

    Kerotest Electrofusion Processors are equipped with internal memory for data storage and can be downloaded to determine installation conditions and fusion cycle status. Kerotest Electrofusion Processors are capable of scanning and recording both ASTM F2897-11 and ISO 12176- 4 Traceability barcodes.

  • Page 9: Processor Overview

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Processor Overview Shannon The Shannon is a full-featured, transformer-based Electrofusion Processor designed to meet all of your electrofusion needs in one convenient package. The internal transformer ensures access to the full output capability of the processor every time you take it to a job site.

  • Page 10: Specifications

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Specifications Parameters Shannon AC Portafuse III Battery 48 Volts DC Supply Voltage 97 VAC to 150 VAC 97 VAC to 150 VAC with the optional AC transformer Supply Frequency...

  • Page 11: Descriptions Of Controls

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Descriptions of Controls NOTES References to controls in this section are displayed exactly as they appear throughout the remainder of this document. The START button may mean START, CONTINUE, OK or SAVE depending upon the context of the operation being performed at the time.

  • Page 12: Faceplate View: Shannon Usb

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Faceplate View: Shannon USB Download Port AutoCal® Port Replaceable Display Shield 4X20 LCD Display START button STOP button UP button DOWN button Page 10 of 60...

  • Page 13: Faceplate View: Shannon Bluetooth

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Faceplate View: Shannon Bluetooth Bluetooth Antenna Replaceable Display Shield 4X20 LCD Display START button STOP button UP button DOWN button Page 11 of 60...

  • Page 14: Faceplate View: Portafuse Iii

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Faceplate View: Portafuse III AutoCal® Port 4X20 LCD Display Replaceable Display Shield Download Port START button STOP button UP button DOWN button Page 12 of 60...

  • Page 15: Left Side View

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Left Side View Shannon Output Cable Portafuse III Power Switch Buzzer Battery Pigtail Connector Output Cable Page 13 of 60...

  • Page 16: Right Side View

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Right Side View Shannon Power Switch Fuse Input Cable Back Side View Portafuse III External Transformer Connector Page 14 of 60...

  • Page 17: Output Cable Options

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Output Cable Options Output Lead Ends Temperature Sensor Barcode Wand / SMART Scanner™ Output Cable Fitting Adapters 4.7mm 90 degree 4.0mm 90 degree Adapter Wrench Page 15 of 60...

  • Page 18: Scanner Options

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Scanner Options SMART Scanner™ Barcode Wand Page 16 of 60...

  • Page 19: Customer Responsibilities

    Subscribe to the recommended calibration service offered by the manufacturer (see page 18). Kerotest Electrofusion Processors provide the proper outputs for a complete fusion based on the inputs received from a scanned barcode (in Barcode Mode) or from the operator (in one of the alternate fusion modes).

  • Page 20: Service Recommendations

    Always store the barcode wand or SMART Scanner™ in its sheath when not in use. Proper care of the processor and output cable will greatly extend the life of your Kerotest Electrofusion Processor and help reduce service times and costs.

  • Page 21: Service Contact Information

    There are two (2) options for calibrating your Kerotest Electrofusion Processor: Send the processor in to a KEROTEST MANUFACTURING CORP service center and let our technicians do it. This is the recommended method and will help ensure the maximum service life of the processor.

  • Page 22: General Operation

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 GENERAL OPERATION Modes of Operation Kerotest Electrofusion Processors have multiple modes of operation: Primary Fusion Mode Barcode Fusion Mode Barcode Fusion Mode infers that fusion parameters are input into the processor by scanning a barcode label attached to the fitting being fused.

  • Page 23: Power Up

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Manual Mode FOR EXPERT OPERATORS ONLY! Manual Mode infers that the fusion voltage and time are obtained directly from the operator at the time of the fusion. Manual Mode should only be used when the barcode is malfunctioning or unavailable.

  • Page 24: Portafuse Iii

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Portafuse III The correct power up sequence for the Portafuse III Electrofusion Processor depends on whether you are powering the processor with the battery pack or with the external transformer. The correct sequence for each...

  • Page 25: Boot Sequence

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Boot Sequence After the processor has turned ON, start-up screens similar to the following will be displayed one after another: INTERNAL SELF TEST Please wait... INTERNAL SELF TEST SHANNON CAL DUE –...

  • Page 26: Barcode Fusions

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Pressing and holding down the UP button while the processor is at the CONNECT FITTING screen will show a screen similar to the following: 1.2.3 SN:9690123 SW: ON 03...
  • Page 27 If the scanning device is inoperative, see page 26 for details about how a fusion can be completed without using a scanning device. Once the barcode has been successfully scanned, the Kerotest Electrofusion Processor will display a screen similar to the following:...

  • Page 28: Alternate Fusion Methods

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 NOTE: If Calculated Resistance is enabled and the operator receives a Warning Code 55, refer to the appropriate section on page 42 for instructions that detail how to proceed.

  • Page 29: Manual Data Entry

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 If no errors were encountered, the Kerotest Electrofusion Processor will display a screen similar to the following: VERIFY SETUP INNO 2” COUPL 40.0V 60 sec PRESS START The VERIFY SETUP screen allows the operator a final opportunity to verify that the fusion parameters displayed are correct and match the parameters specified by the fitting manufacturer before starting the fusion.
  • Page 30 When the desired number of seconds are displayed, press the START button. Once the data has been successfully entered, the Kerotest Electrofusion Processor will display a screen similar to the following:...

  • Page 31: Monitoring A Fusion's Progress

    See page 29 for instructions on monitoring the progress of a fusion. Monitoring a Fusion’s Progress Once the START button is pressed the fusion process will begin. The fusion process begins with a Fitting Resistance Verification. The Kerotest Electrofusion Processor will display a screen similar to the following: VERIFYING FUSION...
  • Page 32 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 As the fusion proceeds, the following screen will be displayed: FUSION NUMBER: 0125 60 sec This screen shows the number of the current fusion as well as the time remaining (In this case, 60 seconds). If...
  • Page 33 OUTPUT LEADS FUSION NOT COMPLETE Errors Encountered After the Output Lead Ends are disconnected, the Kerotest Electrofusion Processor will retu rn to the CONNECT FITTING screen and will be ready to accept information for the next fusion. NOTE: If Operator Traceability is enabled, remember that the Operator ID codes entered previously will remain attached to any additional fusions until the power is shut off or until the information is changed by the operator.

  • Page 34: User Menus

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 USER MENUS Basic User Menu The Basic User Menu is accessed by holding the UP button when the processor is first powered up. Keep holding the UP button through the INTERNAL SELF TEST until the processor displays a screen similar to the...

  • Page 35: Setting The Language

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Setting the Language When Option 3 is highlighted, press the START button to select it. Use the UP/DOWN buttons to toggle between all supported languages. When the desired language is displayed, press the START button to save.

  • Page 36: Operator Id

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Operator ID This setting controls the Operator Traceability functions. This option is different than Pipe/Fitting Traceability. Pipe/Fitting Traceability is discussed below. Values for Operator Traceability are “OFF”, “ON”, or “SCAN”: •...

  • Page 37: Features Menu

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Features Menu The Features Menu is accessed by holding the UP and DOWN buttons at the same time when the processor is first powered up. Keep holding the UP/DOWN buttons through the INTERNAL SELF TEST screen, until the...

  • Page 38: Appendix

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 APPENDIX Scanning Barcodes Barcode Wand When using a Barcode Wand, make sure the SMART SCANNER setting is “OFF” (See page 33). While holding the wand at a slight angle as you would a pencil, position the point slightly to one side of the label and move the wand rapidly across the barcode stopping at a point slightly off the label on the other side.
  • Page 39 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Once the barcode has been successfully scanned, the fitting information will be shown on the display. It could look something like this: INNO 2” COUPL 60 sec START? This should be the same data that is displayed on the screen of the processor and is an indication that the fusion is ready to be started.
  • Page 40 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 When the device is first started, it may take up to 2 minutes to acquire 5 satellites. During the acquisition process the display will look something like this: CONNECT FITTING GPS Searching .
  • Page 41 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Scanning Techniques To scan a barcode, start by holding the SMART Scanner™ about 6-8 inches from the barcode to be scanned. Next, press and hold the button. A red aiming light will emanate from the end of the device as long as the button is held.

  • Page 42: Using An External Transformer

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Using an External Transformer The Portafuse III Electrofusion Processor can be optionally equipped with an external transformer to increase its output capability from 30 amps to 80 amps. The transformer plugs into the red connector located on the back right corner of the processor (also see page 14).

  • Page 43: Traceability

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Traceability Pipe/Fitting The Gas industry has been promoting the adoption of traceability barcodes by manufacturers of pipe and fittings, through the ASTM F2897-11 and ISO 12176-4 standards. These barcodes contain the manufacturer’s data that pertains to the construction of the pipe/fittings that are being fused.

  • Page 44: Operator Id

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Operator ID The Operator ID codes are an option that can only be enabled through the Advanced User Menu (See page 33). When enabled, Operator ID codes can be entered in two ways: •...
  • Page 45 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 IT IS THE RESPONSIBILITY OF THE OPERATOR TO VERIFY THAT ALL THE INFORMATION DISPLAYED IS CORRECT PER THE FITTING MANUFACTURER’S RECOMMENDATIONS FOR FUSING THE ATTACHED FITTING UNDER THE CURRENT AMBIENT CONDITIONS.
  • Page 46 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 To PERFORM SECONDARY CHECK: Press the START button to begin a Calculated Resistance check and attempt to continue the fusion. The processor will begin the fusion process and display a screen similar following:...

  • Page 47: Downloading Data

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Downloading Data Data Stored The following data is stored for each fusion that the processor performs. Depending on the processor model, data stored in the processor can be downloaded to a USB Flash drive or wirelessly via Bluetooth with the EF Utilities app.

  • Page 48: Downloading To A Usb Flash Drive (Usb Models Only)

    Downloading to a USB Flash Drive (USB models only) Fusion data from a Kerotest USB Electrofusion Processor is downloaded onto an external USB flash drive. The data is output in a binary format that is compatible with a free macro-enabled Excel Spreadsheet available from KEROTEST MANUFACTURING CORP.

  • Page 49: Downloading Wirelessly (Bluetooth Models Only)

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Downloading Wirelessly (Bluetooth models only) Fusion data from a Shannon Bluetooth Electrofusion Processor is downloaded wirelessly through the EF Utilities app. Once the data has been downloaded, it can be viewed at any time with a smart phone, tablet, or computer.

  • Page 50: Position Accuracy

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Position Accuracy GPS accuracy is affected by a number of factors, including satellite positions, noise in the radio signal, atmospheric conditions, and natural barriers to the signal. Noise can create an error between 1 to 10 meters and results from static or interference from something near the receiver or something on the same frequency.

  • Page 51: General Maintenance

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 General Maintenance Changing the Fuse (AC Processors Only) Important Notes • The fuse protects the internal electronic circuitry. If the display lights up when power is turned on, you DO NOT need to replace the fuse.

  • Page 52: Generators

    Sizing a Power Supply KEROTEST MANUFACTURING and EF TECHNOLOGIES, INC. do not recommend or endorse any particular type or brand of generator. Power requirements will vary depending on the fitting manufacturer, fitting size and ambient temperature.

  • Page 53: Battery Care & Maintenance

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Battery Care & Maintenance Battery Pack The battery pack used in the Portafuse III Electrofusion Processor is a 48 volt 9 ah sealed lead acid design which contains internal short circuit protection.

  • Page 54: Extension Cords

    Temperature Compensation When using the Kerotest Electrofusion Processor in Barcode Fusion Mode or Manual Barcode Mode to fuse fittings that require temperature compensation, it is essential that care be given to ensure the correct initial fusion temperature is measured. The processor will automatically adjust the fusion time per the measured temperature as specified by the fusion parameters.

  • Page 55: Warning & Error Codes

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 WARNING & ERROR CODES Warning Codes A warning code will be displayed when a situation exists that (in the manufacturer’s opinion) may adversely affect the performance of the processor over time. Warning codes are designed for informational purposes only and have no effect on the outcome of a fusion.

  • Page 56: Error Codes

    Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Error Codes Code Problem Resolution The barcode was scanned successfully, however the This is not a barcode wand error or scanning problem. Verify processor cannot decode the that the barcode is an ISO standard 24 digit fitting barcode.
  • Page 57 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Code Problem Resolution The processor is not capable of As long as the fitting’s fusion requirements are within the outputting the current required specified output range of the processor. This could be an to fuse this fitting.
  • Page 58 Kerotest Manufacturing – SHANNON & PAF III OPERATORS MANUAL - REV 3 Code Problem Resolution Not all control boxes support current or energy control. Attach Control box supports voltage a fitting that requires voltage control or contact an authorized control only and fusion specified representative (See page 19) to see if an update is available for is not voltage control.
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  • Page 64 KEROTEST MANUFACTURING CORP K-1499 Rev B 5500 Second Avenue, Pittsburg, PA 15207 EAN S-1632 www.kerotest.com 412-521-5942...

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