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Highland Supercell Operation Manual

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Lithium-ion powered electrofusion processor
Operations Manual

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Summary of Contents for Highland Supercell

  • Page 1 Lithium-ion powered electrofusion processor Operations Manual...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Operating Controls ..............4 Delivered Items ..............5 Intended Use ................5 Introduction................5 Product Specification ..............6 Safety Notes ................7 Electrical Safety ..............8 Transport of Dangerous Goods ..........9 Capacity ................10 Battery Charging ..............10 Using the Equipment – Screen Symbols .......12 Using the Equipment – On / Off ...........13 Using the Equipment –...

  • Page 3: Operating Controls

    OPERATING CONTROLS...

  • Page 4: Delivered Items

    DELIVERED ITEMS Carefully remove the welding processor from its packaging and check that you have the follow- ing items: • Welding processor. • Wireless bar code scanner. • Mains powered battery charger. • +12V dc car charging lead. • USB memory drive. Note: to download a copy of this manual, visit www.supercellef.com INTENDED USE This equipment is intended to fuse constant voltage electrofusion fittings suitable for low, me-...

  • Page 5: Product Specification

    550W (@ 240V) #1 The batteries can only be charged between 32 F to 113 Highland 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.

  • Page 6: Safety Notes

    SAFETY NOTES • WARNING: RISK OF ELECTRIC SHOCK! Do not open. No user serviceable parts inside. Only to be opened by an approved service agent. • WARNING: RISK OF EXPLOSION! This electrofusion processor is NOT intrinsically safe and must NOT be used in a gaseous atmosphere. Do not use this equipment in the trench.

  • Page 7: Electrical Safety

    The operator should carry out a visual inspection of Supercell every time it is used. If the case is split or broken, or any connectors are damaged, then the equipment must not be used, and it should be returned to your distributor for immediate repair.

  • Page 8: Transport Of Dangerous Goods

    TRANSPORT OF DANGEROUS GOODS Supercell contains a battery pack made from Lithium-ion batteries. These have been classified by the United Nations as hazardous materials and been assigned to Class 9 - Miscellaneous Hazard Classification. Additionally, the United Nations Committee of Experts on the Transport of Dangerous Goods have classified them under UN 3481 Lithium-ion batteries contained in equipment.

  • Page 9: Capacity

    Note: This is given as a guide only, and exact capacity will depend on a range of factors. BATTERY CHARGING IMPORTANT. Supercell can only be charged at temperatures between 32° and 113° Fahren- heit. If the battery pack is above 113F then you must allow it to cool before charging.
  • Page 10 • using the +12V dc charger cord, connected to a 12V vehicle auxiliary socket. Wall Charger 1. Make sure Supercell is turned off, (hold the red stop button in for 3 seconds to power off the machine). 2. Plug the charger into the wall and power it on. The green light will flash once per sec- ond.

  • Page 11: Using The Equipment - Screen Symbols

    USING THE EQUIPMENT – SCREEN SYMBOLS The left-hand side of the screen shows prompts to the operator for the next steps that need to be taken, in this example, connect the welding cord to the fitting or press the star key for the menu.

  • Page 12: Using The Equipment - On / Off

    USING THE EQUIPMENT – ON / OFF Turning the machine ON. To turn the machine on, press and hold in the green START button for three seconds. The dis- play will show: The manufacturer logo. The product name. The owner details. The main screen.

  • Page 13: Using The Equipment - Barcode Welding

    TEMPERATURE COMPENSATION When using the Highland Electrofusion Processors in Barcode Fusion Mode or Manual Barcode Mode, to fuse fittings that require temperature compensation it is essential that care be given to ensure that the correct initial fusion temperature is measured. The processor will automat- ically adjust the fusion time per the measured temperature as specified by the fusion parame- ters.
  • Page 14 The capacity of the battery is checked and the number of this type of fitting that can be fused is shown. The resistance of the fitting is checked with the barcode to make sure the right code has been scanned. Scan the traceability code on the fitting or press the A key to move on.
  • Page 15 As fusion progresses, the welding voltage and current are shown. The time counts down to zero and the clock on the graphic fills up to show the fusion progress. When fusion is complete the cooling time is shown. Allow to complete or press the A key to skip.

  • Page 16: Using The Equipment - Manual Welding

    USING THE EQUIPMENT – MANUAL WELDING Make sure that a barcode scanner/dongle is NOT attached to the USB port or, during the bar- code fusion option, press the B key when the scan fitting message is shown. Connect the output leads to the fitting. Enter the fusion time and press the A key.
  • Page 17 The capacity of the battery is checked and the number of this type of fitting that can be fused is shown. The fitting details are shown. Press the green START button to begin fusion. A couple of seconds after the start, the calibration is checked. This is the smart-calibration check.
  • Page 18 When fusion is complete the cooling time is shown. This will count upwards, press the A key to stop. At the end of the cooling time, the fusion number is shown. Disconnect the output leads from the fitting to reset the machine.

  • Page 19: Using The Equipment - Checking Battery Capacity

    USING THE EQUIPMENT – CHECKING BATTERY CAPACITY If you want to know what capacity the battery has or if you can fuse a specific fitting, scan the fitting barcode and the required energy will be checked from a lookup table held in memory. When the screen shows connect fitting, with no fitting attached to the output leads, scan the fitting barcode.

  • Page 20: Using The Equipment - Downloading Data Log

    USING THE EQUIPMENT – DOWNLOAD DATA LOG Select data download from the menu. Select the data download type. The default is 1: Encrypted. This requires supporting software to view. Visit www.supercellef.com for more information Option 2 is an unencrypted XML which can be viewed using most spreadsheet software. Insert a USB memory drive into the USB port on the machine.

  • Page 21: Using The Equipment - View Logs

    The screen will show the progress of the downloads. When Success is shown, remove the memory drive from the socket. USING THE EQUIPMENT – VIEW LOGS Select view logs from the menu. Details of stored welds are shown. Press the A key to view the details. Press the B and C keys to scroll between stored welds.

  • Page 22: Using The Equipment - View Details

    USING THE EQUIPMENT – VIEW DETAILS Select view details from the menu. The software version number is shown. Press the A key to display the serial number of the machine.

  • Page 23: Service And Calibration

    SERVICE AND CALIBRATION It is important that the case of Supercell is not damaged. Regularly check for defects such as cracks, broken connectors, or damage that would allow water to enter the machine. If damage is found, stop using the unit immediately and contact your distributor.
  • Page 24 8: Ambient temperature more than +113 The unit has detected that the ambient temperature is very hot, or the sensor has broken, or a wire has gone open circuit. The unit must be returned to a service agent for repair. 14: Relay failed to latch on weld start This fault could happen when the start button is pressed.
  • Page 25 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. Con- nect 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.
  • Page 26 101: Converter electronics error – Low battery voltage The battery voltage into the electronics is too low. The unit should be returned for service. 102: Converter electronics error – High battery voltage The battery voltage into the electronics is too high. The unit should be returned for service. 103: Converter electronics error –...
  • Page 27 115: Converter electronics warning – BMS fault The battery management system has developed a fault. The unit should be returned for ser- vice. 127: Power off failure. If the power is turned off while the unit is welding, this fault will be recorded to the data log.

  • Page 28: Hardware Reset

    HARDWARE RESET Because this machine is battery powered, if things go wrong, it is not possible to do a hardware reset by unplugging it from the mains supply. In case this happens, a reset fuse is provided. RESET FUSE. If the machine software locks-up and it cannot be turned off by pressing any of the buttons, the reset fuse can be removed.

  • Page 29: Disposal - End Of Life

    DISPOSAL – END OF LIFE The equipment and packaging should be sorted for environmentally friendly recycling.

  • Page 30: Warranty

    Unless otherwise agreed, all warranty work will be carried out by Highland or an authorized and approved service facility.
  • Page 31 Highland makes no other warranty of any kind, whether expressed or implied, with respect to its products. To the extent that this warranty statement is inconsistent with the law of the locality where the customer uses the product, this warranty statement shall be deemed modified by the mini- mum necessary to be consistent with such local law.

  • Page 32: Repair

    REPAIR For all service and repair of this machine, please contact your distributor. DISTRIBUTED BY: ISCO Industries 800-345-ISCO (4726) www.isco-pipe.com Mailing Address: 100 Witherspoon Street 2 West Louisville, KY 40202 Calibration and Service Shipping Address: 453 Shields Rd Huntsville, AL 35811...

  • Page 33: Helpful Tips

    8 HELPFUL TIPS 1. Always refer to this User Manual on how to correctly operate the machine. 2. If any visible damage to the machine, contact your supplier immediately as failure to do so could render the machine unusable. 3. Always charge the machine with the correct charging source provided. 4.
  • Page 34 Commitment We know you have work to do, and downtime is the enemy. That is why our commitment to customers is a guaranteed five-day or less turn around on calibration and service evaluation along with an industry leading two-year warranty. With multiple service locations across the US and Canada, we are equipped to get you back in operation as soon as possible.

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