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ACT 40
ACT40 Electrofusion Welding Unit - Operator Manual
Operating Controls
Operating Controls ........................................................................................................................
Safety Notes .....................................................................................................................................
Product Specification ...................................................................................................................
Intended Use ....................................................................................................................................
Introduction ......................................................................................................................................
Delivered Items ................................................................................................................................
Electrical Safety ................................................................................................................................
Using the Equipment .....................................................................................................................
Data Log Memory ............................................................................................................................
Manual Welding .............................................................................................................................
Fusamatic Welding .......................................................................................................................
Bar Code Welding .........................................................................................................................
Fusion Operator Badge ..............................................................................................................
GPS Location .................................................................................................................................
(Automatic 40v welding unit)
Extreme Low Temperature Operation .................................................................................
Downloading the Weld Memory .............................................................................................
Upgrading the Operating Software .......................................................................................
Set Up Options ..............................................................................................................................
Information .....................................................................................................................................
Fault Finding ...................................................................................................................................
Operating manual
Maintenance ..................................................................................................................................
Disposal ............................................................................................................................................
Calibration and Warranty ...........................................................................................................
Declaration of Conformity ........................................................................................................
Service and Repair.........................................................................................................................
Quick Start Guide ..........................................................................................................................
© 2019. Advance Welding
ACT 40V
1
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Table of Contents
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Summary of Contents for Advance Welding ACT40
- Page 1 ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Operating Controls Operating Controls ........................Safety Notes ............................. Product Specification ........................Intended Use ............................ Introduction ............................Delivered Items ..........................Electrical Safety ..........................Using the Equipment ........................Data Log Memory ..........................Manual Welding ..........................
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Page 2: Table Of Contents
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Index Operating Controls ........................Safety Notes ............................. Product Specification ........................Intended Use ............................ Introduction ............................Delivered Items ..........................Electrical Safety ..........................Using the Equipment ........................Data Log Memory ..........................Manual Welding .......................... -
Page 3: Operating Controls
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Operating Controls Welding Cable (can be provided with optional right angle plug) USB Memory Drive Bar Code Scanner (Optional) Bar Code Pen (Standard) USB Socket Welding Cable Socket Protective Lid Display Buttons 10. -
Page 4: Safety Notes
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Safety Notes • RISK OF EXPLOSION! This welding unit must not be used in a gaseous atmosphere. • 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. -
Page 5: Product Specification
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Product Specification Input Power Connections for this model: • 110V version • 120V version ONLY AVAILABLE IN 110/120V SUPPLY AREAS Input plug for your region or country are available Contact us for more information... -
Page 6: Intended Use
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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 UK by Transco to the standard T/SP/ECE/1 2005 ‘Specification for Electrofusion Control Boxes’, and is approved for use on all UK gas... -
Page 7: Electrical Safety
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Electrical Safety WARNING! Switch off and remove the plug from the mains before adjusting, cleaning or if the cable is cut, damaged or entangled. This welding unit is Class 1 and requires an earthed (grounded) connection. An earth spike must be used with generators. -
Page 8: Using The Equipment
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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. -
Page 9: Data Log Memory
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Data Log Memory (Optional) 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... -
Page 10: Manual Welding
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Manual Welding (Optional) 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. -
Page 11: Fusamatic Welding
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Fusamatic Welding (Optional) 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. -
Page 12: Bar Code Welding
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Bar Code Welding (Optional) This mode of operation is designed to weld bar coded fittings in fully automatic mode. Make sure that the bar code pen or (optional) bar code scanner is connected to the USB socket on the unit. -
Page 13: Fusion Operator Badge
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Fusion Operator Badge (Optional) 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. -
Page 14: Gps Location
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual GPS Location (Optional) The welding unit has the ability to record the GPS satellite location of the weld. This is stored as Northings and Eastings and entered into the data log along with an optional depth. -
Page 15: Downloading The Weld Memory
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Downloading the 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 unauthorised alteration of the information. -
Page 16: Set Up Options
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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. -
Page 17: Information
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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. -
Page 18: Fault Finding
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Fault Finding During operation, the welding unit monitors all aspects of its operation. If a fault occurs then an error message will be shown. 0: Weld OK No Fault, weld completed OK. - Page 19 ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 7: Ambient temperature less than -40ºC. The unit has detected that the ambient temperature is very cold or the sensor has broken. If the temperature is not below -40oC then the unit will need to be returned to a service agent for repair.
- Page 20 ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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.
- Page 21 ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 26: Relay unlatched During welding, if the main power relay disconnects then this fault will be shown. It could be caused by the unit being knocked or a temporary dip in the power supply. If the fault persists then the unit should be returned for repair.
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Page 22: Maintenance
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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. -
Page 23: Disposal
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Disposal The equipment and packaging should be sorted for environmentally friendly recycling. DO NOT DISPOSE OF THIS EQUIPMENT INTO HOUSEHOLD WASTE ! According to the European Directive 2002/96/EC Waste Electrical and Electronic... -
Page 24: Calibration And Warranty
If during this period, notice of a defect which is covered by this warranty is received, then Advance Welding will either repair or replace the product at its option. Any replacement product will have functionality at least equal to that of the product being replaced, and will in our opinion, perform consistently with its age and usage. - Page 25 This equipment has been designed for use with the range of fittings and pipe available at the time of its design and development. Advance Welding can accept NO liability for the equipments ability or otherwise to be used with new or different fittings or pipe that subsequently appear in the market place.
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Page 26: Declaration Of Conformity
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Declaration of Conformity This welding unit has been designed to comply with the harmonised standards under the “New Approach” directives, and has been CE marked accordingly. The applicable standards are: 89/336/EEC... -
Page 27: Service And Repair
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual Service and Repair Manufactured in the UK by: ADVANCE WELDING Units 1 & 2 Taylor Street Cleckheaton West Yorkshire BD19 5DZ United Kingdom Tel: UK 0844 880 7748 +44 1274 870112... -
Page 28: Quick Start Guide
ACT 40 ACT40 Electrofusion Welding Unit - Operator Manual 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. •...
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