7/31/2019 526ba Engl

1/202/2007 Subject to alteration without notice

Mounting Instructions forHA-WELD Electrofusion Saddles for PE pipesOrder No. 526

1. Intended use and product description

The fusion saddle of polyethylene (PE 100) is fused and welded at the contact surfaces (pipe outside surface andinside surface of resistance welding saddle) by means of the resistance wires (invisible heating spirals) integratedin the top half. The metal connections integrated in the top part of the saddle serve the purpose of accommodating

valves and/or drilling saddles and/or pipelines or drilling tees.

2. Installation

Warning! Please use only welding devices that have been approved by the manufacturer as to their function forprocessing HA-WELD electrofusion saddles (see DVS 2207, part 1, 5.2). The described sequence of the workingsteps must be absolutely complied with.

General:The welding quality will be determined to a great extent by careful pre-paration. Electrofusion joints may be established only by trained person-nel. Only material of the same kind can be welded. In this context PE 80and PE 100 are regarded as being of the same kind and can thereforebe welded together.

Alignment: Align the top part of the fusion saddle on the pipeline and mark thefusion zone (the pipe surface covered by the saddle) by means of anappropriate marker.

Cleaning of fusion zone:Immediately prior to mounting the marked area of the pipe surface mustbe completely and absolutely cleaned from the oxide layer by means ofa hand scraper or spokeshave. Depending on the condition of the sur-face this layer may be 0.2 to 0.7 mm in thickness.

Warning!If the oxide layer is not completely removed, the weld joint may be lea-king or defective. At least 0.2 mm must be removed completely.The created surface should be even and free from dimples and scrat-ches at the pipe surface. Sandpapering, filing or cleaning with solventwill not be sufficient and is not admissible. The surfaces thus processedshall be protected from dirt and grease (such as handcream, oily rags,etc.) running water as well as rainwater and frozen fog.The pipe surfaces to be welded and the inside surfaces of the fusionsaddles must be absolutely clean, dry and free from grease.Immediately prior to mounting (after scraping) the welding surfaces shallbe cleaned by means of ethanol 99.9% (or Tangit KS / Tangit KS clea-

ning tissues), using only absorbent, lintfree and undyed paper. Makesure not to carry any dirt from the edges to the welding surface.The cleaning agent must be completely vaporized before welding.

Mounting of drilling saddle:Put the top half with the outlet onto the cleaned pipe surface, align it andengage the clamps of the bottom half into the top half.Take the screws out of the holders and push them into the bores provi-ded for this purpose. Tighten all 4 screws regularly by hand. Check themounting position again and tighten the screws until the saddle halvesare in contact by means of a socket spanner or a screwdriver. Check thecontact surface between the saddle and the pipe visually. In the crestarea the top half must rest snugly on the pipe.

Warning!When mounting from the side make sure that the bar code for weldingis visible at the top side. During mounting make sure not to damage theinside surface of the fusion saddle.

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7/31/2019 526ba Engl

2/202/2007 Subject to alteration without notice

Welding of drilling saddle:Connect contacts (designed acc. to EN 1555-3 type B) to the welding unit. Ma-ke sure that the contacts are clean and dry, clean them, if necessary.The welding parameters are contained in a bar code applied laterally to the fu-sion saddle. The parameters are read into the welding unit via a reading wand.(Observe mounting instructions of welding unit).

Start fusion.Compare the data shown in the display of the welding unit with those on thefusion saddle (see table T.1)

If the bar code is not legible the parameters can be input manually.Warning! For general safety reasons during welding keep a distance of 1 m tothe welding point. Never weld with medium emerging. Do not interrupt the wel-ding procedure. Fusion with other materials than PE 80/100 is not possible. Wel-ding may take place only at ambient temperatures between 0C and +45C.

Warning! If the cooling-down period is not observed, the fusion saddle may beisolated from the pipe at fusion level. During this time the bottom half must notbe dismantled or released.

Examination: After finishing the fusion process check if welding has been performedproperly:

- No fault indication at the welding unit display (observe operating instruc-tions of welding unit)

Indicator PIN:The indicator PIN only indicates the fact that fusion has been performed.It does not tell anything about the quality achieved. Depending on the gapconditions between the fusion saddle and the pipe the movement andappearance of the indicator pin may vary. The successful performance ofthe welding process is indicated only by the welding unit.

Marking:By means of proper marking (e.g. inscription with SNOWMAN SILVER MARKER)

the welding point shall be permanently provided with the position from the installation drawing. Welding must besubstantiated by the record of the welding unit.

Welding defect:If a welding defect (interwinding fault) is indicated at the welding unit, welding has to be discarded. If the pipe hasnot yet been penetrated (drilled), the saddle may be left on the pipe. However, it must be permanently marked asdefective welding. Mounting and welding shall be repeated at another place.

T.1 Fusion parameters

If you have any more questions or need more detailed information please dont hesitate to contact us:

Hawle Armaturen GmbH- Anwendungstechnik -

Liegnitzer Str. 683395 FreilassingTelefon: +49 (0)8654 6303-0Telefax: +49 (0)8654 6303-222E-Mail: anwendungstechnik@hawle.deInternet: www.hawle.de

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Pipe Welding voltage Resistance Welding time Cooling-down period

63 mm 10 V 0,40 100 sec. 20 min.90 mm 18 V 0,90 190 sec. 30 min.

110 mm 18 V 0,90 190 sec. 30 min.125 mm 18 V 0,90 190 sec. 30 min.160 mm 18 V 0,90 190 sec. 30 min.225 mm 18 V 0,90 190 sec. 30 min.

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Indicator pin

before fusion after fusion