Electrofusion Fittings

Transcription

1 Electrofusion Fittings

2 QUESTIONS ABOUT PE? PLASSON HAS THE ANSWERS. Plasson s pedigree in PE reaches back 40 years internationally and over 30 years locally. It is the only company in Australia focused purely on PE connections, making Plasson the unchallenged leader. Plasson PE products boast a design life in excess of 100 years. They have a complete range of connections for water and wastewater systems certified to AS4129. And their specialist systems for hydrant and tapping connections hold WSAA approvals. With a team of knowledgeable specialists, local expertise and authoritative field support, the answer to any questions on PE is waiting at Plasson.

3 Note: unless otherwise stated all Plasson EF fittings supplied with 4.7mm terminal resitor pins Suitable Plasson Control Boxes DN Monomatic PolymaticPlusUSB PolyControlPlus V ü ü ü ü ü ü x ü* ü *May require cooling period between welds Standard dimension ratios (s) for series 1 pipes (BAR) Compound PE PE COUPLER GAS * * * * * * * Couplers have dual weld zones Series 3 couplers up to DN300 available on request. Wholesale prices do not include 10% GST 67

4 COUPLER - FOR THICK WALLED PPE GAS POA LONG COUPLER GAS LIGHTFIT COUPLER - FOR THIN WALLED PIPE GAS * * * * * Lightfit coupler is 42V Fitting - not 40V * Lightfit Couplers have dual weld zones Max 26 for pipes 63-90mm. Max 33 for pipes mm except 400, 450 & 560 Max Wholesale prices do not include 10% GST

5 REDUCING COUPLER GAS *20 x x **25 x 20NB x x x x x x x **50 x 40NB x x x **63 x 50NB x x x x x x x x x x x x *Only 1 x rising pin indicator **Series 3, 25x20, 150x40, 63x50 available on request. Wholesale prices do not include 10% GST 69

6 90 ELBOW GAS DUCKFOOT ELBOW GAS 90 x DUCKFOOT ELBOW W/32 OUTLET GAS 90 x 32 x Wholesale prices do not include 10% GST

7 45 ELBOW GAS LIGHTFIT ELBOW GAS LIGHTFIT ELBOW GAS ELBOW GAS LIGHTFIT ELBOW GAS Wholesale prices do not include 10% GST 71

8 ADJUSTABLE ELBOW Innovation solution adding flexibility to PE Pipe installations Plasson s Adjustable Elbow and One Sided Adjustable Elbow allows welding to pipes at any angle up to 12º per side. The Plasson adjustable elbow simply and easily solves situations such as: Misaligned pipes Connections at an undefined angle Connection of misaligned pipes to valves, pumps and other stationary devices Connection of buried pipes where only a short section is exposed Prior to welding, the ball joints are fully adjustable within the ±12º range. After welding, the joint is a fixed ElectroFusion welded connection. The Adjustable Elbow is pressure rated as the rest of Plasson ElectroFusion line: Water 16 Gas PE (MOP 10 bar) ADJUSTABLE ELBOW - COUPLER TO COUPLER GAS Ideal for jointing misaligned pipes in trenches and tight locations. ADJUSTABLE ELBOW ONE SIDED - COUPLER AND SPIGOT GAS Ideal for jointing misaligned pipes in trenches and tight locations Wholesale prices do not include 10% GST

9 90 EQUAL TEE GAS 20 x 20 x x 25 x x 32 x x 40 x x 50 x x 63 x x 75 x x 90 x x 110 x x 125 x x 160 x x 180 x x 200 x x 225 x x 250 x = Main 2 = Main 3 = Offtake Wholesale prices do not include 10% GST 73

10 90 REDUCING TEE GAS 25 x 25 x x 25 x x 32 x x 32 x x 40 x x 40 x x 40 x x 50 x x 50 x x 50 x x 50 x x 63 x x 63 x x 63 x x 63 x x 75 x x 90 x x 110 x x 110 x x 125 x x 125 x x 160 x x 160 x x 160 x x 180 x x 180 x x 180 x x 180 x x 180 x x 200 x x 200 x x 225 x x 225 x x 250 x x 250 x = Main 2 = Main 3 = Offtake 90 REDUCING TEE WITH DOUBLE OUTLET GAS 40 x 40 x 25 x x 40 x 32 x x 50 x 25 x x 50 x 32 x x 50 x 40 x x 63 x 25 x x 63 x 32 x x 63 x 40 x = Main 2 = Main = Offtake 4= Offtake 74 Wholesale prices do not include 10% GST

11 FULL FACED FLANGED HYDRANT TEE (W/SS 316 BACKING RING) DUCTILE IRON FLANGED TEE GAS 110 x 110 x x 125 x x 160 x x 180 x x 200 x x 225 x x 250 x = Main 2 = Main 3 = Offtake Elongated slots suitable for four or eight hole flange drilling w/ PCD b/w 145 and 180mm. Full faced flange and SS ring drilled 4 x 46 PCD and 4 x 178 PCD FLANGE: PP COATED STEEL x 110 x x 125 x x 160 x x 180 x x 200 x X 225 X X 250 X PCD GAS = Main 2 = Main 3 = Offtake PE CAST IRON FLANGE COUPLER PCD GAS PE + FLANGE 63 x x x *160 x *180 x x *use M16 bolts with 150 flanges Wholesale prices do not include 10% GST 75

12 END CAP - INCLUDES COUPLING & PLUG END PLUG 1 * Monolithic End Cap GAS * * * * GAS May be fitted into any Plasson electrofusion ended fitting. Must be spot welded in 3 places or held firmly, without movement, during electrofusion and cooling cycle. 76 Wholesale prices do not include 10% GST

13 MALE ADAPTOR E/F - PE100 FEMALE ADAPTOR E/F - PE100 GAS 25 x 3/4" x 1" x 1" x 1.1/4" x 1.1/2" x 1.1/2" x 1.1/2" x 2" Fits any electrofusion socket GAS 20 x 1/2" x 3/4" x 1" x 1.1/4" x 1.1/2" x 2" Fits any electrofusion socket BRASS REDUCING NIPPLE FOR TRANSITION UNIONS GAS 1.1/4" x 1" /2" x 1.1/4" " x 1.1/2" /2" x 2" TRANSITION COUPLING - MALE BRASS BSP OUTLET GAS 20 x 1/2" x 3/4" x 1/2" x 3/4" x 1" x 1.1/4" x 1.1/2" x 1" x 1.1/4" x 1.1/2" x 2" x 1" x 1.1/4" x 1.1/2" x 2" x 1.1/4" x 1.1/2" x 2" x 2" x 2.1/2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. Wholesale prices do not include 10% GST 77

14 TRANSITION COUPLING - MALE STAINLESS STEEL (316) BSP OUTLET TRANSITION COUPLING - FEMALE BRASS BSP OUTLET GAS 32 x 1.1/2" x 1.1/4" x 1.1/2" x 1.1/2" x 2" x 1.1/2" x 2" The SS component can be turned inside the body of the fittings after welding and cooling is completed. GAS 20 x 1/2" x 3/4" x 3/4" x 1" x 1" x 1.1/4" x 1.1/2" x 1.1/2" x 2" x 1.1/2" x 2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. TRANSITION UNION (FREE NUT) - MALE BRASS BSP OUTLET GAS 32 x 1" x 1" x 1.1/4" x 1.1/2" x 1.1/2" x 2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. TRANSITION UNION (FREE NUT) - FEMALE BRASS BSP OUTLET GAS 20 x 3/4" x 3/4" x 1" x 1" x 1.1/4" x 1.1/4" x 1.1/2" x 1" x 2" x 2" x 2.1/2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. 78 Wholesale prices do not include 10% GST

15 90 TRANSITION ELBOW - MALE BRASS BSP OUTLET GAS 20 x 1/2" x 3/4" x 1/2" x 3/4" x 1.1/4" x 1.1/2" x 1" x 1.1/4" x 1.1/2" x 2" x 1" x 1.1/4" x 1.1/2" x 2" x 1.1/4" x 1.1/2" x 2" x 2" x 2.1/2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. 90 TRANSITION ELBOW - FEMALE BRASS BSP OUTLET GAS 20 x 1/2" x 3/4" x 1" x 1" x 1.1/4" x 1.1/2" x 1.1/2" x 2" x 1.1/2" x 2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. 90 TRANSITION UNION (FREE NUT) ELBOW - FEMALE BRASS BSP OUTLET GAS 20 x 3/4" x 3/4" x 1" x 1" x 1.1/4" x 1.1/2" x 2" x 1.1/2" x 2" x 2.1/2" Wholesale prices do not include 10% GST 79

16 45 TRANSITION ELBOW - MALE BRASS OUTLET GAS 32 x 1/2" x 3/4" x 1" x 1.1/4" x 1.1/2" x 1" x 1.1/4" x 1.1/2" x 2" x 1" x 1.1/4" x 1.1/2" x 2" x 1.1/4" x 1.1/2" x 2" x 2" x 2.1/2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. 45 TRANSITION ELBOW - FEMALE BRASS OUTLET GAS 32 x 1" x 1" x 1.1/4" x 1.1/2" x 1.1/2" x 2" x 1.1/2" x 2" The brass component can be turned inside the body of the fittings after welding and cooling is completed. 45 TRANSITION UNION (FREE NUT) ELBOW - FEMALE BRASS BSP OUTLET 1 GAS 32 x 1" x 1.1/4" x 1.1/2" x 2" x 2" x 2.1/2" Wholesale prices do not include 10% GST

17 WELDABLE TRANSITION - POLYETHYLENE TO ROLL GROOVED GAS (DN100) (DN150) Plasson Polyethene (PE) to Steel Roll Groove Adaptors Plasson PE to Steel Roll Groove Adaptors provide a simple solution for joining PE ring mains to surface hydrant assembly pipework TECHNICAL SPECIFICATIONS Complies to AS/NZS 4129:2008 Fittings for polyethylene (PE) pipes for pressure applications Steel pipe is protected by zinc coating and 3mm layer of PE100 Available in sizes DN125 PE to DN mm (4 ) Roll Groove Steel and DN180 PE to DN mm (6 ) Roll Groove Steel Pressure rating 16 Long PE pipe section allows for up to two electrofusion welds with Plasson couplers L1 L L2 t1 steel ring, corrosion protected PE coating t2 D 3 d PE100 pipe, black Steel pipe, zinc coated after maching PE Size D d L L1 L2 t1 t2 DN (4 ) ( 11) 6.02 DN (6 ) (11) 5.5 Wholesale prices do not include 10% GST 81

18 WELDABLE TRANSITION - POLYETHYLENE TO UNTREATED STEEL 16 Water GAS 32-1" (25) SCH /4" (32) SCH /2" (40) SCH " (50) SCH " (50) SCH " (80) SCH " (100) SCH " (100) SCH " (150) SCH " (200) SCH " (250) SCH " (300) SCH " (300) SCH " (400) SCH " (500) SCH " (600) SCH BALLOON SADDLE 1 2 GAS /2" /2" /2" /2" /2" /2" /2" /2" Note: Sizes have fabric understraps. 82 Wholesale prices do not include 10% GST

19 BRANCH SADDLE - WITH UNDERPART GAS 63 x x x x x x x x x x x x *90 x x x x x *110 x x x x x *125 x x x x x *140 x x x x x x x x x x x x x x x x x x x *Underpart is the same as a Balloon Saddle strap. SADDLE CLAMPS NOT REQUIRED. Cut after 4 x cooling period indicated on fitting barcode. Wholesale prices do not include 10% GST 83

20 BRANCH SADDLE - LARGE BORE GAS x x x x x x x x x x x x Requires specialised installation tools - see page 107 for information Weld Integrity Test A test port is incorporated into the saddle to enable a pressure test before cutting into the pipe Correct Clamp Indicator Stamp Clamping Tool leaves a mark on the saddle to show if the correct sized clamps have been used at the correct tension Correct Tightening Torque Indicator Indicated with visual gauge built into strap mechanism Larger sizes tightened with a torque wrench Embedded Heating Wires Embedded heating wire limit the risk of physical damage to the wire Embedded wires are protected from enviroment during storage Instant heat transfer between coil and PE for fast gap closure Single welding time for ambient temperatures between -10 C to +45 C No temperature compensation required 84 Full Bore Outlet Full bore 11 Better flow characteristics Large Fusion Areas The welding zone reaches up to the internal bore of the outlet Ensures area of highest stress in the fitting occurs at the strongest part of the electrofusion weld Better durability under hard operating conditions Wholesale prices do not include 10% GST

21 FULL FACED FLANGED HYDRANT BRANCH SADDLE (W/SS 316 BACKING RING) GAS 90 x 90 x x 90 x x 110 x x 110 x x 125 x x 125 x x 140 x x 140 x x 160 x x 160 x x 180 x x 180 x x 200 x x 200 x x 225 x x 225 x x 250 x x 250 x x 280 x x 280 x x 315 x x 315 x = Main 2 = Main 3 = Offtake Elongated slots suitable for four or eight hole flange drilling w/ PCD b/w 145 and 180mm SS ring drilled 3 AS / AS2129 Table D SS ring drilled 3 and 4 AS / AS2129 Table D Refer Page 134 and following for flange dimensions FULL FACED HYDRANT FLANGE ADAPTOR KIT 90mm Full Faced Flange with 3"/4" SS316 Table D / 16 Universal Backing Ring mm Full Faced Flanged Pupped to 450mm with 3/4" Table D / 16 SS316 Universal Backing Ring mm Full Faced Flange with 3" SS316 Table D / 16 Backing Ring mm Full Faced Flanged Pupped to 450mm with 3" Table D / 16 SS316 Backing Ring UNIVERSAL BACKING RING: 90 x 80/100 S/S 316 Backing Ring to suit FFF Adaptors (Drilled 4 x 146 PCD and 4 x PCD) Suits 80 to 100mm fire hydrant mountings - max ID of mating flange 80mm. The Plasson 11/PE mm full face flange complies with AS and AS/NZS4129, is pressure rated at 16 and can be connected to the various 90mm PE pipes using the following methods. PE 63 PE 80 PE EF EF EF or BW 12.5 EF EF EF 10 EF or BW EF or BW EF 8 EF EF EF - - Wholesale prices do not include 10% GST 85

22 TAPPING VALVE - WITH UNDERPART GAS 63 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Wholesale prices do not include 10% GST

23 TAPPING SADDLE - WITH UNDERPART * A Welding Cap can be permanently fixed to the Tapping Saddle via the electrofusion process. This prevents any accidental disassembly which can occur with the standard cap. Refer to page 88 for details of the Welding Cap. WELDING CAP TYPE* GAS 40 x 20 mb Type C x 32 mb Type C x 20 mb Type C x 25 mb Type C x 32 mb Type C x 20 mb Type C x 25 mb Type C x 32 mb Type C x 40 Type A x 50 Type A x 63 Type A x 20 mb Type A x 32 Type A x 40 Type A x 50 Type A x 63 Type A x 20 mb Type A x 25 mb Type A x 32 mb Type B x 40 mb Type B x 50 Type A x 63 Type A x 20 mb Type A x 32 mb Type B x 40 mb Type B x 50 Type A x 63 Type A x 20 mb Type A x 32 mb Type B x 40 mb Type B x 50 Type A x 63 Type A x 20 mb Type A x 32 Type A x 40 Type A x 50 Type A x 63 Type A x 20 mb Type A x 32 mb Type A x 40 mb Type A x 50 mb Type A x 63 mb Type A x 20 mb Type A x 32 mb Type A x 40 mb Type A x 50 mb Type A x 63 mb Type A *200 x 20 Type A *200 x 32 Type A *200 x 40 Type A *200 x 50 Type A *200 x 63 Type A Wholesale prices do not include 10% GST 87

24 TAPPING SADDLE - WITH UNDERPART CONT. WELDING CAP TYPE* GAS *225 x 20 Type A *225 x 32 Type A *225 x 40 Type A *225 x 50 Type A *225 x 63 Type A *250 x 20 Type A *250 x 32 Type A *250 x 40 Type A *250 x 50 Type A *250 x 63 Type A mb = Mono Block with fully moulded offtake. *Strap underpart. +12 x 195mm Hex Key required to operate cutter. 13mm socket to tighten saddle-nuts elongated 25 x 13 socket for saddles 180 Cut hole after welding and cooling completed. Standard 30 mm cutter in mm saddles will cut up to 25 mm wall. d (main pipe diameter) OD of Cutter (mm) MONOBLOCK NON-MONOBLOCK LIGHTFIT TAPPING SADDLE GAS Suitable for wastewater 63 x WELDING CAP FOR TAPPING SADDLES WELDING CAP TYPE GAS 40 Type C Type B Type A Cut hole after welding and cooling completed. HEX KEY FOR TAPPING SADDLES The Plasson Hex Key is designed for use with all Plasson tapping saddles. It comes with a 12mm square drive connection. Wrench not included * Cut hole after 4x the inidicated cooling period on the fitting label. *Net price. No discount applicable. 88 Wholesale prices do not include 10% GST

25 REPAIR SADDLE - WITH UNDERPART GAS DOUBLE REPAIR SADDLE GAS TRANSITION SADDLE - BRASS FEMALE THREAD Sizes , GAS 63 x 1.1/4" x 1.1/4" x 1.1/2" x 2" x 1.1/2" *110 x 2" x 1.1/2" *125 x 2" x 1.1/2" *140 x 2" x 1.1/2" x 2" x 1.1/4" x 1.1/2" *180 x 2" *200 x 2" *225 x 2" *250 x 2" x 2" x 2" Cut hole after welding and cooling completed. *Strap underpart. Saddle size requires specialised installation strap clamp. See page 107 for details. Wholesale prices do not include 10% GST 89

26 TRANSITION SADDLE - WITH UNDERPART PLASTIC FEMALE THREAD GAS 63 x 1" x 1.1/4" x 1.1/2" FLEX RESTRAINT GAS *160 to 1600 (6"-63") Each unit restrains 31,000N (3,100kg) of axial force. Use multiple units to restrain higher forces. *Welding with barcode Unit Only. Requires specialised installation strap clamp. See page 107 for details. 4.0 mm welding pins. Plasson Flex Restraint Advantages: Terminals are side mounted, enabling use of a wide 50 mm/2 strap, for better clamping. Clips for attaching the restraint to the clamping strap facilitates installation Concealed wire - eliminates risk of smoke or unintentional contact with hot wire Technical Specifications: Fits any PE pipe in the size range of mm Made of PE 100 / PE4710 resin. Can be welded by any standard EF control box with barcode reading or manual input. Designed and tested to support 3100 dn (kg) of axial force. Use multiple units to achieve required force. L H B Wt. 202 mm 40 mm 65 mm 300g 90 Wholesale prices do not include 10% GST

27 GAS ELECTROFUSION FITTINGS TAPPING SADDLE - PE TO NYLON WITH UNDERPART 400kPa gas 1 2 GAS (F) (M) *48 18 (F) (F) (F) (M) (F) (M) (F) (M) (F) (M) (F) (M) (F) (M) Cut hole after welding and cooling completed. +12mm Hex Key required to operate cutter. 13mm socket to tighten saddle nuts. Elongated 25 x 13 socket for saddles 180 *Supplied with curved bolts for AS4130 Series 3 GAS pipe PE - NYLON COUPLING SYSTEM 400kPa gas GAS 20PE(M) x 18(F) Nylon PE(M) x 23(F) Nylon PE(M) x 18(F) Nylon PE(M) x 18(F) Nylon PE(M) x 18(F) Nylon PE(M) x 40(M) Nylon PE(M) x 40(M) Nylon PE(M) x 50(M) Nylon Wholesale prices do not include 10% GST 91

28 GEOTHERMAL ELECTROFUSION SYSTEM REDUCING TEE GAS 32 x 32 x x 40 x x 40 x x 50 x x 50 x x 50 x x 63 x x 63 x = Main 2 = Main 3 = Offtake REDUCING TEE TWO OUTLETS = Main 2 = Main 3 = Offtake 4= Offtake GAS 40 x x x x x x x x x x x x x x x x Y REDUCER GAS 32 x 25 x x 32 x x 40 x ELBOW GAS Wholesale prices do not include 10% GST

29 GEOTHERMAL ELECTROFUSION SYSTEM 180 ELBOW CONNECTING BOLT KIT GAS 25 Bolt Type M6 x Bolt Type M6 x Bolt Type M6 x PROB HEAD WEIGHT CONNECTION KIT GAS 25 Bolt Type M8 x 70 - TBA TBA 32 Bolt Type M8 x 90 - TBA TBA 40 Bolt Type M8 x TBA TBA 180 ELBOW CLAMP GAS o Elbow Clamp POA Wholesale prices do not include 10% GST 93

30 ELECTROFUSION WASTE SYSTEMS WASTE SADDLE - FIXED 110MM 45 0 OUTLET Note: Fittings comply w/ AS/NZS Pipes to 33. Lightfit fittings to be used w/ all wastewater spigots. 45 LIGHTFIT ELBOW - FOR PIPES 11 TO 33 GAS x x Require specialised installation tool see page 107. GAS WASTE SADDLE - ADJUSTABLE 160MM OUTLET ADJUSTABLE ELBOW FOR WASTE 0-12 GAS x x x Require specialised installation tool see page 107. GAS MANHOLE ADAPTOR GAS Require special shortened Plasson Lightfit coupler to connect to PE pipe contact Plasson. 94 Wholesale prices do not include 10% GST

31 Tooling

32 PF-Schweißtechologie GmbH (PFS) Plasson s range of electrofusion tooling is designed and manufactured by our joint venture partner, PFS. The company was founded in 1997 in the picturesque town of Alsfeld, Germany. It developed quickly into one of the world s leading manufacturers of plastic welding technologies for pipeline construction. The product range includes a wide variety of electrofusion control units, butt fusion machines, extensive accessories and a complete portfolio of tools for the preparation of plastic pipes for welding. High Quality Products Countless customers around the globe rely on the high quality of PFS products. Product development is conducted by employees with many years of experience, know-how, dedication and with a high capacity to innovate. A number of product patents confirms this. Of equal importance is close cooperation with end users of PFS products and systems. This cooperation provides real field feedback to allow refinement of products, even at component level, resulting in products robust enough to handle even the most difficult site conditions. For more information and our online catalogue please visit

33 Register and turn your Plasson Control Box into the ultimate welding machine with our new Smartphone App. GET SMART THE PLASSON FREE UPGRADE. MAKING SMART CONTROL BOXES EVEN SMARTER. Features of the Free Upgrade Smartphone control of your box, with no mobile network coverage needed Improved quality control with guided welding process and photo capture of crucial steps (kept with the weld record) Data recording including physical location of each weld Ability to identify installer of each weld Ability to weld all fittings* To register visit upgrade.plasson.com.au Smarter plumbing with Plasson. *Monomatic Control Boxes will be limited to emergency welds of other fittings For more information visit upgrade.plasson.com.au Or call 1300 PLASSON ( )

34 TOOLING Introduction The tools in this catalogue are designed for use with Polyethylene electrofusion fittings. Plasson SmartFuse(Automatic) Electrofusion Fittings Plasson SmartFuse electrofusion fittings have the following features: Automatic Weld Time Recognition System - avoids operator input errors Single Weld Time C to +45 C means temperature compensation is not required, no need for operator judgement and possible errors 16 water/1000 kpa Gas systems - meets the most demanding technical requirements 10 water/630 kpa Gas systems - for PE pipes down to 33 Approvalmark International (API) licensed system for EF fittings - No. 2018, AS/NZS 4129 A Single Weld Time According to the latest Standards, all electrofusion fittings must be able to produce welds at a temperature range of between -10 and +45 C. Manufacturers have responded to this in different ways resulting in a variety of designs available to the market. The Plasson SmartFuse Electrofusion system ensures that the energy supplied will weld fittings from a minimum -10 to +45 C at one standard time. Fittings are tested within this range and are supplied with Approvalmark International (API) Licence. Temperature Compensation Other fittings being supplied to the Australasian market may meet ISO/CEN standards and have the capability of acheiving a satisfactory weld. However, to do so temperature compensation may be required; creating a more complex, lengthier process that is more susceptible to human error. Where welding time is dependent on the ambient temperature, this requires a special bar-code reading EF control box to sense the temperature, read the fittings bar-code and adjust the weld time accordingly. As well as the additional work required this can also cause problems. Firstly, it relies on the legibility of the bar-code and secondly, the point at which the temperature is read may vary widely from the temperature at the pipe/fitting assembly. Without a special bar-code reading EF control box, the weld operator will need to estimate the temperature at the joint site, read the temperature compensation tables correctly (if supplied and legible) and enter the new weld time into the box before the weld can proceed. This process relies on operator skill/judgement, is open to mistakes and may need a complex QC form to record the weld conditions used. A Smoother Process By using Plasson SmartFuse fittings and PF control boxes there is no need for special bar-code reading EF control boxes, or reference to temperature compensation tables, virtually eliminating the margin for error in this area, (provided the process is being carried out within a temperature range of -10 and +45 C.) however, if users wish to have a control box capable of welding Plasson SmartFuse Fitting as well as manual or barcode fitting, Plasson has a control box that can operate both The Polymatic Plus. 98 Wholesale prices do not include 10% GST

35 TOOLING Plasson Automatic (PF) Welding Control Boxes PF control boxes dynamically monitor the welding process when used with Plasson Electrofusion fittings. Benefits include: By continually monitoring the weld current, a PF control box will shut down if the current increases above the dynamic tolerance range, thereby avoiding the overheating and anti-oxidant depletion of PE materials which can adversely affect long-term weld integrity. PF control boxes are tolerant to generator variability as they accept a large voltage range and frequency variation. Servicing centres for PF welding equipment are available in New Zealand and Australia. What can go wrong? Without the dynamic monitoring of a Plasson Automatic Welding Control Box, faults may occur unnoticed during the weld process causing the fitting to fail once in general use. Common causes of this can be seen in the diagram below. TYPICAL ELECTROFUSION WELDING FAULTS Short Insertion Oval Pipe Pipe OD too low Fitting Fitting Pipe Pipe Pipe not cut square Pipe from coil not inserted square Pipe moves during the weld Fitting Pipe Pipe unevenly scraped Fitting Pipe Pipe damaged through gouging Fitting damaged through forced insertion of oversize pipe Please note: Plasson Automatic Control Boxes will not carry out this dynamic monitoring process on other manufacturers fittings. Wholesale prices do not include 10% GST 99

36 TOOLING Control Boxes Control Box Comparison Table Features PF Monomatic PF Polymatic Plus USB PF PolyControl Plus V2 5M Lead M Lead M Lead Welds Only Plasson Automatic Fittings up to 355mm All EF Fittings up to 800* (*Sizes above 355mm require a cooling period between welds.) All EF Fittings. Continuous welding. (No cooling between welds) Weld Tip Size 4.7mm 4.7mm (Opt 4.0mm) 4.7mm (Opt 4.0mm) Plasson SmartFuse Mode (Automatic) Y Y Y Manual Input of Welding Time N Y Y Welding Voltage 39.5V 8-48V 8-48V Output Current (Maximum) 60A (80A) 80A (110)A 90A (105A) USB Data Interface N Y Y Multilingual Display Messages (7) Y Y Y Error messages in plain text Y Y Y Adjustable display contrast Y Y Y Dynamic process supervision Y Y Y Auto software check Y Y Y Resistance check Y Y Y Ramped start Y Y Y Service Message After 200 Hours or 12 After 200 Hours or 12 Months After 200 Hours or 12 Months Months Barcode reading capability N Y Y Fitting and Operator traceability N Y Y Earth Pin 15A 15A 15A Active Cooling N N Y *Detailed Specifications for each model available from Plasson. REQUIRED GENERATOR SPECIFICATIONS MINIMUM REQUIRED GENERATOR OUTPUT POWER Input Voltage Range V 240 V, 50Hz, 1-PHASE. Frequency 40-70V DIAMETER OUTPUT POWER Minimum Output 18A at 240V - one phase 20-75mm 2kW Must be able to drive inductive loads mm 3.2kW Must have phase cut control mm 4.5 kva - (Mechanically Controlled) Mechanically regulated with brushes is the preferred system 5 kva - (Electronically Controlled) Synchronized generator 500mm 6.5 kva - (Mechanically Controlled) Minimum 6.5 kva - Mechanically Controlled 7.5 kva - (Electronically Controlled) 7.5 kva - Electronically controlled 100 Wholesale prices do not include 10% GST

37 TOOLING ELECTROFUSION CONTROL BOXES Monomatic 5m Lead Monomatic 10M Lead Monomatic 15M Lead Dualmatic 3M Lead Fixed Lead Polymaticplus USB 5M Lead Polymatic plus USB 10M Lead Polymaticplus USB 15M Lead PolyCONTROL Plus V2 10M Fixed Lead WELDING CABLES & ACCESSORIES WELDING CABLES FOR MONOMATIC OR DIGIMATIC WITH 4.7MM TERMINALS 5M Detachable Lead M Detachable Lead M Detachable Lead WELDING CABLES FOR POLYMATIC PLUS USB WITH 4.7MM TERMINALS (READING PEN SOLD SEPERATELY) 5M Detachable Lead M Detachable Lead M Detachable Lead EXTENSION CABLES FOR POLYCONTROL V2 Extension Cable 15M Extension Cable 30M WELDING TERMINALS Welding Plug 4.7mm (Black outlet) Welding Plug 4.7mm (Red outlet) SPARE PARTS FOR WEDING CABLES PVC Cap (Black) PVC Cap (Red) WELDING TERMINAL PIN ADAPTORS ADAPTORS Adaptor 4.0/4.7 angle (pair) Adaptor 4.7/4.0 angle (pair) SMARTFUSE ADAPTORS Adaptor 4.7/4.7 90Deg angle For use with Plasson SmartFuse and other fittings Adaptor 4.7/4.0 90Deg angle For use with Plasson SmartFuse and other fittings Adaptor 4.0/4.7 90Deg angle For use with Plasson SmartFuse and other fittings Wholesale prices do not include 10% GST 101

38 TOOLING BAR READERS AND ACCESSORIES READING PENS Reading Pen 2DL (incl. Reading pen cable) Barcode Scanner DL (Powerscan incl. Cable & Hooded Bag) TRANSPORT CASE Orange Transport Case Monomatic/ Digimatic/ Polymatic Plus Flight Case Monomatic/ Digimatic/ Polymatic Plus RULING AND MARKING Magnetic Circular Pipe Ruler Pi-Meter mm with Vernier 0.1mm Pi-Meter mm with Vernier 0.1mm MARKING PENS Marking pens broad white (12pens/1box) Marking pens fine white (12pens/1box) PIPE CUTTING SECATEUR PIPE CUTTER Pipe Cutter up to 63mm (Single Hand) Pipe Cutter Spare Blade for 63mm (Single Hand) Pipe Cutter up to 63mm (Two Hand Use) Spare Blade ROTATIONAL PIPE CUTTER (S-TYPE) Rotational Pipe Cutter mm Rotational Pipe Cutter Spare Blade 20-75mm Rotational Pipe Cutter mm Rotational Pipe Cutter mm Rotational Pipe Cutter Spare Blade & mm + T ROTATIONAL PIPE CUTTER Rotational Pipe Cutter Spare Rotational Pipe Cutter Knife Pipe Cutter Rotational Pipe Cutter Blade for Rotational Pipe Cutter & mm - cement carbide ROTARY CIRCULAR SAW KIT mm (Max. Cutting Depth 65mm) mm (Max. Cutting Depth 85mm) mm (Max. Cutting Depth 85mm) POA Extension links for the mm Rotary Circular Saw Kit 102 Wholesale prices do not include 10% GST

39 TOOLING PIPE SCRAPING HAND SCRAPER Hand Scraper - Small 1.1/ Blades for Small Hand Scraper (2) Hand Scraper - Large 2.1/ Blades for Large Hand Scraper (2) DRILL MOUNTED SCRAPER TOOL Scraping depth suitable for repair fittings. Hexagon spigot for cordless driller. Scraper head 16mm for Pipe Ends Scraper Head 20mm for Pipe Ends Scraper Head 25mm for Pipe Ends Scraper Head 32mm for Pipe Ends Scraper head 40mm for Pipe Ends Scraper Head 50mm for Pipe Ends Scraper Head 63mm for Pipe Ends Spare Blade for Scraping Head ROTATIONAL SCRAPER TOOL Rotational Pipe Scraper Rotational Pipe Scraper Tool mm Spare Blade for Rotational Scrapers 63/110mm Rotational Pipe Scraper Tool mm Spare Blade for Rotational Scraper mm ROTATIONAL PIPE END SCRAPER TOOL Rotational Pipe End Scraper Tool mm Rotational Pipe End Scraper Tool mm Rotational Pipe End Scraper Tool mm Spare Blade for Rotational ScraperTool ,90-315, mm ROTATIONAL CHAIN SCRAPER TOOL Rotational Scraper Tool mm Rotational Scraper Tool mm Extension Links mm for Rotational Chain Scraper mm Rotational Scraper Tool mm Spare Blade for Rotational Chain Scraper Tools CHAMFER/ BEVELER RI Pipe Beveler mm mm-315mm and wall thickness up to 30mm To prepare the ends of pipe (suitable for PE, PP, PVDF, PVC) Helps to prevent damage to electrofusion zones during pipe insertion. Recommended for diameter above 125mm and all pipes from coils. RI Pipe Beveler Spare Blade Wholesale prices do not include 10% GST 103

40 TOOLING PIPE CLEANING PLASSON XL PIPEWIPES Plasson XL Pipewipes These specialised moist wipes are impregnated with a high specification solution containing 70% Isopropyl Alcohol. Plasson Pipewipes ensure surfaces are clean before electrofusion jointing (scraping of pipe surface is still required). 120 sheets per canister. PIPE CLAMPING Pipe Clamp 16-63mm With Quick Adjustment Adjustable to suit couplers, reducers, & 90 ebows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, 16-63mm. Quick tightening operation, lightweight & easy to use. Pipe Clamp mm with Quick Adjustment Adjustable to suit couplers, reducers, & 90 ebows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, mm. Quick tightening operation, lightweight & easy to use. Pipe Clamp mm with Quick Adjustment Adjustable to suit couplers, reducers, & 90 elbows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, mm. Quick tightening operation, lightweight & easy to use. Pipe Clamp mm with Quick Adjustment Adjustable to suit couplers, reducers, & 90 elbows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, mm. Quick tightening operation, lightweight & easy to use. STRAP CLAMPS Used to prevent movement during the weld process. The Plasson Strap Clamp, a convenient, flexible system for holding PE pipes steady during the electrofusion process. Does not assist with rerounding. For larger dimensions it is recommended to combine two or more Pipe Clamps (Strap Clamp). Pipe Clamp mm pipe clamps, 2 base bars, angled adaptor 22.5, 45, 90 & 180 Pipe Clamp mm With 2 fixed clamps, 2 clamps required Pipe Clamp mm Set Included in set: 2 complete clamps each with a pulling clamp, a fixed clamp and pulling shoes for couplers. This allows you to pull the coupler over the pipe and the opposite pipe into the coupler to complete the insertion. Pipe Support Pipe support to 225mm 104 Wholesale prices do not include 10% GST

41 TOOLING REROUNDING TOOLS Two required - one rounding tool for each side of fitting. REROUNDING CLAMP 32-63MM 40mm (incl.adaptor for 32mm) mm (incl. adaptor for 50mm) REROUNDING CLAMP MM mm (Deforming force 0.85 tonne) mm (Deforming force 1.2 tonne) mm (Deforming force 2.2 tonne) mm (Deforming force 3.5 tonne) REROUNDING RING MM 63mm mm mm mm mm mm mm mm mm mm mm (Heavy Duty) mm Rerounding Shell mm Rerounding Shell mm Hydraulic Rerounding Tool mm HYDRAULIC ROUNDING SHELL MM mm Hydraulic Jack ( ) Rounding Shell 315mm (without jack) Rounding Shell 355mm (without jack) Rounding Shell 400mm (without jack) mm Hydraulic Jack ( ) Rounding Shell 450mm (without jack) Rounding Shell 500mm (without jack) Rounding Shell 560mm (without jack) Rounding Shell 630mm (without jack) mm Hydraulic Jack ( ) Rounding Shell 710mm (without jack) Rounding Shell 800mm (without jack) Rounding Shell 900mm (without jack) Note: 1 x Hydraulic Jack rquired for each Shell - 2xShells required (1xShell for each side of fitting) Use wil PF Strap Clamps HYDRAULIC ROUNDING TOOL MM mm Hydraulic Tool. Use with PE pipes mm (Max. 11) Mechanical Rerounding Tool mm MECHANICAL ROUNDING TOOL mm mm Wholesale prices do not include 10% GST 105

42 TOOLING REROUNDING TOOLS CONT. POST SQUEEZE OFF REROUNDING SHELL MM Used to round pipe after squeezing 63mm mm mm mm mm mm mm mm mm mm SQUEEZE OFF TOOLS 50NB (Gas Services) Suits NB 10, 18, 25 (1 ), 32 (1.1/4 ),40 (1.1/2 ), or 50mm (2 9.9 Pipes). The SQT service squeeze tool is for flow stopping on either metric or imperial sizes of pipe mm Suits 11 16/20,25,32,40,50,63mm & 17 63mm Squeeze off is affected by turning the handle in a clockwise direction mm (Excl. 140mm) Suits mm 11 & 17 (incl. 2 complete stopper sets). Sizes: 63,75,90,110,125,160,180 and 200mm. Hydraulic operation. Metric limit plates set at 1.6t. Safety stops to prevent creep. Springs return jack to park position after squeeze off. Integral safety valve. DEBEADING TOOLS External Bead Remover EBR 25-90mm External Bead Remover (Chain) mm External Bead Remover Extension Chain mm for m Pipe Wholesale prices do not include 10% GST

43 TOOLING SPECIALIZED INSTALLATION TOOLING FOR PLASSON PRODUCTS WASTE SADDLE INSTALLATION TOOLS Waste Water Clamping & Cutting Tool Set mm X 45Deg fixed outlet saddle clamp kit. For mains pipe sizes mm. Includes: Saddle clamp unit. Coupon removal tool (drill not incl.) Tool for Waste Water Saddle mm Flexible Outlet Saddle Clamp Kit. For main pipe sizes mm. Includes: Saddle clamp unit. Core drill kit. FLEX RESTRAINT Flex Restraint installation clamp ( ) LARGE BORE INSTALLATION TOOLS CLAMPS Saddle Clamp Kit mm Includes: 90, 110, 125 & 160mm Splitable Outlets, PTPRT and Transport Suitcase Saddle Clamp mm - Splitable clamping plate 250mm outlet Includes: Suitcase and rounding ring Saddle Clamp mm - Splitable clamping plate 400mm outlet Includes: Suitcase Straps for clamping plates 180mm mm Includes: Straps/ratchets/torque wrench/suitcase CORE CUTTERS Core Kit mm Includes: 1 x ( ) Core drill for 90mm with SDS-MAX connector mounted. 1 x ( ) Core drill for 110mm with SDS-MAX connector mounted. 1 x ( ) Core drill for 125mm with SDS-MAX connector mounted. 1 x ( ) Core drill for 160mm with SDS-MAX connector mounted. 1 x ( ) Centre drill. 1 x ( ) Core drill connector for driller chuck. 1 x ( ) Core drill connector for SDS-Plus. 1 x Transport Case. *Requires seperate drill with power rating 1200W, speed 360RPM. Must include safety clutch. Core Cutter for Plasson saddle - 250mm/11; Borehole 199mm Includes: Adaptor, drill and case Core Cutter for Plasson saddle - 400mm/11; Borehole 319mm Includes: Adaptor, drill and case DRILLS Drill BE75-X3 Quick for Plasson core cutter mm Drill+drill support+straps 400mm outlet POA SCRAPERS Electrical Saddle Scraper (230V)-(In 1450W out 830W) (230V) 110mm pipes. Cordless available on request (18V). Pneumatic Saddle Scraper Wholesale prices do not include 10% GST 107

44 Plasson recommends installation of electrofusion fittings in accordance with PIPA guideline POP001. The following excerpts from POP001 relate to tooling available from Plasson. Peeling In order to achieve a good weld the oxidised surface of the pipe must first be removed. The removal of this oxidised surface layer is achieved using a mechanical peeling tool. Mechanical or rotational peeling tools must be capable of removing a continuous and uniform peel thickness from the outer oxidised surface, in the case of socket type fittings over the required insertion depth, and in the case of saddle fittings over the full area of the saddle base when preparing the fusion zone. Pipe Peel Depth Requirements Pipe DN DN25 Peel Depth (mm) see note 0.2 Maximum DN32 - DN DN75 - DN >DN Cleaning The surfaces to be EF welded must be completely clean and free of contaminants. It is essential to clean the peeled surface with unused approved alcohol wipes to remove traces of dirt, mud and other contamination. Re-rounding and Alignment Clamps Alignment clamps are required for restraining, aligning or reducing the annular gap between the pipe and fitting during the fusion cycle. Re-rounding clamps should be readily available for every electrofusion weld and must be used when the dimensions of the pipe fall out of the dimensions specified within POP014. More information can be found at