Advance Welding ACT 4 User manual
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 1
ACT 4
(Data logging 80v welding unit)
Operating manual
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 2
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 3
Index
Operating Controls............................................4
Safety Notes .....................................................5
Product Specification........................................6
Intended Use.....................................................7
Introduction.......................................................7
Delivered Items.................................................8
Electrical Safety................................................8
Using the Equipment.........................................9
Data Log Memory ...........................................10
Manual Welding..............................................11
Easigrip Welding.............................................12
Extreme Low Temperature Operation.............14
Downloading the Weld Memory......................15
Upgrading the Operating Software .................15
Set Up Options................................................16
Information......................................................17
Fault Finding...................................................18
Maintenance ...................................................21
Disposal..........................................................22
Calibration and Warranty................................22
Declaration of Conformity ...............................25
Service and Repair .........................................26
Quick Start Guide............................................28
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 4
Operating Controls
1. Welding Cable (can be provided with optional right angle
plug)
2. USB Memory Drive
3. USB Socket
4. Welding Cable Socket
5. Protective Lid
6. Display
7. Buttons
8. Protective Frame
9. Supply Breaker
10. Supply Cable
1. Welding Cable
2. USB Memory
10. Supply Cable
8. Protective Frame
9. Supply Breaker
3. USB Socket
4. Welding Cable Socket
7. Buttons
6. Display
5. Protective Lid
IMPORTANT!
80 volt welding units
require a BLUE
welding cable.
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 5
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. Replace the
damaged part before welding.
Switch off and remove the plug from the mains before
adjusting, cleaning, or if the cables are entangled and before
leaving the equipment unattended for any period.
To avoid damaging the unit, do not interrupt the supply voltage
or disconnect the welding cable, while the unit is welding a
fitting.
Do not lift or pull the equipment by its cables.
Do not disconnect the welding cables by pulling on them,
always pull off the connectors from the fitting.
Do not start a weld without the pipe correctly inserted into the
fitting.
Do not touch the fitting while welding.
Do not weld in the rain or leave the equipment outdoors whilst
it is raining.
Weld only in daylight or in good artificial light.
The operator is responsible for accidents or hazards occurring
to other people or their property while using this equipment.
Keep the work area safe!
Keep bystanders a safe distance away from the machine while
welding.
Never allow people unfamiliar with these instructions to use
the welding unit.
!
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 6
Product Specification
Operating Type: Controlled voltage.
Operating Modes: Manual, Easigrip #1
Operating Languages: English, French, Dutch, Polish,
Russian. (others on request)
Operating Temperature: -10oC to +40oC #2
Welding Voltage: 79 V ac
Welding Current: 1 to 63 A ac (true rms)
Welding Power: 80 VA to 4977 VA
Welding Time: 1 to 3600 seconds
Apparent Power Factor: 0.72
Supply Voltage: 110 V ac (+/- 20%) 40 to 60 Hz
Supply Current: 1 to 63 A ac (true rms)
Supply Power: 6,930 W
Supply Protection: Class 1 –Earthed
Data log memory: 2048 welds
Data download/upload: USB flash memory drive
Weight: 20 kg
Size: 38 cm x 38 cm x 39 cm
Protection Level: IP65
#1 Easigrip is a registered name of Radius Systems Ltd
#2 An extended temperature unit is available with limits -40oC to +50oC.
Advance Welding 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.
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 7
Intended Use
This equipment is intended to weld large diameter (“80v”) constant
voltage electrofusion fittings suitable for low, medium and high
pressure pipe work systems.
The equipment has been approved by Radius
Systems for use with Easigrip fittings.
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 distribution networks.
This welding unit complies with the UK Water Industry Specification
WIS 04-32-08 ‘Specifications for the fusion jointing of polyethylene
pressure pipeline systems using PE80 and PE100 materials’, and is
suitable for use on all UK water distribution networks.
This welding unit has been designed to comply with the
International Organization for Standardization standard ISO12176-
2:2000 "Plastic pipes and fittings, equipment for fusion jointing
polyethylene systems , part 2, electrofusion".
Introduction
This manual gives instructions on the correct assembly and safe
use of your welding unit. It is important that you read these
instructions carefully, and keep these instructions for the life of the
unit.
This manual does not detail the specific welding procedure for the
fittings: scraping, clamping and assembly of joints. For this
information you must contact the manufacturer of the fittings.
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 8
Delivered Items
Carefully remove the welding unit from its packaging and check that
you have the following items:
Welding unit.
Welding cable.
USB flash memory drive.
When parts are missing or damaged, please contact your dealer.
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.
This unit is 110 volt operation.
The power source must be capable of providing 6930 Watts.
This equipment must be fitted with a 63 amp mains plug.
Extension cables should only be used if they comply with the
H07RNF harmonized standard. They must be fitted with connectors
to the BS EN 60309-2 standard. All cables must be unwound from
the reel to stop inductive heating effects. Only use one 10m
extension cable with a conductor size 4.0mm2.
This equipment is fitted with a Residual Current Device (RCD) with
a tripping current of 30 mA. Always check the RCD every time you
use it.
The supply cable must be inspected for signs of damage before
each use and the equipment may only be used if in perfect
condition. Damaged cables must be replaced by an approved
service agent.
This equipment is classified as “Portable for use on industrial
applications”, and must undergo a formal electrical safety check
(Portable Appliance Test) as per local regulations.
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 9
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.
Prepare and clamp the pipe and fittings inline with the
manufacturers recommendations.
Connect the welding cable to the unit and the fitting to be welded.
Connect the supply cable to the correct supply voltage and switch
the unit on.
The screen will show a welcome message along with the software
version and date. The owner details are then shown
The main menu is now shown on the display. During operation,
except while welding, pressing the star key on the keypad will jump
back to this menu.
Notes:
The operation of the unit can be customised by turning welding
modes on and off, along with some features like the cooling time
and data logging. This manual details all available modes and
features. For information on how to customise the welding unit see
the “Set Up” section later on in this manual.
The welding unit is fitted with an alpha-numeric keypad, which is
used by the operator to input data. Down the right hand side there
are four Quick-Keys, A B C D. These act as quick shortcut keys,
their function being prompted on the screen.
When entering data, letters and numbers can be selected by
repeatedly pressing the same key, e.g. A B C 2 A B C 2 . After a
short pause the cursor will move to the next position. Special
characters and spaces can be selected by pressing the 1 or 0 keys.
(This is the same method used for text with mobile cell phones.)
Pressing the B Quick-Key will step Back one position. Pressing the
C Quick-Key will Clear the input field.
ACT4 Electrofusion Welding Unit –Operator Manual –Rev: 4.1.G
© 2008. Advance Welding. Page 10
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 third is an Information field for more
details.
The display will show all three pieces of information:
Pressing the B Quick-key will select the ‘Operator Name’ and allow
changes to be made. Enter the required information and press the
A Quick-key to accept it.
Pressing the C Quick-key will select the ‘Location’ and allow
changes to be made. Enter the required information and press the
A Quick-key to accept it.
Pressing the D Quick-key will select the ‘Information Field’ and
allow changes to be made. Enter the required information and press
the A Quick-key to accept it.
When all the information has been entered, press the A Quick-key
to accept it.
This information will be saved when the weld has been completed,
and will be prompted the next time a new weld is carried out.
The display will also ask if the pipe/fitting has been scraped and
clamped. Select yes or no using the Quick-Keys. This information
will be saved on the data log memory.
The unit can save 2048 welds in memory. When the memory is full,
it will be overwritten from the beginning in blocks of 24 welds. This
will allow the last 2000 welds to be held in memory.
An optional “lifetime weld memory” feature is available. This uses
an SD memory card fitted internally that records every weld carried
out by the unit. This is designed as a backup device and can only
be downloaded by an approved service agent.
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