UPP Piping Systems

Electrofusion Welding Instructions

Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA

Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com
Safety
Important!
UPP Systems must only be installed by fully trained and certified installers.
Failure to follow installation instructions will invalidate warranty and installer
certification!

Electrofusion Safety
• UPP Welding Units must never be operated in Zone 1 or Zone 0 areas (Hazardous area definitions are from
European Directive 1999 / 92 / EC and guidelines can be found in the APEA Blue Book 2nd Edition).
• Ensure Welding Units are connected to a power supply that meets the requirements detailed in the user manual
and are within the requirements of any local authority or regional legislation.
• An important requirement of any type of piping system is to safely connect all metallic components to ground.
Metallic components, and more general conductive materials, due to their high capacitance, can have the
potential to store a high amount of electrostatic energy (sparks discharge can only be observed over conductive
elements).
• All exposed metal parts used in UPP System installations should be adequately grounded to a dedicated earth
ground electrode and brought to a potential equal to that of other metal parts in the close proximity.
• Use ONLY FFS EF1-110 or EF1-230 welders with UPP Piping. Do NOT use these welders with other
manufacturer’s piping or fittings.
Chemical Safety
• Where using chemicals (such as Acetone) during the installation of UPP systems products, be sure to follow all
safety guidelines given on the chemical containers themselves or on any accompanying literature.
Confined Space
• Some installation of UPP products may occur in confined spaces where a lack of oxygen and a concentration of
toxic vapors is likely to be experienced.
Such working conditions are dangerous and all local health and safety guidelines for working in such
environments should be followed.

Material Handling
Protective Equipment
• Ensure the correct personal protective equipment (PPE) is used at all times in line with local health and safety
requirements.
Material Safety Data
• Ensure all safety data is accessed and used while installing UPP Systems (Material Safety Data Sheets are
available in the download area of the UPP website).
Transport & Storage
• UPP products should be transported and stored in accordance with the guidelines contained in Section 1.
Heavy items
• Heavy items should be handled using suitable lifting equipment operated by authorised personnel.

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Contents
Safety.................................................................................................................................2
Overview...........................................................................................................................4
Installation Guidelines.....................................................................................................4
Electrofusion Instruction.......................................................................................................... 4
Electrofusion Procedure Overview.................................................................................5
Electrofusion Preparation Details...................................................................................6
Cutting pipe.............................................................................................................................. 6
Scraping................................................................................................................................... 6
Cleaning................................................................................................................................... 7
Mark Insertion Depth............................................................................................................... 7
Marking Insertion Depth by Pre-Fitting.................................................................................... 7
Clamping . ............................................................................................................................... 8
Welding.................................................................................................................................... 8
Verify Weld Completion............................................................................................................ 9
Welding Secondary Containment Pipe And Fittings...................................................10

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Overview Electrofusion Instruction
The polyethylene construction of UPP pipe allows all Organise all necessary tools and equipment on the job
connections to be joined using an electrofusion welding site prior to commencing the installation of pipe and
process. This provides a joint which is stronger than the fittings.
pipe itself, and with no leak paths. The basic installation tool set should always include:
Electrofusion is carried out quickly and simply using • UPP Electrofusion welder.
specialist tools available from FranklinFueling.
• Pipe cutter.
A large variety of electrofusion fittings are available, • Pipe Scraper.
from simple couplers (for making in-line pipework joints),
• Cleaning Solvent.
to welded terminations (for terminating double wall
secondary containment pipework) and entry seals. • Straight and angled clamps.
• Permanent marker or Chinagraph pencil (white,
Installation Guidelines yellow or red).
Follow the guidelines below to insure a successful • Tape measure.
installation: Refer to the following sections for more detailed
• All pipe must be cut square. information on the above tooling.
• All pipes must be scraped to remove the oxidation
area before Electrofusion.
• All Spigot fittings supplied un-bagged must be
scraped to remove the oxidation area before
electrofusion.
• Pipes, fittings and sockets must be cleaned with
acetone where they join.
• All joints should have the pipe inserted into the
electrofusion fitting ensuring that the marked
insertion depth is reached.

• Joints must not be under any stress during welding

or until ambient temperature is reached after
welding.

4
Electrofusion Procedure Overview

1 2

Measure and cut pipe to required length Use one of the scraping tools provided in the
allowing for correct insertion depth into UPP installation box to prepare the pipes and
welding coupler. fittings for welding.

3 4

Clean scraped areas of pipe / fitting using a Measure and mark pipe to indicate correct
lint free cloth moistened with Acetone. insertion depth into fusion fitting.

5 6

Clean bore of the welding coupler with Acetone. Assemble the joint and hold in place with
clamp. Check that insertion is up to the marked
depth indication.

7 8

Connect welder to clamped assembly and • Check insertion depth mark for movement.
follow welding unit instructions. Ensure • Check that welding completion indicators are out.
appropriate welding cables are used. • Allow joint to cool to ambient temperature. Wait at
Note: Case-mounted EF1-110 shown. EF1-230 least 20 minutes before any stresses are exerted
Handheld welder can also be used. upon the assembly.

5
Electrofusion Preparation Details Scraping
It is imperative that the scraping of pipes and fittings is
Cutting pipe
carried out exactly as described here to remove the layer
Primary pipe (single wall pipe)
of oxidised material that builds up on the pipe when it is
• Cut primary pipe only by using the appropriate UPP
exposed to air. This oxidised layer hinders the quality of
pipe cutter tool and never using a hand saw. The UPP
the weld and must be removed.
cutting tool gives 100% straight cuts every time and
no burring ensuring that the cut ends fit flush into any Note: NEVER, under any circumstance, use sand paper
welding couplers or fittings. on primary or secondary pipe.
Primary pipe (single wall pipe)
Primary pipe must be scraped using the UPP
scraping tool. These tools remove a controlled outer
layer of oxidised polyethylene over the length of the pipe
which is inserted into a coupler or electrofusion fitting.

Cutting primary pipe using UPP cutting tool

• There are two different pipe cutters available for
varying pipe diameters.
Pipe Diameter Pipe Diameter
Tool Scraping UPP Primary Pipe Using Scraping Tool
(mm) (inches)
P.CUT 50-110 1½-4 Secondary containment pipe (double wall pipe)
• Secondary containment pipe has to be scraped using
P.CUT MED 110-160 4-6
the UPP hand scraper (SCR.HAR). A layer of plastic
Secondary containment pipe (double wall pipe)
must be removed all along the length of pipe to be
• Cut secondary containment pipe in exactly the same
inserted into the welding coupler or electrofusion
way as primary pipe, using the UPP pipe cutting tools.
fitting.
• When cutting coaxial pipe it is possible to cut through
both pipe layers in one go. Be careful of this if
you want your primary pipe length longer than the
secondary sheath (inside sumps and chambers etc.).

Scraping UPP Secondary Pipe Using Hand Scraper

Cutting Secondary Pipe Using UPP Cutting Tool

Duct pipe
• It is not possible to cut UPP corrugated duct pipe
using the UPP pipe cutting tools. A hand saw should
be used to cut the duct using the corrugations as
guides to help create a clean, straight cut.

6
Non-Electrofusion Fittings Mark Insertion Depth
Non electrofusion fittings (i.e. those that need an Mark the insertion depth on pipe ends using a permanent
electrofusion coupler to be welded) if supplied Un-bagged, marker or China-graph pencil and a ruler
must be scraped with the UPP hand scraper before
welding’

Using a Ruler to Mark Insertion Depth

The following table shows the correct insertion
depth into UPP primary electrofusion fittings
Scraping UPP Non-Electrofusion Fitting with Hand Scraper
The polyethylene area of these fittings must be scraped Insertion
Ø Product Length
using the UPP hand scraper to remove a layer of oxidised Description
mm Code
polyethylene along the whole length that is to be inserted mm Inches
into the welding coupler.
Welding 50 02-50 25 1
Electrofusion Fittings / Welding Couplers Coupler 63 02-63 30 1  3/16
Electrofusion fittings are those with welding elements built
90 02-90 36 1  3/8
into them - these do not require scraping before being
used, but must be cleaned with a solvent (See below). 110 02-110 41 1  9/16
90º Elbow 50 03-050-EIF 44 1  3/4
Cleaning Electro- 63 03-063-EIF 48 1  7/8
To ensure that there is no grease, moisture or dirt in fusion
the electrofusion zone during welding it is important to 90 03-090-EIF 62 2  7/16
clean all the pieces of the assembly prior to welding. The 110 03-110-EIF 71 2  3/4
following solvents may be used: 45º Elbow 63 04-063-EIF 48 1  7/8
• A cetone (preferred) Electro- 90 04-090-EIF 62 2  7/16
fusion
• Isopropyl alcohol 110 04-110-EIF 71 2  3/4
• Trichloroethane
Marking Insertion Depth by Pre-Fitting
The insertion depth can also be marked by inserting the
cleaned pipe fully into the fitting and marking around the
fitting.

Using An Acetone-Soaked Cloth To Clean A Welding Socket

and Seal Spigot
Do NOT USE solvents that leave an oily film on the joining
surface such as turpentine, petrol or synthetic dilutents.
The surfaces to be cleaned include:
Marking Insertion Depth
• All scraped areas of pipes and fittings Inscribe a line around the junction of the pipe and fitting.
• The inside of electrofusion fittings and welding
couplers Note: When using this method, make sure the pipe
Once the areas of pipes and fittings to be welded have is fully inserted. Visually check if possible, or
been wiped clean, avoid touching the cleaned areas or listen / feel for the pipe positively contacting the
allowing contact with any sources of grease / dirt. stop.

Note: In wet weather, protect the fittings from water.

Water in the fittings can contaminate the welds
and cause failures. 7
Clamping Welding
Check for correct alignment of the assembly both Overview
vertically and horizontally and ensure that it is not UPP 230 volt and 115 volt intelligent Welding Units
subjected to any bending load or weight that could supply the precise electrical energy to fuse two UPP
deform to the joint while it is in a molten state. products together safely on site. The heat causes
Use UPP clamps to keep the assembly in the correct the pipe and joint surfaces to melt and fuse. After
alignment position, preventing any movement during the electrofusion, the assembly is left to cool while the
welding and subsequent cooling process. polyethylene solidifies to form a homogenous union
If a clamp cannot be used, for example in a small tank stronger than either pipe or fittings.
chamber, precautions need to be taken to ensure that
Note: UPP welders use a constant current output. UPP
the assembly is not under any stress.
components must never be welded with other
brands of welding unit.
Both types of welder can be used from the mains supply
or from a generator.
The welding machine measures the ambient temperature
and the welding coupler / electrofusion fittings resistance
values. The welder must be close to the same
temperature as the joint it is welding.
Bridging
A maximum of three primary couplers or primary
electrofusion fittings may be welded at the same time by
Screw Clamps using bridging leads. Most electrofusion couplers and
fittings have a resistance index number marked onto
The screw clamps on some fittings are used to hold
them inside a circle: i.e. ⑥. The total value of the index
the pipe in place for clamping. The piping may have a
number of the three items to be welded must not exceed
pre-load force that could pull the pipe out slightly before
10. If the fitting lacks a resistance index number then it
clamping. Tighten the screws to hold the piping in place
must be treated as having an index number of 10. A list
while the clamps are installed.
of resistance numbers can be seen in the following table.

Resistance
Description Part number
index number
Primary welding socket 02-50 2
Primary welding socket 02-63 2
Primary welding socket 02-90 4
Primary welding socket 02-110 6
Primary welding socket 02-160 10
Primary welding socket 02-200 10
Electrofusion elbow 90º 03-050-EIF 4
Electrofusion elbow 90º 03-063-EIF 4
Electrofusion elbow 90º 03-090-EIF 7
Angled Clamp Installed
Electrofusion elbow 90º 03-110-EIF 9
Electrofusion elbow 45º 04-063-EIF 4
Electrofusion elbow 45º 04-090-EIF 7
Electrofusion elbow 45º 04-110-EIF 9
Electrofusion equal tee 08-050-EIF 4
Electrofusion equal tee 08-063-EIF 4
Electrofusion equal tee 08-090-EIF 7
Electrofusion equal tee 08-110-EIF 9
Electrofusion reducer 09-090-063-EIF 5
Electrofusion reducer 09-110-090-EIF 7
Electrofusion entry seal 302 Flange 1
Electrofusion entry seal 303 Flange 2
Electrofusion entry seal 305 Flange 3
Straight Clamp Installed
Electrofusion entry seal 308 Flange 3
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Welding Cables Chart Verify Weld Completion
Size of Weld Time The first indication of a successful weld is that the
Type Welding welder’s green 100% LED is lit.
Welding Current @ 20C
of Cable
Pim (amps) Most fittings have a weld indicator built in. After the weld
Fitting Colour (Seconds)
(mm) the center of the indicator should protrude above the
Primary Red 4 4 184 surrounding area.
Secondary Green 2 5 80
Fusion
White 2.3 7 360 Weld Indicator
Chamber (Before welding)
Large
Diameter Black 2 10 365
(10amp)

Note: A resistance value of X means that there is no

marked resistance value on the fittings and these
should be treated as having values of 10.
Connect the leads from the welding unit to the fittings
per the chart above. The leads should fit firmly. It is very
important to use the correct cable.
Welding Process
After the welder is turned on, press the start button to
begin the welding process. The weld time is determined
by the welder and no further input is required.
Note: Before pushing the start button, the welder must
show a green ready light. Hold the start button down Weld Indicator Location
momentarily and then release it.
The welder display will show welding progress. Once
Weld Indicator
completed it is good practice to write the time on the
(After welding)
fitting to determine when clamps can be removed.
Wait 20 minutes for the weld to cool before removing
clamps.
Resetting the welder
Always reset the welder between welds by depressing
and holding the start button for 3 seconds.

Weld Indicator Completed

Look in the Tightness Testing Section for complete
inspection procedure.
Troubleshooting
• Refer to the welder documentation for complete
welder operation and error codes.
• If power is lost during the weld, allow the fitting to cool
in place for at least an hour and then restart the weld
process.

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Welding Secondary Containment Pipe And 5. Clean primary pipe end with acetone.
Fittings

• Green welding cables should be used for welding

secondary containment pipe
• Some welding unit displays will read: “Secondary
Mode” and after five seconds “Connect welding
element”
Procedure
1. Cut Co-axial pipes to required length using the
pipe cutter as shown.

Clean Secondary with Acetone

6. Pre-clean secondary pipe 200 mm (8.0") from
end.
7. Clean reducer with acetone and slide it along
secondary pipe - small end first.

Cut Secondary Pipe

2. Trim or slide the secondary pipe back 40 mm
(1 9/16").

Slide Reducer on Secondary

8. Ensure elbow or tee primary spigots measure
30 mm (1 3/16"), and cut to length if required.
40 mm (1 9/16")
30 mm
(1 3/16")
Trim or Slide Secondary
3. Prepare primary and secondary pipe using hand
scraper.
4. Secondary pipe must be scraped all the way up
to 150 mm (6.0") from its end.

Measure Primary Spigots

m
150 m ")
(6 . 0

Scrape Secondary
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9. Prepare Primary and Secondary spigots of 15. Before welding check that the secondary
tee / elbow with hand scraper. containment reducer is fitted in correct location
over scraped zone of secondary pipe.
16. Weld Primary couplers.
17. Once weld is complete allow to cool for at least
30 minutes.
18. If needed, do not weld the secondary until the
primary piping has been inspected.
19. Clean inside of reducer spigot and outside of
the Tee / Elbow spigots with acetone.

Scrape Primary and Secondary

10. Clean Primary spigots of tee / elbow with
acetone.
11. Clean Secondary spigots of tee / elbow with
acetone.

Clean Inside of Secondary

20. Slide reducers into place (ensure full insertion).
21. Weld secondary.
22. Allow to cool for at least 30 minutes before
putting any stress on the joint.
Clean with Acetone
12. Clean primary welding coupler using acetone.
13. Fit couplers to primary Tee / Elbow spigots.

Assembled Secondary Fittings

Clean Weld Coupler with Acetone

14. Insert Primary pipe into welding couplers (ensure
pipe is fully inserted).

Insert Primary Pipe into Coupler

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 Franklin Fueling Systems LTD
8 Olympus Close • Whitehouse Industrial Estate
Ipswich, Suffolk IP1 5LN • United Kingdom
©FFS 2011 408001007 Rev1 Tel: +44 1473 243300 • Fax: +44 1473 243301