Electric fusion

  • · By using the electric resistance heat generated from the heat pipe inside the joint pipe, we can program the standard value for temperature and time, and if the specification is out of order, the wrong point of fusion is recorded by the outputted data. The ease of construction as it can be constructed in a simple manner even in a narrow space.
  • · Types include socket fusion, saddle (service tee) fusion, and elbow fusion.

Cosmo I&D’s Electric fusion welded tube

  • · When the E / F is connected to the welding machine, the welding time and the cooling time are automatically set and the equipment operation is easy.
  • · It is a standard product of KS M 3408-3 and ISO 4427-3, and it is convenient to use because the dimensions conform to gas and water pipes.
  • · Electric fusion of 160mm or more is easy to move because there is a carrying knob in the sound tube.
  • · It is convenient to select ISO user because of various product dimensions.
  • · Excellent airtightness due to wide hot wire width.

Performance of E / F FITTING

Test categories Contents
Dimensions Inspection Inspection according to KS 3408-3, ISO 4427-3
Hot Strength Creep Test
(Water)
PE80 – Test temperature: 20 ° C, Test pressure: 10.0Mpa, Break time ≥100h
– Test temperature: 80 °C, Test pressure: 4.5 Mpa, Break time ≥165 h
– Test temperature: 20 °C, Test pressure: 4.0 Mpa, Break time ≥1000 h
PE100 – Test temperature: 20 ° C, Test pressure: 12.4Mpa, Break time ≥100h
– Test temperature: 80 °C, Test pressure: 5.4 Mpa, Breaking time ≥165 h
– Test temperature: 20 °C, Test pressure: 5.0 Mpa, Break time ≥1000 h
Peeling test The brittle peeling length should be 1/3 or less of the length of the fused part.
Dropping test Test temperature and condition control: 4h at 0 ℃, height of weights: 2m, weight of weights: 2.5kg
There is no abnormality in the secrets after the test, and there are no other defects
Short-term water pressure test PE80 Test temperature: 20 ℃, pressure increase rate: 0.5 MPa / min, breaking pressure: 3.2 MPa or more
PE100 Test temperature: 20 ℃, pressure increase rate: 0.5 MPa / min, breaking pressure: 4.0 MPa or more
Tensile load resistance Test temperature: 23 ℃, tensile rate: 5 mm / min, minimum change ratio with pipe yield point: 25%

Advantages of E / F (Electro fusion fitting)

  • · Gas welding (F / F) is connected to the automatic welding machine, thereby setting the welding time, and is set by welding, and operation of automatic welding machine is easy.
  • · KS M ISO 8085-2, 3 and KS M 3408-3 compliant with the specifications of pipes and fittings.
  • · Constructability is excellent because it is light in weight compared to other piping.
  • · Due to the characteristics of raw material, polyethylene (PE), it has excellent corrosion resistance, chemical resistance and cold resistance,
  • · Automatic welding machine is small and light, so it is convenient to use even in narrow or small space or difficult construction area.
  • · Process is simpler than that of butt fusion welding, so welding is easy.
  • · Electric fusion is a resistance heat generated by the electric resistance of the heat wire when the electricity is supplied because the heat line is installed inside the electric fusion welded tube. The electric fusion causes the outer surface of the pipe and the outer surface of the pipe to be melted and joined. The gap between the joint pipe and the PIPE is filled and welded to ensure perfect airtightness and watertightness. (For water / gas) same condition.
Pipe cleaning, marking

Pipe cleaning, marking

Scraping / display

Scraping / display

Clean with alcohol

Clean with alcohol

Insert / Fix

Insert / Fix

Fusion / cooling

Fusion / cooling

Inspection

Inspection

Comparison of Gas / Water / Sewage E/F

Usage Material Color Terminal type Welder Raw material Applicable standard
Gas E / F Medium density (MDPE) Yellow 3Pin/1Pin Automatic welding machine PE80,PE100 KS M ISO 8085-3
Water E / F High density (HDPE) Black 3Pin/1Pin Automatic welding machine PE80,PE100 KS M 3408-3
Sewer E / F High density (HDPE) Black 1Pin/1Pin Automatic welding machine PE80 KWWA M 203

E / F FITTING construction

E / F FITTING Construction and Cautions

  1. Prepare the necessary tools for joint work.
    * Pipe cutter, electric welder, power line, cleaner, fire extinguisher
  2. Before using electric fusing machine, make sure that it is in good condition firstly.
    * When using generator, maximum capacity should be 5Kwatt or more and it should be used after idling for more than 10 minutes.
    * The lead wire diameter should be 5Ø or more.
    * The supplied power must be within the rated power (110V ± 5V, 220V ± 10V, 60Hz) required for the fusion welding machine.
    * Electric fusing machines should not be used with electric appliances that use a lot of current.
  3. Check whether the electric welder to be used is a normal safety device and safety-certified equipment within one year or not.
  4. Check that the pipe used is the standard product defined by KSA or equivalent.
  5. Cut each pipe to be connected at right angles and remove surface impurities.
  6. Insert the pipe to the stopper inside the E / F, and mark the length of the insert on the outside of the pipe.
  7. The welding surface of the pipe shall be chamfered (scraping) at least 0.2mm.
  8. Pipes and E / F used before fusing are cleaned with methyl alcohol (80% or more) to remove impurities.
  9. Slide the pipe into the E / F joint pipe to the point of the pipe indicating the insertion length.
  10. Each pipe to be joined to the E / F joint pipe shall be inserted and aligned in a straight line.
  11. Check the alignment between the pipe and the joint pipe, and perform the electric fusion work according to the “welding and cooling time table”.
  12. Make sure that the fusion time indicated on the sticker matches the fusion time indicated on the welder.
  13. After fusing, check the protruding condition of the projecting pin and follow the specified “cooling time”.
  14. Check the leakage of the welded area and finish the work.
  15. ※ If you have a technical inquiry or require service when constructing the product, please follow our instructions after preserving the welding condition.

E / F FITTING Construction Order

1. Cleaning Removal of impurities on the surface of PIPE Methyl alcohol (80% or more)
2. Marking (Marking) Insertion mark Oil based marker
3. Chamfering Surface scraping of PIPE Dedicated scraper
4. Cleaning Removal of impurities on the surface of PIPE Methyl alcohol (80% or more)
5. Insert (fixed) Fusing fixture and terminal connection Clamp
6. Fusion Fuser start button operation Welder
7. Cooling Standby until cooling time by specification
8. Release Remove output line after cooling

Method of Joining PE Pipes and Fittings

Heat Fusion Joining

The joining method can be broadly divided into “heat fusion” and “electric fusion.” As it is possible to bond the base material, which is an advantage of polyethylene, these methods are easier to perform and offer a higher performance than the conventional method. On the other hand, the specified processes must strictly be observed because the completeness of fusion is determined by the three factors of fusion (i.e., temperature, pressure, and time).

Types

  1. Butt Fusion :

    A flat plate (heater plate) is inserted between the cross section of a pipe/fitting to fuse the cross section. The inserted heater plate is removed, and then the fused parts are pressed against each other and joined together. During these processes, the temperature, pressure, and time must be strictly observed.
  2. Socket Fusion :

    The fused parts (i.e., the inner surface of the socket-type fitting and the outer surface of the pipe) are inserted into a rugged heater plate (fixed with a heater face) and fused together. The heater plate is removed, and then insertion is carried out to join them together. This method is suitable for pipes No. 75 and below.
  3. Screw-Type Joining :

    A pipe is inserted into a fitting, and the cap and body are tightened using a chain wrench. This method is normally applied to pressurized water piping because it is easy to perform. It is suitable for the joining of pipes No. 100 and below.
  4. Joining Process Chart

Joining Processes

Pipe heat
Pipe heat
Chamfering
Chamfering
Check alignment
Check alignment
Pressurized melting, Maintain heat
Pressurized melting,
Maintain heat
Compress, cool
Compress, cool