Views: 0 Author: ERA Technical Team Publish Time: 2024-11-26 Origin: Site
Introduction：
HDPE electrofusion fittings are widely used in various industries due to their reliability, durability, and ease of installation. Proper installation is crucial to ensure the strength and integrity of the joint, preventing leaks and prolonging the pipeline's service life. This guide provides detailed step-by-step instructions for installing HDPE electrofusion fittings, including preparation, cleaning, welding, and post-installation care. By following these instructions carefully, you can achieve a secure and long-lasting connection.
Preparation：
1. Prepare PE electrofusion fittings and pipes.
2. Gather tools Gather necessary tools：
a. Alcohol
b. Measuring tape
c. Scraper
d. Dust-free paper
e. Gloves
f. Scissors
g. Markers
h. Scanner
i. Electrofusion welder
Before operation：Cleaning and Inspection
1. Clean the pipe surface：
Use dust-free paper and alcohol to wipe the surface of the pipe.
2. Inspect the electrofusion fittings：
Take out the fittings with packaging and carefully inspect for any defects.
Step 1：Marking and Preparing the Pipe
Measure and Mark：
a. Measure the socket depth of the electric fusion fitting and mark the corresponding length on the pipe.
b. Draw cross lines on the pipe surface to ensure the oxide layer is evenly removed.
Step 2：Remove the oxide layer on the surface of the pipe.
1. Remove Oxide Layer：
a. Use a scraper to remove the oxide layer from the pipe surface at a constant speed.
b. Note：Do not use angle grinders as they will cause rapid heating and secondary oxidation.
2. Inspection：
Ensure the entire surface has been properly scraped.
3. Pareparation before installing：
a. Take out the manual and the electrofusion fitting, and check whether each accessory is complete, if good, start installation.
b. Insert the oxide-layer-removed pipe end into the fitting, marking aligns with the end according to the socket depth, and repeat the same steps for the other end.
c. Wiping the socket part.
Step 3：Cleaning and Installing the Fitting
1. Spray alcohol on dust-free paper and clean the socket area of both the pipe and fittings.
2. Install the fitting：
a. Insert the pipe end (with the oxide layer removed) into the fitting, ensuring the marked line is flush with the pipe end.
b. Repeat this process for the other end of the pipe an fittings.
c. Tighten screws and use a feeler gauge to confirm the assembly gap (≤0.3mm).
Step 4：Welding Operation
Check that the welding machine is functioning normally.
Step 5：Start Welding：
1. Scan the barcode on the fitting using the scanner.
2. Connect the welding machine to the fitting and set the welding voltage and time as per the manual and begin welding.
3. Observe the middle cap of the fittings rising during welding, which confirms the completion of pipe welding poeration.
4. After cooling, the welding machine will print a receipt.
Step 6：Once welding is completed, sign the data
Important Note：During the welding process and the cooling phase, do not move or step on the pipeline to maintain welding strength.
Saddle Fittings Installation
1. Marking and Preparation：
a. Mark and draw lines on saddle fittings according to the shape of the saddle surface.
b. Mark and draw cross-hatch on fittings and valves according to the socket size.
c. Remove the oxide layer from the pipe surface using a scraper (avoid angle grinders)
2. Clean the prepared surface with alcohol and ensure no debris remains.
3.Fitting Installation：
a. Clean the inner surface of the pipe with alcohol (avoid touching the inner wall).
b. Insert the fusion sleeve halfway into the fitting according to the scale lines.
c. Mark the joints at both ends of the sleeve.
4. Welding：
Follow the same welding steps as outlined above.
Tapping Tee Installation
1. Close the valve to ensure in a sealed state.
2. Unscrew the black cap of the tapping tee.
3. Align the “T” wrench of the special hole-opening tool with the hexagonal slot of the built-in tool.
4. Hold the "T" wrench and turn the outer cap of the toolo make the outer cap screwed and connected with the saddle.(Note：Tapping tee can be installied under air-carrying working condition.)
5. Rotate the wrench clockwise to reach the drilling surface.If resistance increases, adjust and proceed steadily until the drill reaches the highest point inside the saddle body.
6. Rotate the tool. (Note: The rotation resistance is very small at this time.) When the ratation resistance becomes large again, it needs to be rotated again until it cannot be rotated.
7. Rotate the outer cap of the special tool counterclockwise until it is separated, remove the tool,and the hole-opening operation is completed.
8. Install the outer cap of the tapping tee. (Note：When presssing, use our special outer cap tool)
This completes the connection of the electrofusion fittings and the valve.
This is the specific installation video of HDPE electrofusion pipe fittings：https://youtu.be/QdSECd5mXR4?si=us0-fOZlXrx957Kx
If you have any inquiries or needs, please contact ERA pipe fittings.
Compiled by: Mercy Ruan
