Electro Fusion Welding_1 Electro Fusion Welding_2 Electro Fusion Welding_3
1. Cut pipe to length using appropriate cutters.2. Use scraper BWPS 16063 to remove oxide layer from pipe for full fitting insertion length to approximate depth of 0.3mm. 3. Wipe surfaces to be welded with Welding Wipes (BEFPW) to remove dust etc, and allow cleaner to evaporate. 4. Assemble pipe and fitting making sure pipe is FULLY inserted. Clamps may be attached to stabilise joint during welding.
Electro Fusion Welding_4 Electro Fusion Welding_5
5. Connect welder leads onto fitting terminals. Set correct weld time (marked on each fitting). Follow instructions for particular welder. Press start for weld cycle to commence. Allow to cool, time is marked on each fitting. 6. Rising melt indicators confirm successful completion of weld. When weld cycle is completed, allow assembly to cool without any movement or strain.

Electro Fusion

Fittings for electro fusion comply with AS4129. Automatic control box reads resistor and sets and welds the correct time, fittings also labelled for manual setting times. Weld surfaces must be clean and dry.

Do not overscrape pipe. Use correct scrapers.

Do not use emery paper or metal files. IMPORTANT: Do not allow movement in the joint until cooling period has been completed. In some cases clamps may be required. Ensure continuous electricity supply during weld cycle.


2. FOR SOCKET FUSION PRE-MANUFACTURE MAIN LINES ON GROUND.

Socket fusion

Heating element socket fusion to welding guideline AS 2033-1980. Weld surfaces must be clean and dry. Welding machine must be up to temperature 230° – 250° C before commencing. Avoid cold windy conditions. Do not realign joint after adjusting time, see table below. Do not overscrape pipe – interference fit must be retained. Do not twist pipe into fitting when fusing.

Socket Fusion Welding Time/Temperature Chart

Pipe OD mm Pre-Heating Sec. Adjusting Sec. Cooling Min
20 5 4 2
25 7 4 2
32 8 6 4
40 12 6 4
50 18 6 4
63 24 8 6
90 40 8 6
110 50 10 8

Socket fusion Welding Instructions BLUTUBE 20 to BLUTUBE 63

Use Socket Fusion Bench Machine for up to BLUTUBE90.

Socket Fusion Welding_1 Socket Fusion Welding_2 Socket Fusion Welding_3
1. Turn on Welder BSFHM. Do not attempt welding unless tool is up to temperature (250°C). The light will flash on/off with thermostat control when temp. is correct.2. Cut pipe to length required with (BPC…) cutters for a swarf free finish. 3. Clean pipe & fitting. Use scraper (BWPS…) to remove oxide layer from pipe and ensure correct tolerance. Welding wipes (BEFPW) may be used if required. 4. Simultaneously insert pipe and fitting onto socket and spigot to full depth without twisting. Hold for correct time as per table ‘Pre-heating seconds’ (left)
Socket Fusion Welding_4 Socket Fusion Welding_5
5. Remove pipe & fitting from heating element, immediately insert pipe into fitting without twisting. 6. Check alignment within ‘adjusting seconds’ as per table (left). During cooling avoid mechanical strain or movement on welded joint.

Blutube®
Installation Instructions

PROCEDURE:
3. Install Pipe work into Clips

Compression Fittings
BLUTUBE 20 to BLUTUBE 63

CompressionFitting20to63_1 CompressionFitting20to63_2 CompressionFitting20to63_3
1. Cut pipe to length with appropriate cutter (BPC…) for a swarf-free finish. 2. Chamfer with appropriate chamfering tool. (BCHAM…) This may not be necessary for BLUTUBE 20, 25, 32. 3. Remove nut and conical grip ring from fitting and mount on pipe in the same order with the large end of the grip ring facing fitting. Lubricate, see notes*, **.
CompressionFitting20to63_4 CompressionFitting20to63_5
4. Insert the pipe into fitting with a twisting motion until it passes through the ”0” ring and meets the internal shoulder. Ensure that grip ring is touching the fitting. 5. Screw and tighten the nut onto the fitting firmly by hand. The larger pipe sizes 40mm & upward will need tightening with the appropriate wrench (BNW1) however, do not use excessive torque.

** Lubricate with silicone spray, soapy water or vaseline except on specialist applications. ie: powder coating, spray painting, breathing & quality air, etc. DO NOT use penetrating fluids such as WD40, 5-56, Penetrene etc.


4. INSTALL BRANCHES & OUTLETS.

Compression Fittings BLUTUBE 90 to BLUTUBE 110

CompressionFitting90to110_1 CompressionFitting90to110_2 CompressionFitting90to110_3
1. Cut pipe to length and chamfer.2. Remove nut, conical grip ring, bushing and ”0” ring and mount on pipe in the same order leaving out grip ring.3. Lubricate pipe end and inside of fitting. (See note below**) 4. Insert pipe into the fi tting until it meets the internal shoulder. 5. Bring up the ”0” ring and bushing and tighten nut until they are fully in place.
CompressionFitting90to110_4 CompressionFitting90to110_5
6. Unscrew nut, open grip ring and put on pipe with the large end touching the bushing. 7. Tighten nut with the appropriate wrench (BNW2) taking care not to use excessive force.*Fitting may be supplied with a tapered seal instead of O-Ring,
– in this case nut need not be removed,
– simply chamfer pipe, lubricate, fully insert, and tighten.

** Lubricate with silicone spray, soapy water or vaseline except on specialist applications. ie: powder coating, spray painting, breathing & quality air, etc. DO NOT use penetrating fluids such as WD40, 5-56, Penetrene etc.


5. TEST AND COMMISSION PIPE SYSTEM.

BCL Pipe Clips Installation

BCL Pipe Clips_1 BCL Pipe Clips_2 BCL Pipe Clips_3
1. Mount pipe clip using appropriate fastener. In vertical mounting situations (horizontal pipe-work) ensure female ratchet is uppermost as shown below.BCL Pipe Clips_1a 2. Pull clip apart and put the pipe in. 3. Press the pipe into clip towards the clip base and set to appropriate setting.
BCL Pipe Clips_4
To remove pipe from clip push the 2 bands sideways in opposite directions to disengage.

Pipe Support Spacings

HORIZONTAL SUPPORT SPACING
PIPE SIZE UP TO 25˚C UP TO 50˚ C
BLUTUBE 20 700 600
BLUTUBE 25 900 750
BLUTUBE 32 1200 900
BLUTUBE 40 1400 1100
BLUTUBE 50 1600 1200
BLUTUBE 63 1800 1400
BLUTUBE 90 2000 1600
BLUTUBE 110 2400 1800
BLUTUBE 160 2700 2100


Spacings may need to be altered for various ambient temperatures encountered.
Spacings may also be increased using Continuous Support Channel, see P15.

Spacings will need to be decreased if pipework is conveying fluids. Refer to Technical Department.