electrofusion fittings & tools - …auspolyspec.com.au/resources/aps-ef-16rev1.pdf · female...

› ELECTROFUSION FITTINGS & TOOLS Australian Standard

2016 Revision 1

03

APS Electrofusion Fittings & Tools

APS (Australian Poly Specialists) isn’t an electrofusion fittings manufacturer

and as such we commonly source and fabricate using product from a

variety of suppliers.

We offer an expert fabrication service in butt welding, extrusion and

electrofusion, aided by state-of-the-art procedures, machinery as well as

stringent quality control.

Any weld failure is unacceptable.

APS has become heavily involved in numerous coal seam, gas

projects and their stringent testing regimes with zero failures. On one

of these projects the testing requirements were relaxed specifically

for our company – as the principal was completely satisfied with the

quality of our output and workmanship.

We can also site measure and will give advice as required to help you

complete your project on budget / on time / every time. We are also able

to site manage (a limited capacity service), supply, weld and also install

your polyethylene systems.

Our core business is in-house fabrication but we are always happy to talk

to our customers to satisfy their needs – whatever they are.

If you can’t find it in our catalogue, give us a call as we are specialists

in custom fittings and fabrications.

[email protected] | www.auspolyspec.com.au | 07 3889 7511


05

www.auspolyspec.com.au

› CONTENTS

›


Electrofus ion F i t t ings 09

COUPLER 10

COUPLER PN 25 11

LONG COUPLER 11

LIGHTFIT COUPLER – FOR THIN WALLED PIPE 12

LIGHTFIT 15º ELBOW 13



EQUAL TEE 14

REDUCING COUPLER 15

REDUCING TEE 16

FULL-FACED FLANGED BEND – STAINLESS STEEL 316 BACKING RING 17

FULL-FACED FLANGED BRANCH SADDLE – STAINLESS STEEL 316 BACKING RING 17

FULL-FACED FLANGED ADAPTOR 18

ADJUSTABLE ELBOW – COUPLER TO COUPLER 18

ADJUSTABLE ELBOW ONE SIDED – COUPLER AND SPIGOT 19

22.5° ELBOW 20

45° ELBOW 20

90° ELBOW 21

90° DUCKFOOT ELBOW 22

90° DUCKFOOT ELBOW – 32 OUTLET 22

MALE ADAPTOR E/F 23

TRANSITION COUPLING – FEMALE BRASS BSP OUTLET 24

TRANSITION UNION – FEMALE BRASS BSP OUTLET 25

TRANSITION COUPLING – MALE BRASS BSP OUTLET 26

TRANSITION UNION – MALE BRASS BSP OUTLET 27

TRANSITION COUPLING – MALE STAINLESS STEEL (316) BSP OUTLET 28

45º TRANSITION ELBOW – FEMALE BRASS OUTLET 29

45º TRANSITION UNION ELBOW – FEMALE BRASS BSP OUTLET 30

45º TRANSITION ELBOW – MALE BRASS OUTLET 31

45º TRANSITION UNION ELBOW – MALE BRASS BSP OUTLET 32

90º TRANSITION ELBOW – FEMALE BRASS BSP OUTLET 33



07


CONTENTS›

90º TRANSITION ELBOW – MALE BRASS BSP OUTLET 35

END CAP – INCLUDES COUPLING & PLUG 36

BRANCH SADDLE – WITH UNDERPART 37/38

BRANCH SADDLE – LARGE BORE 39

TAPPING SADDLE – WITH UNDERPART 40/42

REPAIR SADDLE – WITH UNDERPART 43

TRANSITION SADDLE – WITH UNDERPART BRASS FEMALE THREAD 44

Wastewater E lectrofus ion F i t t ings 47

WASTEWATER SADDLE – FIXED 45° OUTLET 48

ADJUSTABLE SADDLE – 160mm OUTLET 48




ADJUSTABLE ELBOW PE – PVC 50

ELECTROFUSION COUPLERS – LIGHTFIT 50

MANHOLE ADAPTOR 51

ASSEMBLY TOOLS FOR WASTEWATER SADDLES 51

Tools & Accessor ies 53

T PLASSON SMARTFUSE(AUTOMATIC) ELECTROFUSION FITTINGS 54

T PLASSON AUTOMATIC (PF) WELDING CONTROL BOXES 55

T CONTROL BOX COMPARISON TABLE 56

CONTROL BOXES 57

WELDING CABLES AND ACCESSORIES 57

WELDING TERMINAL PINS ADAPTORS 58

BAR CODE READERS AND ACCESSORIES 58

PIPE CUTTING 59

PIPE CLEANING 59

PIPE SCRAPING 60/61

PIPE CLAMPING 62/63

ROUNDING TOOLS 64/66

SQUEEZE OFF TOOLS 66/67

DEBEADING TOOLS 67

SPECIALISED INSTALLATION TOOLING FOR PLASSON PRODUCTS 68/69

T SERVICE REQUIREMENTS 69

Weld Schedules & Weld Sheets 71

T BUTT WELD SCHEDULE 72

T ELECTROFUSION WELD SCHEDULE 73

T EXTRUSION WELD SCHEDULE 74

SINGLE PRESSURE T HIGH FUSION JOINTING PRESSURE (SHP) 76

SINGLE PRESSURE T LOW FUSION JOINTING PRESSURE (SLP) 77


0909

COUPLER 10

COUPLER PN 25 11

LONG COUPLER 11

LIGHTFIT COUPLER – FOR THIN WALLED PIPE 12




EQUAL TEE 14

REDUCING COUPLER 15

REDUCING TEE 16

FULL-FACED FLANGED BEND – STAINLESS STEEL 316 BACKING RING 17

FULL-FACED FLANGED BRANCH SADDLE – STAINLESS STEEL 316 BACKING RING 17

FULL-FACED FLANGED ADAPTOR 18

ADJUSTABLE ELBOW – COUPLER TO COUPLER 18

ADJUSTABLE ELBOW ONE SIDED – COUPLER AND SPIGOT 19

22.5° ELBOW 20

45° ELBOW 20

90° ELBOW 21

90° DUCKFOOT ELBOW 22

90° DUCKFOOT ELBOW – 32 OUTLET 22

MALE ADAPTOR E/F 23

TRANSITION COUPLING – FEMALE BRASS BSP OUTLET 24

TRANSITION UNION – FEMALE BRASS BSP OUTLET 25

TRANSITION COUPLING – MALE BRASS BSP OUTLET 26

TRANSITION UNION – MALE BRASS BSP OUTLET 27

TRANSITION COUPLING – MALE STAINLESS STEEL (316) BSP OUTLET 28

45º TRANSITION ELBOW – FEMALE BRASS OUTLET 29


45º TRANSITION ELBOW – MALE BRASS OUTLET 31

45º TRANSITION UNION ELBOW – MALE BRASS BSP OUTLET 32

90º TRANSITION ELBOW – FEMALE BRASS BSP OUTLET 33


Electrofus ion F i t t ings

90º TRANSITION ELBOW – MALE BRASS BSP OUTLET 35

END CAP – INCLUDES COUPLING & PLUG 36

BRANCH SADDLE – WITH UNDERPART 37/38

BRANCH SADDLE – LARGE BORE 39

TAPPING SADDLE – WITH UNDERPART 40/42

REPAIR SADDLE – WITH UNDERPART 43

TRANSITION SADDLE – WITH UNDERPART BRASS FEMALE THREAD 44


www.auspolyspec.com.au›


ELECTROFUSION FITTINGS›


COUPLERPN 16 Water / SDR 11 Gas

DN PIPESDR RANGE

L D

16 7 - 11 71 35

20 7 - 11 76 31

25 7 - 11 82 36

32 7 - 11 88 44

40 7 - 11 97 56

50 7 - 11 101 67

63 7 - 11 117 82

75 7 - 11 126 98

90 7 - 11 148 112

110 7 - 11 162 140

125 7 - 11 173 157

140 7 - 11 183 174

160 7 - 11 195 194

180 7 - 11 212 218

200 7 - 11 223 242

225 7 - 11 240 272

250 7 - 11 251 311

280 7 - 11 275 340

315 7 - 11 282 387

355 7 - 11 277 431

400 7 - 11 293 485

450 7 - 11 306 539

500 7 - 11 340 603

560 7 - 11 376 674

630 7 - 11 418 759

710 7 - 11 472 853

800 7 - 11 500 955

450-800 Couplers have dual weld zones. Series 3, 40 and 50mm Couplers available on request.

11

COUPLER PN 25PN 25 Water / SDR 7.4 Gas

DN PIPESDR RANGE

L D

50 7 - 11 101 67

63 7 - 11 118 82

75 7 - 11 126 97

90 7 - 11 148 117

110 7 - 11 163 140

125 7 - 11 173 157

160 7 - 11 198 198

180 7 - 11 212 224

200 7 - 11 223 249

225 7 - 11 240 280

250 7 - 11 251 311

280 7 - 11 275 340

315 7 - 11 282 387

*400 7 - 11 293 485

* PN 20 Water / SDR 9 Gas

LONG COUPLERPN 16 Water / SDR 11 Gas

DN PIPESDR RANGE

L D

32 7 - 11 104 44

40 7 - 11 121 56

50 7 -11 139 68

63 7 - 11 166 82

SUITABLE PLASSON CONTROL BOXES

DN DUALMATIC MONOMATIC POLYMATICPLUSUSB POLYCONTROLPLUS

16 - 160 Yes Yes Yes Yes

180 - 355 No Yes Yes Yes

400 - 800 No No No Yes

Note: Unless otherwise stated all PlassonEF fittings supplied with 4.7mm terminal resistor pins.

D

L

D

L




LIGHTFIT COUPLER – FOR THIN WALLED PIPEPN 10 Water / SDR 17 Gas

DN PIPESDR RANGE

L D

40 11 - 17 90 56

50 11 - 17

63 11 - 17 118 77

75 11 - 17 126 90

90 11 - 26 148 108

110 11 - 33 163 131

125 11 - 33 173 149

140 11 - 33 182 167

160 11 - 33 198 193

180 11 - 33 212 215

200 11 - 33 232 235

225 11 - 33 240 264

250 11 - 33 256 293

280 11 - 33 275 332

315 11 - 33 284 374

355 11 - 33 280 421

400 11 - 41 296 474

+450 11 - 41 310 518

*500 11 - 33 340 576

*560 11 - 41 376 645

*630 11 - 33 418 726

*710 11 - 33 472 817

*800 11 - 33 500 913

+ 450 Lightfit Coupler is 42v fitting - not 40v. *500 - 800 Lightfit Couplers have dual weld zones. Max SDR 26 for pipes 63-90mm. Max SDR 33 for pipes 110-800mm except 400, 450 & 560 Max SDR 41.

13







D

L

LIGHTFIT 15° ELBOWPN10 Water / SDR17 Gas

SDR RANGE d D A L L1

11 - 33 160 193 106 265 98

A

L1

D d

L



11 - 33 160 193 106 300 98

A

L1

D d

L




15

EQUAL TEEPN 16 Water / SDR 11 Gas

SIZE SDR RANGE D d1 H L L1

20 x 20 x 20 7 - 11 33 20 60 96 37

25 x 25 x 25 7 - 11 44 25 66 103 39

32 x 32 x 32 7 - 11 44 32 74 104 39

40 x 40 x 40 7 - 13.6 56 40 90 120 43

50 x 50 x 50 7 - 13.6 68 50 102 139 48

63 x 63 x 63 7 - 13.6 82 63 119 167 58

75 x 75 x 75 7 - 13.6 96 75 129 196 63

90 x 90 x 90 7 - 21 113 90 137 294 71

110 x 110 x 110 7 - 21 143 110 160 326 71

125 x 125 x 125 7 - 17 165 125 177 382 86

160 x 160 x 160 7 - 21 208 160 206 440 86

180 x 180 x 180 7 - 17 245 180 250 422 106

200 x 200 x 200 7 - 17 261 200 265 451 114

225 x 225 x 225 7 - 17 293 225 290 494 122

250 x 250 x 250 7 - 17 326 250 315 538 129







H

L1L

d1 D

d1



11 - 33 160 193 106 323 98

A

L1

D d

L

REDUCING COUPLERPN 16 Water / SDR 11 Gas

SIZE SDR RANGE L L1 L2

20 x 16 7 - 11 71 35 35

25 x 20 7 - 11 71 35 35

25 x 20 NB 7 - 11 71 35 35

32 x 20 7 - 11 81 40 35

32 x 25 7 - 11 81 40 35

40 x 25 7 - 11 90 44 40

40 x 32 7 - 11 90 44 40

50 x 25 7 - 11 100 49 41

50 x 32 7 - 11 100 49 40

50 x 40 NB 7 - 11 100 49 44

50 x 40 NB 7 - 11 100 49 44

60 x 32 7 - 11 119 57 40

63 x 40 7 - 11 119 57 44

63 x 50 7 - 11 119 57 49

63 x 50 NB 7 - 11 119 57 49

75 x 63 7 - 11 126 66 57

90 x 50 7 - 11 143 71 49

90 x 63 7 - 11 143 71 57

90 x 75 7 - 11 143 71 61

110 x 63 7 - 11 161 78 57

110 x 90 7 - 11 161 78 72

125 x 90 7 - 11 171 85 72

125 x 110 7 - 11 171 85 78

160 x 90 7 - 11 193 94 72

160 x 110 7 - 11 193 94 81

160 x 125 7 - 11 195 94 85

180 x 125 7 - 11 212 103 85

L

L2L1




REDUCING TEEPN 16 Water / SDR 11 Gas

SIZE SDR RANGE D d d1 H L L1

25 x 20 x 25 7 - 11 44 25 20 66 104 39

25 x 32 x 25 7 - 11 44 25 32 74 104 39

32 x 20 x 32 7 - 11 44 32 20 66 104 39

32 x 25 x 32 7 - 11 44 32 25 66 104 39

40 x 20 x 40 7 - 13.6 56 40 20 72 120 43

40 x 25 x 40 7 - 13.6 56 40 25 72 120 43

40 x 32 x 40 7 -13.6 56 40 32 75 120 43

50 x 20 x 50 7 - 13.6 68 50 20 78 139 48

50 x 25 x 50 7 - 13.6 68 50 25 78 139 48

50 x 32 x 50 7 -13.6 68 50 32 86 139 48

50 x 40 x 50 7 - 13.6 68 50 40 90 139 48

63 x 20 x 63 7 - 13.6 82 63 20 85 167 58

63 x 32 x 63 7 -13.6 82 63 32 93 167 58

63 x 40 x 63 7 - 13.6 82 63 40 104 167 58

63 x 50 x 63 7 - 13.6 82 63 50 109 167 58

75 x 63 x 75 7 -13.6 96 75 63 122 196 63

90 x 63 x 90 7 - 21 113 90 63 124 294 68

110 x 63 x 110 7 - 21 143 110 63 134 326 71

110 x 90 x 110 7 - 21 143 110 90 147 147 71

125 x 90 x 125 7 -21 165 125 90 161 382 86

125 x 110 x 125 7 - 21 165 125 110 173 382 86

160 x 90 x 160 7 - 21 208 160 90 180 440 86

160 x 110 x 160 7 - 21 208 160 110 193 440 86

160 x 125 x 160 7 - 21 208 160 125 198 440 86

180 x 90 x 180 7 - 17 245 180 90 200 422 106

180 x 110 x 180 7 - 17 245 180 110 219 422 106

180 x 125 x 180 7 - 17 245 180 125 225 422 106

180 x 140 x 180 7 - 17 245 180 140 237 422 106

180 x 160 x 180 7 - 17 245 180 160 250 422 106

200 x 90 x 200 7 -17 261 200 90 205 451 114

200 x 110 x 200 7 - 17 261 200 110 210 451 114

225 x 90 x 225 7 - 17 293 225 90 220 494 122

225 x 110 x 225 7 -17 293 225 110 225 494 122

250 x 90 x 250 7 - 17 326 250 90 235 538 129

250 x 110 x 250 7 - 17 326 250 110 240 538 129

17

FULL-FACED FLANGED BEND – STAINLESS STEEL 316 BACKING RINGPN 16 Water

MAIN 1 MAIN 2 OFFTAKE

125 125 90

180 180 90

Elongated slots suitable for four or eight hole flange drilling w/ PCD b/w 145 and 180mm.

Full-faced flange and stainless steel ring drilled 4x18 @ 146 PCD and 4x18 @ 178 PCD.

FULL-FACED FLANGED BRANCH SADDLE – STAINLESS STEEL 316 BACKING RINGPN 16 Water

MAIN 1 MAIN 2 OFFTAKE

125 125 90

180 180 90

225 225 90

250 250 90

Elongated slots suitable for four or eight hole flange drilling w/ PCD b/w 145 and 180mm.

Full-faced flange and stainless steel ring drilled 4x18 @ 146 PCD and 4x18 @ 178 PCD.







H

L1L

d D

d1




FULL-FACED FLANGED ADAPTORPN 16 Water

OD LENGTH

90 118

90 450 Pupped 450mm

Suits 80 to 100mm fire hydrant mountings – max ID of mating flange 80mm.

The Plasson SDR11/PE100 100mm full face flange complies with AS/NZS4129, is pressure rated at PN16 and can be connected to the various 90mm PE pipes using the following methods.

90 x 80 / 100 S/S316 Backing Ring to suit FFF Adaptors

(Drilled 4 x 18 @ 146 PCD and 4 x 18 @178 PCD)

PE 63 PE 80 PE 100

PN 16 EF EF EF or BW

PN 12.5 EF EF EF

PN 10 EF or BW EF or BW EF

PN 8 EF EF -

PN 6.3 EF - -

19







ADJUSTABLE ELBOW – COUPLER TO COUPLERPN 16 Water / SDR 11 Gas – Maximum Deflection 24º

d SDR RANGE D A L L1

110 7 - 17 140 83 362 80

125 7 - 17 157 95 382 85

160 7 - 17 200 114 456 92

180 7 - 17 224 128 511 104

200 7 - 17 250 125 512 104

225 7 - 17 282 141 600 105

Ideal for jointing misaligned pipes in trenches and tight locations.

A

d

L

D

L1

24º

ADJUSTABLE ELBOW ONE SIDED – COUPLER TO SPIGOTPN 16 Water / SDR 11 Gas – Maximum Deflection 12º

d SDR RANGE D d1 A L L1 L2

110 7 - 17 140 110 83 276 80 85

125 7 - 17 157 125 95 292 85 90

160 7 - 17 200 160 114 335 96 100

180 7 - 17 223 180 128 365 104 138

200 7 - 17 250 200 125 370 104 116

225 7 - 17 282 225 141 426 105 124

Ideal for jointing misaligned pipes in trenches and tight locations.

A

d

L2

d1

L

D

L1

12º




21







22.5° ELBOWPN 16 Water / SDR 11 Gas


90 7 - 17 113 71 214 72

110 7 - 17 143 81 232 71

125 7 - 17 165 88 274 86

160 7 - 21 209 106 302 86

180 7 - 21 244 115 391 105

45° ELBOWPN 16 Water / SDR 11 Gas


32 7 - 11 45 43 95 39

40 7 - 13.6 55 46 108 42

50 7 - 13.6 68 51 125 49

63 7 - 13.6 81 59 148 57

75 7 - 13.6 96 62 180 71

90 7 - 17 112 69 243 75

110 7 - 17 143 78 271 81

125 7 - 17 165 88 304 86

140 7 - 17 182 95 342 92

160 7 - 17 209 105 350 95

180 7 - 17 244 114 434 105

200 7 - 17 261 125 472 112

225 7 - 17 294 140 520 120

250 7 - 17 326 151 571 129

A

L1

D d

L

A

L1

D d

L

90° ELBOWPN 16 Water / SDR 11 Gas


25 7 - 11 36 38 66 37

32 7 - 11 44 43 83 40

40 7 - 13.6 55 47 92 44

50 7 - 13.6 68 52 108 48

63 7 - 13.6 81 59 131 57

75 7 - 13.6 97 62 158 69

90 7 - 17 113 69 213 78

110 7 - 17 143 79 243 79

125 7 - 17 165 89 271 100

140 7 - 17 183 94 309 93

160 7 - 17 209 106 323 87

180 7 - 17 244 115 412 105

200 7 - 17 262 124 449 112

225 7 - 17 295 140 498 121

250 7 - 17 327 152 550 130

A

L1

D d

L




23







90° DUCKFOOT ELBOWPN 16 Water / SDR 11 Gas

d SDR RANGE D A A1 H H1 L L1

90 7 - 17 112 71 115 146 160 261 69

A

L1

A1

D d

L

H H1

A

L1

A1

D d

L

Hd1 H1

90° DUCKFOOT ELBOW – 32 OUTLETPN 16 Water / SDR 11 Gas

d SDR RANGE D d1 A A1 H H1 L L1

90 7 - 17 112 32 71 115 146 160 261 69

MALE ADAPTOR E/FPN 16 Water / SDR 11 Gas

SIZE SDR RANGE d D A L L1

25 x 3/4" - 25 18 37 113 31

32 x 1" - 32 24 42 123 35

40 x 1" - 40 30 46 134 37

40 x 1.1/4" - 40 30 46 137 40

40 x 1.1/2" - 40 30 46 137 40

50 x 1.1/2" - 50 38 51 141 40

63 x 1.1/2" - 63 49 57 161 44

63 x 2" - 63 49 57 165 48

Fits any electrofusion socket PE100 SDR 11.

L

D

L1

A

d




25







TRANSITION COUPLING – FEMALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas

SIZE SDR RANGE d D A L L1 L2

20 x 1/2" 7 - 11 20 14 35 96 37 20

25 x 3/4" 7 - 11 25 19 38 105 40 23

32 x 3/4" 7 - 11 32 23 42 113 42 25

32 x 1" 7 - 11 32 23 42 113 42 25

32 x 1.1/2" 7 - 11 32 23 42 113 42 25

40 x 1" 7 - 11 40 29 46 122 47 25

40 x 1.1/4" 7 - 11 40 29 46 122 47 25

40 x 1.1/2" 7 - 11 40 29 46 122 47 25

50 x 1.1/2" 7 - 11 50 38 51 126 49 25

50 x 2" 7 - 11 50 38 51 131 49 30

63 x 1.1/2" 7 - 11 63 48 57 147 57 30

63 x 2" 7 - 11 63 48 57 147 57 30


L

D

L2 L1

A

d

TRANSITION UNION – FEMALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


20 x 3/4" 7 - 11 20 14 34 106 37 30

25 x 3/4" 7 - 11 25 14 37 112 40 30

25 x 1" 7 - 11 25 19 37 115 40 33

32 x 1" 7 - 11 32 19 42 124 42 36

32 x 1.1/4" 7 - 11 32 23 42 124 42 34

40 x 1.1/2" 7 - 11 40 29 46 135 47 38

50 x 1" 7 - 11 50 19 52 136 49 36

50 x 2" 7 - 11 50 38 52 141 49 41

63 x 2" 7 - 11 63 38 57 161 57 44

63 x 2.1/2" 7 - 11 63 48 57 166 57 49


L

D

L2 L1

A

d




27







TRANSITION COUPLING – MALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


20 x 1/2" 7 - 11 20 14 34 105 37 29

25 x 3/4" 7 - 11 25 19 37 111 40 29

32 x 1/2" 7 - 11 32 23 42 117 42 29

32 x 3/4" 7 - 11 32 23 42 117 42 29

32 x 1" 7 - 11 32 23 42 122 42 34

32 x 1.1/4" 7 - 11 32 23 42 124 42 36

32 x 1.1/2" 7 - 11 32 23 42 124 42 36

40 x 1" 7 - 11 40 29 46 131 47 34

40 x 1.1/4" 7 - 11 40 29 46 133 47 36

40 x 1.1/2" 7 - 11 40 29 46 133 47 36

40 x 2" 7 - 11 40 29 46 138 47 41

50 x 1" 7 - 11 50 38 51 135 49 34

50 x 1.1/4" 7 - 11 50 38 51 137 49 36

50 x 1.1/2" 7 - 11 50 38 51 137 49 36

50 x 2" 7 - 11 50 38 51 142 49 41

63 x 1.1/4" 7 - 11 63 48 57 153 57 36

63 x 1.1/2" 7 - 11 63 48 57 153 57 36

63 x 2" 7 - 11 63 48 57 158 57 41

75 x 2" 7 - 11 75 59 64 172 61 46

75 x 2.1/2" 7 - 11 75 59 64 167 61 46

The brass component can be turned inside the body of the fittings after welding and cooling is completed.

L

D

L2 L1

A

d

TRANSITION UNION MALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas

SIZE SDR RANGE d D D1 A L L1 L2 L3

32 x 1.1/4" 7 - 11 32 23 24 42 159 42 124 34

40 x 1.1/2" 7 - 11 40 29 30 45 173 47 136 38

50 x 2" 7 - 11 50 38 38 50 182 49 142 41

63 x 2" 7 - 11 63 38 38 57 201 57 162 41

63 x 2.1/2" 7 - 11 63 48 48 57 210 57 167 49


L2

D

L3 L1

L

A

d




29







TRANSITION COUPLING – MALE STAINLESS STEEL (316) BSP OUTLETPN 16 Water / SDR 11 Gas


32 X 1" 7 - 11 32 23 41 124 44 34

32X 1 1/2" 7 - 11 32 23 41 126 44 36

40 X 1 1/4" 7 - 11 40 29 45 134 48 36

40 X 1 1/2" 7 - 11 40 29 45 134 48 36

50 X 1 1/2" 7 - 11 50 38 50 137 49 36

63 X 1 1/2" 7 - 11 63 48 57 154 57 36

63 X 2" 7 - 11 63 48 57 159 57 41

The stainless steel component can be turned inside the body of the fittings after welding and cooling is completed.

L

D

L2 L1

A

d

45° TRANSITION ELBOW – FEMALE BRASS OUTLETPN 16 Water / SDR 11 Gas


20 x 1/2" 7 - 11.0 20 14 38 86 35 20

25 x 3/4" 7 - 11.0 25 19 38 89 37 23

32 x 1" 7 - 11.0 32 23 43 108 40 25

40 x 1" 7 - 13.6 40 29 47 117 44 25

40 x 1.1/4" 7 - 13.6 40 29 47 117 44 25

40 x 1.1/2" 7 - 13.6 40 29 47 117 44 25

50 x 1.1/2" 7 - 13.6 50 38 52 133 48 25

50 x 2" 7 - 13.6 50 38 52 138 48 30

63 x 1.1/2" 7 - 13.6 63 48 59 161 57 30

63 x 2" 7 - 13.6 63 48 59 161 57 30


L

D

L2

d

A

L1




31







45° TRANSITION UNION ELBOW – FEMALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


32 x 1" 7 - 11.0 32 19 43 131 39 36

32 x 1.1/4" 7 - 11.0 32 23 43 129 39 34

40 1.1/2" 7 - 13.6 40 29 47 146 44 38

50 x 2" 7 - 13.6 50 38 51 166 49 41

63 x 2" 7 - 13.6 63 38 59 189 57 41

63 x 2.1/2" 7 - 13.6 63 48 59 197 57 44

Free Nut.

45° TRANSITION ELBOW – MALE BRASS OUTLETPN 16 Water / SDR 11 Gas


32 x 1/2" 7 - 11.0 32 23 43 124 39 29

32 x 3/4" 7 - 11.0 32 23 43 123 39 29

32 x 1" 7 - 11.0 32 23 43 129 39 34

32 x 1.1/4" 7 - 11.0 32 23 43 130 39 36

32 x 1.1/2" 7 - 11.0 32 23 43 130 39 36

40 x 1" 7 - 13.6 40 29 47 142 44 34

40 x 1.1/4" 7 - 13.6 40 29 47 144 44 36

40 x 1.1/2" 7 - 13.6 40 29 47 144 44 36

50 x 1" 7 - 13.6 50 38 51 161 49 34

50 x 1.1/4" 7 - 13.6 50 38 51 161 49 36

50 x 1.1/2" 7 - 13.6 50 38 51 166 49 36

50 x 2" 7 - 13.6 50 38 51 165 49 41

63 x 1.1/4" 7 - 13.6 50 38 51 161 49 36

63 x 1.1/2" 7 - 13.6 63 48 59 184 57 36

63 x 2" 7 - 13.6 63 48 59 189 57 41

75 x 2" 7 - 13.6 75 59 62 221 71 41

75 x 2.1/2" 7 - 13.6 75 59 62 226 71 46

The brass component can be turned inside the body of the fittings after welding and cooling is completed.L

D

L2

L1 d

A

L

D

L2

L1 d

A




33







L

D

L2

L1 d

A

45° TRANSITION UNION ELBOW – MALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas

SIZE SDR RANGE d D D1 A L L1 L2 L3

32 x 1.1/4" 7 - 11.0 32 23 24 47 164 39 129 34

40 x 2.1/2" 7 - 13.6 40 29 30 47 189 44 147 44

50 x 2" 7 - 13.6 50 38 38 51 206 49 165 41

63 x 2" 7 - 13.6 63 41 38 59 231 57 193 58

63 x 2.1/2" 7 - 13.6 63 48 48 59 240 57 198 49

Free Nut.

90° TRANSITION ELBOW – FEMALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


20 x 1/2" 7 - 11.0 20 14 38 86 35 20

25 x 3/4" 7 - 11.0 25 19 38 89 37 23

32 x 1" 7 - 11.0 32 23 43 108 40 25

40 x 1" 7 - 13.6 40 29 47 117 44 25

40 x 1.1/4" 7 - 13.6 40 29 47 117 44 25

40 x 1.1/2" 7 - 13.6 40 29 47 117 44 25

50 x 1.1/2" 7 - 13.6 50 38 52 133 48 25

50 x 2" 7 - 13.6 50 38 52 138 48 30

63 x 1.1/2" 7 - 13.6 63 48 59 161 57 30

63 x 2" 7 - 13.6 63 48 59 161 57 30


L

D

L2

dA

L1




35







90° TRANSITION UNION ELBOW – FEMALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


20 x 3/4" 7 - 11.0 20 14 38 96 35 30

25 x 3/4" 7 - 11.0 25 14 38 96 37 30

25 x 1" 7 - 11.0 25 19 38 99 37 33

32 x 1" 7 - 11.0 32 19 43 119 40 36

32 x 1.1/4" 7 - 11.0 32 23 43 119 40 36

40 x 1.1/2" 7 - 13.6 40 29 47 132 44 40

50 x 2" 7 - 13.6 50 38 52 149 48 41

63 x 2" 7 - 13.6 63 41 59 175 57 44

63 x 2.1/2" 7 - 13.6 63 48 59 180 57 49

Free Nut.

L

D

L2

dA

L1

90° TRANSITION ELBOW – MALE BRASS BSP OUTLETPN 16 Water / SDR 11 Gas


20 x 1/2" 7 -11.0 20 14 38 95 35 29

25 x 3/4" 7 - 11.0 25 19 38 95 37 29

32 x 1/2" 7 -11.0 32 23 43 112 40 29

32 x 3/4" 7 - 11.0 32 23 43 112 40 29

32 x 1" 7 -11.0 32 23 43 117 40 34

32 x 1.1/4" 7 - 11.0 32 23 43 119 40 36

40 x 1" 7 - 13.6 40 29 47 126 44 34

40 x 1.1/4" 7 - 13.6 40 29 47 128 44 36

40 x 1.1/2" 7 - 13.6 40 29 47 128 44 36

40 x 2" 7 - 13.6 40 29 47 133 44 41

50 x 1" 7 - 13.6 50 38 52 142 48 34

50 x 1.1/4" 7 - 13.6 50 38 52 144 48 36

50 x 1.1/2" 7 - 13.6 50 38 52 144 48 36

50 x 2" 7 - 13.6 50 38 52 149 48 41

63 x 1.1/4" 7 - 13.6 63 48 59 167 57 36

63 x 1.1/2" 7 - 13.6 63 48 59 167 57 36

63 x 2" 7 - 13.6 63 48 59 172 57 41

75 x 2" 7 - 13.6 75 59 62 199 69 41

75 x 2.1/2" 7 - 13.6 75 59 62 204 69 46


L

D

L2

dA

L1




37







END CAP – INCLUDES COUPLING & PLUGPN 16 Water / SDR 11 Gas

SIZE d D A L L1

20 20 31 34 84 37

25 25 36 37 92 40

35 32 44 42 103 42

40 40 56 46 114 47

50 50 67 51 121 49

63 63 82 57 142 57

75 75 98 64 156 61

90 90 117 70 183 73

110 110 140 81 206 78

125 125 157 87 222 85

140 140 174 97 237 90

160 160 194 105 261 93

180 180 218 116 283 105

200 200 242 126 289 109

225 225 272 138 318 119

250 250 311 156 344 123

* Monolithic end cap.

A

d D

L

L1

BRANCH SADDLE – WITH UNDERPARTPN 16 Water / SDR 11 Gas

SIZE / d SDR RANGE D b B H H1 L

63 7 - 11 32 - 100 59 49 118

63 7 - 11 40 - 100 78 66 118

63 7 - 11 50 - 100 93 82 118

63 7 - 11 63 - 100 94 85 118

75 7 - 11 32 - 117 59 49 118

75 7 - 11 40 - 117 78 66 118

75 7 - 11 50 - 117 93 82 118

75 7 - 11 63 - 117 94 85 118

90 7 - 11 32 - 126 59 49 118

90 7 - 11 40 - 126 78 68 118

90 7 - 11 50 - 126 93 82 118

90 7 - 11 63 - 126 94 85 118

90 7 - 11 90 - 139 105 90 176

110 7 - 11 32 - 148 59 49 118

110 7 - 11 40 - 148 78 68 118

110 7 - 11 50 - 148 93 82 118

110 7 - 11 63 - 148 94 85 118

110 7 - 11 90 - 162 105 90 176

125 7 - 11 32 - 162 59 49 118

BL

d

D

H1H


39








BRANCH SADDLE – WITH UNDERPARTPN 16 Water / SDR 11 Gas

SIZE / d SDR RANGE D b B H H1 L

125 7 - 11 40 - 162 78 68 118

125 7 - 11 50 - 162 93 82 118

125 7 - 11 63 - 162 94 85 118

125 7 - 11 9 - 169 105 90 176

140 7 - 11 32 - 180 59 49 118

140 7 - 11 40 - 180 78 68 118

140 7 - 11 50 - 180 93 82 118

140 7 - 11 63 - 180 94 85 118

140 7 - 11 90 - 174 105 90 176

160 7 - 11 32 - 200 59 49 118

160 7 - 11 40 - 200 78 68 118

160 7 - 11 50 - 200 93 82 118

160 7 - 11 63 - 200 94 85 118

160 7 - 11 90 - 176 105 90 176

180 7 - 11 32 - 219 59 49 118

180 7 - 11 40 - 219 78 68 118

180 7 - 11 50 - 219 93 82 118

180 7 - 11 63 - 219 94 85 118

180 7 - 11 90 - 182 105 90 176

200 7 - 11 63 - 202 102 85 176

200 7 - 11 90 - 202 105 90 176

225 7 - 11 63 - 227 102 85 176

225 7 - 11 90 - 227 105 90 176

250 7 - 11 63 - 252 102 85 176

250 7 - 11 90 - 252 105 90 176

280 - 400 7 - 11 90 315 300 117 102 306

280 7 - 11 90 - 282 105 90 176

281 - 400 7 - 11 110 315 300 120 105 306

282 - 400 7 - 11 125 315 300 125 110 306

283 - 400 7 - 11 160 315 300 136 121 306

315 7 - 11 90 - 317 105 90 176

450 - 710 7 - 11 160 315 300 136 121 314

* Underpart is the same as a Balloon Saddle as below, strap. SADDLE CLAMPS NOT REQUIRED. Cut hole after welding and cooling completed.

BRANCH SADDLE – LARGE BOREPN 16 Water / SDR 11 Gas

SIZE / d SDR RANGE D d1 B H H1 L

250 - 400 7 - 17 16 90 305 102 115 300

250 - 400 7 - 17 16 110 305 104 117 300

250 - 400 7 - 17 16 125 305 109 121 300

250 - 400 7 - 17 16 160 305 119 132 300

400 7 - 26 16 250 390 140 200 420

450 - 800 7 - 26 16 90 315 105 117 300

450 - 800 7 - 26 16 110 315 105 117 300

450 - 800 7 - 26 16 125 315 109 117 300

450 - 800 7 - 26 16 160 315 115 130 300

560 - 630 7 - 26 16 250 400 225 203 420

BL

D

d1

d

H1H




41







TAPPING SADDLE – WITH UNDERPARTPN 16 Water / SDR 11 Gas – Leak free under pressure tapping: Gas and Water


40 x 20 7 - 11 20 66 107 7 94 100

40 x 32 7 - 11 32 66 121 12 94 100

50 x 20 7 - 17 20 76 110 7 98 100

50 x 25 7 - 17 25 76 91 10 98 100

50 x 32 7 - 17 32 76 122 12 98 100

63 x 20 7 - 17 20 100 90 10 90 118

63 x 25 7 - 17 25 100 93 12 90 118

63 x 32 7 - 17 32 100 99 12 90 118

63 x 40 7 - 17 40 100 142 60 177 118

63 x 50 7 - 17 50 100 123 64 177 118

63 x 63 7 - 17 63 100 175 64 177 118

75 x 20 7 - 17 20 117 125 50 177 118

75 x 32 7 - 17 32 117 132 65 177 118

75 x 40 7 - 17 40 117 142 60 177 118

75 x 50 7 - 17 50 117 123 64 177 118

75 x 63 7 - 17 63 117 175 64 177 118

90 x 20 7 - 17 20 126 117 16 114 118

90 x 25 7 - 17 25 126 108 16 114 118

90 x 32 7 - 17 32 126 126 16 114 118

90 x 40 7 - 17 40 126 134 21 114 118

90 x 50 7 - 17 50 126 123 64 177 118

90 x 63 7 - 17 63 126 175 64 177 118

110 x 20 7 - 17 20 148 118 16 114 118

110 x 32 7 - 17 32 148 127 16 114 118

110 x 40 7 - 17 40 148 138 21 114 118

110 x 50 7 - 17 50 148 123 64 177 118

110 x 63 7 - 17 63 148 175 64 177 118

BL

H

d

H1H2

d1



125 x 20 7 - 17 20 162 116 16 114 118

125 x 32 7 - 17 32 162 131 16 114 118

125 x 40 7 - 17 40 162 141 21 114 118

125 x 50 7 - 17 50 162 123 64 177 118

125 x 63 7 - 17 63 162 175 64 177 118

140 x 20 7 - 17 20 180 125 50 177 118

140 x 32 7 - 17 32 180 132 56 177 118

140 x 40 7 - 17 40 180 142 60 177 118

140 x 50 7 - 17 50 180 123 64 177 118

140 x 63 7 - 17 63 180 175 64 177 118

160 x 20 7 - 17 20 199 118 21 138 118

160 x 32 7 - 17 32 199 144 16 138 118

160 x 40 7 - 17 40 199 157 21 138 118

160 x 50 7 - 17 50 199 175 24 138 118

160 x 63 7 - 17 63 199 197 20 138 118

180 x 20 7 - 17 20 219 125 50 177 118

180 x 32 7 - 17 32 219 144 18 138 118

180 x 40 7 - 17 40 219 155 21 138 118

180 x 50 7 - 17 50 219 174 24 138 118

180 x 63 7 - 17 63 219 197 20 138 118

200 x 20 7 - 17 20 202 125 50 177 176

200 x 32 7 - 17 32 202 132 56 177 176

200 x 40 7 - 17 40 202 142 60 177 176

200 x 50 7 - 17 50 202 123 64 177 176

200 x 63 7 - 17 63 202 175 64 177 176

225 x 20 7 - 17 20 227 125 50 177 176

225 x 32 7 - 17 32 227 132 56 177 176



43




225 x 40 7 - 17 40 227 142 60 177 176

225 x 50 7 - 17 50 227 123 64 177 176

225 x 63 7 - 17 63 227 175 64 177 176

250 x 20 7 - 17 20 252 125 50 177 176

250 x 32 7 - 17 32 252 132 56 177 176

250 x 40 7 - 17 40 252 142 60 177 176

250 x 50 7 - 17 50 252 123 64 177 176

250 x 63 7 - 17 63 252 175 64 177 176

MB = Mono Block with fully moulded offtake. * Strap underpart. + 12 x 195mm Hex Key required to operate cutter. 13mm socket to tighten saddle-nuts, elongated 25 x 13 socket for saddles ≤ 180. Cut hole after welding and cooling completed.

D (MAIN PIPE DIAMETER) OD OF CUTTER (MM)

MONOBLOCK

40 ÷ 63 20

90 ÷ 125 25

160 ÷ 180 30

NON-MONOBLOCK

63 ÷ 250 30

REPAIR SADDLE – WITH UNDERPARTPN 16 Water / SDR 11 Gas

SIZE / d SDR RANGE B H L

63 7 - 11 100 29 118

75 7 - 11 117 29 118

90 7 - 17 126 29 118

110 7 - 17 148 29 118

125 7 - 17 162 29 118

140 7 - 17 180 29 118

160 7 - 17 199 29 118

180 7 - 17 219 29 118

BL

d

H









45


TRANSITION SADDLE – WITH UNDERPART BRASS FEMALE THREADPN 16 Water / SDR 11 Gas

SIZE SDR RANGE d B H L

63 x 1.1/4" 7 - 11 63 100 53 118

75 x 1.1/4" 7 - 11 75 117 53 118

90 x 1.1/2" 7 - 17 90 126 53 118

90 x 2" 7 - 17 90 142 76 176

110 x 1.1/2" 7 - 17 110 142 53 118

110 X 2" 7 - 17 110 158 76 176

125 x 1.1/2" 7 - 17 125 158 53 118

125 x 2" 7 - 17 125 166 76 176

140X 1.1/2" 7 - 17 140 175 53 118

140 x 2" 7 - 17 140 174 93 118

160 x 1.1/2" 7 - 17 160 176 53 118

160 x 2" 7 - 17 160 196 76 176

180 x 1.1/2" 7 - 17 180 182 53 118

180 x 2" 7 - 17 180 216 76 176

200 x 2" 7 - 17 200 202 76 176

225 x 2" 7 - 17 225 227 76 176

250 x 2" 7 - 17 250 252 76 176

280-400 x 3" 7 - 17 280 - 400 300 86 306

450-710 x 3" 7 - 17 450 - 710 300 86 314

* Strap underpart. Cut hole after welding and cooling completed.







BL

d

H


[email protected] | www.auspolyspec.com.au | 07 3889 7511 APS Electrofusion Fittings & Tools


47

Wastewater E lectrofus ion F i t t ings

WASTEWATER SADDLE – FIXED 45° OUTLET 48

ADJUSTABLE SADDLE – 160mm OUTLET 48




ADJUSTABLE ELBOW PE – PVC 50

ELECTROFUSION COUPLERS – LIGHTFIT 50

MANHOLE ADAPTOR 51

ASSEMBLY TOOLS FOR WASTEWATER SADDLES 51


WASTEWATER ELECTROFUSION›


49

WASTE WATER SADDLE – FIXED 45° OUTLETRated PN 0.5

SIZE SDR RANGE d1 B H L

160 - 200 11 - 26 110 182 158 255

225 - 315 11 - 26 110 221 158 255



11 - 33 160 193 106 265 98

H

d1

LB

45º

A

L1

D d

L



11 - 33 160 193 106 300 98

A

L1

D d

L



11 - 33 160 193 106 323 98

A

L1

D d

L

ADJUSTABLE SADDLE – 160MM OUTLETRated PN 0.5

SIZE SDR RANGE d1 A B H L

200 11 - 26 160 105 208 202 290

225 - 250 11 - 26 160 105 225 202 290

280 - 318 11- 26 160 105 247 202 290

355 - 560 11 - 26 160 105 263 202 290

560 -7 10 11 - 26 160 105 277 202 290

H

12º

d1A

LB

WASTEWATER ELECTROFUSION›

51


ELECTROFUSION COUPLERS – LIGHTFITPN10 Water / SDR17 Gas

DN LENGTH

110 162

160 195

250 251

315 282

MANHOLE ADAPTORRated PN 0.5

SIZE D d1 H L

110 216 97 37 135

125 235 111 39 135

140 254 123 39 135

160 280 141 39 135

180 335 157 66 135

200 355 176 56 135

225 355 198 44 135

250 400 220 54 135

280 400 247 39 135

315 450 278 46 135

355 500 313 50 135

400 560 353 59 135

450 592 397 50 135

500 651 441 54 135

560 705 494 51 135

DN

L

d1 H

D

ADJUSTABLE ELBOW PE – PVCRated PN 0.5

SIZE SDR RANGE D d1 D1 A L L1 L2

160 11 - 17 193 160 180 105 253 78 80

A

d

L2

D1 d1

L

D

L1

12º

ASSEMBLY TOOLS FOR WASTEWATER SADDLES

SIZE

110 X 450 fixed outlet for 7080 items

160 flexible outlet for 7580 items



› TOOLS &ACCESSORIES


53

Tools & Accessor ies

T PLASSON SMARTFUSE(AUTOMATIC) ELECTROFUSION FITTINGS 54

T PLASSON AUTOMATIC (PF) WELDING CONTROL BOXES 55

T CONTROL BOX COMPARISON TABLE 56

CONTROL BOXES 57

WELDING CABLES AND ACCESSORIES 57

WELDING TERMINAL PINS ADAPTORS 58

BAR CODE READERS AND ACCESSORIES 58

PIPE CUTTING 59

PIPE CLEANING 59

PIPE SCRAPING 60/61

PIPE CLAMPING 62/63

ROUNDING TOOLS 64/66

SQUEEZE OFF TOOLS 66/67

DEBEADING TOOLS 67

SPECIALISED INSTALLATION TOOLING FOR PLASSON PRODUCTS 68/69

T SERVICE REQUIREMENTS 69


TOOLS & ACCESSORIES›


PLASSON SMARTFUSE(AUTOMATIC) ELECTROFUSION FITTINGS

PLASSON SMARTFUSE ELECTROFUSION FITTINGS HAVE THE FOLLOWING FEATURES:• Automatic Weld Time Recognition System – avoids operator input errors• Single Weld Time: -10°C to +45°C means temperature compensation is not required, no need for operator judgement and possible errors• PN 16 water/1000 kPa Gas systems – meets the most demanding technical requirements• PN 10 water/630 kPa Gas systems – for PE pipes down to SDR 33• QAS Standardsmark licensed system for EF fittings – No. 2018, AS/NZS 4129

A SINGLE WELD TIMEAccording to the latest Standards, all electrofusion fittings must be able to produce welds at a temperature range of between -10° and +45°C. Manufacturers have responded to this in different ways resulting in a variety of designs available to the market. The Plasson SmartFuse Electrofusion system ensures that the energy supplied will weld fittings from a minimum -10° to +45°C at one standard time. Fittings are tested within this range and are supplied with QAS Standardsmark Licence.

TEMPERATURE COMPENSATIONOther fittings being supplied to the Australasian market may meet ISO/CEN standards and have the capability of acheiving a satisfactory weld. However, to do so temperature compensation may be required; creating a more complex, lengthier process that is more susceptible to human error. Where welding time is dependent on the ambient temperature, this requires a special bar-code reading EF control box to sense the temperature, read the fittings bar-code and adjust the weldtime accordingly. As well as the additional work required this can also cause problems. Firstly, it relies on the legibility of the bar-code and secondly, the point at which the temperature is read may vary widely from the temperature at the pipe/fitting assembly.Without a special bar-code reading EF control box, the weld operator will need to estimate the temperature at the joint site, read the temperature compensation tables correctly (if supplied and legible) and enter the new weld time into the box before the weld can proceed. This process relies on operator skill/judgement, is open to mistakes and may need a complex QC form to record the weld conditions used.

A SMOOTHER PROCESSBy using Plasson SmartFuse fittings and PF control boxes there is no need for special bar-code reading EF control boxes, or reference to temperature compensation tables, virtually eliminating the margin for error in this area, (provided the process is being carried out within a temperature range of -10° and +45°C.) however, if users wish to have a control box capable of welding Plasson SmartFuse Fitting as well as manual or barcode fitting, Plasson has a control box that can operate both – The Polymatic Plus.

55

PLASSON AUTOMATIC (PF) WELDING CONTROL BOXES

PF CONTROL BOXES DYNAMICALLY MONITOR THE WELDING PROCESS WHEN USED WITH PLASSON ELECTROFUSION FITTINGS. BENEFITS INCLUDE:• By continually monitoring the weld current, a PF control box will shut down if the current increases above the dynamic tolerance range, thereby avoiding the overheating and anti-oxidant depletion of PE materials which can adversely affect long-term weld integrity.• PF control boxes are tolerant to generator variability as they accept a large voltage range and frequency variation.• Servicing centres for PF welding equipment are available in New Zealand and Australia.

WHAT CAN GO WRONG?Without the dynamic monitoring of a Plasson Automatic Welding Control Box, faults may occur unnoticed during the weld process causing the fitting to fail once in general use. Common causes of this can be seen in the diagram below.

TYPICAL ELECTROFUSION WELDING FAULTS

Please note:Plasson Automatic Control Boxes will not carry out this dynamic monitoring process on other manufacturers’ fittings.




CONTROL BOX COMPARISON TABLE

FEATURES PF MONOMATIC PF DUALMATIC LX PF POLYMATIC PLUS USB

PF POLYCONTROL PLUS V2

5M Lead MONO5DL30023T020

(with fixed 3M lead.)

POLYPLUSUSB5DLPOLYCONTROLPLUSV2 (with fixed 10M lead)

10M Lead MONO10DL POLYPLUSUSB10DL

15M Lead MONO15DL POLYPLUSUSB15DL

Welds Only Plasson Automatic

Fittings up to 355mm

Only Plasson Automatic Fittings up to 160mm & 240V

Drainage Fittings up to 160mm

All EF Fittings up to 800* (*Sizes above 355mm

require a cooling period between welds.)

All EF Fittings. Continuous welding. (No cooling between

welds)

Weld Tip Size 4.7mm 4.7mm 4.7mm (Opt 4.0mm) 4.7mm (Opt 4.0mm)

Plasson SmartFuse Mode (Automatic)

Y Y Y Y

Manual Input of Welding Time N Y Y Y

Welding Voltage 39.5V 39.5V or 240V (AC) 8-48V 8-48V

Output Current (Max) 60A (80A) 80A (110A) 80A (110A) 90A (105A)

USB Data Interface N N Y Y

Multilingual Display Messages (7)

Y Y Y Y

Error messages in plain text Y Y Y Y

Adjustable display contrast Y Y Y Y

Dynamic process supervision Y Y Y Y

Auto software check Y Y Y Y

Resistance check Y Y Y Y

Ramped start Y Y Y Y

Service Message After 200 Hours or 12 Months

After 200 Hours or 12 Months



Barcode reading capability N N Y Y

Fitting and Operator traceability N N Y Y

Earth Pin 15A 15A 15A 15A

Active Cooling N N N Y

*Detailed Specifications for each model available from Plasson.

REQUIRED GENERATOR SPECIFICATIONS

Input Voltage Range 190-300V

Frequency 40-70V

Minimum Output 18A at 240V – one phase

Must be able to drive inductive loads Must have phase cut control Mechanically regulated with brushes is the preferred system Synchronized generator Minimum 4.5 kVA – Mechanically Controlled 5.0kVA – Electronically controlled

REQUIRED GENERATOR SPECIFICATIONS 240 V, 50Hz, 1-PHASE. GENERAL USE MINIMUM 4.5kW

DIAMETER OUTPUT POWER

20-75mm 2kW

90-160mm 3.2kW

≥180mm 4.5 kVA – (Mechanically Controlled)

5 kVA – (Electronically Controlled)

57

CONTROL BOXES

DESCRIPTION LEAD

Monomatic 5M

Monomatic 10M

Monomatic 15M

Dualmatic 3M fixed

Polymatic Plus USB 5M



PolyControl Plus V2 10M fixed

WELDING CABLES AND ACCESSORIES

Welding cables for Monomatic or Digimatic with 4.7mm terminals

DESCRIPTION

5M Detachable Lead

10M Detachable Lead

15M Detachable Lead

Welding Cables for Polymatic Plus USB with 4.7mm terminals(Reading pen sold seperately)

DESCRIPTION

5M Detachable Lead

10M Detachable Lead

15M Detachable Lead

Extension Cables for Polycontrol V2

DESCRIPTION

Extension Cable 15M

Extension Cable 30M

Welding Terminals

DESCRIPTION

PF Welding Plug 4.7mm (Black outlet)

PF Welding Plug 4.7mm (Red outlet)

Spare Parts for Weding Cables

DESCRIPTION

PVC Cap (Black)

PVC Cap (Red)




WELDING TERMINAL PINS ADAPTORS

Adaptors

DESCRIPTION

Adaptor 4.0/4.7 angle

Adaptor 4.7/4.0 angle

SmartFuse Adaptors For use with Plasson SmartFuse and other fittings

DESCRIPTION

Adaptor 4.7/4.7 90Deg angle



Bar Code Reader and Accessories

Reading Pens

DESCRIPTION

Reading Pen 2DL (incl. Reading pen cable)

Barcode Scanner DL (Powerscan incl. Cable & Hooded Bag)

Transport Case Monomatic/ Digimatic/ Polymatic Plus

DESCRIPTION

Orange Transport Case

Flight Case

Ruling and Marking

DESCRIPTION

PF Magnetic Circular Pipe Ruler

PF Pi-Meter 20-700mm with Vernier 0.1mm

PF Pi-Meter 20-1200mm with Vernier 0.1mm

59

PIPE CUTTING

Secateur Pipe Cutter

DESCRIPTION

Pipe Cutter up to 63mm

Pipe Cutter Spare Blade for 63mm

Rotational Pipe Cutter (S-Type)

DESCRIPTION

Rotational Pipe Cutter 20-75mm

Rotational Pipe Cutter Spare Blade 20-75mm



Rotational Pipe Cutter Spare Blade 50-140mm & 90-160mm + T4

Rotational Pipe Cutter

DESCRIPTION

Rotational Pipe Cutter 32-110

Spare Rotational Pipe Cutter Knife 32-110MM Pipe Cutter

Rotational Pipe Cutter 110-225MM


Blade for Rotational Pipe Cutter 110-225mm & 110-315mm – cement carbide

RI Rotational Pipe Cutter T4 180-315mm

RI Rotational Pipe Cutter T4 Spare Blade (Max cutting depth 19.4mm)

Rotary Circular Saw Kit

DESCRIPTION

250-500mm (Max. Cutting Depth 65mm)



Extension links for the 500-1200mm Rotary Circular Saw Kit




PIPE CLEANING

Plasson Welding Wipes

DESCRIPTION

Plasson Pipewipes

These specialised moist wipes are impregnated with a high specification solution containing 70% Isopropyl Alcohol. Plasson Pipewipes ensure surfaces are clean before electrofusion jointing (scraping of pipe surface is still required). 75 sheets per canister.

PIPE SCRAPING

Hand Scraper

DESCRIPTION

Hand Scraper – Small 1.1/2”

Spare Blades for Small Hand Scraper (2)

Hand Scraper – Large 2.1/2”

Spare Blades for Large Hand Scraper (2)

Drill Mounted Scraper ToolScraping depth suitable for repair fittings. Hexagon spigot for cordless driller.

DESCRIPTION

Scraper head 16mm for Pipe Ends

Scraper Head 20mm for Pipe Ends



Scraper head 40mm for Pipe Ends



Spare Blade for Scraping Head

Rotational Scraper Tool

DESCRIPTION

Rotational Pipe Scraper 25-63

Rotational Pipe Scraper Tool 25-110mm

Spare Blade for Rotational Scrapers 63-110mm

Rotational Pipe Scraper Tool 90-315mm

Spare Blade for Rotational Scraper 90-315mm

61

PIPE SCRAPING

Rotational Pipe End Scraper Tool

DESCRIPTION

Rotational Pipe End Scraper Tool 63-180mm



Spare Blade for Rotational ScraperTool 63-180mm, 90-315mm, 180-400mm

Rotational Chain Scraper Tool

DESCRIPTION

Rotational Scraper Tool 250-450mm


Extension Links 900-1000mm for Rotational Chain Scraper 250-800mm


Spare Blade for Rotational Chain Scraper Tools

Chamfer/ Beveler

DESCRIPTION

RI Pipe Beveler 40-315 mm

40mm-315mm and wall thickness up to 30mm. To prepare the ends of pipe (suitable for PE, PP, PVDF, PVC). Helps to prevent damage to electrofusion zones during pipe insertion. Recommended for diameter above 125mm and all pipes from coils.

RI Pipe Beveler Spare Blade




PIPE CLAMPING

DESCRIPTION

CA Mini Pipe Clamp 16-32mm

The mini clamp suits pipe sizes 16, 20, 25 & 32mm. Promotes restraint during the electrofusion process. Interchangeable jaws for use on reducing connections. Quick tightening operation, lightweight and easy to use.

DESCRIPTION

RI Alignment Clamp 20-63mm

Suitable for reducers, couplers, tees or 45° & 90° elbows. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, 20-63mm. Quick tightening operation, lightweight & easy to use.

DESCRIPTION

Pipe Clamp 32-110mm with Quick Adjustment

Adjustable to suit couplers, reducers, 22.5° 45° & 90° ebows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, 32-110mm. Quick tightening operation, lightweight & easy to use.

DESCRIPTION

Pipe Clamp 63-180mm with Quick Adjustment

Adjustable to suit couplers, reducers, 22.5° 45° & 90° elbows and tees. Promotes restraint during the electrofusion process. Infinitely variable grip clamps to suit any combination of sizes, 63-180mm. Quick tightening operation, lightweight & easy to use.

63

PIPE CLAMPING

DESCRIPTION

Strap Clamps

Used to prevent movement during the weld process. The Plasson Strap Clamp, a convenient, flexible system for holding PE pipes steady during the electrofusion process. Does not assist with rerounding. For larger dimensions it is recommended to combine two or more Pipe Clamps (Strap Clamp).

DESCRIPTION

Pipe Clamp 110-560mm

4 pipe clamps, 2 base bars, angled adaptor 22.5°, 45°, 90° & 180°

DESCRIPTION

Pipe Clamp 250-800mm

With 2 fixed clamps – 2 clamps required.

Pipe Clamp 250-800mm Set

Included in set: 2 complete clamps each with a pulling clamp, a fixed clamp and pulling shoes for couplers. This allows you to pull the coupler over the pipe and the opposite pipe into the coupler to complete the insertion.

DESCRIPTION

Pipe Support

Pipe support to 225mm.




ROUNDING TOOLSTwo required – one rounding tool for each side of fitting

Rounding Clamp 32-63mm

Description

40mm (incl.adaptor for 32mm)

63mm (incl. adaptor for 50mm))

Rounding Clamp 63-400mm

Description

63-180mm (Deforming force 0.85 tonne)




Rounding Ring 63-250mm

Description

63mm

75mm

90mm

110mm

125mm

140mm

160mm

180mm

200mm

225mm

250mm (Heavy Duty)

Hydraulic Rounding Shell 315-900mm315-400mm

Description

Hydraulic Jack (315-400)

Rounding Shell 315mm (without jack)



65



Description







Description





Note: 1 x Hydraulic Jack required for each shell. 2 x Shells required (1 shell each side of fitting). Use with PF Strap Clamps.

Hydraulic Rounding Tool 450-800mm

Description

450-800mm

Hydraulic Tool. Use with PE pipes 450-800mm (Max. SDR 11)

Mechanical Rounding Tool

Description

450-560mm

630-710mm



APS Electro-Fusion Fittings & Tools


Post Squeeze Off Rerounding Shell 63-225mm (Used to round pipe after squeezing)

Description

63mm

75mm

90mm

110mm

125mm

140mm

160mm

180mm

200mm

225mm

SQUEEZE OFF TOOLS

DESCRIPTION

16-32mm

Suits 16-32mm SDR11. Compact robust design ensures easy use. Built-in safety stops to prevent damage to pipe.

DESCRIPTION

50NB (Gas Services)

Suits NB 10, 18, 25 (1”), 32 (1.1/4’),40 (1.1/2”), or 50mm (2” SDR 9.9 Pipes). The SQT service squeeze tool is for flow stopping on either metric or imperial sizes of pipe.

DESCRIPTION

20-63mm

Suits 20-63mm SDR 11 & 63mm SDR 17. Squeeze off is affected by turning the handle in a clockwise direction.

67

SQUEEZE OFF TOOLS

DESCRIPTION

75-200mm

Suits 75-200mm SDR 11 & 17 (incl. 2 complete stopper sets). Hydraulic operation. Metric limit plates set at 1.6t. Safety stops to prevent creep. Springs return jack to park position after squeeze off. Integral safety valve.

DEBEADING TOOLS

DESCRIPTION

External Bead Remover 25-90mm

External Bead Remover 90-315mm

Extension Links 355-800mm for External Bead Remover 90-315mm




SPECIALISED INSTALLATION TOOLING FOR PLASSON PRODUCTS

Waste Water Saddle Installation Tools

DESCRIPTION

Waste Water Clamping & Cutting Tool Set 110

110mm X 45Deg fixed outlet saddle clamp kit. For mains pipe sizes 160-315mm. Includes: Saddle clamp unit. Coupon removal tool (drill not included).

Tool for Waste Water Saddle 160

160mm Flexible Outlet Saddle Clamp Kit. For main pipe sizes 225-560mm. Includes: Saddle clamp unit. Coupon removal tool.

Cable Adaptors

DESCRIPTION

Cable adaptor for EF leads into manhole adaptors 4.7mm

Large Bore Saddle Installation Tools

DESCRIPTION

Saddle Clamp Kit 250-800mm

Includes: 90, 110, 125 & 160mm Outlets and Transport Suitcase.

69

SPECIALISED INSTALLATION TOOLING FOR PLASSON PRODUCTS

Waste Water Saddle Installation Tools

DESCRIPTION

Core Drill Kit 250-800mm*

Includes: 1 x (14702006) Core drill for 90mm with SDS-MAX connector mounted. 1 x (14702007) Core drill for 110mm with SDS-MAX connector mounted. 1 x (14702008) Core drill for 125mm with SDS-MAX connector mounted. 1 x (14702009) Core drill for 160mm with SDS-MAX connector mounted. 1 x (14702001) Centre drill. 1 x (14702003) Core drill connector for driller chuck. 1 x (14702004) Core drill connector for SDS-Plus. 1 x Transport Case. *Requires seperate drill with power rating 1200W, speed 360RPM. Must include safety clutch.

Electrical Saddle Scraper

(230V) ≥ 110mm pipes. Cordless available on request (18V).

Pneumatic Saddle Scraper

SERVICE REQUIREMENTS

TAKE GOOD CARE OF YOUR PLASSON CONTROL BOXIt is recommended that control boxes are serviced every 12 months or 200 hours of operation.Frequent servicing of your control box reduces the risk of unnecessary operational problems interrupting the flow of work.The service includes:• Calibration• Installation of latest software• Inspection and testing of all components• Tag and TestTurnaround time is approximately 5 days from receipt of control box.Any broken parts or replacements required will be quoted on prior to work being carried out.It is recommended services are carried out every 12 months or after 200 hours of operation.


www.auspolyspec.com.au› www.auspolyspec.com.au›

7171

WELD SCHEDULES & WELD SHEETS

T BUTT WELD SCHEDULE 72

T ELECTROFUSION WELD SCHEDULE 73

T EXTRUSION WELD SCHEDULE 74

SINGLE PRESSURE T HIGH FUSION JOINTING PRESSURE (SHP) 76

SINGLE PRESSURE T LOW FUSION JOINTING PRESSURE (SLP) 77

APS have included copies of various weld sheets and

schedules that we commonly use that can be down

loaded and used by our customers on their own

projects.

These sheets will down load without our company

name and logo on them.

›


WELD SCHEDULES›

Isometric / Draw

ing #Line / Branch #

Butt Weld Schedule

Operator Details

Welder ID

Date

Project Nam

e

Time

Iso Weld No.

Weld N

o.

Description (Pipe, Tee) Manufacturer, Batch Date UPSTREAM

Description (Pipe, Tee) Manufacturer, Batch Date DOWNSTREAM

Pipe OD

Pipe SDR

Pipe Swab (Y/N)

Pipe Alignment Acceptable (Y/N)

Pipe Ends Square (Y/N)

Drag (Kpa)

Bead / Weld Pressure (Kpa) (=Fusion + Drag)

Soak Time (mins)

Cool Time (mins)

Bead Dimensions (C/DNC)

Visual Accept (Y / N)

Weld Procedure N

umber

Heater Plate Temperature

Heater Plate Clean (Y/N)

Weather

Weld / Pipe Details

Pre-Weld Check

Weld Param

etersInspect

Nam

eW

eld Machine ID

Machine Serial #

Customer N

ame

Order N

umber

Works O

rder #Project N

ame

7373

Isometric / Draw

ing #Electrofusion W

eld Schedule

Operator Details

Welder ID

Project Nam

e

Fitting Type(C coupler / S saddle)

Iso Weld No.

Weld N

o.Description (Pipe, Tee) Manufacturer, Batch Date UPSTREAMOD / SDR

Fitting # (Coupler / Saddle)

Pipe/Fitting Scraped (Y / N)

Peeled area wiped with alcholic tissue (Y / N)

Alcohol Completely Evaporated (Y / N)

Pipe/Fitt Secured / Aligned prior to Welding (Y/N)

Ambient Temperature(⁰C)

Weld Time

Cool Time

Visual Inspection (C / DNC)

Description (Pipe, Tee) Manufacturer, Batch Date DOWNSTREAMOD / SDR

Line / Branch #

Date

If Saddle Used w

as Core drilled and removed

Weather

YES / NO

Customer N

ame

Project Nam

eO

rder Num

berW

orks Order #

Nam

eElectrofusion M

achine IDM

achine Serial #


›


WELD SCHEDULES›

Extrusion Weld Schedule

Operator Details

Welder ID

Date

Project Nam

eW

orks Order #

Weld #

(Pipe No. / Branch N

o.)

Date andTim

e ofW

eldW

eld Description (1)

ExtruderN

ozzleTem

p.(⁰C)

Machine

#Filler RodSerial #

Other

Consumables

(eg wipes)

C or DNC (2)

Comm

ents(incl. w

eather, pipe & fittings free from

damage etc.)

(Mark W

eld on Plan (3))

Notes:

(1) - Adequate to describe weld to a person w

ho did not witness the task

(2) - Weld Com

pliesC = W

elder has reviewed w

eld process and confirms com

pliance with procedure, or

DNC = W

eld does not comply w

ith procedure (Extrusion Welds require surface be adequately cleaned, prepared, dried, pre-heated and sufficient w

eld applied)(3) - W

eld must be m

arked on weld plan

Isometric / Draw

ing #Line / Branch #

Customer N

ame

Project Nam

eO

rder Num

ber

Nam

eW

elding Machine N

umbers

_____________________ [1], _____________________ [2], _____________________ [3]

7575


›


WELD SHEETS›

Single Pressure - High fusion jointing Pressure (SHP) ISO 21307

Operator DetailsWelder ID Date

Project NameWorks Order #

Pipe / Material DetailsType

PE100

Machine DetailsSerial Number Cylinder Area mm2 Ambient Temp °C

Pressure Parameters Result UnitP1 (Bead-up)&P3 (Weld/Cool) + Bar + Drag

P2 (Heat Soak) Bar

Time / Visual Parameters Unit

T1 (Bead Up) Visual

T2 (Heat Soak) Seconds

T3 (Changeover) Seconds(Max)

T4 (Pressure up) Seconds

T5 (In machine) Minutes

Bead (minimum) mm

Product Manufacturer Batch #

Pipe / Fitting

Pipe / Fitting

Notes:

To convert Bar to Kpa: Bar X 100 = Kpa (1 Bar = 100 Kpa)

Time IN

Time OUT

(0.5 x en) + 3

(0.1 x en) + 8

(as part of T3 - refer PIPA 003) 0

0.43 x en

ResultThe time taken to generate a continuous bead around the

circumference of the ends of the pipe and fittings

(11 ± 1) x en = range between 10 x en to 12 x en

Manufacturer and Model Heater Plate Temp °C

215 - 230

((Dn - en) x en x 3.142 x 0.52 ÷ Ram) x 10

Drag Only

Dn (OD) SDR en (wall thickness)

Customer Name Project Name Order Number

Isometric / Drawing #

Weld NumberName

7777

Single Pressure - Low fusion jointing Pressure (SLP) ISO 21307

Operator DetailsWelder ID Date

Project NameWorks Order #

Pipe / Material DetailsType

PE100

Machine DetailsSerial Number Cylinder Area mm2 Ambient Temp °C

Pressure Parameters Result UnitP1 (Bead-up)&P3 (Weld/Cool) + Bar + Drag

P2 (Heat Soak) Bar

Time / Visual Parameters Unit

T1 (Bead Up) Visual

T2 (Heat Soak) Seconds

T3 (Changeover) Seconds(Max)

T4 (Pressure up) Seconds

T5 (In machine) ± Minutes

Bead (minimum) mm

Bead (maximum) mm

Product Manufacturer Batch #

Pipe / Fitting

Pipe / Fitting

Notes:

To convert Bar to Kpa: Bar X 100 = Kpa (1 Bar = 100 Kpa)

Time OUT

(0.5 x en) + 3

(0.75 x en) + 5

Time IN

(0.1 x en) + 4

(0.4 x en) + 2

(en + 3) - (plus 1 minute for every degree over 25°C)or (minus 1 minute for every degree below 25°C)

ResultThe time taken to generate a continuous bead around the

circumference of the ends of the pipe and fittings

(11 ± 1) x en = range between 10 x en to 12 x en

Manufacturer and Model Heater Plate Temp °C

215 - 230

((Dn - en) x en x 3.142 x 0.17 ÷ Ram) x 10

Drag Only

Dn (OD) SDR en (wall thickness)

Customer Name Project Name Order Number

Isometric / Drawing #

Weld NumberName


[email protected]

phone +61 7 3889 7511 fax +61 7 3889 6922

office & warehouse 31-33 Strathwyn Street, Brendale, Queensland, Australia 4500

post office box 5391, Brendale, Queensland, Australia 4500

www.auspolyspec.com.au

2016 Revision 1

mailto:austpoly%40bigpond.net.au?subject=Enquiry

electrofusion fittings & tools - …auspolyspec.com.au/resources/aps-ef-16rev1.pdf · female...

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