Welding & Installation Guidelines
Important: If the air around the pipe is below 5°C (40°F), the heating times will be increased by 50%. Remember to take greater care with the pipe as it can become brittle in cold temperatures. Using power cutters on cold pipe can cause cracking and is not recommended. Use standard ratchet or wheel cutters instead. Never pre-heat the pipe beyond 38°C (100°F)
9. Pipes and fittings should be heated at the same time. Heating times vary depending on the diameter of the pipe. Heating for too short a time can result in improper bonding. Heating for too long can result in ID restriction.
Diameter (mm)
Welding Depth (mm)
Heating Time (sec)
Welding Time (sec)
Cooling Time (sec)
20 MM 14 25 MM 15 32 MM 16.5 40 MM 18 50 MM 20 63 MM 24 75 MM 28 90 MM 29 110 MM 32.5 125 MM 40
5 7 8
4 4 5 6 7 8 8 8
2 2 3 4 4 6 6 8 8 8
Safety precautions
• The surface temperature of the welding iron and heads will normally be between 240°C (400°F) and 260°C (500°F) during operation, and they can remain at these temperatures for as long as 30 minutes after being un- plugged. • When working with the welding irons, always wear the appropriate hand and arm protection to avoid the risk of burns. Protective eyewear is also recommended. • During operation, always be aware of the location of the iron. Do not leave the iron hanging loosely or allow it to brush up against flammable materials. Make sure to keep the iron clear of other people. Inform those working nearby that the iron is hot and could pose a safety risk to them. Do not leave the iron unattended while it is plugged in. After unplugging the iron, protect it with a heat-resistant covering or place the iron back in its container. Do not allow the cord to contact the welding surfaces. • All welding tools must be free from impurities. Make sure they are clean and dry before assembling. If necessary, clean the welding tools with a coarse, non-fibrous tissue and with rubbing alcohol. • Pipes must be cut perpendicular to the axis with suitable cutting tools. Always ensure that cutters are sharp. Cutting pipes with dull or damaged ratchet cutters can cause the pipe to crack. Only use the cutters to cut PP-R material. It is also acceptable to use power saws with plastic- appropriate blades. Take care that the pipe sur-face is free from burrs or cutting debris and remove where necessary. • For perfect fusion, damaged or dirty welding heads must be replaced, as only impeccable heads guarantee a perfect connection. If the device has been unplugged (e.g. during longer breaks) the heating process must be restarted.
12 18 24 30 40 50 70
10 10
Table 6
10. After the heating time, quickly remove the pipe and the fitting from the welding tools.
Figure 6
11. Join them immediately, by inserting the pipe straight into the fitting without turning. The result of the fusion is an inseparable material joining of pipe and fitting.
Figure 7
12. After jointing, wait until the cooling period has elapsed. 13. After the cooling period, the fused joint is ready for use. 14. After use, switch off and unplug the welding device. Let it cool down. Never use water to cool the welding device, as this will destroy the tempered metal. Always keep the welding heads dry. 15. After completion of the welding process, clean the layouts with a clean cloth or absorbent paper.
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