Installation: UPP Electrofusion Entry Seal - Franklin Fueling Systems

UPP Electrofusion Entry SealInstallation GuideFranklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USATel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433 • www.franklinfueling.com

SafetyImportant!UPP Systems must only be installed by fully trained and certified installers.Failure to follow installation instructions will invalidate warranty and installercertification!Electrofusion Safety• UPP Welding Units must never be operatedin Zone 1 or Zone 0 areas (Hazardous areadefinitions are from European Directive 1999/92/EC and guidelines can be found in the APEA BlueBook 2nd Edition).• UPP Welding units are suitable for use in Zone 2areas with just the welding leads and fitting beingwelded positioned in a Zone1 area.• Ensure Welding Units are connected to a powersupply that meets the requirements detailed in theuser manual and are within the requirements ofany local authority or regional legislation.• UPP piping complies with all the requirementsimposed by EN14125 concerning electrostaticsafety.Chemical Safety• Where using chemicals (such as Acetone) duringthe installation of UPP systems products, besure to follow all safety guidelines given onthe chemical containers themselves or on anyaccompanying literature.Confined Space• Some installation of UPP products may occurin confined spaces where a lack of oxygen anda concentration of toxic vapors is likely to beexperienced.Such working conditions are dangerous and all localhealth and safety guidelines for working in suchenvironments should be followed.Material HandlingProtective Equipment• Ensure the correct personal protective equipment(PPE) is used at all times in line with local healthand safety requirements.Material Safety Data• Ensure all safety data is accessed and used whileinstalling UPP Systems (Material Safety DataSheets are available in the download area of theUPP website).Transport & Storage• UPP products should be transported and stored inaccordance with the guidelines contained in thismanual.Heavy items• Heavy items should be handled using suitablelifting equipment operated by authorisedpersonnel.2

Entry Seal Assembly ProcedureThe Electrofusion Entry Seal is used only withpolyethylene sumps. For fiberglass or FRP sumps, use amechanical entry seal.General Rules• ALL entries into sumps and chambers must beperpendicular to entry face.• Rubber boots and mechanical entry seals allow somevariation in entry angle up to ±5° (10°inclusive).• Rubber boots and mechanical entry seals alloweccentric entry of up to +5 mm.• For all electrofusion entry seals, follow the samewelding steps as for pipe fittings, i.e. Cut, scrape,clean, mark and weld. Refer to FFS manual FFS-0123for Electrofusion Welding Instructions.• FRP seals – Bond one at a time only.Installing a UPP electrofusion entry seal1. Cut hole in sump wall. Use correct size hole sawfor fitting (See Table 1 on page 4).2. Mark area under seal.4. Clean the fusion area on sump with Acetone; thisremoves oils, fingerprints and moisture.Inhalation of vapors and skin contactCaution with acetone can cause irritation. Useonly with adequate ventilation. Wearnitrile gloves when cleaning withacetone.Areas to CleanClean Bonding Areas with Acetone5. Clamp seal to sump. The inboard and outboardclamp bars should be oriented 90º to each other.Test tightness against sump wall all around theseal using a piece of card (such as a businesscard). Ensure surfaces are in close contact. Realignseal with sump until all gaps are removed.Slightly increase tightness of clamp if needed.Cut hole and Mark Area of Entry Seal3. Scrape around fusion area. Use scraperprovided in UPP tool kit.Clamp Seal to Sump With Cross Bars 90º to Each Other6. Connect welder and weld (using red (orange)leads) - Mark the time of the weld near the fitting.(See Table 2)20MinutesScrape the area7. Allow joint to cool to ambient temperature:3

approximately 20 minutes.Remove Clamp8. Remove clamp and note the time on the fitting.Seal CodeHolesaw(mm) (in.)ColorDia. Dia.ClampClamp302-040 HSCS2 51 2 302-CLAMP Orange303-063-EIF HS3 102 4 303-CLAMP Blue303-075-EIF HS3 102 4 303-CLAMP Blue304-110-050-TP HS5 140 5½ 304-CLAMP Yellow304-110-063-TP HS5 140 5½ 304-CLAMP Yellow304-110-075-TP HS5 140 5½ 304-CLAMP Yellow304-110-090 HS5 140 5½ 304-CLAMP Yellow304-110-090-TP HS5 140 5½ 304-CLAMP Yellow305 HS5 140 5½ 305-CLAMP-1 Green305-R-1 HS5 140 5½ 305-CLAMP-1 Green305-125-110 HS6 160 6 5 / 16305-EXT- RedCLAMP305-125-110-TP HS6 160 6 5 / 16305-EXT- RedCLAMP308 HS8 210 8 ¼ 308-CLAMP Silver308-R HS8 210 8 ¼ 308-CLAMP SilverTable 1: Entry Seal / Hole Saw Compatibility TableThe entry seals do no have a resistance numberembossed on the component. This is to avoidconfusion between the flange connections and thesecondary connections. The following table show theresistance Index Number for the flange connections.FlangeResistance Index Number302 Flange 1303 Flange 2305 Flange 3308 Flange 3Table 2: Flange Resistance Index Numberswww.franklinfueling.com3760 Marsh RoadMadison, WI 53718, USATel: +1 608 838 8786Fax: +1 608 838 6433USA & Canada Tel: 1 800 225 9787México Tel: 001 800 738 7610Brazil Tel: +55 11 3395 0606UK Tel: +44 1473 243300Franklin Fueling Systems GmbhRudolf-Diesel-Strasse 2054516 WITTLICH, GermanyTel: +49 6571 105 380Fax: +49 6571 105 510France Tel: +49 6 57 11 05 380©FFS 2011 FFS-0124 Rev1China:Tel: +86 10 8565 4566Fax: + 86 10 8565 4766A802, ChaowaiMEN CenterNo. 26 Chaowai StreetChaoyang DistrictBeijing 100020, China