04 Equipment for processing 05

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1 01 Product description / delivery 02 General information 03 Notes on storage and safety 2x vent plugs 2x weldable plugs 1x uncross-linked shrinkable sleeve 2x stainless steel heat conductor The indujoint-sleeve is packed in white plastic film for delivery, which protects it from moisture and dirt. This film must not be removed before processing! Foil must be pushed over this sleeve before welding the pipes. In extreme weather conditions (below 5 C cold casing pipes), the areas of the exposed pipe ends are to be preheated by means of the function at the generator. To ensure optimal and lasting functional quality the unprocessed isoplus-products should be stored in a dry and well-ventilated place. Avoid storage in direct sunlight, rain, snow, dust or other adverse environmental conditions. The processing of isoplus products must be in compliance with the relevant regional health and safety regulations. The induction welding sleeve is a shrink sleeve, for example for pre-insulated pipe systems. It is supplied with a standard mounting kit consisting of: - 1 pc. uncross-linked shrinkable sleeve - 2 pc. stainless steel heat conductors - 2 pc. vent plugs - 2 pc. weldable plugs 04 Equipment for processing 05 The distance depends on the dimensions. For example: Space requirements in the trench 06 Notes on working with the propane torch a Leak detection spray b Propane tank with a pipe, torch and safety valve Cleaning wipes Fat-free marking pen Ethanol / alcohol (min. 99,9 %) Emery cloth / sandpaper (grain 40 60) Tape measure, knife, scissors, trianglescrapers, chisels Temperature measuring device (sensor) Electric drill Plug welding equipment (with plug welding machine, HDPEwelding and vent plugs, welding plug holder, drills with stopper in a general conical design Drill Ø 20 mm with stopper Drill Ø 6 mm 60 conical drill Push-off mechanism Leak detection spray Welding generator Ohm or multimeter Tension tapes PE-wedges To ensure the required quality and durable function in the processing of isoplus products in the trench, there must be sufficient working space around the places of application available. The trench bottom has to be water and mudfree. The piping and bedding must meet the requirements. The propane torch is to be adapted to the respective construction sites and trench conditions: a. Harder, blue flame with thick-walled casing pipes and shrink products, with wind and low outdoor temperatures. b. Soft, yellow flame with thin-walled casing pipes and shrink products, with no wind and at high ambient temperatures. The vertical guidance of the propane flame only to the shrink product and a constant movement in the circumferential direction minimizes the risk of burning the HDPE casing pipes. 1

2 07 Slide on sleeve 08 Remove foil / Drying 09 Processing of KMR-end faces No moisture allowed! The sleeve and the white protective foil must be pushed over the pipe before the welding of the medium pipe and must be protected from burning during the welding process. The sleeve and its accessories must be checked for damage before processing. Remove the white protective foil from the sleeve. Dry the whole sleeve area and all sealing surfaces (outer surface of the PEHD-jacketpipe ends and inner surface of shrinking ends) and the medium pipe. Cutting out the PUR-ends faces of the plastic casing pipes and fittings to remove capillarybound moisture. 10 Removing coarse contamination 11 Marking the sleeve position 12 Removing loose contamination / degreasing Remove plastic ridges and burrs and adhering impurities from all sealing faces with a triangular scraper. Place the sleeve centrally over the total cutback of the HDPE casing pipe. Mark the shrinking area (2) and the centering marks (1). Finally, push the sleeve back. Clean and degrease all sealing faces with ethanol / alcohol (min. 99.9%) with a dry, grease and lint-free cloth. 2

3 13 Roughening of the sealing portions 14 Final cleaning of the sealing / welding area 15 Attaching the stainless steel heat conductor Roughen all sealing surfaces (casing pipe and the sleeve inside) with an emery cloth (grain 40-60). Finally clean all waterproofing and welding areas of loose HDPE and sand particles with ethanol / alcohol (99,9 %) and a grease and lint-free cloth. Position the steel heat conductor mm away from the sleeve edge (V) respectively the centering marks close to the jacket pipe and fix it in 12:00 o clock position. Apply markings from the center of the heat conductor 50 mm to the outside (W). 16 Filling and venting holes / preheating 17 Shrinking the sleeve ends 18 Drilling the 1st vent hole < 40 C Ø 6 mm Ø 20 mm Now slide on the sleeve and centre using the two centering marks. Drill the first vent hole with a 6 mm diameter bit. Centre the sleeve with PE wedges vertically. Warm through both sleeve ends with a soft propane gas flame and shrink on to the casing pipe. In doing so, do not burn. With sleeves with outer diameter over 560 mm, each sleeve end must be shrunk with two propane burners. Drill the Ø 6 mm vent hole to Ø 20 mm. Allow the sleeve to further cool to below 40 C. 3

4 19 Attaching the tension tapes 20 Attaching the induction loop 21 Connecting the induction loop Position the tensioners centrally over the stainless steel heat conductors. Position the inductor over the stainless steel heating conductor and the tension tape and align it with the marking. Connect the inducton loop into the 12 o clock position and hold it together with the U-shaped clamp (here red). Connect the inductor to the welding generator and start the welding process. Repeat points 20 and 21 on the second side of the sleeve. 22 Leak test 23 Drilling 2nd venting hole 24 Closing the 2nd venting hole Ø 20 mm Allow the sleeve to cool to below 40 C before every subsequent working step. Now carry out an air pressure test of 0.2 bar over a period of 3 minutes on the sleeve, whereby the sleeve / casing pipe transition area is soaped. Wash off the soap liquid after a successful test. Document the execution parameters in the sleeve protocol. Drill the second vent hole with Ø 20 mm analogous to figure 18. Close the drilled second venting hole in figure 23 with a beatable vent plug. 4

5 25 Foaming of the sleeve 26 Removing vent plugs / removal of foam remnants 27 Insert the weldable plugs C ca 45 min Determine the necessary amount of foam using the foam table and foam the sleeve through the filling hole. Close the opening for foam filling immediately with the beatable vent plug. After a minimum of 45 minutes, the foam has reacted (= out-gassing time). Remove all vent plugs again. Then, remove the foam remnants with the triangular scraper around the areas of the two holes. Drill all openings with a conical drill compatible with the weldable plugs. For the closure of the first opening, preheat the welding plugs and the borehole with the plug welder to 220 C to 230 C. For this purpose, set the plug welding machine with the mandrel in the borehole and press the welding plug with the handle strongly in the hole on the welding machine. Check the temperature of the plug welder and observe the melting process. Proper preheating can be recognized by silky matt shiny welding plugs and a pad formation at the edge of the hole. Then pull the plug out of the welder and immediately press into the hole. Maintain the pressure for 30 seconds. Remove the handle with a rotary motion from the plug. 28 Labelling by the installer Notes Carry out the same process with the second opening. The installer must attach the following identification labels with a permanently durable marking pen that is suitable for the ground: - Name of the installer or installer s number - Sleeve number - Weld seam number - Measured data - Installation date - Foam system The labelling must be done outside the plug area! 5