Post on 31-Jan-2022
Fuseal®
Corrosive WastePiping SystemsTechnical Reference
Fuseal® PP
Fuseal® PP LD
Fuseal® PP MJ
Fuseal 25/50™ PVDF
Electro Plus®
MSA 250
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Table of ContentsMaterial Characteristics
GeneralInformation
Fuseal®PPCorrosiveWaste
Fuseal25/50™PVDFCorrosiveWaste
MechanicalProperties
Chemical,WeatheringandAbrasionResistance
ThermalProperties
ElectricalProperties
CompleteSystemofPipe,Fittings
ReliableFusionJoining
ElectrofusionJoining
MechanicalJoining
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General Properties - Fuseal® Polypropylene 9
General Properties - Fuseal 25/50™ PVDF 10
Fuseal® Corrosive Waste (PP) Specification 11
Fuseal 25/50™ Corrosive Waste (PVDF) Specification 13
Dimensional Pipe Size
PipeSizeComparison(FusealPPandFuseal25/50CorrosiveWaste)
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15
Calculating Line Size - Gravity Drain Systems
FlowRateforGravityDrainSystems
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Above Ground Installations
AllowingforLengthChangesinGravityPipelines
CalculationandPositioningofFlexibleSections
DeterminingtheLengthChange
DeterminingtheLengthofFlexibleSections
Restraint
ExpansionJointAssemblies
SupportDuringInstallation
SupportSpacing
Hangers
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Below Ground Installations
InstructionsforUndergroundTrenching
BeddingandBackfillMaterial
BeddingandBackfilling-ASTMD2321
FusealSoilLoadandPipeResistance
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Cold Weather Installations 27
Flammability and Fire Rated Construction
LaboratoryFireTests
LargeScaleTests
FireProtectionMethods(FusealPPWasteandVentPiping)
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27
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29
Testing 29
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Neutralization Tanks/pH Monitoring and Treatment Systems 30
Sample Specification - Neutralization and pH Monitoring System 32
Electrofusion Procedure - Fuseal® PP (1½” to 6”)
JointPreparation
SettingUpJoints
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Electrofusion Procedure - Fuseal LD (Large Diameter - 8” to 12”)
JointPreparation
SettingUpJoints
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Electrofusion Procedure - Fuseal 25/50 PVDF (1½” to 6”)
JointPreparation
SettingUpJoints
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Joint Fusion with the Electro Plus® or MSA 250 Fusion Machines
FusionProcessusingtheElectroPlusfusionmachine
FusionProcessusingtheMSA250fusionmachine
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Mechanical Joint Procedure - Fuseal® MJ (Mechanical Joint - 1½” to 4”)
JointPreparation1½”to4”
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Electro Plus® Electrofusion Unit
ElectrofusionProcess
ElectroPlusSpecification
CalibrationRequirements
ErrorsthatCanOccurBeforetheFusionCycle
ErrorsthatCanOccurDuringtheFusionCycle
ErrorsthatCanOccurAftertheFusionCycle
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MSA 250 Electrofusion Unit
ElectrofusionProcess
MSA250Specification
CalibrationRequirements
MSA250ErrorCodes
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46
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Material Characteristics
General InformationFuseal®isapolypropylenecorrosivewastepipingsystem.Fusealprovidesexcellentchemicalandphysicalproperties,
makingittheidealsystemforhandlingcorrosivechemicalwastesolutionspresentinlaboratoryandindustrialDWV
(Drain,WasteandVent)applications.Fusealissuitableforuseinchemicalandindustrialplants,aswellasinhospital
anduniversitylaboratorieswheremixturesofacids,basesandsolventsareconveyed.Itisalsousedinthebeverageand
foodprocessingindustrieswherestandardcastironorothermetallicmaterialsfailtostanduptothecorrosivenatureof
certainwastestreams.
Fuseal25/50™isaPVDF(polyvinylidenefluoride)corrosivewastepipingsystemideallysuitedforhandlingcorrosive
chemicalwastesolutionswhereanon-combustiblematerialisrequiredorwherethetemperatureofthewastestream
exceedsthetemperatureratingofpolypropylene.Forconstructioninareasdesignatedas“returnairplenums,”Fuseal
25/50exceedstheflamespreadindex0–25andasmokedevelopmentindex0–50(25/50rating)whentestedinaccordance
withUL723(ASTME84).ItalsoexceedstherequirementsofNFPA255andmodelbuildingcodespublishedbyICC(1)and
IAPMO(2)foruseinreturnairplenumapplications.
(1)InternationalBuildingCodeCouncil(R)
(2)InternationalAssociationofPlumbingandMechanicalOfficials
Fuseal® PP Corrosive WasteAllFusealproductsaremanufacturedofpolypropylene,amaterialthatisknowntohavewideacceptanceasasuperior
thermoplasticmaterialforhandlingharsh,corrosivefluids.
TheFusealcorrosivewastepipingsystemforabove-groundinstallationismanufacturedfromaflameretardant(PPFR)
polypropylenecompoundthatprovideslimitedflamespread,whileyieldingacombinationofhighchemicalresistance,
toughnessandhighstrengthatelevatedtemperatures.Fuseal’sexcellentchemicalandphysicalpropertiesmakethe
systemidealforuseinchemicalandindustrialplants,hospitalanduniversitylaboratoriesandfood/beverageprocessing
facilities.MostmajorpharmaceuticalmanufacturingfacilitiesandthetopuniversitiesworldwidehaveFusealinstallations
currentlyinstalled.ContactGFforareferencelist.
FusealLDisthelargediameterFusealpipingsystemavailablein8”,10”and12”sizes.Itutilizesoriginalelectrofusion
processfromGeorgFischerwiththeadditionofaneasyconnectduplexplug.Itismanufacturedinbothflameretardant
(PPFR)andnon-flameretardant(PPNFR)polypropyleneandmeetsallthebasicsystembenefitsofFuseal.
FusealMJisthemechanicaljointFusealsystem.Itisavailableinsizes1½”–4”.Thissystemismanufacturedofthesame
flameretardant(PPFR)materialasourFusealsystem.
Advantages
• Fusealfittingsutilizeafusioncollarwithintegratedduplexplugonallfittingsockets1½”–6”.Thecollarisfully
rotatable(360°)toallowforpositioningofplugwhereitcanbeeasilyaccessedbytheinstaller.
• Plasticclampsarefactoryinstalledon1½”–4”collars,loosemetalclampsfor6”–12”allowfordry-fittingofentire
sectionspriortofusing.
•AllFusealandFusealLDfittingsutilizesockettypeconnections,removingtheneedforadditionallaborand
materialcostsassociatedwiththeuseofsecondarycouplingsaswithsimilarsystemsinthemarkettoday.
•Fastersetupandfusiontimesthanmostcompetitiveproducts.
•InstallationofFusealMJfittingsdoesnotrequiretheinstallertogroovepipeendsaswithcompetitivesystems.
•Fusealmaybeinstalledwithinapressurecorrosivewastesystem(50PSImax@72°F).
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Fuseal 25/50™ PVDF Corrosive WasteTheFuseal25/50CorrosiveWastePipingSystemismadefromPolyvinylideneFluoride(PVDF).PVDFisamaterialwith
superiorchemicalresistancecapabilitiesatelevatedtemperatures(upto280°F[137°C]intermittently).Aspecialgradeof
PVDF,asavailablefromGeorgFischer,istheonlythermoplasticmaterialthatwhentestedinaccordancetoUL723/ASTM
E84(25/50)hasaflamespreadindexoflessthan25andsmokegenerationindexlessthan50,respectively,makingFuseal
25/50acost-effectivesolutionforreturnairplenumapplications.
PVDFexhibitsexcellentimpactresistanceandmaintainsitsstrengthcharacteristicsoverawiderangeoftemperatures.
Advantages
• Pipeandfittingsarejoinedviafusioncoilswithduplexplug.Metalclampsallowfordry-fittingofentiresections
priortofusing.
• Fastersetupandfusiontimesthanmostcompetitiveproducts.
•AllFuseal25/50PVDFfittingsutilizesockettypeconnections,removingtheneedforadditionallaborandmaterial
costsassociatedwiththeuseofsecondarycouplingsaswithsimilarsystemsinthemarkettoday.
•TransitionseasilytoourstandardFusealPP(Polypropylene)system,enhancingversatility.
• Fuseal25/50maybeinstalledinapressurecorrosivewastesystem(50PSImax@72°F).
Mechanical PropertiesPolypropylene(Fuseal,FusealLD,FusealMJ)hasahightensilestrengthandstiffness,preventingexcessivesagand
allowingforgreaterdistancebetweensupportsispossible.Polypropylenehasaverygoodlong-termcreepstrengthat
highertemperatures,forexample,180°F(82°C)atcontinuousstress.
PVDF(Fuseal25/50)hasahightensilestrengthandstiffness.Theimpactstrengthisexcellentoverawiderangeof
temperatures,evento32°F(0°C).PVDF’sadvantagesareparticularlyprevalentathighertemperatures.Thisisduetothe
highfluorinecontentwhichcausesstronginteractionsbetweenthePVDFchains.This,inturn,preventssofteningandthe
lossofpropertiestohighertemperatures.Thisalsohasaneffectonthelong-termcreepstrength.
Chemical, Weathering and Abrasion ResistancePolypropylene(Fuseal,FusealLD,FusealMJ)isresistanttothecorrosiveactionofalkalis,alcohols,acids,solvents
andsaltsolutions.Dilutemineralacidsandaqueoussolutionsofacidsalts,whicharedestructivetomostmetals,have
noaffectonthepolypropylenepipingsystems.Ingeneral,polypropyleneisattackedonlybystrongoxidizingacidsand
weakenedbycertainorganicsolventsandchlorinatedhydrocarbons.Polypropylenewillnotrust,pit,scale,corrodeorbe
affectedbyelectrolysis.
Wheninstalledaboveground,thepigmentationprotectsFusealPPfromsunlight.Thepigmentationishighlyresistantto
ultravioletradiationandisheat-stabilizedtoprovidelonglifewhilehandlinghotreagents.
PVDF(Fuseal25/50)isresistanttomostinorganicsolventsandadditionallytoaliphaticandaromatichydrocarbons,
organicacids,alcoholandhalogenatedsolvents.PVDFisalsonotattackedbydryandmoisthalogenswiththeexceptionof
fluorine.PVDFisnotresistanttostrongbasicamines,alkalis,andalkalinemetals.
OutstandingresistancetoUVlightandgammaradiationpermitstheuseofPVDFpipingoutdoorswithouttheneedforUV
stabilizers.Abrasionresistanceisconsiderableandapproximatelycomparabletothatofpolyamide.
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Thermal PropertiesTheFusealpolypropylenecompoundyieldsacombinationofhighchemicalresistance,toughnessandhighstrengthat
elevatedtemperatures.
ThethermalconductivityofPPis1.2BTU-in/ft2/hr/°F.Incertain
applicationsPP’sinherentthermalinsulatingpropertieswillactasan
insulatorandpreventtheformationofcondensationontheexternal
surfaceofthepipe.Intheseinstances,therearenotablymore
economicaladvantageswhencomparedtoasystemmadeofmetals
suchasstainlesssteelandcopper.
TheFuseal,FusealLD,FusealMJpolypropylenepipingsystemshandle
corrosivedrainagefluidsupto212°F(100°C)intermittently.
Comparison of Common Materials of Construction
Material BTU-in/ft2/hr/°F.
PP 1.2
Glass 8.0
CastIron 360.0
Aluminum 1000.0
Copper 2700.0
TheFuseal25/50PVDFpipingsystemhasexcellentthermalstability.Prolongedexposureto280°F(137°C)doesnotlead
tolossofstrength.NooxidativeorthermaldegradationhasbeendetectedduringthecontinuousexposureofPVDFresin
at302°F(150°C)foraperiodof5years.Therefore,operatingconditionsof280°F(137°C)orbelowarewellwithinthe
functionalrangeofthesystem.Fuseal25/50PVDFistheonlyplasticpipingmaterialthatmeetsthestrictrequirementsof
recentbuildingandplumbingfirecodes.PVDFisUL94Listed(V-O)andisconsideredanon-combustiblematerial.
Electrical PropertiesSincepolypropyleneisanon-polarhydrocarbonpolymer,itisanoutstandingelectricalinsulator.Theinsulativeproperties,
however,canbecompromisedconsiderablyfromtheeffectsofoxidizingmediaorweatheringasaresultofpollution.
Becauseofthepossibilityofelectrostaticcharges,Fuseal25/50PVDFisnotrecommendedinapplicationswhere
flammableliquids,combustion,orexplosionispresent.
Complete System of Pipe and FittingsTheFusealpolypropylenecorrosivewastepipingsystemscontainallcommonlyrequireddrainagepipefittings,including
sweepbends,wyes,sanitaryteesandnumeroustransitionfittings.Specificdrainageproducts(traps,floordrains,
strainersandcleanouts)arealsoavailableandallowforacompletesysteminstallation.
Pipe and Fittings range in sizes as follows:
FusealPPCorrosiveWaste(1½”to6”)
FusealLDPPCorrosiveWaste-LargeDiameter(8”to12”)
FusealMJPPCorrosiveWaste-MechanicalJoint(1½”to4”)
TheFuseal25/50PVDFCorrosiveWastepipingsystemscontainallcommonlyrequireddrainagepipefittings,including
sweepbends,wyes,sanitaryteesandnumeroustransitionfittings.Specificdrainageproducts(traps,floordrains,
strainersandcleanouts)arealsoavailableandallowforacompletesysteminstallation.
Pipe and Fittings range in sizes as follows:
Fuseal25/50PVDFCorrosiveWaste(1½”to6”)
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Reliable Fusion JoiningElectrofusionisdefinedasthejoiningprocesswheretwoplasticpartsarefusedutilizingelectricalheatresistancetoform
apermanentjoint.
ForFuseal1½”–6”fittings,aplastic-coatedcopperwireiswoundintoacoilandthenformedintoapolypropylenefusion
collarwithduplexplugconnector.Thefinishedfusioncollaristhenplacedonthefittingsocketsatthefactory.
ForFusealLDandFusealPVDF25/50,aplastic-coatedcopperwireiswoundintoacoilwithaduplexplugreceptaclecon-
nectionattached.Thefinishedcoilistheninsertedintothefittingsocketatthefactory.
Whensetupforinstallationiscompletedattheprojectsite,anelectriccurrentisappliedtothecoilviaourElectroPlus®
fusionmachine,producingheatthatgeneratessufficienttemperaturestomeltthesurroundingplasticandcreatea“melt
zone.”
Fusionoccurswhenthejointcoolsbelowthemelttemperatureoftheplasticmaterial,leavingapermanentjointthatis
proventobeasstrongas,ifnotstrongerthan,theindividualcomponents.
Advantages
• Fast,positiveelectricalconnectionwithaclearduplexplug
• Simpleinsertionofpipewithoutcoilremoval
• Integralplasticclampsareprovidedonallfusioncollars1½”to4”
• Rotationoffusioncollarallowsexactpositioningoftheduplexplugforeasyaccessbytheinstaller
• Abilitytodryfitanentiresystempriortofusion
Electrofusion JoiningElectrofusionjoiningisanexcellentjoiningsolutionthatprovidesnumerousadvantages.Theprocessofjoiningpipetoa
fittingsocketuseswirestotransfertheheatenergytotheplasticmaterial.Theheatenergyissufficienttomelttheplastic
surroundingthewires.Thisgeneratesazonecalledthe“meltzone.”This“meltzone”encapsulatesthewires,whichareat
itsoriginalongthecenterline.
Thesefeaturesmakethisoneofthesafestandeasiestfusiontechnologiesonthemarket.
Advantages
• Fasterfusiontimesthanmostcompetitivesystems
• Fusemultiplejointsinoneheatcycle
• ElectroPlus®fusionmachinedesignedtoallowforautomaticadjustmentoffusioncycletimesbasedonenviron-
mentaltemperaturelevelsthroughATC(AutomaticTemperatureCompensation)
• ElectroPlus®fusionmachinedesignedforautomaticadjustmentoffusioncycletimesorautomaticshutdownof
fusioncyclebasedonpowersourcefluctuations.
• Parallelwiringconnectionstofusioncollarsallowforquickermoresecureduplexplugconnectionthantheseries
wiringconfigurationrequiredbyallcompetitivesystems
Mechanical JoiningMechanicaljoiningmakesfast,leakproofjointsintwoeasysteps.Slidethenut,grabring,and“O”ringonthepipe.Insert
thepipeintothesocketandtighten½turnpasthandtight.That’sit!
Asthenutistightened,thegrabringgripsandcutsaretaininggrooveinthepipe.Furthertighteningsealsthe“O”ringto
ensurealeakproofjoint.
Thissimplemethodofjoiningcutsinstallationtimeinhalfandrequiresnohotwater,electricity,orpipegrooving.
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General Properties - Fuseal® Polypropylene
Material Data
Thefollowingtableliststypicalphysicalpropertiesofpolypropylenethermoplasticmaterials.Variationsmayexist
dependingonspecificcompoundsandproduct.
MechanicalProperties Unit Flame
RetardantSchedule 40
Non-Flame RetardantSchedule 40
FlameRetardantSchedule 80
Non-FlameRetardantSchedule 80
ASTM TestMethod
Density lb/in3 0.034 0.033 0.034 0.033 ASTMD792
Tensile Strength @ 73°F (Yield) PSI 4,500 4,800 4,500 3,900 ASTMD638
Tensile Strength @ 73°F (Break) PSI n/a 3,000(2) n/a n/a ASTMD638
Flexural Modulus @ 73°F PSI 250,000 175,000 250,000 175,000 ASTMD790
Izod Impact @ 73°FFt-Lbs/Inof
Notch2.1 1.5 2.1 NoBreak ASTMD256
Relative Hardness @ 73°FDurometer
“D”80 80 80 80 ASTMD2240
ThermodynamicsProperties Unit Flame
RetardantSchedule 40
Non-Flame RetardantSchedule 40
FlameRetardantSchedule 80
Non-FlameRetardantSchedule 80
ASTM Test
Coefficient of Thermal Linear
Expansion per °Fin/in/°F 6.1x10-5 5.0x10-5 6.1x10-5 3.9x10-5 ASTMD696
Thermal ConductivityBTU-in/ft2/
hr/°F1.3 1.3 1.3 1.15 ASTMD177
Maximum Operating Temperature °F 212 212 212 212 GFSpecified
Heat Distortion Temperature @
66 PSI°F 210 205 210 190 ASTMD648
OtherProperties Unit Flame
RetardantSchedule 40
Non-Flame RetardantSchedule 40
FlameRetardantSchedule 80
Non-FlameRetardantSchedule 80
ASTM Test
Water Absorption % <0.03 <1.90 <0.03 <1.90 ASTMD570Industry Standard Color Blue Black Blue BlackBurning Rate Seestd. V-2 HB V-2 HB UL94Flame Spread/Smoke Generation Seestd. 115/412 N/A 115/412 N/A ASTME84
Note: This data is based on information compiled from multiple sources.
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General Properties - Fuseal 25/50™ PVDF
Meets or exceeds the requirements of UL723 (ASTM E84)
Material Data
ThefollowingtableliststypicalphysicalpropertiesofPVDFthermoplasticmaterials.Variationsmayexistdependingon
specificcompoundsandproduct.
MechanicalProperties Unit Fuseal 25/50
PVDFSchedule 40
ASTM TestMethod
Density lb/in3 0.0640 ASTMD792
Tensile Strength @ 73°F (Yield) PSI 7,250 ASTMD638
Tensile Strength @ 73°F (Break) PSI 6,500 ASTMD638
Modules of Elasticity Tensile @
73°FPSI 267.500 ASTMD638
Compressive Strength @ 73°F PSI 12,500 ASTMD695
Flexural Modulus @ 73°F PSI 267,500 ASTMD790
Izod Impact @ 73°FFt-Lbs/Inof
Notch3.8 ASTMD256
Relative Hardness @ 73°FDurometer
“D”78 ASTMD2240
ThermodynamicsProperties Unit Fuseal 25/50
PVDFSchedule 40
ASTM Test
Melt Index gm/10min 1.10 ASTMD1238Melting Point °F 334 ASTMD789Coefficient of Thermal Linear
Expansion per °Fin/in/°F 7.3x10-5 ASTMD696
Thermal ConductivityBTU-in/ft2/
hr/°F1.18 ASTMD177
Specific Heat CAL/g/°C 0.32 DSCMaximum Operating Temperature °F 284
Heat Distortion Temperature @
264 PSI°F 221 ASTMD648
OtherProperties Unit Fuseal 25/50
PVDFSchedule 40
ASTM Test
Water Absorption % <0.03 ASTMD570Industry Standard Color BlueBurning Rate V-0 UL94
Flame Spread/Smoke Generation 0/10UL723
(ASTME84)
Note: This data is based on information compiled from multiple sources.
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Fuseal® Corrosive Waste (PP) - Specification
PART 2 - PRODUCTS – MATERIALS
2.01 SPECIAL WASTE PIPE AND FITTINGS (Under Slab)A. PolypropylenePipeSchedule40shallbejoinedbythecoilfusionmethod.Pipeshallbe
manufacturedofnon-flameretardanthomopolymerpolypropylene(inburiedapplicationswherelongpipingrunsmaybeaffectedbyliveloadsabove,Schedule80non-flameretardantcopolymerpipeshallbeused).
B. PolypropylenefittingsshallbemanufacturedtoSchedule40dimensions.Fittingsshallbejoinedtothepolypropylenepipebymeansofcoilfusionmethod.
C. AllcomponentsofthesystemshallconformtothefollowingapplicableASTMStandards,D4101,D3311,D1599,D2122,F1290andF1412.Allpipeshallbemarkedwithmanufacturer’sname,pipesize,schedule,type,qualitycontrolmarkandASTMinformation.Allfittingsshallbelegiblymarkedshowingmanufacturer’strademark,fittingsize,manufacturer’spartnumber,andsymbolindicatingthematerial.
D. ThesystemshallbeFusealpipeandfittingsasmanufacturedbyGFPipingSystems,orapprovedequal.
2.02 SPECIAL WASTE PIPE AND FITTINGS (Above Slab Only)A. PolypropylenePipeSchedule40shallbejoinedbythecoilfusionmethod.Pipeshallbe
manufacturedofnon-flameretardanthomopolymerpolypropylene(inburiedapplicationswherelongpipingrunsmaybeeffectedbyliveloadsabove,Schedule80non-flameretardantcopolymerpipeshallbeused).
B. PolypropylenefittingsshallbemanufacturedtoSchedule40dimensions.Fittingsshallbejoinedtothepolypropylenepipebymeansofcoilfusionmethod.
C. AllcomponentsofthesystemshallconformtothefollowingapplicableASTMStandards,D4101,D3311,D1599,D2122,F1290andF1412.Allpipeshallbemarkedwithmanufacturer’sname,pipesize,schedule,type,qualitycontrolmarkandASTMinformation.Allfittingsshallbelegiblymarkedshowingmanufacturer’strademark,fittingsize,manufacturer’spartnumber,andsymbolindicatingthematerial.
D. ThesystemshallbeFusealpipeandfittingsasmanufacturedbyGFPipingSystems,orapprovedequal.
2.03 SPECIAL WASTE PIPE AND FITTINGS ABOVE SLAB (Under Bench)A. PolypropylenePipeSchedule40shallbejoinedbythemechanicaljointmethod.Pipeshallbe
manufacturedofflame-retardanthomopolymerpolypropylene.FlammabilityrequirementsarebasedonASTMD635“StandardTestMethodforRateofBurningand/orExtentandTimeofBurningofSelfSupportingPlasticsinaHorizontalPosition.”
B. Flame-RetardantPolypropylenefittingsshallbemanufacturedtoSchedule40dimensions.Fittingsshallbejoinedtothepolypropylenepipebymeansofmechanicaljointconnection.Fittingsshallmeetthesameflammabilityrequirementsasdescribedforpipeabove.
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C. AllcomponentsofthesystemshallconformtothefollowingapplicableASTMStandards:D4101,D3311,D1599,D2122,F1290andF1412.Allpipeshallbemarkedwithmanufacturer’sname,pipesize,schedule,type,qualitycontrolmarkandASTMinformation.Allfittingsshallbelegiblymarkedshowingmanufacturer’strademark,fittingsize,manufacturer’spartnumber,andsymbolindicatingthematerial.
D. ThesystemshallbeFuseal®PPMJfittingsasmanufacturedbyGFPipingSystemsorapprovedequal.
PART 3 - EXECUTION
3.1 INSTALLATIONA. Pipeandfittingsshallbeinstalledaccordingtocurrentinstallationinstructionsasdelivered
inprintordocumentedonlineatwww.gfpiping.com.Anon-siteinstallationseminarshallbeconductedbycertifiedGFpersonnel.Seminartopicsshallincludeallaspectsofproductinstallation(storage,setup,supportspacing,fusionprocess,mechanicaljointprocess,testingprocedure,etc.).Attheconclusionoftheinstallationseminar,allinstallerswillbegivenacertificationtestand,uponsuccessfulcompletionofsaidtest,willbeissuedacertificationcardverifyingthattheyhavemettherequirementsofthemanufacturerwithregardstoknowledgeofproperproductinstallationandtestingmethods.
B. OnlytheGFPipingSystemsfusionunitsMSA250SEor“ElectroPlus®”maybeusedintheinstallationoftheFuseal®andFuseal25/50™pipingsystems.Underthisspecification,thecontractorshallberesponsibleforpurchasingeitheroneMSA250SEorone“ElectroPlus®”fusionunitforuseininstallationoftheproducton-site.
C. Installershallensurethatallpipeandfittingsusedfortheacid-resistantpipesystemarecomponentsofthesamesystem.Nomixingofvariousmanufacturers’pipeandorfittingsshallbeallowed.AcceptablemanufacturersareGFPipingSystemsorapprovedequal.
3.2 TESTINGA. Thesystemshallbetestedinaccordancewithalllocalplumbingcodes.Allsectionsofthepiping
systemshallbetestedwithamaximumof30footheadofwater(approx.15PSI)forfusionsystem.Undernocircumstancesshouldthesystembetestedwithairoranyothergas.Jointsmaybepressuretested10minutesafterfusioniscompleted.(Mechanicaljointsshallbetestedtoamaximum10footheador5PSI).
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Fuseal 25/50™ Corrosive Waste (PVDF) - Specification
PART 2 - PRODUCTS – MATERIALS
2.01 SPECIAL WASTE PIPE AND FITTINGS (For Return Air Plenum/High Temperature - Flow)
A. Pipeandfittings1½”through6”forspecialwastepipeandfittingsystemsshallbeinstalledinplenumratedareasand/orconveyinghightemperatureflowstreamsshallbemanufacturedofSchedule40PVDF(polyvinylidenefluoride),Fuseal25/50™asproducedbyGFPipingSystems(orapprovedequal).AllsystemcomponentsshallconformtoASTMD3222andbedefinedinASTMF1673“StandardSpecificationforPolyvinylideneFluoride(PVDF)CorrosiveWasteDrainageSystems.”
B. FlammabilityrequirementsarebasedonASTMD635“StandardTestMethodforRateofBurningand/orExtentandTimeofBurningofSelfSupportingPlasticsinaHorizontalPosition.”Thepipeandfittingsshallhaveaflamespreadoflessthan25andsmokedevelopedindexoflessthan50whentestedinaccordancetoASTME84,UL723andNFPA255.
C. PipeshallbeproducedtoSchedule40IronPipeSizedimensionalstandardsandshallmeetthedimensionsandtolerancesforoutsidediameters.Allpipeshallbemarkedwith“+GF+,PVDF,Schedule40Size,ASTMF-1673,E84,UPC,ULClassifieddatestamp,MadeinUSA”,stampingsclearlylegibleontheouterwallofthepipe.
D. FittingsshallbelegiblymarkedaspertherequirementsofASTMF1673withthefollowing:MoldedFittings–PartNo.,+GF+PVDF,FittingSize,ASTMF1673,UPC,USA.
E. Eachfusioncoilshallconsistofapolyvinylidenefluoride(PVDF)jacketedwire,mandrelwound,andheat-fusedontheoutersurface.Thewireisinsertedintothefittingsocketatthefactoryandisdesignedtohaveasnugfit.Thewireleadsareterminatedviaaduplexreceptacleconnectorforattachmenttothefusionunitcable(s).
F. Anycustomfittingswhichmayneedtobefabricatedduetofieldsituationsshallconformtotherequirementsofthisspecification.
PART 3 - EXECUTION
3.1 SPECIAL WASTE PIPE AND FITTINGS (For Return Air Plenum/High Temperature - Installation)
A. PipeandfittingsshallbeinstalledaccordingtocurrentFuseal25/50™installationinstructionsasdeliveredinprintorfoundonlineatwww.gfpiping.com.Anon-siteinstallationseminarshallbeconductedbyGFPipingSystemspersonnelwhoarecertifiedtoconductsaidinstallationseminars.Seminarshallincludeallaspectsofproductinstallation(storage,set-up,supportspacing,fusionprocedure,transitionfittinginstallationprocedure,producttestingprocedures,etc.).Attheconclusionoftheinstallationseminar,allinstallerswillbegivenacertificationtestand,uponsuccessfulcompletionofsaidtest,willbeissuedacertificationcardverifyingtheyhavemettherequirementsofthefactorywithregardstoproperproductinstallationmethodstherebymeetingtheintentofthisspecification.
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B. OnlytheGFPipingSystemsfusionunitsMSA250SEor“ElectroPlus”maybeusedintheinstallationoftheFuseal25/50™pipingsystem.GFPipingSystemspersonnelshallalsoconductanon-siteinstallationseminarwithcertificationtestforallinstallersusingthesefusionunits.Underthisspecification,thecontractorshallberesponsibleforpurchasingeitheroneMSA250SEorone“ElectroPlus”fusionunitforuseininstallationoftheproducton-site.
3.2 TESTINGA. Thesystemshallbetestedinaccordancewithalllocalplumbing/mechanicalcodeshaving
jurisdictionintheterritorywheretheinstallationistotakeplace.Allsectionsofthefusedpipingsystemshallbetestedwithamaximumofa30footheadofwater(approx.15PSI).Undernocircumstancesshouldthesystembetestedwithairoranyothergas.Jointmaybepressuretested10minutesafterthefusioncycleiscompleted
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Dimensional Pipe SizePipe Size ComparisonFuseal® PP Corrosive Waste, Fuseal 25/50™ PVDF Corrosive Waste
Outside Dimensions Minimum Wall Thickness
Nominal OutsideDiameter
Fuseal PPSchedule 40
Fuseal PPSchedule 80
Fuseal 25/50Schedule40
Fuseal PPSchedule 40
Fuseal PPSchedule 80
Fuseal 25/50Schedule40
1½” 1.900 1.900 1.900 0.145 0.200 0.145
2” 2.375 2.375 2.375 0.154 0.281 0.154
3” 3.500 3.500 3.500 0.216 0.300 0.216
4” 4.500 4.500 4.500 0.237 0.337 0.237
6” 6.625 6.625 6.625 0.280 0.432 0.280
8” 8.625 0.322
10” 10.750 0.365
12” 12.750 0.406
TableperASTMF1412andASTMF1673
16
Calculating Pipe Size - Gravity Drain Systems
Flow Rate for Gravity Drain SystemsDrainageflowiscausedbygravityduetotheslopeofalldrainagepiping.Drainagepipingisdeliberatelydesignedtorun
onlypartiallyfull;afullpipe,particularlyastack,couldblowoutorsuckoutallthetrapsealsinthesystem.Foragiven
typeofpipe(friction),thevariablesindrainageflowareslopeanddepthofliquid.Whenthesetwofactorsareknown,the
flowvelocityVandflowrateQcanbecalculated.Theapproximateflowratesandvelocitiescanbecalculatedasfollows:
Q -FlowRate(gpm)
A -SectionAreaPipe(ft2)
n-ManningFrictionFactor0.009
R-HydraulicRadiusofpipe0D(ft)/4
S-HydraulicGradient-Slope(in/ft)
Example Problem:System InformationMaterial: 8in Fuseal® PP Schedule 40Outer Diameter: 8.625 (in)Inside Diameter: 7.981 (in)
Q = A · · R2/3 · S1/21.486n
FORMULA
Q = .1737 · · (0.1663)2/3 · (0.0208)1/21.4860.009
Q = 28.68 · 0.302 · 0.144
Q = 1.251 (ft3/sec)
Q = 561.4 (gpm)
FORMULA
V = · R2/3 · 1.486
nS1/2
12
V = 165.1 · 0.248 · 0.012
V = 0.599 (ft/sec)
V = · (0.1663)2/3 · 1.4860.009
0.14412
Q-FlowRate(gpm)
A-SectionAreaPipe0.3474full=0.1737½full(ft2)
n-ManningFrictionFactor 0.009
R-HydraulicRadiusofpipe0.1663(ft)
S-HydraulicGradient-Slope1/8(in/ft)=0.0104
Slope1/4(in/ft)=0.0208
Slope1/2(in/ft)=0.0416
Approximate Discharge Rates and Velocities in Sloping Drains Flowing Half-Full
Nominal
Pipe
Diameter
Fuseal PP Schedule 40 Fuseal PP Schedule 801⁄8 (in/ft) Slope ¼ (in/ft) Slope ½ (in/ft) Slope 1⁄8 (in/ft) Slope ¼ (in/ft) Slope ½ (in/ft) Slope
Flow
rat
e(g
pm)
Velo
city
(fps
)
Flow
rat
e(g
pm)
Velo
city
(fps
)
Flow
rat
e(g
pm)
Velo
city
(fps
)
Flow
rat
e(g
pm)
Velo
city
(fps
)
Flow
rat
e(g
pm)
Velo
city
(fps
)
Flow
rat
e(g
pm)
Velo
city
(fps
)
1½” 5.6 0.15 7.9 0.21 11.1 0.29 4.6 0.14 6.5 0.20 9.2 0.28
2” 10.8 0.17 15.3 0.24 21.6 0.34 7.6 0.16 10.8 0.22 15.3 0.32
3” 31.0 0.22 43.9 0.32 62.0 0.45 26.7 0.22 37.7 0.31 53.4 0.43
4” 64.0 0.27 90.5 0.38 128.0 0.54 55.9 0.26 79.0 0.37 111.8 0.52
6” 190.9 0.35 270.0 0.50 381.8 0.71 166.4 0.34 235.4 0.48 332.9 0.68
8” 396.9 0.42 561.4 0.60 793.9 0.85
10” 728.2 0.49 1029.8 0.70 1456.3 0.99
12” 1161.6 0.55 1642.8 0.78 2323.2 1.11
Fuseal 25/50 PVDF Schedule 40
1½” 5.6 0.15 7.9 0.21 11.1 0.29
2” 10.8 0.17 15.3 0.24 21.6 0.34
3” 31.0 0.22 43.9 0.32 62.0 0.45
4” 64.0 0.27 90.5 0.38 128.0 0.54
6” 190.9 0.35 270.0 0.50 381.8 0.71
8”
Q = A · · R2/3 · S1/21.486n
FORMULA
Q = .1737 · · (0.1663)2/3 · (0.0208)1/21.4860.009
Q = 28.68 · 0.302 · 0.144
Q = 1.251 (ft3/sec)
Q = 561.4 (gpm)
FORMULA
V = · R2/3 · 1.486
nS1/2
12
V = 165.1 · 0.248 · 0.012
V = 0.599 (ft/sec)
V = · (0.1663)2/3 · 1.4860.009
0.14412
Q = A · · R2/3 · S1/21.486n
FORMULA
Q = .1737 · · (0.1663)2/3 · (0.0208)1/21.4860.009
Q = 28.68 · 0.302 · 0.144
Q = 1.251 (ft3/sec)
Q = 561.4 (gpm)
FORMULA
V = · R2/3 · 1.486
nS1/2
12
V = 165.1 · 0.248 · 0.012
V = 0.599 (ft/sec)
V = · (0.1663)2/3 · 1.4860.009
0.14412
17
Above Ground Installations
Allowing for Length Changes in Gravity PipelinesVariationsintemperaturecausegreaterlengthchangesinthermoplasticmaterialsthaninmetals.Inthecaseofabove
ground,wallorductmountedpipework,particularlywheresubjectedtovaryingworkingtemperatures,itisnecessaryto
makesuitableprovisionsforlengthchangestopreventadditionalstresses.
Calculation and Positioning of Flexible SectionsItispossibletotakeadvantageoftheverylowmodulusofelasticityofpolypropylenebyincludingspecialsectionsofpipe
whichcompensatethermallengthchanges.Thelengthoftheflexiblesectionmainlydependsuponthepipediameterand
theextentofthelengthchangetobecompensated.Tosimplifyplanningandinstallation,thethirdinfluencingfactor—the
pipewalltemperature—isnottakenintoaccount,particularlyasinstallationusuallytakesplaceinthetemperaturerange
between37°F(3°C)and77°F(25°C).
Wherethepipeworkchangesdirectionorbranchesoff,thereisalwaysanaturalflexiblesection.
Therearetwoprimarymethodsofcontrollingorcompensatingforthermalexpansionofplasticpipingsystems:(1)taking
advantageofoffsetsand(2)changesofdirectioninthepipingandexpansionloops.
Type 1 - Offsets/Changes in Direction
Mostpipingsystemshaveoccasionalchangesindirectionswhichwillallowthethermallyincludedlengthchangestobe
takenupinoffsetsofthepipebeyondthebends.Wherethismethodisemployed,thepipemustbeabletofloatexceptat
anchorpoints.
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Changes in Direction
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Offsets
Type 2 - Expansion Loops
Forexpansionloops,theflexiblesectionisbrokenintotwo
offsetsclosetogether.Byutilizingtheflexiblemembersin
thisexample,the“a”lengthisslightlyshorterthanthe“a”
inthestand-aloneoffset.
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Expansion Loop
18
Determining the Length Change (ΔL)Todeterminethelengthoftheflexiblesection(a)required,theextentofthelengthchangemustbeascertainedfirstofall
bymeansofthefollowingformulawhere:
ΔL = L · ΔT · δ (inch) = (inch) · (ºF) · (inch/inchºF)
ΔL =Lengthchangeininches
L =Lengthininchesofthepipeorpipesectionwherethelengthchangeis
tobedetermined
ΔT =Differencebetweeninstallationtemperatureandmaximumor
minimumworkingtemperaturein°F
Coefficient of Linear Expansion
δ =FusealPPSchedule40Non-FlameRetardant-0.00005in/in°F
δ =FusealPPSchedule40FlameRetardant-0.000061in/in°F
δ =FusealPPSchedule80Non-FlameRetardant-0.000061in/in°F
δ =Fuseal25/50PVDFSchedule40-0.00008in/in°F
Installation Temperature
+∆l
-∆l
L
Expansion
Contraction
L = 315in
Fixed Point
L = 315in
Fixed Point
+∆l2
L = 315in
Fixed Point
-∆l1
Expansion
Contraction
Installation
Important:
Iftheoperatingtemperatureishigherthantheinstallationtemperature,thenthepipebecomeslonger.If,ontheother
hand,theoperatingtemperatureislowerthantheinstallationtemperature,thenthepipecontractsitslength.The
installationtemperaturemustthereforebeincorporatedintothecalculationaswellasthemaximumandminimumoper-
atingtemperatures.
ProblemUtilizingSchedule40,FusealPPNon-FlameRetardantasacoolant
wastepipeasanexample:
Thelengthofthepipefromthefixedpointtothebranchwherethe
lengthchangeistobetakenup:L=315in.
Temperature Requirements
Installed Temp Operating Temp Defrost/Cleaning
Tv=73°F T1=40°F T2=95°F
Difference in Contraction Temperature
ΔT1=Tv-T1=73°F-40°F=33°F
Difference in Expansion Temperature
ΔT2=T2-Tv=95°F-73°F=22°F
Contraction during service with coolant
–ΔL1=L·ΔT1·δ=315in·33·(0.00005)=0.52in
Expansion during defrosting and cleaning
+ΔL2=L·ΔT2·δ=315in·22·(0.00005)=0.35in
Installation Temperature
+∆l
-∆l
L
Expansion
Contraction
L = 315in
Fixed Point
L = 315in
Fixed Point
+∆l2
L = 315in
Fixed Point
-∆l1
Expansion
Contraction
Installation
19
Length Change (ΔL) in Inches
Fuseal PP Schedule 40 Non-Flame Retardant
Length of Pipe Section (ft)
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Tem
pera
ture
Cha
nge
in (°
F)
5 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3
10 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.6 0.6
15 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.5 0.6 0.6 0.7 0.7 0.8 0.8 0.9 0.9
20 0.1 0.1 0.2 0.2 0.3 0.4 0.4 0.5 0.5 0.6 0.7 0.7 0.8 0.8 0.9 1.0 1.0 1.1 1.1 1.2
25 0.1 0.2 0.2 0.3 0.4 0.5 0.5 0.6 0.7 0.8 0.8 0.9 1.0 1.1 1.1 1.2 1.3 1.4 1.4 1.5
30 0.1 0.2 0.3 0.4 0.5 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.4 1.5 1.6 1.7 1.8
35 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1
40 0.1 0.2 0.4 0.5 0.6 0.7 0.8 1.0 1.1 1.2 1.3 1.4 1.6 1.7 1.8 1.9 2.0 2.2 2.3 2.4
45 0.1 0.3 0.4 0.5 0.7 0.8 0.9 1.1 1.2 1.4 1.5 1.6 1.8 1.9 2.0 2.2 2.3 2.4 2.6 2.7
50 0.2 0.3 0.5 0.6 0.8 0.9 1.1 1.2 1.4 1.5 1.7 1.8 2.0 2.1 2.3 2.4 2.6 2.7 2.9 3.0
55 0.2 0.3 0.5 0.7 0.8 1.0 1.2 1.3 1.5 1.7 1.8 2.0 2.1 2.3 2.5 2.6 2.8 3.0 3.1 3.3
60 0.2 0.4 0.5 0.7 0.9 1.1 1.3 1.4 1.6 1.8 2.0 2.2 2.3 2.5 2.7 2.9 3.1 3.2 3.4 3.6
65 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.1 2.3 2.5 2.7 2.9 3.1 3.3 3.5 3.7 3.9
70 0.2 0.4 0.6 0.8 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.2 3.4 3.6 3.8 4.0 4.2
80 0.2 0.5 0.7 1.0 1.2 1.4 1.7 1.9 2.2 2.4 2.6 2.9 3.1 3.4 3.6 3.8 4.1 4.3 4.6 4.8
90 0.3 0.5 0.8 1.1 1.4 1.6 1.9 2.2 2.4 2.7 3.0 3.2 3.5 3.8 4.1 4.3 4.6 4.9 5.1 5.4
100 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 5.4 5.7 6.0
Fuseal PP Schedule 40 Flame Retardant / Fuseal PP Schedule 80 Non-Flame Retardant
Length of Pipe Section (ft)
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Tem
pera
ture
Cha
nge
in (°
F)
5 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.3 0.3 0.4
10 0.1 0.1 0.1 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.4 0.5 0.5 0.5 0.6 0.6 0.7 0.7 0.7
15 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.7 0.7 0.8 0.8 0.9 0.9 1.0 1.0 1.1
20 0.1 0.1 0.2 0.3 0.4 0.4 0.5 0.6 0.7 0.7 0.8 0.9 1.0 1.0 1.1 1.2 1.2 1.3 1.4 1.5
25 0.1 0.2 0.3 0.4 0.5 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.6 1.7 1.8
30 0.1 0.2 0.3 0.4 0.5 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.8 1.9 2.0 2.1 2.2
35 0.1 0.3 0.4 0.5 0.6 0.8 0.9 1.0 1.2 1.3 1.4 1.5 1.7 1.8 1.9 2.0 2.2 2.3 2.4 2.6
40 0.1 0.3 0.4 0.6 0.7 0.9 1.0 1.2 1.3 1.5 1.6 1.8 1.9 2.0 2.2 2.3 2.5 2.6 2.8 2.9
45 0.2 0.3 0.5 0.7 0.8 1.0 1.2 1.3 1.5 1.6 1.8 2.0 2.1 2.3 2.5 2.6 2.8 3.0 3.1 3.3
50 0.2 0.4 0.5 0.7 0.9 1.1 1.3 1.5 1.6 1.8 2.0 2.2 2.4 2.6 2.7 2.9 3.1 3.3 3.5 3.7
55 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0
60 0.2 0.4 0.7 0.9 1.1 1.3 1.5 1.8 2.0 2.2 2.4 2.6 2.9 3.1 3.3 3.5 3.7 4.0 4.2 4.4
65 0.2 0.5 0.7 1.0 1.2 1.4 1.7 1.9 2.1 2.4 2.6 2.9 3.1 3.3 3.6 3.8 4.0 4.3 4.5 4.8
70 0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.6 2.8 3.1 3.3 3.6 3.8 4.1 4.4 4.6 4.9 5.1
80 0.3 0.6 0.9 1.2 1.5 1.8 2.0 2.3 2.6 2.9 3.2 3.5 3.8 4.1 4.4 4.7 5.0 5.3 5.6 5.9
90 0.3 0.7 1.0 1.3 1.6 2.0 2.3 2.6 3.0 3.3 3.6 4.0 4.3 4.6 4.9 5.3 5.6 5.9 6.3 6.6
100 0.4 0.7 1.1 1.5 1.8 2.2 2.6 2.9 3.3 3.7 4.0 4.4 4.8 5.1 5.5 5.9 6.2 6.6 7.0 7.3
20
Fuseal 25/50 PVDF Schedule 40
Length of Pipe Section (ft)
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Tem
pera
ture
Cha
nge
in (°
F)
5 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.4 0.4 0.4 0.4 0.5 0.5
10 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.6 0.7 0.7 0.8 0.8 0.9 0.9 1.0
15 0.1 0.1 0.2 0.3 0.4 0.4 0.5 0.6 0.6 0.7 0.8 0.9 0.9 1.0 1.1 1.2 1.2 1.3 1.4 1.4
20 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9
25 0.1 0.2 0.4 0.5 0.6 0.7 0.8 1.0 1.1 1.2 1.3 1.4 1.6 1.7 1.8 1.9 2.0 2.2 2.3 2.4
30 0.1 0.3 0.4 0.6 0.7 0.9 1.0 1.2 1.3 1.4 1.6 1.7 1.9 2.0 2.2 2.3 2.4 2.6 2.7 2.9
35 0.2 0.3 0.5 0.7 0.8 1.0 1.2 1.3 1.5 1.7 1.8 2.0 2.2 2.4 2.5 2.7 2.9 3.0 3.2 3.4
40 0.2 0.4 0.6 0.8 1.0 1.2 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.1 3.3 3.5 3.6 3.8
45 0.2 0.4 0.6 0.9 1.1 1.3 1.5 1.7 1.9 2.2 2.4 2.6 2.8 3.0 3.2 3.5 3.7 3.9 4.1 4.3
50 0.2 0.5 0.7 1.0 1.2 1.4 1.7 1.9 2.2 2.4 2.6 2.9 3.1 3.4 3.6 3.8 4.1 4.3 4.6 4.8
55 0.3 0.5 0.8 1.1 1.3 1.6 1.8 2.1 2.4 2.6 2.9 3.2 3.4 3.7 4.0 4.2 4.5 4.8 5.0 5.3
60 0.3 0.6 0.9 1.2 1.4 1.7 2.0 2.3 2.6 2.9 3.2 3.5 3.7 4.0 4.3 4.6 4.9 5.2 5.5 5.8
65 0.3 0.6 0.9 1.2 1.6 1.9 2.2 2.5 2.8 3.1 3.4 3.7 4.1 4.4 4.7 5.0 5.3 5.6 5.9 6.2
70 0.3 0.7 1.0 1.3 1.7 2.0 2.4 2.7 3.0 3.4 3.7 4.0 4.4 4.7 5.0 5.4 5.7 6.0 6.4 6.7
80 0.4 0.8 1.2 1.5 1.9 2.3 2.7 3.1 3.5 3.8 4.2 4.6 5.0 5.4 5.8 6.1 6.5 6.9 7.3 7.7
90 0.4 0.9 1.3 1.7 2.2 2.6 3.0 3.5 3.9 4.3 4.8 5.2 5.6 6.0 6.5 6.9 7.3 7.8 8.2 8.6
100 0.5 1.0 1.4 1.9 2.4 2.9 3.4 3.8 4.3 4.8 5.3 5.8 6.2 6.7 7.2 7.7 8.2 8.6 9.1 9.6
21
Determining the Length of the Flexible Section (a)
a = k ∆L · d
Formula forFlexible Sections (a)
a = Length of Flexible Section
∆L = Change in Lengthd = Outside Diameter of Pipe
k = Constant (k = 30 PP)k = Constant (k = 21.7 PVDF)
Thevaluesrequiredtodeterminethelengthoftheflexible(a)sectionare:
ThemaximumlengthchangeΔLincomparisonwiththezeropositionduring
installation(whichcanbeeitheranexpansionoracontraction),andthepipe
diameter(d).
IfvaluesΔLand(d)areknown,Table 7showsthelengthofflexiblesection(a)
required.
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
ChangeofDirection
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
ExpansionLoop
¼ a
½ a
¼ a
a ½ a
½ a
52
51
6”min. 6”min.
L
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Fixed Guide
FixedGuide
Fixed Guide
Guide
Fixed
Guide Guide
Offset
Table 7: Flexible Sections (a) in Inches
Fuseal PP Schedule 40/80 Fuseal 25/50 PVDF Schedule 40
1½”
2” 3” 4” 6” 8” 10”
12”
1½”
2” 3” 4” 6”
Leng
th C
hang
e -
ΔL
(in)
0.1 13 15 18 20 24 28 31 34 9 11 13 15 18
0.2 18 21 25 28 35 39 44 48 13 15 18 21 25
0.3 23 25 31 35 42 48 54 59 16 18 22 25 31
0.4 26 29 35 40 49 56 62 68 19 21 26 29 35
0.5 29 33 40 45 55 62 70 76 21 24 29 33 39
0.6 32 36 43 49 60 68 76 83 23 26 31 36 43
0.7 35 39 47 53 65 74 82 90 25 28 34 39 47
0.8 37 41 50 57 69 79 88 96 27 30 36 41 50
0.9 39 44 53 60 73 84 93 102 28 32 39 44 53
1.0 41 46 56 64 77 88 98 107 30 33 41 46 56
2.0 58 65 79 90 109 125 139 151 42 47 57 65 79
3.0 72 80 97 110 134 153 170 186 52 58 70 80 97
4.0 83 92 112 127 154 176 197 214 60 67 81 92 112
5.0 92 103 125 142 173 197 220 240 67 75 91 103 125
6.0 101 113 137 156 189 216 241 262 73 82 99 113 137
7.0 109 122 148 168 204 233 260 283 79 88 107 122 148
8.0 117 131 159 180 218 249 278 303 85 95 115 130 158
9.0 124 139 168 191 232 264 295 321 90 100 122 138 168
10.0 131 146 177 201 244 279 311 339 95 106 128 146 177
22
RestraintRestraintisrigidlyanchoringthepiperunstothebuildingstructureatappropriateplacessothatthermally-induced
dimensionchangeswillbereplacedbythermally-inducedstresses.Thiscanbeaccomplishedbyuseofadequatelystrong
clampsorsupportstoholdthepipeinplace.Thefollowingtableshowstheforcestoberesisted.Forhorizontalruns,
bracedclamptypehangersmaybeused.Forfloorpenetrations,extensionriserclampsmaybeused.
Undergroundinstallationinproperlybackfilledtrenchesmaybeconsideredtobearestrainedsystemandnotsubjectto
thermally-induceddimensionalchanges.
Itshouldbenotedthattwounusualpropertiesofpolypropylenemakeforthesuccessofthesemethodsofhandlingthermal
expansion.Polypropyleneisnotsubjecttostresscracking.Itcanbestressedforlongperiodsoftimeinwhatmightbe
consideredunfriendlyenvironmentswithoutharm.Inaddition,polypropylenehasanextremelyhighfatiguelife.Its“self-
hinge”characteristicsarewellknownandthepipingmaterialswillstandrepeateddrasticflexureswithoutharm.
Restraint Force (lbs)
Nominal Size (in)
Schedule 40 *Schedule 80
A (in2)ΔT = 50˚F
S = 500 PSIΔT = 100˚F
S = 1000 PSI A (in2)ΔT = 50˚F
S = 500 PSIΔT = 100˚F
S = 1000 PSI
1½ 0.799 400 800 1.068 534 1070
2 1.075 538 1080 1.477 739 1478
3 2.228 1110 2220 3.016 1510 3020
4 3.173 1590 3180 4.407 2200 4400
6 5.584 2790 5580 8.405 4200 8400
8 8.399 4610 4220 12.763 7020 14040
10 11.908 6536 13070 18.922 10405 20810
12 15.745 8645 17290 16.035 14320 28640
S
e
*e
∆T
=
=
=
=
Thermal Stress (lbs/in2)
Coefficient of Thermal Expansion = 5.0 x 10-5 (in/in˚F)
Coefficient of Thermal Expansion = 6.1 x 10-5 (in/in˚F)
Temperature Difference (˚F)
E
*E
F
A
=
=
=
=
Modulus of Elasticity = 2.0 x 10-5 (lbs/in2)
Modulus of Elasticity = 1.8 x 10-5 (lbs/in2)
Restraint Force Necessary (lbs)
Cross Section Area of Pipe Wall (in2)
=S e • ∆T • E =F A • S
*Note: Indicates copolymer polypropylene
Expansion Joint AssembliesFusealPPexpansionjointassembliesaredesignedtoabsorbexpansionandcontractioninpipingruns.
Theexpansionjointsarefactoryassembledandconsistoftwocomponents:
1) O-ringfittingwithpre-lubricatedEPDMo-ringgasketjoint
2) Pistonspigot
ExpansionjointassembliesarequicklyandeasilyinstalledbymeansofstandardFusealjoiningprocessbyGF.
Availableinsizes:1½”,2”,3”and4”
23
Support During Installation
Whenthermoplasticpipingsystemsareinstalledaboveground,theymustbeproperlysupportedtoavoidun-necessarystressesandpossiblesagging.
Horizontalrunsrequiretheuseofhangersasdescribedonthenextpage,spacedapproximatelyasindicatedinthetablebelow.Notethatadditionalsupportisrequiredastemperaturesincrease.Continuoussupportcanbeaccomplishedbytheuseofsmoothstructuralangleorchannel.
Wherethepipeisexposedtoimpactdamage,protectiveshieldsshouldbeinstalled.
Tablesarebasedonthemaximumdeflectionofauniformlyloaded,continuouslysupportedbeamcalculatedfrom:
Table 8: Support Spacing
Pipe Size (in)
Pipe Bracket Intervals (ft) for Fuseal PP
Pipe Size (in)
Pipe Bracket Intervals (ft) for Fuseal 25/50 PVDF
73°F
120°
F
140°
F
160°
F
180°
F
200°
F
212°
F
73°F
120°
F
140°
F
180°
F
212°
F
250°
F
284°
F
1½ 4.7 4.5 4.5 4.5 4.2 4.0 3.7 1½ 5.0 5.0 4.6 4.6 3.5 3.5 3.5
2 5.2 5.0 5.0 4.7 4.5 4.2 4.0 2 5.0 5.0 4.6 4.6 3.5 3.5 3.5
3 6.2 6.0 5.7 5.7 5.5 5.2 5.0 3 5.0 5.0 4.6 4.6 3.5 3.5 3.5
4 6.7 6.5 6.2 6.2 6.0 5.7 5.5 4 5.0 5.0 4.6 4.6 3.5 3.5 3.5
6 8.0 7.5 7.5 7.2 7.0 6.5 6.0 6 5.0 5.0 4.6 4.6 3.5 3.5 3.5
8 8.5 8.0 7.5 6.7 6.5 6.2 6.0
10 9.5 8.7 8.0 7.5 7.0 6.7 6.5
12 10.0 9.5 8.5 8.0 7.5 7.2 7.0
Continuous Support Arrangements
v
Typical Support Arrangements
A Pipe Clip (Vertical)
B U-Type Clamp
C Pipe Clip (Horizontal)
D Roller Carrier
E Angle Bracket with U-Clamp
F Clamp (Vertical)
G Suspended Ring Clamp
Note:Pipes must be free tomove axially
24
Single Pipe Roll
Recommended Hangers for Plastic Piping Systems
Band Hanger with Protective Sleeve
Clevis
Adjustable Solid Ring Swivel Type
Roller Hanger
Pipe Roll and Plate
Riser Clamp
Double-Bolt Clamp
Hangers
Therearemanyhangersandsupportssuitableforuseinplasticpipingsystems,althoughsomemayrequiremodification.Itisimportantinaplas-ticpipingsystemtoprovideawideload-bearingsurfaceandthatanyrestraintsrecognizethatplasticpipingsystemsaresomewhatnotchsensi-tive.Also,ifthethermalmovementofaplasticpipingsystemmightcausethepipelinetoabradeonaroughsurface,suchasconcrete,somemeansofisolatingthepipeshouldbeconsidered.Wearpadsofplasticcanbefashionedfromthepipeorwoodenisolatorscanbeused.
Itisalsoimportanttorecognizethethermalmove-mentinanyplasticpipingsystemandthehangersandsupportstructuresshouldallowfor,ordirect,theexpansionthatmaybeinaparticularsystem.Pipehangersmustbecarefullyalignedandmusthavenoroughorsharpedgesthatcouldcontactandpotentiallydamagethepipe.Thehangerorsupportsystemshouldrecognizethethermalexpansioninaplasticpipesystemandpipeshouldbeallowedtomove.
Verticallinesmustalsobesupportedatintervalssothatthefittingsatthelowerendofariserorcolumnarenotoverloaded.Thesupportsshouldnotexertacompressivestrainonthepipe,suchasriser–typeclampsthatsqueezethepipe.Adoublebolttype,inconjunctionwithusingafittingshoul-der,mayaffordthebestmethodforsupportingverticalsystems.
25
Below Ground Installations
Instruction for Underground Trenching 1.Thebottomofthetrenchshallbeofstablematerial.Wheregroundwaterisencountered,thebottomshallbestabilizeda
withgranularmaterialof½”maximumparticlesize.A4”cushionshallbeplacedoverrockorhardpan.
2.Trenchwidthshouldbesufficienttoprovideworkingroomifthepipeistobejoinedinthetrench.Minimumwidthmaybe
usedifpipeistobejoinedbeforeplacinginthetrench.
3.Trenchdepthunderbuildingslabsshouldallowfor12”coveroverthepipe.Trenchesinexposedlocationsshouldpermit
burialofpipeatleast12”belowmaximumexpectedfrostpenetration.Aminimumof24”covershouldbeprovidedwhere
pipemaybeexposedtoheavyoverheadtraffic.Applicableplumbingcodesmayrequiregreatertrenchdepthandcover
thantechnicallyrequired.
Trench Widths for Polypropylene
WH
WH
WH WH
Note: “W” = Width of Trench at Top of Pipe
Bedding and Backfill MaterialThebackfillmaterialsurroundingthepipeshallbereadilycompactibleandshallconsistofcoarsesand,sandwithgravelorclay,sandthatisfreefromfrozenlumps,stoneslargerthan½”andfinecompactsiltorclay.ThematerialshallfallwithintheHighwayResearchBoardClassificationGroupA-1,A-2(PlasticityIndexlessthan10)orA-3.
Bedding and Backfilling - ASTM D23211. Bedding—Installin6”maximumlayers.Levelfinalgradebyhand.Minimumdepth4”(6”inrockcuts).
2. Haunching—Installin6”maximumlayers.Workaroundpipebyhandtoprovideuniformsupport.
3. Initial Backfill—Installtoaminimumof6”abovepipecrown.
4. Embedment Compaction—Minimumdensity95%StandardProctorperASTMD698.Usehandtampersor
vibratorycompactors.
5. Final Backfill—Compactasrequiredbytheengineer.
26
Fuseal® Soil Load and Pipe Resistance
Nom. Size
Wc’ = Load Resistance of Pipe (lb./ft.) H=height of fill above pipe
Wc = soil loads at various trench widths at top of pipe (lb./ft.)Schedule 40 Pipe Schedule 80 Pipe
E’ = 200 E’ = 700 E’ = 200 E’ = 700 (ft.) 2 ft 3 ft. 4 ft.
1½ 556 764 1375 1561
10 106 125 136
20 138 182 212
30 144 207 254
2 466 718 1161 1400
10 132 156 170
20 172 227 265
30 180 259 317
2½ 701 1005 1593 1879
10 160 191 210
20 204 273 321
30 216 306 377
3 614 988 1416 1772
10 196 231 252
20 256 336 392
30 266 384 469
3½ 578 1011 1318 1731
10 223 266 293
20 284 380 466
30 300 426 524
4 564 1055 1266 1735
10 252 297 324
20 328 432 504
30 342 493 603
5 555 1170 1206 1796
10 310 370 407
20 395 529 621
30 417 592 730
6 573 1313 1323 2028
10 371 437 477
20 484 636 742
30 503 725 888
8 638 1612 1319 2250
10 483 569 621
20 630 828 966
30 656 945 1156
10 721 1944 1481 2649
10 602 710 774
20 785 1032 1204
30 817 1177 1405
12 809 2266 1676 3067
10 714 842 918
20 931 1225 1429
30 969 1397 1709
Wc’
∆x
E
=
=
=
Load Resistance of the Pipe (lb./ft)
Deflection in Inches @ 5% (.05 x I.D.)
Modulus of Elasticity = 2.0 x 105 (lbs/in2)
t
r
E’
H
I
=
=
=
=
=
Pipe Wall Thickness (in)
Mean Radius of Pipe (O.D. - t)/2
Modulus of Passive Soil Resistance (lbs/in2)
Height of Fill Above top of Pipe (ft)
Moment of Inertia t3/12
=Wc’ ∆x • (E • l + 0.061 • E’ • r3) • 80r3
Note 1:Figuresarecalculatedfromminimumsoilresistancevalues(E’=200PSIforuncompactedsandyclayloam)andcompactedsoil(E’=700forside-fillsoilthatiscompactedto90%ormoreofProctorDensityforadistanceoftwopipediametersoneachsideofthepipe).IfWc’islessthanWcatagiventrenchdepthandwidth,thensoilcompactionwillbenecessary.
Note 2:Thesearesoilloadsonlyanddonotincludeliveloads.
27
Cold Weather InstallationsIngeneral,itisgoodpracticewhenpossible,tomaintainanambienttemperatureabove40˚F(4˚C).However,low
temperaturefusionsto14˚F(−10˚C)areeasilyaccomplishedutilizingautomatictemperaturecompensationcapablefusion
machines(MSA250andElectroPlus®)fromGF.
Note:Materialandfusionmachinesmustbethesametemperaturepriortofusion.Thiscanbeachievedwhencomponents
andmachinesareinthesameenvironmentfor2ormorehours.
Forfurtherinformation,pleaseconsultyoulocalsalesrepresentative.
Flammability and Fire Rated ConstructionThefireprotectionofficialsandcodeofficialsarebecomingsensitivetothesmokegenerationandflammabilityofplastic
materialsusedinbuildingconstruction,andplasticpipingisnaturallyincludedintheseconcerns.Tosatisfythefiresafety
requirementssetoutbytheauthorities,theengineersandarchitectsmusthaveabetterunderstandingoftheplasticsused
inpiping,appropriatetestmethodsandmeansofprotectionagainstfiredangersattributedtoplasticpiping.
Toputthisintotheproperperspective,thearchitect,engineerandadministrativeauthoritymustrealizethat,inthevast
majorityofcases,firescommonlystartandcontinuetodevelopinoccupiedareasofabuildingandnotwithinthewallsand
chaseswhereplasticpipingismorecommonlyinstalled.
Laboratory Fire TestsThefollowingarecommonlaboratorytestsconductedonsmallsamplesofplasticmaterialandareusefulincharacterizing
andcomparingdifferentplastics.However,thesetestsareofonlylimiteduseinpredictingthebehaviorofthematerialsin
realfiresituations.
ASTM D635 - Rate of Burning and/or Extent and Time of Burning of Self Supporting Plastics in a Horizontal Position.
Onehalf-inchwidebyfive-inchlonghorizontalspecimensareexposedtoaburnerflame.Thetimeofburning
anddistanceburnedarerecorded.Theresultsarereportedasmeasured,exceptinthecasewheretheminimum
valuesapply(timeofburningis“lessthanfiveseconds”andtheminimumextentofburningis“lessthanone
quarter-inch”).
UL94 - Standard for Safety of Flammability of Plastic Materials
Onehalf-inchwidebyfive-inchlongverticalspecimensareexposedrepeatedlytoaburnerflame.Timeofburning,
possibledrippingofburningparticlesandafterglowareobserved.ResultsarereportedasV-0,V-1orV-2,
dependingontestresults.
ASTM D2843 - Density of Smoke from the Burning or Decomposition of Plastics.
Aone-quarterinchbyoneinchbyoneinchsampleisexposedtoapropaneburnerflameandlighttransmission
throughthesmokegeneratedbytheburningplasticismeasuredwithastandardlampandphotocellforfour
minutes.Resultsarereportedaslightabsorptionandsmokedensity.
ASTM D2863 - Minimum Oxygen Concentration to Support Candle-Like Combustion of Plastics (Oxygen Index).
Aone-eighthinchbyone-quarterinchbythreetosixinchlongspecimenisburnedinavariableoxygen-nitrogen
mixturetodeterminethepercentageoxygenrequiredtomaintaincombustion.
28
Large Scale Tests Thesetestsarerunonfull-sizedwallorfloor(floor-ceiling)assembliesoronlargematerialspecimens.Theyareintended
todeterminetheresponseofvaryingconstructionmethodsandmaterialsinactualfireconditions.
ASTM E119 - Fire Tests of Building Construction and Materials.
NFPA251
UL263
UBC43-1
Wallsectionsofatleast100squarefeetinsizeareattachedasthefrontwallofafurnaceandexposedtoaflaming
environment.Thetemperaturerisesaccordingtoastandardtimetemperaturecurve.Thetestspecimenmay
ormaynotbeexposedtoverticalorhorizontalloads.Thespecimen,afterexposure,maybesubjectedtoahigh
pressurehosestreamtodetermineitsintegrityafterexposure.
Thistestisuniversallyacceptedasthemethodofratingwallassembliesforfireresistanceasrelatedtotimeof
exposure.Ratingsmaybe1,2,3or4hours,dependingonthetimeforthetemperaturetorisetonotmorethan
250°F(121°C)aboveitsinitialtemperatureonthenon-exposedface.Floorandfloor-ceilingassembliesofatleast
180squarefeetinsizearealsotestedperASTME119astheroofsofafloor-ceilingfurnace,andratedonthebasis
ofthetimeforthetemperaturetorise250°F(121°C)abovetheinitialtemperatureontheunexposedface,asfor
walls.
ASTM E814 - Fire Tests of Through-Penetration Fire Stops.
Thistestmethod(publishedSpring1982)isessentiallyidenticaltotheASTME119testexceptthatitisintendedto
determinetheabilityoffire-stoppingmethodsanddevicestomaintainthefirerating(integrity)ofratedfire-resistive
walls,floorsorfloor-ceilingassemblieswhicharepenetratedbypipe,conduitsorcables.
ASTM E84 - Surface Burning Characteristics of Building Materials.
NFPA255
UL723
UBC42-1
Asstated,thistestisintendedfortestingofsurfacefinishmaterialswhicharecapableofsupportingthemselvesor
ofbeingsupportedotherthanbysupportontheunder-sideofthetestspecimen.Samplesare20inches(min.)wide
by24feetlongandareattachedtotheroofofan18inchby30footfurnace.
Burningcharacteristicsofthesamplesarestatedaspercentageoftherateofburningofredoak.
Thistest,beingspecificallyaimedattestingsurfacefinishmaterials,isrecognizedasnotapplyingtoplasticpipeby
thosewhounderstandthetestmethodandapplicationenvironment.TheNationalFireProtectionAssociationhas
statedthatthetestisnottobeappliedtoplasticpipeandthatthepipeshouldbetestedasacomponentofawallor
floorassemblyintheASTME119test,wherethematerialsaremostcommonlyused.
29
Fire Protection Methods (Fuseal® PP Waste and Vent Piping)Forfireresistanceratedwallpenetrations,penetrationsthroughhorizontalassemblies,etc.usefirestoppingwithratings
determinedbyASTME814orUL1479forusewithplasticpiping.
Inplenumspacesbetweenafloorandasuspendedceilingwherepolypropylenematerialisrequired,protectioncanbe
providedby3MFireMasterPlenumWrap.ThisPlenumWrapisanon-combustibleinsulationmaterialencapsulatedwith
aluminumfoil.ItisclassifiedbyOmegaPointLaboratoriesforuseonPVC,CPVC,PB,PE,PP,PVDFandABSpipeinreturn
airplenums.TestedtotheUL910flammabilitytest.The3MFireMasterPlenumWrapprovidesprotectionfromexternal
flame-propagationandsmoke.Itprotectsplasticpipesthataretobeinstalledinducts,plenumsandotherspacesusedfor
environmentalair.
TestingJointsmaybepressuretested10minutesaftercompletionoffusion.Testinaccordancewithlocalplumbingcodes.All
sectionsofthesystemcanbetestedwithupto30ftheadofwater.
Itisagoodplumbingpracticetotestasmallsection(approx.20fittings)ofthefusedpipingsystemfirst,toensureproper
installationproceduresarebeingperformedbeforecontinuingwiththecompletionofthesystem.
GFPipingSystemsDOES NOT RECOMMENDtheuseofthermoplasticpipingproductsforsystemstotransportorstore
compressedairorgases,orthetestingofthermoplasticpipingsystemswithcompressedairorgasesinaboveorbelow
groundlocations.TheuseofGFPipingSystemsproductsincompressedairorgassystemsautomaticallyvoidsthewar-
rantyforsuchproducts,andtheiruseagainstourrecommendationisentirelytheresponsibilityandliabilityoftheinstaller.
GFPipingSystemswillnotacceptresponsibilityfordamageorimpairmentfromitsproducts,orotherconsequentialor
incidentaldamagescausedbymisapplication,incorrectassembly,and/orexposuretoharmfulsubstancesorconditions.
30
Neutralization Tanks/pH Monitoring and Treatment SystemsWhilecoderequirementsmaybedirectiveastomaterialsusedinconveyanceofcorrosivewasteflowstreams,thereoften
isnoinformationsetforthastotherequiredtreatmentofthesestreamspriortotheirbeingtiedinto(connectedto)the
building,privateormunicipalsanitarypipingsystem.
Whendesigningacorrosivewaste(specialwaste)system,oneshouldbeawareofthefollowing:
• Facility(onsite)protocolsforcorrosivetreatment
• Local,stateorfederalregulationsregardingprohibiteddischargesintosurfacewaterorpiped
IntheU.S.,facilitieswhichdischargetheirwasteflowstreamsdirectlytosurfacewatersmustbepermittedundertheEPA
NPDES(NationalPollutantDischargeEliminationSystem).Withregardstodischargeofcorrosivewastes,thesystem
designermustrefertoTheProhibitedDischargeStandardsasfoundinregulation40CFR:
Section403.5(b)states,“Specificprohibitions.Inaddition,thefollowingpollutantsshallnotbeintroducedintoa
POTW(PubliclyOwnedTreatmentWorks)(2)states,“Pollutantswhichwillcausecorrosivestructuraldamagetothe
POTW(PubliclyOwnedTreatmentWorks):
Subparagraph(2)underSection403.5(b)states,“Pollutantswhichwillcausecorrosivestructuraldamagetothe
POTW,butinnocaseDischargeswithapHlowerthan5.0,unlesstheworksisspecificallydesignedtoaccommo-
datesuchDischarges;”
ThepHdischargelimitassetforthinSection403.5(b)isthebasisofdesignforthestandardlimestone-filledneutralization
tanksusedtoneutralizetheacidic(lowpH)levelswithinafacilitiescorrosivewastedrainagesystem.Thesetanksmustbe
installedupstreamofthetie-intothesanitarypipingsystem.Mostofthespecificationswrittenoncorrosivewastepiping
systemsrequiresuchtankstobeinstalled.Forassistanceinspecifyingtheproperly-sizedtankforaparticularfacility,
pleasecontactyourlocalGFPipingSystemsAreaSalesManagerorgotowww.gfpiping.comfordesignassistance.
Thesystemdesignermustinvestigatethedischargerequirementsofthelocalauthoritieshavingjurisdiction(municipality,
DEQ[DepartmentofEnvironmentalQuality],DEP[DepartmentofEnvironmentalProtection],SewerageDistrict,etc.)within
theareainwhichthefacilityislocated.
AlthoughmostAuthoritiesHavingJurisdiction(AHJ)sewerageconnectionpermitsincorporateSection403.5(b)(2)wording
directlyintotheirownProhibitedDischargesection,therearemanythatarealsoconcernedwithcaustic(highpH)dis-
chargesintothemunicipalofsurfacewatersystem.ThesejurisdictionswillclearlydefineahighpHdischargelimit
(usuallyaround11pH)withintheirprohibitivedischargeregulations.
Inthesecases,theinstallationofalimestonefilledneutralizationtankwillnotbesufficienttomeetthedischargeparam-
etersassetforthbytheauthority.ThedesignerwillberequiredtoinstallanautomaticinjectionpHneutralizationsystem
whichwilltreat/neutralizebothhighandlowpHlevelsenteringthesystemtank(s)priortodischargeintothesanitaryor
surfacewatersystem.Shouldyourfacilityrequirethedesignofanautomaticinjectionsystem,pleasecontactyourlocalGF
PipingSystemAreaSalesManagerorgotowww.gfpiping.comfordesignassistance.
31
ManyauthoritiesrequirethefacilitydischargingintotheirsystemstovalidatethefacttheireffluentwastestreampHfalls
withinthepermittedlevels.ThisrequiresamonitoringpHprobetobeinstalleddownstreamoftheneutralizationtankor
system.ThispHprobeiswiredbacktoacontrolpanelwheretheeffluentlevelsarerecordedforreviewbytheAHJ.
Important Note Regarding the Design of Corrosive Waste Piping Systems
Designprofessionalsarebeingaskedtospecifycertainpipingsystems,thedocumentationofwhichstatethefacilities
personnelmustdischargeun-specifiedamountsofcleanwaterintosaidsystemwheneveranychemicalwasteisdisposed.
TheNPDESandallAHJdischargepermitsasreferencedaboveclearlystatethefollowingwithregardstoafacility’s
effluentwastestreamtreatmentpriortodischarge:
“Dilutionprohibitedassubstitutefortreatment.Exceptwhereexpresslyauthorizedtodosobyanapplicable
PretreatmentStandardorRequirement,noindustrialUsedshalleverincreasetheuseofprocesswater,or
inanyotherwayattempttodiluteaDischargeasapartialorcompletesubstituteforadequatetreatment
toachievecompliancewithaPretreatmentStandardorRequirement.TheControlAuthoritymayimpose
masslimitationsonIndustrialUserswhichareusingdilutiontomeetapplicablePretreatmentStandardsor
Requirements,orinothercaseswheretheimpositionofmasslimitationsisappropriate.”
Thedischargeofcleanpotableorprocesswaterinanattempttoneutralizewastestreamswhether“dumped”intothe
pipingsystemor“piped”intoaneutralizationtank.Thisaddedflowstreammayaffectthedesignparametersofthe
neutralizationsystemand/orunnecessarilyoverburdenthemunicipalorsurfacewaterconveyancesystem.
32
Sample Specification - Neutralization and pH Monitoring System
Section 226600 - Neutralization and pH Monitoring Systems
Part 1 - General
1.1 Section IncludesA. InstallationofpHmonitoringsystemaspartofthefacilityspecialwastepipingsystemasspecified
underSection____________.
1.2 Submittals A. Submitmanufacturer’sproductdata,includinginstallationinstructions,drawingoftankwith
mountingdetailsandinlet/outlet/ventlocationsandconnectiontypes.
B. Closeoutsubmittals:Provide5setsofoperationandmaintenancemanuals.
Part 2 - Products-Materials
2.1 pH Monitoring StationA. ThepHelectrodeshallbeGeorgFischerSignetLLCDryLoc®partno.3-2726-10withprotected
glassbulbinstalledtogetherwithaSignetDryLoc®Preamplifierpartno.3-2760-1.Maximumcurrentshallbe<1mAdualsupply.ConnectionbacktopHanalyzershallbeprovidedvia6conductorfoilshieldcable.
B. ThepHtransmittershallbeGeorgFischerSignetLLCmodelno.8750-2manufacturedforpanelmountinstallation.TransmittershallbedesignedtoacceptsignalfrompHsensorandconvertsametoameasuringrangeof0-14pHshownonadigitaldisplay.Transmittershallbeprovidedwithtwoalarmrelays(highandlowpHlevels),systemerrorLED,pushbuttoncontrolandcalibrationcapabilityanda4–20mAoutputsignalforconnectiontothesystemchartrecorder.
C. Thechartrecordershallbeacirculartypewithmaximum10”diametercharts.Recordershallbemanufacturedforpanelmountinstallation,designedtoreceivea4–20mAsignalfromthepHtransmitter.RecordershalldocumenteffluentpHsystemlevelsonapre-printed7day/0–14pHscaledchartusingredinkpencartridges.Systemmanufacturershallprovide100pre-printedcharts.
D. Thecontrolpanelshallbecompletelypre-wired,pre-assembledandpre-testedpriortodelivery.ThecabinetshallbeaNEMAIVtypeenclosurereadyforwallmounting.Thepanelfrontshallbehingedwithmeansoflockingprovided.Panelpowerrequirementstobe120Vsinglephase20amp.Thepanelcomponentsshallbeasfollows:
•pHtransmitter•Circularchartrecorder•pHoutofspechigh/lowlight•Systemon/offswitch/light•Alarmtestandsilencebuttons•Alarmhorn
33
E. Theu-trapassemblyshallbemanufacturedofpolypropylenepipeandfittingsjoinedbytheelectro-fusionmethod.Inletsideofthetrap(connectedtotankoutletpiping)istohaveanextendedsectionwhichwillhousetheeffluentpHprobe.ThepurposeofthisunitistomaintainapocketofeffluentwhichallowsthepHprobetoremainwetwhileensuringtheflowstreampassesbytheprobe.Theinletandoutsidesoftheunitshallbeprovidedwithconnectionsasshownonthecontractdocuments.
F. CompletesystemasdescribedhereinshallbeType530pHMonitoringSystemasmanufacturedbyGFPipingSystems,TustinCA.
Part 3 - Execution
3.1 InstallationA. Allcomponentsandinstrumentationshallbefurnished,readyforinstallationfromasinglesource.
B. Themonitoringsystemshallbeinstalledinstrictaccordancewiththemanufacturers’
C. Recommendationsanddrawings,incompliancewithprojectspecificationsandallstate/localcodes.
D. Contractorshallberesponsibleforinstallingallcomponentsofthesystem(U-trap,pHprobe).
E. Siteelectricalcontractorshallberesponsibleformountingcontrolpanel,providingpowerfeedtocontrolpanel,andwiringpHprobefromU-trapassemblylocationtocontrolpanel.
3.2 System Start-upA. Allcomponentsandinstrumentationshallbefurnished,readyforinstallationfromasingle
source.
B. Themonitoringsystemshallbeinstalledinstrictaccordancewiththemanufacturers’recommendationsanddrawings,incompliancewithprojectspecificationsandallstate/localcodes.
C. Systemcalibrationshallbeconfirmedbythesystemmanufacturerensuringtheinstalledsystemisinproperworkingorder.
3.2 System WarrantyD. Allcomponentsandinstrumentationprovidedbythemanufacturershallbewarrantedagainst
defectsinworkmanshipandmaterialforaperiodofoneyearfromthedateofdelivery.
34
Electrofusion Procedure - Fuseal® PP (1½” to 6”)
Joint Preparation
1. Cut pipe end squarewithaxisofpipe.Useafinetoothhandsawandmitrebox,apowerchop/cut-offsawwithabladeforcuttingplasticsorawheeltypeplasticpipecutter.Donotuseratchet-typecutters!
2. Remove all burrs from pipe end.Chamferthepipeendtoeaseinsertionofthepipeandtopreventthefusioncoilfrombeingdamaged.
3. Using a clean, dry cloth wipe the pipe surface and inside of fitting socketfreeofalldebris.Donotremovefusioncollarfromfitting.Iffusioncollarwasremoved,thentheinsideofthefusioncollarhastobewipedcleanedpriortoputtingitbackontothefittingsocket.
4. Sand the pipe surfacewhereitentersthefittingsocket.Usea60gritabrasivecloth.
5. Clean sanded pipe surface and inside of fitting socket with 70% Isopropyl Alcohol Solution(i.e.IPA).Allowthesurfacestodrybeforeinsertingpipeintosocket.(Pleaseseesupplier’sMaterialSafetyDataSheetsforproperuseandsafetyregulationsofIsopropylAlcohol.)
NOTE: Donothandlethefreshlycleanedsurfacesbeforeassembling.
6. Mark socket depthonthepipe.
Fitting Socket Depth
inches cm1½” 7⁄8 2.2
2” 1 2.5
3” 11⁄16 2.7
4” 11⁄16 2.7
6” 19⁄32 3.3
Setting Up Joints 1. Rotate the fusion collarforeasyaccesstotheduplexreceptacle.
2. Rotate the plastic clamptoorienttheratchetclosuretotherightorleftoftheduplexreceptacle.For6”joints,fitthesteelclamptoorienttheT-handletotherightorleftoftheduplexreceptacle.
3. Insert the pipe into the fitting socket and push to the pipe stop.Thepipemustbefullyinsertedintothefittingsockettothepipestop.Rotatethecollarsothesocketdepthmarkisvisiblewhenlookingattheduplexreceptacle.Checksocketdepthmarktobesurethepipeisfullyinserted.
4. The fusion collar must be fully seated on the hub of the fitting socket. Thiscanbeeasilycheckedvisuallyifthereisagapbetweenthefusioncollarandthefitting.Tapthefusioncollarcarefullyonthetop,forexamplewithachannellockpliers,ifitisnotfullyseatedinthefitting.Amarkcanbeappliedtothebottomofthecollartoverifyproperseating.Thegapisnotvisibleon6“fusioncollarswithsteelbandclamps,sothemarkisrequired.
5. Tighten the clamp.Properclamptightnesswillresultwhenthepipecannotbeeasilyrotatedinthefittingsocket.
• Channel-lock#440pliersworkwellfor1½“,2”and3”plasticclamps.
• Channel-lock#460pliersworkwellfor4”plasticclamps.
• For6”only:TightenthesteelbandclampusingtheT-handle.
NOTE:Clampdoesnotpreventpipefrombeingpulledoutduringhandling.
6. Check the continuity of every fusion collar with the continuity tester before fusing. Agreenlightwillindicateagoodfusioncollar.
7. Connect the factory-supplied fusion cables to the duplex receptacle of the fusion collars. Checkhowmanyjointsarepossibleperfusioncycle.
35
8. Tighten the band clamps within 30 seconds after the fusion cycle is finished.
• For1½”–4”,compresstheratchetclampclosureonthebandclamp;donotexceed1to2clicks.Iftheclamp
breaks,replaceimmediately.
• For6”only:Tightenthesteelbandclampapproximatelyonefullturn.
9. Allow the joint to cool to the touch before testing.
• Theplasticclampsfor1½”–4”canstayonthefittings.Ifyoumustremovethem,waitforthejointtocooland
removewithcaution,astheclampisunderpressureandmayfracture.
• Thesteelbandclamponthe6”fittingscanberemovedafteracoolingtimeof10minutes.
36
Electrofusion Procedure - Fuseal® LD (8” to 12”)
Joint Preparation
1. Cut pipe end squarewithaxisofpipe.Useafinetoothhandsawandmitrebox,apowerchop/cut-offsawwithabladeforcuttingplasticsorawheeltypeplasticpipecutter.Donotuseratchettypecutters!
2. Remove all burrs from pipe end.Chamferthepipeendtoeaseinsertionofthepipeandtopreventthefusioncoilfrombeingdamaged.
3. Using a clean, dry cloth wipe the pipe surface and inside of fitting socketfreeofalldebris.Donotremovefusioncollarfromfitting.Iffusioncollarwasremoved,thentheinsideofthefusioncollarhastobewipedcleanedpriortoputtingitbackontothefittingsocket.
4. Sand the pipe surfacewhereitentersthefittingsocket.Usea60gritabrasivecloth.
5. Clean sanded pipe surface and inside of fitting socket with 70% Isopropyl Alcohol Solution(i.e.IPA).Allowthesurfacestodrybeforeinsertingpipeintosocket.(Pleaseseesupplier’sMaterialSafetyDataSheetsforproperuseandsafetyregulationsofIsopropylAlcohol.)
NOTE: Donothandlethefreshlycleanedsurfacesbeforeassembling.
6. Marksocketdepthonthepipe.
Fitting Socket Depth
inches cm8” 17⁄8 4.7
10” 2¾ 6.9
12” 2¾ 6.9
Setting Up Joints1. Insert the pipe carefully into the fitting socket with fusion coil.Pushinuntilpipeendtoucheslargeshoulder.Check
socketdepthmarktobesurethepipeisfullyinserted.
2. Fit two steel band clamps around the fitting or socket flush to the end and at an angle of 90° from each other. Properclamptightnesswillresultwhenthepipecannotbeeasilyrotatedinthefittingsocket.
NOTE:Clampdoesnotpreventpipefrombeingpulledoutduringhandling.
3. Check the continuity of every fusion collar with the continuity tester before fusing. Agreenlightwillindicateagoodfusioncollar.
4. Tie a loop at the end of the fusion cables and loop it onto the T-handle of the clamp. Afterward, connect the cable connectors to the male plug of the fusion coils. Thispreventsthewiresofthefusioncoilfrompullingoutduringthefusionprocess.
NOTE:Amaximumof2jointsarepossibleperfusioncyclefor8“through12“fittings.
5. Allow the joint to cool to the touch before testing.
• Thesteelbandclampsonthefittingscanberemovedaftercoolingfor10minutes.
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Electrofusion Procedure - Fuseal 25/50™ PVDF (1½” to 6”)
Joint Preparation
1. Cut pipe end squarewithaxisofpipe.Useafinetoothhandsawandmitrebox,apowerchop/cut-offsawwithabladeforcuttingplasticsorawheeltypeplasticpipecutter.Donotuseratchettypecutters!
2. Remove all burrs from pipe end.Chamferthepipeendtoeaseinsertionofthepipeandtopreventthefusioncoilfrombeingdamaged.
3. Clean pipe surface and inside of fitting socket with 70% Isopropyl Alcohol Solution(i.e.IPA).Allowthesurfacestodrybeforeinsertingpipeintosocket.(Pleaseseesupplier’sMaterialSafetyDataSheetsforproperuseandsafetyregulationsofIsopropylAlcohol.)
NOTE: Donothandlethefreshlycleanedsurfacesbeforeassembling.
4. Mark socket depthonthepipe.
Fitting Socket Depth
inches cm1½” ¾ 1.8
2” 7⁄8 2.2
3” 15⁄16 2.3
4” 15⁄16 2.3
6” 1¼ 3.2
Setting Up Joints 1. Fit the appropriate steel band clamp over the fitting and turn for easy access, depending on the installation location.
2. Insert the pipe into the fitting and push to the pipe stop. Thepipemustbefullyinsertedpasthecoiltothepipestop.Checksocketdepthmarktobesurethepipeisfullyinserted.
3. Tighten the steel band clamp. Theclampshouldbetightenedsufficientlytopreventanymovementofthepipeorfitting.Properclamptightnesswillresultwhenthepipecannotbeeasilyrotatedinthefittingsocket.
4. Check the continuity of every fusion collar with the continuity tester before fusing. Agreenlightwillindicateagoodfusioncollar.
5. Connect the factory-supplied fusion cables to the plugs of the fusion coils. AttachthecableconnectorswithVelcroself-grippingstrapstothepipe,topreventthefusionwiresfrompullingoutduringthefusionprocess.
NOTE:Checkhowmanyjointsarepossiblepercycle.
6. Allow the joint to cool to the touch before testing.
• Thesteelbandclampsonthefittingscanberemovedaftercoolingfor10minutes.
38
Fusion with the Electro Plus® or MSA 250 Fusion Machine1. Ensurethatthemachineisstandingfirmlyandtheventilatorsorcoolingdeviceshaveanunobstructedairflow.
2. PlugthepowercordintoadedicatedACpowersource:
Electro Plus®
Volts 100to130VAC@60Hz
200-250VAC@50Hz
InputCurrent 15ampsMax.
LengthofPowerCord 150‘Max.(10gauge/3strand)
MSA 250SE
Volts 90to130VAC@60Hz
InputCurrent 15ampsMax.
LengthofPowerCord 150‘Max.(10gauge/3strand)
MSA 250 Multi
Volts 200-250VAC@50Hz
InputCurrent 15ampsMax.
LengthofPowerCord 150‘Max.(10gauge/3strand)
Fusion process using the Electro Plus® fusion machine1. SwitchtheElectroPlusmachinetoon.
Whenpoweredup,theLCDwillshowGEORGEFISCHERfollowedbyinformationaboutthefirmware.Thisstartuptakesabout10seconds.Afterwardsthemainmenuwillbedisplayedasshownbelowandthemachineisreadytouse.
TheElectroPlus®fusionmachinerunsasystemstartupcheckeverytimewhenswitchedon.Themachineautomaticallyconfiguresitselfforthevoltageitisconnectedto,andadjustsfortheambienttemperature.
2. Connectthefusioncablestotheduplexconnectorofthefittings.(Makesureyounotethenumberofjointsallowedpercycle).AgreenlightintheplugofthefusioncableandanumberdisplayedintheLCDindicatesthecableisconnectedandthefusioncoilhascontinuity.Ifalightdoesnotilluminate,thecoilispossiblydamagedandhastobereplaced.
3. Onceeverythingissetupcorrectly,presstheredFUSEbuttontostartthefusion.Redlightsinthefusionplugsindicatethefusionisinprogress.TheremainingfusiontimeandtheinputlinevoltageisshownontheLCD.
NOTE:(SeetheseparateinstallationinstructionsforthecorrectinstallationoftheGFproductbeingfused)
4. Afterthefusiontimeisup,greenlightsinthefusionplugswillilluminateand“FusionOK”messageontheLCDwillappear.
5. Allfusioncablesmustbedisconnectedfromthefittings.
NOTE:(Machinewillnotacceptadditionalfusionpromptsuntilcontinuityisbroken)
6. Allowthejointtocooltothetouchbeforetesting.
• Thesteelbandclampsonthefittingscanberemovedaftercoolingfor10minutes.
7. Ifanerroroccurs:
• Aftercheckingthecausefortheerrorduringthefusioncycle,eraseitfromthedisplay.Iftherearemultiple
fittingsfusedatthesametime,thenumberoftheconnectorsthatfailedwillblink.Alltheotherfittingswerefused
properly.
• Disconnectallthefusioncables
• Pressthebackbutton
39
Fusion process using the MSA 250 fusion machine1. AfterpluggingintheMSA250,thedisplayshows4dashes(----)indicatingthemachinehasstartedupandisreadyto
fuse.
NOTE:TheMSA250FusionMachinesoperateinthefollowingtemperaturerange:+14°F(−10°C)to+113°F(+45°C).Ifitisoutofthisrange,E5orE6isshownonthedisplay.
2. Selecttheappropriatebarcode(i.e.correctmaterialandsize)andscanthebarcodewiththebarcodereader.Thebarcodereaderoperatesbestwhenheldatanangleof10°–30°fromtheverticalpositionandisrunacrossthebarcodestripinonecontinuousmovement.
NOTE:Treatthebarcodereaderpenwithcare!
3. Thefusionunitscreenwilldisplaythetimerequiredforthefusion.Aftertheappropriatebarcodeisreadandthefusioncablesareconnectedtothefittings,thegreenlightwillilluminateonthedisplayoftheMSA250.
4. Ifeverythingissetupcorrectly,pressthestart/stopkeyontheMSA250fusionunit.Oncethefusioncycleisstarted,thetimewillcountdownuntilzeroisreached.Tointerruptthefusioncycle,pressthestart/stopkeyagain.
Thefusiontimereadonthedisplaycanbeafewsecondsdifferentfromthetimeonthebarcodecard,dependingontheambienttemperature.Thisisanadjustmentthatthemachinedoesautomatically.
5. Theaudiblehornsoundswhenthefusioncycleisfinished.Thefollowinginformationshowsalternatelyonthedisplayafterasuccessfulfusioncycle:
E0indicatesnoerrors.Alistoferrorcodesiswiththebarcodescards,intheinstructionmanualoftheMSA250,andinthistrainingdocumentation.
10‘indicatesacoolingtimeof10minutes,dependingonthedimensionandmaterial.
7.9indicatestheenergywhichwasusedforthefusioncycleinKJ(Kilojoules),dependingonthedimension,materialandhowmanyfusioncablesareconnected.
ThefusioncablescanberemovedfromthefittingsifE0isshownonthedisplay.Ifanerrorcodecomesup,checkwhatthiscodeindicatesandsolvetheproblembeforeyoudothenextfusion.Itmightbenecessarytore-fusethisjoint.
6. Allowthejointtocooltothetouchbeforetesting.
• Themachinedisplaywillindicatetheapplicablecoolingtime.
7. Special-Ifthebarcodereaderpenbreaks,itispossibletoenterthefusionvoltageandtimemanuallyusingthefollowingprocedure:
Enteringthefusiontime:
• PresstheUPkeyapproximately1second.Theunitisnowintheprogrammingmode.Thedigittobeprogrammed
willblink.Channel-lock#440pliersworkwellfor1½“,2”and3”plasticclamps.
• PresstheUPkeyseveraltimesuntilthedesirednumberappearsonthedisplay.Witheverypushofthekey,the
activedisplaymovesuponeposition.0,1,2,3…9,0.
• ThenextdigitisreachedbypressingtheUPkeyforapproximately1second.
• Repeatsteps2and3untilall4digitsareinserted.
• Bypressingandholdingonthelastdigit,theinputisconfirmedandtheprocesscontinueswiththeinputofthe
fusionvoltage.
Enteringthefusionvoltage:
• Enteringthefusionvoltageworksthesameasenteringthefusiontime.Thefusionvoltageisdisplayedinvolts.Itcanbeprogrammedtoanaccuracyof0.1volts.Bypressingandholdingonthelastdigit,theinputisconfirmedandtheMSA250SEreadyforfusion.
40
Mechanical Joint Procedure - Fuseal® MJ (1½” to 4”)
Joint Preparation
1. LubricatethreadsoffittingwithasiliconebasedlubricantsuchasDowCorning111.
2. Slidenutandgrabberringoverpipe,withtaperedsideofgrabberringfacingthenut.
3 Slideo-ringoverpipe,approx.¾”fromtheend.
4 Insertpipeintosocketbottom,thenslidegrabberringagainsto-ring.
5 Tightennutbyhand,thenwithourspannerwrench(P/N8100for1½”–2”,P/N8101for3”–4”)untiljointissecurelytightened.Thisisachievedwhenthespannerwrench“pops”offthenutridges.
41
Electro Plus® Electrofusion UnitAdvantages
•Intuitiveuserinterface•Multiplejointcapabilityforspeedyinstallations•Integralcarryingcaseforeaseoftransportation•Networkandgeneratorcompatibleforsimpleoperation•Self-diagnosticsystemtakestheguessworkoutoferror
detection•Automaticcompensationforambienttemperature•One-buttonrepeatfusioncycleforsamesizejoints
Applications
TheElectroPluscanbeusedtojointhefollowingpiping
systems:
•Fuseal®PPFRandPPNFR(1½”–12”)
•Fuseal25/50™PVDF(1½–6”)
Electrofusion ProcessElectrofusionisdefinedasthejoiningprocesswheretwoplasticpartsarefusedutilizingelectricalheatresistancetoform
apermanentjoint.
Aplastic-coatedcopperwireiswoundintoa“coil”andistheninsertedintoafittingsocket.
Thepipeistheninsertedintothefittingsocketandanelectriccurrentisappliedtothecoilproducingheatthatgenerates
sufficienttemperaturestomeltthesurroundingplasticandcreatea“meltzone.”
Fusionoccurswhenthejointcoolsbelowthemelttemperatureoftheplasticmaterial,leavingapermanentjointthatis
proventobeasstrongas,ifnotstrongerthan,theindividualcomponents.
Thecomputersimulationshowstheheatdistributionaroundthe“meltzone”region.
Melt Zone Computer Simulation
42
Multiple Joint Capability
TheElectroPlushasthetimeandlaborsavingfeaturesofmultiplejointfusion.Multiplejointcapabilitysignificantlyreduces
installationtimeandcontributesdirectlytoyourbottomline.
Electro Plus® SpecificationParameter Requirement
InputVoltage 100–130VAC,60HzACRMSor200–250VAC,50HzACRMS
InputCurrent 15AmpsMax
OutputVoltage 0to28.5VACgalvanicallyseparated
OutputCurrent 0to50Amps
PowerConsumption 1,200WattsMax
GeneratorOutputPerformance
3,500WattsMin
FuseRequirement (1)15ampceramicslo-blo(2)7ampceramicslo-blo
OperatingTemperature 14˚F(−10˚C)to113˚F(45˚C)
Dimensions Width:22in(56cm)Depth:14in(36cm)Height:10in(25cm)
Weight 45lbs(20.5kg)
PowerCableLength 5ft.(1.5m)
FusionCableLength 18ft.(5.5m)
RemoteControlCableLength 20ft.(6m)
ExtensionCordRequirements
150ft(46m)maximumlength10gauge/3strandminimum
Calibration Requirements:Therearetwocomponentsthatrequirecalibration.Thefusioncablerequiresanannualcalibrationandthefusionpower
unitrequirescalibrationeverytwoyears.Thisiseasytomanagebecausetheunititselfremindstheuserthatcalibrationis
due.
Errors that can occur before the fusion cycleError Message Cause/Remedy
"TOO COLD TO FUSE" Theambienttemperatureisbelow14°F(−10°C).
"TOO HOT TO FUSE" Theambienttemperatureisabove113°F(45°C).
"TOO MANY FITTINGS" Disconnectallfittingsfromfusioncables.Checkhowmanyfittingscanbeconnectedforthesize,thenreconnecttherightnumberoffittingsandpress"FUSE."
"SSR TOO HOT" SolidStateRelaytoohot.Allowthemachinetocoolfor5minutesandtryagain.
"XMFR TOO HOT" Transformertoohot.Allowthemachinetocoolfor5minutesandtryagain.
"FUSION ERROR COIL SHORTED" Coilinfittingisshorted.Disconnectallfittingsfromthefusioncables.Replacedamagedcoilsifnecessary.
Errors that can occur during the fusion cycleError Message Cause/Remedy
"HI VOLTS EXCURSION" Outputvoltageabovetherange.Verifytheinputpowersupply.
"LO VOLTS EXCURSION" Outputvoltagebelowtherange.Verifytheinputpowersupply.
"CAN'T REGULATE" Unabletomaintainoutputvoltage.Verifytheinputpowersupply.
"FUSION TERMINATED COIL SHORTED"
Coilinfittingshortedduringthefusion.Disconnectallfittingsfromthefusioncables.Replacedamagedcoilsifnecessary.
43
Errors that can occur after the fusion cycleError Message Cause/Remedy
"COIL FAILURE" Afusioncablehasbeendisconnectedduringthefusioncycleorafusioncoillostcontinuity.Thecablenumber(1–4)forthefailedcoilwillblinkontheLCDscreen.
44
MSA 250SE, MSA 250EX Multi Electrofusion Unit
Advantages•Barcodefusionparameterinput•Multiplejointcapability•Advancedtransformertechnology•Networkandgeneratorcompatible•Selfdiagnosticsystem•Automaticcompensationforambienttemperature
Applications
TheMSA250canbeusedtojointhefollowingpiping
systems:
•Fuseal®PPFRandPPNFR(1½”–12”)
•Fuseal25/50™PVDF(1½”–6”)
Barcodes also provide the capability to perform program updates for new products in the field.
Electrofusion ProcessElectrofusionisdefinedasthejoiningprocesswheretwoplasticpartsarefusedutilizingelectricalheatresistancetoform
apermanentjoint.
Aplastic-coatedcopperwireiswoundintoa“coil”andistheninsertedintoafittingsocket.
Thepipeistheninsertedintothefittingsocketandanelectriccurrentisappliedtothecoilproducingheatthatgenerates
sufficienttemperaturestomeltthesurroundingplasticandcreatea“meltzone.”
Fusionoccurswhenthejointcoolsbelowthemelttemperatureoftheplasticmaterial,leavingapermanentjointthatis
proventobeasstrongas,ifnotstrongerthan,theindividualcomponents.
Thecomputersimulationbelowshowstheheatdistributionaroundthe“meltzone”region.
Melt Zone Computer Simulation
Fusion Barcodes
AllrequiredfusionparametersareprogrammedintotheMSA250bysimplyscanningabarcodespecifictoeachsizedjoint.
Multiple Joint Capability
TheMSA250hasthetimeandlaborsavingfeaturesofmultiplejointfusion.Multiplejointcapabilitysignificantlyreduces
installationtimerequirementsandcontributesdirectlytoyourbottomline.
45
MSA 250 SpecificationPart Number MSA 250-SE MSA 250-EX Multi
InputVoltage 90–130VACNominalVoltage:110V/Generator:110–120VACNominalVoltage
200–250VACNominalVoltage:230V/Generator:210–230VACNominalVoltage
InputCurrent 15Amps 15Amps
OutputVoltage 0to45VAC 0to45VAC
OutputCurrent 0to30Amps 0to30Amps
PowerConsumption max.1200Wnominaloutput max.1200Wnominaloutput
GeneratorOutputPerformance 2KVASinusoidalunipolaroperation)dependingonthefittingdiameter
2KVASinusoidalunipolaroperation)dependingonthefittingdiameter
Back-upFuse 10–16ATdependingonthefittingsize 10-16ATdependingonthefittingsize
FusionVoltage 3,7-32VACgalvanicallyseparated 3,7-32VACgalvanicallyseparated
ProtectionType Protectionclass1/IP65 Protectionclass1/IP65
OperatingTemperature 14˚F(−10˚C)to113˚F(45˚C) 14˚F(−10˚C)to113˚F(45˚C)
OperationTime 24%-100%dependingonthefittingsize,withelectronictemperaturemonitoringoftheunit
24%-100%dependingonthefittingsize,withelectronictemperaturemonitoringoftheunit
DutyCycle 100% 100%
Dimensions Width:11in(280mm)Depth:77/8in(200mm)Height:133/4in(350mm)(measuredinc.carryinghandle)
Width:11in(280mm)Depth:77/8in(200mm)Height:133/4in(350mm)(measuredinc.carryinghandle)
Weight 25lbs(11.5kg)(withcables) 25lbs(11.5kg)(withcables)
PowerCableLength 10ft.(3m) 10ft.(3m)
ExtensionCordRequirement 150ft(46m)maximum 150ft(46m)maximum
Calibration Requirements:TheMSA250fusionmachineneedstobecalibratedandservicedeveryyearaccordingtotheservicelabelonthemachine.
46
MSA 250 Error CodesNot Description Comments
E2 MAINSVOLTAGETOOHIGH Checkgenerator,110VACNominal
E5 AMBIENTTEMP.TOOLOW Mustbebetween+14°F/+113°F
E6 AMBIENTTEMP.TOOHIGH Mustbebetween+14°F/+113°F
E7 INTERNALTEMP.TOOLOW AllowMSA250towarmupinaheatedroom
E8 INTERNALTEMP.TOOHIGH AllowMSA250tocooloff
E9 FITTINGRESISTANCETOOLOW Checkfitting.(Displayswitchesbetweenerrorcodeandmeasuredresistance)
E10 FITTINGRESISTANCETOOHIGH Checkfitting.(Displayswitchesbetweenerrorcodeandmeasuredresistance)
E11 FUSIONVOLTAGETOOLOW Checkgeneratoroutput/extensioncable
E12 FUSIONVOLTAGETOOHIGH Ifthisoccursfrequently,sendMSA250inforservicing
E13 FUSIONCIRCUITINTERRUPTED CheckthepowercableTodismissthiserrormessage,switchoffMSA250
E14 FUSIONCURRENTTOOHIGH Damagedcoil.Ifthisoccursfrequently,returnMSAforservicing.
E15 POWERSUPPLYTEMP.TOOLOW AllowMSA250towarmupinaheatedroom
E16 POWERSUPPLYTEMP.TOOHIGH AllowMSA250tocooloff
E21 OUTAGEDURINGLASTFUSION Checkthelastfusionoperation
E22 FUSIONINTERRUPTEDWITHSTOP Checkthelastfusionoperation
E28 UNITRANGEEXCEEDED UseafittingwhichcanbejoinedwiththeMSA250
E71 SYS.-ER.MEASUR.AMBIENTTEMP. SendMSA250inforservicing
E74 FUSIONPOWERTOOLOW Checkthegeneratoroutput/extensioncable
E75 FUSIONPOWERTOOHIGH Allowedfusion-powerexceeded.UseMSA250SEwithlessfittingsinparallel.
E78 POWERSUPPLYERROR SendMSA250inforservicing
E100 FUSIONPROGRAMINCORRECT UseabarcodefromthestandardISO/TR13950
E101 WRONGBARCODETYPE UseabarcodefromthestandardISO/TR13950
E102 CONFIGURATIONERROR SendMSA250inforservicing
E103 RESISTANCEMEASUREMENTERROR DisconnectMSA250andfittingfromthegenerator,checktheconnection
E104 VENTILATORERROR Checkventilatoropening.Ifunobstructed,sendMSA250forservicing
47
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