Caldervale Technology

Manufacturing tools for plastic-based water and gas distribution systems

Frequently Asked Questions

Electrofusion Boxes

A range of electrical units used for joining pipes of all diameters commonly used in the gas and water industries.

Not necessarily, I.P. codes are generally applied to fixed objects, for example a high I.P. rating would be required for example by a permanently fixed box contaning power supplies for exterior lights, this would switch high levels of electrical power, and be fixed to an exterior wall or column exposed to all types of weather, whereas, a control box is only used irregularly and being easily transportable, can be moved undercover should local weather conditions dictate, additionally it is unlikely to be used in heavy rain or floods.

An I.P. rating of IP 55 (number 5 protection against objects as fine as dust with a limited level of intrusion, and number 5 protection against low pressure water sprayed in all directions,) should be ample for a portable control box.

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The I.P. code is a 2 digit number, the first digit is a number between 0 to 6 and is the level of protection against intrusion of a solid (non liquid,) form afforded by the particular product, for example number 0 means no protection or unguarded, number 1 means protection against objects up to 50mm in size for example a hand and so on down to number 6 which means total protection from ingress of any solid form including dust.

The second digit is a number from 0 to 8 and is the level of protection against the entry of a liquid afforded by the object, for example number 0 means there is no protection, number 1 means protection against vertically falling water drops and so on down to number 8 which means total protection from intrusion after long term submersion in water under pressure.

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The other barcode has traceability information regarding the raw material used and the place of manufacture of the fitting. The traceability barcode has a maximum of 26 characters. The fitting data barcode has a maximum of 24 characters.

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The barcode contains information in a format that can be understood by the control box after it has been scanned by a reader wand or scanner, the information is used by the control box to set the fusion time and record other data for example the fitting brand, size etc. The fitting data barcode has a maximum of 24 characters.

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Depending upon the brand of e/f fittings, the connector terminals could be either 4.0mm diameter or 4.7mm diameter, sets of fitting plug adapters are available to allow both sizes to be fused.

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Yes, the Proxima Taurus range with 2 output connector chords will fuse both types of fitting.

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No an 80 volt control box should only be used with 80 volt fittings, in addition the fitting connector plugs will be larger and not connect securely to a 40 volt fitting.

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Yes providing the minimum size of the extension cable conductor wires is the same as the fixed power cable. The maximum length of an extention cable should be no longer than 10 metres.

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At no time should the control box be opened except in a workshop by trained persons.

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Disconnect the control box from the power supply and leave it in a cool place, out of direct sunlight if possible preferably with an airflow.

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Allow the control box an adequately cool down period between fusion cycles, avoid disconnecting the control box from the fitting, but disconnecting from the power supply till the end of the cooling time will help cooling, disconnect the control box from the power supply when not in use, avoid leaving the control box in direct sunlight or near to the exhaust when using a generator. Where a heat radiator is fixed to the enclosure, ensure that it is not obstructed or the fins are clogged with mud.

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The internal power transformer and regulators naturally produce heat when operating, the longer the box is supplying power, the warmer it becomes, also the more power it is supplying, for example when fusing a larger diameter coupler will also effect the temperature, in addition the local air temperature also has an effect.

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The control circuits inside the enclosure start to work erratically when the temperature of the components reaches around 70 degrees, to prevent bad fusion control or excessive/insufficient power being supplied to the fusion, internal safety features prevent the fusion cycle operating.

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At no time should the control box be opened except in a workshop by trained persons.

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Positioning Clamps

Our positioning clamps are designed to hold two or more pipes in place during the electrofusion process to avoid any movement caused by heat expansion or physical disturbance.

Using 2 clamps or holding carriages each side of the fitting on a single base can help greatly in making a good joint.

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A positioning clamp holds the pipes each side of the joint assembly in a fixed position, therefore any movement or twisting on one side of the pipe is transmitted to the other side without disturbing the joint while it is in the cooling and solidification stage. A clamp will also help in assembling a joint made between lengths of curved pipe that have been stored on a coil of drum.

Using a clamp with curved pipe can help manage the curvature and hold the pipe and fittings in alignment.

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At the time of fusion between the pipe and fitting when heating power is being applied and for a time afterwards. The material forming the joint is a molten liquid, as the material starts to cool and solidify into a solid it should not be disturbed or the resulting joint may be imperfect.

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Pipe Preparation Tools

Tools used for surface preparation prior to electrofusion jointing including surface scraping.

Fit the clamp to the out of round pipe near to the end that is to be assembled into the fitting, leave in position for a long as possible (minimum 10 minutes,) remove the re rounding clamp, scrape and prepare the pipe, assemble the joint as quickly and safely as possible, when fully assembled fit, joint into positioning clamp.

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No, using undue force can damage the fitting, also forced contact between the fitting and pipe can pull the thermal heating wire out of the inner wall of the fitting, this can result in a short circuit or other damaging occurance when the fusion cycle is started.

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Out of round (oval,) pipe should be treated with a re rounding clamp to temporarily return it to the correct shape before using a scraping tool and then assemble it into a fitting.

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Providing you are certain that the pipe is being prevented from assembling into the fitting because it is slightly oversize and not because it is out of round (ovality,) then take a second pass with the scraping tool.

The pipe diameter will have been reduced by 0.8mm after the second pass.

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The thickness of the swarf is the same as the depth of the cut of the tool, we set Caldervale Technology branded tools to remove a nominal depth of 0.2mm of material.

As the majority of scraping tools (except hand scraping tool,) rotate around the pipe, the diameter of the pipe being scraped reduces by 0.4mm for every pass of the tool.

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Removing excessive pipe wall makes it undersize, this can prevent correct pressure build up inside the joint at the time of fusion, eventually producing a poor quality joint.

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A hand scraping tool cannot control the depth of cut of the scraping operation, it is difficult to use underneath an already installed pipe leaving patches un prepared, it is energy and time consuming to use.

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Failure to carry our adequate preparation will cause dirt, chemicals and other impurities to enter the fusion zone which can produce a poor quality joint.

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Squeeze Tools

We manufacture both mechanical and hydraulic squeeze tools used to reduce the flow of liquids and gases in plastic pipes.

Yes but they will probably be a special order.

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Using a standard nut cracker model re rounding clamp would probably work for pipes up to 50mm, for pipe sizes 63mm and greater it is necessary to use a Caldervale Technology after squeeze pipe reforming clamp.

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This would be a decision of the pipe manfacturer, the likely answer would be no.

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Yes the 125mm Iron man squeeze tool with hydraulic power.

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We consider the 125mm x sdr11 pipe to be very difficult to close without power assistance.

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Where there is any doubt about the suitability of a particular pipe, always contact the pipe manufacturer before starting.

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Insufficient closure or over closure can occur if the buffer plates are set to the wrong pipe diameter or SDR rating.

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All hydraulic squeeze tools are supplied with anti leak pins which should be screwed down to maintain the squeeze operation independent of the jack.

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Caldervale Technology squeeze tools should give a good level of pipe closure, however where 100% closure is required against an open end, then a double squeeze using 2 squeeze tools approximately 6 pipe diameters apart should be used, to release any build up between the 2 squeeze tools a drain can be connected.

Where a section of pipe is to be removed for example to install a branch tee in a pipeline then a double squeeze off with 2 squeeze tools either side should be considered.

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Insufficient squeeze or over squeeze dependent upon which way round the mistake was made.

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For the same size pipe, sdr 11 pipe will require a larger amount of pressure to close than sdr 17 pipe as the walls are thicker, sdr 17 pipe will require longer travel of the closure squeeze bars on the tool as the distance between the inner pipe walls is greater.

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The sdr rating is the relationship between the thickness of the pipe wall and the pipe diameter, this means that sdr 11 pipe will have a thicker pipewall than sdr 17 pipe, this will usually mean that

(i) sdr 11 pipe has a higher pressure rating than sdr 17 pipe.

(ii) sdr 17 pipe has a bigger internal diameter (bore.)

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Latest News

TUV Rheinland Approval

Monday, February 13, 2012

Our range of electrofusion control units have been awarded the prestigious TUV mark by the German test house TUV Rheinland.

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