Electrofusion Welding Machine

Description

Barcode-Driven Parameter Automation The integration of an industrial-grade barcode scanner allows for the automatic identification of pipe fitting specifications, including voltage, heating time, and cooling cycles. This eliminates the risk of manual input errors by on-site operators, ensuring that every joint is processed according to the manufacturer’s precise thermal requirements to maintain structural integrity.
Comprehensive Data Logging and Traceability Equipped with an internal memory for up to 2,000 welding cycles and an integrated thermal printer, the system records essential data such as operator ID, fusion parameters, and timestamps. This provides verifiable evidence of construction quality that meets ISO 12176-2 standards, facilitating seamless project inspection and long-term asset management for municipal authorities.
Wide-Range Voltage Stabilization The power system features an adaptive input range of 180V–250V with automatic voltage compensation, specifically designed for site conditions where field generators may fluctuate. By stabilizing the energy output during the fusion process, the machine prevents inconsistent melt zones, ensuring stable welds even in remote or unstable power environments.
Compact Structural Design for Narrow Trenches Unlike bulky butt fusion equipment, this electrofusion welder features a compact, lightweight metal chassis designed for high portability. This allows technicians to perform reliable jointing in confined spaces, such as narrow underground trenches or urban utility galleries, significantly reducing the need for extensive excavation and site preparation.
IP54-Rated Environmental Protection The rugged metal enclosure is rated at IP54 and tested for operation in ambient temperatures ranging from -15°C to +50°C. This protection level ensures the internal electronics remain functional against dust ingress and water splashes, minimizing equipment downtime and maintenance costs in harsh construction environments.
Multi-Material and Universal Fitting Compatibility The control software and multi-purpose connectors are compatible with all major brands of electrofusion fittings across SDR11 and SDR17 pressure ratings. This versatility allows contractors to use a single unit for HDPE, PP, and PVDF piping materials, optimizing equipment ROI and simplifying logistics across diverse engineering projects.
Digital Monitoring and Real-Time Error Detection The system continuously monitors electrical current and temperature throughout the welding cycle, providing immediate alerts if deviations occur. By automatically terminating the process during a fault, it prevents the completion of compromised joints, thereby reducing the long-term risk of leaks and environmental contamination in gas and water networks.
Sustainable Material Processing Designed for use with recyclable HDPE and PP pipes, this welding method requires no chemical adhesives or additional solvents. The resulting homogenous joint maintains the same chemical resistance as the pipe itself, ensuring the longevity of the pipeline system while supporting sustainable infrastructure development goals.

Product Manual

Welding Machine - Product Manual

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Scope of application

Municipal Gas Distribution Networks Engineered for joining PE80/PE100 gas pipes in urban distribution. Ensures high-pressure gas containment with zero-leakage performance. Automated data logging meets strict municipal safety audits and international ISO standards for buried gas infrastructure, providing full traceability for combustible media transport.
Potable Water Supply Systems Ideal for HDPE drinking water mains and distribution lines. Ensures homogenous, leak-proof joints under fluctuating network pressures. The machine facilitates safe transport of potable water and neutralized wastewater, providing durable connections for municipal utility projects with verifiable pressure-test data.
ndustrial Chemical Piping Used for welding PP, PP-R, and PVDF pipes in chemical processing plants. Facilitates the safe transport of corrosive media like weak acids and alkalis. Stable output in temperatures from -15°C to +50°C ensures joint integrity in demanding industrial environments and factory discharge systems.
Mining and Slurry Pipelines Designed for heavy-duty HDPE pipe jointing in mining dewatering and slurry transport. Built-in voltage stabilization allows reliable performance using field generators in remote sites. IP54 rating ensures the equipment survives high-dust and high-moisture conditions typical of open-pit and underground mining operations.
Urban Repair and Trench Maintenance Facilitates rapid repair of underground utilities in confined spaces or narrow trenches. The compact design allows for quick installation of electrofusion repair sleeves on existing HDPE gas or water networks, minimizing service downtime and reducing excavation costs in crowded urban development projects.
Industrial Drainage and Sewage Applied in gravity-fed HDPE drainage networks for rainwater and factory effluent management. Ensures leak-free joints that resist environmental contamination. Maintains the piping system's chemical resistance and homogenous structure, providing long-term reliability for industrial sewage treatment and wastewater discharge infrastructures.

Parameters

Parameter	HDM200	HDM315	HDM500
Welding Range	20mm – 200mm	20mm – 315mm	20mm – 500mm
Input Voltage	190V – 240V	190V – 240V	190V – 240V
Frequency	40Hz – 60Hz	40Hz – 60Hz	40Hz – 60Hz
Output Power	3KW	3KW	4KW
Output Voltage	10V – 48V	10V – 48V	10V – 48V
Control Type	Constant Current/Volt	Constant Current/Volt	Constant Current/Volt
Time Adjust Range	1 – 9999 Seconds	1 – 9999 Seconds	1 – 9999 Seconds
Time Deviation	≤ 1%	≤ 1%	≤ 1%
Relative Humidity	≤ 80%	≤ 80%	≤ 80%
Weight	20kgs	20kgs	25kgs

FAQ

What is an electrofusion welding machine?

An electrofusion welding machine is a specialized digital power control unit designed for joining thermoplastic pipes, primarily HDPE and PP. Unlike manual welding, it acts as a high-precision processor that delivers a specific electrical current to the resistive coils embedded within an electrofusion fitting. This process creates a homogenous, leak-proof bond that is structurally as strong as the pipe itself, making it the standard for high-pressure gas and water infrastructure.

How does an electrofusion welding machine work?

The machine operates on the principle of electrical resistance heating. Once connected to a fitting, the control unit regulates the output voltage based on the fitting's specific requirements. As current flows through the fitting's internal copper coils, it generates controlled thermal energy that melts both the outer surface of the pipe and the inner surface of the fitting. As the molten material expands under pressure within the "fusion zone," the polymer chains intermix, creating a permanent molecular bond upon cooling.

How to use an electrofusion welding machine? (Step-by-Step)

1.Preparation: Square the pipe ends and use a professional mechanical scraper to remove the oxidation layer from the fusion zone. Clean the area thoroughly with 90%+ isopropyl alcohol.
2.Assembly: Mark the insertion depth and push the pipe into the fitting until it hits the center stop. Use clamps to ensure the assembly is stress-free and aligned.
3.Connection: Plug the machine’s output terminals into the fitting’s pins.
4.Programming: Use the industrial barcode scanner to scan the fitting’s barcode; the machine will automatically set the required voltage and time.
5.Fusion: Press "Start." The machine will monitor the process and alert you once the cycle is complete.
6.Cooling: Observe the mandatory cooling time indicated on the fitting before removing clamps or applying pressure.

How do I use an electrofusion welding machine? (Best Practices)

To ensure a successful weld, always verify that your power source (such as a field generator) is stable, as the machine requires consistent voltage for a perfect melt. Before starting, confirm that the pipe is completely dry and free of debris. During the process, monitor the digital display for any error codes related to "ambient temperature" or "resistance fluctuations." Finally, always utilize the data-logging feature to print or export the welding record; this serves as your primary quality assurance document for project handover and municipal inspections.