fuseal corrosive waste technical handbook

Fuseal®

Corrosive WastePiping SystemsTechnical Reference

Fuseal® PP

Fuseal® PP LD

Fuseal® PP MJ

Fuseal 25/50™ PVDF

Electro Plus®

MSA 250

3

Table of ContentsMaterial Characteristics

GeneralInformation

Fuseal®PPCorrosiveWaste

Fuseal25/50™PVDFCorrosiveWaste

MechanicalProperties

Chemical,WeatheringandAbrasionResistance

ThermalProperties

ElectricalProperties

CompleteSystemofPipe,Fittings

ReliableFusionJoining

ElectrofusionJoining

MechanicalJoining

5

5

5

6

6

6

7

7

7

8

8

8

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)

15

15

Calculating Line Size - Gravity Drain Systems

FlowRateforGravityDrainSystems

16

16

Above Ground Installations

AllowingforLengthChangesinGravityPipelines

CalculationandPositioningofFlexibleSections

DeterminingtheLengthChange

DeterminingtheLengthofFlexibleSections

Restraint

ExpansionJointAssemblies

SupportDuringInstallation

SupportSpacing

Hangers

17

17

17

18

21

22

22

23

23

24

Below Ground Installations

InstructionsforUndergroundTrenching

BeddingandBackfillMaterial

BeddingandBackfilling-ASTMD2321

FusealSoilLoadandPipeResistance

25

25

25

25

26

Cold Weather Installations 27

Flammability and Fire Rated Construction

LaboratoryFireTests

LargeScaleTests

FireProtectionMethods(FusealPPWasteandVentPiping)

27

27

28

29

Testing 29

4

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

34

34

34

Electrofusion Procedure - Fuseal LD (Large Diameter - 8” to 12”)

JointPreparation

SettingUpJoints

36

36

36

Electrofusion Procedure - Fuseal 25/50 PVDF (1½” to 6”)

JointPreparation

SettingUpJoints

37

37

37

Joint Fusion with the Electro Plus® or MSA 250 Fusion Machines

FusionProcessusingtheElectroPlusfusionmachine

FusionProcessusingtheMSA250fusionmachine

38

38

39

Mechanical Joint Procedure - Fuseal® MJ (Mechanical Joint - 1½” to 4”)

JointPreparation1½”to4”

40

40

Electro Plus® Electrofusion Unit

ElectrofusionProcess

ElectroPlusSpecification

CalibrationRequirements

ErrorsthatCanOccurBeforetheFusionCycle

ErrorsthatCanOccurDuringtheFusionCycle

ErrorsthatCanOccurAftertheFusionCycle

41

41

41

42

42

42

43

MSA 250 Electrofusion Unit

ElectrofusionProcess

MSA250Specification

CalibrationRequirements

MSA250ErrorCodes

44

44

45

45

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





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





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

15

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 25/50Schedule40



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


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


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!


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.)


6. Marksocketdepthonthepipe.


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.


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.


• Thesteelbandclampsonthefittingscanberemovedaftercoolingfor10minutes.

37

Electrofusion Procedure - Fuseal 25/50™ PVDF (1½” to 6”)

Joint Preparation

1. Cut pipe end squarewithaxisofpipe.Useafinetoothhandsawandmitrebox,apowerchop/cut-offsawwithabladeforcuttingplasticsorawheeltypeplasticpipecutter.Donotuseratchettypecutters!


3. Clean pipe surface and inside of fitting socket with 70% Isopropyl Alcohol Solution(i.e.IPA).Allowthesurfacestodrybeforeinsertingpipeintosocket.(Pleaseseesupplier’sMaterialSafetyDataSheetsforproperuseandsafetyregulationsofIsopropylAlcohol.)


4. Mark socket depthonthepipe.


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.


5. Connect the factory-supplied fusion cables to the plugs of the fusion coils. AttachthecableconnectorswithVelcroself-grippingstrapstothepipe,topreventthefusionwiresfrompullingoutduringthefusionprocess.

NOTE:Checkhowmanyjointsarepossiblepercycle.



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



MSA 250 Multi

Volts 200-250VAC@50Hz



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.


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.”



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.”



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

Item #1280 (5/2012)©2012GeorgFischerLLCPrintedinUSA

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