Answers to the most frequently asked questions about electrofusion welding machines and the electrofusion welding process.
What is electrofusion welding?
Electrofusion welding is a method of joining pipes and fittings made of PE (polyethylene) using electrofusion fittings. After surface preparation and positioning the fitting, the welder supplies current for a defined time; in the joint area the material melts and after cooling forms a durable, leak-tight connection.
For which pipes are electrofusion welders used?
Labtronik electrofusion welders are used to join pipes and fittings made of PE (polyethylene) in pressure systems – water and gas networks. In such applications PE-HD and PE 100 pipes are commonly used.
How long does a single welding cycle take?
The welding time depends on the type and size of the fitting and on conditions (ambient temperature). The welder reads the barcode from the fitting and automatically sets the parameters; typical times range from several dozen seconds to many minutes, plus cooling time.
How should the pipe be prepared before welding?
The pipe surface must be cleaned (scraped) to the depth and length specified in the fitting instructions, removing the oxidised layer and contaminants. Use a scraper appropriate for the pipe diameter and check the insertion depth (mark on the pipe).
What is a scraper and what is it used for?
A scraper is a tool used to remove the outer (oxidised) layer from the end of a PE pipe before welding. Correct scraping is essential for a durable joint.
Does the welder store welding reports?
Yes. Labtronik PRO welders store data for each weld (time, parameters, result). Reports can be exported to a USB drive in PDF and XLS formats and viewed in the DataLoader program.
Do Labtronik welders have GPS?
A GPS module is available as an option for PRO models (ZK90PRO, ZK160PRO, ZK315PRO, ZK400PRO). When equipped with GPS, the coordinates of the weld location are stored in the report.
How often should the welder be calibrated?
Calibration should be carried out once a year. After repairs or if there are doubts about the correct operation of the welder, it is advisable to have it calibrated by the service centre.
What should I do if the welder reports an error?
Check the message on the screen and the operating manual. Typical causes include poor contact with the fitting, barcode reading error or a power supply problem. If errors recur, contact Labtronik service.
Can welding be carried out at low temperatures?
Electrofusion welding is only possible at positive temperatures (above 0°C). This limitation results from the welding technology itself and does not depend on the welder model or fitting type.
For which pipe diameters are Labtronik welders designed?
The diameter range depends on the welder power. We manufacture devices in four power classes. Details for each model can be found
here.
What is an alignment clamp and why is it used?
An alignment clamp is a device used to precisely centre the pipe inside the fitting before welding. Proper centring ensures an even distribution of the molten material and the durability of the joint.
Do the welders require a 230 V supply?
Labtronik welders are powered from a 230 V AC supply. Before use, make sure the mains is stable and meets the parameters given in the manual. When powering the welder from a generator, units with voltage stabilisation should be used.
How should the welder be stored in winter?
Store the welder in a dry room at a positive temperature. Avoid leaving the unit in frost; during precipitation use tents or rain covers.
Can reports be exported to PDF and Excel?
Yes. PRO welders save welding reports in PDF and XLS (Excel) formats. Files can be copied to a USB drive and opened on a computer or in DataLoader Online.
How should interchangeable heating tips be used?
The welder is supplied with heating tips with diameters of 4.0 mm and 4.7 mm. Before starting welding, make sure that the correct heating tips matching the fitting are installed. The vast majority of fittings have 4.0 mm connectors, but for some manufacturers or larger diameters 4.7 mm may occur. Heating tips must be clean and in good condition. If they fit too tightly or are damaged, replace them immediately.
Where should a Labtronik welder be serviced?
Service, calibration and repairs of Labtronik welders are carried out by the manufacturer. Contact us via the Contact page or by phone; we will be happy to help you choose a date and scope of service.
Are Labtronik welders suitable for non-pressure systems?
Labtronik welders are intended for pressure systems (water supply, gas networks). Pressure and non-pressure systems (e.g. gravity sewer systems) are two different types of application – different standards, requirements and often different types of fittings and devices. They are not interchangeable.
Can the same fitting be welded again if an error occurred during welding?
Electrofusion fittings are in principle designed for a single welding cycle. If an error occurs during the process, the joint should be cut out and re-made using a new fitting. Manufacturers allow the cycle to be restarted only in special cases, such as a power failure, provided that the component has completely cooled down and has not moved. This does not apply to technological errors, incorrect surface preparation or exceeding process parameters. To ensure the durability and safety of the installation, it is recommended to always use a new fitting after an unsuccessful weld.
