Electrofusion welding instruction for large size PE100 EF couplers

355 < d 1600

– Below instructions should be followed absolutely step by step.
– We recommend using pipes with limited dimension tolerance range.
– The fusable pipe series are shown in the SDR labeling on coupler.
– Installation technician must be trained and certified to install Tega large diameter couplers.
– Fusion with other pipe materials such as PP, PVC etc. is not possible.
– Installation can be done at ambient temperatures between 0 °C and +45 °C. If ambient temperature is not within these limits use of welding tent is required.
– For general safety reasons, keep a distance of min. 1 m to the fusion site during fusion process.



1. Pipe Cutting:
For the pipe cutting, a suitable cutter for plastics must be used. The pipes are to be cut square with this cutting tool.

If the pipe is not cut at right angles, fusion coil partially may not being covered by pipe, which causes uncontrolled flow of molten due to  overheating. (Fig. 1)



2. Marking the fusion zone:
Fusion zone which is the insertion depth of coupler, must be marked with a marker on the pipe end or on the spigot end. Measure the total length of coupler and calculate the half length. (Fig. 2) Mark the coupler half length + 10 mm on pipe surface (Fig. 3)


3. Controlling ovality
PE pipes may loose their roundness during storage. For this purpose measure pipe ovality as illustrated in Fig. 4 and 5.


If pipe is out of round or has a flat spot, use of the rerounding clamp is required (Fig.6).


After installation of the re-round clamp, check roundness of pipe against measuring pipe diameter. If pipe is still oval, re-position the re-rouding clamp (Fig. 7 and 8).


4. Scraping The Pipe Surface
In order to remove the oxide layer of the pipe, scrape carefully the fusion zone (Fig. 9).


In order to remove the oxide layer completely, the pipe must be scraped so that shavings are formed and marking line is removed.
The prepared surface must be protected against unfavorable weather conditions.
After that,the internal edge must be deburred and the outher edge rounded off as illustrated in fig.10



5. Degresing of the Fusion Zone:
Remove coupler from its packaging without touching the  fusion surface. Make a visual check to ensure coupler is undamaged (Fig.11).


The prepared pipe end or spigot end and internal face of coupler must be degreased with a suitable cleaning agent and a white absorbent and nonfibrous paper (Fig. 12 and 13)


As a cleaning agent; isopropyl alcohol can be used  (The alcohol content mustn’t be less than 96% by volume).

Degresed surfaces must be protected against dirt or unfavorable weather conditions.

6. Inserting of the pipe end or spigot end into the coupler:
Push coupler onto pipe up to the marking zone (contact terminals of coupler must be easily accessible).


Do not let pipes support their own weight in the coupler (if necessary support under pipe).
Prepare the second pipe same as first one and follow same steps.
Ensure coupler and pipes are both on the same axis (Fig.14). Ensure tension-free fixing of the joint. A nontension free joint may result in a defective joint during fusion.


Check the gap between pipe and coupler on whole  circurmference. Use metal sticks to distribute local gaps (length of sticks must be 30 mm max)( Fig. 15). So ensure equalized gaps on whole circumference. Measure gaps all around the pipe. If it is less than 2 mm pass Fusion procedure. If it is between 2-3mm first apply “Preheating Procedure” and then pass to Fusion procedure.


7. Fusion:
Provided that information given in intructions are followed step by step, connect fusion cables to the terminals of the first side of the coupler (Fig.16). Fusion parameters are contained in the main barcode. Fusion data can be transfered to machine by using reader (Fig.17).
After reading of barcode, compare data on barcode and data shown on display. Start fusion process. Wait until cooling time has elapsed before moving pipe and coupler. Cooling time is given on barcode and identified by CT.


As a safety precaution, be careful to stay at least 1 m away from the fusion area. If the fusion process is interrupted for any reason (e.g. due to power failure) the fusion process can be repeated after the joint cooled adequately. Find these cooling times on TEGA Couplers’ barcode labels.

– Ensure that coupler is centralized on the pipe so that gap on whole circumference is as equal as possible.
– In order to prevent heat losses during pre-heating process, close gap with adhesive tape.
– Close open pipe ends.
– Introduce pre-heating parameters (on pre-heating barcode) to EF machine.
– Start pre-heating process.
– Check gaps; if it is still not less than 2 mm, repeat pre-heating second time. If gap is ok, start fusion process (fusion parameters are on fusion barcode)