I. Scientifically set welding parameters to avoid exceeding current limits.
Set parameters according to pipe specifications: Strictly follow the recommended current, voltage, and time for PE pipe diameter, wall thickness, and electrofusion fittings, avoiding a "one-size-fits-all" approach.
Dynamically adjust to adapt to working conditions: In low-temperature or high-humidity environments, appropriately extend the heating time but do not blindly increase the current to prevent actual power exceeding limits due to resistance changes.
II. Ensure a stable power supply system.
Use power cables with sufficient cross-section: It is recommended to use ≥4mm² copper core cables to reduce line voltage drop and prevent the welding machine from increasing current to compensate for voltage loss.
Independent power supply circuit: The electrofusion welding machine should use a dedicated socket to avoid sharing the same circuit with high-power equipment such as welding machines and air compressors, preventing total load overload.
Pay attention to power margin when using generator power: If a generator is used on site, its rated power should be at least 1.5 times the welding machine's power, and ensure stable output voltage.
III. Control Continuous Operation Time to Prevent Heat Accumulation
Follow Duty Cycle: Most electrofusion welding machines are designed for intermittent operation (e.g., 60% duty cycle). After welding several sets continuously, the machine should be stopped and allowed to cool for 10–15 minutes to prevent coil overheating.
Avoid Prolonged Operation in High-Temperature Environments: When operating in summer or enclosed spaces, a fan can be installed to assist cooling, or welding can be done in batches to reduce the rate of temperature rise.
IV. Regular Inspection and Maintenance of Key Components
Inspect Terminals and Cables: Ensure the output copper caps are securely fastened and free of oxidation, with a contact resistance ≤0.01Ω to prevent poor contact leading to localized overheating.
Clean Internal Dust: Regularly blow away accumulated dust inside the machine with dry compressed air, especially around the cooling fan and rectifier module, to maintain good heat dissipation.
Test Insulation Performance: After a new machine is put into use or after long-term storage, use a megohmmeter to test the insulation resistance between the input and the casing. It should be ≥1MΩ to prevent leakage current from inducing abnormal current.
V. Reliance on and Verification of Protective Device Effectiveness
Activate Overcurrent, Overvoltage, and Short Circuit Protection: Modern electrofusion welding machines all have built-in electronic protection circuits to ensure automatic output cutoff in case of abnormal current.
Install a Secondary Voltage Step-Down Protector: Optional dedicated safety devices can reduce the voltage to 15–20V under no-load conditions, saving energy, reducing coil heat load, and extending equipment life.
