Equipment and Tooling Product Guide

Fusion Group

Fusion Group is a multinational company with its headquarters and principal manufacturing site
located in Chesterfield, England.

When you choose Fusion Group as your supply partner you get much more than just a product.

Scale

With a turnover in 2014 of £43m and a main manufacturing

and distribution site covering 5 hectares, you will be partnering
with a major player in the world of polyethylene pipe jointing.

Range

Complete range of Butt fusion and Electrofusion welding

equipment and tooling for use on polyethylene piping systems.

Stability

Established in 1971, Fusion has supported its clients through

global recessions and technological revolutions. We will be
here when you need us.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

2
 www.fusiongroup.com

Quality

Fusion has extensive manufacturing, test and inspection

facilities. Fusion are ISO9001 accredited and have a continued
commitment to improving quality standards and customer
satisfaction.

Service and support

Fusion has a global network of wholly-owned distribution
subsidiaries, joint-venture companies and agents which sells and
supports all Fusion products in markets as diverse as Australia,
China, Kazakhstan, Poland, South America, Italy, Malaysia,
Romania, Indonesia and - of course - the United Kingdom. You
will never be far away from expert advice, guidance and support.

Knowledge

Fusion is one of the original pioneers in polyethylene pipe

jointing systems. You have the reassurance of partnering with a
company which truly understands your needs.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

3
Contents

Gator - Automatic
Pipe Lifter 400 Universal Scraper
Butt Fusion
Page 17 Page 29
Page 6

Gator Liners Pipe Support Rollers Multi Scrape

Page 10 Page 18 Page 30

Manual Butt Printer/Data

Multi Clamp
Fusion Machine Retrieval
Page 32
Page 11 Page 19

Manual Butt SBOX-Max

Mini Clamp
Fusion Liners Electrofusion
Page 34
Page 12 Page 20

SBOX-Lite 220V
External Debeaders Versaclamp
Electrofusion
Page 13 Page 35
Page 24

SBOX-Lite 110V
Internal Debeaders Elbow Clamp
Electrofusion
Page 14 Page 36
Page 26

ClearBore Mini and Maxi Posi

Uniprep Scraper
Internal Debeaders Clamps
Page 28
Page 16 Page 37

4
 www.fusiongroup.com

200 Hydraulic Mains

Alignment Clamps T-Adaptor
Squeeze Tool
Page 38 Page 45
Page 52

Hydraulic Pipe 250 Mains

Top Load Clamp
Clamps Squeeze Tool
Page 39
Page 46 Page 53

Strap Clamp Rerounding/Post 400 Mains

200 Straight Squeeze off Clamps Squeeze Tool
Page 40 Page 47 Page 54

Strap Clamp
Rerounding Tools Generators
200 Knuckle
Page 48 Page 55
Page 41

Strap Clamp Mini Squeeze

Fast Cut Drill
Titan 200 Tool 32
Page 56
Page 42 Page 49

Strap Clamp Service Squeeze

Ancilliary Equipment
500 Straight Tool 63
Page 58
Page 43 Page 50

Strap Clamp Mechanical Squeeze

Titan 500 Tool 125
Page 44 Page 51

5
Gator - Automatic Butt Fusion

The gator range of machines have been designed and developed to be used on gas and water pressure polyethylene pipes for
distribution networks. The best possible control of the joining process is achieved through an integral computer which will control
and monitor all the jointing parameters: time, temperature, pressure, movement and sequence. The welding process will not
continue if any of these parameters are not within the specified limits contained in the selected welding standard.

Designed and manufactured to meet or exceed GIS/PL2-3:2006 and ISO 12176-1:2012

• New computer, simplified and improved user interface, bright screen display and multilingual operation.

• New blue-tooth connectivity to facilitate real time transfer and control of joint data, using BlueWeld by ControlPoint.

• Will work in conjunction with new BDI bead testing equipment to ensure 100% success on every joint.

• On screen access to joint records, download to USB, and upload in JointManager website.

PUT SIMPLY - THE BEST FULLY AUTOMATIC BUTT FUSION MACHINE IN THE WORLD

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

6
 Gator - NEW Computer www.fusiongroup.com

PROVIDES THE ULTIMATE IN CONTROL AND USER EXPERIENCE

Download to USB and upload Bright screen with

Multilingual display in the JointManager website strong back light

On screen access to
Simple user interface joint records

Buetooth connectivity to facilitate real

time transfer and control of joint data
Works in conjunction with new Improved data entry
using BlueWeld by ControlPoint
BDI testing equipment

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

7
Fully Automatic Process

Operator contribution
1. Input pipe and operator details

2. Inspect and approve trim

Fully automatic features Continuously monitored

1. Machine sequencing
Temperature °C
2. Trim and feathering cycle

3. Pipe slippage check Movement mm

4. Static and dynamic drag

Pressure Bar
measurement

5. Heater plate temperature control Time Secs

6. Initial bead up distance control Trimmer current Amps

7. Heater retraction
Heater continuity Ω
8. Pressure control at bead up, soak,

fusion, and cool time phases Pipe slippage mm

9. Out of specification early warnings

Oil Level ml
Preprogrammed parameters
1. 15 internationally approved welding
standards containing specified:
Heater temperatures
Fusion pressures
Soak times
Cooling times
2. Data management systems
3. Diagnostic routines

SPECIFICATION

GATOR 180 GATOR 250 GATOR 315 GATOR 400

Range (mm) 63 - 180 63 - 250 90 - 315 160 - 400
Nominal Input voltage (V) 110 220 110 220 110 220 110 220
Input frequency (Hz) 50 /60 50/60 50/60 50/60 50/60 50/60 50/60 50/60
Generator rating (KVA) 3.5 3.5 4.0 4.0 6.0 6.0 7.0 7.0

DATA OUTPUT
Printer Thermal paper
USB Memory device Text file/JointManager
Bluetooth ControlPoint/BlueWeld

MEMORY
Internal memory capacity Up to 2,000 records
Back up to SD card Up to 100,000 records
Via ControlPoint Unlimited

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

8
Gator - Automatic Butt Fusion www.fusiongroup.com

ORDER CODES

GATOR 180 GATOR 250 GATOR 315 GATOR 400

110 volt - yellow 3 pin plug G180110AFE G250110AFE G315110AFE G400MK2110AFE

220 volt - black 2 pin plug G180220AFG G250220AFG G315220AFG G400MK2220AFG

220 volt - blue 3 pin plug G180220AFE G250220AFE G315220AFE G400MK2220AFE

OPTIONAL EXTRAS PRODUCT CODE

Liners See page 10 overleaf
Advanced thermal printer 705892
Barcode reader for ISO standard traceability 704504
BlueWeld Contact ControlPoint for details

STANDARDS

• ISO12176 - 1: 2012
• GIS / PL2 - 3 : 2006
• ISO12176 - 3 Operator Badge (with optional barcode reader fitted)
• ISO12176 - 4 Traceability Coding (with optional barcode reader fitted)

AVAILABLE ON REQUEST

• Knife-edge conversion
• Stub flange adaptor

REMOVABLE CLAMP

• The fourth clamp on the Gator can be removed to facilitate the butt fusion of long spigot fittings.

ANCILLARIES

• Pipe support rollers

• Debeaders
• Generators

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

9
 Gator Liners

SPECIFICATION

Size (mm) Aluminium product code Plastic product code To fit machine sizes

400x355 BFL400355 N/A 400

400X315 BFL400315 N/A 400
400X250 BFL400250 N/A 400
315x280 BFL315280 N/A 400, 315
315x250 BFL315250 N/A 400, 315
315x200 BFL315200 N/A 400,315
250x225 BFL250225 N/A 400,315,250
250x200 BFL250200 N/A 400,315,250
250x180 BFL250180 BFL250180PT 400,315,250
250x160 BFL250160 N/A 400,315,250
180x160 BFL180160 BFL180160PT 400,315,250,180
180x140 BFL180140 BFL180140PT 315,250,180
180x125 BFL180125 BFL180125PT 315,250,180
180x110 BFL180110 BFL180110PT 315,250,180
180x90 BFL18090 BFL18090PT 315,250,180
180x75 BFL18075 BFL18075PT 250,180
180x63 BFL18063 BFL18063PT 250,180

Butt Fusion liners are designed to maximise the size range of the machine. All sizes are available in cast aluminium, and sizes up to 180mm
diameter are also available in an engineering plastic called Noryl. Noryl liners are extremely tough and very light.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

10
Manual Butt Fusion www.fusiongroup.com

SPECIFICATION

Machine Range (mm) Weight (kg) Voltage - frequency Power specification (kW) Product code
Welda 160 40-160 90 230V - 50/60Hz 2.6 W160230OM
Welda 250 90-250 118 230V - 50/60Hz 3.1 W250230OM
Welda 315 90-315 143 230V - 50/60Hz 3.8 W315230OM
Welda 500 250-500 300 230V - 50/60Hz 6.0 W500230OM
Welda 630 250-630 430 400V 3P+N - 50/60Hz 10.7 W630400OM
Welda 800 400-800 1020 400V 3P+N - 50/60Hz 15.7 W800400OM
Welda 1000 500-1000 1934 400V 3P+N - 50/60Hz 20.9 W1000400OM
Welda 1200 630-1200 2130 400V 3P+N - 50/60Hz 20.0 W1200400OM
All machines supplied without liners. Please specify liners when ordering if required.

STUB FLANGE ADAPTORS LIFTING CRANE

Product code Machine (mm) Overall dimension (mm) Weight (kg) Product code
WSFA160 160 Ø 215 4 N/A
WSFA250 250 Ø 318 8 N/A
WSFA315 315 Ø 385 10 N/A
WSFA500 500 Ø 585 32 N/A
WSFA630 630 Ø 685 40 WLC630
WSFA800 800 Ø 905 90 WLC800
WSFA1000 1000 Ø 1110 105 WLC1000
WSFA1200 1200 Ø 1330 140 WLC1200

Welda machines are part of the hydraulic range of butt fusion machines. They are suitable for welding polyethylene pipes for gas and
water pipeline projects and also polypropylene pipes used in industrial applications.

FEATURES
• 150 bar system pressure • Anti-drip quick release hydraulic couplings
• Versatile 4 piece design ideal for in trench work • Electronic adjustment of temperature
• Protective heater and trimmer stand • Safety micro switch on trimmer
• Sliding 3rd chassis clamp allows for jointing of fittings • Double edge trimmer blades

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

11
Manual Butt Fusion Liners

SPECIFICATION

Size (mm) Product code To fit machine sizes

1200x1000 WFL12001000 1200
1000x900 WFL1000900 1200, 1000
1000x800 WFL1000800 1200, 1000
800x710 WFL800710 1200, 1000, 800
800x630 WFL800630 800
630x560 WFL630560 800, 630
630x500 WFL630500 800, 630
500x450 WFL500450 630, 500
500x400 WFL500400 630, 500
500x355 WFL500355 630, 500
500x315 WFL500315 630, 500
315x280 WFL315280 500, 315
315x250 WFL315250 500, 315
250x225 WFL250225 315, 250
250x200 WFL250200 315, 250
250x180 WFL250180 315, 250
250x160 WFL250160 315, 250
250x140 WFL250140 315, 250, 160
250x125 WFL250125 315, 250, 160
250x110 WFL250110 315, 250, 160
250x90 WFL25090 315, 250, 160
160x140 WFL160140 250, 160
160x125 WFL160125 250, 160
160x110 WFL160110 250, 160
160x90 WFL16090 250, 160
160x75 WFL16075 160
160x63 WFL16063 160
160x50 WFL16050 160
160x40 WFL16040 160

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

12
External Debeaders www.fusiongroup.com

SPECIFICATION

Product code Range (mm) Weight (kg) Spare blade code

EXTDB 75mm - 400mm 3 EXTDBBLADE
EXTDBL 355mm - 630mm 4 EXTDBLBLADE
EXTDBXL 400mm - 900mm 5 EXTDBXLBLADE

Used to remove external beads after butt fusion joint completion. External bead removal plays a key role in establishing joint integrity
and is necessary when undertaking slip-lining or swage lining projects.

FEATURES

• Easily adjusts to pipe diameter, allowing the blade to cut under the bead without damaging the surface of the pipe
• High quality heat treated ground cutting blades
• Replacement blades available
• Comes complete with storage box
• National Grid approved (GIS/PL2-3:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

13
Internal Debeaders

SPECIFICATION

Product code Description Weight (kg)

IBRTKIT Internal bead removing tool 110 - 400mm 70
31681 Spare blade for head 1 and 2 N/A
32187 Spare blade for head 3 and 4 N/A

IBRTKIT CONTAINS SELECTION CHART

Product code Description SDR 44 32 26 17 11 7.3

11769 1 x storage box O/D Head Size
11560 1 x drive handle 110 1(B) 1(A)
125 1(D) 1(C) 1(A)
21459 1 x no. 1 size head
140 1(A) 1(D) 1(C)
21457 1 x no. 2 size head
160 2(B) 2(B) 2(B) 2(B) 2(B) 1(D)
21453 1 x no. 3 size head 180 3(A) 2(C) 2(C) 2(C) 2(B) 2(B)
21451 1 x no. 4 size head 200 3(A) 3(A) 3(A) 3(A) 2(C) 2(B)
N/A 2 x Allen keys 225 3(B) 3(B) 3(B) 3(B) 3(A) 2(C)
N/A 1 x set operating instructions 250 3(C) 3(C) 3(C) 3(C) 3(B) 3(A)
32740 3 x size 1 rod supports 280 4(B) 4(B) 4(B) 3(C) 3(C) 3(B)
315 4(C) 4(C) 4(C) 4(B) 4(A) 3(C)
31754 3 x size 2 rod supports
355 4(D) 4(D) 4(D) 4(C) 4(C) 4(A)
21803 3 x size 3 rod supports
400 4(D) 4(C) 4(B)
21310 3 x size 4 rod supports 450 4(D) 4(D)
21859 3 x size 4b rod supports
69046 1 x rod bag Note: Each debeader head size has multiple settings. These are referred to in the table as A, B,
C or D. To select the correct head size you will need to know the outer diameter of the pipe you
21560 6 x 2 meter rods wish to debead (see first column) and its SDR (see top row).
21618 1 x 1 meter rod

Note: the above items are also available as spares

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

14
Internal Debeaders www.fusiongroup.com

OPTIONAL EXTRAS

Product code Description

91425 Adaptor for 450mm SDR11
91474 Adaptor for 450mm SDR17.6
51416 Screw (2 per adaptor)

The internal debeader is a manual kit for the simple and effective removal of internal beads formed during the butt fusion process. The
internal debeader can debead polyethylene pipes in the size range 110mm - 400mm (450mm with adaptor).

FEATURES
• Rods can be quickly clipped together to debead pipe lengths up to 13m
• Bead retained in head after removal process for later inspection/archiving
• Robust build quality
• Simple to assemble
• Facilitates quality control procedures from visual bead inspection and bend back test
• Rods come in robust canvas bag
• Heads and ancillary components are housed in a steel box with carry handles
• National Grid approved (GIS/PL2-3:2006)

Rod Supports

Allen Keys

Debeader Heads

Drive Handle

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

15
ClearBore Internal Debeader

SPECIFICATION

Product code Description Range (mm) Weight (kg)

IBRTKIT100 Internal bead removal tool 110 - 250mm (SDR 9 and 11) 63

Note - Other sizes are available upon request.

The ClearBore internal debeader is specifically designed to leave an absolutely ‘snag free’ passage in cable ducting applications.

FEATURES

• Simple to use and similar fuctionality to Fusion’s standard internal debeader.

• Simple and solid construction with a sprung cutter giving positive location on the bead.
• The debeader works on both PE80 and PE100 pipe up to 13m in length and diameters up to 250mm

Note - Not suitable for pressure pipe applications

IBRTKIT100 CONTAINS SELECTION CHART

Description Quantity Support
Rod Support
Debeading head 1 Pipe Diameter SDR Drive plate No. Diameter
part number
Drive plate 1* (mm)
Drive adaptor 1 110 11 23475 36119/110SDR11 80
2 metre rod 6 125 9 23513 36119/125SDR9 87
1 metre rod 1 125 11 23477 36119/125SDR11 92
Handle 1 160 11 23479 36119/160SDR11 121
Rod supports 3* 180 11 23481 36119/180SDR11 137
Rod bag 1 200 11 23511 36119/200SDR11 154
Storage box 1 225 11 23483 36119/225SDR11 174
Flat blade screw driver 1 250 11 23485 36119/250SDR11 195
17mm spanner 1
6mm Allen Key 1
Operating instructions 1

Note - * Kit includes 1 drive plate and corresponding rod supports. Please specify size of drive plate and rod supports required at the time of ordering from the table above.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

16
Pipe Lifter 400 www.fusiongroup.com

SPECIFICATION

Product code Description Range (mm) Weight (kg)

PIPELIFT400 Pipe Lifter 400 up to 400mm 22

The Pipe Lifter 400 is a simple, robust and effective device which assists with the ejection and movement of polyethylene
pipes during the welding process.

FEATURES
• Simple lever mechanism which improves productivity
• Heavy duty construction
• Folds flat for easy storage and transportation
• Works in conjunction with pipe support rollers
• Compatible with all butt fusion machines from 180mm to 400mm
• National Grid approved (GIS/PL2-3:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

17
Pipe Support Rollers

315 Adjustable roller 400 Adjustable roller 630 Adjustable roller

SPECIFICATION

Product code Description Range (mm) Weight (kg) per roller

PSROLL315 315 adjustable roller (pair) 63-315mm 5

PSROLL400 400 adjustable roller (pair) 63-400mm 18

PSROLL630 630 adjustable roller (pair) 315-630mm 52

A range of adjustable pipe support rollers, used to assist the butt fusion welding process

FEATURES

• 3 adjustable pipe rollers covering the range 63mm to 630mm

• Rigid construction, with all models supplied as a pair
• National Grid approved (GIS/PL2-3:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

18
Printer/Data Retrieval www.fusiongroup.com

Printer, lead and roll Gator controller with printer in operation

SPECIFICATION

Product code Description

705892 Advanced thermal printer, lead and roll

705893 Lead only

705799 Paper roll

Portable printer for use with Gator controller.

FEATURES

• The printer provides the installer with documentary evidence of good working practices
• Lightweight, compact and portable

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

19
SBOX-Max - Electrofusion

SBOX-Max you are in control

• SBOX-Max can weld fittings from 20mm to 630mm diameter.

• The screen is protected by hard-wearing scratch-resistant polycarbonate.

• Pin adaptors included as standard. You can weld both 4mm and 4.7mm pin fittings.

• Comes with hard protective carry case. Easy to carry and designed to withstand knocks and scratches.

• On screen instructions in 15 languages. New languages being added all the time.

• Graphics display with adjustable contrast and a wide viewing angle.

• The SBOX-Max’s internal ‘Black Box’ SD card holds up to 100,000 joint records: a lifetime’s joints safely stored.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

20
 www.fusiongroup.com

Welds fittings between

Only 18kg in tough protective case Display your logo on screen
20mm and 630mm

Cable tidy USB data download Multiple languages

Welds 4mm and 4.7mm pin fittings ControlPoint ready Barcode, manual and Fusamatic fittings

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

21
 SBOX-Max - Electrofusion

SPECIFICATION

SBOX-Max/SBOX-MaxBC CABLE LENGTH SBOX-Max/SBOX-MaxBC

SUPPLY MINIMUM TYPICAL MAXIMUM Input Cable 3m
Input Voltage 195v 230v 265v Output Cable 2.5m
Input Frequency 40Hz 50Hz 60Hz
Generator Rating 4.2KVA - 6KVA
DIMENSIONS WIDTH DEPTH HEIGHT
(with cables coiled in 30cm 29cm 43cm
SBOX-Max/SBOX-MaxBC cable storage)
OUTPUT MINIMUM TYPICAL MAXIMUM
Output 40v Auto Fitting 39.0v 39.5v 40.0v
Output Voltage Barcode and Manual 10.0v - 48.0v STANDARDS SBOX-Max SBOX-MaxBC
Output Current 2A - 60A ISO12176-2 Electrofusion YES
60% Duty Cycle output ISO12176-2 60A
ISO12176-2 Classification P23US2FVKADX
Peak Current <60seconds 80A
ISO12176-3 Operator Badge - YES

ISO12176-4 Traceability Coding - YES

OPERATING MODES SBOX-Max SBOX-MaxBC
Fusamatic 20 - 900 Seconds
Manual 10 - 3500 Seconds ORDER CODES
Barcode NO YES

All 220/230V automatic electrofusion control boxes

come with carry case and 4.0mm/4.7mm lead end
MEMORY SBOX-Max/SBOX-MaxBC
adaptors as standard.
Internal Memory Capacity Up to 2,000 records
PRODUCT CODE PLUG TYPE BAR CODE SCANNER
Backup to SD Card Up to 100,000 records
Via ControlPoint Unlimited

SBOXMAXBCG

DATA OUTPUT SBOX-Max/SBOX-MaxBC

USB memory device YES - text file/JointManager
Bluetooth ControlPoint
SBOXMAXBCE

SBOX-Max/SBOX-MaxBC
ENVIRONMENT MINIMUM MAXIMUM

x
o
Operating Temperature -10 C +50oC
SBOXMAXG
Storage Temperature -15oC +55oC
Environmental Protection IP54

WEIGHTS SBOX-Max SBOX-MaxBC SBOXMAXE x

Box with leads 16.8Kg 17.0Kg

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

22
Joint Data - ControlPoint www.fusiongroup.com

What is ControlPoint?
• ControlPoint is a patented quality assurance system
which helps you – contractors and utilities – to improve
the installation quality on your gas and water pipelines.
The result? Reduced leakage, fewer costly repairs, better
service levels for customers.

How does ControlPoint work? ControlPoint works with your smartphone

• ControlPoint uses an app on your smartphone linked via
Bluetooth to your SBOX-Max. The app sends your SBOX-
Max joint data – including photographs of the joint prior
to fusion, machine parameters, GPS location, ISO12176-4
traceability data and more – to ControlPoint’s inspection
team for real time verification. If there is any doubt about
the integrity of a joint you will receive an alert by text
or email. You can also view and analyse all your data,
including photographs, via the JointManager website.

Can I access ControlPoint with my SBOX-Max?

ControlPoint verifies your joints
• Yes. Your SBOX-Max comes with basic ControlPoint
functionality and support as standard:
• BlueBox communications app for Apple, Android and
Windows platforms
• JointManager web account: 24/7 access to your joint data
• JointManager search and analysis including full ISO12176
traceability
• GPS location within the joint record

You can map the GPS location of your

How can I activate ControlPoint? joints with JointManager

• Simply contact your local SBOX-Max distributor. Your

distributor can also talk you through the benefits of a
ControlPoint subscription.
• You can also contact the ControlPoint international
support team on +44(0)1246 262383 or
email: [email protected]

JointManager stores your joint data

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

23
SBOX-Lite 220v - Electrofusion

SPECIFICATION

SBOXLITE220BC
Diameters range (OD) 20 - 125mm *
Weldable materials PE / PP/ PP-R
Dimensions (W x D x H) 200 x 250 x 210mm
Weight 8 kg
Power supply (V) 230V ±15%
Frequency 50 - 60 Hz
Maximum absorbed power 2000W
Nominal absorbed current 8A
Peak output current 60 A
Welding nominal current
23A
Duty cycle 60% (ISO 12176-2)
o o
Working temperature - 10 C to + 40 C
Welding voltage (V) 8V-48V
Protection degree IP 54
Barcode scanner Yes
Pin connector sizes 4mm and 4.7mm universal
Memory capacity 350 joints
Ambient temperature compensation Yes

* OD 140mm and 160mm couplers can also be welded but with precaution; wait for the machine to cool off completely after each welding cycle.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

24
 www.fusiongroup.com

ORDER CODES

Product code Description Range (mm) Weight (kg)

SBOXLITE220BC SBOX-Lite 220 volts 20-125mm 8

The SBOX-Lite is a lightweight and versatile electrofusion control box which is capable of welding any brand of electrofusion fittings for
gas, water and other pressure pipe applications.

• Can weld electrofusion fittings in sizes 20mm - 125mm (140mm and 160mm couplers can be welded by letting the machine cool
down between operations).

• The 220V SBOX-Lite can be used in 2 different modes -

1. By barcode reading (8 - 48 volts)

2. Manual entry of fusion voltage and time

FEATURES
• Extremely lightweight - only 8kg
• Joint data memory of 350 welds- downloadable to USB memory stick
• Fusion data transfer CD and USB cable adaptor included
• Ambient temperature compensation is applied when required
• 4.0 - 4.7mm diameter universal collet adaptor
• Multi-lingual selectable display
• Manual scraper included
• Transport bag included

Universal lead ends I/P Plug

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

25
SBOX-Lite 110v - Electrofusion

SPECIFICATION
SBOXLITE110
Diameters range (OD) 20 - 125mm *
Weldable materials PE / PP/ PP-R
Dimensions (W x D x H) 200 x 250 x 210mm
Weight 8 kg
Power supply (V) 110V ±10%
Frequency 50 - 60 Hz
Maximum absorbed power 2000W
Nominal absorbed current 16A
Peak output current 60 A
Welding nominal current
23A
Duty cycle 60% (ISO 12176-2)
o o
Working temperature - 10 C to + 40 C
Welding voltage (V) 8V-48V
Protection degree IP 54
Barcode scanner No
Fusamatic auto pin recognition Yes
Pin connector sizes 4.7mm diameter
Memory capacity 350 joints
Ambient temperature compensation No

* OD 140mm and 160mm couplers can also be welded but with precaution; wait for the machine to cool off completely after each welding cycle.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

26
 www.fusiongroup.com

ORDER CODES

Product code Description Range (mm) Weight (kg)

SBOXLITE110 SBOX-Lite 110 volts 20-125mm 8

The SBOX Lite is a lightweight and versatile electrofusion control box which is capable of welding any brand of electrofusion fittings for gas,
water and other pressure pipe applications.

• Can weld electrofusion fittings in sizes 20mm - 125mm (140mm and 160mm couplers can be welded by letting the machine cool
down between operations).

• The 110V SBOX-Lite can be used in 2 different modes -

1. Fusamatic - automatic pin recognition

2. Manual entry of fusion voltage and time

FEATURES
• Extremely lightweight - only 8kg
• Joint data memory of 350 welds- downloadable to USB memory stick
• Fusion data transfer CD and USB cable adaptor included
• Multi-lingual selectable display
• Manual scraper included
• Transport bag included

Lead ends I/P Plug

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

27
Uniprep Scraper

SPECIFICATION

Product code Description Weight (kg) Spare blade code

UNIPREP250 Uniprep scraper 63mm - 250mm 3 UNIPREP22
UNIPREP400 Uniprep scraper 90mm - 400mm 3.5 UNIPREP22
UNIPREP500 Uniprep scraper 125mm - 500mm 4 UNIPREP22
UNIPREP710 Uniprep scraper 450mm - 710mm 5 UNIPREP22

Uniprep scrapers are high productivity tools, used for preparing pipe ends prior to electrofusion. Suitable for all pipe SDR’s and pipe with
ovality.

FEATURES

• Fast scraping action

• Heat treated ground steel cutting blade
• Accurately controlled depth of cut
• Quick release after pipe scraping using post locking screw
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

28
Universal Scraper www.fusiongroup.com

SPECIFICATION

Product code Description Weight (kg) Spare blade code

UNISCRP Universal scraper 63mm-250mm 4.5 370300

The universal scraper provides a convenient means of preparing pipe ends prior to electrofusion jointing. It can operate on all pipe
diameters and commonly used SDR sizes from 63mm to 250mm inclusive, and can be used on coiled pipe and pipes with ovality.

FEATURES

• Correct length of scrape is pre-set

• Fixed, serrated blade driven around the pipe using ratchet handle
• Internal roller action holds the cutting blade against the pipe
• Carry case, spare blade and cleaning brush
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

29
Multi Scrape

SPECIFICATION

Diameter range SDR Range Case dimensions Weight (kg) complete kit
20, 25, 32, 40, 50, 55 and 63mm 11 and 17 275 x 225 x 90mm 2.5

Product code Description

MULTISCRAPEKIT Tool including complete set of solid mandrels and spare blade in case
MULTISCRKITUK Tool including 63mm SDR11/32mm/25mm solid mandrels only in case
Tool including 20mm and 25mm solid mandrels and
MULTISCRKITEM
small, medium and large expanding mandrels in case

Multi Scrape is a versatile pipe scraper designed specifically with coiled pipe in mind. Mandrels support the pipe ends and a spring loaded
blade, ensures that the optimum depth of cut is achieved.

FEATURES

• Comes with choice of solid or expandable mandrels

• Hardened steel blade design, indexable with two cutting edges
• Blade design ensures a consistent depth of cut
• Sprung loaded arm facilitates use on coiled and oval pipe
• All mandrels aid pipe re-rounding and cover a variety of pipe sizes and SDR’s
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

30
 www.fusiongroup.com

EXPANDING MANDRELS KIT SOLID MANDRELS KIT

SPARE PARTS

Product code Description

MULTISCRAPE Tool only
35571 20mm solid mandrel
35572 25mm solid mandrel
35573 32mm solid mandrel
35574 40mm solid mandrel
35575 50mm SDR11 solid mandrel
35576 50mm SDR17 solid mandrel and 55mm SDR11
35577 63mm SDR11 solid mandrel
35578 63mm SDR17 solid mandrel
35559 Spare blade
22902 Case
35794 Small expanding mandrel covers 32mm and 40mm
35795 Medium expanding mandrel covers 50mm (all SDR’s)
35796 Large expanding mandrel covers 63mm (all SDR’s)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

31
Multi Clamp

SPECIFICATION

BASIC UNIVERSAL
Product code Weight (kg) Product code Weight (kg)
MCKIT180B 21 MCKIT180 31
1 x carrying bag 1 x plastic container
2 x basic 180mm rings + slide blocks 2 x basic 180mm rings + slide blocks
4 x 180mm x 125mm liner segments 4 x 180mm x 125mm liner segments
4 x 125mm x 90mm liner segments 4 x 125mm x 90mm liner segments
4 x 125mm x 63mm liner segments 4 x 125mm x 63mm liner segments
1 x 600mm base 2 x 460mm bases
1 x allen key 1 x allen key
1 x spanner
1 x ‘T’ connector

OPTIONAL EXTRAS AND SPARES

Product code Description Product code Description

12390 180mm ring 33812 160mm x 75mm liner segments
132000 460mm base 33354 125mm x 90mm liner segments
148500 600mm base 33356 125 x 63mm liner segments
22541 180mm x 160mm liner segments 33358 T-connector
22540 180mm x 140mm liner segments 33470 Locking handle with screw (for base)
o
21607 180mm x 125mm liner segments 21692 45 convertor
31784 160mm x 110mm liner segments

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

32
 www.fusiongroup.com

The multi-clamp kit has been specifically designed for easier alignment and restraint of a whole range of electrofusion fittings and suits
narrow trenching techniques.

FEATURES

• Facilitates full rerounding and restraint during electrofusion

• Top clamp hinges facilitates use in narrow trenches
• The dovetail assembly allows complete rotation through 360o to suit any pipe and fitting configuration (large diameter tees require
extra base, ring and liners)
• Extruded lightweight base
• National Grid approved (GIS PL2-5:2006)

APPLICATION AND USAGE - (See pictures below)

90° Electrofusion Elbows

(1 base / 2 Rings)

Couplers and reducers

E/F tees and reducing tees

(3 bases / 3 rings / 1 ‘T’ connector )
45° Electrofusion Elbows
(1 base / 2 Rings)

Electrofusion of Seamless Bends (2 bases / 4 rings )

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

33
Mini Clamps

Interchangeable
arms

SPECIFICATION

Product code Description Weight (kg)

MINICLAMP 20, 25 and 32mm mini clamp 1

Mini clamps are designed to retain and align pipe and fittings for service connections during the electrofusion process. The mini clamp is
suitable for pipe sizes 20, 25 and 32mm.

FEATURES
• Interchangeable arms for each pipe size
• Reducers, couplers and tapping tee outlets can be accommodated
• Robust construction with cast aluminium body
• Promotes re-rounding and restraint during electrofusion
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

34
Versaclamp www.fusiongroup.com

SPECIFICATION

Product code Description Weight (kg)

VERSACLAMP20 20mm multi angled clamp 0.2
VERSACLAMP25 25mm multi angled clamp 0.2
VERSACLAMP32 32mm multi angled clamp 0.2

A range of clamps that can be used on 90° and 45° elbows and straight connections. Available for use with 20, 25 and 32mm diameter pipe.

FEATURES
• Pocket size and ultra lightweight design
• Manufactured from a tough engineering plastic (Noryl)
• Works in tight spaces with flextee and multiseal
• National Grid approved (GIS/PL2-5:2006)

45° Elbows

Straight Connections

90° Elbows

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

35
Elbow Clamps

SPECIFICATION

Product code Description Weight (kg)

ELBOWCLAMP20 Elbow clamp 20mm 0.1
ELBOWCLAMP25 Elbow clamp 25mm 0.1
ELBOWCLAMP32 Elbow clamp 32mm 0.1

o
A very simple hand tool for clamping either 20, 25 or 32mm service pipe when fusing 90 elbows giving stress free joints.

FEATURES

• Compact lightweight design

• Manufactured from a tough engineering plastic (Noryl)
• National Grid approved (GIS/PL2-5:2006)

90° Elbow clamp - 25mm pipe

90° Elbow clamp - 20mm pipe

90° Elbow clamp - 32mm pipe

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

36
Mini and Maxi Posi Clamps www.fusiongroup.com

SPECIFICATION

Product code Description Range Weight (kg)

20mm, 25mm,
MINIPOSI Couplers, reducers, end caps, equal and reducing tees, 45° and 90° elbows 0.5
32mm and 40mm
32mm, 40mm,
MAXIPOSI Couplers, reducers, end caps, equal and reducing tees, 45° and 90° elbows 1.0
50mm and 63mm

Two lightweight versatile electrofusion clamps working in the range 20 - 40mm and 32 - 63mm.

FEATURES
o o
• Can be used for couplers, reducers, end caps, equal tees, 45 and 90 elbows and reducing tees
• Can be used on multiseal tapping tees where couplers are connected to the outlet
• Aligns, and secures the pipe to prevent movement of fittings during fusion and cooling
• Made from a tough engineering plastic (Noryl)
• All nuts and adjustments are fully captive and therefore cannot be lost
• National Grid approved (GIS/PL2-5:2006)

Maxi Posi clamp coupler

Maxi Posi clamp 90° Elbow

Maxi Posi clamp on Multiseal

tapping tee

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

37
Alignment Clamps

250 Alignment clamp 315 Alignment clamp

SPECIFICATION

Product code Description Weight (kg)

MC250H 250mm alignment clamp 14
MC315H 315mm alignment clamp 29

Heavy duty alignment clamps, used for jointing of 250mm and 315mm electrofusion couplers.

FEATURES
• Hinged with pins for ease of pipe positioning in trench - facilitates use in narrow trenches
• Offers full rerounding and restraint of pipe and fitting during welding
• Fixed clamp position
• Robust construction
• Liners available for smaller sizes
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

38
Top Load Clamp www.fusiongroup.com

Quality Check - When the

indicator at the top of the clamp
is flush this shows that the correct
clamping force is applied to the
fitting.

SPECIFICATION

Product code Description Weight (kg)

TLOADCLAMPA 63mm - 500mm top load clamp 1

Strap clamp for use on top loaded saddles.

FEATURES

• Lightweight
• Universal
• Ideal for use in confined spaces
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

39
Strap Clamp 200 Straight

SPECIFICATION

Product code Description Range Weight (kg)

SC200-2-S Straight runner bar with 2 clamps 40mm - 200mm 2.5
SC200-2-S-4 Straight runner bar with 4 clamps 40mm - 200mm 4.6

Lightweight, fast set up, alignment clamps for use on 40mm - 200mm pipe. Used on couplers only.

FEATURES

• Lightweight construction
• Fast acting ‘tug and tension’ straps
• Works above, below or alongside the joint
• Compact design
• No liners required
• National Grid approved (GIS/PL2-5:2006)

Note: to use the strap clamp 200 straight to clamp tees, a T-Adaptor is required - see page 45 for further details.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

40
Strap Clamp 200 Knuckle www.fusiongroup.com

SPECIFICATION

Product code Description Range Weight (kg)

SC200-2-K Knuckle bar with 2 clamps 40mm - 200mm 2.7
SC200-2-K-4 Knuckle bar with 4 clamps 40mm - 200mm 4.6

Lightweight, fast set up, alignment clamps for use on 40mm - 200mm pipe. A centrally located adjustable knuckle allows the SC200-2-K
to be used for 22.5°, 45° and 90° elbows, reducers and couplers.

FEATURES
• Lightweight construction
• Fast acting ‘tug and tension’ straps
• Works above, below or alongside the joint
• Compact design
• No liners required
• National Grid approved (GIS/PL2-5:2006)

Note: to use the strap clamp 200 knuckle to clamp tees, a T-Adaptor is required - see page 45 for further details.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

41
Strap Clamp Titan 200

SPECIFICATION

Product code Description Range Weight (kg)

SC200T Straight ratchet runner bar with 4 clamps 40mm - 200mm 6.5

Lightweight, fast set up, alignment clamp for use on 40mm - 200mm pipe. Used on couplers only. The Titan clamp pulls the pipe into
position with minimal effort using a rack and pinion system.

FEATURES

• Ratchet handle included

• Lightweight construction
• Fast acting ‘tug and tension’ straps
• Works above, below or alongside the joint
• Compact design
• No liners required
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

42
Strap Clamp 500 Straight www.fusiongroup.com

SPECIFICATION

Product code Description Range Weight (kg)

SC500 Plain runner bar with 2 clamps 160mm - 500mm 8
12799 V block clamp assembly 160mm - 500mm 1.5

Fast set up alignment clamp, for use on 160mm - 500mm pipe. Used on couplers only.

FEATURES

• Lightweight robust construction

• Fast acting ‘tug and tension’ straps
• Works above, below or alongside the joint
• Compact design
• No liners required
• National Grid approved (GIS/PL2-5:2006)

Note: to use the strap clamp 500 straight to clamp tees, a T-Adaptor is required - see page 45 for further details.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

43
Strap Clamp Titan 500

SPECIFICATION

Product code Description Range Weight (kg)

SC500T Straight ratchet runner bar with 4 clamps 160mm-500mm 20

Fast set up, alignment clamp for use on 160mm - 500mm pipe. Used on couplers only. The Titan clamp is capable of pulling 12m lengths of
pipe into position, using a rack and pinion system.

FEATURES

• Ratchet handle included

• Fast acting ‘tug and tension’ straps
• Works above, below or alongside the joint
• Compact design
• No liners required
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

44
T-Adaptor www.fusiongroup.com

Strap clamp with T-Adaptor fixed in place T-Adaptor

SPECIFICATION

Product code Description Range Weight (kg)

SC200ADT T-Adaptor for strap clamp 200 40mm-200mm 0.3
SC500ADT T-Adaptor for strap clamp 500 160mm-500mm 3.4
34989 V block clamp assembly for 200 T-Adaptor 40mm-200mm 0.6
12799 V block clamp assembly for 500 T-Adaptor 160mm-500mm 1.5

The T-adaptor is an add-on tool enabling strap clamps to be used for clamping tees. To use the T-Adaptor a further V-Block clamp needs to
be purchased.

FEATURES

• The T-adaptor can either be used on the SC200 or SC500 range.

• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

45
Hydraulic Pipe Clamps

SPECIFICATION

Product code Description Weight (kg)

HRR400KIT Hydraulic rerounding clamp 400mm* 50
HRR500KIT Hydraulic rerounding clamp 500mm* 68
HRR630KIT Hydraulic rerounding clamp 630mm* 79
HRR710KIT Hydraulic rerounding clamp 710mm* 89
HRR800KIT Hydraulic rerounding clamp 800mm 125
HRR900KIT Hydraulic rerounding clamp 900mm 155

Note - Each kit is supplied with two clamps, two hand pumps, two hydraulic cylinders, and two alignment bars.

Hydraulically powered re-rounding and positioning clamps for supporting and restraining large diameter pipes and couplers throughout
the electrofusion process.

FEATURES
• Made from fabricated steel construction
• Hydraulic power provided by 2 hand pumps
• Excellent re rounding capability
• 3 segment pipe clamps, disassemble for ease of transportation
• Available with straight base only
• Can be used as alignment kit
• Steel reducing liners available on request
• Single clamp available on request
• National Grid approved (GIS/PL2-5:2006) where marked*

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

46
Rerounding/Post Squeeze Off Clamps www.fusiongroup.com

SPECIFICATION

Product code Range Weight (kg)

RRC50 50mm 2.9
RRC63 63mm 3
RRC75 75mm 3.5
RRC90 90mm 3.5
RRC110 110mm 5.8
RRC125 125mm 5.5
RRC140 140mm 5.5
RRC160 160mm 7.5
RRC180 180mm 6.8
RRC200 200mm 9.3
RRC225 225mm 11.5
RRC250 250mm 12

Designed for re rounding pipes after squeeze off has been applied.

FEATURES
• Rerounds the pipe effectively covering a large surface area.
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

47
Rerounding Tools

Rerounding tool 20mm - 32mm Rerounding tool 40mm - 90mm Rerounding tool 110mm - 250mm

SPECIFICATION

Product code Range Weight (kg)

RRT20 20mm 0.5
RRT25 25mm 0.5
RRT32 32mm 0.5
RRT40 40mm 1.5
RRT50 50mm 1.3
RRT63 63mm 1.3
RRT75 75mm 1.5
RRT90 90mm 1.5
RRT110 110mm 2.0
RRT125 125mm 2.0
RRT160 160mm 2.3
RRT180 180mm 3.0
RRT200 200mm 3.0
RRT225 225mm 3.0
RRT250 250mm 3.0

A range of re rounding tools for use on polyethylene coiled or oval pipe prior to electrofusion.

FEATURES
• Quick and simple to use.
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

48
Mini Squeeze Tool www.fusiongroup.com

SPECIFICATION

Product code Description Weight (kg)

SQT32 16mm - 32mm mini squeeze tool 1

The mini squeeze tool is designed solely for use on SDR 11 service pipes in the range 16mm to 32mm diameter.

FEATURES
• Manufactured from cast stainless steel
• Compact robust design
• User friendly
• Unique design incorporates built-in safety stops to prevent damage to the pipe
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

49
Service Squeeze Tool

SPECIFICATION

Product code Description Weight (kg)

SQT63 16mm - 63mm service squeeze tool (UK) 6
SQT63X10 16mm - 63mm service squeeze tool (Export) 6

The service squeeze tool is for flow stopping on 16, 20, 25, 32, 40, 50 and 63mm pipes.

FEATURES
• Cast steel construction
• Hand indexable stops
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

50
Mechanical Squeeze Tool www.fusiongroup.com

SPECIFICATION

Product code Description Weight (kg)

SQT125M 63 - 125mm mechanical squeeze tool 9

Mechanical squeeze off tool for pipe 63mm-125mm diameter

FEATURES
• Can be used on SDR 11 pipe between sizes 63 and 90mm
• Can be used on SDR17.6 pipe between sizes 90, 110 and 125mm.
• Fabricated steel construction
• Hand indexable stops
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

51
200 Hydraulic Mains Squeeze Tool

SPECIFICATION

Product code Description Weight (kg)

SQT200 200mm squeeze tool with stops for SDR 11 and 17 39
SQT200UK 200mm squeeze tool with stops for SDR 11, 17 and SDR21 39

Hydraulic mains squeeze tool used as a flow stop on 63mm - 200mm diameter pipes.

FEATURES

• High quality hydraulic jack

• Spring return after squeeze off
• Fabricated steel construction
• Controlled release through hydraulic shut off valve
• Integral safety relief valve
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

52
250 Mains Squeeze Tool www.fusiongroup.com

SPECIFICATION

Product code Description Weight (kg)

SQT250AHP SQT250 manual squeeze off tool 4 beam set with hand pump 180
SQT250AAI SQT250 auto hydraulic squeeze off tool 4 beam set with air intensifier 190

The 250 mains squeeze tool can be used for flow stopping on 180mm-250mm pipe. Pipe stops need to be ordered separately for each
diameter and SDR rating. Tool supplied with 4 beam sets

FEATURES
• ‘A’ frame design, robust construction for in-trench work
• The ‘A’ frame can be detached and used with an additional beam set which allows up to four squeeze- off points to be carried out
efficiently with one tool.
• Controlled release through hydraulic shut off valve
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

53
400 Mains Squeeze Tool

SPECIFICATION

Product code Description Weight (kg)

SQT400 SQT400 auto hydraulic squeeze off tool, 4 beam set with air intensifier 430
SQT400E SQT400 auto hydraulic squeeze off tool, 4 beam set with electric pump 430

The 400 mains squeeze tool can be used for flow stopping on 250mm-400mm pipe. Pipe stops need to be ordered separately for each
diameter and SDR rating. Tool supplied with 4 beam sets.

FEATURES

• Very robust construction

• The cylinders can be detached and used with other beam sets which allows up to four squeeze off points to be carried out
efficiently with one tool
• Controlled release through hydraulic shut off valve
• National Grid approved (GIS/PL2-7:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

54
 Generators www.fusiongroup.com

SPECIFICATION
Generator product code Description
P501 Generator 5KVA on frame (skids)
P501WF Generator 5KVA on wheeled frame
P750 Generator 7.5KVA on frame (skids)
P750WF Generator 7.5KVA on wheeled frame

Please state which output voltage and sockets required at the time of ordering.

BUTT FUSION POWER REQUIREMENTS

Select generator output voltage (V) Minimum power required

Machine description
110V single phase 220V single phase kW kVA
GATOR 180   2.9 3.6
GATOR 250   3.2 4.0
GATOR 315   4.8 6.0
GATOR 400   5.6 7.0

ELECTROFUSION POWER REQUIREMENTS

Select generator output voltage (V) Minimum power required

Machine description
110V single phase 220V single phase kW kVA
SBOX LITE 110  - 2.2 2.8
SBOX LITE 220 -  2.2 2.8
SBOX-MAX -  4.8 6.0

Fusion’s range of generators are specifically manufactured for powering both electrofusion control boxes and automatic butt fusion machines. All Fusion generators
produce a high quality, smooth, regular power output. All generators comply with the Tin12 (EC3) specification, are available in petrol or diesel engines, and meet
the current EC regulations.

Generators are tailored to suit your own specific requirements, please contact us for further details.

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

55
Fastcut Drill

SPECIFICATION

Product code Description Range Weight (kg)

FASTCUT355110V Fastcut drill UK 225mm-500mm 197
FASTCUT355220V Fastcut drill Export 225mm-500mm 197

Fusion’s range of large diameter electrofusion branch saddles provides the gas and water installer with a simple alternative to the high
cost of by-pass systems or the inconvenience and associated costs of supply interruptions. Under pressure drilling provides the operator
with a simple, safe and cost-effective method of branch installation.

FEATURES

• Installation training provided

• Modular construction ensures ease of handling and assembly
• Hydraulic operation of cutter head helps the operator with cutting through the pipe
• Can be used with plate or gate valves
• Dedicated cutter drive prevents penetration beyond centre line of main
• Swarf and coupon retained inside cutter
• Drill comes complete with 3 heads as standard - 250, 200 and 150 NP16
• ANSI standard version available upon application
• Rotational/adjustable jack to aid alignment
• Pendant cutter control with timer to allow single operator cut through
• National Grid approved (GIS/PL2-5:2006)

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

56
 Large Diameter Branch Saddles www.fusiongroup.com

190mm
140mm
• Complete with sacrificial under parts - no additional 130mm

tooling needed 250 NP16

200 NP16
• Minimal pressure drop due to large bore through fitting
150 NP16
• Large electrofusion area ensures integrity of weld
• 39.5 volt fittings
• Tested in accordance with industry specifications
Outlet sizes available: 150, 200, 250 NP16

UK GAS APPLICATIONS (GIS) UK / EUROPEAN WATER APPLICATIONS EUROPEAN GAS APPLICATIONS
Branch Saddle Size Pipe
Maximum Pipe SDR Maximum Pipe SDR Maximum Pipe SDR
Operating Operating Operating
Material Pressure 11 17.6 21 26 Pressure 11 17.6 21 26 Pressure 11 17.6 21 26
PE80    -    -    -
250mm x 150 NP16 5.5 bar 16 bar 10 bar
PE100   -    -    -

PE80    -    -    -
250mm x 200 NP16 5.5 bar 16 bar 10 bar
PE100   -    -    -

PE80
280mm x 150 NP16 TBA - - - - TBA - - - - TBA - - - -
PE100

PE80    -    -    -
280mm x 200 NP16 5.5 bar 16 bar 10 bar
PE100 -   -    -    -

PE80            
315mm x 150 NP16 7 bar 16 bar 10 bar
PE100            

PE80            
315mm x 250 NP16 7 bar 16 bar 10 bar
PE100            

PE80            
355mm x 150 NP16 7 bar 16 bar 10 bar
PE100            

PE80            
355mm x 250 NP16 7 bar 16 bar 10 bar
PE100            

PE80            
400mm x 150 NP16 5.5 bar 16 bar 10 bar
PE100 -           

PE80           
400mm x 250 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

PE80           
450mm x 150 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

PE80           
450mm x 250 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

PE80           
500mm x 150 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

PE80           
500mm x 250 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

PE80           
630mm x 150 NP16 2 bar - 10 bar 6 bar
PE100    -    -   

Flow stop PE80   

2 bar - - - - - - - - - - -
315mm x 150 NP16 PE100   

Flow stop PE80   

2 bar - - - - - - - - - - -
355mm x 150 NP16 PE100   

Flow stop PE80   

2 bar - - - - - - - - - - -
400mm x 150 NP16 PE100   

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

57
Ancillary Equipment
All ancillary equipment is National Grid approved.

HAND SCRAPER

Product code Description Weight (kg) Spare blade code

HARRIS 1.5” hand scraper 0.1 60122
HARRISLGE 2.5” hand scraper 0.1 60233

SECATEURS

Product code Description Weight (kg)

PCS2032M 16mm - 42mm small secateur cutter 0.3
PCS2063SH 20mm - 63mm large secateur cutter (short handle) 1.5
PCS2063 20mm - 63mm large secateur cutter (long handle) 2

JUMBO PIPE CUTTER

Product code Description Weight (kg) Spare blade code

PCJ355 160 - 355mm jumbo pipe cutter 24 PCJBLADE
PCJ630 355mm - 630mm jumbo pipe cutter 28 PCJBLADE
PCJ800 355mm - 800mm jumbo pipe cutter 31 PCJBLADE

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

58
 www.fusiongroup.com

GUILLOTINE CUTTER

Product code Description Weight (kg) Spare blade code

PCG125 63mm - 125mm guillotine cutter 7.5 60449
PCG200 63mm - 225mm guillotine cutter 15 11774
PCG315 63mm - 315mm guillotine cutter 33 11923

CUTTER KEY

Product code Description Weight (kg)

CUTKEY12 Universal tapping tee cutter key (with cutter key and wrench) 0.6
CUTTERKEYEXL Universal tapping tee cutter key extended length - 1000mm 1.3

TEST CAPS

Product code Description Weight (kg)

22869 63mm aluminium multiseal test cap 0.4
34571 63mm multiseal test cap 0.1
34263 32mm multiseal test cap 0.1

Every effort has been made to ensure the information in this brochure is correct at the date of issue. Fusion operates a policy of continuous product improvement and range
extension and, therefore, reserves the right to modify product specifications in line with market requirements. All dimensions in this catalogue are nominal.

Date July 2015

59 Issue: 01
 Fusion Group Limited
Chesterfield Trading Estate
Chesterfield
Derbyshire
S41 9PZ
United Kingdom

www.fusiongroup.com

Sales
Tel: +44 (0) 1246 268666
Fax: +44 (0) 1246 268052
[email protected]