UPP PIPING

INSTALLATION GUIDE
The information in this publication is provided for reference only. While every effort has been made to ensure the
reliability and accuracy of the information contained in this manual at the time of printing, we recommend that
you refer to “franklinfueling.com” for the most current version of this manual. All product specifications, as well as
the information contained in this publication, are subject to change without notice. Franklin Fueling Systems does
not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way
connected with, installation, operation, use, or maintenance by using this manual. Franklin Fueling Systems assumes
no responsibility for any infringement of patents or other rights of third parties that may result from use of this
manual or the products. We make no warranty of any kind with regard to this material, including, but not limited to,
the implied warranties of merchantability and fitness for a particular purpose.

Copyright © 2019 Franklin Fueling Systems, LLC, Madison, WI 53718. All world rights reserved. No part of this
publication may be stored in a retrieval system, transmitted, or reproduced in any way, including, but not limited to,
photocopy, photograph, magnetic, or other record, without the prior written permission of Franklin Fueling Systems.

For technical assistance, please contact:

Franklin Fueling Systems

3760 Marsh Rd.
Madison, WI 53718
USA

Web: franklinfueling.com
Tel: +1 608 838 8786 • Fax: +1 608 838 6433
Tel: USA & Canada +1 800 225 9787 • Tel: UK +44 (0) 1473 243300
Tel: Mex 001 800 738 7610 • Tel: DE +49 6571 105 308 • Tel: CN +86 10 8565 4566

UPP is a registered trademark of Franklin Electric Company, Inc,

408001016 r6
Contents
Introduction.......................................................................................................................................1
Questions and concerns.................................................................................................................1
Conventions used in this manual...................................................................................................1
Operating precautions....................................................................................................................1
Site Preparation..............................................................................................................................3
Underground Fuel Pipe Systems.......................................................................................................5
Underground Fuel Pipe Construction.............................................................................................6
Pressure Ratings..........................................................................................................................6
Transit, Off-Loading, and Storage......................................................................................................7
Storage on site................................................................................................................................8
Uncoiling Pipe.................................................................................................................................8
Pipe Burial Guidelines........................................................................................................................11
Bend Radius....................................................................................................................................14
Pipe Bend Radius.........................................................................................................................14
Pipe Detector Tape......................................................................................................................15
Pressure Testing.................................................................................................................................17
Testing Guidelines ..........................................................................................................................17
Equipment...................................................................................................................................17
General Guidelines......................................................................................................................17
Recommended Pipe Test Procedure..............................................................................................18
Primary Pipe Hydrostatic Pressure Testing Method....................................................................18
Equipment................................................................................................................................18
Conditioning Phase...................................................................................................................18
Testing Phase............................................................................................................................18
Pneumatic Tightness Testing Procedure.....................................................................................19
Test Procedure..........................................................................................................................19
Pressure Testing Safety.............................................................................................................19
Sump Inspection Register...............................................................................................................21
Introduction
Questions and concerns
In case of emergency, follow the procedures for your facility. If you have questions or concerns,
or need assistance, use the information below to contact Franklin Fueling Systems (FFS):
franklinfueling.com
3760 Marsh Rd. • Madison, WI 53718, USA
Tel: +1 608 838 8786 • Fax: +1 608 838 6433
Tel: USA & Canada +1 800 225 9787 • Tel: UK +44 (0) 1473 243300
Tel: Mex 001 800 738 7610 • Tel: DE +49 6571 105 308 • Tel: CN +86 10 8565 4566

Conventions used in this manual

This manual includes safety precautions and other important information in the following format:
NOTE: Provides helpful supplementary information.
IMPORTANT: Provides instructions to avoid damaging hardware or a potential hazard to the
environment, for example: fuel leakage from equipment that could harm the environment.
CAUTION: Indicates a potentially hazardous situation that could result in minor or moderate
injury if not avoided. This may also be used to alert against unsafe practices.
WARNING: Indicates a potentially hazardous situation that could result in severe injury or
death if not avoided.
DANGER: Indicates an imminently hazardous situation that will result in death if not avoided.

Operating precautions
FFS equipment is designed to be installed in areas where volatile liquids such as gasoline and
diesel fuel are present. Working in such a hazardous environment presents a risk of severe injury
or death if you do not follow standard industry practices and the instructions in this manual.
Before you work with or install the equipment covered in this manual, or any related equipment,
read this entire manual, particularly the following precautions:
CAUTION: Use only original FFS parts. Substituting non-FFS parts could cause the device to
fail, which could create a hazardous condition and/or harm the environment.
WARNING: Follow all codes that govern how you install and service this product and the
entire system. Always lock out and tag electrical circuit breakers while installing or servicing

1
 this equipment and related equipment. A potentially lethal electrical shock hazard and the
possibility of an explosion or fire from a spark can result if the electrical circuit breakers are
accidentally turned on while you are installing or servicing this product. Refer to this manual (and
documentation for related equipment) for complete installation and safety information.
WARNING: Before you enter a containment sump, check for the presence of hydrocarbon
vapors. Inhaling these vapors can make you dizzy or unconscious, and if ignited, they can explode
and cause serious injury or death. Containment sumps are designed to trap hazardous liquid
spills and prevent environmental contamination, so they can accumulate dangerous amounts
of hydrocarbon vapors. Check the atmosphere in the sump regularly while you are working in
it. If vapors reach unsafe levels, exit the sump and ventilate it with fresh air before you resume
working. Always have another person standing by for assistance.
WARNING: Follow all federal, state, and local laws governing the installation of this product
and its associated systems. When no other regulations apply, follow NFPA codes 30, 30A, and 70
from the National Fire Protection Association. Failure to follow these codes could result in severe
injury, death, serious property damage, and/or environmental contamination.
WARNING: Always secure the work area from moving vehicles. The equipment in this manual
is usually mounted underground, so reduced visibility puts service personnel working on it in
danger from moving vehicles that enter the work area. To help prevent this safety hazard, secure
the area by using a service truck (or some other vehicle) to block access to the work area.
WARNING: UPP® Welding Units must never be operated in Zone 1 or Zone 0 areas (Hazardous
area definitions are from European Directive 1999/92/EC and guidelines can be found in the
APEA Blue Book 3rd Edition).
WARNING: Ensure Welding Units are connected to a power supply that meets the
requirements detailed in the user manual and are within the requirements of any local authority
or regional legislation.
WARNING: Important to any type of piping system is to safely connect all metallic
components to ground. Metallic components, and more general conductive materials, due
to their high capacitance, can have the potential to store high amount of electrostatic energy
(sparks discharge can only be observed over conductive elements).
WARNING: All exposed metal parts used in UPP® System installations should be adequately
grounded to a dedicated earth electrode and brought to a potential equal to that of other metal
parts in the close proximity.
WARNING: Where using chemicals (such as Acetone) during the installation of UPP® systems
products, follow all safety guidelines given on the chemical containers themselves or on any
accompanying literature.
WARNING: Some installation of UPP® products may occur in confined spaces where a lack of
oxygen and a concentration of toxic vapors is likely to be experienced.
WARNING: Such working conditions are dangerous and all local health and safety guidelines
for working in such environments should be followed.
WARNING: Ensure the correct personal protective equipment (PPE) is used at all times in line
with local health and safety requirements.

2
 WARNING: Ensure all safety data is accessed and used while installing UPP® Systems (Material
Safety Data Sheets are available in the download area of the UPP® website).
WARNING: UPP® products should be transported and stored in accordance with the
guidelines contained in this manual.
WARNING: Heavy items should be handled using suitable lifting equipment operated by
authorised personnel.
DANGER: Make sure you check the installation location for potential ignition sources such as
flames, sparks, radio waves, ionizing radiation, and ultrasound sonic waves. If you identify any
potential ignition sources, you must make sure safety measure are implemented.

Site Preparation
IMPORTANT: Site inspection: Make sure the site is prepared and ready. The tanks, sumps, fill
points, vents etc. should be in place.
IMPORTANT: The site should be free from previous fuel contamination.

3
Underground Fuel Pipe
Systems

Figure 1: Installation Overview

Several types of UPP® underground fuel pipe are available for different applications and to meet
various engineering and legal requirements:
• Primary pipe can be used as a fuel-proof liner for product, suction, pressure, vapor vent,
and fill lines.
• Secondary containment pipe can be used with EN primary pipe  for pressure systems or
environmentally sensitive sites.
• Integral secondary containment pipe (UL971 spec) can be used for pressure systems or
environmentally sensitive sites.
• Electrical conduit pipe can be used for underground electrical wiring protection.
• Duct can provide a watertight, underground channel for pipes or electrical cables.
UPP® piping systems are designed in various diameters, from 32-160 mm (I- 6") to transfer fuels
in filling station forecourts, marinas, and airports. UPP® systems are also used for government
and military installations as well as many industrial sites such as mines and rail depots.

5
 There is no requirement for a concrete trench because fusion welded HDPE pipe is structurally
resistant to weight of backfill material and dynamic traffic loads. Over 30 years experience
showing no failures in underground fuel pipe systems and no loss into the ground.

Underground Fuel Pipe Construction

The black outer structural layer of the pipe is High Density Polyethylene (HDPE), grade PE100
that allows the use of electrofusion couplers and fittings to construct a variety of pipeline
configurations. HDPE PE100 has well-proven resistance to: stress cracking, puncture, scratch,
impact, microbial and rodent attack.
The intermediate tie-layer causes a permanent bond to occur between the polyethylene and
the liner material. The liner of UPP® primary pipe is a specially formulated “fuel proof” barrier
layer manufactured from EVOH (EN / UL). This liner has exceptional resistance to absorption and
permeation of both hydrocarbon and alcohol fuel blends.
The smooth bore and low friction loss of UPP® pipe permits higher fuel and vapor flows than
steel pipe, reducing the pumping energy costs.
UPP® primary fuel pipe is pressure rated to 10 bar (EN) or (90 psi) to UL971. Rupture pressure is
typically exceeding 40 bar (580 psi) providing a large margin of safety.

Carrier - PE - Black

Tie Layer

Liner - EVOH -clear (EN / UL)

Figure 2: UPP® Pipe Structure

Pressure Ratings
Pressure Rating (UL 971)
Pipe type Pressure Rating (Bar) Pressure Rating (PSI)
UPP® Primary 6.2 90
UPP® Secondary 4 58
Table 1: UL971 Pipe  Maximum Pressure Rating

Pressure Rating (EN14125)

Pipe type Pressure Rating (Bar) Pressure Rating (PSI)
UPP® Primary 10 145
UPP® Secondary 5 72.5
Table 2: EN14125 Pipe  Maximum Pressure Rating

6
Transit, Off-Loading, and
Storage
Although UPP® polyethylene pipe and fittings are extremely hard wearing and resilient, it is
important to handle and store them with care to prevent scuffing or gouging. Any damaged pipes
may need to be rejected and not installed.
UPP® products should be transported in a flat-bedded vehicle, free from sharp objects and
projections. Wide polypropylene slings must be used when lifting pipe crates by crane. Avoid
using chains, hooks or hawsers. A spreading beam should be used when lifting crates containing
pipe lengths greater than 6 m (19 ft 8"):
• Allow for a slight bending of the pipe crates when on and off-loading.
• Standard 6 m (19 ft 8") crates may be moved using a forklift. A side loader fitted with a
minimum of four supporting forks should be used for longer lengths. Otherwise use a crane
fitted with a spreader beam.
• When using a forklift to on or off-load coils, the forks should be covered to avoid damage to
the coiled pipe.

Figure 3: Moving Coils

7
 Storage on site
• Individual pipe lengths should be stacked not more than 1 m (3 ft) high with the bottom
layer fully restrained by wedges. The bottom layer of pipes should be laid on timber battens
at 1 m (3 ft) centres to avoid any damage from sharp objects lying on the ground.
• Pipe crates should be stored on clear, level ground and should never be stacked more than
three crates high.
• Coils should be stored on firm level ground that has suitable protection for the bottom of
the coil. Primary pipe can be stacked four coils high, but EN double wall pipe should never
be stacked more than three coils high. Individual coils should be stacked flat. If stored on
edge, they must be secured against a properly anchored support and stored like this for a
short period of time only, particularly in warm weather conditions.
• Badly stacked coils and pipe lengths can slip causing personal injury or damage to the
product. Facilities for safe lifting and moving must be available.
• Pipes are supplied with end caps to prevent entry of any contamination. These end caps
must be kept in place during storage.
• UPP® fittings: All electrofusion fittings are packed in heat-sealed polyethylene bags and
delivered in cardboard cartons. Fittings should be stored in their packaging and in a dry
area, away from direct sunlight, until ready for use. This is particularly important for
electrofusion fittings. These must be kept in their packaging until ready for use to prevent
any contamination or oxidation.

Uncoiling Pipe

Figure 4: Uncoiling Pipe

8
 CAUTION: The pipe can straighten with considerable force. Take care when releasing pipe
from the coil and secure the straightened pipe.
Let the pipe rest in its uncoiled state for about eight hours. High ambient temperatures can
reduce this “layout” time and low temperatures may increase it. Pipe can be laid in its final
position to “relax” before connecting up.
• You need at least three people to uncoil and cut pipe. The coil is taped up in layers to make
it easier to uncoil at manageable intervals.
• The area in which the pipe is uncoiled on site must be clear, safe and free of sharp objects.
• Remove the tape around the tail end on the outer winding and secure this end.
• With the coil in the vertical position, roll the coil out cutting and removing tape as you find it
(ensuring to release only the next turn of pipe in the coil).
• Do not drag the pipe.
• The natural curves from coiling can be used to change pipe direction and bags of sand, pea
gravel or stakes can be used to hold it in place until it is ready for connecting.
• One person should hold the pipe whilst another cuts it to the desired length.
• The cut ends will have a prominent hook that can be partially removed when weight is
placed on it (bags of sand or pea gravel), or use the hook end to your advantage when
turning direction into a chamber or pump sump.

9
Pipe Burial Guidelines
Recommended burial depth of UPP® pipe is a minimum of 300 mm (12").
• All trenches should be sloped back towards the storage tanks. The fall back (slope) for all
pipework to the tank chambers should be a minimum of 1 m every 100 m or ⅛" per foot
(Figure 7). This may vary to meet local requirements. The position of the entry fittings at
the furthest dispenser sump away from the tank chambers may be considerably higher than
that of the entry fittings on the closest dispenser sump.
• Vapor return lines should have a slope of 2 m every 100 m (¼" per foot) and never less
than 1 m every 100 m (⅛" per foot) back towards the tank farm, unless in-line joints such as
elbows are to be used.
• Trench corners should have a radius of 1.5 m (5').
• A recommended 150 mm (6") bed of backfill material should be laid underneath the pipe
prior to installation and there must never be voids under or around the pipe. Acceptable
backfill materials are:
• Well-rounded pea gravel size 3 mm  (⅛") to 20 mm  (¾").
• Crushed rock size 3 mm (⅛") to 16 mm (⅝").
• Clean washed sand.
• At installation, backfill cannot be contaminated with petroleum products or other
contaminants.

D1 D2 D3 300mm (6")
min
150mm (6")
min

150mm (6")
min

150mm (6") D1 D2 150mm (6")

min min

Figure 5: Pipe Spacing

11
 • When laying duct onto a concrete base a 150 mm (6") thick bed of compacted sand should
be laid on the concrete, below the duct. (The minimum amount of sand should be 50 mm
(2") of compacted sand)
• All beds should be laid so that the pipe will not dip or sag when it is installed.
• Laying of pipe should start from the tank farm.
• Any mechanical joints or compression fittings must be located within a containment
chamber or sump or be adequately protected from the environment when used on buried
vent lines.

Figure 6: Electrofusion Welded Fitting Detail

NOTE: Refer to FFS manual 408001007 for information about the electrofusion process.

12
 1:100 Fall-back (Slope) to tank

Figure 7: Fall-back (slope) to Tank

• UPP® pipe that is located between dispenser containment or that exceeds 12 m (39 ft) should
be laid in a series of large snake-like curves and not in straight lines. Uncoiled pipe, when
laid, will settle in a natural curve.

13
 Figure 8: Using Temporary Stakes to Snake Pipe

• Generally any thermal expansion will be accounted for by following our guidelines for
spacing, backfilling and ensuring runs are “snaked”.
• Pipes should be separated from each other by at least the diameter of the largest pipe.
• If pipe-runs cross each other they must be separated by at least as much backfill material
as the diameter of the largest pipe or protected using at least 25 mm (1" ) of expanded
polystyrene.
• If used above ground, UPP® pipe should be protected against mechanical, climatic damage.
Additional supports and anchor points may also be required. Check fire codes for proper
installation. Also see the document UPP® Piping Above Ground and Marina Installations.
• Mark positions on the tank access chamber/sump for penetration locations and install UPP®
seals.

Bend Radius

14
The UPP® piping systems have a semi-rigid construction which gives both strength and flexibility.
To achieve absolute minimum bend radius in cold conditions, use a heated trailer or equivalent to
precondition the pipe. In Figure 9, “X” is the bend radius, the distance between the pipe axis and
“+,” the center of the pipe's arc.

X Bend radius

Center of pipe's arc

Figure 9: Bend Radius

NOTE: Refer to Table 3 for allowable bend radius of UPP® Pipe.

IMPORTANT: Completion Records—On completion of UPP® installation make an “as constructed”
drawing showing the exact location of all below ground lines. It is also recommended that, in
addition, a photographic record is preserved.

Pipe Bend Radius

Single Wall Pipe
32 mm (1 ")  50 mm (1½")  63 mm (2")  90 mm (3")  110 mm (4") 
0.5m (1 ft 7") 0.75 m (2 ft 6") 0.9 m (3 ft) 1.35 m (4 ft 5") 1.65 m (5 ft 5")

Double Wall Pipe

40/32 mm 63/50 mm 75/63 mm 110/90 mm 
125/110 mm (4")
(1 ")   (1½")  (2") (3")
0.5m (1 ft 7") 0.75 m (2 ft 6") 0.9 m (3 ft) 1.35 m (4 ft 5") 1.65 m (5 ft 5")

UL971 Pipe
63 mm   90 mm 63/50 mm 75/63 mm 110/90 mm 125/110 mm
(2") (3") (1½") (2") (3") (4")
1m (3 ft 3") 3 m (9 ft 10") 1m (3 ft 3") 1m (3 ft 3") 4 m (13 ft 2") 4 m (13 ft 2")
Table 3: Allowable Bend Radius

Pipe Detector Tape

UPP® Detectable tape is used to allow the piping location to be found after it has been covered.

15
 The tape is installed below ground at 250 mm (9.8 inches) height directly above pipe runs to
indicate the position of each pipe.

Detector Tape

Max Depth
Detection 3 m

Pea Gravel
or Sand 250 mm

Subsoil

UPP Pipe
Figure 10: Detector Tape Installation

Both ends of the tape should be grounded during installation.

Earthing Rod Ends of Tape Must be Grounded at Sumps

Figure 11: Detector Tape must be Grounded

When using a detection tool, the near end of the detectable tape should be disconnected from
the grounding point to allow the red cable from the transmitter to be connected to the tape and

16
the black cable from the transmitter to be connected to the grounding point. The far end of the
tape should remain grounded to give the highest signal strength and the earth spike should be as
far away from the trace path as possible at a 90 degree angle.
Use the lowest frequency possible from the transmitter around 577 Hz or 8 KHz to eliminate
coupling to other grounded cables. Use the receiver to follow the path of the tape to locate the
buried pipe. Follow direction included with the receiver and transmitter for detecting buried pipe
location.

17
 Pressure Testing
Following inspection, prior and subsequent to backfilling, a tightness test should be carried out
by a competent person on each pipe run, chamber and sump to verify the integrity of joints and
seals. This testing should meet the requirements of local officials and engineers and comply with
local health and safety regulations. The following testing procedure is suggested for guidance
only and should in no way override oil companies or local regulator’s requirements.

Testing Guidelines
Equipment
• Target test pressure should be 50% of scale on gauge, e.g. if the test pressure is 1 Bar
(14.5 psi), use a 2 Bar (29 psi) gauge.
• Gauges should have serial numbers and be tested and certified every year.
• Pressure testing equipment should have fitted a relief valve set at around 0.5 bar (7.25 psi)
above the test pressure.
General Guidelines
• When applying pressure from gas cylinders, use suitable valves to ensure test pressure is
not exceeded.
• Apply pressure or vacuum slowly to minimise risks.
• When you test primary pipe for tightness, the secondary should be open to atmosphere.
• Secondary pipe should not be welded prior to testing primary to allow inspection of joints.
• When you test secondary pipe for tightness, the primary should be open to atmosphere.
(The exception is when you test the secondary pipe at a pressure higher than the
recommended value. When this is the case, pressurize the primary pipe to at least 1 bar
before you pressurize the secondary pipe.)
• Wipe each joint with soapy water to check for leaking.
CAUTION:
• To avoid explosion hazards, nitrogen or an inert gas from a pressure cylinder should be used
in place of compressed air for tightness testing if fuel has been used to ballast underground
storage tanks or if pipe-work has previously contained petroleum.
• Pipe-work should be disconnected (isolated) from underground storage tank prior to
commencing tightness testing.
• Any water used for testing should be disposed of through the oil / water separator or by
a specialist contractor and in accordance with any local environmental health and safety
requirements and regulations.

18
There are two recommended tightness test methods for UPP® primary pipe-work: hydrostatic
and pneumatic. In all instances the hydrostatic method is to be preferred as it allows high
pressures to be used with relative safety. However, there will be instances where the introduction
of water into the pipe-work is undesirable, in these cases the pneumatic method should be
adopted paying particular attention to the safety aspects of working with compressed gas due to
the high levels of potential energy that can be stored.
IMPORTANT: Always test secondary pipe after you perform the pneumatic procedure.

Recommended Pipe Test Procedure

Primary Pipe Hydrostatic Pressure Testing Method
Equipment
• Pump rated for more than 10 bar (145 psig)
• Hydrofor (reservoir or pressure tank)
• Two pressure gauges, rated for 12 bar (174 psig), min. reading 0.1 bar (2 psig)
• Check valve
• Ball valve
• Pressure relief valve rated for 20 bar (290 psig), set at 11 bar (159 psig)
Conditioning Phase
• Fill the pipe work system to be tested with water, making sure that any air relief valves are
opened while filling the pipe work.
• After filling the pipe work wait 1 hour for the temperature to stabilize.
• Pressurize the system to 10 bar (145 psi) and maintain this pressure for 30 minutes.
(System pressure shall be maintained by means of refilling in order to compensate for the
increase in volume due to the expansion of the pipe-work). At this time the system should
be thoroughly inspected for leakage. After any such areas have been remedied repeat the
conditioning before proceeding to the testing phase.
Testing Phase
• Rapidly reduce the system pressure to 3 bar (43.5 psi) by bleeding water from the pipe-
work. (Due to the visco-elastic properties of polyethylene the pipe will contract).
• During the test period of 90 minutes the pressure should be recorded with the frequency
shown below:
Test period (mins) Frequency of readings (mins) Number of readings
0-10 2 6
10-30 5 4
30-90 10 6
Table 4: Recording Test Results
• The test is passed if all the readings during the testing cycle are 3 bar (43.5 psi) or above.
• Decreasing readings = failure of pressure test. (Note that the readings are likely to increase).

19
 • If the system fails the pressure test make the following checks:
• Check all mechanical connections.
• Check welded joints.
• When the failure point has been located and remedied repeat the full conditioning and
testing sequence.
Maintain 145 PSI (10 bar) for 30 minutes
145 (10)
130.5 (9)
116 (8)
Pressure PSI (bar)

101.5 (7)
87 (6)
72.5 (5)
58 (4)
43.5 (3)
29 (2) drop to 43.5 PSI (3 bar) for 90 minutes
To Pass Test Pressure Must remain at 43.5 PSI (3 bar) or above
14.5 (1)
0
0 10 20 30 0 2 4 6 8 10 15 20 25 30 40 50 60 70 80 90
Conditioning Time (mins) Test Reading Times (mins)
Hydrostatic Testing Graph

Pneumatic Tightness Testing Procedure

The following testing procedure is suggested for guidance only and should in no way override oil
companies or local regulator’s requirements. Never exceed the pressure ratings of components
shown on Table 1 and Table 2 when testing.
Test Procedure
• Record Temperature and Pressure at start of each test time.
• Condition and test the piping as follows:
1. Pressurise the piping to 10% of test pressure, hold pressure for 30 minutes and inspect
for leakage or pressure drop.
2. Increase pressure to 50% of test pressure and again inspect for leakage while holding
pressure for 30 minutes.
3. Increase pressure to 100% of test pressure and again inspect for leakage while holding
pressure for 30 minutes.
• Record Temperature and Pressure at end of each test time.
• If results are within criteria of Table 6 Tightness Test is passed.
Pressure Testing Safety
Follow these guidelines when conducting pneumatic testing:
• Wear Safety glasses.
• Relieve air pressure before any corrective actions are taken.
• Allow only necessary and authorized persons in the proximity of pipe being tested.
• Restrain the movement of connections, joints and seals during testing.
Recommended Pipe Tightness Testing Pressure

20
 Pipe Type Bar PSI
Primary pipe 3.5 50
Secondary pipe with Welded Reducers 1.0* 15
Secondary pipe with Rubber Reducers 0.5 7
Table 5: Recommended Pipe Tightness Testing Pressures

NOTE: When you test the secondary pipe at a pressure that is higher than the recommended
value, pressurize the primary pipe to at least 1 bar before you pressurize the secondary pipe.

Acceptable Pressure Variation

Initial Pressure 3.5 bar
Temperature variation Δ T (°C) -15 -10 -5 0 5 10 15
Final pressure due to temperature change (bar) 3.27 3.35 3.42 3.50 3.58 3.65 3.73

Initial Pressure 50 psi

Temperature variation Δ T (°F) -30 -20 -10 0 10 20 30
Final pressure due to temperature change (psi) 46.3 47.6 48.8 50.0 51.2 52.4 53.7

Initial Pressure 3.0 bar

Temperature variation Δ T (°C) -15 -10 -5 0 5 10 15
Final pressure due to temperature change (bar) 2.80 2.86 2.93 3.00 3.07 3.14 3.20

Initial Pressure 44 psi

Temperature variation Δ T (°F) -30 -20 -10 0 10 20 30
Final pressure due to temperature change (psi) 40.7 41.8 42.9 44.0 45.1 46.2 47.3

Initial Pressure 0.5 bar

Temperature variation Δ T (°C) -15 -10 -5 0 5 10 15
Final pressure due to temperature change (bar) 0.42 0.45 0.47 0.50 0.53 0.55 0.58

Initial Pressure 7 psi

Temperature variation Δ T (°F) -30 -20 -10 0 10 20 30
Final pressure due to temperature change (psi) 5.8 6.2 6.6 7.0 7.4 7.8 8.2

Table 6: Acceptable Pressure Variation

21
Sump Inspection Register
• Required monthly and/or annual inspection: Containment sumps located on the property at which the FFS
products are installed must be visually inspected for liquid monthly. Sump sensorsif installed, must be tested
annually. Any leaks must be corrected at the time they are found.
• Recommended monthly inspection: Verify sump lids are tight and sealed. Inspect sumps for dirt, debris,
liquid or any physical cracks or holes that would allow leakage. Check for evidence of staining or new staining.
Verify penetration boots are in good condition and the pipe entry into the sump is positioned properly (near
perpendicular entry). Verify sump liquid sensors are positioned correctly if installed. Verify the piping and
other equipment in the sump are in good condition.
• Record any faults on this Sump Inspection Register and have the fault(s) corrected at the time found.
• You can download this form (part number 408001011) from the FFS website at www.franklinfueling.com.
• End user proprietary inspection check register logs or any form to record these inspections is acceptable.

Date of Inspection or Test Results of Inspection or Test Signature of Inspector or Tester

 ANNEX 02

EF1-230V Hand-Held Welder

Operating Manual
For use Only with UPP™ Electrofusion Components

Franklin Fueling Systems • 3760 Marsh Rd. • Madison, WI 53718 USA

Tel: +1 608 838 8786 • 800 225 9787 • Fax: +1 608 838 6433
• www.franklinfueling.com
 UPP™ welding units must never be operated in Zone1
Warning
or Zone 0 areas!
Hazardous area definitions are from European Directive 1999/92/EC (further
guidelines can be found in the APEA Blue Book 2nd Edition).Further guidelines
are found in IEC 60079-10-1, “Explosive atmospheres - Part 10-1: Classification
of areas - Explosive gas atmospheres”
Safety
• The EF1 is designed for usage on construction sites and meets applicable
European and International safety standards. The machine should be
handled with the care usually given to electrical equipment, especially during
transport.
• The machine must only be used outside of hazardous areas (zones 0, 1 and 2).
• Each time it is used, check the condition of the machine, particularly the
mains power cable. If any damage is discovered, contact the supplier
immediately and do not use the machine.
• Check the state of the welding cables before use and replace them if there is
any doubt about their condition.
• Protect the welder from getting wet.
• Always check that the power source is within the parameters shown below
before using the EF1.
• Never lift or pull the machine by its power cable or the welding cables. Never
disconnect welding cables by pulling the cable; always pull off the connectors.
• Never re-weld a fitting that is still warm. Serious fire or burn damage
can occur and hot material may be ejected from the weld zone. Power
conducting elements may become exposed creating an electrical shock
hazard.
Liability Restrictions
All liabilities of the supplier are invalidated in the following cases:
• The EF1 is used outside the indicated application area.
• Non-UPP™ fittings or pipe are used.
• The operator has not been trained to use the EF1 or the UPP™ system.
• Operating instructions have not been observed.
• Unauthorised repairs, maintenance or modifications have been carried out.
• The EF1 has been used outside of its technical specification.
• Safety instructions have not been observed.
• Improper or inadequate maintenance.
• Misuse, physical abuse or any use not in accordance with the operating
manual or good industry practice.
• Improper site preparation or site maintenance.
2
Technical Specifications
Stock code__________________ EF1-230V
Supply voltage_______________ 230 V +/- 15% (194 V to 264 V)
Supply frequency_____________ 50/60 Hz (40 Hz to 70 Hz)
Supply power________________ 2.8 kW / 3.5 kVA
Supply protection_____________ Class 1 earthed (grounded)
Environmental protection_______ IP65
Operating temperature_________ -15 ºC (5 ºF) to +45 ºC (113 ºF)
Shipping dimensions 460 mm (18") wide x 210 mm (8.3") deep
x 210 mm (8.3”) high
Shipping weight______________ 3.6 kg (8 lb)

Power Supply
Welder must be powered with:
• A quality 230 VAC, 50 Hz power supply with maximum tolerance of ± 15%.
• A quality generator capable of supplying a minimum of 2.8 kW (3.5 kVA).
Note that an earth-spike (grounding rod) must be used with generators.
If used with a 110v to 230v step-up transformer follow these specifications:
• Safety Isolating transformer: 3.3 kVA minimum.
• Auto transformer: 3.3 kVa minimum.

Extension Cords / Cables
Extension cables must comply with or be equivalent to H07RN-F
specifications. Cable use must comply with the following table.

Maximum
Wire Size AWG Wire Maximum
Length,
Metric Size Length, feet
meters
1.5 mm 15 25 82
2.5 mm 13 50 164
4.0 mm 11 75 246

Note: All cable must be unwound from reel to prevent inductive heating
effects.

3
 Note: EF1 welding cables use special 7 pin connectors.

Parts
Bridging cables (x2)
EF1 Electrofusion Welder

7pin Secondary
welding cable

7 pin Primary and Gemini

Secondary welding cable

Power cable

7 Pin Fusion chamber welding cable

Application
The EF1 is designed to automatically weld UPP™ Primary and Secondary
Containment electrofusion fittings, Electrofusion Chambers and Large
diameter 10 amp fittings. This is done by using color-coded welding leads as
shown below.
Size of Weld Time
Type Welding
Welding Current @ 20C
of Cable
Pin (amps)
Fitting Colour (Seconds)
(mm)
Primary and Gemini
Red 4 4 184
Secondary fittings
Secondary Green 2 5 80
Fusion Chamber White 2.3 7 360
Large Diameter (10amp) Black 2 10 365

The EF1 can be used in ambient temperatures between -15 °C (5 ºF) and
+45 °C (113 ºF). Only personnel fully trained and certified in the use and
installation of the UPP™ system should use this equipment.

4
Main Features
UPP™ electrofusion fittings are welded using a constant current. The EF1
automatically recognizes the fitting when connected and applies the correct
amount of energy for a successful weld.
7 pin Weld cable
Power on Indicator connector

ON / OFF Switch (on

side of unit) Fault
indicator

Temperature sensor

Weld progress
LED’s

START / STOP button

The EF1 takes the ambient temperature into account when calculating the
energy required to weld correctly. It must therefore be allowed to reach
ambient temperature before use and must be at the same temperature as the
fitting to be welded. The temperature sensor is located adjacent to the power
cable entry gland.
The EF1 works on standard alternating current and either a mains connection
or a generator can be used. Generators must have a rated output of at least
3.5 kVA and power input must be between 194 and 264 volts at 40 to 70 Hz.
The EF1 has an on / off button, a weld start button and an LED display
showing the weld progress. The LEDs can also show any fault conditions that
may affect the weld.

5
 Using the EF1
• Ensure that the machine is positioned outside hazardous zones
ATEX 0, 1 and 2.
• Allow the machine and fittings to reach the ambient temperature of the site.
• Keep the machine out of direct sunlight and free of any obstruction.
• Make sure fittings and pipe have been prepared in accordance with UPP™
Installation instructions.
Follow the steps below to weld Electrofusion fittings.
1. Connect the required welding lead to the EF1 Welder:
PRIMARY and GEMINI SECONDARY fittings = RED (ORANGE) cable
SECONDARY fittings = GREEN cable
FUSION CHAMBER = WHITE cable
10 AMP fittings = BLACK cable
2. Connect the welding lead to the UPP™ fusion fitting(s), making sure
connectors are firmly pushed onto the pins.
3. Connect the EF1 Welder to suitable 230V power supply.
4. Turn the unit ON. All LEDs light in sequence, then green Power LED
remains on.
5. Momentarily depress the orange START button until first weld light
illuminates. The first weld light comes on, then successive LEDs light
up until green 100% LED is lit, showing weld is complete.
6. Disconnect welding lead from fitting. The 100% LED and Power LED
remains on.
7. ALWAYS Reset for next weld by holding START button for 3 seconds.
All LEDs will light in sequence, then the green power LED remains on.
Other Important Tips
• Switch off the machine during breaks and at the end of the job.
• The weld cycle can be stopped at any time by pressing the START/STOP
button. This will generate an error code and you must wait for the fitting to
cool before attempting to continue.
• If you have any doubt about a welded joint, UPP™ fittings can be welded
again provided they are left to cool at ambient temperature for a minimum of
one hour.
Warning Never re-weld a fitting that is still warm. Serious fire
damage can occur and hot material may be ejected from
the weld zone creating a burning hazard.

Warning Power conducting elements may become exposed

creating an electrical shock hazard.

6
Multiple Welds
In Primary mode the EF1 can
simultaneously weld up to three
UPP™ fittings, provided that:
• The sum of the resistance values
(circled number on UPP™
fittings) does not exceed 10.
• The UPP™ fittings are A
connected to the EF1 in series
using the bridging leads provided
(see photos A & B).
You can ensure that you have
connected the fittings correctly and
that the welds are successful by
checking that all of the connected
fittings get warm and that all of the
indicator pins are exposed at the
end of the welding time. Fusion
fittings with X or no marking may
B
NOT be welded in series.

Maintenance
• There are no user serviceable parts inside the EF1 welding unit.
• Damaged or defective products should be returned to an approved service agent for
repair or calibration.
• Welding unit and cables should be checked for damage or defects and parts repaired
or replaced prior to each use.
• The welding unit can be cleaned using a soft brush or cloth.
• After use, carefully coil cables and store in the compartments provided in the carry
case.
• Electrical Safety Testing “Portable Appliance Test” (PAT) should be carried out in
accordance with local legislation.
• It is recommended that the welder is returned to Franklin Fueling Systems on a
regular basis, at around 3 year intervals, for checking and recalibrating.

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 Fault Indicators
When an error has occurred during the weld cycle that will have an effect on
the success of the joint, the red warning LED on the right side of the display
will light up. Also one of the “weld progress” lights will light up at the same time
to show what type of fault has occurred.
Error Fault
Meaning Solution
LED Indicated
• Check and repair power supply
• Check plug connection
Power supply The power supply was
• Check cables are not damaged or
1 failure during off at sometime during
broken
weld the weld
• Re-weld fitting only after it is allowed
to cool to ambient temperature
Stop button
Stop button was • Re-weld fitting only after it is allowed
2 pressed
pressed to cool to ambient temperature
during weld
Supply frequency not • Check and rectify generator output
Power supply between 40 and 70 • Check mains supply
3
out of limits Hz, or Voltage not • Make sure supply is to required
between 194 & 264V specification
Temperature of the • Allow EF1 and fitting to cool in the
Ambient
EF1 is not between shade
4 temperature
-15° C (5º F) and • Wait for ambient temperature to return
out of range
+45° C (113º F) to range
Loose connection to • Make sure connectors are pushed
terminal pin firmly on to terminal pins
Loose contact in the • Check welding cable connection and
No output
welding circuit continuity
5 current
Faulty fitting • Move generator closer and use shorter
(open circuit)
Start button not extension cord
depressed for long • Replace fitting
enough • See operating sequence, step 5
• Use only UPP™ electrofusion fittings
Resistance value of
and correct welding cable
fitting is too high
• Check resistance codes on fittings - do
Low output Too many fittings
6 not exceed a sum total of 10
current connected in series
• Check supply voltage
(Primary mode only)
• Check extension leads being used are
Input voltage too low
to specification
• Switch off machine and switch on
again after 10 seconds.
High output Regulation error in • Ensure welder is within temperature
7
current electronics range
• If problem persists, return EF1 to
supplier

The EF1 can be reset after a fault has been remedied by pressing and holding
the START / STOP button for 3 seconds.
8
Disposal
The equipment and packaging should be sorted for
environmentally friendly recycling.

IMPORTANT!
Do not dispose of this equipment into
household waste.

RoHS Compliant According to the European Directive 2008/34/EC

Directive 2008/ Waste Electrical and Electronic Equipment (WEEE),
35/ EC when no longer suitable for use, this equipment must
be separately collected and sent for recycling.

According to the European Directive 2008/35/EC

Restriction of Hazardous Substances (RoHS), this
equipment does not contain more than the agreed levels
of Lead, Cadmium, Mercury, Hexavalent Chromium,
Polybrominated Biphenyl (PBB) and Polybrominated
Diphenyl Ether (PBDE) flame retardants.

Declaration of Conformity
This welding unit has been designed to comply with the harmonised standards
under “New Approach” directives and has been CE Marked accordingly.
The applicable standards are:
• 2004/108/EC Electromagnetic compatibility.
• 2006/95/EC Low voltage equipment.
• 98/37/EC Machinery safety.
• 94/62/EC Packaging and packaging waste.
• 2008/34/EC Waste electrical and electronic equipment.
• 2008/35/EC Restriction of hazardous substances.

Andrea Ticci Signed on behalf of Franklin Fueling Systems