McElroy A714201 Operator'S Manual Download Page 5

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Table of Contents

Safety

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Read and Understand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electric Motors are Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . 1-2

Overhead Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Carriage Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Overview

Theory of Heat Fusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Acrobat Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Fluid Reservoir (Acrobat HPU) . . . . . . . . . . . . . . . . . . . . . . . 2-3

Filter (Acrobat HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Carriage Control Box (Acrobat HPU) . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

DynaMc EP Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Fluid Reservoir (DynaMc EP HPU) . . . . . . . . . . . . . . . . . . . . 2-5

Filter (DynaMc EP HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic Manifold Block (DynaMc EP HPU) . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Electrical Power Receptacles (Acrobat HPU) . . . . . . . . . . . . . . . . . . . . . 2-6

Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Heater Latch (Acrobat 250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Stripper Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Clamp Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

McELROY MANUFACTURING, INC.

Tulsa, Oklahoma, USA

All product names or trademarks are property of their respective owners. All information,

illustrations and specifications in this manual are based on the latest information available

at the time of publication. The right is reserved to make changes at any time without notice.

Summary of Contents for A714201

Page 1: ...Manual 2501601 Revision C 11 18 Operator s Manual Original Language English Acrobat 160 180 250 and 315 Fusion Machines ...

Page 2: ...roduct and other products could be protected by patents or have patents pending All the latest patent information is available at patent mcelroy com Cancer and Reproductive Harm www P65warnings ca gov 8163361 ...

Page 3: ...perating this machine please read this manual thoroughly and keep a copy with the machine for future reference This manual is to be considered part of your machine McElroy University For more than 30 years McElroy has been the only pipe fusion machine manufacturer to continuously offer advanced training Course offerings are meant to enhance your efficiency productivity and safety in the proper use...

Page 4: ...h Fulton Street Tulsa Oklahoma 74158 0550 PHONE 918 836 8611 FAX 918 831 9285 EMAIL fusion McElroy com Note Certain repairs warranty work and inquiries may be directed at McElroy s discretion to an authorized service center or distributor TX02486 11 4 13 DISCLAIMER OF LIABILITY McElroy accepts no responsibility of liability for fusion joints Operation and maintenance of the product is the responsi...

Page 5: ...arriage Control Box Acrobat HPU 2 4 DynaMc EP Hydraulic Power Unit HPU 2 4 Hydraulic Fluid Reservoir DynaMc EP HPU 2 5 Filter DynaMc EP HPU 2 5 Hydraulic Manifold Block DynaMc EP HPU 2 5 Hydraulic Cylinders 2 6 Electrical Power Receptacles Acrobat HPU 2 6 Facer 2 6 Heater 2 7 Heater Latch Acrobat 250 2 8 Insulated Heater Stand 2 8 Stripper Bar 2 8 Clamp Knobs 2 8 COPYRIGHT 2018 2017 McELROY MANUFA...

Page 6: ...3 10 Check Heater Temperature 3 10 Select the Fusing Position 3 11 Inserting Heater 3 11 Heating the Pipe 3 12 Fusing the Pipe 3 13 Opening Jaws 3 14 Position Pipe for Next Joint 3 14 Install Next Piece of Pipe 3 14 Special Operations Vertical Fusion Movable Pipe Below Vertical Fusion 4 1 Support Pipe 4 1 Attach Carriage to Pipe 4 2 Prepare Heater 4 3 Begin Facing 4 4 After Facing 4 4 Check Alignm...

Page 7: ...Vertical Fusion Pressure 5 11 Opening Jaws 5 12 Special Operations Fusion in Explosive Atmosphere Facer 6 1 Heater 6 1 Hydraulic Power Unit HPU 6 2 Maintenance Preventative Maintenance 7 1 Washing the Machine 7 1 Check Hydraulic Fluid 7 1 Change Hydraulic Fluid and Filter 7 2 Check Pressure Gauges 7 2 Change Gearbox Oil Acrobat 315 7 3 Bleeding Air From Hydraulic System 7 3 Bleeding Air From Acrob...

Page 8: ...ressure 9 1 Hydraulic Fluids Hydraulic Fluids 10 1 Specifications Fusion Machine Specifications Acrobat 160 11 1 Fusion Machine Specifications Acrobat 180 11 2 Fusion Machine Specifications Acrobat 250 11 3 Fusion Machine Specifications Acrobat 315 11 4 Generator Sizing Form 11 5 Optional Accessories DataLogger 5 12 1 ...

Page 9: ...IMPORTANT can help you do a better job or make your job easier in some way PELIGRO PELIGRO WR00051 11 30 92 TX00030 12 1 92 Read and Understand Do not operate this equipment until you have carefully read and understand all the sections of this manual and all other equipment manuals that will be used with it Your safety and the safety of others depends upon care and judgment in the operation of thi...

Page 10: ...loose fitting clothing or long hair that could catch on controls or moving machinery WR00053 12 2 92 TX00114 4 22 93 TX00032 4 7 93 Heater Is Not Explosion Proof This heater is not explosion proof Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death When operating in an explosive atmosphere the heater should be brought up to tem...

Page 11: ...ausing serious injury Keep hands and body away from pinholes which eject fluid under pressure Use a piece of cardboard or paper to search for leaks If any fluid is injected into the skin it must be immediately removed by a doctor familiar with this type of injury Unwanted movement of the machine could result in serious injury or damage to machine Unwanted movement of the machine may take place if ...

Page 12: ...nect machine power and remove the facer blades before attempting any maintenance or adjustment NOTICE Never extend the facer blades beyond the inner or outer circumference of the facer TX02378 04 18 16 WR00073 4 6 93 Heater is Hot The heater is hot and will burn clothing and skin Keep the heater in its insulated heater stand or blanket when not in use and use care when heating the pipe NOTICE Use ...

Page 13: ...e joining standard for the pipe being fused Follow the procedure carefully and adhere to all specified parameters NOTICE Failure to follow the pipe manufacturer s fusion procedures or appropriate joining standard could result in a bad fusion joint TX02984 04 18 16 WR00079 1 24 96 Safety 1 5 ...

Page 14: ...eak tight connection is the result The principal operations include Clamping The pipe pieces are held axially and radially to allow all subsequent operations to take place Facing The pipe ends are faced to establish clean parallel mating surfaces perpendicular to the centerline of the pipes Aligning The pipe ends are aligned with each other to minimize mismatch of the pipe walls Heating A melt pat...

Page 15: ... and two hydraulically operated movable jaws bolted to a skid For more compact fusion the 3 Jaw carriage can be separated from the 4 Jaw carriage without tools The carriage assembly connects to the HPU with quick disconnect QD fittings Always relieve hydraulic pressure before connecting disconnecting QD fittings TX04791 05 05 16 Overview 2 2 CD01327 10 1 15 ...

Page 16: ...ycle on and off to meet the demands of the hydraulic system which reduces noise and power consumption 3 Carriage control box Includes all the McElroy standard carriage controls DataLogger port Pressure gauge Hour meter Carriage Control Box Filter Bypass Indicator Electric motors are not explosion proof Operation of these components in an explosive atmosphere will result in serious injury or death ...

Page 17: ...e to the HPU On the bottom side of the electrical box is a motor circuit breaker Electric motors are not explosion proof Operation of these components in an explosive atmosphere will result in serious injury or death Refer to Special Operation Fusion in Explosive Atmosphere for safety precautions TX04796 05 05 16 CD01153 03 06 14 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE...

Page 18: ...ng pressure to a maximum of 400 psi E The middle knob adjusts heating pressure to a maximum of 400 psi F The bottom knob adjusts fusion pressure The maximum fusion pressure may vary by model TX04663 05 05 16 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE CD01434 11 16 15 Overview 2 5 Filter DynaMc EP HPU This mac...

Page 19: ... the correct accessory into its correct corresponding receptacle as indicated by the labeling The HPU uses current sensing and logic to actively control the power to the heater receptacle If the facer receptacle current sensor senses that the facer is on or if the HPU motor is running the heater receptacle will be disabled Otherwise the heater receptacle will be enabled NOTICE Always plug accessor...

Page 20: ...vent damage NOTICE Never extend the blade beyond the inner or outer circumference of the facer Acrobat 315 Facer The facer is a McElroy rotating planer block design The blade holders each contain two cutter blades The block rotates on ball bearings and is chain driven with an electric motor mounted to a gearbox The gearbox contains 80 90W gear oil This facer cannot be operated manually Electric mo...

Page 21: ...ture scale When the heater is plugged in and preheating the light glows steadily until the set temperature is reached The light then goes off and on slowly as the heater maintains temperature Heater plates are not shipped from McElroy installed The heater body is not coated Coated butt fusion heater plates are available for all butt fusion applications Ensure the butt fusion heater plates are inst...

Page 22: ...ll burn clothing and skin Keep the heater in its insulated heater stand or blanket when not in use and use care when heating the pipe TX04664 03 24 14 CD01383 10 5 15 CD01403 10 5 15 Clamp Knobs Clamp knobs are equipped with a thrust bearing which permits the operator to develop high clamping forces with minimal effort TX03099 4 12 10 CD01330 10 1 15 Heater Latch Acrobat 250 and 315 The heater has...

Page 23: ...ilure to do so will result in serious injury or death Refer to Special Operation Fusion in Explosive Atmosphere for safety precautions Each device must be connected to a source rated for each device s power requirements Each device has a plate or label with the device s power requirements Consult generator sizing form in the back of this manual to determine the proper size generator to power all e...

Page 24: ...tand Plug heater into a proper power source For Acrobat HPUs equipped with electrical power receptacles the heater may be plugged into its proper accessory receptacle on the HPU IMPORTANT The HPU must be powered on for the heater receptacle to be enabled Allow heater to warm up to operating temperature Refer to the Maintenance section of this manual for instructions on how to adjust heater tempera...

Page 25: ...rd into a proper power source Turn on main power switch TX04803 11 18 15 Connect HPU to Carriage Assembly With HPU on adjust carriage pressure to its minimum setting then turn HPU off NOTICE Always relieve hydraulic pressure before connecting disconnecting quick disconnect QD fittings Connect QD fittings on HPU hoses to the carriage QD fittings Turn on main power switch TX05042 05 05 16 Butt Fusio...

Page 26: ...receptacle will be disabled TX05212 12 20 17 PELIGRO Butt Fusion Procedure 3 4 Hydraulic Pressure The pressure gauge indicates the pressure at the carriage directional control The pressure shown on the gauge is determined by the position of the pressure selector and the pressure setting of the selected pressure reducing knobs TX04805 05 05 16 CD01434 11 18 15 0 100 200 300 400 500 600 700 800 900 ...

Page 27: ... the fixed jaw brace B Rotate the fixed jaw brace away from the inner fixed jaw C Repeat for the fixed jaw brace on the opposite side of the carriage D Slide the 3 Jaw carriage away from the outer fixed jaw and away from the tabs holding the carriage E The 3 Jaw carriage is ready to be used for fusion TX04689 05 05 16 CD01331 10 1 15 CD01332 10 1 15 CD01333 10 1 15 CD01336 10 1 15 A B D E ...

Page 28: ...76 10 5 15 Clamp the Pipe Tighten the clamp knobs on the outside jaws to prevent pipe from slipping Hand tighten the inside clamp knobs to allow for HI LO adjustment The clamp knobs are equipped with a ball thrust bearing which permit the operator to develop high clamp forces with minimal effort NOTICE When clamping do not over tighten the clamp knobs because machine damage can result Check to see...

Page 29: ...e neutral position Allow the facer to run for several revolutions to ensure that there are no chips hanging on the end of the pipe Turn facer off TX04808 05 05 16 CD01372 10 5 15 CD02320 06 20 18 CD01378 10 5 15 After Facing Ensure the facer has come to a complete stop Move the carriage directional control to the right to open the carriage Turn off the HPU Release the handle lock and lift the face...

Page 30: ...sen the low side When the pipe is properly aligned tighten outside clamps to insure against slippage Ensure there is no unacceptable gap between the pipe ends If there is an unacceptable gap reinsert facer and reface NOTICE When clamping do not over tighten the clamp knobs because machine damage can result Check to see if there is space between the upper and lower jaws If the two jaws are touching...

Page 31: ...TX05040 05 05 16 CD1434 11 18 15 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE A Carriage Directional Control B Pressure Selector Control C Heating Pressure Reducing Knob D Carriage Pressure Gauge B D A C FUSES MOTOR POWER SUPPLY CD01941 02 07 17 A B C CD01889 02 01 17 D Calculate Fusion Pressure With the select...

Page 32: ...or appropriate joining standard for proper heater temperature IMPORTANT The dial thermometer on the heater indicates internal temperature which varies from the actual surface temperature The dial thermometer can be used as reference once the surface temperature has been verified and is never a substitute for actual surface temperature TX04011 4 12 10 WR00077 4 16 93 PH00420 11 1 94 Position Carria...

Page 33: ...ocedure 3 11 Inserting Heater The heater is not explosion proof Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death Refer to Special Operation Fusion in Explosive Atmosphere for safety precautions Use a clean dry lint free non synthetic cloth to clean the butt fusion heater adapter surfaces Insert heater between the pipe ends A...

Page 34: ...arriage away from the heater shift the carriage directional control D to neutral TX04774 05 05 16 CD01435 11 16 15 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 200 300 400 5...

Page 35: ...he pipe ends together under the pipe manufacturer s recommended pressure Allow joint to cool under pressure according to pipe manufacturer s or appropriate joining standard s recommendations TX04814 CD01341 10 5 15 CD01437 11 16 15 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 200 300 400 500 600 700 800 9...

Page 36: ...he jaws TX04815 05 05 16 CD01342 10 5 15 Position Pipe for Next Joint Move the fusion machine to end of pipe or pull the pipe through the jaws until the end of the pipe is protruding approximately 1 25 4mm past the fixed jaw TX04816 12 01 15 Install Next Piece of Pipe Open the carriage completely Insert a new piece of pipe in movable jaws and repeat all previous steps in the procedures TX04817 11 ...

Page 37: ... performing vertical fusions TX04818 05 05 16 CD01382 10 5 15 Support Pipe The Acrobat carriage is not designed to support overhead or overhung loads Adequately support the pipe using appropriate support devices If not supported overhead loads could fall causing serious injury or death Ensure the pipe is properly supported before attaching the carriage to the pipe Ensure there is enough travel in ...

Page 38: ...osition Once the carriage is around the pipes reinstall the top jaws to the carriage Close the fixed jaws on the pipe Allow approximately 1 25 4mm of pipe to protrude from the fixed jaws for proper face off Tighten the clamp knobs on the fixed jaws With the HPU off connect the hydraulic hoses to the carriage Ensure the carriage control is in the neutral position Turn on the HPU Use the carriage di...

Page 39: ... fusion heater plates NOTICE The heater should never be used without butt fusion heater plates installed Refer to the Maintenance section of this manual for installation procedure Place heater in insulated heater stand Plug heater into a proper power source For Acrobat HPUs equipped with electrical power receptacles the heater may be plugged into its proper accessory receptacle on the HPU IMPORTAN...

Page 40: ...th sides Shift the carriage directional control to the neutral position Allow the facer to run for several revolutions to ensure that there are no chips hanging on the end of the pipe Turn facer off TX04822 05 05 16 CD01372 10 5 15 CD02321 06 20 18 CD01351 10 5 15 CD01352 10 5 15 After Facing Ensure facer has come to a complete stop Open the carriage Release the handle latch and lift the facer out...

Page 41: ...be taken into account when setting pressures for vertical fusion Set Heating Drag Pressure 1 Open carriage so pipe ends are approximately 2 50 8mm apart 2 Shift pressure selector to heating drag pressure 3 Turn the heating pressure reducing knob to its lowest setting 4 Move carriage directional control to the close position 5 Turn the pressure reducing knob up until the carriage starts moving then...

Page 42: ...o Pipe TX00971 5 31 96 CD01354 10 5 15 Special Operations Vertical Fusion Movable Pipe Below 4 6 Position Carriage for Heater Insertion Open the carriage until there is approximately a 2 1 2 63 5mm gap for inserting the heater NOTICE Do not open a gap too large as this could damage the heater stripper bar TX04833 11 18 15 CD01353 10 5 15 ...

Page 43: ...RO Check Heater Temperature NOTICE Incorrect heating temperature can result in questionable fusion joints Check heater plates periodically with a pyrometer and make necessary adjustments Refer to the Maintenance section of this manual for instructions how to adjust heater temperature Check heater surface temperature with a pyrometer Refer to the pipe manufacturer s recommendations or appropriate j...

Page 44: ...emains in contact with heater throughout the entire process If the pipe loses contact with the heater abort the joint and go to Attach Carriage to Pipe TX04827 05 05 16 CD01435 11 16 15 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESS...

Page 45: ...ical fusion pressure Allow joint to cool under pressure according to pipe manufacturer s or appropriate joining standard s recommendations TX04828 12 21 17 CD01382 10 5 15 Special Operations Vertical Fusion Movable Pipe Below 4 9 CD01437 11 16 15 FUSES MOTOR POWER SUPPLY CD01892 12 07 16 A C B D 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE F...

Page 46: ...nob to its minimum setting Turn off the HPU Disconnect the hydraulic hoses from the carriage Loosen the clamp knobs on movable jaws and open the jaws Support the carriage and loosen the clamp knobs on the fixed jaws and open the jaws Rotate the carriage out from around the pipe The upper jaws may need to be removed to remove the carriage from the pipe TX04829 05 05 16 Special Operations Vertical F...

Page 47: ... 10 5 15 Support Pipe The Acrobat carriage is not designed to support overhead or overhung loads Adequately support the pipe using appropriate support devices If not supported overhead loads could fall causing serious injury or death Ensure the pipe is properly supported before attaching the carriage to the pipe Ensure there is enough travel in the pipe to complete the fusion TX04819 05 05 16 CD01...

Page 48: ...nto position Once the carriage is around the pipes reinstall the top jaws to the carriage Close the fixed jaws on the pipe Allow approximately 1 25 4mm of pipe to protrude from the fixed jaws for proper face off Tighten the clamp knobs on the fixed jaws With the HPU off connect the hydraulic hoses to the carriage Ensure the carriage directional control is the neutral position Turn on the HPU Use t...

Page 49: ...tt fusion heater plates NOTICE The heater should never be used without butt fusion heater plates installed Refer to the Maintenance section of this manual for installation procedure Place heater in insulated heater stand Plug heater into a proper power source For Acrobat HPUs equipped with electrical power receptacles the heater may be plugged into its proper accessory receptacle on the HPU IMPORT...

Page 50: ...both sides Shift the carriage directional control to the neutral position Allow the facer to run for several revolutions to ensure that there are no chips hanging on the end of the pipe Turn facer off TX04822 05 05 16 CD01389 10 5 15 CD01360 10 5 15 After Facing Ensure facer has come to a complete stop Open the carriage Release the handle latch and lift the facer out Remove chips from pipe ends us...

Page 51: ... the carriage directional control to open position 5 Adjust the pressure reducing knob until the carriage moves up then adjust down until the carriage stops Then adjust the pressure reducing knob down until the carriage moves down then adjust up until the carriage stops 6 Repeat steps 1 5 to verify the heating drag pressure The heating pressure will represent the same as drag pressure on a horizon...

Page 52: ...o Pipe TX00971 5 31 96 CD01390 10 5 15 Special Operations Vertical Fusion Movable Pipe Above 5 6 Position Carriage for Heater Insertion Open the carriage until there is approximately a 2 1 2 63 5mm gap for inserting the heater NOTICE Do not open a gap too large as this could damage the heater stripper bar TX04833 11 18 15 CD01361 10 5 15 ...

Page 53: ...RO Check Heater Temperature NOTICE Incorrect heating temperature can result in questionable fusion joints Check heater plates periodically with a pyrometer and make necessary adjustments Refer to the Maintenance section of this manual for instructions how to adjust heater temperature Check heater surface temperature with a pyrometer Refer to the pipe manufacturer s recommendations or appropriate j...

Page 54: ...e pipe remains in contact with heater throughout the entire process If the pipe loses contact with the heater abort the joint and go to Attach Carriage to Pipe TX04834 05 05 16 CD01391 10 5 15 FUSES MOTOR POWER SUPPLY CD01892 12 07 16 A C B D CD01635 05 11 16 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 2...

Page 55: ...essure Allow joint to cool under pressure according to pipe manufacturer s or appropriate joining standard s recommendations TX04835 12 21 17 CD01382 10 5 15 CD01438 11 18 15 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE SELECTOR VALVE 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING...

Page 56: ...n NOTICE Ensure that the pipe remains in contact with heater throughout the entire process If the pipe loses contact with the heater abort the joint and go to Attach Carriage to Pipe TX04836 05 05 16 CD01391 10 5 15 FUSES MOTOR POWER SUPPLY CD01892 12 07 16 A D B C CD01634 05 05 16 0 100 200 300 400 500 600 700 800 900 1000 DIRECTIONAL CONTROL VALVE FACING PRESSURE HEATING PRESSURE FUSING PRESSURE...

Page 57: ...under that pressure will push the melt out of the fusion area If that happens cut out the fusion joint and repeat the steps to fuse the pipe Allow joint to cool under pressure according to pipe manufacturer s or appropriate joining standard s recommendations TX04837 12 21 17 CD01382 10 5 15 Special Operations Vertical Fusion Movable Pipe Above 5 11 FUSES MOTOR POWER SUPPLY CD01892 12 07 16 A C B E...

Page 58: ... knob to its minimum setting Turn off the HPU Disconnect the hydraulic hoses from the carriage Loosen the clamp knobs on movable jaws and open the jaws Support the carriage and loosen the clamp knobs on the fixed jaws and open the jaws Remove the carriage out from around the pipe The upper jaws may need to be removed to remove the carriage from the pipe TX04829 05 05 16 CD01393 10 5 15 CD01394 10 ...

Page 59: ...posite side Store the brushes in a safe location until needed A 7 8 hex shaft allows for manual operation in an explosive atmosphere Remove brushes on the Milwaukee facer motor The armature brushes must be removed from the electric motor when manually operating in explosive atmospheres Unscrew the brushes from both sides of the motor Both brushes must be removed A 7 8 hex shaft allows for manual o...

Page 60: ...ration of these components in an explosive atmosphere will result in serious injury or death The HPU is not explosion proof and must be located outside of the explosive atmosphere Locate HPU in a safe environment Plug the electrical cord into a proper power source TX04840 11 18 15 PELIGRO CD01153 03 06 14 CD01889 02 01 17 ...

Page 61: ...with a lint free cloth Screw dipstick in completely then remove to check fluid level Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations TX04841 05 09 16 Preventative Maintenance To insure optimum performance the machine must be kept clean and well maintained With reasonable care this machine will give years of service Therefore it is important that a regular s...

Page 62: ... on the filter housing The hydraulic fluid should be replaced every year Fill the reservoir from a clean container Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations DynaMc EP HPU The hydraulic filter and fluid should be replaced every year Fill the reservoir from a clean container Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recomm...

Page 63: ...re no oil leaks TX05336 02 15 18 Bleeding Air From Hydraulic System The two carriage cylinders have air bleed screws and must be bled if the system ever runs low on fluid or leaks air on inlet side of pump Air in the system is indicated when carriage movement becomes cushioned To bleed the system proceed as follows The bleed screws are on the ends of the rod glands Tilt machine so the fixed jaw en...

Page 64: ...s shown on the carriage pressure gauge E 8 Turn the Acrobat HPU off C 9 Refill the hydraulic reservoir according to procedure Check Hydraulic Fluid in the Maintenance section of the manual 10 Disconnect the quick disconnects at the end of the hoses 11 Turn the Acrobat HPU on C 12 Move the carriage directional control D to the close position and set the fusing pressure between 30 and 40 PSI 13 Atta...

Page 65: ...n Eyebolt Threads Keep the clamp knob eyebolt threads brushed clean TX00435 9 13 94 Clean Thrust Bearings The thrust bearings located in the clamp knobs must turn freely Wash the clamp knob bearing assembly with a solvent and then lubricate with 30W or lighter oil TX00434 9 13 94 CD01330 10 5 15 CD01330 10 5 15 Fasteners Must Be Tight Check all nuts bolts and snap rings to make certain they are se...

Page 66: ...ck coating TX04035 4 12 10 CD01397 10 5 15 7 6 Facer Blades Blades bolt directly to the blade holder and should be inspected for damage and sharpness Dull or chipped blades must be replaced NOTICE Never extend the blade beyond the inner or outer circumference of the facer TX02475 3 29 05 CD01371 10 5 15 Clean Heater Surfaces The heater faces must be kept clean and free of any plastic build up or c...

Page 67: ... and off This indicates that the controller is operating normally If the green indicator is not flashing then the controller may not be operating properly If this occurs disconnect power and have the heater repaired by an McElroy Authorized Service Center The heater has a red indicator light on the handle at the bottom of the temperature scale When the heater is plugged in and preheating the red l...

Page 68: ...is filled to correct level Machine is free of hydraulic leaks Hydraulic gauges read correctly Jaws are properly aligned Facer operates smoothly Face off is square Inserts fit and pin properly Carriage and Selector controls operate smoothly Pressure Reducing Knobs operate in their range Electrical Power Receptacles function properly Heater surface is clean and in good condition Thermometer is in go...

Page 69: ...8 625 inch DRAG as measured in PSI for this example use 30 PSI Recommended IFP 75 PSI Using a Model 28 High Force Fusion Unit O D 8 625 t 0 784 SDR 11 TEPA 4 71 From Table O D t t IFP GAUGE PRESSURE DRAG TEPA 8 625 784 784 3 14 75 GAUGE PRESSURE 30 PSI 338 PSI 4 71 TX02893 04 18 16 Fusion High Force Medium Low Force Model A160 A180 0 90 A250 1 66 0 90 A315 3 14 1 47 28 4 71 3 24 1 66 250 4 71 3 24...

Page 70: ... F over the ambient temperature depending on the pressure setting age of the pump wind etc Mobil Univis N46 hydraulic fluid is installed at our factory The advantage of this fluid is a wider temperature range however this fluid should not be used for continuous operation below 24 F NOTE This chart is based on pump manufacturer recommendations of 13 to 500 cSt NOTE Temperatures shown are fluid temp...

Page 71: ... 50 60Hz 1Ph 4 5A 0 3HP 240V package not including receptacles Electrical Power Receptacles 15A Max each non protected DynaMc EP HPU 1 6 kVA 1 25 kW 120V and 240V package Plug Type 120V NEMA 5 15 240V CEE 7 7 Hydraulic Pressure Acrobat HPU 800 psi max 55 2 bar fusion pressure low pressure HPU DynaMc EP HPU 1500 psi max 103 4 bar fusion pressure high pressure HPU Total effective piston area 0 90 sq...

Page 72: ...0 60Hz 1Ph 4 5A 0 3HP 240V package not including receptacles Electrical Power Receptacles 15A Max each non protected DynaMc EP HPU 1 6 kVA 1 25 kW 120V and 240V package Plug Type 120V NEMA 5 15 240V CEE 7 7 Hydraulic Pressure Acrobat HPU 800 psi max 55 2 bar fusion pressure low pressure HPU DynaMc EP HPU 1500 psi max 103 4 bar fusion pressure high pressure HPU Total effective piston area 0 90 squa...

Page 73: ...cles 208 240V 50 60Hz 1Ph 4 5A 0 3HP 240V package not including receptacles Electrical Power Receptacles 15A Max each non protected DynaMc EP HPU 1 6 kVA 1 25 kW 120V and 240V package Plug Type 120V NEMA 5 15 240V CEE 7 7 Hydraulic Pressure Acrobat HPU 800 psi max 55 2 bar fusion pressure low pressure HPU DynaMc EP HPU 1500 psi max 103 4 bar fusion pressure high pressure HPU Total effective piston...

Page 74: ...50 60Hz 1Ph 4 5A 0 3HP 240V package not including receptacles Electrical Power Receptacles 15A Max each non protected DynaMc EP HPU 1 6 kVA 1 25 kW 120V and 240V package Plug Type 120V NEMA 5 15 240V CEE 7 7 Hydraulic Pressure Acrobat HPU 800 psi max 55 2 bar fusion pressure low pressure HPU DynaMc EP HPU 1500 psi max 103 4 bar fusion pressure high pressure HPU Total effective piston area 1 47 squ...

Page 75: ...or cycling on and off at varied intervals heater cycling on and off at varied intervals facer continuous Fuel _______________ Gasoline or Diesel Special requirements for customer application ____________________________________________________________ ___________________________________________________________________________________________________ ________________________________________________...

Page 76: ...matically enter pipe material size manufacture date and lot Add operator and machine information along with GPS location of each joint and photos of the completed fusion and more Go to www mcelroy com for more information DataLogger 6 Specs Model DL18001 Supported Standards ASTM F3124 ASTM F2620 12 ISO 21307 2011 05 GIS PL2 3 07 Profuse DS INF 70 2 PE HD 1992 05 WIS 4 32 08 2002 04 DVS 2207 1 PE H...

Page 77: ...This manual is waterproof tear resistant grease resistant abrasion resistant and the bonding quality of the printing ensures a readable durable product The material does not contain any cellulose based materials and does not contribute to the harvesting of our forests or ozone depleting constituents This manual can be safely disposed of in a landfill and will not leach into ground water TX001660 8...

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