McElroy Hornet XL ASW31401 Operator'S Manual Download | Manualshive

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Hornet™ XL

Hornet™ XL

Fusion Machine

Models: ASW31401, ASW31402

Manual: SW31301

Revision A 09/19

Original Language: English

Operator’s

Manual

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Summary of Contents for Hornet XL ASW31401

Page 1: ...Foreword 1 Hornet XL Hornet XL Fusion Machine Models ASW31401 ASW31402 Manual SW31301 Revision A 09 19 Original Language English Operator s Manual ...

Page 2: ...Copyright 2019 McElroy Manufacturing Inc All rights reserved P O Box 580550 Tulsa Oklahoma 74158 0550 USA ...

Page 3: ...portant information The meaning of these signal words are as follows NOTICE Can keep you from doing something that might damage the machine or someone s property It may also be used to alert against unsafe practices IMPORTANT Can help you do a better job or make your job easier in some way McElroy cannot anticipate every possible circumstance that might involve a potential hazard The warnings in t...

Page 4: ... Electrical Safety 2 2 Power Tool Safety 2 2 Heater is Hot 2 2 Fusion Procedures 2 3 Do Not Modify Machine 2 3 GENERAL INFORMATION Theory of Heat Fusion 3 1 Nomenclature 3 1 Attach Drill to Drill Adapter 3 4 Attach Extension Chains 3 5 Install Heater Adapters 3 6 Detachable Handle 3 6 OPERATION FUSION OUTLET Attach Hornet XL to Pipe 4 1 Prepare Heater 4 2 Drill Main Pipe 4 3 Insert Fitting 4 4 Ins...

Page 5: ...1 MAINTENANCE Preventative Maintenance 7 1 Clean Machine 7 1 Check Machine Operation 7 1 Fasteners Are Tight 7 1 Changing Heater Plates Adapters 7 1 Clean Chains 7 2 Clean Fitting Adapter 7 2 Clean Drill Adapter 7 2 Adjust Gearbox Chain Tension 7 2 SPECIFICATIONS Specifications 8 1 NOTES Notes 9 1 For Digital Copy Press Alt Left Arrow to return to the link that was clicked ...

Page 6: ... is a guide to equipment care The maintenance schedule lists the items to be maintained at a specific service interval Items without specific intervals are listed under the As Needed service interval The schedule lists the page for the step by step instructions required to accomplish the scheduled maintenance Use the schedule as an index for all maintenance procedures Some maintenance procedures m...

Page 7: ...ery machine has a name plate that includes the machine s model number serial number and power requirements The model and serial numbers can be used to register the machine online and activate the warranty Reference warranty card for information on registering your product Replacement Parts Refer to the McElroy parts finder at www mcelroy com to locate parts for purchase Reference the model number ...

Page 8: ...550 833 North Fulton Street Tulsa Oklahoma 74158 0550 PHONE 918 836 861 1 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 Disclaimer of Liability McElroy accepts no responsibility of liability for fusion joints Operation and maintenance of the product is the responsibil...

Page 9: ...be ordered from McElroy using the part number listed General Safety Safety is important Report anything unusual that you notice during set up or operation LISTEN for thumps bumps rattles squeals air leaks or unusual sounds SMELL odors like burning insulation hot metal burning rubber hot oil or natural gas FEEL any changes in the way the equipment operates SEE problems with wiring and cables hydrau...

Page 10: ...orking in a wet environment with electrical devices Proper ground connections help to minimize the chances of an electric shock Frequently inspect electrical cords and unit for damage Have damaged components replaced and service performed by a qualified electrician Do not carry electrical devices by the cord NOTICE Always connect units to the proper power source as listed on the unit or in the own...

Page 11: ... 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 Do Not Modify Machine Make no modifications to your equipment unless specifically recommended or requested by McElroy TX05398 03 15 19 ...

Page 12: ...t patterns must be joined with a specified force The force must be constant around the interface area Holding The molten joint must be held immobile with a specified force until adequately cooled Inspecting Visually examine the entire circumference of the joint for compliance with standards established by your company customer industry federal state or local regulations Nomenclature Hornet XL Carr...

Page 13: ...ket Inserts into the stripper bars to allow the heater to be stripped from the main pipe and fitting Fitting Adapter O Fitting Puck Rubber puck that fits inside the inner diameter of the fitting The pucks are sized to fit a specific size fitting P 110mm to 125mm Clamp Channel Used with the 63mm pipe inserts to clamp the fitting adapter in the carriage for 1 10mm to 125mm fittings Q 63mm to 90mm Cl...

Page 14: ...circular pilot size of 1 29 32 48 5mm U Drill Adapter Sleeve Used inside the drill adapter for drills with a circular pilot size of 1 13 16 46mm V 3 8 Square to 5 16 Hex Adapter Attaches to one of the sockets to connect the drill to the hex of drill adapter W 7 16 Deep Socket 3 8 Drive Socket used to connect a standard drill with the drill adapter X 7 16 Socket 3 8 Drive Socket used to connect a 9...

Page 15: ... tightened to the drill pilot Align the slot on the drill sleeve with the slot of the drill adapter 4 Ensure the drill is fully inserted over the drill pilot of the drill If the drill will not insert completely you may need to adjust the socket adapter Tighten the drill adapter clamp 5 Check the function of drill by pressing the trigger The chuck of the drill adapter should turn when operated If t...

Page 16: ...ns 1 Position the extension chain next to the end of the base chain 2 Insert the pins of the master link into the base chain and the extension chain Place the link cover over the pins of the master link 3 Insert the link clip between the grooves of the master link to secure the link cover 4 Ensure the clip is seated completely on the pins of the master link Repeat these instructions for the other ...

Page 17: ...adapters with the mark on the heater body 4 After both adapter are aligned tighten the screw to secure the position of the adapters Detachable Handle The handwheel can be removed and positioned on either side of the carriage 1 Push the button of the detent pin grasp the handwheel and pull away from the carriage 2 Align the tab on the back of the handwheel with the slot on the carriage to attach th...

Page 18: ...on the other side of the carriage if needed 3 Position the tailstock against the main pipe 4 Wrap the chains around the pipe and up to the clamp knobs of the tailstock 5 Pull the chain tight and insert the closest link of the chain into the slot of the clamp bracket 6 Tighten the clamp knob until the tailstock is firmly secured to the main pipe Repeat these steps for the other chain The clamp knob...

Page 19: ...Turn knob to point to the temperature of the pyrometer reading Tighten set screw in the knob Turn knob to desired temperature Allow heater to stabilize at the new temperature 5 to 10 minutes after adjusting The thermometer on the heater body indicates internal temperature and should be used as a reference only The heater has a green indicator light which will flash on and off This indicates that t...

Page 20: ...he carriage completely then lock the brake Insert the drill and drill adapter in the lower jaws of the carriage There are two steps in the drill adapter and each one will rest in the pipe inserts Close the jaws and tighten the clamps to secure the adapter in the carriage 4 Unlock the brake on the carriage Pull the trigger on the drill and close the carriage toward the main pipe Apply extra pressur...

Page 21: ... There are two grooves on the adapter one for 1 10mm 125mm fittings and the other for 63mm 90mm fittings Ensure the adapter is inserted with the appropriate groove in the lower jaw closest to the main pipe Close the jaws and tighten the clamps to secure the adapter in the carriage 4 Insert the fitting over the fitting puck and against the backing plate of the adapter 5 Close the carriage and bring...

Page 22: ... serious injury or death 2 Use a clean dry lint free non synthetic cloth to clean the fusion heater adapters 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 4 Open carriage completely Insert heater in the heater strippers between the main pipe and fitting Ensure the tabs of the heater inse...

Page 23: ...otal cooling time specified by the pipe manufacturer or appropriate joining standard Remove Hornet XL After completing the specified cooling time inspect the joint for compliance with the appropriate joining standard There should be no gaps or voids between the fitting and the pipe If the joint is not acceptable cut out the pipe section and fuse a new pipe in the removed section 1 Unclamp the fitt...

Page 24: ...hould never be used without fusion heater adapters installed 2 Place heater in insulated heater bag 3 Plug heater into a proper power source Refer to Heater Information Label for power information Adjusting Heater Temperature 4 Turn knob to desired temperature Allow heater to reach temperature Measure the heater surface temperature with a pyrometer Any variance must be corrected to the pyrometer r...

Page 25: ... pipe as well as determine the insertion depth Mark the insertion depth along the edge of the chamfer depth gauge The chamfer depth gauge is pipe size specific Clean Fitting and Pipe 1 Fitting and pipe must be clean and dry Use a clean lint free cloth to wipe the mating surfaces NOTICE Do not touch fusion area with hands Load Pipe 1 Ensure the Acrobat pipe inserts are installed for the size of pip...

Page 26: ...s when the pipe and fitting are fully inserted onto the heater adapters Heat fitting and pipe for the pipe manufacturer s specified period of time or appropriate joining standard 2 Engage the carriage brake to hold the position of the carriage during heating time 3 When the heating time is complete release the carriage brake Open the carriage completely Quickly remove the heater from heater stripp...

Page 27: ...itting and the pipe If the joint is not acceptable cut out the pipe section and fuse a new pipe in the removed section 1 Open the jaws of the carriage 2 Remove the machine from the main pipe by loosening the chains on the tailstock and removing the chains from the chain brackets Lift the machine away from the pipe IMPORTANT Support the machine while unclamping to avoid the machine falling or swing...

Page 28: ...n be used to store drill battery and charger not included 2 Hornet XL Fusion Machine Clamp the fitting adapter B in the fusion machine Close the carriage against tailstock and apply the carriage brake Attach the handwheel to the brake side of the carriage Insert the fusion machine into the case 3 Hornet XL Accessory Case Insert the accessory case in front of the tailstock of the fusion machine 4 H...

Page 29: ...Storage Transport 6 2 Storage Transport Hornet XL Hornet XL Storage Case with All Items Stored ...

Page 30: ...th hands If the brake slips and doesn t hold the carriage position replace the brake 4 Inspect the jaw clamps for proper operation Replace any damaged jaw clamps 5 Inspect chain clamps for proper operation Replace any damaged chain clamps Fasteners Are Tight 1 Inspect all machine fasteners for tightness Tighten any loose fasteners Changing Heater Plates Adapters The heater body of this assembly is...

Page 31: ...rill Adapter 1 Clean any debris from the adapter using a clean cloth Adjust Gearbox Chain Tension 1 Tighten the set screw to adjust the chain tension NOTICE Over tightening the screw will apply too much chain tension and will cause the carriage to not move easily and damage the chain and gears of the gearbox 2 Move the handwheel to the other gearbox and adjust the chain tension on the second gearb...

Page 32: ...ower 1 600 Watt Package Inclusions Package includes Hornet XL carriage heater 63mm jaw inserts drill adapter drill adapter sleeve 7 16 deep socket 7 16 socket 3 8 square drive fitting adapter fitting clamp puck kit chain extensions accessory case and storage case Drill and hole saws are not included Heater adapters plates other jaw inserts sold separately Carriage weight can be reduced by removing...

Page 33: ...Notes 9 1 Notes Hornet XL NOTES Notes ...

Page 34: ......

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