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Introduction

Thank you for choosing McElroy

The McElroy TracStar

Series 2 Auto 28/250/412/618

machines are self-contained, self-propelled, all terrain

fusion machines, and are designed to butt fuse

polyethylene pipe.
The Coach

Fusion Control system guides the operator

through a step-by-step procedure for fusing pipe. It has

built-in data logging feature that keeps a record of each

fusion joint, which allows you to verify joint integrity.
If fusing other thermoplastic pipe materials, refer to the

pipe manufacturer's fusion procedures or appropriate

joining standard.
The TracStar

28 model fuses 2" IPS (63mm) minimum to

8" DIPS (225mm) maximum pipe.
The TracStar

250 model fuses 63mm (2" IPS) minimum

to 250mm (8" DIPS) maximum pipe.
The TracStar

412 model fuses 4" IPS (110mm) minimum

to 12" DIPS (340mm) maximum pipe.
The TracStar

618 model fuses 6" IPS (180mm) minimum

to 18" IPS (450mm) maximum pipe.
Different force cylinders are available machine models in

low force, medium force and high force cylinders.

With reasonable care and maintenance, this machine

will give years of exemplary service.
Before operating 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.
Always return the manual to the literature compartment.

TX05273-03-28-17

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 of McElroy machines. McElroy University

classes are structured so that the skills learned and the

machines used in each class closely match the machines

found on pipelining jobsites. We offer training at

our facility or yours. Our uniquely qualified McElroy

University course instructors offer years of industry

experience.
Tuition for each course includes lunches, course materials

and a certificate of completion. Online registration,

as well as up-to-date course offerings and dates, is

available at

www.mcelroy.com/university

This manual is intended as a guide only and does not

take the place of proper training by qualified instructors.

The information in this manual is not all inclusive and

can not encompass all possible situations that can be

encountered during various operations.

MU2

-0

3-13-14

TX04659-03-24-14

Содержание TracStar 250 2 Auto Series

Страница 1: ...Manual T1829801 Revision B 03 19 TracStar 28 250 412 618 Series 2 Auto Fusion Machines Operator s Manual Original Language English...

Страница 2: ...This product and other products could be protected by patents or have patents pending All the latest patent information is available at patent mcelroy com...

Страница 3: ...ing 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 Always return the manual to the literatur...

Страница 4: ...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 aut...

Страница 5: ...age Assembly 2 2 Chassis 2 2 Diesel Engine 2 3 Operator Panel 2 3 Battery Disconnect Switch 2 4 Hydraulic Fluid Reservoir 2 4 Hydraulic Fluid Filter 2 4 Fusion Control Pendant 2 5 Control Box 2 5 Face...

Страница 6: ...ening Jaws 4 12 Raise Pipe 4 12 Position Pipe for Next Joint 4 12 Install Next Piece of Pipe 4 12 Auto Report Menu 4 13 Operation Semi Auto Fusion Semi Auto Fusion 5 1 Determine Drag Pressure 5 1 Set...

Страница 7: ...heck Add Antifreeze 9 5 Facer Blades 9 5 Clean Heater Surfaces 9 5 Installing Butt Fusion Heater Plates 9 6 Track Tension 9 6 Adjusting Track Tension 9 6 Clean Jaws and Inserts 9 7 Clean Thrust Bearin...

Страница 8: ...better job or make your job easier in some way PELIGRO ATENCI N CUIDADO ATTENTION Read and Understand Do not operate this equipment until you have carefully read and understand all the sections of thi...

Страница 9: ...ther applicable personal protective equipment Remove jewelry and rings do not wear loose fitting clothing and tie back long hair that could catch on controls or moving machinery WR00053 12 2 92 TX0011...

Страница 10: ...g hydraulic extension hoses to the carriage Help prevent fires by keeping machine clean of accumulated trash debris and facer shavings WR00080 4 12 93 TX04881 03 14 16 PELIGRO PELIGRO Do Not Operate i...

Страница 11: ...moving equipment and pipe and locate that person Do not continue until all persons are accounted for and in sight Never push roll dump or drop pipe lengths bundles or coils off the delivery truck off...

Страница 12: ...ric shock Refer service to a qualified technician TX03003 3 30 11 ATENCI N ATENCI N WR00055 4 7 93 WR00025 11 30 92 Crush Points Hydraulically operated equipment operates under high pressure and gener...

Страница 13: ...power is turned on NOTICE Wear safety glasses and keep face clear of area when bleeding air from hydraulic system to avoid spraying oil into eyes TX03007 04 18 16 WR00078 4 8 93 ATENCI N ATENCI N Keep...

Страница 14: ...ine by flatbed trailer or similar means and make sure the unit is properly secured TX04245 04 18 16 CD01782 08 04 16 Heater Is Hot The heater is hot and will burn clothing and skin Keep the heater in...

Страница 15: ...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 fac...

Страница 16: ...04 CD01854 11 16 16 CD01785 08 04 16 Carriage Assembly The carriage assembly consists of two fixed jaws and two hydraulically operated movable jaws The carriage assembly can be removed from the machin...

Страница 17: ...If you hear the alarm while operating the machine turn the machine off and check oil level If oil is at proper level wait for machine to cool and then check coolant level and mixture The fuel shut of...

Страница 18: ...793 08 17 16 Hydraulic Fluid Reservoir The hydraulic fluid reservoir is located above the engine Refer to the Hydraulic Fluids section of this manual for hydraulic fluid recommendations TX02322 02 27...

Страница 19: ...erature in a safe environment then unplugged before entering the explosive atmosphere for fusion The heater body is not coated Coated butt fusion heater plates are available for all butt fusion applic...

Страница 20: ...hen the inner jaws are opened the jaws lift and press against the stripper bar separating the heater from pipe ends TX05355 04 09 18 CD01799 08 17 16 CD02025 03 06 17 Power for Heater The heater cord...

Страница 21: ...to meet selected fusion standards The control pendant is equipped with a handheld computer which operates the fusion control system program A Carriage directional control B Pressure selector control C...

Страница 22: ...computer has a display with function keys below the display that are used to operate the installed software The software can also be operated by the touch screen TX05056 07 07 16 Navigation Pad and E...

Страница 23: ...fying SIM card Searching for cell network Connected shows signal strength Data is turned off No signal No service Data connection unavailable or network error EDGE available EDGE connected GPRS availa...

Страница 24: ...Internet With features such as automatic grouping and sorting of joint data custom tagging and filtering it s very easy to sort view and analyze joint data by job operator machine etc without having t...

Страница 25: ...other foreign matter to enter the tank Use only clean oil from an unopened container TX02323 02 27 14 Diesel Engine Read the operating and maintenance instructions for the engine before operating Comb...

Страница 26: ...lectric power to the heater Allow heater to warm up to operating temperature TX05279 04 06 17 Operation General 3 2 PELIGRO Moving Machine Into Position Make sure all personnel are safely clear of the...

Страница 27: ...pipe with enough material protruding past the jaw faces to allow for facing of the pipe end TX02339 3 30 11 CD01864 11 17 16 Install Clamping Inserts Select and install appropriate clamping inserts fo...

Страница 28: ...ses the fixed jaws and the right knob B opens closes the movable jaws To unclamp the jaws With your free hand hold the tie bar between two cylinders Rotate the valve knob up to unclamp Pull the tie ba...

Страница 29: ...neutral position and allow facer to turn 2 to 3 additional revolutions Turn facer off A TX05280 04 06 17 CD01805 08 31 16 CD01862 11 16 16 ATENCI N A CD01859 11 16 16 B D D C After Facing Move the ca...

Страница 30: ...he stop on the bottom of the inner upper jaws and then reclamp the jaw IMPORTANT Always tighten the side that is higher never loosen the low side Repeat adjustment until pipe is aligned Insert facer a...

Страница 31: ...Select and confirm the machine type by tapping Accept at the bottom right Tap Change to select a different machine type IMPORTANT Verify the cylinder size of your machine and select the machine that m...

Страница 32: ...cess change DataLogger Vault account See Auto Report Menu section for details IMPORTANT The information used in these examples is for simulation purposes only and does not reflect information of an ac...

Страница 33: ...the identifications System password may be required Tap Yes to proceed with these identifications and proceed to Parameters To Change the Identifications Input a machine ID The machine ID can be any...

Страница 34: ...nter Parameters Confirm if the parameters listed are correct These parameters will be displayed in the joint report Press to change the parameters Tap Yes to proceed with these parameters To Change Pa...

Страница 35: ...to select the appropriate units Tap Enter Use the up down arrows to select the bead up mode and input values The bead up mode can be entered by time in minutes and seconds displacement in millimeters...

Страница 36: ...for details on pipe facing and Hi Lo alignment check Tap Next when the pipe has been prepared for fusion Input any notes about the fusion joint optional The notes can be appended after the fusion joi...

Страница 37: ...achine while operated Always ensure machine power is off before entering the machine for any reason Tap Proceed when ready to begin the auto fusion operation To abort the fusion operation at anytime t...

Страница 38: ...uto Fusion 4 7 Auto Fusion continued After the fusion joint the joint report will appear TX05269 04 16 18 Quickly Remove Heater Self retracting heaters will remove automatically during the heater remo...

Страница 39: ...Elroy ID ID number given to McElroy qualified operators 8 Machine ID Identification number for the fusion machine 9 Machine Model Fusion machine model used to perform the fusion 10 Piston Area The tot...

Страница 40: ...been recorded Append the previously entered notes with any additional information about the fusion joint Add Photo Add an optional photo of the fusion joint to the joint report Take one photo of the p...

Страница 41: ...DataLogger Vault if a Vault account is logged into and a data connection is available If not the joint report is saved on the handheld computer for transfer at a later time The joint completed menu a...

Страница 42: ...abort the joint or record a Dummy Joint report Tap Dummy Joint to continue the automatic fusion operation performing a dummy joint Tap Abort to stop the automatic fusion operation When the dummy joint...

Страница 43: ...01869 11 29 16 CD01865 12 05 16 Position Pipe for Next Joint Position pipe with enough material protruding past the inner fixed jaw face to allow for complete facing of the pipe end If you choose to d...

Страница 44: ...shows joint reports not sent to DataLogger Vault Tap a report to view These reports will be sent to DataLogger Vault if Send Reports is selected on previous Auto Report Menu screen and a data connecti...

Страница 45: ...ed Displays a log in screen with user name and password fields Log in using a registered account If you do not have a registered account go to vault mcelroy com to create a new account Delete Logs out...

Страница 46: ...ake pressure adjustments for each selection choose either of these options On the Fusion Control Pendant turn the carriage pressure adjustment knob to the desired pressure setting On the Pendant Handh...

Страница 47: ...dheld computer Enter the difference in the System Menu Check Heater Offset TX05293 04 13 17 CD01866 11 29 16 PH05669 04 13 17 PH05670 04 13 17 Inserting Heater Open the carriage completely Self Retrac...

Страница 48: ...heating mode before returning carriage directional control to neutral TX05076 07 07 16 CD01868 11 29 16 CD01859 11 16 16 Fusing the Pipe NOTICE Failure to follow the pipe manufacturer s heating time...

Страница 49: ...D01869 11 29 16 CD01865 12 05 16 Position Pipe for Next Joint Position pipe with enough material protruding past the inner fixed jaw face to allow for complete facing of the pipe end If you choose to...

Страница 50: ...es to the fusion control software The system password is required to access the system menu Input the system password and tap Enter to continue The default system password is 123 System Menu 1 Set Dat...

Страница 51: ...set 3 different alarms Set the different days of the week and the time the alarm is to sound Select the More tab at the bottom of the screen to tab to the additional settings Check the first option t...

Страница 52: ...Password To change the password Input the current system password The default system password is 123 Tap Enter Input the new system password Tap Enter Re input the new system password Tap Enter PH055...

Страница 53: ...o the previously entered heater offset Let the heater cycle 3 times and recheck the surface temperature and compare to the displayed temperature IMPORTANT Ensure the degree units F or C of the measure...

Страница 54: ...on installing a SIM card The Trimble Nomad handheld computer uses GPRS Edge or 2 5G SIM cards Wi Fi connection icons SIM connection icons No connectivity Identifying SIM card Establishing connection...

Страница 55: ...raulic pressure Enter a value between 1000mV to 10 000mV Press the Windows and Quick Launch Key together to open the diagnostic screen The entered voltage is shown and the pressure can be viewed to co...

Страница 56: ...downloaded and installed automatically IMPORTANT A WIFI data connection is recommended for downloading updates Delete All Data Deletes all joint reports and user data from the handheld computer If yo...

Страница 57: ...Removal Includes the 4 Jaw skid and allows more area to fuse tees or perform tie ins easier The facer can be used attached on the pivot arm or disconnected and top loaded Self retracting heater and f...

Страница 58: ...Using one person to lift the facer or carriage may result in an injury Use a lifting strap and an overhead lifting device to lift facer or carriage For manual lifting two people are required to lift t...

Страница 59: ...l pendant and to the existing cable on the pendant arm Convert Self Retracting Heater to Top Loading Allow the heater to cool if it is hot Place the heater into the storage position between the fixed...

Страница 60: ...ees or perform tie ins Remove both fixed jaw braces A Loosen 2 bolts B on the jaw and remove the jaw The pipe lift control bracket C can be loosened and rotated down from the vehicle to allow clearanc...

Страница 61: ...nd to the facer Disconnect both sets of hoses IMPORTANT Machines with hydraulic clamping will have an extra set of hoses at the carriage location Remove braces from inner fixed jaw Remove the four bol...

Страница 62: ...port the facer with a person or sling so it does not fall once the facer locking bolts are removed Remove facer locking bolts Lift facer out of the carriage and set on cardboard or wood blocks off of...

Страница 63: ...and 250 Facer Removal Loosen facer locking bolt Lift facer out of the carriage and set on cardboard or wood blocks off of ground Remove rear guide rod bracket Attach rear guide rod bracket in the pos...

Страница 64: ...tar 412 and 618 use a lifting strap or a two person lift to lift the facer The TracStar 28 and 250 can be lifted by a single person Lock onto back guide rod then latch on front guide rod TX05294 04 06...

Страница 65: ...to Pipe Position carriage assembly on side of the pipe Lift pipe and slide carriage assembly under pipe Rotate carriage assembly around to a normal upright position Attach the top jaws and loosely cla...

Страница 66: ...oses on the machine and to the carriage The other set connects to the facer hoses on the machine and to the facer Connect all hoses IMPORTANT Machines with hydraulic clamping will have an extra set of...

Страница 67: ...uspended load over persons 5 Do not leave a suspended load unattended 6 Do not remove or obscure warning labels 7 Read and understand the lifting device operator s manual before use 8 Stay clear of th...

Страница 68: ...4 CD01880 11 30 16 A CD01881 11 30 16 B C Lift 4 Jaw or 3 Jaw Carriage 4 Jaw Carriage Attach lifting sling to the manifold bracket and the far side lift point on the fixed jaw brace Self Retracting He...

Страница 69: ...The third represents the number of particles equal to or larger than 14 m per milliliter of fluid Fluid should also be changed as extreme weather conditions dictate To drain tank remove the cowling a...

Страница 70: ...he cowling To Remove Front Cowlings Loosen and remove the nuts B that attach the cowling to the machine Remove the cowling To Remove Back Cowling Loosen the nuts C and slide the bottom of the cowling...

Страница 71: ...r moderate injury TX05179 09 22 16 CUIDADO ATTENTION PH05642 09 21 16 PH05644 09 26 16 A B Setting Engine Speed With the engine running at max speed plug the heater in Check the voltmeter above the he...

Страница 72: ...the system ever runs low on oil or leaks air on inlet side of pump Air in the system is indicated when carriage movement becomes jerky and erratic To bleed the system proceed as follows The bleed plug...

Страница 73: ...use care when heating the pipe The butt fusion heater plate faces must be kept clean and free of any plastic build up or contamination Plastic build up is best removed when the heater surfaces are at...

Страница 74: ...bottom frame after lifting Measure the deflection between the bottom center roller and the inside surface of the rubber track Track tension is normal when this distance is about 1 2 If the deflection...

Страница 75: ...X00434 9 13 94 CD01845 09 21 16 CD01845 09 21 16 Clean Jaws and Inserts Ensure the machine is off and disconnected from power source To prevent slippage and insure proper alignment the jaws and insert...

Страница 76: ...attery holders Replace the battery with one that meets all of the requirements listed below Group Size 70 battery Cold cranking amperes at 0 F 18 C 525 CCA Cranking amperes at 32 F 630 CA Battery Char...

Страница 77: ...and remove the 4 screws A from the back cover and remove Remove the battery to expose the SIM card holder B Slide the holder to the Unlock position C and open the holder Insert the SIM card D into the...

Страница 78: ...Card setting based on the APN of your SIM card Tap Add Settings to add the configured data setting Tap the close icon to close the data settings screen and return back to the System Menu The configure...

Страница 79: ...led to correct level Cooling system level is correct Hydraulic hoses are in good condition Engine starts and runs properly Jaws are properly aligned Facer pivot operates properly Facer operates smooth...

Страница 80: ...SDR 11 O D 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 GAUG...

Страница 81: ...80 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 temper...

Страница 82: ...z 15 Amp Specifications A D C B Machine Dimensions Weight Model A B C D Entire Machine 28 97 53 53 28 1957 lbs 2464mm 1346mm 1346mm 711mm 888 Kg 250 97 53 53 29 1953 lbs 2464mm 1346mm 1346mm 737mm 886...

Страница 83: ...762 29 737 29 737 29 737 208 1750 94 44 19 9 25 635 25 635 19 483 19 5 495 32 5 826 31 787 38 965 37 940 42 1067 38 965 43 1092 21 42 9 5 19 Heater with Bag Dimensions with hydraulic clamping Carriage...

Страница 84: ......

Страница 85: ...his 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...

Страница 86: ......

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