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Summary of Contents for McElroy DynaMc 28
- Page 1 Operator’s Manual 28, 250, 412 and 28 Sidewall Electric Pump (EP) Fusion Machines Manual: 1272601 Revision: C 10/15 Original Language: English...
- Page 3 9 5/8" diameter base on any size main. TX04044-04-08-14 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.
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Page 4: Limited Warranty
McElroy or has become damaged McElroy reserves the right to make any changes in or due to misuse, negligence or casualty, or has not been improvements on its products without incurring any operated or maintained according to McElroy’s printed... -
Page 5: Table Of Contents
Clamp Knobs ......... 2-7 COPYRIGHT © 2015, 2014, 2010 McELROY MANUFACTURING, INC. Tulsa, Oklahoma, USA All rights reserved All product names or trademarks are property of their respective owners. - Page 6 Table of Contents Butt Fusion Procedure Read Before Operating ........3-1 Check Fluid Level .
- Page 7 Table of Contents Special Operations - Saddle Fusion Procedures (Continued) Inserting Heater ........5-4 Heat Pipe and Fitting .
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Page 8: Safety Alerts
Follow all applicable federal, state, local, and industry specific regulations. McElroy Manufacturing, Inc. cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this manual and on the machine are therefore not all inclusive. -
Page 9: General Safety
Fusion Equipment Safety 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. -
Page 10: Units With Hydraulics
Fusion Equipment Safety Units With Hydraulics For hydraulically operated equipment, it is important to remember that a sudden hydraulic oil leak can cause serious injury, or even be fatal if the pressure is high enough. Escaping fluid under pressure can penetrate the skin causing serious injury. -
Page 11: Crush Points
Fusion Equipment Safety Crush Points Hydraulically operated jaws are operated under pressure. Anything caught in the jaws will be crushed. Keep all body parts out of the jaw area. Always check pipe alignment with a pencil or similar object. TX03091-4-7-10 Facer Blades Are Sharp Facer blades are sharp and can cut. -
Page 12: Fusion Procedures
Fusion Equipment Safety Fusion Procedures Obtain a copy of the pipe manufacturer's procedures or appropriate joining standard for the pipe being fused. Follow the procedure carefully, and adhere to all specified parameters. NOTICE: Failure to follow pipe manufacturer's procedure could result in a bad joint. Always follow pipe manufacturer's procedures. -
Page 13: Overview
Overview Theory of Heat Fusion The principle of heat fusion is to heat two surfaces to a designated temperature, and then fuse them together by application of force. This pressure causes flow of the melted materials, which causes mixing and thus fusion. When the thermoplastic material is heated, the molecular structure is transformed from a crystalline state into an amorphous condition. -
Page 14: Introduction To The Electric Pump (Ep) Fusion Machines
Overview Introduction to the Electric Pump (EP) Fusion Machines The McElroy DynaMc® Electric Pump (EP) fusion machines are hydraulically operated fusion machines designed to fuse thermoplastic pipe. When fusing thermoplastic pipe materials, refer to the pipe manufacturer's fusion procedures or appropriate joining standard. -
Page 15: Dynamc Ep Hydraulic Power Unit (Hpu)
Valve "N" is adjusted completely in (clockwise). Valve "DR" is adjusted completely out (counter-clockwise). The non-labeled valve is the main system pressure relief valve that protects against over-pressurization. NOTICE: These valves are properly set at McElroy and should never be re-adjusted. TX04661-10-5-15 Hydraulic Fluid Reservoir The reservoir is incorporated in the HPU. -
Page 16: Filter
Overview Filter This machine is equipped with a 10 Micron filter on the return line. TX02132-07-08-03 Hydraulic Manifold Block Mounted on this block are a carriage directional control valve, a pressure reducing selector valve, three pressure reducing valves, and a 1500 psi gauge. A) The carriage control valve, mounted on the top of the manifold, determines whether the carriage is moving left, right, or is in neutral. -
Page 17: Facer
Overview Facer The facer is of the McElroy rotating planer-block design. The blade holders each contain multiple cutter blades. The block rotates on ball bearings and is chain driven (enclosed in lubricant) by an electric motor. The facer has a release mechanism for quick and easy removal from the machine. -
Page 18: Heater
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 a McElroy Authorized Service Center. The heater temperature is controlled by a microprocessor. It has a red indicator light on the handle at the bottom of the temperature scale. -
Page 19: Stripper Bar
Overview Stripper Bar The heater stripper bar can be attached to the heater to assist in separating the heater from the molten pipe. Refer to the instruction sheet packaged with the stripper bar for assembly instructions. TX03095-4-7-10 Carriage Shut-off Valve A shut-off valve is installed on the carriage. -
Page 20: Butt Fusion Procedure
Butt Fusion Procedure Read Before Operating Before operating this machine, please read this manual thoroughly, and keep a copy with the machine for future reference. When fusing thermoplastic pipe materials, refer to the pipe manufacturer's suggested procedures or appropriate joining standard. -
Page 21: Prepare Heater
Butt Fusion Procedure Prepare Heater Heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious ¡PELIGRO! injury or death. If operating in an explosive atmosphere, heater should be brought up to temperature in a safe environment, then unplugged before entering the explosive atmosphere for fusion. -
Page 22: Hydraulic Power Unit (Hpu)
Butt Fusion Procedure Hydraulic Power Unit (HPU) Electric motors are not explosion proof. Operation of these components in an explosive atmosphere will result in serious injury or death. ¡PELIGRO! Locate HPU in a safe environment. Plug the electrical cord into a proper power source. -
Page 23: Facer
Butt Fusion Procedure Facer Electric motors are not explosion proof. Operation of these components in a hazardous environment without necessary safety precautions will result in ¡PELIGRO! serious injury and death. Ensure facer power switch is in the off position. Connect facer to proper power source. Don't turn on facer until ready to face. -
Page 24: Hydraulic Pressure
Butt Fusion Procedure Hydraulic Pressure The pressure gauge above the manifold block indicates the pressure at the carriage control valve. The pressure shown on the gauge is determined by the position of the selector valve and the pressure setting of the selected pressure reducing valve. A - Carriage Control Valve B - Pressure Gauge C - Pressure Selector Valve... -
Page 25: Jaw Configuration
Butt Fusion Procedure Jaw Configuration 2 Movable/2 Fixed Jaw Configuration The DynaMc EP 4 jaw machines can be configured to a 2 movable/2 fixed jaw configuration or a 3 movable/1 fixed jaw configuration. This will allow work in close proximity to ells and tees without the removal of the outer jaw. -
Page 26: Clamp The Pipe
Butt Fusion Procedure 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. -
Page 27: After Facing
Butt Fusion Procedure After Facing Move the carriage control valve to the right to open the carriage. Release the handle lock, and lift the facer out. Close carriage shut off valve. Jaws are operated hydraulically by a remote operator. Anything caught in the jaws will be crushed. -
Page 28: Determine Drag Pressure
Butt Fusion Procedure Determine Drag Pressure Drag pressure should be determined using the following procedure: Move the carriage so that the faced pipe ends are approximately 1" apart. Shift the carriage control valve to the middle (neutral) position. Select the heating mode, and adjust the middle pressure reducing valve to its lowest pressure by turning the valve completely counterclockwise. -
Page 29: Check Alignment
Butt Fusion Procedure Check Alignment Close the carriage until the ends of pipe butt together. Check pipe joint for proper alignment. Do not use finger to check for HI/LO (misalignment). The unit is under pressure, and slippage could result in crushed fingers. Always keep hands clear of the jaw area. -
Page 30: Check Heater Temperature
Butt Fusion Procedure 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. -
Page 31: Inserting Heater
Butt Fusion Procedure Inserting Heater The heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious ¡PELIGRO! injury or death. If operating in an explosive atmosphere, heater should be brought up to temperature in a safe environment, then unplugged before entering the explosive atmosphere for fusion. -
Page 32: Fusing The Pipe
Butt Fusion Procedure Fusing the Pipe NOTICE: Failure to follow pipe manufacturer's fusion procedures may result in a bad joint. After following the pipe manufacturer's suggested heating procedure: A) Shift carriage control valve to neutral position, if it is not already in that position. -
Page 33: Position Pipe For Next Joint
Butt Fusion Procedure 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 .75" for 28 and 1.25" for 250/412 past the fixed jaw. TX04015-4-12-10 Install Next Piece of Pipe Move the carriage control valve and open the carriage completely. -
Page 34: Special Operations - In Ditch
Special Operations - In Ditch Remove Carriage from Skid The carriage can be removed from the base for close quarters in ditch fusion. To remove the carriage: Remove the rod out of the carriage and through the opening on the base. Slide the carriage forward to release it from the back of the base. -
Page 35: Lower The Carriage Into Ditch
Special Operations - In Ditch Lower the Carriage into Ditch Lowering carriage without the skid Open the jaws. Attach lifting strap (not included) to carriage base. Lift carriage assembly and lower into ditch. Lower carriage on top of the pipe and rotate the carriage underneath the pipe. -
Page 36: Removing Top Jaws
Special Operations - In Ditch Removing Top Jaws If the carriage needs to be hoisted and slid underneath the pipe, the top jaws may need to be removed. Loosen all clamp knobs. Take out the detent pins securing the top jaws and remove the jaws. -
Page 37: Make Fusion Joint
Special Operations - In Ditch Make Fusion Joint Refer to the "Butt Fusion Procedure" for operating instructions. After facing operation, remove the facer from ditch. TX00450-9-16-94 Remove Carriage Assembly from Ditch Loosen clamp knobs and remove top jaws if needed. Rotate carriage assembly from under the pipe. -
Page 38: Special Operations - Saddle Fusion Procedures
Special Operations - Saddle Fusion Procedure Saddle Fusion Procedure The 28 Sidewall fuses branch saddles up to 8" DIPS outlet and up to a 9-5/8" diameter base on any size main. IMPORTANT: Optional chain extension kit is available for larger main sizes. -
Page 39: Install Clamping Inserts
Special Operations Saddle Fusion Procedure Install Clamping Inserts Select and install appropriate clamping inserts in the movable jaw. TX04023-4-12-10 Attach Carriage Assembly to Main Place the machine on the main. Place a line bolster on main opposite the carriage assembly if required. -
Page 40: Set Hydraulic Pressure
Special Operations - Saddle Fusion Procedure Set Hydraulic Pressure Check hydraulic pressure. Shift the selector valve to the center position to set the pressure for heat/soak. With the selector valve in the down position, the initial heat (bead-up) pressure can be set. -
Page 41: Prepare Heater
Special Operations - Saddle Fusion Procedure Prepare Heater 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. -
Page 42: Heat Pipe And Fitting
Special Operations - Saddle Fusion Procedure Heat Pipe and Fitting Move selector valve to the bottom position. Move the fitting against the Flexible Heat Shield under bead- up pressure, and observe melt bead formation on the main all around the heater faces. When a melt bead is first visible on the main all around the heating tool faces, in a quick continuous motion, open the carriage slightly and remove the Flexible Heat Shield. -
Page 43: Allow Joint To Cool
Special Operations - Saddle Fusion Procedure Allow Joint to Cool Allow the joint to cool under pressure as specified by the pipe manufacturer's recommendation or appropriate joining standard. To maintain fusion pressure during cooling, the carriage control valve must be positioned in the left hand direction. TX04043-4-12-10 5 - 6... -
Page 44: Special Operations - Lifting Fusion Machine
Special Operations - Lifting Fusion Machine Lifting Safety Follow all applicable federal, state, local, and industry specific regulations when lifting. Safety warnings: Do not exceed rated load or lift loads greater than the rated load rating of the lifting device. Do not operate a damaged or malfunctioning lifting device. -
Page 45: Powered Lifting
Special Operations - Lifting Fusion Machine Powered Lifting Powered lifting requires a hoist or lifting equipment of proper lifting capacity to lift the machine. Close jaws and tighten the jaw clamp knobs on each jaw. Attach a properly rated lifting strap through the center of the movable jaws and a strap through the center of the fixed jaws. -
Page 46: Maintenance
Maintenance 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 schedule of preventive maintenance be kept. Store machine inside, out of the weather, whenever possible. TX00428-8-10-95 Washing the Machine The machine should be cleaned as needed with a soap and water... -
Page 47: Accumulator Charge
Maintenance Accumulator Charge The precharge should be checked every 6 months. The accumulator must be charged by a qualified hydraulic service facility to a nitrogen precharge of 500 psi. An approximate amount of charge can be noted on the system pressure gauge when the HPU is turned on. -
Page 48: Clean Eyebolt Threads
Maintenance Clean Eyebolt Threads Keep the clamp knob eyebolt threads brushed clean. TX00435-9-13-94 Clean the Clamping Chains On the 28 sidewall unit, clean the tailstock chains as needed. Clean using a stiff-bristled brush and oil generously. Wipe away any excess oil. TX04034-4-12-10 Fasteners Must Be Tight Check all nuts, bolts, and snap rings to make certain they are... -
Page 49: Clean Heater Surfaces
Maintenance Clean Heater Surfaces The heater faces must be kept clean and free of any plastic build up or contamination. Before each fusion joint the heater surfaces must be wiped with a clean, non-synthetic cloth. NOTICE: Do not use an abrasive pad or steel wool. Use a non-synthetic cloth that won't damage surfaces. -
Page 50: Installing Butt Fusion Heater Plates
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. -
Page 51: Fusion Machine Checklist
Maintenance Checklist Fusion Machine Checklist Item to Check Satisfactory Needs Repair Comments Repair UNIT Machine is clean All pins and snaprings are in place All nuts and bolts are tight All placards and handles are in place All clamp knobs turn freely Cords and plugs are in good condition Oil reservoir is filled to correct level Machine is free of hydraulic leaks... -
Page 52: Determining Fusion Pressure
Determining Fusion Pressure Variable Definitions O.D. = Outside Diameter = Wall Thickness = 3.1416 = Standard Dimensional Ratio = Manufacturer’s Recommended Interfacial Pressure TEPA = Total Effective Piston Area Formulas O.D. t = ------------ AREA = (O.D. - t) x t x FORCE = AREA x IFP (O.D. -
Page 53: Determining Fusion Pressure - Sidewall
Determining Fusion Pressure - Sidewall Variable Definitions O.D. = Outside Diameter of Base (not branch) = Wall Thickness BASE = 3.1416 ∏ = Standard Dimensional Ratio O.D. = Manufacturer’s Recommended Interfacial Pressure TEPA = Total Effective Piston Area Formulas O.D. t = ------------ ROUND BASE AREA = (O.D. - Page 54 Hydraulic Fluids Hydraulic Fluids The use of proper hydraulic fluid is mandatory to achieve maximum performance and machine life. Use a clean, high quality, anti-wear hydraulic fluid with a viscosity index (VI) of 135 minimum. It should have a maximum viscosity of 500 cSt (2000 SSU) at startup (ambient temperature) and a minimum viscosity of 13 cSt (65 SSU) at the maximum fluid temperature (generally 80°F above ambient).
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Page 55: Hydraulic Fluid
1500 psi max. fusion pressure Reservoir Capacity: 1 gallon filling volume Hydraulic Fluid: Refer to Hydraulic Fluids Section Total effective piston area: 1.66 square inches 28/250 and 3.14 square inches 412 Designed for connecting the McElroy Datalogger® unit . 11 - 1... - Page 56 Specifications Fusion Machine Specifications: 28 Sidewall EP Carriage Dimensions 28 Sidewall Width: C 18" (457 mm) Length: B 31" (787 mm) Height: A 22" (559 mm) Weights Carriage Assembly: 88 lbs (40Kg) EP Hydraulic Power Unit (HPU) Dimensions Width: C 11"...
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Page 57: Generator Sizing Form
Specifications Generator Sizing Form Complete this form and provide a copy to your generator supplier. This information will enable your generator supplier to correctly size a generator for your application. Pump Motor: 2.2 Horsepower Pump Motor Voltage: (120 or 220 VAC) Pump Motor Phases: 1 Pump Motor Frequency: ____________ (50 or 60 Hz) Facer Motor: 1.6 Horsepower... -
Page 58: Optional Accessories
® DataLogger Compatible The DataLogger® from McElroy offers the ability to record and document the parameters of the pipe fusion process. The latest generation of the DataLogger is similar in size to the DataLogger 4, and like the DataLogger 4 has a rechargeable internal battery, and a pressure sensor with a 0 to 3,000 PSI pressure range. - Page 59 About this manual . . . McElroy Manufacturing continually strives to give customers the best quality products available. This manual is printed with materials made for durable applications and harsh environments. This manual is waterproof, tear resistant, grease resistant, abrasion resistant and the bonding quality of the printing ensures a readable, durable product.
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