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Summary of Contents for McElroy T-500 I Series
- Page 1 Hydraulic Butt Fusion Machine Procedure © Copyright 2007 ISCO Industries, LLC All rights reserved.
- Page 2 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure 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 polyethyl- ene material is heated, the molecular structure is transformed from a crystalline state into an amorphous condition.
- Page 3 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Hydraulic Manifold Block Mounted on this block are a carriage directional control valve, a selector valve, three pressure reducing valves, and a pressure gauge. A) The carriage control value, mounted on the top of the manifold, determines whether the carriage is moving left, right, or in neutral.
- Page 4 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Check Hydraulic Pressure The pressure gauge on the manifold block indicates the pressure of the carriage valve. How much pressure depends on the position of the selec- tor valve and the pressure set on the specific pressure reducing valve. With the selector valve up, the facing pressure can be set.
- Page 5 Pressure (Shown Above) TEPA = Total Effective Piston Area DRAG = Force Required to Move Pipe Example: Using a McElroy No. 250 Standard Fusion Machine (Low Force, Yellow Cyl.) OD of Pipe = 200 mm DR of Pipe = 11 Recommended Interfacial Pressure = 5.2 Bar...
- Page 6 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure N N o o t t i i c c e e : : See Reference Section, pages 80-85, for fusion pressure charts show- ing pressures precalculated to include 2 Bar (30 psi) for system drag. Determining Fusion Pressure (Continued) TEPA = Total Effective Piston Area High Force...
- Page 7 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Facing The Pipe Pivot the facer into place and secure. Move the carriage to the right. Open the ball valve on the facer motor. Assure the selector valve handle is up in the facing position. Move the carriage to the left.
- Page 8 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Remove Facer Pivot the facer out to the storage position. Remove chips from pipe ends, careful not to touch faced pipe ends. If faced pipe ends are touched, use clean non-synthetic cloth to clean affected area before proceeding.
- Page 9 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Position Carriage For Heater Insertion Move carriage to the right to open a gap large enough to insert the heater. FACING TING FUSING C C h h e e c c k k H H e e a a t t e e r r T T e e m m p p e e r r a a t t u u r r e e CAUTION Incorrect heating temperature can result in questionable fusion joints.
- Page 10 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure I I n n s s e e r r t t i i n n g g H H e e a a t t e e r r DANGER Heater is Not Explosion Proof. Operation of heater in a hazardous environment without necessary safety pre- cautions could result in explosion and...
- Page 11 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Fusing The Pipe CAUTION Failure to follow the proper shift sequence, verify proper melt pattern and achieve proper cooling time may result in a bad joint. After proper melt pattern has been established, use the Approximate Melt Bead Size chart on page to determine the proper size, then: FACING...
- Page 12 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Approximate Melt Bead Size (Pipe Ends) Approximate Pipe Size Melt Bead Size 40 mm (1-1/4") - 90 mm (3") About 2 mm (1/16") 90 mm (3") - 200 mm (8") 3 mm (1/8") - 5 mm (3/16")
- Page 13 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure C C o o o o l l i i n n g g O O f f T T h h e e F F u u s s i i o o n n J J o o i i n n t t The fusion joint must be kept under fusion pressure until joint is cool.
- Page 14 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Opening Movable Jaws After the joint has cooled for the recom- mended time, shift the carriage control valve to the neutral position. Loosen all clamp knobs, and move carriage to the right far enough to open the jaw nearest the facer.
- Page 15 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure B B u u t t t t F F u u s s i i o o n n J J o o i i n n t t T T r r o o u u b b l l e e s s h h o o o o t t i i n n g g G G u u i i d d e e The Inspection Of The Fusion Joint Golden Rule: If in doubt, cut it out and redo.
- Page 16 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure B B u u t t t t F F u u s s i i o o n n J J o o i i n n t t T T r r o o u u b b l l e e s s h h o o o o t t i i n n g g G G u u i i d d e e What Is Present Attributing Factors Misalignment, component...
- Page 17 ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Position Pipe For Next Joint Move the fusion machine to the end of pipe, or pull the pipe through the jaws until the end of the pipe is protruding more than 25 mm (1") past the jaw face of the fixed jaw.
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