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Summary of Contents for McElroy 2CU
- Page 1 Operator’s Manual Fusion Machine Manual: 201001 Revision: F 09/20 Original Language: English...
- Page 2 Cancer and Reproductive Harm - www.P65warnings.ca.gov 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...
- Page 3 The 2CU model fuses 1/2" CTS to 2" IPS pipe (20mm to 63mm). Sidewall clamps with chain vise permit fixing unit to centerline of pipe main for saddle fusion.
- Page 4 No information of knowledge heretofore or hereafter disclosed that disclaimer of warranty shall be construed against McElroy to McElroy in the performance of or in connection with the terms and agrees that such disclaimers herein shall be construed hereof, shall be deemed to be confidential or proprietary, unless liberally in favor of McElroy.
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Page 5: Table Of Contents
Transporting 2LC and 2CU Units ........ - Page 6 2CU Fusion Machine Checklist ........
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Page 7: 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. You must satisfy yourself that a procedure, tool, work method, or operating technique is safe for you and others. -
Page 8: 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 9: Electrical Safety
Fusion Equipment Safety Electrical Safety Always ensure equipment is properly grounded. It is important to remember that you are working in a wet environment with electrical devices. Proper ground ¡ADVERTENCIA! connections help to minimize the chances of an electric shock. Frequently inspect electrical cords and unit for damage. -
Page 10: Fusion Procedures
Always follow pipe manufacturer's procedures. TX04469-10-24-12 Transporting 2LC and 2CU Units On smaller machines it is easiest to carry the unit if the facer is securely installed and locked on the fusion unit. The facer has a handle that allows the unit to be firmly grasped and carried. -
Page 11: Overview
Overview Theory of Heat Fusion The principle of heat fusion is to heat two pipe surfaces to a designated temperature, and then fuse them together by application of force. This develops pressure which causes flow of the melted materials, which causes mixing and thus fusion. -
Page 12: 2Cu Tools Nomenclature
Overview 2CU Tools Nomenclature 2CU Machine Facer Heater Line Pipe Bolster Sidewall Clamping Inserts Heater Adapter Screws Insert Attaching Screws Fitting Inserts Convex Heater Adapters Concave Heater Adapters Clamping Inserts TX01053-7-22-96 2CU Machine Nomenclature Tailstock Chain Chain Hook Handle Yoke... -
Page 13: Manual Facer
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 14: 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. TX00838-1-5-96 Prepare Heater Heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death. -
Page 15: Loading Pipe Into Machine
Butt Fusion Procedure Loading Pipe Into Machine Clean the inside and outside of pipe ends that are to be fused. Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed. Let the ends of the pipe protrude about 1" past the face of the jaws. -
Page 16: Check For Slippage
Butt Fusion Procedure Check for Slippage Bring the pipe ends together under fusion pressure to check for slippage. If slippage occurs, return to Loading Pipe into Machine. TX01 165-12-1 1-96 Check Heater Temperature NOTICE: Incorrect heating temperature can result in questionable fusion joints. -
Page 17: Heating The Pipe
Butt Fusion Procedure Heating the Pipe With heater in position between the pipe ends, snap pipe ends sharply against the heater to ensure alignment. Follow the pipe manufacturer's recommendations for heating time and pressure. TX01040-7-18-96 Fusing the Pipe After the heating cycle is completed, remove the heater and quickly apply fusion force with the lever handle in accordance with the pipe manufacturer's recommended fusion procedure or appropriate joining standard. -
Page 18: Remove Pipe From Machine
Butt Fusion Procedure Optional Use of Torque Wrench When a specified Interfacial Pressure is required in the fusion procedure, a torque wrench can be used. To calculate the proper torque reading see Section "Determine Fusion Force." Add the torque required to overcome Drag (the force required to move the pipe at or near the point of fusion) to the torque reading to assure the proper joining force. -
Page 19: Saddle Fusion Procedure
Saddle Fusion Procedure Prepare Heater Heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety precautions will result in serious injury or death. ¡PELIGRO! ¡PELIGRO! 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 20: Unfasten Chains
Saddle Fusion Procedure Unfasten Chains Loosen the chain clamping knobs and unhook chain from chain hooks. TX01044-7-22-96 Install Sidewall Clamping Inserts Select the appropriate sidewall clamping inserts. (Not required for 6" main size and larger). Attach the inserts to the tailstock jaws. The attaching screws install through the back of the tailstock and screw into the insert. -
Page 21: Clean Surfaces
Saddle Fusion Procedure Clean Surfaces Use 50 or 60 grit utility cloth to clean and rough the main to expose fresh material. Rough the base of the fitting unless the manufacturer specifies otherwise. TX00460-9-16-94 Clamp Fitting Position the fitting loosely in the movable jaw and move fitting against the main. -
Page 22: Heat Pipe And Fitting
Saddle Fusion Procedure Heat Pipe and Fitting Heater is not explosion proof. Operation of heater in an explosive atmosphere without necessary safety ¡PELIGRO! ¡PELIGRO! precautions will result in serious 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 23: 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 Cleaning Machine Clean the machine with a soap and water wash as needed. -
Page 24: Pivot Pins And Shafts
Maintenance Pivot Pins and Shafts Occasionally add a drop of oil to pivot pins and shafts. TX00864-1-30-96 Clean Jaws and Inserts To prevent slippage and insure proper alignment, the jaws and inserts must be clean. Clean the jaws and inserts of any dirt or residual material using a stiff- bristled brush. -
Page 25: Fasteners Must Be Tight
Maintenance Fasteners Must Be Tight Check all nuts, bolts, and snap rings to make certain they are secure and in place. TX00437-9-13-94 Installing Butt Fusion Heater Plates The heater body of this assembly is not coated. Coated butt fusion heater plates are available for all butt fusion applications. -
Page 26: Adjusting Heater Temperature
If the heater is not operating properly, the control will attempt to turn the heater off and the indicator light will flash rapidly. If this occurs, disconnect the power and take it to a McElroy Authorized Service Center for repair. TX02213-09-16-03... -
Page 27: Facer And Blades
Maintenance Facer and Blades The facers are packed with a high temperature grease at assembly. The facer does not require repacking of grease. Inspect the facer blades for damage and sharpness. If dullness or damage appears on one section of the blade, installing the blade on the opposite side of the blade holder will normally position a sharp edge in the facing zone. -
Page 28: Maintenance Checklist
Maintenance Checklist 2CU Fusion Machine Checklist Item to Check Satisfactory Needs Repair Comments Repair UNIT Machine is clean Clamp knob bearings lubricated and move freely Movable jaw lubricated and moves freely Chains are clean and lubricated Guide rods are not damaged... -
Page 29: Determining Fusion Force
Pipe Size = 2" SDR 1 1 O.D. of Pipe = 2.37" SDR of Pipe = 1 1 Recommended Interfacial Pressure = 75 PSI Using a Model 2CU Fusion Unit O.D. 2.37 t = ------------- = --------------- = 0.2154 REQUIRED FORCE = (O.D. - t) × t × ∏ × IFP + DRAG REQUIRED FORCE = (2.37 - .2154) ×... - Page 30 Determining Fusion Force 7 - 2...
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Page 31: Specifications
Specifications Model 2CU Specification: Designed for 1/2” CTS to 2” IPS pipe (20mm to 63mm) Dimensions: Width: 1 1.5” (29.2cm) Length: 20” (50.8cm) Height: 16” (40.64cm) Heater: 800 W, 120 VAC, 60 Hz (240 V, 50 Hz) Weight: Machine: 28 lbs. (12.7kg) Heater: 5.5 lbs. - Page 33 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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