Page 1
Operator’s Manual Acrobat™ 160, 180, 250 and 315 Fusion Machines Manual: 2501601 Revision: C 11/18 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
(2" through 12") maximum pipe. TX04785-02-01-17 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.
Page 4
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...
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.
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. FEEL any changes in the way the equipment operates.
Safety Overhead Loads The Acrobat fusion carriage is not designed to support overhead or overhung loads. Adequately support the pipe using appropriate support devices. If not supported, overhead loads could fall causing serious injury or death. Unclamping jaws in an overhead position could have jaws swing into the head resulting in serious injury or death.
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 Carriage Handling Disconnect carriage from HPU before attaching carriage to pipe.
Safety Fusion Procedures Obtain a copy of the pipe manufacturer's fusion procedures or appropriate joining standard for the pipe 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.
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. When the thermoplastic material is heated, the molecular structure is transformed into an amorphous condition.
Overview Carriage Assembly The Acrobat carriage assembly is a 4-Jaw carriage but can be converted to a 3-Jaw carriage. The carriage assembly consists of two fixed jaws and two hydraulically operated movable jaws bolted to a skid. For more compact fusion, the 3-Jaw carriage can be separated from the 4-Jaw carriage without tools.
Hydraulic accumulator - Allows the power pack to cycle on and off to meet the demands of the hydraulic system, which reduces noise and power consumption. Carriage control box - Includes all the McElroy standard carriage controls. DataLogger® port Pressure gauge...
Carriage manifold assembly - Standard McElroy design for familiar operation and common service parts with other McElroy equipment. There are two pressure gauges on the HPU. The carriage pressure gauge above the carriage directional control displays fusion pressure.
Overview Hydraulic Fluid Reservoir (DynaMc EP HPU) The reservoir is incorporated in the HPU. The fluid level is read from a dipstick and has a notch to indicate the proper fluid level. Never allow dirt or other foreign matter to enter the open tank. Refer to the "Hydraulic Fluids"...
NOTICE: Always plug accessories into the correct receptacle. Plug the accessory into the specifically labeled receptacle. Do not plug Facer Receptacle Heater Receptacle anything other than the intended McElroy accessories into these receptacles or an over-current condition could occur. TX05210-02-16-17 2 - 6...
Facer Acrobat™ 160, 180 and 250 Facer: The facer is a McElroy rotating planer block design. The blade holders each contain two cutter blades. The block rotates on ball bearings and is chain driven (enclosed in lubricant) by a heavy duty electric motor. When operating in an explosive atmosphere, operate the facer manually.
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.
Overview Heater Latch (Acrobat 250 and 315) The heater has a latch that locks the heater to the carriage guide rod. The latch is actuated by pulling the latch handle into the heater handle. The latch locks onto the guide rod automatically when the heater is inserted.
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.
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 injury or ¡PELIGRO! death. Refer to Special Operation - Fusion in Explosive Atmosphere for safety precautions. Install butt fusion heater plates.
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! Refer to Special Operation - Fusion in Explosive Atmosphere for safety precautions. Locate HPU in a safe environment.
Butt Fusion Procedure Prepare Facer Electric motors are not explosion proof. Operation of these components in an explosive atmosphere without necessary safety precautions will result in serious injury or death. Refer ¡PELIGRO! to Special Operation - Fusion in Explosive Atmosphere for safety precautions.
Butt Fusion Procedure Removing 3-Jaw Carriage (If Required) The 3-Jaw carriage can be removed from the base for close quarters fusion. To remove the 3-Jaw carriage: Actuate the release on the fixed jaw brace. Rotate the fixed jaw brace away from the inner fixed jaw. Repeat for the fixed jaw brace on the opposite side of the carriage.
Butt Fusion Procedure Support Pipe The Acrobat carriage is not designed to support overhead or overhung loads. Adequately support the pipe using appropriate support devices. If not supported, overhead loads could fall causing serious injury or death. Ensure the pipe is properly supported before attaching the carriage to the pipe.
Butt Fusion Procedure Begin Facing Open the carriage and install the facer, ensuring the facer handle latches onto the carriage guide rod. Turn on the facer. Assure the pressure selector control is in the facing position. Close the carriage. If the facer stalls, reduce the facing pressure so the facer continues to cut.
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.
Butt Fusion Procedure Determine Drag Pressure Determine drag pressure using the following steps: Move the carriage so that the faced pipe ends are approximately 1" (25.4mm) apart. Shift the carriage directional control to the middle (neutral) position (A). POWER MOTOR SUPPLY Shift the pressure selector control (B) to FUSES...
Butt Fusion Procedure Position Carriage for Heater Insertion Open the carriage until there is a gap large enough to insert the heater. NOTICE: Do not open a gap too large as this could damage the heater stripper bar. TX04009-04-01-14 Check Heater Temperature NOTICE: Incorrect heating temperature can result in questionable fusion joints.
Butt Fusion Procedure Select the Fusing Position With the carriage directional control in the middle position, change the pressure selector to the fusing position. POWER MOTOR SUPPLY FUSES 1000 DIRECTIONAL CONTROL VALVE FACING SELECTOR PRESSURE VALVE HEATING PRESSURE FUSING PRESSURE TX04812-05-05-16 Inserting Heater The heater is not explosion proof.
Butt Fusion Procedure Heating the Pipe 1) Verify that the pressure selector control (A) is in the fusing position. 2) Close carriage (B) to bring pipe ends in contact with the heater. 3) Wait for manufacturer's recommended bead POWER MOTOR SUPPLY 4) After the proper bead-up, move pressure selector control to middle (heating mode)
Butt Fusion Procedure Fusing the Pipe Failure to follow pipe manufacturer's fusion procedures NOTICE: may result in a questionable joint. After following the pipe manufacturer's suggested heating procedure: POWER MOTOR SUPPLY A) Shift carriage directional control to neutral position, if it is not FUSES already in that position.
Butt Fusion Procedure Opening Jaws After the joint has cooled for the pipe manufacturer's recommended time or appropriate joining standard, shift the carriage directional control to the neutral position. Turn off HPU. Loosen all clamp knobs. Turn on HPU and open the carriage. Open all of the jaws.
Special Operations - Vertical Fusion (Movable Pipe Below) Vertical Fusion The Acrobat fusion machines can be used to fuse pipes in a vertical position using the 4-Jaw or 3-Jaw carriage. The vertical fusion with the movable pipe below is the recommended method for performing vertical fusions.
Special Operations - Vertical Fusion (Movable Pipe Below) Attach Carriage to Pipe Position the pipe to be fused below the fixed pipe. Relieve pressure in the system. Turn off HPU. Disconnect hoses from the carriage. Disconnect carriage from HPU before attaching carriage to pipe.
Special Operations - Vertical Fusion (Movable Pipe Below) Attach Carriage to Pipe (continued) Stop the carriage and close the movable jaws on the pipe. Tighten the clamp knobs on the movable jaws. Open the carriage. TX04820-05-05-16 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.
Special Operations - Vertical Fusion (Movable Pipe Below) Begin Facing Ensure the carriage is open. Insert the facer, ensuring the facer handle latches onto the carriage guide rod. Turn on the facer. Assure the pressure selector control is in the facing position. Move the carriage directional control to close the carriage.
Special Operations - Vertical Fusion (Movable Pipe Below) Check Alignment Move the carriage until 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.
Special Operations - Vertical Fusion (Movable Pipe Below) Check for Slippage Bring the pipe ends together under fusion pressure to check for slippage. If slippage occurs, return to Attach Carriage to Pipe. TX00971-5-31-96 Position Carriage for Heater Insertion Open the carriage until there is approximately a 2 1/2" (63.5mm) gap for inserting the heater.
Special Operations - Vertical Fusion (Movable Pipe Below) 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.
Special Operations - Vertical Fusion (Movable Pipe Below) Heating the Pipe Acrobat HPU A) Verify that the pressure selector control is in the fusing position. B) Close the carriage to bring pipe ends in contact with the heater. Allow for bead-up according to pipe manufacturer's or appropriate joining standard recommendations.
Special Operations - Vertical Fusion (Movable Pipe Below) Fusing the Pipe Acrobat HPU NOTICE: Failure to follow pipe manufacturer's fusion procedures may result in a questionable joint. After following the pipe manufacturer's suggested heating procedure: A) Shift the carriage directional control to the neutral position. POWER MOTOR SUPPLY...
Special Operations - Vertical Fusion (Movable Pipe Below) Opening Jaws After the joint has cooled for the pipe manufacturer's or appropriate joining standard recommended time, shift the carriage directional control to the neutral position. Relieve hydraulic pressure in the carriage by turning fusing pressure reducing knob to its minimum setting.
Special Operations - Vertical Fusion (Movable Pipe Above) Vertical Fusion The Acrobat fusion machines can be used to fuse pipes in a vertical position using the 4-Jaw or 3-Jaw carriage. TX04830-05-05-16 Support Pipe The Acrobat carriage is not designed to support overhead or overhung loads. Adequately support the pipe using appropriate support devices.
Special Operations - Vertical Fusion (Movable Pipe Above) Attach Carriage to Pipe Position the pipe to be fused on top of the fixed pipe. Relieve pressure in the system. Turn off HPU. Disconnect hoses from the carriage. Disconnect carriage from HPU before attaching carriage to pipe.
Page 49
Special Operations - Vertical Fusion (Movable Pipe Above) Attach Carriage to Pipe (continued) Stop the carriage and close the movable jaws on the pipe. Tighten the clamp knobs on the movable jaws. Open the carriage. TX04831-05-05-16 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.
Special Operations - Vertical Fusion (Movable Pipe Above) Begin Facing Ensure the carriage is open. Insert the facer, ensuring the facer handle latches onto the carriage guide rod. Turn on the facer. Assure the pressure selector control is in the facing position. Move the carriage directional control to close the carriage.
Special Operations - Vertical Fusion (Movable Pipe Above) Check Alignment Move the carriage until 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.
Special Operations - Vertical Fusion (Movable Pipe Above) Check for Slippage Bring the pipe ends together under fusion pressure to check for slippage. If slippage occurs, return to Attach Carriage to Pipe. TX00971-5-31-96 Position Carriage for Heater Insertion Open the carriage until there is approximately a 2 1/2" (63.5mm) gap for inserting the heater.
Special Operations - Vertical Fusion (Movable Pipe Above) 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.
Special Operations - Vertical Fusion (Movable Pipe Above) Heating the Pipe (Positive Vertical Fusion Pressure) Acrobat HPU A) Verify that the pressure selector control is in the fusing position. B) Close the carriage to bring pipe ends in contact with the heater. Allow for bead- up according to pipe manufacturer's or appropriate joining standard recommendation.
Special Operations - Vertical Fusion (Movable Pipe Above) Fusing the Pipe (Positive Vertical Fusion Pressure) Acrobat HPU NOTICE: Failure to follow pipe manufacturer's fusion procedures may result in a questionable joint. After following the pipe manufacturer's suggested heating procedure: A) Shift the carriage directional control to neutral position. POWER MOTOR SUPPLY...
Special Operations - Vertical Fusion (Movable Pipe Above) Heating the Pipe (Negative Vertical Fusion Pressure) Acrobat HPU A) Verify that the pressure selector control is in the fusing position. B) Close the carriage to bring pipe ends in contact with the heater. C) When pipe ends contact the heater, immediately shift the carriage directional control to the open position.
Special Operations - Vertical Fusion (Movable Pipe Above) Fusing the Pipe (Negative Vertical Fusion Pressure) Acrobat HPU NOTICE: Failure to follow pipe manufacturer's fusion procedures may result in a questionable joint. After following the pipe manufacturer's suggested heating procedure: A) Shift the carriage directional control to neutral position. POWER MOTOR SUPPLY...
Special Operations - Vertical Fusion (Movable Pipe Above) Opening Jaws After the joint has cooled for the pipe manufacturer's or appropriate joining standard recommended time, shift the carriage directional control to the neutral position. Relieve hydraulic pressure in the carriage by turning the fusing pressure reducing knob to its minimum setting.
Special Operations - Fusion in Explosive Atmosphere Facer Electric motors are not explosion proof. Operation of these components in an explosive atmosphere without necessary safety precautions will result in serious injury or death. ¡PELIGRO! The brushes of the facer motor must be removed and the facer manually operated in an explosive atmosphere.
Special Operations - Fusion in Explosive Atmosphere 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! The HPU is not explosion proof and must be located outside of the explosive atmosphere.
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 soap and water.
Maintenance Change Hydraulic Fluid and Filter Acrobat HPU: This HPU is equipped with a 3 micron pressure filter with a bypass indicator below the accumulator. If the indicator is activated, the filter needs to be changed otherwise the filter should be replaced every 500 hours.
Maintenance Change Gearbox Oil (Acrobat 315) Unplug the facer from the power source. Lay the facer in a horizontal position with the gearbox cover facing upward. Remove the 6 screws from the cover. Remove with cover and carefully remove the gasket from the gearbox housing.
Maintenance Bleeding Air From Acrobat HPU Fill hydraulic reservoir according to procedure "Check Hydraulic Fluid" in the Maintenance section of the manual. Connect the quick disconnects together at the end of the hoses. Move the pressure selector control (A) to fusing pressure. Set the fusing pressure reducing knob (B) to max setting by POWER MOTOR...
Maintenance 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. TX00433-9-15-94 Clean Thrust Bearings The thrust bearings located in the clamp knobs must turn freely. Wash the clamp knob bearing assembly with a solvent, and then lubricate with 30W or lighter oil.
Maintenance Facer Blades Blades bolt directly to the blade holder and should be inspected for damage and sharpness. Dull or chipped blades must be replaced. NOTICE: Never extend the blade beyond the inner or outer circumference of the facer. TX02475-3-29-05 Clean Heater Surfaces The heater faces must be kept clean and free of any plastic build up or contamination.
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.
Maintenance Checklist Fusion Machine Checklist Item to Check 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 Fluid reservoir is filled to correct level Machine is free of hydraulic leaks Hydraulic gauges read correctly...
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).
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: Pump Motor Voltage: Pump Motor Phases: Pump Motor Frequency: ____________ (50 or 60 Hz) Facer Motor: Facer Motor Voltage: ______________ Facer Motor Phases: 1...
New standards, including ASTM F3124, have been implemented to govern the collection of data from plastic pipe fusions. The DataLogger® 6 from McElroy meets these requirements by capturing the most important information related to fusion operations. It is now easier than ever before to add improved traceability and a higher level of assurance that pipelines were fused properly before they go into service.
Page 77
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.
Need help?
Do you have a question about the Acrobat 160 and is the answer not in the manual?
Questions and answers