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Roughneck Jackman Fusion Equipment Operator's Manual

Electrofusion processor
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Summary of Contents for Roughneck Jackman Fusion Equipment

  • Page 3: Safety

    Processor. • Gas company safety standards and precautions should be followed at all times. • Do not use or store the Roughneck Electrofusion Processor where volatile gas concentrations may be present. • Only properly trained and qualified personnel should operate the Roughneck Electrofusion Processor.

  • Page 4: Table Of Contents

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 CONTENTS Safety ..................................1 CONTENTS ................................2 Warranty And Limitation Of Liability ........................4 Introduction ................................6 Preface ................................. 6 Features ................................6 Specifications ............................... 7 Descriptions of Controls ............................8 Carrying Case ..............................
  • Page 5 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 SMART Scanner™ ............................30 Entering Data with the Keypad .......................... 33 Traceability ................................ 33 Pipe/Fitting ..............................33 Operator ID..............................34 Calculated Resistance ............................35 Downloading Data ............................. 37 Data Stored ..............................37 Downloading Wirelessly ..........................

  • Page 6: Warranty And Limitation Of Liability

    THE MANUFACTURER does not warrant that the operation of the Roughneck Electrofusion Processor will be uninterrupted or error free.
  • Page 7 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 5. THE MANUFACTURER’S LIABILITY IN RESPECT TO THE SALE IS STRICTLY LIMITED TO THE REPLACEMENT OF PROCESSORS OR SERVICES AS HEREIN BEFORE SPECIFIED AND THE MANUFACTURER SHALL NOT, IN ANY EVENT, BE LIABLE FOR ANY DAMAGES WHETHER FOR THE LOSS OF USE OR BUSINESS INTERRUPTION OR ANY OTHER CLAIM FOR INCIDENTAL, CONSEQUENTIAL, SPECIAL OR PUNITIVE DAMAGES.

  • Page 8: Introduction

    The Roughneck Electrofusion Processor is capable of scanning and recording both ASTM F2897-11 and ISO 12176-4 Traceability barcodes. The Roughneck Electrofusion Processor can be operated from any AC power source meeting the input power requirements listed in the Specifications Table on page 7.

  • Page 9: Specifications

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Specifications Parameter Value Supply Voltage 97 VAC to 150 VAC Supply Frequency 47 Hz to 70 Hz Supply Waveform Sine Wave or Square Wave Maximum Supply 30 Amps Current Output Voltage 8 VAC to 48 VAC +/- 1.5% 4 AAC to 60 AAC +/- 1.5% up to 48 volts output (80 AAC @ up to 42 VAC...

  • Page 10: Descriptions Of Controls

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Descriptions of Controls NOTES 1 References to controls in this section are displayed exactly as they appear throughout the remainder of this document. 2 The START button may mean START, CONTINUE, OK or SAVE depending upon the context of the operation being performed at the time.

  • Page 11: Faceplate View

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Faceplate View 4X20 LCD Display Replaceable Display Shield STOP button START button UP button DOWN button Page 9 of 48...

  • Page 12: Left Side

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Left Side Input Cable Right Side Power Switch Buzzer Fuse Output Cable Page 10 of 48...

  • Page 13: Output Cable

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Output Cable Smart Scanner Output Cable Temperature Sensor Output Lead Ends Fitting Adapters 4.7mm 90 degree 4.0mm 90 degree Adapter Wrench Page 11 of 48...

  • Page 14: Smart Scanner With Gps

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Smart Scanner with GPS Smart Scanner Scanner Sheath Page 12 of 48...

  • Page 15: Customer Responsibilities

    Subscribe to the recommended calibration service offered by JACKMAN FUSION EQUIPMENT (See page 14). The Roughneck Electrofusion Processor will provide the proper outputs for a complete fusion based on the inputs received from a scanned barcode (in Barcode Mode) or from the operator (in one of the other alternate fusion modes).

  • Page 16: Service Recommendations

    Refer to page 40 for instructions and guidelines to use when choosing a power source. 5. Always store the SMART Scanner™ in its sheath when not in use. Proper care of the processor and output cable will greatly extend the life of your Roughneck Electrofusion Processor and help reduce service times and costs.

  • Page 17: Service Contact Information

    There are two (2) options for calibrating your Roughneck Electrofusion Processor: 1. Send the processor in to a JACKMAN FUSION EQUIPMENT service center and let our technicians do it. This is the recommended method and will help ensure the maximum service life of the processor.

  • Page 18: General Operation

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 GENERAL OPERATION Modes of Operation The Roughneck Electrofusion Processor has multiple modes of operation: Primary Fusion Mode Barcode Fusion Mode Barcode Fusion Mode infers that fusion parameters are input into the processor by scanning a barcode label attached to the fitting being fused.

  • Page 19: Power Up

    Make sure the unit’s Power button is in the OFF position. Make sure the generator is running smoothly in high speed manual mode before plugging in the Roughneck Electrofusion Processor. It is strongly recommended that the Roughneck Electrofusion Processor is the only device being powered by that generator.
  • Page 20 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 After the Operator Traceability Data is entered, the processor will display the CONNECT FITTING screen. An example of the CONNECT FITTING screen is shown below: CONNECT FITTING Temperature: +75° F Gen: 120V 60.0Hz On the CONNECT FITTING screen, the second line indicates the ambient temperature the processor is...

  • Page 21: Barcode Fusions

    If the scanning device is inoperative, see page 20 for details about how a fusion can be completed without using a scanning device. Once the barcode has been successfully scanned, the Roughneck Electrofusion Processor will display a screen similar to the following:...

  • Page 22: Alternate Fusion Methods

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 The VERIFY SETUP screen shows the following information: • The fitting type (CPL 2” Coupler). • The requested output (40.0 Volts) • The total temperature-compensated fusion time in seconds (In this case, 60 seconds). The VERIFY SETUP screen allows the operator a final opportunity to verify that the fusion parameters displayed are correct and match the parameters specified by the fitting manufacturer before starting the fusion.
  • Page 23 (see page 33). When the START button is pressed after the last character is entered, the processor will move to the next screen. If no errors were encountered, the Roughneck Electrofusion Processor will display a screen similar to the following.

  • Page 24: Manual Data Entry

    When the desired number of seconds are displayed, press the START button. Once the data has been successfully entered, the Roughneck Electrofusion Processor will display a screen similar to the following:...
  • Page 25 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 IT IS THE RESPONSIBILITY OF THE OPERATOR TO VERIFY THAT ALL THE INFORMATION DISPLAYED IS CORRECT PER THE FITTING MANUFACTURER’S RECOMMENDATIONS FOR FUSING THE ATTACHED FITTING UNDER THE CURRENT AMBIENT CONDITIONS. The processor will BEEP once per second and the text “PRESS START”...

  • Page 26: Monitoring A Fusion's Progress

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Monitoring a Fusion’s Progress Once the START button is pressed the fusion process will begin. The fusion process begins with a Fitting Resistance Verification. The Roughneck Electrofusion Processor will display a screen similar to the following: VERIFYING FUSION...
  • Page 27 OUTPUT LEADS FUSION NOT COMPLETE Errors Encountered After the Output Lead Ends are disconnected, the Roughneck Electrofusion Processor will return to the CONNECT FITTING screen and will be ready to accept information for the next fusion. NOTE: If Operator Traceability is enabled, remember that the Operator ID codes entered previously will remain attached to any additional fusions until the power is shut off or until the information is changed by the operator.

  • Page 28: User Menus

    When Option 3 is highlighted, press the START button to select it. Use the UP/DOWN buttons to toggle between all supported languages. When the desired language is displayed, press the START button to save. The languages supported by the Roughneck Electrofusion Processor are English, French, and Spanish. Page 26 of 48...

  • Page 29: Smart Scanner

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 SMART Scanner™ When Option 4 is highlighted, press the START button to select it. Use the UP/DOWN buttons to toggle between the SMART SCANNER activation values. When the desired activation value is displayed, press the START button to save.

  • Page 30: Operator Id

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Operator ID This setting controls the Operator Traceability functions. This option is different than Pipe/Fitting Traceability. Pipe/Fitting Traceability is discussed below. Values for Operator Traceability are “OFF”, “ON”, or “SCAN”: •...

  • Page 31: Features Menu

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Features Menu The Features Menu is accessed by holding the UP and DOWN buttons at the same time when the processor is first powered up. Keep holding the UP/DOWN buttons through the INTERNAL SELF TEST screen, until the processor displays a screen similar to the following: FEATURES 1.

  • Page 32: Appendix

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 APPENDIX Scanning Barcodes SMART Scanner™ THE SMART SCANNER™ IS NOT MULTI LINGUAL. THE ONLY LANGUAGE AVAILABLE IS ENGLISH. Smart Scan Mode To operate the SMART Scanner™ in Smart Scan Mode, set the SMART SCANNER option in the Basic User Menu to “YES”.
  • Page 33 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 If errors are encountered during the fusion process, the SMART Scanner™ will alert the operator by showing the following message: ERROR RECEIVED Check Processor! At this point, you should consult the display of the processor for the specific error code and take appropriate corrective action based on the information displayed.
  • Page 34 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Scanning Techniques To scan a barcode, start by holding the SMART Scanner™ about 6-8 inches from the barcode to be scanned. Next, press and hold the button. A red aiming light will emanate from the end of the device as long as the button is held.

  • Page 35: Entering Data With The Keypad

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Entering Data with the Keypad To enter data in any field manually, press the UP button or the DOWN button to scroll through the list of valid characters. When you find the one you wish to use press the START button to move to the next character. If an invalid character is entered, press the STOP button to back the cursor up to the previous character and change it.

  • Page 36: Operator Id

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 SCAN TRACEABILITY BARCODE 1 Press START if done. You can scan one (1) or more traceability barcodes at this time, up to six (6) barcodes. When you scan multiple barcodes, the display will update accordingly to indicate the number of barcodes scanned. THE OPERATOR MUST SCAN AT LEAST ONE (1) TRACEABILITY BARCODE UNLESS THE PIPE/FITTING OPTION IS SET TO “OPT”...

  • Page 37: Calculated Resistance

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Calculated Resistance An operator can perform a secondary Calculated Resistance check. See page 28 for an explanation how Calculated Resistance works and instructions how to turn the option on. NOTE: A secondary Calculated Resistance check can only be performed when fusing in Barcode or Manual Barcode Modes.
  • Page 38 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 To CANCEL THE FUSION: 1. Press the STOP button to cancel the fusion now. The processor will display a screen similar to the following: ERROR 102 RECEIVED Resistance 16.578 Min:1.21 Max:1.78 Hold START to clear...

  • Page 39: Downloading Data

    The following data is stored for each fusion that the processor performs. The data stored in the processor can be downloaded wirelessly via Bluetooth. The data is output in a binary format that is compatible with a free macro-enabled Excel Spreadsheet available from JACKMAN FUSION EQUIPMENT. Field Description The serial number of the processor.

  • Page 40: Downloading Wirelessly

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Downloading Wirelessly Wireless downloading of fusion data is handled entirely through the EF Technologies app (EF Utilities). Turn the processor ON. Allow it to proceed through the INTERNAL SELF TEST to the CONNECT FITTING screen before attempting a download.

  • Page 41: Position Error Indicator

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Position Error Indicator The Position Error Indicator gives the operator an indication of how much confidence the operator should place in the accuracy of the current position reading: Value Rating Description This is the highest possible confidence level to be used for applications demanding the highest...

  • Page 42: General Maintenance

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 General Maintenance Changing the Fuse Important Notes • The fuse protects the internal electronic circuitry. If the display lights up when power is turned on, you DO NOT need to replace the fuse. •...

  • Page 43: Inverters

    Sizing a Power Supply JACKMAN FUSION EQUIPMENT does not recommend or endorse any particular type or brand of generator. Power requirements vary depending on the fitting manufacturer, fitting size and ambient temperature.

  • Page 44: Extension Cords

    15 minutes. Direct exposure to sun light and other heat sources will adversely affect accuracy. Temperature Compensation When using the Roughneck Electrofusion Processor in Barcode Fusion Mode or Manual Barcode Mode to fuse fittings that require temperature compensation, it is essential that care be given to ensure the correct initial fusion temperature is measured.

  • Page 45: Warning & Error Codes

    JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 WARNING & ERROR CODES Warning Codes A warning code will be displayed when a situation exists that (in the manufacturer’s opinion) may adversely affect the performance of the processor over time. Warning codes are designed for informational purposes only and have no effect on the outcome of a fusion.
  • Page 46 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Verify that the Output Lead Ends are clean, the power supply is sized Can’t maintain output correctly for the fitting you are fusing, and the power supply is operating voltage.
  • Page 47 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 then there is a processor problem and it must be returned for service. Invalid operator ID card Verify the system date is correct and, if so, contact the agency that scanned.
  • Page 48 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 specified heat soak time was observed. The output is cycling and This is more than likely caused by a fluctuating power supply. Eliminate cannot be controlled to all extension cords and make sure that the processor is the only device the requested level.
  • Page 49 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Page Intentionally Left Blank Page 47 of 48...
  • Page 50 JACKMAN FUSION EQUIP – ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0 Page Intentionally Left Blank Page 48 of 48...
  • Page 52 JACKMAN FUSION EQUIPMENT 715 S 59 Ave W, Duluth, MN 55807 USA www.jackmanfusion.com (218) 302-4770...

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