Asahi/America McELROY SmartFab 125 User manual

Operator’s
Manual
SmartFab™
125
Manual: 460801
Revision: Rev C 06/19
Original Language: English
Asahi/America, Inc.
ProWeld
®
Equipment
Powered by
800
-
343
-
3618

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
Cancer and Reproductive Harm -
www.P65warnings.ca.gov
8163361

Thank you for purchasing this McElroy
product through Asahi/America
McElroy has created a smarter way to socket fuse pipe and
fittings for polypropylene piping systems with the SmartFab™
125 benchtop machine. Its portable design allows it to be
positioned on any flat surface for precise prefabrication,
providing versatility in the field as well as the shop.
Advanced features of the SmartFab 125 provide more efficiency
with innovative inserts that reduce ovality in pipe and fittings.
The heater pivots to easily accommodate fittings situated on
either side of the machine, which eliminates having to reposition
the entire machine. Its four jaws adjust to any desired spacing
and each jaw clamps individually to the desired pipe and fitting
size.
The SmartFab 125 socket fuses 20mm to 125mm pipe and
fittings.
When fusing thermoplastic pipe materials, refer to the pipe
manufacturer's fusion procedures or appropriate joining
standard.
With reasonable care and maintenance, this machine will give
years of satisfactory service.
TX04887-03-15-16
Before operating this machine, please read this manual
thoroughly, and keep a copy with the machine for future
reference. This manual is to be considered part of your machine.
MU2-03-13-14
CD01407-11-12-15
Asahi/America Training Standards
Since 1984, Asahi/America, Inc. has been teaching contractors the benefits of welding thermoplastic piping systems in
industrial and high purity applications. Our partnership with McElroy allows us to leverage their state-of-the-art Learning
Management System (LMS) using Asahi/America technical standards across all Asahi piping systems.
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. Asahi/America learning portal classes powered by McElroy University are structured so that the skills learned
and the machines used in each class closely match the machines found on pipelining jobsites.
Training modules specific to Asahi/America piping systems available for purchase online and required to be completed
prior to onsite training by Asahi/America personnel.
This manual is intended as a guide only and does not take the place of proper training by qualified instructors. The
information in this manual is not all inclusive and cannot encompass all possible situations that can be encountered during
various operations.

LITERATURE INFORMATION
This manual should be stored in a protected location for future reference. Use the literature holder if provided with the
product.
This manual contains safety information, operation instructions, transportation information, lubrication information
and maintenance information.
Some photographs or illustrations in this publication show details or equipment that can be
different from your machine. Guards and covers might have been removed for illustrative purposes. Continuing
improvement and advancement of product design might have caused changes to your machine which are not included in
this publication. Read, study, and keep this manual with the machine. Whenever a question arises regarding your
machine, or this publication, please contact Asahi/America Technical Services at 1-800-343-3618 or pipe@asahi-
america.com.
SAFETY
The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs
and labels used on the machine. Read and understand the basic precautions listed in the safety section before
operating or performing maintenance and repair on this machine.
OPERATION
The operation section is a reference for the new operator and a refresher for the experienced operator. This section
includes a discussion of gauges, switches, machine controls, accessories, and transportation. Photographs and
illustrations guide the operator through correct procedures of setting up, checking, and operating the machine.
Operating techniques outlined in this publication are basic. Proficiency develops as the operator gains knowledge and
experience with the machine and its capabilities.
MAINTENANCE
The maintenance section is a guide to equipment care. The maintenance schedule lists the items to be maintained at a
specific service interval. Items without specific intervals are listed under the “As Needed” service interval. The schedule
lists the page for the step-by-step instructions required to accomplish the scheduled maintenance. Use the schedule as
an index for all maintenance procedures. Some maintenance procedures may be referenced in a manual pertaining to
that component of the machine. For example, maintenance for an engine component would have its intervals and
procedures in the engine operator’s manual.
Use the hour meter (if equipped) to determine servicing intervals. Calendar
intervals will be used instead of hour meter intervals if no hour meter is equipped on
a machine. Recommended
service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating
conditions, more frequent lubrication than is specified in the maintenance schedule might be necessary.

PATENT INFORMATION
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
REPLACEMENT LITERATURE
This product is shipped with a printed operator’s manual. If the manual becomes lost or damaged, order a replacement
manual or download and print a copy of the manual from our website at https://www.asahi-america.com/images/x-
assets/PDF/Datasheet_McElroy_SmartFab_125.pdf.
NAMEPLATE LOCATIONS
Every machine has a name plate that includes the machine’s model number, serial number, and power requirements. The
model and serial numbers can be used to register the machine online and activate the warranty. Reference warranty card
for information on registering your product. Asahi America's rental tools also have the rental serial number on tool and
shipping crate, as well. This serial number required when calling Asahi America with questions for rental tools.
REPLACEMENT PARTS
Contact Asahi/America for replacement parts on Asahi-owned rental tools. Refer to the McElroy parts finder at
www.mcelroy.com to locate parts for purchase. Reference the model number on the nameplate of the machine when using
the parts finder. Contact your McElroy distributor to order replacement parts. Find your closest distributor on our website at
www.mcelroy.com.

ASAHI/AMERICA RENTAL WARRANTY
Asahi/America’s comprehensive rental equipment policies can be found on our website here: https://www.asahi-
america.com/support/rental-equipment-policy
All rental equipment is warranted for six (6) months of on-site usage. All tool failures within this six-month period are
handled as indicated in Section V. After six months usage it is recommended that the equipment be returned for
regular maintenance and warrantee renewal. Equipment held longer than six months without return is held at the
renter's risk.
USED EQUIPMENT WARRANTY
Purchase of refurbished/used equipment carries a 90-day warranty.
NEW EQUIPMENT WARRANTY
Purchase of new Asahi/America versions of McElroy equipment carries a 5-year limited warranty. Details can be found here:
https://www.mcelroy.com/warranty.htm
ASAHI/AMERICA TOOL DEPARTMENT CONTACTS
For technical or tool related questions, please contact:
Rental Equipment Manager – 781-388-4618 or [e-mail]
For Rental Administration, Billing, and Returns – 781-388-4623 or [e-mail]
Welding and Standards Manager – 781-388-4577
To schedule field service or training, please enter information here: https://www.asahi-america.com/support/field-
technician-request
For technical service related questions, please contact:
High Purity, Double Wall, or Industrial Piping – 781-321-5409 or [e-mail]
Asahi/America Corporate Headquarters – 800-343-3618 or [e-mail]
Asahi/America, Inc.
655 Andover St.
Lawrence, MA 01843

Equipment Safety
Safety Alerts ........................................................................................................................... 1-1
Read and Understand .......................................................................................................... 1-1
General Safety ........................................................................................................................ 1-2
Wear Safety Equipment ....................................................................................................... 1-2
Heater is Not Explosion Proof ............................................................................................. 1-2
Electrical Safety ...................................................................................................................... 1-3
Pinch Points............................................................................................................................. 1-3
Heater is Hot .......................................................................................................................... 1-3
Fusion
Procedures ................................................................................................................. 1-3
Overview
Set Up
Theory of Heat Fusion
............................................................................................................ 2-1
SmartFab™ 125 Fusion Machine .......................................................................................... 2-2
Carriage Assembly ................................................................................................................ 2-2
Heater ..................................................................................................................................... 2-3
Carriage Jaws and Inserts ................................................................................................... 2-4
Depth
Star ............................................................................................................................... 2-4
Jaw Clamp Handles .............................................................................................................. 2-5
Jaw Frame Lock Handles ....................................................................................................... 2-5
Set Up Gauge ......................................................................................................................... 2-5
Set Up Calibration ................................................................................................................. 3-1
Fusion Procedure
Read Before Operating ........................................................................................................ 4-1
Level Machine
.......................................................................................................................
4-1
Connecting to Power
............................................................................................................ 4-1
Prepare Heater ..................................................................................................................... 4-1
Install Inserts .......................................................................................................................... 4-2
Load Pipe and Fitting ........................................................................................................... 4-2
Support Pipe .......................................................................................................................... 4-3
Verify Alignment ................................................................................................................... 4-3
Check Heater Temperature ................................................................................................. 4-3
Heating the Pipe and Fitting ............................................................................................... 4-4
Remove
Heater ..................................................................................................................... 4-4
Inspect Melt ............................................................................................................................ 4-4
Fusion and Cooling............................................................................................................... 4-5
Opening Jaws ........................................................................................................................ 4-5
COPYRIGHT © 2019, 2016, 2015
McELROY MANUFACTURING, INC.
Tulsa, Oklahoma, USA
All rights reserved
All product names or trademarks are property of their respective owners. All information, illustrations
and specifications in this manual are based on the latest information available at the time of
publication. The right is reserved to make changes at any time without notice.

Maintenance
Preventative
Maintenance ..................................................................................................... 5-1
Cleaning the Machine ........................................................................................................... 5-1
Clean Jaws and Inserts ........................................................................................................ 5-1
Fasteners Must Be Tight ........................................................................................................ 5-2
Installing Socket Fusion Adapters ........................................................................................ 5-2
Clean Heater Surfaces .......................................................................................................... 5-2
Adjusting Heater Temperature ............................................................................................ 5-2
Heater Indicator Light............................................................................................................ 5-3
Maintenance Checklist
Fusion Machine Checklist ................................................................................................... 6-1
Specifications
Fusion Machine Specifications: SmartFab™ 125 .............................................................. 7-1

1 - 1
Fusion Equipment Safety
This
hazard
alert
sign
appears
in
this
manual.
When
you
see
this
sign,
carefully
read
what
it
says.
YOUR
SAFETY
IS
AT STAKE.
You will see the hazard alert sign with these words: DANGER,
WARNING, and CAUTION.
Indicates
an
imminently
hazardous
situation
which, if not avoided, will result in death
or
serious injury.
Indicates a potentially hazardous
situation
which, if not avoided, could result
in
death or serious injury.
Indicates a hazardous situation which,
if not avoided, may result in minor or
moderate injury.
In this manual you should look for two other words: NOTICE
NOTICE: can keep you from doing something that might
damage the machine or someone's property. It may also be
used to alert against unsafe practices.
IMPORTANT: can help you do a better job or make your job
easier in some way.
TX00030
-
12
-
1
-
92
Do not operate this equipment until you have carefully read, and understand
all the sections of this manual, and all other equipment manuals that will be
used with it.
Your safety and the safety of others depends upon care and judgment in
the operation of this equipment.
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. You should also ensure that the machine will not be
damaged or made unsafe by the method of operation or maintenance you
choose.
TX02946-4-15-09
WR00052-12-1-92
WR00051-11-30-92

This heater is not explosion proof. Operation of heater in an
explosive atmosphere will result in serious injury or death.
Heater components are attached to the machine and the machine must not be used
in an explosive atmosphere.
TX04846-12-14-15
1 - 2
Fusion Equipment 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.
SEE problems with wiring and cables, hydraulic connections, or other
equipment.
REPORT anything you see, feel, smell, or hear that is different from what
you expect, or that you think may be unsafe.
TX00114-4-22-93
Wear a hard hat, safety shoes, safety glasses, and other applicable
personal protective equipment.
Remove jewelry and rings, and do not wear loose-fitting clothing or long
hair that could catch on controls or moving machinery.
TX00032-4-7-93
WR00053-12-2-92
SAFE1ST-12-22-92
WR00034-11-30-92

Fusion Equipment Safety
1
-
3
The heater is hot and will burn clothing and skin. Use
care when heating the pipe and fitting.
NOTICE: Use only a clean dry lint free non-synthetic cloth to clean the
heater adapters.
TX04848-12-14-15
Moving components of the machine can create pinch
points. Use caution while operating the machine not to
expose body parts to pinch points. Pinch points may
cause minor to moderate injury.
TX04847-12-14-15
Always ensure equipment is properly
grounded. It is important to remember that
you are working in a wet environment with
electrical devices. Proper ground connections
help to minimize the chances of an electric
shock.
Frequently inspect electrical cords and unit for damage. Have
damaged components replaced and service performed by a
qualified electrician.
Do not carry electrical devices by the cord
NOTICE: Always connect units to the proper power source as listed on the
unit, or in the owner's manual.
TX00105-6-12-13
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.
TX04469-10-24-12
WR00025-11-30-92
WR00055-4-7-93
WR00079-1-24-96
WR00030-2-10-93
WR00114-11-30-15

2
-
1
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
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 from semi-crystalline into
an amorphous condition. When fusion pressure is applied, the molecules
from each thermoplastic part mix. As the joint cools, the molecules return
to their semi-crystalline form, the original interfaces are gone, and the
fitting and pipe have become one monolithic unit. A strong, fully leak tight
connection is the result.
The principal operations include:
Clamping The pipe and fitting must be held firmly to allow all
subsequent operations to take place.
Cleaning The area of pipe that the fitting will come in contact with
must be cleaned.
Aligning The fitting, heater adapters, and pipe must be properly
aligned.
Heating
A melt pattern must be formed that penetrates into the pipe
and into the fitting.
Joining The pipe and fitting must be joined and the pipe fully seated
within the fitting.
Holding The molten joint must be held immobile until adequately
cooled.
Inspecting Visually examine the entire circumference of the joint for
compliance with standards established by your company,
customer, industry, federal, state, or local regulations.
TX04696-04-10-14-
PH05429-11-24-15

Overview
2
-
2
The SmartFab 125 carriage assembly has 4 jaw frames which can be
individually spaced and clamped allowing the operator flexibility to fuse
the greatest combination of pipe and fittings.
The carriage consists of two fixed jaws and two movable jaws.
The movable jaws are actuated by a rack and pinion.
The movable jaws are opened and closed using the hand wheel on the
side of the machine.
The movable jaws can be locked in position by tightening the handle near
the hand wheel.
TX04850-12-14-15
McElroy has created a smarter way to socket fuse pipe and fittings for
polypropylene piping systems with the SmartFab™ 125 benchtop machine.
Its portable design allows it to be positioned on any flat surface for precise
prefabrication, providing versatility in the field as well as the shop.
When fusing thermoplastic pipe materials, refer to the pipe manufacturer's
fusion procedures or appropriate joining standard.
The SmartFab 125 socket fuses 20mm to 125mm pipe and fittings.
TX04849-12-14-15
CD01407-11-30-15
CD01417-11-30-15
CD01407-11-12-15
CD01407-11-12-15

Overview
2
-
5
Heater
Heater is not explosion proof. Operation of heater in an
explosive atmosphere will result in serious injury or death.
The heater has a green indicator light which will flash on and off. This
indicates that the controller is operating normally. 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 bottom of the temperature scale. When the heater is plugged in
and preheating the light glows steadily until the set temperature is reached. The
light then goes off and on slowly as the heater maintains temperature.
The heater body is not coated. Coated socket fusion heater adapters are
available for all socket fusion applications.
NOTICE: The heater should never be used without socket fusion heater
adapters installed.
To prevent a build-up of plastic pipe residue from accumulating on the heater
adapters (loss of surface temperature and pipe sticking may result), the heater
adapters should be cleaned with a clean dry lint free non-synthetic cloth before
every fusion joint.
The heater pivots in and out of the fusion area. The heater can be rotated to
change the position of the heater adapters from one side to the other to allow
fusion on both ends of the machine.
To rotate the heater, pull the handle of the heater with the round ball toward
the heater and rotate the heater.
Pipe Heater Adapter
Fitting Heater Adapter
TX04851-12-14-15
CD01452-12-01-15
CD01415-11-23-15
CD01440-11-23-15
CD01411-11-30-15
CD01411-11-30-15

Overview
2 - 4
The depth star is used to change the stab depth of movable jaws by providing
a stop for the movable jaws to rest against. It rotates to change the pipe size to
fuse and each size is labeled on the face of the depth star.
There is a depth star to match the appropriate heater adapters. The depth stars
have a marking that will match the marking of the heater adapters.
The depth stars that are not being used are stored at the end of the machine
next to the heater controls when not in use.
TX04853-12-14-15
Each jaw frame has two insert holders and the jaws are opened
and closed using the handle at the end of the jaw frame.
Inserts are installed into the insert holders on each jaw frame.
Inserts are locked into place by a spring detent in the insert
holder. The inserts with the stop tabs are for the fitting and are
installed on the inner jaw frame on the same side as the socket
heater adapter on the heater.
TX04852
-
12
-
14
-
15
CD01456-12-10-15
CD01457-12-09-15
CD01412-12-10-15
CD01408-11-12-15

Overview
2
-
5
At the end of each jaw frame are adjustable handles for
clamping and unclamping of pipe and fittings. By pulling out on
the handles, the handle position can be adjusted.
Rotating the handle will open and close the jaws on the jaw
frame.
TX04854
-
12
-
14
-
15
At both ends of three of the jaw frames are adjustable handles
for locking and unlocking the position of the jaw frames. By
pulling out on the handles, the handle position can be adjusted.
Rotating the handle will loosen and tighten the jaw frames on the
guide rods of the machine.
TX04855
-
12
-
14
-
15
The machine comes with set up gauges for use during the set
up calibration procedures. There is a set up gauge to match the
appropriate heater adapters. The set up gauges will have a marking
that will match the marking of the heater adapters. There are 3 different
gauges on the block.
Pipe
Side
Heater
Stop
-
to
measure
the
long
heater
stop
distance.
Fitting Side Heater Stop - to measure the short heater stop
distance.
Stop Block - to measure the distance between the two inner jaw
frames.
The
gauges
are
stored
with
the
additional
depth
stars
when
not
in
use.
TX04856
-
03
-
14
-
16
CD01444-11-30-15
CD01444-11-30-15
CD01413-11-20-15

Overview
3
-
1
Set Up Calibration
Install the appropriate type depth star that will match the heater
adapters used.
Select the appropriate Set Up Gauge for the heater adapters
being used and use that gauge for the calibration procedures.
Loosen the bolts attaching the setting stop block and depth star
block to the frame.
Push in and hold the setting stop. Insert the appropriate Set Up
Gauge that matches the heater adapters used, between the inner
jaw frames with the stop block portion down. Close the carriage
until the inner jaw frames are resting against the Set Up Gauge.
Set Up Gauge
Setting Stop Block
Lock the carriage. Adjust the setting stop block until it rests against
the inner jaw frame on the movable jaws.
Tighten the bolts on setting stop block.
Unlock the carriage. Open and close the carriage against the
setting stop and verify the measurement between the inner jaw
frames.
Setting Stop Block
CD01420-11-23-15
CD01419-11-23-15
CD01418-11-23-15
CD01423-11-23-15

3
-
2
Set Up
Set Up Calibration (continued)
Open movable jaws to release the setting stop.
Set the depth star to 125mm. The 125mm will point to the left
toward the bolt of the movable jaws.
Close the movable carriage against the inner fixed jaw frame.
There should be no gap.
Lock the carriage.
CD01424-11-20-15
CD01423-11-23-15
CD01422-11-23-15
CD01421-11-23-15

3
-
3
Set Up
Set Up Calibration (continued)
Slide the depth star block to the left until it contacts the bolt.
Tighten the bolts on the depth star block to lock the position.
Loosen the set screws for the short heater stop bolts.
CD01426-11-20-15
CD01425-11-20-15