McElroy TP-300 Series User manual

Manual: TP-901 Revision: E 1/14
Test Caps
TP-300 Series
Operator’s
Manual

Warranty
LIMITED WARRANTY
McElroy Manufacturing, Inc. (McElroy) warrants all
products manufactured, sold and repaired by it to be
free from defects in materials and workmanship, its
obligation under this warranty being limited to repairing
or replacing at its factory and new products, within
5 years after shipment, with the exception of purchased
items (such as electronic devices, pumps, switches, etc.),
in which case that manufacturer’s warranty applies.
Warranty applies when returned freight is prepaid and
which, upon examination, shall disclose to have been
defective. This warranty does not apply to any product
or component which has been repaired or altered by
anyone other than McElroy or has become damaged
due to misuse, negligence or casualty, or has not been
operated or maintained according to McElroy’s printed
instructions and warnings. This warranty is expressly
in lieu of all other warranties expressed or implied.
The remedies of the Buyer are the exclusive and sole
remedies available and Buyer shall not be entitled to
receive any incidental or consequential damages. Buyer
waives the benefit of any rule that disclaimer of warranty
shall be construed against McElroy and agrees that such
disclaimers herein shall be construed liberally in favor of
McElroy.
RETURN OF GOODS
Buyer agrees not to return goods for any reason except
upon the written consent of McElroy obtained in advance
of such return, which consent, if given, shall specify the
terms and conditions and charges upon which any such
return may be made. Materials returned to McElroy, for
warranty work, repair, etc., must have a Return Material
Authorization (RMA) number, and be so noted on the
package at time of shipment. For assistance, inquiry
shall be directed to:
McElroy Manufacturing, Inc.
P.O. Box 580550
833 North Fulton Street Tulsa, Oklahoma 74158-0550
PHONE: [phone], FAX: [phone].
EMAIL: [e-mail]
Note: Certain repairs, warranty work, and inquiries
may be directed, at McElroy’s discretion, to an
authorized service center or distributor. TX02486-04-06-05
DISCLAIMER OF LIABILITY
McElroy accepts no responsibility of liability for fusion
joints. Operation and maintenance of the product is the
responsibility of others. We recommend qualified joining
procedures be followed when using McElroy fusion
equipment.
McElroy makes no other warranty of any kind whatever,
express or implied; and all implied warranties of
merchantability and fitness for a particular purpose
which exceed the aforestated obligation are hereby
disclaimed by McElroy.
PRODUCT IMPROVEMENT
McElroy reserves the right to make any changes in or
improvements on its products without incurring any
liability or obligation to update or change previously
sold machines and/or the accessories thereto.
INFORMATION DISCLOSED
No information of knowledge heretofore or hereafter
disclosed to McElroy in the performance of or in
connection with the terms hereof, shall be deemed
to be confidential or proprietary, unless otherwise
expressly agreed to in writing by McElroy and any such
information or knowledge shall be free from restrictions,
other than a claim for patent infringement, is part of the
consideration hereof.
PROPRIETARY RIGHTS
All proprietary rights pertaining to the equipment or
the components of the equipment to be delivered by
McElroy hereunder, and all patent rights therein, arising
prior to, or in the course of, or as a result of the design
or fabrication of the said product, are exclusively the
property of McElroy.
LAW APPLICABLE
All sales shall be governed by the Uniform Commercial
Code of Oklahoma, U.S.A.
Register your product online to activate your warranty:
www.McElroy.com/fusion
(Copy information listed on the machine nameplate here
for your records).
Model No.
Serial No.
Date Received
Distributor
COPYRIGHT © 2014, 2004
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.

1 - 1
Safety
Safety Alerts
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 and IMPORTANT.
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.
¡PELIGRO!
Read and Understand
Do not operate this equipment until you have carefully read, and
understand 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.
¡PELIGRO!
WR00051-11-30-92
WR00052-12-1-92
TX00030-12-1-92
TX00031-12-8-92

1 - 2
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.
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.
SAFE1ST-12-22-92
Wear Safety Equipment
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.
WR00053-12-2-92
Pressurized Air Safety
This test equipment uses high pressure air which
can cause severe injury or death from flying
parts. Always install properly before pressurizing.
Always relieve pressure before removing test cap.
The test cap is designed for testing polyethylene
pipe to a maximum of 165 psi. Be aware of
yourself and others when using this equipment.
Always stand to the side of test cap, never in
front.
TX00489-6-1-95
CD00144-6-2-95
TX00114-4-22-93
TX00032-4-7-93

Operation
Introduction
Thank you for purchasing this McElroy product.
The TP-300 Series Test Caps are designed for quick and easy air
pressure testing testing of Polyethylene pipe.
The many features include:
• Quick installation and removal
• Pressure rated to 165 psi
• One piece tool installs in one operation
• One cap required per pipe (OD) size
• Corrosion resistant material, durable construction
• The test cap is designed with a NPT ¼” threaded female inlet.
• Grip plates secure cap in place
• Can not be pressurized unless cap is properly installed
TX02255-3-8-04
PH02692-4-1-04
Inspect Tooling
Inspect the grip plates in test cap. The plates must be clean to prevent
slippage and ensure proper fit. Clean the plates of any dirt or
residual material.
NOTICE: All four Grip Plates must be in place before using Test Cap.
Verify that the size marked on the test cap matches the size of the
pipe being tested.
The O-ring is lubricated with silicone lubricant for ease of pipe
installation. It may be necessary to lubricate the O-ring periodically.
Use only Parker Super-O-Lube®. The lubricant is not intended to
provide extra sealing capability.
Lubricating the O-ring:
1. First, remove the plates, one at a time, and then remove the
spring.
2. Inspect the O-ring in the test cap for signs of damage. If an O-ring
is scored or cut, it must be replaced. Apply the lubrication sparingly
(1 or 2 drops) to the inside circumference of the O-ring, with your
finger or swab (O-ring does not need to be removed).
3. Lastly, re-assemble test cap, spring first, then the grip plates one at
a time.
NOTICE: Remove any grease, oil or any other foreign material from
grip plates before use.
TX02256-3-8-04
PH00456-6-2-95
1 - 3

1 - 4
Operation
Insertion Depth
Measure and mark the insertion depth on the pipe before
installing the test cap to ensure proper set up.
The gauge line (Caption “A” of diagram) on the outside of the
test cap, is used for correctly marking the pipe to its proper
insertion depth
To correctly mark the insertion depth, place the pipe alongside the
test cap, marking the length from the gauge line (A) to the end of
the test cap on the pipe.
Insertion depths for all sizes of test caps are shown in the table.
IMPORTANT: The proper gripping action of the grip plates
requires that the pipe move out of the test cap as the pressure is
applied. This movement can be as much as 3/8".
TX02257-3-8-04
CD00180-10-26-95
CD00637-1-2-01
1/2" IPS 3-1/8"TP-302
1/2" CTS 3-1/8"TP-301
3/4" IPS 3-1/8"TP-304
3/4" CTS 3-1/8"TP-303
1" IPS 3-3/8"TP-306
1" CTS 3-3/8"TP-305
1-1/4" IPS 3-5/8"TP-308
1-1/4" CTS 3-3/8"TP-307
1-1/2" IPS 3-5/8"TP-309
2" IPS 4-1/8"TP-310
Size Insertion
Depth
Part #
Test Cap Lanyard
This device consists of a cable with rings on both ends. In the
event that the test cap is accidentally dislodged, the lanyard is
designed to minimize the travel of the test cap by wedging itself
on the pipe and the cap plumbing. The lanyard may be required
by your local regulations.
Install the adapter ring (smallest ring) of the lanyard around the
fitting (user supplied) behind the test cap. This will ensure that the
lanyard will remain secured to the test cap at all times.
Inspect the lanyard for damage or wear prior to each use.
Replace if damaged or worn.
TX02258-3-8-04
CD00399-4-1-04
PH01238-4-1-04 PH02702-5-6-04

Operation
1 - 5
Conduct Pressure Test
Follow all applicable federal, state, local, and industry specific
regulations to conduct the pressure test on the pipe. All
components must be rated for the pressure supplied and testing
requirements.
This illustration shows a typical setup for plumbing the test cap,
with a customer provided gauge, filler valve and purge valve.
This test equipment uses high pressure air which
can cause severe injury or death from flying
parts. Always install properly before pressurizing.
Always relieve pressure before removing test
caps. The test cap is designed for testing
polyethylene pipe to a maximum of 165 psi.
A failed test may be due to nicks or scratches on the surface of
the pipe end which would result in a seal that is not air tight.
If the test cap leaks after installation, check to make sure that the
pipe has been fully inserted.
TX02260-3-8-04
PH01238-4-1-04
Install Test Cap
Check the end of the pipe to be tested. Make sure the outside
of the pipe is free of dirt and scratches that would prevent an
airtight seal.
Slide the pipe ring (stamped with the pipe size) on to the pipe
first. The hole in the pipe ring is designed to be larger than the
OD of the pipe, allowing for an easy slip fit.
Pull back the tabs on the grip plates and fully insert the pipe (as
straight as possible) into the test cap until the marked insertion
depth is inline with the edge of the test cap. It may be necessary
to rotate the cap as you install it. It is important that the pipe be
inserted completely to minimize the possibility of leakage.
IMPORTANT: When insertion of the pipe is difficult: Chamfer the
outside edge of the pipe. Never use grease or oil on end of pipe.
If pipe is out-of-round, use a cold ring clamp to re-round the pipe.
TX02259-3-8-04
PH01238-4-1-04PH02701-5-6-04

Operation
Remove Test Cap
Pull back on the tabs of the grip plates.
Remove the test cap from the end of the pipe. It may be necessary
to rotate the test cap to remove. Slide the pipe ring of the test cap
lanyard off the tested pipe.
If test cap does not remove easily, there may be
pressure in the line. Make sure all pressure has
been bled from line before removing test cap.
NOTICE: Test caps are not designed to be used as a permanent
cap.
TX02261-3-8-04
Remove Pipe End
Cut and discard the pipe to a length of at least 1 inch beyond
the furthest position that the safety lanyard pipe ring was
situated.
NOTICE: The O-ring in test cap uses a lubricant which could
contaminate a butt, socket or electrofusion weld. Always remove
the end of the pipe that was inside the test cap before fusing
any pipe or fittings.
TX02262-3-8-04
PH02700-5-6-04
PH00450-6-2-95
Bleed All Pressure
Bleed all pressure from the test line. Verify that all pressure has
been bled by reading the gauge. The gauge should read zero
psi.
Always relieve pressure before removing test cap.
This test equipment uses high pressure air which
can cause severe injury or death from flying
parts.
TX00494-6-1-95
PH02693-4-1-04
1 - 6
Preventive Maintenance
Inspect the test cap before each use.
Remove any grease, oil or other foreign material from grip plates.
Replace grip plates and lanyard if damaged or worn.
Care must be taken when storing the test cap to ensure the
apparatus is kept free of dirt or other residual materials.
TX02263-3-8-04
PH02703-5-6-04

PDF00001-4-2-04

TEST CAP ASSEMBLY PG. 1 OF 1
TP-301 TP-302 TP-303 TP-304 TP-305 TP-306 TP-307 TP-308 TP-309 TP-310
1/2 CTS
TEST CAP
1/2 IPS
TEST CAP
3/4 CTS
TEST CAP
3/4 IPS
TEST CAP
1 CTS
TEST CAP
1 IPS
TEST CAP
1 1/4 CTS
TEST CAP
1 1/4 IPS
TEST CAP
1 1/2 IPS
TEST CAP
2 IPS TEST
CAP
ITEM No. DESCRIPTION PART NUMBER
1 TEST CAP TP-401 TP-402 TP-403 TP-404 TP-405 TP-406 TP-407 TP-408 TP-409 TP-410 2 LOCKING RING TP-601 TP-602 TP-603 TP-604 TP-605 TP-606 TP-607 TP-608 TP-609 TP-610 3 COMPRESSION SPRING TP-701 TP-701 TP-701 TP-701 TP-702 TP-702 TP-702 TP-703 TP-703 TP-704 4 O-RING MDL00131 MDL00170 MDL00170 MDL00122 MDL00171 MDL00172 MDL00173 MDL00174 MDL00175 MDL00176 5TESTCAPHANDLE---- -----TP-501 6BLACKHANDGRIP ---- -----MJJ00011 71/4-20NCx1/2LGFHSCSSS---- -----MAN00014 8 TEST CAP WARNING LABEL TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 TP-1201 9 LANYARD ASSEMBLY TP-1101 TP-1102 TP-1103 TP-1104 TP-1105 TP-1106 TP-1107 TP-1108 TP-1109 TP-1110
TP-300.xls.XLS 11/19/04

Other McElroy Services
www.mcelroy.com
McElroy strives to stay on the leading edge of technology and
innovation in the industry. Providing our customers with the
tools to succeed is our number one priority. McElroy's web site
has raised the standard for the fusion industry. We provide
our customers with up-to-date information on McElroy products
that includes assembly drawings, specifications, parts lists, and
product manuals. We have also added product demonstration
and technical animations.
TX02295-4-1-04
4 - 3
McElroy University
For over 30 years, McElroy Manufacturing, Inc. has been the only
pipe fusion machine manufacturer to continuously offer advanced
training to enhance your efficiency, productivity and safety in the
proper use of our machines, at our facility, or yours. Our uniquely
qualified McElroy University course instructors are professionals,
each offering over 20 years industry experience.
Tuition costs vary by course attended. Each includes daily
transportation to and from the McElroy Technical Center, lunches,
and a complete course guide.
For course dates, tuition, registration information or details about
on-site training at your location, please contact our representatives
at McElroy Manufacturing today or register on-line at:
www.mcelroy.com.
TX02296-4-1-04