McElroy 1LC User manual

Manual: CTS15901 Revision: C 12/18
1LC
Fusion Machine
Operator’s
Manual
Original Language: English

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

Introduction
Thank You for purchasing this
McElroy product
The 1LC fusion machine is small and compact, and offers
the benefit of McElroy's Patented Centerline Guidance
System previously offered only in larger machines. The
1LC butt fuses 1/2" CTS to 1" IPS (16mm - 34mm)
polyethlene pipe.
If fusing other 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.
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.
TX04109-7-8-10
CD02039-05-8-17
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. McElroy University
classes are structured so that the skills learned and the
machines used in each class closely match the machines
found on pipelining jobsites. We offer training at
our facility or yours. Our uniquely qualified McElroy
University course instructors offer years of industry
experience.
Tuition for each course includes lunches, course materials
and a certificate of completion. Online registration,
as well as up-to-date course offerings and dates, is
available at www.mcelroy.com/university
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
can not encompass all possible situations that can be
encountered during various operations.
MU2-03-13-14
TX04659-03-24-14

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.
TX02486-11-4-13
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

Table of Contents
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
Heater is Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Periodically Check Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Overview
Theory of Heat Fusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
1LC Fusion Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fusion Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Clamp Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Cam Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operation
Read Before Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Install Clamping Inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Loading Pipe into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Facing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Check Alignment of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Check Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fusing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove the Pipe from the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remove Dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Clean and Lubricate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Facer and Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
COPYRIGHT © 2018, 2017, 2014, 2010
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.

Table of Contents
Maintenance Checklist
1LC Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications
1LC Fusion Machine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

1 - 1
Fusion Equipment 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!
¡PELIGRO!
WR00051-11-30-92
TX00030-12-1-92
Read and Understand
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.
WR00052-12-1-92
TX02946-4-15-09

1 - 2
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.
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
Heater Is Not Explosion Proof
This heater is not explosion proof. Operation
of heater in an explosive atmosphere without
necessary safety precautions will result in serious
injury or death.
If operating in an explosive atmosphere, the heater should be
brought up to temperature in a safe environment, then unplugged
before entering the explosive atmosphere for fusion.
WR00034-11-30-92
TX00114-4-22-93
TX00032-4-7-93
TX00100-04-28-14
¡PELIGRO!

Heater is Hot
The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater shroud
when not in use, and use care when heating the
pipe.
NOTICE: Use only a clean non-synthetic cloth to clean the heater
plates.
TX04244-10-12-10
WR00030-2-10-93
Fusion Equipment Safety
1 - 3
Electrical Safety
Always ensure power cords are 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: Disconnect the equipment from the power source before
attempting any maintenance.
TX02947-4 -15-09
WR00055-4-7-93
WR00025-11-30-92
Facer Blades Are Sharp
Facer blades are sharp and can cut. Use care
when operating the facer, and when handling the
unit.
NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.
TX04128-7-27-10
WR00073-4-6-93

Fusion Equipment Safety
1 - 4
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
WR00079-1-24-96

Overview
2 - 1
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.
When fusion pressure is applied, the molecules from each
thermoplastic part mix. As the joint cools, the molecules return
to their 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 pieces are held axially and radially to
allow all subsequent operations to take place.
Facing The pipe ends are faced to establish clean,
parallel mating surfaces perpendicular to the
centerline of the pipes.
Aligning The pipe ends are aligned with each other to
minimize mismatch of the pipe walls.
Heating A melt pattern that penetrates into the pipe is
formed around both pipe ends.
Fusing The melt patterns are joined with a specified
force, which is constant around the pipe interfacial
area.
Cooling The fusion joint is held immobile with a specified
force until adequately cooled.
Inspecting Visually examine the entire circumference of the
joint for compliance with the standard or fusion
procedure used.
TX04660-04-18-16
CD02053-05-08-17

1LC Fusion Machine
1 1LC Fusion Machine
2 Facer
3 Heater
4 Heater Sling
5 Ratchet Wrench
6 Case
Overview
2 - 2
5
4
3
2
1
Heater
The heater temperature is controlled by a microprocessor. The
heater has a green indicator light which will flash on and off. This
indicates that the controller is operating normally. It has a red
indicator light. When the heater is plugged in and preheating
the red light glows steadily until the set temperature is reached.
The red light then goes off and on as the heater maintains
temperature.
The heater should always be stored in the insulated heater sling
for protection of the operator and to minimize heat loss and risk of
mechanical damage.
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.
Heater is not explosion proof. Operation of heater
in an explosive atmosphere without necessary
safety precautions will result in serious injury or
death.
TX04110-8-28-14
¡PELIGRO!
PH02314-4-24-02 CD02040-05-08-17 PH04336-7-27-10PH04337-7-27-10
6

Overview
2 - 3
Facer
The facer is manually operated by using the ratchet wrench to
turn the facer. The facer latches into place on the guide rods. The
handle must be pressed in to unlatch and remove facer. The facer
is symmetrical and can be inserted from either side.
Turn the ratchet counter-clockwise for facing.
TX04120-7-9-10
Fusion Machine
The fusion machine offers McElroy's Patented Centerline Guidance System
for equal distribution of force around the joint. A 2 position handle for
facing and for heat/fuse. The machine is equipped with a locking cam to
maintain force during the cooling cycle.
TX04129-7-27-10
Clamp Knobs
Clamp knobs are equipped with a thrust bearing, which permits the
operator to develop high clamping forces with minimal effort.
TX03099-4-12-10
Cam Lock
The cam lock assists in holding force on the joint during the cooling cycle.
The lock has a latch for quick release and application of the lock.
TX04130-7-29-10
CD02041-05-08-17CD02039-05-08-17CD02042-05-08-17
CD02043-05-08-17

Operation
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.
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.
NOTICE: Place heater in insulated heater sling while allowing the
handle to remain outside the sling.
Plug heater into a proper power source.
Allow heater to heat to operating temperature.
Refer to the "Maintenance" section of this manual for instructions
how to adjust heater temperature.
TX04131-8-28-14
Install Clamping Inserts
Select and install appropriate clamping inserts for the pipe that is
being fused.
TX00368-9-15-94
CD02040-05-08-17
PH04242-7-7-10
¡PELIGRO!
3 - 1
Read Before Operating
Before operating this machine, please read this manual
thoroughly, and keep a copy with the machine for future
reference.
The fusion procedures in this manual are for use with
polyethylene pipe. If fusing other thermoplastic pipe materials,
refer to the pipe manufacturer's suggested procedures or
appropriate joining standard.
TX02953-4-15-09
STOP-12-22-92
PH04228-7-6-10

3 - 2
Operation
Facing the Pipe
Position the facer between the pipe ends.
Depress the lock on the lever handle and rotate the lever
handle to the vertical position.
Attach the ratchet wrench to the facer and drive the facer counter-
clockwise while applying pressure to the lever handles. Face
the pipe until the clamping jaws bottom out on the facer stops.
Continue to face the pipe several revolutions to ensure that there
are no chips hanging on the end of the pipe.
IMPORTANT: It is critical for proper face-off and alignment, that
facing continues until the facer bottoms out.
Open the carriage and remove the facer.
TX04112-7-27-10
Loading Pipe Into Machine
Clean the inside and outside of pipe ends that are to be fused.
Ensure the locking cam is in the latched position.
Open the upper jaws and insert pipe in each jaw with applicable
inserts installed. Let the ends of the pipe protrude about 3/8" past
the face of the jaws. Close upper jaws. Tighten the clamp knobs.
NOTICE: When clamping, do not over-tighten the clamp knobs
because machine damage can result.
TX04132-7-29-10
CD02044-05-08-17
CD02045-05-08-17
CD02047-05-08-17CD02046-05-08-17
CD02048-05-08-17

3 - 3
Operation
Check Heater Temperature
NOTICE: Incorrect heating temperature can result in questionable
fusion joints. Check heater with a pyrometer and make
necessary adjustments.
Refer to the "Maintenance" section of this manual for instructions
how to adjust heater temperature.
Check heater surface temperature.
Refer to the pipe manufacturer's recommendations for proper
heater temperature.
IMPORTANT: The dial thermometer on the heater indicates internal
temperature which varies from the actual surface temperature.
The dial thermometer can be used as reference once the surface
temperature has been verified.
TX04114-8-28-14
WR00077-4-16-93
Check Alignment of Pipe
Remove all pipe shavings. Do not touch the pipe ends.
Bring the pipe ends together under sufficient force to overcome
any pipe drag or friction in the system. Check for alignment
and proper face off. If high/low (misalignment) exists, adjust by
tightening the clamp on the high side and reface the pipe.
NOTICE: When clamping, do not over-tighten the clamp knobs
because machine damage can result. Check to see if there is
space between the upper and lower jaws. If the two jaws are
touching, do not continue to tighten. Bring the pipe ends together
under fusion pressure plus drag to check for slippage. If slippage
occurs, return to Loading Pipe into Machine.
TX04133-7-27-10
CD02050-05-08-17 CD02049-05-08-17
PH04228-7-6-10

Fusing the Pipe
After the heating cycle is completed, open the carriage and
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. Hold this force
for at least 10 seconds.
After 10 seconds, unlatch the locking cam to assist in holding jaw
position during the cooling cycle.
NOTICE: Failure to follow pipe manufacturer's heating time,
pressure and cooling time may result in a bad joint.
TX04134-05-09-17
Operation
3 - 4
CD02043-05-08-17CD02052-05-08-17CD02053-05-08-17
Inserting Heater
Heater is not explosion proof. Operation of
heater in an explosive atmosphere without
necessary safety 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.
Use a clean non-synthetic cloth to clean the butt fusion heater
surfaces.
Verify heater temperature by noting the reading on the dial
thermometer.
Depress the lock on the lever handle and rotate the lever handle
clockwise until it latches.
Insert heater between the pipe ends. Bring the pipe ends against
the heater faces using the pipe manufacturer’s time, temperature
and pressure recommendations or appropriate joining standard for
the heating cycle.
TX04115-8-28-14
CD02051-05-08-17
¡PELIGRO!
CD02046-05-08-17CD02047-05-08-17

3 - 5
Operation
Remove the Pipe from the Machine
When the cooling cycle is completed, relatch the cam lock,
unclamp and remove the pipe from the machine.
TX04117-7-9-10
CD02054-05-08-17

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
Clean and Lubricate Bearings
All clamp knobs are equipped with thrust bearings to reduce
friction and improve efficiency of the clamping screw. Keep these
bearings clean by washing in kerosene or solvent. They should
be lubricated with light machine oil. The knob must be replaced if
they become inoperative.
TX04135-7-27-10
Maintenance
Cleaning the Machine
The machine should be cleaned, as needed with a soap and
water wash.
TX01015-7-8-96
Remove Dirt
Remove dirt from jaw and insert serrations and clamp knob
eyebolts.
TX00865-1-30-96
CD00142-11-2-94
CD00178-5-3-96
PH04247-7-7-10
PH04245-7-7-10
4 - 1

4 - 2
Maintenance
Clean Eyebolt Threads
Keep the clamp knob eyebolt threads brushed clean.
TX00435-9-13-94
PH04244-7-7-10
Facer and Blades
Inspect the facer blades for sharpness and damage. Blades
can not be resharpened and should be replaced when dull or
damaged.
TX04118-7-9-10
CD02055-05-08-17
Clean Heater Surfaces
The heater must be kept clean and free of any plastic build-up,
contamination and scratches.
Before each fusion is made, the surface of the heater must be
wiped with a clean, non-synthetic cloth.
TX04119-7-9-10
CD02040-05-08-17