McElroy Socket Fusion User manual

Manual: SW00401 Revision: E 10/18
Socket Fusion
Tooling System
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 choosing McElroy
The McElroy Socket Fusion Tooling System is designed
for socket fusion on 1/2" CTS to 4" IPS pipe. All system
components comply with ASTM standards.
With reasonable care and maintenance, these tools will
give years of satisfactory service.
Before operating these tools, please read this manual
thoroughly, and keep a copy with the tools for future
reference. This manual is to be considered part of your
Socket Fusion Tooling System.
TX01399-10-23-17
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

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
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operation
Prepare Pipe End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Secure 2" and Larger Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Clean Fitting and Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Heating the Pipe and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Remove Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspect Melt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Fusion and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspecting Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance Installing Socket Fusion Heater Adapters. . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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.
TX04094-6-18-10
Table of Contents

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 stand or
blanket when not in use, and use care when
heating the pipe.
NOTICE: Use only a clean non-synthetic cloth such as a cotton
cloth to clean the heater plates.
TX00104-8-12-94
WR00030-2-10-93
Fusion Equipment Safety
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 machine from the power source before
attempting any maintenance or adjustment.
TX02947-4 -15-09
WR00055-4-7-93
WR00025-11-30-92
1 - 3
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.
TX02984-5-22-12
WR00079-1-24-96

Periodically Check Temperature
NOTICE: Incorrect heating temperature can result in bad fusion
joints. Check heater plate surface temperature periodically with a
properly calibrated pyrometer, and make necessary adjustments.
The thermometer on heaters indicates internal temperature, and
should be used as a reference only.
TX00107-11-13-95
WR00077-4-16-93
Fusion Equipment Safety
1 - 4

Overview
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 pressure causes flow of the melted materials, which causes
mixing and thus fusion. When the polyethylene material is heated,
the molecular structure is transformed from a crystalline state into
an amorphous condition. When fusion pressure is applied, the
molecules from each polyethylene part mix. As the joint cools, the
molecules return to their crystalline form, the original interfaces are
gone, and the fitting and pipe have become one homogeneous
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 must be properly seated on the pipe for
proper alignment.
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.
TX04092-05-30-14
PH01194- 6- 24- 97

Nomenclature
1 Heater Sling
2 Heater
3 Cold Ring Clamp
4 Heater Adapters
5 Chamfer Tool/Depth Gauge
6 Fitting Holder
7 Heater Handle
8 Pipe Cutter
9 Socket Fusion Toolbox
TX01414-6-14-10
Overview
2 - 2
PH04212-6-14-10
8
9
2
3
45
7
6
1

Operation
Prepare Pipe End
Cut off damaged or oval ends of pipe squarely with a pipe cutter.
Place the chamfering tool on end of pipe and turn to cut off sharp
edge on top end of pipe.
Remove shavings and burrs inside pipe end.
TX01400-6-20-97
PH04200-6-11-10
Clean Fitting and Pipe
Fitting and pipe must be clean and dry. Use a clean cloth to wipe
the mating surfaces.
NOTICE: Do not touch with hands.
TX01404-6-20-97
PH04202-6-11-10
Depth Gauge
The chamfering tool is also a depth gauge for measuring the
length of pipe that will go into the fitting.
Place chamfering tool on end of pipe.
Place cold ring clamp on pipe at the bottom of the chamfering
tool.
Remove chamfering tool.
TX01401-6-20-97
PH04201-6-11-10
Secure 2" and Larger Fittings
Place fitting in socket fitting holder.
Tighten socket fitting holder around fitting.
TX01402-6-20-97
PH01197- 6- 24- 97
3 - 1

3 - 2
Operation
Heater Temperature
The socket faces of the heater must be at the temperature specified
by the pipe manufacturer.
Use a pyrometer to check the temperature on the socket faces.
TX01405-6-20-97
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.
Use a clean non-synthetic cloth to clean the heater adapter
surfaces.
TX01411-05-30-14
PH04211-6-14-10
PH04203-6-11-10
¡PELIGRO!
Heating The Pipe and Fitting
Firmly seat the socket fitting on the male adapter of the heater.
Place the female adapter of the heater over the end of the pipe,
firmly against the cold ring clamp.
Heating time starts when the heater is bottomed out on the cold
ring clamp.
Heat fitting and pipe for the pipe manufacturer’s specified period
of time.
NOTICE: Do not twist fitting, pipe or heater
TX01406-6-20-97
PH04204-6-11-10

3 - 3
Operation
Remove Heater
Remove the pipe and the fitting from the heater.
TX01407-6-17-10
PH04205-6-11-10
Inspect Melt
Quickly inspect the heated parts to make sure all surfaces have
been melted properly.
If melt is not complete, cut off melted pipe end. Use a new fitting
and repeat preparation and heating process.
TX01408-6-20-97
PH04207-6-11-10
Fusion and Cooling
Within 3 seconds after the heater has been removed, firmly push
the melted fitting squarely onto the pipe until it makes firm contact
with the cold ring clamp.
NOTICE: Do not twist or rotate the fitting.
Hold the fitting firmly in place for the total cooling time specified
by the pipe manufacturer to ensure proper alignment.
TX01409-6-20-97
PH04208-6-11-10
Inspecting Fusion Joint
After completing the pipe manufacturer’s specified cooling time,
remove the cold ring clamp and the socket fitting holder.
Inspect the joint. A good joint will have a uniform melt ring that is
flat against the socket fitting and perpendicular to the pipe.
There should be no gaps or voids between the fitting and the
pipe.
TX01410-6-20-97
PH04209-6-11-10

Installing Socket Fusion Heater Adapters
The heater body of this assembly is not coated. Coated heater
adapters are available for all fusion applications.
Heater adapters are installed with Stainless Steel Cap Screws.
Care should be taken to assure that the heater adapters are
seated on the heater body, and that there is no foreign matter
trapped between these surfaces.
IMPORTANT: Do not over-tighten the bolts.
The surface of the heater adapters are coated with an anti-stick
coating.
NOTICE: Only install heater adapters when the heater is cool.
TX01413-6-17-10
Maintenance
PH04199-6-11-10
4 - 1
Adjusting Heater Temperature
Turn knob to desired temperature. Measure the heater surface
temperature with a pyrometer. Any variance must be corrected to the
pyrometer reading.
Loosen setscrew in the knob. Turn knob to point to the same
temperature as the pyrometer. Tighten setscrew in the knob.
Turn knob to desired temperature. Allow heater to stabilize at the new
temperature (5 to 10 minutes) after adjusting.
The thermometer on the heater body indicates internal temperature and
should be used as a reference only.
TX02009-3-13-02
PH02313-4-24-02
Heater Indicator Light
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 an McElroy
Authorized Service Center.
The heater has a red indicator light on the handle at the bottom of the
temperature scale. 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.
If the heater is not operating properly, the control will attempt to turn the
heater off and the red indicator light will flash rapidly. If this occurs,
disconnect the power and take it to a McElroy Authorized Service
Center for repair.
TX04036-4-12-10
PH02314-4-24-02
PH02571-09-16-03

5 - 1
Specifications
Specifications
The McElroy Socket Fusion Tooling System is designed for socket
fusion on 1/2" CTS to 4" IPS pipe. All system components comply
with ASTM standards.
Heaters:
2" Heater Power - 100V - 120V, 50/60Hz, 800 Watt, 1Ph
2" Heater Power - 200V - 240V, 50/60Hz, 800 Watt, 1Ph
4" Heater Power - 100V - 120V, 50/60Hz, 1200 Watt, 1Ph
4" Heater Power - 200V - 240V, 50/60Hz, 1200 Watt, 1Ph
Weight:
2" Heater: 6 lbs.
4" Heater: 7 lbs.
Toolbox Dimensions:
Length: 24"
Width: 10"
Height: 9.5"
TX04093-6-18-10

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.
The material does not contain any cellulose based materials and does not contribute to the
harvesting of our forests, or ozone-depleting constituents. This manual can be safely disposed
of in a landfill and will not leach into ground water.
TX001660-8-19-99