Roughneck Jackman Fusion Equipment User manual

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SAFETY
•Please read and understand this instruction manual before using the Roughneck Electrofusion
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.
•Treat electrical equipment as a potential source of ignition and follow proper practices for working in
an explosive atmosphere.
•Power source and the Roughneck Electrofusion Processor must be located out of the trench.
•For protection against the risk of electric shock, connect the Roughneck Electrofusion Processor to
properly grounded outlets only.
•Only use fusion information supplied by the manufacturer of the fitting.
•Under no circumstances should the Roughneck Electrofusion Processor enclosure be opened. All
warranties are void if the factory seal has been broken.
•Before any fusion is performed, it is the responsibility of the operator to always verify that all the
information displayed is correct per the fitting manufacturer’s recommendations for fusing the
attached fitting under the current ambient conditions.

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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.................................................................................................................................................... 8
Faceplate View ................................................................................................................................................. 9
Left Side.......................................................................................................................................................... 10
Right Side........................................................................................................................................................ 10
Output Cable .................................................................................................................................................. 11
Fitting Adapters.............................................................................................................................................. 11
Smart Scanner with GPS................................................................................................................................. 12
Customer Responsibilities ................................................................................................................................. 13
Service Recommendations ................................................................................................................................ 14
Customer Maintenance.................................................................................................................................. 14
Calibration Recommendations....................................................................................................................... 14
Service Contact Information .......................................................................................................................... 15
General Operation ................................................................................................................................................ 16
Modes of Operation .......................................................................................................................................... 16
Primary Fusion Mode ..................................................................................................................................... 16
Alternate Fusion Modes................................................................................................................................. 16
Power Up ........................................................................................................................................................... 17
Barcode Fusions................................................................................................................................................. 19
Alternate Fusion Methods................................................................................................................................. 20
Manual Barcode Entry.................................................................................................................................... 20
Manual Data Entry ......................................................................................................................................... 22
Monitoring a Fusion’s Progress ......................................................................................................................... 24
User Menus........................................................................................................................................................... 26
Basic User Menu................................................................................................................................................ 26
Setting the Date and Time ............................................................................................................................. 26
Setting the Temperature Units ...................................................................................................................... 26
Setting the Language...................................................................................................................................... 26
SMART Scanner™ ........................................................................................................................................... 27
Advanced User Menu ........................................................................................................................................ 27
Short Stab Detect ........................................................................................................................................... 27
Operator ID..................................................................................................................................................... 28
Profiles............................................................................................................................................................ 28
Calculated Resistance..................................................................................................................................... 28
Features Menu................................................................................................................................................... 29
Traceability..................................................................................................................................................... 29
Appendix ............................................................................................................................................................... 30
Scanning Barcodes............................................................................................................................................. 30

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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................................................................................................................................. 38
GPS..................................................................................................................................................................... 38
Trouble ........................................................................................................................................................... 38
Position Accuracy ........................................................................................................................................... 38
Position Error Indicator .................................................................................................................................. 39
General Maintenance........................................................................................................................................ 40
Changing the Fuse .......................................................................................................................................... 40
Power Sources ................................................................................................................................................... 40
Utility Power................................................................................................................................................... 40
Generators ..................................................................................................................................................... 40
Inverters ......................................................................................................................................................... 41
Sizing a Power Supply..................................................................................................................................... 41
Extension Cords ................................................................................................................................................. 42
Temperature Measurements ............................................................................................................................ 42
Temperature Compensation .......................................................................................................................... 42
Warning & Error Codes ......................................................................................................................................... 43
Warning Codes .................................................................................................................................................. 43
Error Codes ........................................................................................................................................................ 43

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WARRANTY AND LIMITATION OF LIABILITY
1. THE MANUFACTURER warrants the Roughneck Electrofusion Processor against defects resulting from
faulty workmanship or materials for a period of one year from the date of the new unit calibration. Any
Processor repaired or replaced pursuant to this warranty within the original warranty period will be
warranted for the remainder of the original warranty period. THE MANUFACTURER also warrants the
calibration and repair services it provides on the Processor against defects resulting from faulty
workmanship for a period of 60 days upon which the calibration or repair services are complete. These
warranties are subject to the limitations, exceptions, disclaimers and conditions stipulated hereunder or
posted, updated or amended on THE MANUFACTURER’s website with respect to the Roughneck
Electrofusion Processor.
2. If THE MANUFACTURER receives notice of such defects during the warranty period, THE MANUFACTURER
will repair or replace, free of charge, including ground shipping charges, any Processors or Services which
are found to be defective in workmanship or material, provided that the following conditions are met:
a) THE MANUFACTURER is notified in writing of such defect immediately upon discovery of same and the
defective Processor is promptly returned to THE MANUFACTURER (at the location designated by THE
MANUFACTURER for those purposes), freight prepaid. Claimant must provide documentary evidence
of failure, as well as the components that are alleged to have failed and agree to inspection by THE
MANUFACTURER of the circumstances in which the alleged defective Processor(s) was/(were) used.
b) The Processor has been maintained, calibrated, serviced and used in full compliance with this Manual
and other technical information or literature provided by THE MANUFACTURER from time to time.
c) The Processor has not been altered or modified after leaving THE MANUFACTURER premises, shows no
evidence of disassembly or tampering, is not and has not been subjected to abnormal operating
conditions, accident, abuse, misuse, unauthorized alteration or repair and the defect is not due,
without limitation, to faulty installation, maintenance, calibration or use, improper site preparation or
maintenance, ordinary wear and tear, corrosion, acts of nature such as earthquakes, fire, flood or
lightning or any other event of force majeure.
d) THE MANUFACTURER does not warrant that the operation of the Roughneck Electrofusion Processor
will be uninterrupted or error free.
e) Replacement Processor may be either new or like-new.
3. THE MANUFACTURER disclaims any liability or responsibility:
a) for labor, materials and/or other expenses required to replace the defective Processor or Service or to
repair any damage resulting from the use thereof.
b) for loss or damage resulting from failure to abide by manufacturer’s warnings, safety instructions or
other precautionary guidelines.
4. ANY CLAIM OF LIABILITY ASSERTED AGAINST THE MANUFACTURER WHETHER IN CONTRACT OR IN TORT
(INCLUDING NEGLIGENCE) OR OTHERWISE, WITH RESPECT TO OR ARISING OUT OF THE SALE, DELIVERY,
INSTALLATION, REPAIR OR USE OF ANY PROCESSORS OR SERVICES SOLD BY THE MANUFACTURER SHALL
NOT EXCEED THE PURCHASE PRICE OF THE PROCESSORS OR SERVICES FOUND TO BE DEFECTIVE. It is the
responsibility of the owner to obtain and pay for emergency repairs.

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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.
6. THE ABOVE MENTIONED WARRANTIES ARE THE SOLE AND EXCLUSIVE WARRANTIES TO ANY PURCHASER,
CUSTOMER OR USER OF THE PROCESSOR OR SERVICES. THERE IS NO WARRANTY, CONDITION OR
REPRESENTATION OF ANY NATURE WHATSOEVER, EXPRESSED OR IMPLIED, BY STATUTE OR OTHERWISE,
EXCEPT AS HEREIN CONTAINED AND THE MANUFACTURER DISCLAIMS ANY IMPLIED WARRANTIES OF
MERCHANTABILITY AND/OR FITNESS OF ITS PROCESSORS OR SERVICES FOR A SPECIAL PURPOSE OR OTHER
WARRANTY OF QUALITY.

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INTRODUCTION
Preface
The information contained herein is the technical data and specifications for JACKSON FUSION EQUIPMENT’s
Roughneck Electrofusion Processor.
This publication was written to assist trained personnel in the proper procedures and operating functions of
the Roughneck Electrofusion Processor.
Operation of JACKSON FUSION EQUIPMENT should only be performed by trained and qualified personnel.
The technical data and advice contained herein are based upon tests and information believed to be reliable.
However, the operator should not rely upon it absolutely for specific applications. All data is given and
accepted at the user’s risk and confirmation of its validity and suitability in particular cases should be obtained
independently. JACKSON FUSION EQUIPMENT makes no guarantee of results and assumes no obligation or
liability in connection with its advice. The integrity of the piping system is the ultimate responsibility of the
installer. This publication is not to be taken as a license to operate under, or recommendation to infringe, any
patents.
Features
The Roughneck Electrofusion Processor is a reliable, easy-to-use, rugged tool designed to withstand
conditions found at typical construction sites throughout the world.
The Roughneck Electrofusion Processor is splash proof and highly shock resistant.
The Roughneck Electrofusion Processor can fuse all manufacturers’ fittings requiring outputs that are within
the voltage and current values listed in the Specifications Table on page 7.
The Roughneck Electrofusion Processor operates most efficiently and reliably in the Barcode Fusion Mode;
however, it can be operated in Alternate Fusion Modes. The Barcode Fusion Method is always preferred and
should be used whenever possible.
The Roughneck Electrofusion Processor has an intuitive user interface that is easy to learn.
The Roughneck Electrofusion Processor is equipped with internal memory for data storage and can be
downloaded to determine installation conditions and fusion cycle status.
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.

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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
Current
30 Amps
Output Voltage
8 VAC to 48 VAC +/- 1.5%
Output Current
4 AAC to 60 AAC +/- 1.5% up to 48 volts output (80 AAC @ up to 42 VAC
output)
Size
22” x 14” x 9” (20.5” x 11.5” x 8.25” Case interior)
Weight
Approx 45 lbs
Duty Cycle
30%
Operating
Temperature Range
0°F to +140°F (-18°C to +60°C)
Operating Modes
Barcode, Manual, Manual Barcode
Output Cable Length
12 feet
Input Cable Length
12 feet
Downloading
Internal Bluetooth module for downloading fusion data to EF Utilities app.
Languages
English, French, Spanish
Fitting Adapters
Field Replaceable 90 degree (4.0mm and 4.7mm Included)
Environmental
Protection
IP54 Splash-Proof
Warranty
1 Year
Calibration Interval
3 Years
Scanning
Interchangeable Smart Scanner or Smart Scanner with GPS
GPS
Active when using a Smart Scanner with GPS
IEC Protection Class
Class 1 Grounded
Calibration/Service
Field calibration capable
AutoCal® Compatibility
This device is fully compatible with the AutoCal® field calibration system.

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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.
3 The STOP button may mean STOP, RESET or CANCEL depending upon the context of the operation
being performed at the time.
4 The UP button and DOWN button are used to scroll through the various menus. These buttons should
be used when the processor menu displays +/- selection options (UP button for “+”; DOWN button for
“-”).
Carrying Case
Rugged plastic carrying
case with lid CLOSED
Rugged plastic carrying
case with lid OPEN

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Faceplate View
START button
Replaceable Display Shield
UP button
DOWN button
STOP button
4X20 LCD Display

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Left Side
Right Side
Input Cable
Output Cable
Fuse
Power Switch
Buzzer

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Output Cable
Fitting Adapters
Adapter Wrench
4.7mm 90 degree
4.0mm 90 degree
Output Cable
Smart Scanner
Output Lead
Ends
Temperature Sensor

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Smart Scanner with GPS
Smart Scanner
Scanner Sheath

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Customer Responsibilities
The Roughneck Electrofusion Processor is a reliable, easy-to-use, rugged tool designed to withstand
conditions found at construction sites around the world. With proper care, your processor will perform for
many years.
Here are some general guidelines that should be followed to extend the life of your processor and keep it in
warranty:
The Roughneck Electrofusion Processor is splash resistant, NOT WATERPROOF. It should be stored in a
clean, dry environment at a temperature between 0-140ºF. DO NOT STORE THE PROCESSOR OUTSIDE.
DO NOT WASH THE PROCESSOR WITH A HOSE.
The enclosure is very durable and shock resistant; however, do not subject the processor to any unnecessary
shocks or stresses including but not limited to:
•Tossing the processor into or out of a vehicle
•Dropping the processor
•Dragging the processor by the cables or leads
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). Whenever possible, Barcode Mode should be used.
Always scan the fitting manufacturer’s barcode affixed directly to the fitting about to be fused. If this barcode
is missing or damaged to the point it cannot be scanned, use the barcode from an identical fitting made by the
same manufacturer.
UNDER NO CIRCUMSTANCES SHOULD THE BARCODE FROM A SIMILAR FITTING BE USED.
Always verify that the voltage and time displayed on the LCD are the same as the values specified by the fitting
manufacturer. In many cases these values are printed on a tag affixed to the fitting, however, this is not
always true. Remember that manual temperature compensation may be required when fusing fittings in
Manual Mode.
When in doubt, always check the fusion information with data supplied by the fitting manufacturer.
FAILURE TO VERIFY THAT THE FUSION INFORMATION IS CORRECT BEFORE STARTING A FUSION COULD
RESULT IN SIGNIFICANT DAMAGE TO PROPERTY, PERSONAL INJURY, AND/OR DEATH.

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Service Recommendations
Customer Maintenance
There are a few simple services that can be performed by the user to help ensure proper operation:
1. Keep the area around the Temperature Sensor clean and free of obstructions by wiping with a soft dry
towel. This is a critical area to keep clean, as dirt will affect the ambient temperature reading. The
temperature reading is used to compensate fusion time based on the ambient temperature during a
barcode fusion. If this sensor is reading incorrectly, fusion times may be affected, and the integrity of
the fusion may be compromised.
2. Make sure the fitting adapters are clean and properly attached to the Output Lead Ends. Failure to do
so may result in an improper output applied to the fitting.
3. Pull the Output Lead Ends straight off the fitting when disconnecting and avoid side loads.
4. Make sure that power sources are appropriately rated and operating at the manufacturer’s specified
capacity. 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.
Calibration Recommendations
It is strongly recommended that each processor be calibrated at least once every three (3) years. This will help
ensure that the Roughneck Electrofusion Processor is in proper calibration and should enable any potential
problems to be identified early.
When the calibration period has expired the processor will display the message, “Error 113: Calibration
Required,” informing the operator that the calibration date has passed. This will not prevent the processor
from performing fusions; however, the processor should be calibrated as soon as possible.
THE CORRECT OUTPUT VOLTAGE CANNOT BE ASSURED IF THE PROCESSOR IS NOT CALIBRATED AT LEAST
ONCE EVERY THREE (3) YEARS.

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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.
2. Rent one of our field calibration systems and perform as many calibrations as you would like at your
facility and at your convenience.
Call [phone] to make arrangements for service and to obtain an RMA number for the return. Every
effort will be made to return processors within 5-7 business days.
Consult your carrier for the proper method of packaging the processor for return shipments.
Always insure the package for the full replacement value.
Keep in mind that most carriers will not honor insurance claims if the product is not shipped in
accordance with their guidelines.
JACKMAN FUSION EQUIPMENT is not responsible for damage caused in shipping.

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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. When the barcode is scanned at the appropriate prompt, the
processor reads the fitting’s specific fusion parameters. Barcode labels generally provide the following
details needed to fuse that particular fitting: manufacturer, type, size, energy (voltage), fusion time,
cool time, resistance, tolerance, and compensation factors.
It is strongly recommended that Barcode Fusion Mode be used to perform fusions whenever
possible. The Barcode Fusion Mode includes additional automated features and pre-fusion machine
checks which are not always available when using Alternate Fusion Modes. Some of these additional
features include:
•Automatic calculation of fusion time adjustments based on ambient temperature.
•Pre-fusion resistance checks against manufacturer-specified tolerances.
These features help ensure that the proper fusion parameters are entered. However, it is important
to understand that no amount of machine checks will ever negate the requirement for a well-trained
observant operator to make a final GO/NO GO decision, regardless of which Mode of Operation is
being used.
FAILURE TO VERIFY THAT THE FUSION INFORMATION IS CORRECT BEFORE STARTING A FUSION COULD
RESULT IN SIGNIFICANT DAMAGE TO PROPERTY, PERSONAL INJURY, AND/OR DEATH.
Alternate Fusion Modes
Alternate Fusion Modes are used when the SMART Scanner™ is malfunctioning or unavailable. Alternate
Fusion Modes require additional care and attentiveness on the part of the operator to ensure that the proper
fusion parameters are entered. For this reason, the following Alternate Fusion Modes should ONLY be
performed by a fully trained operator using the fitting manufacturer’s specifications regarding fusion time,
voltage, and cooling time:
Manual Barcode Mode
Infers that the fusion parameters are obtained from the 24 digit barcode number that the operator
manually inputs from the keypad.

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Manual Mode
FOR EXPERT OPERATORS ONLY! Manual Mode infers that the fusion voltage and time are obtained
directly from the operator at the time of the fusion. Manual Mode should only be used when the
barcode is malfunctioning or unavailable.The temperature compensation must be calculated and
entered manually, making it difficult to ensure the proper implementation of time/temperature
compensation for fittings requiring this feature. Since compensation factors vary for different fitting
types and manufacturers, the fitting manufacturer should always be consulted to verify proper
fusion time, voltage, and cooling time.
FAILURE TO VERIFY THAT THE FUSION INFORMATION IS CORRECT BEFORE STARTING A FUSION COULD
RESULT IN SIGNIFICANT DAMAGE TO PROPERTY, PERSONAL INJURY, AND/OR DEATH.
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. Do not use an extension cord if it is at all possible. If an extension
cord must be used, see page 42 for guidelines on selecting an appropriately sized cord.
Plug the 30 amp twist-lock into the appropriately sized receptacle on the generator.
NOTE:
Using a receptacle with a rating of less than 30 amps may cause generator breakers to trip while fusing
larger couplings.
Press the Power button to turn the processor ON.
After the processor has turned ON, start-up screens similar to the following will be displayed one after
another:
INTERNAL SELF TEST
Please wait...
INTERNAL SELF TEST
JACKMAN ROUGHNECK
CAL DUE –05/11/2021
PASSED
After the INTERNAL SELF TEST, if the feature is enabled, the TRACEABILITY screen will be displayed, allowing
you to enter Operator Traceability Data. If this screen appears, see page 34 for instructions on how to enter the
data.

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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
measuring and will be used to modify the fusion time if required by the fitting manufacturer.
Check to make sure the temperature reading is accurate. If the processor has been in direct sunlight or has
been moved from a hot or cold environment, the temperature may not be correct. If the temperature
indicated is not correct, allow the processor time to adapt to the correct temperature, approximately 15-20
minutes.
The last line indicates the generator status. The voltage and the frequency are displayed. It is important that
the voltage measurement is within the allowable range and the frequency is stable. See Specifications Table
on page 7.
Pressing and holding down the UP Button while the processor is at the CONNECT FITTING screen will show a
screen similar to the following.
1.2.3 SN:9720000
SW: ON 03 FC:0124
05/11/2018 15:30
CAL DUE –05/11/2021
This screen shows the following information:
•Software version of the processor (In this case, version 1.2.3).
•Processor serial number (In this case, 0000000).
•SMART Scanner™ status (In this case, ON).
•The number of fusions the processor has completed (In this case, 124).
•The Date and Time (In this case, May 11, 2018 at 3:30 PM)
•The date the processor will be due for calibration (In this case, May 11, 2021)
Release the UP button to return to the CONNECT FITTING screen.
To begin the fusion process, follow the instructions in the following section that corresponds to the fusion
method that you wish to perform.