Roughneck Jackman Fusion Equipment User manual

JACKMAN FUSION EQUIP –ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0
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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.

JACKMAN FUSION EQUIP –ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0
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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

JACKMAN FUSION EQUIP –ELECTROFUSION PROCESSOR OPERATORS MANUAL - REV 0
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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