ISCO Fusion Manual

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Just call
1-800-345-ISCO
CO R PO R AT E H Q
ISCO Industries, LLC 926 Baxter Avenue Box 4545 Louisville, Kentucky 40204 Tel. 800.345.4726 Fax 800.831.4726 www.isco-pipe.com
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HDPE Fusion Manual
Coming through.
Version 4.0 2012
Welcome to the most comprehensive Fusion Manual in the industry. After gathering information from Manufacturers and the Plastic Pipe Institute, we feel this is the go to manual when joining HDPE pipe. The procedures shown use Plastic Pipe Institutes Generic Saddle Fusion Joining Procedure, TR-41 and its Generic Butt Fusion Joining Procedure, TR-33 as their foundations. HDPE pipe and fittings manufacturers have approved P.P.I.s Generic Joining Procedures in an attempt to standardize the joining procedures of HDPE. The ASTM STANDARD F2620 and ASTM standard F1056 are still the cornerstones for socket fusion. Its joining procedure is detailed and highlighted in this fusion procedures manual. Do Not join Driscopipe 7000 or 8000 series products using these procedures. Reference ASTM STANDARD F2620 for Cold Weather Procedures when performing Socket, Saddle, and Butt Fusions in extreme cold conditions. Were proud to offer quality products and skilled professionals nationwide, dedicated to providing exceptional customer service, especially our fusion equipment, sales, rental, repair, refurbishment and training support system. If you have a question about fusion, please call our toll free hotline at 1-800-345-ISCO (4726) ext-4790 and a qualified service technician will answer your questions. The ISCO Fusion Manual has been endorsed by McElroy Manufacturing, Inc. and their Technical Support Staff, however this manual should not be considered a substitute for the original manufacturers fusion equipment manuals. Always read and understand the original manufacturers equipment manual before operating any piece of equipment. The operator must be throughly trained in the proper use of fusion equipment and procedures. We are proud to be a distributor of McElroy HDPE Fusion Equipment and feature their equipment in this manual. ISCO is geared towards educating everyone with the proper fusion procdures so that HDPE can continue to grow in the market place as the piping material of choice. The operators training and judgement is paramount to the success of fusing HDPE products. The appropriateness of the procedures involved should be considered before starting any project. We hope this manual aides you in the safe handling and joining of HDPE products in a more effective and efficient manner. Thank you for your business and continued interest in our products and sevices. We look forward to serving you on your next HDPE project. If you have any questions regarding this manual or in joining HDPE pipe, please contact our Fusion Hotline at 1-800-345-ISCO (4726), ext. 4790.
Fusion Equipment and Services

Fusion Equipment for rent or sale:
Butt Fusion Machines Sidewall Fusion Machines Socket Fusion Equipment Coiled Pipe Trailers Electrofusion Equipment Extrusion Welders Hot Air Guns
ISCO Industries LLC., is the worlds largest McElroy Distributor and offers a complete line of fusion accessories and special tooling. Accessories & Special Tooling:
PolyPorter PolyHorse Limited Access Equipment Squeeze Off Tools Split Ring Heaters DataLoggers Pipe Cutting Tools Test Caps Pyrometers Internal and External Bead Removers Pipe Straightening Equipment Pipe Rerounding Tools And Many Others
Rental & Sales Locations:
Sales and rental locations nationwide, which features the new McElroy TracStar line of self propelled and self contained units. New and Used Equipment: Lease to Own Options Available Multiple McElroy Authorized Service and Repair Centers to support you and your equipment.
Field Fusion Technicians

Experienced, Factory Trained, Confined Space Certified and OSHA Compliant
Need Training? ISCO offers Fusion Operating Training Qualification classes or McElroy Certified Fusion Operator Training classes. Contact your ISCO sales rep for more information. Work with It, Not on It!
ISCO Industries has multiple McElroy Authorized Service and Repair Centers with a complete inventory of fusion units and parts. For more information about repairing or refurbishing your fusion unit, call 1-800-345-ISCO(4726), www.isco-pipe.com
Have a problem in the field and need help? - Give us a Call Fusion Troubleshooting Hotline
1-800-345-4726 Ext. 4790
Before and After photos of equipment refurbished by ISCO Industries
ISCO Fusion Manual
Table of Contents
Fusion Equipment Safety Information . . . . . . . . Page 4 Tips For Success . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 15 Manual Butt Fusion Machine Procedure . . . . . . . Page 18 Hydraulic Butt Fusion Machine Procedure . . . . Page 32 Saddle Fusion Machine Procedure . . . . . . . . . . . Page 51 Socket Tooling and Fusion Procedure . . . . . . . . . Page 65 Reference Information: McElroys DataLogger Pendant/Coach , Equipment & Fusion Pressure Charts . . . . . . . . . Page 75
This manual contains accurate and reliable information to the best of our knowledge as of the publication date. The results of using our suggestions and recommendations cannot be guaranteed because the conditions of use are beyond our control. Failure to follow these procedures in this manual may result in damage to or destruction of property and/ or serious injury to or death of a person. The user of such information assumes all risk connected with the use thereof. ISCO Industries, LLC assumes no responsibility for the use of information presented herein and hereby disclaims all liability in regard to such use.
Fusion Hotline 1-800-345-ISCO ext. 4790 Copyright 2012 ISCO Industries, LLC All rights reserved.
Fusion Equipment Safety Information
How was I suppose to know?
Please read the Safety Section first.
ISCO Fusion Manual

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.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
situation which, if not avoided, could result in death or serious injury. if not avoided, may result in minor or moderate injury.
Safety Alerts
!
!
! !
DANGER
WARNING CAUTION
Indicates a potentially hazardous ! WARNING
! CAUTION Indicates a hazardous situation which,
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 someones 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.
Read And Understand Do not operate fusion equipment until you have carefully read, and understand the Safety and Operation 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 judgement in the operation of this equipment. Follow all applicable federal, state, local, and industry specific regulations.
ISCO Fusion Manual

ISCO Industries, LLC cannot anticipate every possible circumstance that may 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. 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.
Sense 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. Wear Safety Equipment Wear a hard hat, safety shoes, safety glasses, and other applicable personal protection equipment. Remove jewelry and rings, and do not wear loose-fitting clothing or long hair that could catch on controls or moving machinery.
ISCO Fusion Manual

Units With Hydraulics Although the hydraulic pressures in the machine are low compared to some hydraulically operated equipment, it is important to remember that a sudden hydraulic leak can cause serious injury or even be fatal if the pressure is high enough.
! WARNING
Escaping fluid under pressure can penetrate the skin causing serious injury. Keep hands and body away from pinholes which eject fluid under pressure. Use a piece of cardboard or paper to search for leaks. If any fluid is injected into the skin, it must be immediately removed by a doctor familiar with this type of injury.
NOTICE: Wear safety glasses, and keep face clear of area when bleeding air from hydraulic system to avoid spraying into eyes. Heaters Are Not Explosion Proof
! DANGER Heaters are not explosion proof. Operation of a heater in a hazardous environment without necessary safety precautions will result in explosion and death. When operating in a hazardous environment, heater should be brought up to temperature in a safe environment, then unplugged before entering the hazardous atmosphere for fusion.
ISCO Fusion Manual

Electric Motors Are Not Explosion Proof
! DANGER Electric Motors are not explosion proof. Operation of these components in a hazardous environment without necessary safety precautions will result in explosion or death. When operating in a hazardous environment, keep pump motor and chassis in a safe area by using hydraulic extension hoses.
Electrical Safety
! WARNING Always ensure power cords are properly grounded. It is important to remember that when 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. Damaged components need to replaced and service performed by a qualified electrician. Do not carry electrical devices by the cord. NOTICE: Always connect units to the proper power source as listed on the unit, or in the owners manual. On units with two power cords, plug each cord into separate power circuits. Do not plug into both outlets of one duplex receptacle. NOTICE: Disconnect the machine from the power source before attempting any maintenance or adjustment.
ISCO Fusion Manual

Crush Points
! WARNING Hydraulically operated jaws are operated under pressure. Anything caught in the jaws will be crushed. Keep fingers, feet, arms, legs, and head out of the jaw area. Always check pipe alignment with a pencil or similar object.
Facer Blades Are Sharp

! WARNING Facer blades are sharp and can cut. Never attempt to remove shavings while the facer is running, or is in the facing position between the jaws. Use care when operating the facer, and handling the unit.
NOTICE: Disconnect power from the facer, and remove the facer blades before attempting any maintenance or adjustment. Heater Is Hot
! CAUTION The heater is hot and will burn clothing and skin. Keep the heater in its insulated heater stand or sling 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. Fusion Procedures
! CAUTION Follow the procedures carefully, and adhere to all specified parameters. Failure to follow procedures could result in a bad weld. Always follow the proper fusion procedures.
ISCO Fusion Manual

Units With Gas Engines
! WARNING Handle fuel with care. Fuel is highly flammable. Do not refuel the machine while smoking or near open flames or sparks. Always stop the engine before refueling machine. Fill fuel tank outdoors. Help prevent fires by keeping machine clean of accumulated trash, grease, debris, and facer shavings. Always clean up spilled fuel. ! WARNING Breathing exhaust gases can cause sickness or death. Always operate machine outdoors in an area with adequate ventilation.
Units With Batteries

! CAUTION Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid contact with eyes, skin, and clothing. Exploding gases from battery could cause blindness or serious injury. Keep sparks, flames and cigarettes away.
Have Tires Properly Serviced

! WARNING Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Have tires mounted by someone that is experienced, and has the equipment to perform the job safely.
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ISCO Fusion Manual

Periodically Check Temperature NOTICE: Incorrect heating temperature can result in bad fusion joints. Check heater plate surface temperature periodically with a pyrometer, and make necessary adjustments. The thermometer on heaters indicates internal temperature, and should be used as a reference only. Do Not Tow Fusion Machine At Speeds Greater Than 5 MPH
! WARNING The chassis is not designed for over-road towing. Towing at speeds greater than five miles per hour can result in machine damage as well as injury. Always transport the machine by flat bed truck or similar means, and make sure that unit is properly secured.
0 7 6
Positioning Fusion Machine Place fusion machine on as level ground as possible, and set the brake on the rear wheel. If it is necessary to operate machine on unlevel grade, chock the wheels and block the unit to make it as stable as possible.
Keep Machine Away From Edge Of Ditch

! WARNING Heavy equipment too close to a ditch can cause the walls of the ditch to cavein. Keep the machine far enough away from the edge of the ditch to prevent injury to personnel and equipment from a cave-in.
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ISCO Fusion Manual

Operating TracStar Fusion Machines Place fusion machine on as level ground as possible.
3
If it is necessary to operate machine on unlevel grade, make sure that the ground is stable. Some unstable conditions maybe ice, snow, mud, and loose gravel.
! WARNING For operation safety, never operate machine on a grade steeper than 30%. (A 3 foot elevation change in 10 feet.)
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Do Not Attempt to Tow A TracStar Fusion Machine

! CAUTION The machine is not designed for towing. Attempting to tow the machine can result in machine damage. Always transport the machine by flat bed truck or similar means, and make sure that unit is properly secured.
Positioning Fusion Machine Place fusion machine on as level ground as possible. If it is necessary to operate machine on unlevel grade, chock the tracks and block the unit to make it as stable as possible.
Hearing Protection Required For TracStar 412 and TracStar 618. When operating machine for more than four hours per day, wear hearing protection.
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ISCO Fusion Manual

Safety Precautions For Guarding Against Static Electricity And Gaseous Ignition
! DANGER Polyethylene plastic pipe does not readily conduct electricity. A static electricity charge can buildup on inside and outside surfaces and stay on the pipe surface until some grounding device, such as a tool or a person comes close enough for the static electricity to discharge to the grounding device.
! WARNING Discharging one part of the pipe surface will not affect other charged areas because static electricity does not flow readily from one area to another. Polyethylene pipe cannot be discharged by attaching grounding wires to the pipe.
Heaters, electric facers and electric power tools are NOT explosion proof. Static electricity discharge can ignite a flammable gas or combustible dust atmosphere. A static electricity discharge to a person, a tool, or a grounded object close to the pipe surface can cause an electric shock or a spark that can ignite a flammable gas or combustible dust atmosphere causing fire or explosion. In gas utility applications, static electricity can be a potential safety hazard. Where a flammable gas-air mixture may be encountered and static charges may be present, such as when repairing a leak, squeezing-off an open pipe, purging, making a connection, etc., arc preventing safety precautions are necessary. Observe all procedures for static electricity safety and control, including procedures for discharging static electricity and requirements for personal protection. Take steps to discharge static electricity from the surface of the polyethylene gas pipe. Such steps include wetting the entire exposed pipe surface with a conductive anti-static liquid or a dilute soap and water solution, then covering or wrapping the entire wetted, exposed pipe surface with grounded wet burlap, conductive poly film, or wet tape conductor. The external covering should be kept wet by occasional re-wetting with anti-static solution. The covering or tape should be suitably grounded such as to a metal pin driven into the ground. Steps that discharge the outer surface do not discharge the inner surface of the pipe. Squeeze-off purging, venting, cutting, etc., can still result in a static electricity discharge. When appropriate, ground tools and remove all potential sources of ignition.
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ISCO Fusion Manual

Safety Precautions For Guarding Against Static Electricity And Gaseous Ignition (Continued) Key items: Do not put a butt fusion machine chassis in a hazardous environment. Set the chassis up out of harms way and use extension hoses to operate upper works in hazardous area. Do not use a butt fusion machine with an electric facer in a gaseous environment. Use a machine equipped with a hydraulic facer or convert the electric facer to a manual by removing the brushes and turning facer manually. When making butt fusions, saddle fusions and socket fusions in a hazardous environment, set the generator up out of harms way and have the heater plugged into it there. Set the heater temperature at the maximum allowed for the application. Use 450 F for butt fusion and 510 F for saddle fusion and socket fusion. These are surface temperatures. The high side temperatures are used to compensate for the drop in temperature experienced when heater is unplugged from the power source to make fusion in hazardous area. Unplug heater prior to using in a hazardous environment. Do not drill hole first prior to making a saddle fusion. When prepping the main pipe for a saddle fusion, do not use an electric grinding tool. Prepare main pipe manually by use of 50-60 grit utility cloth. Do not use an electric drill for punching hole through after saddle fusion has been made. Use your senses and good judgment: Listen, Smell, Feel, See and Report any unsafe situations you see or see coming to your onsite contact, if corrective action is not taken in your opinion, Do not enter into the situation.
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Tips For Success
What can I learn from others before getting started?
15
Tips for Success
ISCO Fusion Manual
Tips for Success

Use Personal Safety Equipment. Always wear a hard hat and protective boots. Gloves protect hands from heater burns and sharp blades on the facer. Protective Eye Glasses are also a good idea. Make sure all equipment is in good working order and power cords are free of cuts with grounding blade on receptacle in tack. Position fusion equipment on level ground whenever possible. If the fusion equipment has wheels, set the wheel lock or block them. Position pipe support stands on either side of the fusion equipment approximately 20 from ends of the fusion equipment. Adjust stands so that pipes are level to reduce drag. When working with McElroy Self-Contained fusion units excluding the T-500 and T-900, make sure to open the facer valve prior to starting the unit and keep it open until started. Close valve once unit is running. This will save the battery and keep you from burning up the starter. Plug heater in on self-contained fusion units only after unit has been started and warmed up. Unplug heater before turning fusion unit off. This will keep you from having heater element and circuitry problems with your heater. Load loose pipe joints into movable side of the fusion equipment and pull joints already fused through non-movable side. Check your pipe before you fuse it. Look for deep scratches, cuts and gouges. Use the 10 percent rule: Any imperfection affecting more than 10 percent of the pipe wall being worked with should not be used. When rough cutting pipe, use a pipe wrap to mark the pipe with a reference line, this will aid you in making a square and even cut. In general, tooling that works with wood works well with HDPE pipe. For cutting pipe, skill saws and chain saws work well. When using chain saws, the cut ends MUST be cleaned with isopropyl alcohol to remove BAR Oil Splash or any other contaminants. For cutting holes in pipe, drills with hole saws and reciprocating saws work well. When making fusions that involve pipe to fittings, special care should be taken. The necking down or toe in at the pipe ends, which is normal, needs to be completely removed in the facing process. This is seen primarily in working with the larger pipe diameters. Do not abuse the facer when facing pipes by using too much pressure. When pulling pipe through the fusion equipment, elevate pipe in the machine using the pipe lifts so the fusion bead clears all obstructions as it is pulled through.
Tips for Success 16
ISCO Fusion Manual
Tips for Success (Continued)

If a fusion weld does not come out exactly as you like or you question the quality of the fusion weld, then cut it out and re-fuse. Always remember IF IN DOUBT, CUT IT OUT and redo. Fusion beads can be removed by means of external and internal bead removers without effecting the integrity of the fusion joint. In inclement weather and especially in windy conditions, the fusion operation should be shielded to avoid precipitation or blowing snow and excessive heat loss from wind chill. Capping ends of pipe that are being fused aides heater from being chilled as fusion joint is being made. The joint area and its parts that are being fused must be completely dry. No liquid of any kind running through the pipe or fittings is permissiable. When fusion is done in cold weather, DO NOT INCREASE HEATING TOOL SURFACE TEMPERATURE. Do not try to shorten cooling times of fusions by applying wet cloths, water or the like. When removing pipe from the fusing unit and pulling into place, use proper lifting slings and pulling heads in good condition. Chains and rope can slip and cause injury/damage to personnel and pipe. When working with coiled pipe 2 - 6, a McElroy LineTamer should be used to straighten and reround coiled pipe to meet or exceed ASTM D2513 Quality Requirements. Squeeze tools can be used on HDPE Pipe to stop flow in a pipeline while a tie in or repair is made. Follow manufacturers squeeze-off tool instructions. A common obstacle when working with HDPE pipe in the field is understanding the thermal expansion and contraction. Rule of thumb - 1.4/ 100/ 10F.
Butt Fusion Joining Rates

Pipe Sizes IPS/DIPS
3/4 - 3 4 - 8 10 - 18 20 - 24 26 - 34 36 - 48 51.5 - 63
Approx. Fusions per 8-10 Hr. Day

30 - 60 24 - 48 12 - 24 10 - 16 8 - 12 6 - 10 4-8
Important: Fusions per day are dependent upon pipe wall thickness, equipment to move and handle pipe, manpower, site conditions and weather. Use lower number for estimation and planning.
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Tips for Success
Manual Butt Fusion Machine Procedure
Manual Butt Fusion Machine Procedure 18

ISCO Fusion Manual

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 two pipes become one homogeneous unit. The principle operations include: Clamping The pipe pieces held axially to allow all subsequent operations to take place. Facing Alignment Heating Joining Holding The pipe ends must be faced to establish clean, parallel mat ing surfaces perpendicular to the centerline of the pipes. The pipe ends must be aligned with each other to minimize mismatch or high-low of the pipe wall. A melt pattern that penetrates into the pipe must be formed around both pipe ends. The melt patterns must be joined with a specified force. The force must be constant around the interface area. The molten joint must be held immobile with a specified force until adequately cooled.
BUTT FUSION OF PIPES AND COMPONENTS WITH DIFFERENT WALL THICKNESSES When Butt Fusion is used to join pipes and other components together they must have the same outside diameter and the difference between minimum wall thickness dimensions for the two components being joined should not exceed 26%. Example: You have a pipe or fitting that has a wall thickness of 1. You can weld that pipe to pipes or fittings that have a wall thickness of 3/4 min. or 1-1/4 max. Important: The pipe line is only as strong as its weakest link. The fusion pressure used to join two different wall thicknesses is always that of the thinner.
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ISCO Fusion Manual

Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused. No. 2LC & No. 2CU machines (1/2 CTS - 2 IPS Pipe) 1-1/2 and smaller inserts are fitted to jaw castings using flat head fasteners. No. 14 Pitbull Machines (1 IPS - 4 DIPS Pipe) 2 Master, 3 & 4 inserts are held in place by spring pins located on upper and lower jaws. 1-1/2 and smaller inserts are fitted to 2 IPS Master inserts using flat head fasteners.
Loading Pipe Into Machine (No. 14 Pitbull Used In the Following Illustrations) Clean the inside and outside of the pipe ends that are to be fused. Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed. Let the ends of the pipe protrude about 1 past the face of the jaws. Close upper jaws but do not overtighten.
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ISCO Fusion Manual

Electric Facer The facer is a McElroy Rotating Planer Block Design. The blade holders each contain two cutter blades. The Block rotates on ball bearings and is chain driven (enclosed in lubricant) by a heavy duty electric motor. When operating in a hazardous environment, operate the facer manually.
! DANGER Electric motors are not explosion proof. Operation of these components in a hazardous environment will result in explosion and death.
The armature brushes must be removed from the electric motor when manually operating in a hazardous condition. Unscrew the brush covers from both sides of the motor. (Both brushes must be removed). A 7/8 hex shaft allows for manual operation in hazardous conditions. The facer has a handle that latches into place on a guide bar. The handle must be pulled out to unlatch and remove facer.
Manual Facer for No. 2LC and No. 2CU The manually operated facer has a hand powered crank. Turn the crank counterclockwise for facing.
Cam Lock A semi-automatic cam locking system locks the movable jaw during the cooling cycle.
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ISCO Fusion Manual

Inserting Facer Place the end opposite the handle onto the far guide rod, then lower the facer handle end down onto the near guide rod and latch.
Positioning Pipe In Machine With facer in position use lever handle to bring pipe ends together against the facer, watching the gap between the facer stops and the pipe clamping jaws. Leave enough gap so that proper face-off will be achieved when the facer stops are bottomed out against the clamps. Tighten the pipe clamp knobs by hand until firm resistance is felt. Do not over-tighten.
Important: Thoroughly clean all dirt and debris from pipe ends before facing.
Facing The Pipe Manually Turn facer handle counterclockwise and apply firm pressure on lever handle. Continue facing until facer stops have bottomed out against the clamping jaws. Stop rotation of facer. Move jaws apart. Unlatch and remove facer. Remove shavings from pipe ends and machine. Do not touch faced pipe ends. Inspect both pipe ends for complete face off. If the face off is incomplete, return to Loading Pipe Into Machine on page 20.
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ISCO Fusion Manual

Electric Facer The electric facer should be started before the pipe is pushed into contact with the blades. Continue facing until the facer stops are against the jaws. Turn off the facer while continuing to hold pressure closed on the lever until the facer stops completely. Reverse force to the lever handle to move the pipe ends away from the facer. Unlatch and remove the facer taking care not to touch the pipe ends. Remove shavings from pipe ends and machine. Do not touch faced pipe ends as this may contaminate them. If faced pipe ends are touched, use a clean white nonsynthetic cloth to clean affected area before proceeding. If after facing, any imperfections are visible, return to Loading Pipe Into Machine on page 20. Any time clamp knobs are tightened, pipe ends should be refaced.
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ISCO Fusion Manual

Check Alignment Of Pipe 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 pipes. Their should be no more than 10% of the wall thickness in misalignment to maintain full joint strength. 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 to check for slippage. If slippage occurs, return to Loading Pipe Into Machine section on page 20. Check Heater Temperature
! CAUTION Incorrect heating temperature can result in questionable fusion joints. Check heater plates periodically in multiple locations with a pyrometer and make necessary adjustments.
For butt fusion heater surface temperature should be Minimum 400 F, Optimum 425 F, Maximum 450 F. 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.
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ISCO Fusion Manual

Inserting Heater
! DANGER Heater Is Not Explosion Proof. Operation of heater in a hazardous environment without necessary safety precautions will result in explosion and death.
If operating in a hazardous environment, heater should be brought up to temperature in a safe environment, then unplugged before entering the hazardous atmosphere for fusion.
Check heater adapters for coating damage, plastic buildup rings and surface imperfections. These conditions could cause a poor fusion. Replace them if conditions exist. Verify heater temperature by referencing the reading on the dial thermometer. Insert heater between the pipe ends. The stripper bar downward legs should be outside of the jaws. (not on top)
Heating The Pipe With heater in position between the pipe ends, bring the pipe or fitting ends into full contact with the heater to ensure proper seating. Raise the locking cam into the engaged position while in the heating cycle. Maintain contact, without force, while a bead of molten polyethylene develops between the heater and the pipe or fitting ends. Continue heating the pipe ends until the minimum melt bead size has developed. (See Minimum Melt Bead Size Chart on page 26). Do not heat under pressure.
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Use a clean white nonsynthetic cloth to clean butt fusion heater adapter surfaces.
ISCO Fusion Manual

Minimum Melt Bead Size (Pipe Ends):
Pipe (OD), in. (mm) < 2.37 (60) > 2.37 (60) < 3.5 (89) > 3.5 (89) < 6.62 (160) Minimum Bead Size in. (mm) 1/32 (1) 1/16 (1.5) 3/16 (5)
Fusing the Pipe Once melt beads are of proper size, remove the heater, QUICKLY inspect the melted ends, which should be flat, smooth, and completely melted. If the melted surfaces are acceptable, immediately and in a continuous motion, bring the ends together and apply enough joining force for the beads to touch, and form a double roll back against the pipe wall. Do not slam. A concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the melted ends to cool and start over. The locking cams will assist by holding force during the cooling cycle.
Unacceptable Concave Melt Appearance What Causes This? Answer - Heating under pressure. Notice: A concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the melted ends to cool and start over.
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ISCO Fusion Manual

Optional Use Of Torque Wrench After the heating cycle is completed, remove the heater and quickly apply fusion force with the lever handle. To use a torque wrench with the No. 14 Pitbull, place an adapter in the lever socket. Required 15 torque wrench is required when using the torque wrench adapter. The locking cams will assist by holding force during the cooling cycle.
! CAUTION Failure to follow the proper heating time, pressure and cooling time may result in a bad joint.
P/N 410802
No. 14 No. 26 Torque No. 2LC Pitbull PitBull Wrench Jaw Axial Jaw Axial Jaw Axial Reading Force Force Force (Ft. Lb.) (Lb.) (Lb.) (Lb.) 10 20 30 40 50 60 70 80 90 100 70 135 200 260 320 400 480 550 635 690 115 215 330 435 545 660 780 915 1025 1140 115 215 330 435 545 660 780 915 1025 1140
Interfacial Pressure (IFP) Minimum 60 psi Optimum 75 psi Maximum 90 psi To determine the amount of force required: (OD-t) x t x 3.1416 x (IFP) 75 +DRAG = Force This value is then read on chart to determine how much torque is needed to apply the force. Drag=Amount of force required to move pipe; measured by torque wrench.
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ISCO Fusion Manual

Cooling Of The Fusion Joint Hold the molten joint immobile under fusion pressure until sufficiently cooled. Cooling under pressure before removal from the butt fusion machine is important in achieving joint integrity. Maintain fusion pressure against the piping component ends for a minimum of 11 minutes per inch of pipe wall. Avoid high stress such as pulling, installation or rough for additional 30 min or more after removal from fusion machine.
Minimum Cooling Time Chart

IPS Pipe 2 2 2 2 DR 7.3 9 11 13.5 MCT 4 4 2 2 IPS Pipe 3 3 3 3 3 5 5 5 5 5 7.3 9 11 13.5 17 8 7 6 5 4 6 6 6 6 6 DR 7.3 9 11 13.5 17 7.3 9 11 13.5 17 MCT 5 4 4 3 2 10 8 7 5 4 IPS Pipe 4 4 4 4 4 DR 7.3 9 11 13.5 17 MCT 7 6 5 4 3
Remove Pipe and Inspect After pipe has cooled sufficiently, apply closing force on the lever handle and push the locking cams down into the unlocked position. Unscrew the clamp knobs enough that they can be swiveled outward. Pull pipe through machine, and prepare for making next fusion. Inspect joint and if it has to be redone, use Trouble Shooting Guides to determine problem and make adjustments before next fusion. (See pages 29 and 30)
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ISCO Fusion Manual

Butt Fusion Joint Troubleshooting Guide
The Inspection Of The Fusion Joint
Golden Rule: If in doubt, cut it out and redo.

The double bead should be rolled over onto the adjacent surfaces, and be uniformly rounded and consistent in size all around the joint. As illustrated in the Figure below, all beads will not necessarily have equal size. The cleavage between the beads must not be lower than the wall of the pipe as shown in the lower right illustration. When butt fusing pipe to molded fittings, the fitting side bead may have an irregular appearance. This is acceptable provided the pipe side bead is correct. It is not necessary for the internal bead to roll over to the inside surface of the pipe.
Butt Fusion Bead Dimensional Guideline
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ISCO Fusion Manual

Observed Condition
Excessive double bead width Double bead v-groove too deep Flat top on bead Non-uniform bead size around pipe One bead larger than the other Beads too small
Possible Cause
Overheating; Excessive joining force Excessive joining force; Insufficient heating; Pressure during heating Excessive joining force; Overheating Misalignment; Defective heating tool; Worn equipment; Incomplete facing Misalignment; Component slipped in clamp; worn equipment; defective heating tool; incomplete facing Insufficient heating; Insufficient joining force Shallow v-groove - Insufficient heating & insufficient joining force; Deep v-groove - Insufficient heating & excessive joining force Excessive heating time Pressure during heating
Bead not rolled over to surface
Beads too large Squarish outer bead edge Rough, sandpaper-like, bubbly, or pockmarked melt bead surface
Hydrocarbon contamination
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ISCO Fusion Manual

Cold Weather and Inclement Weather Procedure Wind and Precipitation - Heating tool shall be shielded in insulated container to prevent excessive heat loss. Shield the pipe fusion area and fusion tools from wind, snow, blowing dust and rain by using a canopy or similar device. Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. Protective measures with auxiliary heating is recommended when temperatures are below -4F (-20C).
Heating Check the temperature of the heating tool regularly with a pyrometer or other surface temperature measuring devise. Do not increase heating tool temperature above the specified temperature (450F - 232C) setting. Work quickly once pipe and fittings have been separated from the heating tool; so that melt heat loss is minimized, but still take time (no more than 3 seconds) to inspect both melt patterns. When the ambient temperature becomes colder, it will require a longer heating time to develop an indication of melt and the final bead size. Pre-Heating When the ambient temperature is below 3F (-16C), the pipe ends shall be pre-heated using a heating blanket or warm air device to elevate the pipe temperature to improve the heating starting condition. With pipe mounted in the fusion machine, an alternate method of pre-heating is to stop the pipe ends within .25-.50 inches (6.4-12.7mm) of the heater plate face to allow the pipe ends to warm for 30 seconds to 2 minutes, depending on the pipe size and wall.
31
Pipe and Fitting Surface Preparation The pipe and fitting surfaces to be joined or held in clamps shall be dry and clean and free of ice, frost, snow, dirt, and other contamination. After regular procedure for facing, the surface shall be protected from contamination until joined
ISCO Fusion Manual
Hydraulic Butt Fusion Machine Procedure
Hydraulic Butt Fusion Machine Procedure 32

ISCO Fusion Manual

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 two pipes have become one homogeneous unit. The principle operations include: Clamping Facing The pipe pieces held axially to allow all subsequent operations to take place. The pipe ends must be faced to establish clean, parallel mating surfaces perpendicular to the centerline of the pipes. The pipe ends must be aligned with each other to minimize mismatch or high-low of the pipe wall. A melt pattern that penetrates into the pipe must be formed around both pipe ends. The melt patterns must be joined with a specified force. The force must be constant around the interface area. The molten joint must be held immobile with a specified force until adequately cooled.
Alignment Heating Joining Holding
BUTT FUSION OF PIPES AND COMPONENTS WITH DIFFERENT WALL THICKNESSES When Butt Fusion is used to join pipes and other components together they must have the same outside diameter and the difference between minimum wall thickness dimensions for the two components being joined should not exceed 26%. Example: You have a pipe or fitting that has a wall thickness of 1. You can weld that pipe to pipes or fittings that have a wall thickness of 3/4 min. or 1-1/4 max. Important: The pipe line is only as strong as its weakest link. The fusion pressure used to join two different wall thicknesses is always that of the thinner.
33

Hydraulic Manifold Block Mounted on this block are a carriage directional control valve, a selector valve, three pressure reducing valves, and a pressure gauge. A) The carriage control value, mounted on the top of the manifold, determines whether the carriage is moving left, right, or in neutral. B) A pressure gauge is mounted on top of the manifold. C) The selector valve, mounted on the front of the manifold, selects a pressure from one of the pressure reducing valves. Each pressure reducing valve is labeled with a different function.
FACING
ISCO Fusion Manual
D E F
D) The top valve adjusts facing pressure, normally 50-100 psi gauge pressure. E) The middle valve adjusts heating pressure, always 0 psi/drag or backed all the way out turning knob counterclockwise. The drag pressure may have to be compensated for when working with heavy wall pipe or more than one joint of pipe on the movable side or with tie-ins. Note: Example of heavy wall pipe is (14 & up; DR 13.5 & Thicker) F) The bottom valve adjusts fusion pressure, this pressure must be determined.
HEATING FUSING
Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused.
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Check Hydraulic Pressure The pressure gauge on the manifold block indicates the pressure of the carriage valve. How much pressure depends on the position of the selector valve and the pressure set on the specific pressure reducing valve. With the selector valve up, the facing pressure can be set. It may be necessary to adjust the carriage speed, while facing, with the top pressurereducing valve to control facing speed. Shift the selector valve to the center position, heating, and set the pressure reducing valve at its lowest setting, or the drag pressure, whichever is higher.
ISCO Fusion Manual
The fusion pressure can be calculated using the Fusion Pressure Calculator (shown on the next page or by using the formula on the next page, or they can be found in the reference section.) An approximate 30 psi drag factor should compensate for seal, and pipe drag with one joint of pipe on a pipe stand. If additional lengths of pipe or heavy wall pipe are being moved by the movable jaws, the actual drag pressure should be determined using the following procedure: After facing the pipe, move the carriage so that the pipe ends are approximately 2 apart. Shift the carriage control valve to the middle (neutral) position, select the heating mode, and adjust the middle pressure reducing valve to its lowest pressure by turning the valve counterclockwise. Shift the carriage control valve to the left. Gradually increase the pressure by turning the heating valve clockwise. Increase the pressure until the carriage moves. Quickly reduce the heating pressure valve counterclockwise until the carriage is just barely moving. Record this actual drag pressure. Take the pressure, determined from the Fusion Pressure Calculator, and add the actual measured drag pressure. This will be the actual fusion pressure to set with the bottom pressure reducing valve. If fusion pressures are used from the reference section, you must subtract 30 psi drag, which is already figured in and then add the actual drag pressure back. Adjust the middle heating valve to show recorded drag so that pipe ends will stay in contact with heater during heating phase.
35
With the selector valve in the down position, the fusion pressure can be set.

Fusion Pressure Calculator Interfacial Pressure (IFP) Minimum 60 psi Optimum 75 psi Maximum 90 psi Interfacial Pressure (IFP) = amount of force per sq. inch of the surface area of the pipe end. Interfacial Pressure (IFP) and Fusion machine gauge pressure are not the same. How to Use the Fusion Pressure Calculator Step 1: Set DR at Pipe Size. Step 2: Align McElroy Fusion Machine with IFP. Step 3: Read Gauge Pressure at red arrow. Step 4: Add Drag Pressure to gauge pressure. Determining Fusion Pressure Variable Definitions OD = Outside Diameter t = Wall Thickness = 3.1416 DR = Dimensional Ratio IFP = Recommended Interfacial Pressure (Shown Above) TEPA = Total Effective Piston Area DRAG = Force Required to Move Pipe
ISCO Fusion Manual
Example: Using a McElroy No. 28 Standard Fusion Machine (High Force, Green Cyl.) Pipe Size = 8 IPS OD of Pipe = 8.625 DR of Pipe = 11 Recommended Interfacial Pressure = 75 PSI Measured Drag 30 PSI Formula: Wall Thickness t= TEPA = 4.710 (chosen from the table on page 37)
+
Gauge Pressure = Gauge Pressure =
36

Notice: See Reference Section, pages 86-91, for fusion pressure charts showing pressures precalculated to include 30 psi for system drag. Determining Fusion Pressure (Continued)
TEPA = Total Effective Piston Area
ISCO Fusion Manual
Fusion High Force Medium Force Low Force Machine Standard High Velocity Extra High Velocity Model (Green Cylinders) (Orange Cylinders) ( Yellow Cylinders)
28 or T-28 412 or T-412 618 or T-618 T-500 Series I or II 824 1236 T-900 1648 2065 4.71 11.78 11.78 NA 29.44 29.44 29.44 31.42 31.42 NA 6.01 6.01 6.01 15.32 15.32 15.32 14.14 NA 1.67 3.14 3.14 NA 9.45 9.45 9.45 NA NA
Loading Pipe Into Machine (No. 412 and No. 618 Used In the Following Illustrations) Clean the inside and outside of pipe ends that are to be fused. Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed. Let the ends of the pipe protrude more than 1 * past the face of the jaws. * This distance changes with fusion machine type. Tighten the clamp knobs on the outer jaws to prevent pipe slippage and lightly tighten inner clamp knobs for possible later alignment adjustments.
37

Facing The Pipe Pivot the facer into place and secure. Move the carriage to the right. Open the ball valve on the facer motor. Assure the selector valve handle is up in the facing position.
ISCO Fusion Manual
Move the carriage to the left. If the facer stalls, adjust the facing pressure so the facer continues to cut. Important: When facing heavy wall pipe, it may be necessary to increase the system pressure. Important: When drag pressure exceeds 300 psi it is necessary to move the carriage to the left bringing the pipe ends into contact with the facer before opening the facer valve. Let the carriage bottom out at the facer stops. Turn the facer off. Move the carriage to the right so the facer can be removed.
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ISCO Fusion Manual

Remove Facer Pivot the facer out to the storage position. Remove pipe shavings from lower side of pipe ends, careful not to touch faced pipe ends. If faced pipe ends are touched, use clean non-synthetic cloth to clean affected area before proceeding. Move the carriage to the left until ends of pipe butt together. Check pipe joint for proper alignment. Do not use finger to check for hi/low (misalignment). The unit is under pressure, and slippage could result in crushed fingers. Always keep hands clear of the jaw area. If pipe is not lined up, tighten the inner high side jaw to bring into alignment. Important: Always tighten the side that is higher, never loosen the low side. When the pipe is properly aligned tighten outside clamps to insure against slippage. If clamp knob adjustment has been made, reinstall facer and begin facing procedure again. Let the carriage bottom out on facer stops. Turn facer off. Move the carriage to the right so the facer can be removed. Remove shavings from pipe ends careful not to touch faced pipe ends. Bring the pipe ends together under fusion pressure to check for slippage. If slippage occurs, return to Loading Pipe Into Machine on page 37. Notice: Their should be no more than 10% of the wall thickness in misalignment to maintain full joint strength.
! WARNING
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ISCO Fusion Manual

Position Carriage For Heater Insertion Move carriage to the right to open a gap large enough to insert the heater.
FACING HEATING
FUSING
Check Heater Temperature

! CAUTION Incorrect heating temperature can result in questionable fusion joints. Check heater plates periodically in multiple locations on both sides of plates with a pyrometer and make necessary adjustments.
For butt fusion heater surface temperature should be Minimum 400 F, Optimum 425 F, Maximum 450 F. Important: The dial thermometer on the heater indicates internal temperature. The dial thermometer can be used as reference once the surface temperature has been verified.
Select the Fusion Position Move selector valve handle down to the fusing position. Use fusion pressure required from Fusion Pressure Calculator or the formula on page 36 . Also see Reference Section, page 86-91.
FACING HEATING
FUSING
40

Inserting Heater Heater is Not Explosion Proof. Operation of heater in a hazardous environment without necessary safety precautions could result in explosion and death. If operating in a hazardous environ ment, heater should be brought up to temperature in a safe environment,then unplugged before entering the hazardous atmosphere for fusion. Use a clean white non-synthetic cloth to clean the butt fusion heater adapter surfaces. Check heater plates for coating damage, plastic buildup rings and surface imperfections. These conditions could cause a poor fusion. Replace them if conditions exist. Verify heater temperature noting the reading on the dial thermometer. Insert heater between the pipe ends. Heating The Pipe A) Move the carriage to the left under the fusion pressure, bringing the heater into full contact with both pipe ends, seating pipe ends against heater. Briefly ensure full contact between piping component ends and heating tool and then reduce the pressure to drag without breaking contact. On Larger pipe sizes, (14in. and larger) maintain the fusion pressure until a slight melt is observed around the circumference of the pipe or fitting before reducing pressure. Once the indication of melt is observed around the circumference of each pipe then move to step B.
FACING HEATING
ISCO Fusion Manual
DANGER
FUSING
FACING HEATING
FUSING
B) Move selector valve to center position, allowing the pressure to drop but maintaining contact without force. When fusing more than one pipe length on the movable side of the fusion unit, drag must be compensated for as described on pg 35.
FACING HEATING
FUSING
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FACING HEATING
FUSING
ISCO Fusion Manual

FACING HEATING
Heating The Pipe C) Return carriage control valve to neutral (middle) position. C The pipe ends are now heating at 0 pressure or the pressure to compensate for drag, allowing the pipe ends to remain in full contact with the heater, while a bead of molten polyethylene develops between the heater and the pipe or fitting ends. For 14 IPS pipe sizes and larger, maintain the heat soak time for a minimum of 4.5 minutes for every inch (25.4mm) of pipe wall thickness. (see Minimum Heat Soak Time & Cooling Time Table pg 45) After the minimum heat soak time for larger pipe sizes and for all other pipe sizes; verify the minimum bead size has been established, using the Minimum Melt Bead Size table to determine the proper size, then: Minimum Melt Bead Size (Pipe Ends) Pipe (OD) ( Outside Diameter, in. (mm)) Melt Bead Size Above 2" (60)through 3"(89) - 1/16" Above 8"(219) through 12"(324) - 1/4" Above 24"(610) through 36"(900) - 7/16" Approximate
FUSING
FACING HEATING
FUSING
Below 2 IPS (60) - 1/32 Above 3"(89) through 8" (219) - 3/16" Above 12"(324) through 24"(610) 3/8" Above 36"(900) through 65(1625) - 9/16"
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Fusing The Pipe Failure to follow the proper shift sequence, verify proper melt appearance pattern and achieve proper cooling time may result in a bad joint. After proper melt pattern has been established, use the Approximate Melt Bead Size chart on page 42 to determine the proper size, then:
! CAUTION
ISCO Fusion Manual
D
FACING HEATING
FACING HEATING
FACING HEATING
FACING HEATING
FUSING
FUSING
FUSING
FUSING
A) Shift carriage control valve to neutral position if not in this position already. B) Shift the selector valve down to fusion position. C) Move the carriage to the right just enough to remove the heater. The stripper bar on the heater should help pop heater loose. Quickly remove the heater without coming into contact with melted pipe ends. D) Quickly inspect pipe ends, which should be flat, smooth, and completely melted. Concave pipe ends are unacceptable, see page 44. If acceptable, shift carriage control valve to the left immediately bringing ends together and apply fusion pressure, calculated from page 36 or obtained from fusion pressure charts in Reference Section, pages 86-91. Notice: Bring pipe ends together being careful not to exceed the Approximate Dwell/ Transfer Times shown on page 44.
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Approximate Dwell/Transfer Times
ISCO Fusion Manual
Pipe Wall Thickness, in (mm) CTS to 1 IPS - 4 sec. >0.36 to 0.55 (9 to 14) 10 seconds >1.18 to 2.5 (30 to 64) 20 seconds
Max. Transfer Time 0.20 to 0.36 (5 to 9) 8 seconds >0.55 to 1.18 (14 to 30) 15 seconds > 2.5 to 4.5 (64 to 114) 25 seconds
Unacceptable Concave Melt Appearance What Causes This? Answer - Heating under pressure. Notice: A concave melt surface is unacceptable; it indicates pressure during heating. Do not continue. Allow the melted ends to cool and start over.
Cooling Of The Fusion Joint The fusion joint must be kept under fusion pressure until joint has sufficiently cooled. Maintain fusion pressure against the piping component ends for a minimum of 11 minutes per inch (25.4mm) of pipe wall. (See Minimum Heat Soak Time & Cooling Time Table on pg 45) Avoid high stress such as pulling, installation or rough handling for an additional 30 minutes or more after removal from the fusion machine.
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ISCO Fusion Manual

Minimum Heat Soak Time & Cooling Time Table
IPS PIPE 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 8 8 8 8 10 10 10 10 12 12 12 12 DR 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 MHST MCT 4 3 2 2 5 4 4 3 7 6 5 4 8 7 6 5 10 8 7 5 13 11 9 7 16 13 11 9 19 16 13 10 IPS PIPE 14 14 14 14 16 16 16 16 18 18 18 18 20 20 20 20 24 24 24 24 26 26 26 26 28 28 28 28 30 30 30 30 DR 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 7.3 9 11 13.5 9 11 13.5 17 9 11 13.5 17 9 11 13.5 17 MHST 9 7 6 5 10 8 7 5 11 9 7 6 12 10 8 7 15 12 10 8 13 11 9 7 14 11 9 7 15 12 10 8 MCT 21 17 14 11 24 20 16 13 27 22 18 15 30 24 20 16 36 29 24 20 32 26 21 17 34 28 23 18 32 30 24 19 IPS PIPE 32 32 32 32 34 34 34 34 36 36 36 36 42 42 42 42 48 48 48 48 54 54 54 54 63 63 63 63 65 65 65 65 DR 9 11 13.5 17 9 11 13.5 17 9 11 13.5 17 11 13.5 17 21 11 13.5 17 21 11 13.5 17 21 11 13.5 17 21 13.5 17 21 26 MHST 16 13 11 8 17 14 11 9 18 15 12 10 17 14 11 9 20 16 13 10 22 18 14 12 26 21 17 14 22 17 14 11 MCT 39 32 26 21 42 34
22 44 36 29 23 42 34 27 22 48 39 31 25 54 44 35 28 63 51 41 33 53 42 34 28
45
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Opening Movable Jaws After the joint has cooled for the recommended time, shift the carriage control valve to the neutral position. Loosen all clamp knobs, and move carriage to the right far enough to open the jaw nearest the facer. Open the movable jaws.
ISCO Fusion Manual
Opening Fixed Jaws Open the fixed jaws
Raise Pipe Raise the joined pipe using the pipe lift(s). Pull Pipe through machine, and prepare for making next fusion. Inspect joint and if it has to be redone, use Trouble Shooting Guides on page 47 and 48 to determine problem and make adjustments before next fusion.
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The Inspection Of The Fusion Joint
ISCO Fusion Manual
Golden Rule: If in doubt, cut it out and redo.

The double bead should be rolled over onto the adjacent surfaces, and be uniformly rounded and consistent in size all around the joint. As illustrated in the Figure below, all beads will not necessarily have equal size. The cleavage between the beads must not be lower than the wall of the pipe as shown in the lower right illustration. When butt fusing pipe to molded fittings, the fitting side bead may have an irregular appearance. This is acceptable provided the pipe side bead is correct. It is not necessary for the internal bead to roll over to the inside surface of the pipe.
Butt Fusion Bead Dimensional Guideline
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Butt Fusion Joint Troubleshooting Guide What Is Present One bead larger than the other
ISCO Fusion Manual
Attributing Factors Misalignment, component slipped in clamp, worn equipment, incomplete facing
Shallow v-groove - insufficient heating & insufficient joining Bead not rolled over to surface force, deep v-groove - insufficient heating & excessive joining force Squarish outer bead edge Excessive double bead width Flat top on bead Beads too small Beads too large Rough, sand-paper like, bubbly, or pockmarked melt bead surface Double v-groove too deep Pressure during heating Overheating, excessive joining force Excessive joining force, overheating Insufficient heating or joining force Excessive heating time Hydrocarbon contamination
Excessive joining force, insufficient heating, pressure during heating Misalignment, defective heating Non-uniform bead size around tool, worn equipment, incompipe plete facing A third bead Excessive joining force
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Position Pipe For Next Joint Move the fusion machine to the end of pipe, or pull the pipe through the jaws until the end of the pipe is protruding more than 1 * past the jaw face of the fixed jaw. * This distance changes with fusion machine type. Install Next Piece Of Pipe Insert a new piece of pipe in the movable jaws and repeat all previous procedures.
ISCO Fusion Manual
49

Cold Weather and Inclement Weather Procedure
ISCO Fusion Manual
Wind and Precipitation - Heating tool shall be shielded in insulated container to prevent excessive heat loss. Shield the pipe fusion area and fusion tools from wind, snow, blowing dust and rain by using a canopy or similar device. Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. Protective measures with auxiliary heating is recommended when temperatures are below -4F (-20C). Pipe and Fitting Surface Preparation The pipe and fitting surfaces to be joined or held in clamps shall be dry and clean and free of ice, frost, snow, dirt, and other contamination. After regular procedure for facing, the surface shall be protected from contamination until joined Heating Check the temperature of the heating tool regularly with a pyrometer or other surface temperature measuring devise. Do not increase heating tool temperature above the specified temperature (450F - 232C) setting. Work quickly once pipe and fittings have been separated from the heating tool; so that melt heat loss is minimized, but still take time (no more than 3 seconds) to inspect both melt patterns. When the ambient temperature becomes colder, it will require a longer heating time to develop an indication of melt and the final bead size. Pre-Heating When the ambient temperature is below 3F (-16C), the pipe ends shall be pre-heated using a heating blanket or warm air device to elevate the pipe temperature to improve the heating starting condition. With pipe mounted in the fusion machine, an alternate method of pre-heating is to stop the pipe ends within .25-.50 inches (6.4-12.7mm) of the heater plate face to allow the pipe ends to warm for 30 seconds to 2 minutes, depending on the pipe size and wall.
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Saddle Fusion Machine Procedure
51
ISCO Fusion Manual

The theory 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 molecule 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. The principle operations include: Clamping Cleaning Alignment Heating Joining Holding The pipe and fitting must be held firmly to allow all subsequent operations to take place. The area of pipe that the fitting will come in contact with must be cleaned and roughed up, as well as the base of the fitting. The fitting must be properly seated on the pipe and then clamped in the machine for proper alignment. A melt pattern must be formed that penetrates into the pipe and into the fitting. The melt patterns must be joined with a specified force. The force must be constant around the interface area. The molten joint must be held immobile with a specified force until adequately cooled.
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ISCO Fusion Manual
Saddle Fusion Procedures

Definitions
Initial Heat (Bead-up): The heating step used to develop a melt bead on the main pipe. Initial Heat Force (Bead-up force): The force (pound) applied to establish a melt pattern on the main pipe. The Initial Heat Force is determined by multiplying the fitting base (in.) area by the initial heat interfacial pressure 60 (LB/ in.). This force is twice the fusion force. Heat Soak Force: The force (pound) applied after an initial melt pattern is established on the main pipe. The Heat Soak Force is the minimum force (essentially zero pounds) that ensures that the fitting, heater, and main stay in contact with each other. Fusion Force: The force (pounds) applied to establish the fusion bond between the fitting base and the pipe. The Fusion Force is determined by multiplying the fitting base area (in.) by the fusion interfacial pressure 30 (LB/in.). Fusion Interfacial Pressure: The amount of pressure determined by ASTM F2620 & PPI TR 41 as the optimum for interaction between HDP pipe and saddle base, 30 (Lb/in.). Total Heat Time: A time that starts when the heater is placed on the main pipe and initial heat force is applied and ends when the heater is removed. Cool Time: The time required to cool the joint to approximately 120 F (49 C). The fusion force must be maintained for five minutes on 1-1/4 IPS or ten minutes for all other main sizes, after which the saddle fusion equipment can be removed. The joint must be allowed to cool undisturbed for an additional thirty minutes before tapping the main or joining to the branch outlet. Interfacial Area for Rectangular Base Fittings: The major width times the major length of the saddle base, without taking into account the curvature of the base or sides, minus the area of the hole in the center of the base. Interfacial Area for Round Base Fittings: The radius of the saddle base squared times (3.1416), without taking into account the curvature of the base or sides, minus the area of the hole in the center of the base. Fitting Label: The Initial Heat Force, Heat Soak Force, and the Fusion Force may be listed in the lower right corner of the fitting label for all saddle fusion fittings. This will eliminate the need to calculate the fusion forces in the field (example 80/0/40). Some manufacturers have this information on fitting labels but not all.
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How To Figure Out Fusion Pressures
Round Base
FF = 0.785 X (D - d) X 30 or FF =(D-wt) X wt X 3.14 x 30 Rectangular Base FF = L X W (0.785 X d) X 30 Where: FF = Fusion Force (lbs) L = rectangular base length (in) W = rectangular base width (in) d = outlet hold inside diameter (in) D = round base outside diameter (in) wt = Wall thickness of round base saddle (in)
ISCO Fusion Manual
W.T.
Base End
OD
Base End
How To Figure Out Fusion Gauge Pressure FGP = FF / TEPA Where: FGP = Fusion Gauge Pressure (psi) FF = Fusion Force for Round or Rectangular Base Saddle (lbs) TEPA = Total Effective Piston Area (in) * Add 30 Psi to your fusion pressure to compensate for drag when using hydraulic pump powered fusion equipment. ** Initial Heating Force is twice the heating force (i.e., twice the Fusion Gauge Pressure) Examples: Sidewinders have 1 in TEPA No. 28 Combo have 4.7 in TEPA
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ISCO Fusion Manual

Prepare Fusion Machine
This procedure requires the use of a Saddle Fusion Tool like the examples shown on the cover page of this procedure. This tool must be capable of holding and supporting the main, rounding the main for good alignment between the pipe and fitting, holding the fitting, applying and indicating the proper force during the fusion process.
Install the Saddle Fusion Tool on the main according to the manufacturers instructions. The tool should be centered over a clean, dry location where the fitting will be fused. Secure the tool to the main. A main bolster or support is recommended under the pipe on 6 IPS and smaller main pipe sizes.
Abrade the fusion surface of the fitting with 50 to 60 grit utility cloth; to remove oxidation layer and contaminants. After abrading, brush residue away with a clean, dry cloth.
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ISCO Fusion Manual

Insert the fitting in the Saddle Fusion Tool loosely.
Abrade the fusion surface of the main with a 50-60 grit utility cloth to remove oxidation layer and contaminates. The abraded area must be larger than the area covered by the fitting base. After abrading, brush residue away with a clean, dry cloth.
Using the Saddle Fusion Tool, move the fitting base and apply about 100 pounds force to seat the fitting. Secure the fitting in the Saddle Fusion Tool.
Heating
! DANGER Heater is Not Explosion Proof. If working in a hazardous environment review pages 7, 13 and 14 in Safety Section.
Incorrect heating temperature can result in questionable fusion joints. Check heater plates periodically in multiple locations with a pyrometer and make necessary adjustments. The heater must be fitted with the correct heater adapters. Serrated heater adapters are recommended to allow for maximum heat penetration. The non-stick coating on the heater adapters should be in good condition. The temperature of the heater adapter fusion surfaces must be 490-510 F, with 500F being Optimum. Important: The dial thermometer on the heater indicates internal temperature. The dial thermometer can be used as reference once the surface temperature has been verified.
! CAUTION
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ISCO Fusion Manual

Installing 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.
Heating Procedure For Small Fittings (<2in.IPS) Place the heating tool on the main centered beneath the fitting base. Immediately move the fitting against the heater faces, apply the Initial Heat Force, (see fitting label or use twice the calculated fusion pressure), and start the heat time. During Heating, Hold the heating tool in position by lightly supporting the heating tool handle. If not supported, the heating tool can slip out of position or displace the main or fitting melt and result in a poor joint. Apply the Initial Heat Force until melt is first observed on the crown of the pipe main, (Initial Heat is the term used to describe the initial heating (bead-up) step to develop a melt bead on the main pipe and usually is 3-5 seconds) and then reduce the force to the Heat Soak Force (Bead-up Force) (see fitting label or use 0 psi.) At the end of the Total Heat Time (See Maximum Heating Time and Minimum Cooling Time Table, Page 59), remove the fitting from the heater and the heater from the main with a quick snapping action. Quickly check the melt pattern on the main pipe and fitting base for even melt patterns (no unheated areas).
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ISCO Fusion Manual

Heating Procedure For Large Fittings (>IPS 3in) and Large Mains (>IPS 6in.) Place the heating tool on the main centered beneath the fitting base while supporting the heating tool handle, and then place the flexible Shield between the heating tool and the fitting base. (This step could require an assistant to handle the Flexible Heat Shield). Move the fitting against the Flexible Heat Shield, apply Initial Heat Force, and observe melt bead formation on the main all around the heating tool faces. When a melt is first visible on the main all around the heating tool faces, in a quick continuous motion, release the Initial Heat Force, raise the fitting slightly, remove the Flexible Heat Shield, move the fitting against the heating tool face, apply Initial Heat Force and start the heat time. When a melt bead is first visible all around the fitting base (usually about 3 to 5 s) immediately reduce applied force to the Heat Soak Force (usually zero). Maintain the Heat Soak Force until the Total Heat Time ends (See Maximum Heating Time And Minimum Cooling Time Table, Page 59). At the end of the Total Heat Time, remove the fitting from the heater and the heater from the main with a quick snapping action. Quickly check the melt pattern on the main pipe and fitting base for even melt patterns (no unheated areas).
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ISCO Fusion Manual

Maximum Heating Time And Minimum Cooling Time
Main Size Maximum Heating Time Stop heating when about 1/16 bead is visible all around fitting base. Do not exceed 15 sec. when hot tapping (blowout may occur if main line is pressurized.) Stop heating when about 1/16 bead is visible all around fitting base. Do not exceed 25 to 35 sec. when hot tapping (blowout may occur if main line is pressurized.) Stop heating when about 1/16 bead is visible all around fitting base. Minimum Cooling Time
1-1/4 IPS all DRs Pressurized
5 min. + 30 min.
10 min. + 30 min.
1-1/4 - 2 IPS all DRs Non-Pressurized 3 IPS all DRs Non-Pressurized
10 min. + 30 min.
Stop heating when about 1/16-1/8 bead is visible all around fitting base.
10 min. + 30 min.
4 IPS and Larger Stop heating when about 1/8-1/4 bead is all DRs 10 min. + 30 min. visible all around fitting base. Non-Pressurized
Notice: It is highly recommended that a trained ISCO Field Service Technician support you on projects involving pressurized mains greater than 2 IPS in size and branch saddles greater than 8 IPS in size.
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2 IPS all DRs Pressurized
ISCO Fusion Manual

Fusion and Cooling
Whether or not the melt patterns are satisfactory, press the fitting onto the main pipe very quickly (within 3 seconds) after removing the heater and apply the Fusion Force (See the fitting label or use the formula on page 54 to calculate). Maintain the Fusion Force on the assembly for 5 minutes on 1-1/4 IPS mains and for 10 minutes on all larger sizes , after which the saddle fusion equipment may be removed. (Fusion Force adjustment may be required during Cooling Time, but never reduce the Fusion Force during the cooling). Important: Visually check the fusion bead around the entire fitting base at the main pipe. The fusion bead should be uniformly sized all around the fitting base, and should have a characteristic threebead shape. The first bead is the fitting base melt bead. The second or outermost bead is produced by the edge of the heating tool face on the main. The third or center bead is the main pipe melt bead. The first and third beads should be about the same 1/8 - 1/4 size all around the fitting base. The second bead is usually smaller, but should also be uniformly sized around the fitting base. The assembly should cool for an additional 30 minutes before rough handling or tapping the main. Inspect fusion using the troubleshooting guide on page 61 for proper melt patterns. If melt patterns are not satisfactory or if the fusion bead is unacceptable, cut off the saddle fitting above the base to prevent use and relocate to a new section of main. Then make a new saddle fusion using a new fitting. Important: These procedures are based on tests conducted under controlled ambient temperature conditions. Environmental conditions on a job site could affect heating and cooling times. Regardless of job site conditions or ambient temperature, the prescribed heating tool temperature is required. Do not increase or decrease the heating tool temperature.
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ISCO Fusion Manual

Troubleshooting Guide
Observed Condition
Non-uniform bead size around fitting base
Possible Cause
Misalignment; Defective heating tool; Loose or contaminated heating tool saddle faces; Worn equipment; Fitting not secured in application tool; Heating tool faces not within specified temperature Misalignment; Component slipped in clamp; Worn equipment; Defective heating tool; Loose or contaminated heating tool saddle faces; Heating tool faces not within specified temperature Insufficient heating; Insufficient joining force Excessive heating time; Excessive force Incorrect pipe main heating tool face or insufficient joining force Normal for serrated heating tool faces Normal for smooth heating tool faces Overheating; Incorrect heating tool faces; Heating tool faces not within specified temperature; Taking too much time to start heating or to remove the heating tool and join the fitting to the main pipe
One bead larger than the other
Beads too small Beads too large No third bead, or third bead widely separated from center bead Serrated bead appearance Smooth bead appearance
Pressurized main pipe blowout (beside base or through fitting center)
Rough, sandpaper-like, bubbly, or pockmarked melt bead surface
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Cold Weather and Incement Weather Procedure
ISCO Fusion Manual
Wind and Precipitation - Heating tool shall be shielded in insulated container to prevent excessive heat loss. Shield the pipe fusion area and fusion tools from wind, snow, blowing dust and rain by using a canopy or similar device. Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. Protective measures with auxiliary heating is recommended when temperatures are below -4F (-20C). Pipe and Fitting Surface Preparation The pipe and fitting surfaces to be joined or held in clamps shall be dry and clean and free of ice, frost, snow, dirt, and other contamination. After regular procedure for facing, the surface shall be protected from contamination until joined Heating Check the temperature of the heating tool regularly with a pyrometer or other surface temperature measuring devise. Do not increase heating tool temperature above the specified temperature (510F - 266C) setting. Work quickly once pipe and fittings have been separated from the heating tool; so that melt heat loss is minimized, but still take time (no more than 3 seconds) to inspect both melt patterns. When the ambient temperature becomes colder, it will require a longer heating time to develop an indication of melt and the final bead size. Pre-Heating When the ambient temperature is below 3F (-16C), the pipe ends shall be pre-heated using a heating blanket or warm air device to elevate the pipe temperature to improve the heating starting condition.
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ISCO Fusion Manual

Heater Adapter Code System
Heater Adapter Heater Size (2 or 4) Pipe OD (i.e. 2.37)

Heater Size (2or 4)
Code System
Serrated Face (Drop for Smooth Face)
1-Concave (Small Round Base) 0 - Convex (Small Round Base) 2-Convex (Rectangular Base) 1 - Concave (Small Round Base) 3-Concave (Rectangular Base) 2 - Convex (Rectangular Base) 4-Convex (Large Round Base) 3 - Concave (Rectangular Base) Serrated Face 5-Concave (Large Round Base) (Drop for Smooth Face) 4 - Convex (Large Round Base) 5 - Concave (Large Round Base)
S 2 0 S 2 0 0 2 3 7 30-Convex (Small Round Base) 00
Pipe OD (i.e. Fusion Width 2.37) Fusion Width 3.00) (i.e. 0237 300 ofof Adapter (i.e. 3.00) Adapter
Fusion Width
0 - Convex (Small Round Base)
Fusion Width
2 - Convex (Rectangular Base)
Fusion Width
4 - Convex (Large Round Base)
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ISCO Fusion Manual

Fusion Width
1 - Concave (Small Round Base)
Saddle Fusion Machine Procedure 64
Fusion Width
3 - Concave (Rectangular Base)
Fusion Width
5 - Concave (Large Round Base)
Socket Tooling and Fusion Procedure

1
4 5 3
6 Socket Tooling and Fusion Procedure 65
Nomenclature 1) Heater Sling 2) Heater 3) Chamfer Tool/Depth Gauge 4) Heater Adapters 5) Pipe Cutter 6) Clean Cloth 7) Fitting Holder 8) Cold Ring Clamp

The theory of heat fusion is to heat two surfaces to a designed 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 molecule 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. The principle operations include: Clamping Cleaning Alignment Heating Joining Holding
ISCO Fusion Manual
The pipe and fitting must be held firmly to allow all subsequent operations to take place. The area of pipe that the fitting will come in contact with must be cleaned, as well as the base of the fitting. The fitting must be properly seated on the pipe for proper alignment. A melt pattern must be formed that penetrates into the pipe and into the fitting. The melt patterns must be joined with pressure. The pressure must be constant around the interface area. The molten joint must be held immobile until adequately cooled.
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ISCO Fusion Manual

Prepare Pipe End
Socket Fusion Tooling and Fusion Procedure

Cut off damaged or oval ends of pipe squarely with a pipe cutter. Clean the pipe end and fitting, both inside and outside, by wiping with a white clean, dry, oil-free, lint-free cloth. 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.
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.
Secure 2 And Larger Fittings Place fitting in socket fitting holder. Tighten socket fitting holder around fitting.
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Clean Fitting And Pipe Fitting and pipe must be clean and dry. Use a clean white cloth to wipe the mating surfaces. Notice: Do not touch with hands.
ISCO Fusion Manual
Heater Is Not Explosive Proof

This heater is not explo sion proof. Operation of heater in a hazardous environment without nec essary safety precautions will result in explosion and death. If operating in a hazarduous environment the heater should be brought up to tem perature in a safe environment, then unplugged before entering the haz arduous atmosphere for fusion. Use a clean white, non-synthetic cloth to clean the heater adapter surfaces.
!
DANGER
Old Style Heater
New Style Heater Heater Temperature

! CAUTION Incorrect heating temperature can result in questionable fusion joints. Check socket faces periodically in multiple locations with a pyrometer and make necessary adjustments.
The non-stick coating on the heater adapters should be in good condition. The socket faces of the heater must be at the correct temperature. Minimum 490 F, Optimum 500 Maximum 510 F. Important: The dial thermometer on the heater indicates internal temperature. The dial thermometer can be used as reference once the surface temperature has been verified.
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Heating The Pipe And Fittings Firmly seat the socket fitting on the male adapter on the heater. Place the female adapter of the heater over the end of the pipe, firmly against the cold ring clamp. Heat the pipe end and the fitting socket for the time required. See chart on page 72 for proper heating time.
ISCO Fusion Manual
Remove Heater At the end of the heating time, simultaneously remove the pipe and fitting straight out from the tool, using a snap action.
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 over again.
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Notice: Do not twist fitting, pipe or heater.

Fusion And Cooling Immediately 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. See chart on page 72 for proper cooling time. Pipe and fitting should be aligned straight with each other.
ISCO Fusion Manual
Inspecting Fusion Joint After completing the specified cooling and waiting 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, voids or unbonded areas between the fitting and the pipe. If the joint is questionable refer to the Troubleshooting Guide (page 71) for possible cause and adjustments that can be done before next fusion. Holding force may be relaxed when the cooling time ends. After an additional 3 minutes undisturbed cooling time, the Cold Ring Clamp can be removed. Allow an additional 10 minutes undisturbed cooling time before testing, backfilling, or stressing the joint. Total Cooling Time equals time shown on chart (page 72) plus an additional 5 minutes.
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ISCO Fusion Manual
Socket Fusion Tooling and Fusion Procedures

Troubleshooting Guide
Observed Condition Possible Cause
No cold-ring impression in socket Depth gauge not used; Cold ring not used, or fitting melt bead set at incorrect depth; Insufficient heat time Pipe or fitting removed straight from heater face (twisting or removing from heater face at an angle); Pipe or fitting not inserted straight into each other when fusing; joining together at an angle; Twisting while joining pipe and fitting together; Cold ring not used or set to deep Incorrect heating sequence-always push the pipe or tubing into the heater after the fitting has been pushed on the heater (inserting the tubing first heats the tubing too long); Cold ring set too deep; Cold ring not used Pipe or fitting not removed straight from heater face (twisting or removing from heater face at an angle); Pipe or fitting not inserted straight into each other when fusing; joining together at an angle; Twisting while joining pipe and fitting together; Cold ring not used or set too deep Cold ring not used or set too deep
Gaps or voids around the pipe at socket fitting edge
(When viewed from inside, or when qualifying lengthwise cut joint) wrinkled or collapsed pipe or tubing end
(When qualifying lengthwise cut joint) voids in fusion bond area
(When qualifying lengthwise cut joint) Unbonded area on pipe or tubing at end of pipe or tubing (When qualifying lenghtwise cut joint) Socket melt extends past end of pipe or tubing Rough, sandpaper-like, bubbly, or pockmarked melt bead surface
Cold ring set too shallow
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Socket Fusion Tooling and Fusion Procedures

Heating and Cooling Times
Pipe Size PE 2406/2708 (Yellow Pipe)
ISCO Fusion Manual
PE 3408/3608/4710 (Black Pipe)
Heating Time Cooling Times Heating Time Cooling Times (Sec.) (Sec.)* (Sec.) (Sec.)* 1/2 CTS 3/4 CTS 1 CTS 1-1/4 CTS 1/2 IPS 3/4 IPS 1 IPS 1-1/4 IPS 1-1/2 IPS 2 IPS 3IPS 4IPS 6-7 6-7 9-10 10-12 6-7 8-10 10-12 12-14 14-17 16-19 20-24 24-29 30 30 30 30 30 30 30 45 45 45 60 60 6-10 6-10 9-16 10-16 6-10 8-14 15-17 18-21 20-23 24-28 28-32 32-37 30 30 30 30 30 30 30 60 60 60 75 75
* After an additional 3 minutes of undisturbed cooling time, the Cold Ring Clamp can be removed. After removing the Cold Ring Clamp allow an additional 10 minutes of undisturbed cooling time before testing, backfilling, or stressing the joint. 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.
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ISCO Fusion Manual
Socket Fusion and Tooling Procedures

Clean Heater Surfaces The heater adapters must be kept clean and free of any plastic buildup or contamination.
! CAUTION Before and after each fusion is made, the surface of the heater adapters must be wiped with a clean, non-synthetic cloth.
Adjusting Heater Temperature

! CAUTION Incorrect adjustment can result in injuries as well as machine damage. Follow these instructions carefully.
The heater thermoswitch adjustment shaft protrudes through the heater handle base. Turn the adjustment shaft clockwise to lower temperature, counter clockwise to raise temperature. Allow sufficient amount of time for unit to stabilize at the new temperature (5 to 10 minutes) after each adjustment. One full turn equals approximately 100 F. (Old Style Heater)
Old Style Heater
New Style Heater
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ISCO Fusion Manual

Cold Weather and Inclement Weather Procedure Wind and Precipitation - Heating tool shall be shielded in insulated container to prevent excessive heat loss. Shield the pipe fusion area and fusion tools from wind, snow, blowing dust and rain by using a canopy or similar device. Protective measures with auxiliary heating is recommended when temperatures are below -4F (-20C). Pipe and Fitting Surface Preparation The pipe and fitting surfaces to be joined or held in clamps shall be dry and clean and free of ice, frost, snow, dirt, and other contamination. After cleaning, the surface shall be protected from contamination until joined. Fittings shall be stored at a warm temperature, such as in a truck cab. Heating Check the temperature of the heating tool regularly with a pyrometer or other surface temperature measuring devise. Do not increase heating tool temperature above the specified temperature (510F - 266C) setting. Work quickly once pipe and fittings have been separated from the heating tool; so that melt heat loss is minimized, but still take time (no more than 3 seconds) to inspect both melt patterns. When the ambient temperature becomes colder, it will require a longer heating time to develop an indication of melt and the final bead size. Make sample welds on scrape pipe to develop melt patterns (particularly for IPS 2, 3 and 4in.pipe) using recommended times. When melt pattern is incomplete, increase the soak time 3 seconds in cycles and observe the melt pattern till acceptable. Pre-Heating When the ambient temperature is below 3F (-16C), the pipe ends shall be pre-heated using a heating blanket or warm air device to elevate the pipe temperature to improve the heating starting condition. Cold Ring Clamps Pipe outside diameter contracts when colder. This results in loose or slipping cold rings. If set (2) cold ring clamps are available, clamp 1st set in normal position in loose fit.. Place shim material (sand paper/emery cloth) in second set and clamp this set directly behind the first cold ring clamp. The first cold ring clamp allows the pipe adjacent to heated pipe to expand to its normal diameter.
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Reference Information: McElroy DataLogger, Pendant/ Coach Equipment & Fusion Pressure Charts More helpful Information!
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ISCO Fusion Manual
Reference
Power Requirements
Machine
MiniMc No. 2LC No. 2CU Socket Fusion
Heater Power
300 Watt @ 120 VAC, 1Ph 800 Watt @ 120 VAC, 1Ph 800 Watt @ 120 VAC, 1Ph 2 - 800 Watt @ 120 VAC, 1Ph 4 - 1,200 Watt @ 120 VAC, 1Ph
Facer Power
Hand Operated Hand Operated Hand Operated Not Applicable 7 Amps @ 120 VAC (Running) 22 Amps @ 120 VAC (Stall) Not Applicable
Hydraulic
None None None None
Min. Req. at sea Level

0.3 KW @ 120 VAC 0.8 KW @ 120 VAC 0.8 KW @120 VAC 2 - Heater - 0.8 KW @120 VAC 4 - Heater - 2.5 KW @120 VAC 2.5 KW @120 VAC 2 - Heater - 0.8 KW @120 VAC 4 - Heater - 2.5 KW @120 VAC Self-Contained Gasoline 3.5 KW @120 VAC 4 KW @120 VAC 3.5 KW @120 VAC Self-Contained Diesel Self-Contained Gasoline 5.5 KW / 6.5 KVA @ 240 VAC 60Hz Self-Contained Diesel Self-Contained Gasoline 6.5 KW / 7.5 KVA @ 240 VAC 60Hz Self-Contained Diesel 17.5 KW / 20 KVA @ 240 VAC 60Hz Self-Contained Diesel 30 KW / 30 KVA @ 240 VAC 60Hz 50 KW / 50 KVA @ 240 VAC 60Hz 50 KW / 50 KVA @ 240 VAC 60Hz
No. 14
1,200 Watt @ 120 VAC, 1Ph
None
Sidewinder TracStar No. 28 No. 28 No. 28 CU Mc. 28 Pitbull TracStar No. 412 No. 412 No. 412E TracStar No. 618 No. 618 No. 618E TracStar 500 No. 824 TracStar 900 No. 1236 No. 1648 No. 2065
2 - 800 Watt @ 120 VAC, 1Ph 4 - 1,200 Watt @ 120 VAC, 1Ph 1,750 Watt @ 120 VAC, 1Ph Saddle- 2,270 Watt @ 240 VAC, 1Ph 1,750 Watt @ 120 VAC, 1Ph 1,750 Watt @ 120 VAC, 1Ph Saddle- 2,270 Watt @ 240 VAC 1,750 Watt @ 120 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 3,000 Watt @ 240 VAC, 1Ph 4,000 Watt @ 240 VAC, 1Ph 10,950 Watt @ 240 VAC, 3Ph 20,461 Watt @ 240 VAC, 3Ph 20,461 Watt @ 240 VAC, 3Ph 35,000 Watt @ 240 VAC, 3Ph 65- 38,437 Watt @ 240 VAC, 3Ph 48- 35,000 Watt @ 240 VAC, 3Ph
None SelfContained 1 1/2HP, 1Ph @ 120 VAC 1 1/2HP, 1Ph @ 120 VAC 1 1/2HP, 1Ph @ 120 VAC SelfContained SelfContained 3 HP, 3Ph @ 240 VAC SelfContained SelfContained 5 HP, 3Ph @ 240 VAC SelfContained 7.5 HP, 3Ph @ 240 VAC SelfContained 10 HP, 3Ph @ 240 VAC 10 HP, 3Ph @ 240 VAC 10 HP, 3Ph @ 240 VAC
Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic
Reference
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ISCO Fusion Manual
Pipe Size Reference Charts

IPS Pipe Sizes
Pipe 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 52 54 63 OD 0.84 1.05 1.32 1.66 1.90 2.37 2.87 3.50 4.50 5.56 6.63 8.63 10.75 12.75 14.00 16.00 18.00 20.00 22.00 24.00 26.00 28.00 30.00 32.00 34.00 36.00 42.00 48.00 52.00 54.00 63.00 Circumference 2.64 3.30 4.13 5.22 5.97 7.46 9.03 11.00 14.14 17.47 20.81 27.10 33.77 40.06 43.98 50.27 56.55 62.83 69.12 75.40 81.68 87.96 94.25 100.53 106.81 113.10 131.95 150.80 163.36 169.65 197.92 Pipe 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48 54 60 64
DIPS Pipe Sizes

OD 3.69 4.80 6.90 9.05 11.10 13.20 15.30 17.40 19.50 21.60 25.80 32.00 38.30 44.50 50.80 57.10 61.61 65.64 Circumference 12.44 15.08 21.68 28.43 34.87 41.47 48.07 54.66 61.26 67.86 81.05 100.53 139.80 159.59 179.38 193.55 206.21 120.32
CTS Pipe Sizes

Pipe 1/2 3/4 1 1 1/4 1 1/2 2 OD 0.63 0.88 1.13 1.38 1.63 2.13 Circumference 1.98 2.75 3.53 4.32 5.11 6.68
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Reference
Reference
Metric ISO Pipe Sizes
Pipe 20 mm 25 mm 32 mm 50 mm 63 mm 75 mm 90 mm 100 mm 110 mm 125 mm 150 mm 160 mm 180 mm 200 mm 225 mm 250 mm 280 mm 315 mm 340 mm 355 mm 400 mm 450 mm 500 mm 560 mm 630 mm 710 mm 800 mm 900 mm 1000 mm 1200 mm 1400 mm 1600 mm OD Circumference 0.79 2.48 0.98 3.09 1.26 3.96 1.97 6.18 2.48 7.79 2.95 9.28 3.54 11.13 3.94 12.37 4.33 13.61 4.92 15.46 5.91 18.55 6.30 19.79 7.09 22.26 7.87 24.74 8.86 27.83 9.84 30.92 11.02 34.63 12.40 38.96 13.39 42.05 13.98 43.91 15.75 49.47 17.72 55.66 19.69 61.84 22.05 69.26 24.80 77.92 27.95 87.82 31.50 98.95 35.43 111.32 39.37 123.68 47.24 148.42 55.12 173.16 62.99 197.90
ISCO Fusion Manual
Pipe Size Reference Charts

Metric JIS-1, 1U, 2, 3 Pipe Sizes
Pipe 40 mm 50 mm 75 mm 100 mm 125 mm 150 mm 175 mm 200 mm 250 mm 300 mm 350 mm 400 mm OD 1.89 2.36 3.50 4.49 5.51 6.49 7.48 8.50 10.51 12.52 14.57 16.54 Circumference 5.94 7.41 11.00 14.10 17.31 20.39 23.50 26.70 33.02 39.33 45.77 51.96
What DR (or SDR) Pipe are we working with? DR (Dimension Ratio) = O.D. Wall Thickness
Reference
OD Pipe Sizes
Pipe 2 5/8 4 1/4 6.27 7 1/8 21 1/2 OD 2.62 4.25 6.27 7.12 21.50 Circumference 8.25 13.35 19.70 22.38 67.54
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ISCO Fusion Manual
Reference
Hydraulic Fluid Characteristic Chart

The use of proper hydraulic oil is mandatory to achieve maximum performance and machine life. Hydraulic oil should have anti-wear and other special additives. The oil must meet 150 SSU at 100F, with the exception of a cold weather operation. The following table specifies the oil temperature at various viscosities. Temperature rise of the hydraulic oil can vary from 30F to about 70F over the ambient temperature depending on the pressure setting, age of the pump, wind, etc. Mobile DTE 15M multi-grade hydraulic oil is installed at the factory. The advantage of this oil is a wider temperature range, however, this oil should not be used for continuous operation below 20F. For use in extremely cold ambient temperatures, we suggest Mobile DTE 11, which can be used to -16F. This oil should not be used for continuous operation above 100F (oil temperature). Note: This chart is based on pump manufacturer recommendations of 100 to 4000 SSU limits. Note: Temperatures shown are fluid temperatures - Not ambient temperatures.
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ISCO Fusion Manual
Reference
Manufacturer Chevron Fluid Name Chevron 32 AW Chevron 46 AW Chervon 68 AW Phillips Magnus A32 Magnus A46 Magnus A68 Shell Tellus T32 Tellus T46 Tellus T68 Sun Sunvis 2105 Sunvis 832 Sunvis 846 Sunvis 868 Unocal Unax AW 32 Unax AW 46 Unax AW 68 Mobil DTE 11M DTE 13M DTE 15M DTE 24 DTE 25 DTE 26 Exxon Univis N-32 Univis N-46 Univis N-68 SSU 100F 173 238 335 170 225 350 150 215 315 206 164 236 352 150 215 315 87 165 225 162 227 335 177 233 376 SSU 210F 45 49 54 45 48 54 44 48 53 52 44 49 55 44 48 54 40 48 53 44 47 53 49 55 68 V.I. 100 98 99 101 98 98 102 103 89 167 99 98 98 107 107 107 145 140 140 95 95 95 164 163 160
Reference 80
ISCO Fusion Manual
Reference
-20F -10F 0F 10F 30F 50F 70F 90F 110F 130F 150F Range Fahrenheit 15-125 25-142 34-155 15-123 24-136 37-151 -2-124 7-135 20-152 5-140 12-121 23-136 34-152 12-125 20-137 30-152 -27-87 5-130 5-140 23-120 37-137 47-150 5-140 25-142 34-155
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ISCO Fusion Manual
Reference
TracStar Pendant/ Coach Setup
To turn pendant on, turn key to right. To turn pendant off, turn key to off. Navigate using numeric keys, <+> and <-> keys, <=> key, and <c> key. Password as shipped from McElroy, 123. Setup Fusion Parameters When starting a job the screen should read time in upper left hand corner. 1 Setup, 2 Pressure, 3 Menu on left side of screen and Face, Soak, Fuse with pressure in center of screen.
Reference Fusion Equipment Safety Information
Follow instructions on each screen for navigation instructions. Select setup, press 1 on the keyboard. CO92 Parameters Screen Press + use parameters on screen Press - enter new parameters If selected, then screen below will appear. D112 Select Pipe Material List of pipe manufacturers in programmed into Coach, Scroll through list using + or key, make selection and press = key SO3O Heater Temperature Use Pipe manufacturers recommend temperature, type in temperature and press = Heater off set (-10 for T500, -60, for T900) Enter -, enter password, and enter 10 for T500 or 60 for T900 D140 Piston Area Press = to default to 6.010, or enter 4.71 for Pit Bull carriage, 15.32 (Orange Cylinders) or 29.44 (Green Cylinders) for T900 SO14 Pipe Size Select IPS, DIPS, OD, mmOD using + or - to scroll up or down Type in pipe size press = SO18 Pipe Wall Thickness Select DR, WT, mmWT using + or - key to scroll Type in parameter selected, press = D122 Heat (IFP) Type in 0, then press =, or enter pipe manufacturers IFP if required D124 Soak (IFP) Press - to skip D126 Fuse (IFP) Type in pipe manufacturers recommended IFP usually 75 and press = D128 Cool (IFP) Press - to skip C092 Parameter Screen To allow you to review parameters entered, press + if ok or - to change S010 Drag (All pendant/coach units use 70 instead of 30) Press + to default to 70 (machine drag) or shift carriage selector valve to close and raise pressure. Using facer pressure valve, raise pressure until carriage starts to move slowly, shift carriage to neutral, let pressure stabilized press + and then = to set drag pressure NOTE: Drag automatically added to Heat and Fuse pressure
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ISCO Fusion Manual
Reference
TracStar Pendant/Coach DataLogger Operation
DataLogger Operation 1ST Screen press 3 for Menu M001 Main Menu Press 2 for Datalogger mode D001 Datalogger Menu Press 1 to Log Data C090 Identifications + To use data recorded on screen or - to enter new data C100 Machine ID (if - pressed above) Type in machine ID press = C102 Employees No. Type in employee ID press = C104 Job No. Type in Job No. press = C106 Joint No. Type in joint No. press = C090 Indentifications Press + if correct data or - to change C092 Pipe Parameters + to use data or - to enter new data (Refer to Setup Fusion Parameters if - selected) D134 Drag Pressure Refer to Drag Pressure Setup in Setup Fusion Parameters
Fusion Operation
D Screen Press 4 to start Logging - Logging will flash on screen during fusion operation D Screen Press 6 to stop Datalogging - Stop logging before opening carriage or unclamping pipe D150 Datalogging Stopped Press + to view report or - to continue D160 Print Report Press + to print or - to continue D170 Log another joint Press + to Log another joint or - to stop *** If + pressed then refer to C090, C092, and C134 above.
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DataLogger Operation
Datalogger DL3
Connect Pressure Transducer to Fusion Machine with a proper hydraulic quick disconnect. Multifunction Switch 1. Turns on the Datalogger if it is off (both LEDs off). Once turned on, the Datalogger will remain on for 2 minutes is there is no communication activity. Otherwise, the Datalogger will stay on as long as there is communication between it and a Recon, Every time this switch is presses, it adds another 2 minutes to the on time. 2. Takes temperature reading if the Datalogger is on but not in the data log in mode. For as long as this switch is held, the temperature will be displayed on the Recon screen. 3. Stops logging is the Datalogger is in data logging mode. This switch must be held for longer than 3 seconds to turn off logging. Note: The Datalogger turns itself off, therefore, it does not have an OFF switch. LEDs Solid Orange LED on Datalogger indicates it is initializing. Flashing Green LED on the Datalogger indicates it is operating normally. Flashing Red LED on the Datalogger indicates it is logging data. Holding the Datalogger button for 3 seconds stops logging. Flashing Blue LED on the Datalogger indicates Bluetooth radio in standby mode. Solid Blue LED indicates Datalogger is communicating with Recon. Recon Turn on the Recon by pressing the Power button. Turn on the Datalogger by pushing the multifunction switch. Turn off the Recon by pressing the Power button if it is on. Note: it is best to disconnect (or stop communications) between the Recon and Datalogger before turning off the Recon. The Datalogger cannot be turned off, especially while logging data. The Datalogger will automatically turn itself off if it is not logging data and 2 minutes elapsed since the Recon last communicated with it. Reset: To reset a TDS Recon, hold down the Power button for 5 seconds. Date and Time: To set date and time: Tap Start> Settings. Tap the System tab. Tap Clock & Alarms. Select the respective time and date field by tapping on it and adjust the values accordingly. For example to change the hour field, tap on it and then use the up and down arrow keys to adjust the number up or down. [For more details, refer to the Setting Time and Date section in the operators manual to check and set the correct date and time. It is very important to set the correct time and date because joint reports are time stamped using the Recons clock].
Reference
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Reference
DataLogger Operation
Set up to Log Data Tap Start > Programs > McElroy DL3-PCC, then Menu > Log/Status. In the Log/Status dialog box, tap Setupto begin entering information for the next joint. A series of dialog boxes will prompt you to enter the information one step at a time. If SDR or DR is unknown, measure the actual wall thickness and select WT. Enter interfacial pressures and the Recon automatically calculates the corresponding carriage pressures. Drag pressure must be entered for each fusion cycle. See fusion machines operations manual for measuring drag. Enter the measured drag pressure and tab Next. If you tab Next without entering a value, the default drag value of 30 psi will be added by the Datalogger. Set the carriage pressures according to the recommended gauge pressures. Measure the heater temperature by holding the top of the Datalogger about 4 inches from the heater plate and perpendicular to the heater plate, pointing the temperature sensor at the heater plate, Press and hold the Datalogger multifunction switch to turn on the guidance lasers. Adjust the distance between the Datalogger and the heater plate until the two laser beams converge to a single point. Use the Recon screen to read the temperature. Once the temperature is stable, release the Dtaalogger multifunction switch to record the temperature. The temperature box flashes *Log xxxoF to indicate the recorded temperature. Log Data The pipes should be faced off and aligned. Open the carriage and place the heater on the guide rods between the faced pipe ends. Tab the Start button and wait till the stopwatch appears at the bottom of the Recon screen. Close the carriage to bring the pipe ends against the heater and follow the proper shift sequence on the fusion unit and the pipe manufacturers recommendations for fusing pipe. To conserve Recon battery, you may exit the Log/Status dialog box by tapping the X at the top right hang corner and then turn off the Recon. You may turn on the Recon and reconnect to the Datalogger at any time or near the end of the fusion process. At the end of the fusion process, stop logging before opening the carriage or changing pressures. To stop logging, press and hold the Datalogger multifunction switch for over 3 seconds or from the Recon. The recording joint report will transfer to the Recon automatically at the end of each joint when the Recon is connected to the Datalogger. The latest report appears on the screen for review. Recommended Precautions Fully charge the Recon before each use for optimal battery performance. Stop communications and then turn off the Recon whenever monitoring is not necessary. Make copies of the reports on a PC or print our hard copied to prevent data loss. For more complete details of the Datalogger see the operators manual.
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ISCO Fusion Manual
Reference
If your cylinders are green
Machines: McElroy No. 28 and McElroy TracStar No.28 Cylinders: Green (High Force) - 4.71 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 2 3 4 5 6 7 8 Pipe Size 3 4 6 8
7
65 105 154 220 299 341 486
9
58 91 130 183 247 281 398
DR 11 13.5 15.5 17 19 21 26 32.5

53 81 114 158 211 240 338 49 72 99 136 181 204 285 47 67 91 123 163 183 255 46 64 86 116 152 171 236 61 81 107 139 157 216 58 76 100 130 145 199 53 67 60 87 76 111 95 124 106 168 141
IPS
Reference
DIPS
7
126 171 322 532
9
107 144 265 435
11
95 125 227 369
DR 13.5
84 109 193 311
17
73 94 162 257
21
82 138 216
26
73 118 182
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ISCO Fusion Manual
Reference
Machines: McElroy No. 412, McElroy No. 618, McElroy TracStar No.412, McElroy TracStar No. 618 Cylinders: Green (High Force) - 11.78 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 4 6 8 10 12 14 16
7
86 147 231 332 457 603 772
9
76 124 192 273 374 492 628
11
68 109 165 234 318 417 530
DR 13.5
62 95 142 199 269 351 445
17
56 83 121 166 223 289 365
21
51 73 104 142 188 242 305
26
47 65 91 121 159 203 254
DIPS
87
Reference
Pipe Size 4 5 6 7 8 10 12 14 16 18
7
80 106 137 154 212 313 428 510 657 824
9
70 91 117 130 177 258 351 417 536 670
DR 11 13.5 15.5 17 19 21 26 32.5

63 81 103 114 153 221 299 354 453 566 58 72 90 100 132 189 253 299 381 474 54 67 83 91 120 170 226 267 339 421 52 64 79 86 112 158 210 247 313 389 50 61 74 81 104 145 192 225 285 353 48 58 70 76 97 135 177 208 262 324 45 53 62 68 85 115 150 175 219 270 42 48 56 60 74 99 127 147 183 223
IPS
ISCO Fusion Manual
Reference
If your cylinders are orange
Machines: McElroy No. 412, McElroy No. 618, McElroy TracStar No. 412, McElroy TracStar No. 618, McElroy TracStar No. 500 Series II (Manifold Equipped) Cylinders: Orange (Medium Force) - 6.01 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 4 5 6 7 8 10 12 14 16 18 T-500 20
7
127 179 241 274 387 585 810 971 1,259 1,585 1,950
9
108 150 200 227 318 477 659 789 1,021 1,285 1,579
DR 11 13.5 15.5 17 19 21 26 32.5

96 130 172 194 271 404 557 665 859 1,080 1,326 84 113 148 167 230 341 467 557 718 901 1,106 78 103 134 150 206 303 415 494 636 797 976 74 97 125 140 191 281 383 455 586 733 898 70 90 116 129 175 256 348 413 530 663 812 66 85 108 120 162 235 319 378 485 606 741 59 75 94 104 138 198 266 314 401 500 610 54 66 81 89 117 165 220 259 329 409 498
IPS
DIPS
Reference
Pipe DR Size 7 9 11 13.5 141 119 105 92 4 259 214 184 158 6 423 347 295 250 8 507 429 361 10 621 705 595 499 12 866 788 659 14 1,154 936 16 1,483 1,202 1,011 844 T-500 18 1,855 1,502 1,262 1,052
17
80 133 208 297 408 538 687 855
21
71 115 176 249 340 446 568 706
26
63 99 149 209 283 369 469 581
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ISCO Fusion Manual
Reference
Machines: McElroy No. 824, McElroy No. 1236, McElroy TracStar No. 900 (Manifold Equipped) Cylinders: Green (High Force) - 29.44 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 8 10 12 14 16 18 20 21.5 22 24 26 28 30 32 34 36 Pipe Size 8 10 12 14 16 18 20 24 30
7
103 143 189 222 281 348 422 483 504 594
9
89 121 158 185 232 286 346 395 413 485 564 650 741 839
DR 11 13.5 15.5 17 19 21 26 32.5

79 106 138 160 199 244 295 336 350 411 477 549 625 707 795 887 71 93 119 138 171 208 250 284 296 346 401 460 524 592 665 741 66 86 109 125 154 187 223 253 264 308 357 409 465 525 588 656 63 81 102 117 143 174 207 235 244 285 330 377 429 484 542 604 60 76 95 108 132 159 190 214 223 260 300 343 389 439 491 547 57 72 89 101 123 148 175 198 206 239 275 315 357 402 450 500 52 64 78 88 106 126 148 167 173 200 230 262 296 333 372 414 48 58 69 77 91 107 125 140 146 167 191 217 245 274 306 339
IPS
7
110 151 201 259 327 403 487
9
95 127 168 215 269 331 399 556
11
84 111 145 185 230 282 339 470 707
DR 13.5
75 98 126 158 196 239 286 395 592
17
66 85 107 134 164 198 237 325 484
21
60 75 93 115 140 168 199 272 402
26
54 66 82 99 120 143 168 227 333
DIPS
89
Reference
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Reference
If your cylinders are orange
Machines: McElroy No. 824, McElroy No. 1236, McElroy TracStar No. 900 (Manifold Equipped) Cylinders: Orange (Medium Force) - 15.32 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 8 10 12 14 16 18 20 21.5 22 24 26 28 30 32 34 36
7
170 248 336 399 512 640 783 901 941 1,115
9
143 206 277 328 419 522 638 732 765 905 1,057 1,221 1,397 1,585
DR 11 13.5 15.5 17
125 177 237 279 355 442 538 618 645 762 889 1,027 1,174 1,332 1,499 1,677 108 152 201 237 300 372 452 518 541 638 743 857 979 1,110 1,249 1,397 99 137 181 212 268 331 401 459 479 565 657 758 865 981 1,103 1,233 93 128 168 197 248 306 371 424 442 520 606 698 796 902 1,014 1,134
19 21 26 32.5
87 119 155 180 226 278 337 384 401 472 548 631 720 815 916 1,024 82 111 143 167 209 256 309 352 368 432 502 577 658 744 836 934 72 96 122 141 176 214 258 293 305 358 414 476 542 612 688 767 64 83 105 120 147 179 213 242 252 294 340 390 443 500 560 624
IPS
Reference 90
Pipe Size 8 10 12 14 16 18 20 24 30
7
184 262 358 471 600 746 909
9
154 217 295 386 490 608 739 1,041
11
134 187 251 328 415 513 623 876 1,332
DR 13.5
116 160 214 277 349 431 522 732 1,110
17
100 135 178 229 288 354 427 597 902
21
87 116 152 193 241 295 355 494 744
26
77 100 129 163 202 246 295 409 612
DIPS
ISCO Fusion Manual
Reference
Machines: McElroy No. 1648 and McElroy No. 2065 Cylinders: Green (High Force) - 31.42 in2 Piston Area Heater Surface Temperature: 425F Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.
Pipe Size 16 18 20 21.5 22 24 26 28 30 32 34 36 40 42 48 51.5 54 63 Pipe Size 16 18 20 24 30 36 42 48
7
265 328 397 454 474 559
9
220 270 326 372 388 457 531 611 697 788
DR 11 13.5 15.5 17 19
189 231 278 316 330 387 449 516 588 665 746 833 162 197 236 268 279 326 378 433 493 557 625 697 827 937 146 177 211 239 249 291 336 385 437 493 553 617 732 828 136 165 196 222 231 269 311 355 404 455 510 568 674 762 987 126 151 180 203 211 245 283 323 367 413 462 515 610 690 891 1,022
21
117 140 166 187 195 226 260 297 336 378 423 471 557 630 814 932 1,022 1,380
26 32.5
101 120 141 158 164 190 217 247 280 314 351 389 460 519 669 766 839 1,131 87 102 119 133 138 159 181 205 231 259 289 320 377 425 545 623 682 918
IPS
7
308 379 458
9
254 312 376 523
11
218 266 319 443 665 939
DR 13.5
186 226 270 372 557 784 1,049
17
156 188 224 306 493 639 852 1,101
21
133 159 189 256 455 529 703 908
26
114 135 159 215 413 437 579 746
DIPS
91
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Reference
Temperature Conversions
Fahrenheit
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Celsius
-18 -12 -7 -1 4 10 16 21 27 32 38 43 49 54 60 65 71 77 82 88 93 99 104 110 115 121
Fahrenheit
260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510
Celsius
127 132 138 143 149 154 160 165 171 176 182 188 193 199 204 210 215 221 226 232 238 243 249 254 260 265
Reference 92
Conversion Formulas
Inches Millimeters Feet Millimeters SQ. Inches SQ. Millimeters Ounces(fluid) US Quarts Liters Gallons Liters Pounds Kilograms Bar mPa 2 Kg/cm X X X X X X X X X X X X X X X X 25.40 0.03937 304.8 .003280839 645.16 .00155 0.02957 0.9463 1.057 3.785 0.2642 0.4536 2.205 14.503 145.03 14.223 = = = = = = = = = = = = = = = = Millimeters Inches Millimeters Feet SQ. Millimeters SQ. Inches Liters Liters Quarts Liters Gallons(fluid) US Kilograms Pounds Psi Psi Psi
ISCO Fusion Manual
Reference
References
1. Plastics Pipe Institute Technical Report-33. Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe, 2001 2. Plastics Pipe Institute Technical Report-41. Generic Saddle Fusion Joining Procedure for Polyethylene Gas Pipe, 2002 3. Plastics Pipe Institute. Polyethylene Joining Procedures, March 1998. 4. ASTM D2657-97. Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings. Volume 8.04. American Society of Testing and Materials. Baltimore, 2002. 5. ASTM F1056-97. Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene Pipe or Tubing and Fittings. Volume 8.04. American Society of Testing and Materials. Baltimore, 2002. 6. Pipeline Safety Regulations. U.S. Department of Transportation. CFR 49. Washington, 2002.
93
Reference
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Notes
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ISCO Fusion Manual
Notes
95
McElroy Manufacturing, Inc. Plastic Pipe Institute
Acknowledgements
Brand Names and product names are trademarks of their respective owners.
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