McElroy DynaMc 28, DynaMc 412, DynaMc 250 Operator's Manual

Operator’s

Manual

28, 250, 412 and
28 Sidewall Electric

Pump (EP) Fusion
Machines

Manual: 1272601 Revision: C 10/15

Original Language: English

Introduction

Thank you for purchasing this
McElroy product

The McElroy DynaMc® Electric Pump (EP) fusion
machines are hydraulically operated fusion machines
designed to fuse thermoplastic pipe.

When fusing thermoplastic pipe materials, refer to the
pipe manufacturer's fusion procedures or appropriate
joining standard.

The 28 model fuses 2" IPS (63mm) through 8" DIPS
(225mm) maximum pipe.

The 250 model fuses 63mm (2" IPS) minimum to 250mm
(8" DIPS) maximum pipe.

The 412 model fuses 4” IPS (110mm) minimum to 12"
DIPS (340mm) maximum pipe.

The 28 Sidewall fuses branch saddles up to 8" DIPS
outlet with up to 9 5/8" diameter base on any size
main.

TX04044-04 -08-14

All models utilizes the Electric Pump (EP) Hydraulic Power
Unit (HPU) to provide hydraulic power to the machines.

With reasonable care and maintenance, this machine
will give years of satisfactory service.

Before operating this machine, please read this manual
thoroughly, and keep a copy with the machine for future
reference. This manual is to be considered part of your
machine.

McElroy University

For more than 30 years, McElroy has been the only
pipe fusion machine manufacturer to continuously
offer advanced training. Course offerings are meant to
enhance your efficiency, productivity and safety in the
proper use of McElroy machines. McElroy University
classes are structured so that the skills learned and the
machines used in each class closely match the machines
found on pipelining jobsites. We offer training at
our facility or yours. Our uniquely qualified McElroy
University course instructors offer years of industry
experience.

Tuition for each course includes lunches, course materials
and a certificate of completion. Online registration,
as well as up-to-date course offerings and dates, is
available at www.mcelroy.com/university

This manual is intended as a guide only and does not
take the place of proper training by qualified instructors.
The information in this manual is not all inclusive and
can not encompass all possible situations that can be
encountered during various operations.

MU2-03-13-14

TX04659-03-24-14

Warranty

LIMITED WARRANTY

McElroy Manufacturing, Inc. (McElroy) warrants all
products manufactured, sold and repaired by it to be
free from defects in materials and workmanship, its
obligation under this warranty being limited to repairing
or replacing at its factory and new products, within 5
years after shipment, with the exception of purchased
items (such as electronic devices, pumps, switches, etc.),
in which case that manufacturer’s warranty applies.
Warranty applies when returned freight is prepaid and
which, upon examination, shall disclose to have been
defective. This warranty does not apply to any product
or component which has been repaired or altered by
anyone other than McElroy or has become damaged
due to misuse, negligence or casualty, or has not been
operated or maintained according to McElroy’s printed
instructions and warnings. This warranty is expressly in
lieu of all other warranties expressed or implied. The
remedies of the Buyer are the exclusive and sole remedies
available and Buyer shall not be entitled to receive any
incidental or consequential damages. Buyer waives
the benefit of any rule that disclaimer of warranty shall
be construed against McElroy and agrees that such
disclaimers herein shall be construed liberally in favor of
McElroy.

RETURN OF GOODS

Buyer agrees not to return goods for any reason except
upon the written consent of McElroy obtained in advance
of such return, which consent, if given, shall specify the
terms and conditions and charges upon which any such
return may be made. Materials returned to McElroy, for
warranty work, repair, etc., must have a Return Material
Authorization (RMA) number, and be so noted on the
package at time of shipment. For assistance, inquiry shall
be directed to:

McElroy Manufacturing, Inc.
P.O. Box 580550
833 North Fulton Street Tulsa, Oklahoma 74158-0550

PHONE: [phone], FAX: [phone].
EMAIL: [e-mail]

Note: Certain repairs, warranty work, and inquiries may
be directed, at McElroy’s discretion, to an authorized
service center or distributor.

DISCLAIMER OF LIABILITY

McElroy accepts no responsibility of liability for fusion
joints. Operation and maintenance of the product is the
responsibility of others. We recommend qualified joining
procedures be followed when using McElroy fusion
equipment.

McElroy makes no other warranty of any kind whatever,
express or implied; and all implied warranties of
merchantability and fitness for a particular purpose which
exceed the aforestated obligation are hereby disclaimed
by McElroy.

PRODUCT IMPROVEMENT

McElroy reserves the right to make any changes in or
improvements on its products without incurring any
liability or obligation to update or change previously sold
machines and/or the accessories thereto.

INFORMATION DISCLOSED

No information of knowledge heretofore or hereafter
disclosed to McElroy in the performance of or in
connection with the terms hereof, shall be deemed to be
confidential or proprietary, unless otherwise expressly
agreed to in writing by McElroy and any such information
or knowledge shall be free from restrictions, other than a
claim for patent infringement, is part of the consideration
hereof.

PROPRIETARY RIGHTS

All proprietary rights pertaining to the equipment or
the components of the equipment to be delivered by
McElroy hereunder, and all patent rights therein, arising
prior to, or in the course of, or as a result of the design
or fabrication of the said product, are exclusively the
property of McElroy.

LAW APPLICABLE

All sales shall be governed by the Uniform Commercial
Code of Oklahoma, U.S.A.

Register your product online to activate your
warranty:www.McElroy.com/fusion

(Copy information listed on the machine nameplate here
for your records).

TX02486-11-4-13

Model No.

Serial No.

Date Received

Distributor

Equipment Safety

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Read and Understand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Heater is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electric Motors are Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . 1-2

Units with Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Crush Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Facer Blades are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Heater is Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Heavy Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Fusion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Overview

Theory of Heat Fusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Introduction to the Electric Pump (EP) Fusion Machines . . . . . . . . . . . . . 2-2

Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

DynaMc® EP Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Insulated Heater Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Stripper Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Carriage Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Clamp Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Table of Contents

All product names or trademarks are property of their respective owners. All information,

illustrations and specifications in this manual are based on the latest information available

at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT © 2015, 2014, 2010

McELROY MANUFACTURING, INC.

Tulsa, Oklahoma, USA

All rights reserved

Butt Fusion Procedure

Read Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Check Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Connecting to Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Pipe Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Install Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Facer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Jaw Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Loading Pipe Into Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Clamp the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Begin Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

After Facing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Determine Drag Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Calculate Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Check for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Check Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Position Carriage for Heater Insertion . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Check Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Select the Fusion Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Heating the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Fusing the Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Opening Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Position Pipe for Next Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Install Next Piece of Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Table of Contents

Special Operations - In Ditch

Remove Carriage from Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Lower the Carriage into Ditch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removing Top Jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Clamp Carriage Assembly to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Make Fusion Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Remove Carriage Assembly from Ditch . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Attach Carriage to Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Special Operations - Saddle Fusion Procedures

Saddle Fusion Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Install Heater Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Assure Saddle Will Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Install Clamping Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Attach Carriage Assembly to Main . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Hydraulic Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Set Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clean Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Clamp Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Test for Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Prepare Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table of Contents

Special Operations - Saddle Fusion Procedures (Continued)

Inserting Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Heat Pipe and Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Remove Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Fuse Fitting to Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Allow Joint to Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Special Operations - Lifting Fusion Machine

Lifting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Manual Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Powered Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Maintenance

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Check Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Change Hydraulic Fluid and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Accumulator Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Check Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Jaws and Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Clean Eyebolt Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Clean the Clamping Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Fasteners Must Be Tight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Facer Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Clean Heater Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Bleeding Air From Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Installing Butt Fusion Heater Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Adjusting Heater Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Heater Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Machine Maintenance Checklist

Fusion Machine Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Determining Fusion Pressure

Determining Fusion Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Determining Fusion Pressure - Sidewall . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Hydraulic Fluid

Hydraulic Fluid Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Specifications

Fusion Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Generator Sizing Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

TX04046-04-15-15

Fusion Equipment Safety

Safety Alerts

This hazard alert sign appears in this manual.
When you see this sign, carefully read what it says.
YOUR SAFETY IS AT STAKE.

You will see the hazard alert sign with these words:
DANGER, WARNING, and CAUTION.

Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.

Indicates a hazardous situation which,
if not avoided, may result in minor or
moderate injury.

In this manual you should look for two other words:
NOTICE and IMPORTANT.

NOTICE: can keep you from doing something that might
damage the machine or someone's property. It may also
be used to alert against unsafe practices.

IMPORTANT: can help you do a better job or make
your job easier in some way.

WR00051-11-30-92

TX00030-12-1-92

Read and Understand

Do not operate this equipment until you have carefully read, and
understand all the sections of this manual, and all other equipment
manuals that will be used with it.

Your safety and the safety of others depends upon care and
judgment in the operation of this equipment.

Follow all applicable federal, state, local, and industry specific
regulations.

McElroy Manufacturing, Inc. cannot anticipate every possible
circumstance that might involve a potential hazard. The warnings
in this manual and on the machine are therefore not all inclusive.
You must satisfy yourself that a procedure, tool, work method, or
operating technique is safe for you and others. You should also
ensure that the machine will not be damaged or made unsafe by
the method of operation or maintenance you choose.

WR00052-12-1-92

TX02946-4-15-09

1 - 1

Fusion Equipment Safety

General Safety

Safety is important. Report anything unusual that you notice during
set up or operation.

LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusual
sounds.

SMELL odors like burning insulation, hot metal, burning rubber, hot
oil, or natural gas.

FEEL any changes in the way the equipment operates.
SEE problems with wiring and cables, hydraulic connections, or other

equipment.
REPORT anything you see, feel, smell, or hear that is different from

what you expect, or that you think may be unsafe.

TX00114-4-22-93

Wear Safety Equipment

Wear a hard hat, safety shoes, safety glasses, and other
applicable personal protective equipment.

Remove jewelry and rings, and do not wear loose-fitting clothing
or long hair that could catch on controls or moving machinery.

SAFE1ST-12-22-92

WR00053-12-2-92

TX00032-4-7-93

Heater Is Not Explosion Proof

This heater is not explosion proof. Operation of heater
in an explosive atmosphere without necessary safety
precautions will result in serious injury or death.

When operating in an explosive atmosphere, the heater should be brought
up to temperature in a safe environment, then unplugged before entering
the explosive atmosphere for fusion.

TX04467-03-24-14

Electric Motors are Not Explosion Proof

Electric motors are not explosion proof. Operation of
these components in an explosive atmosphere without
necessary safety precautions will result in serious injury
or death.

See Section "Facer" in the Overview section for instructions on
removing brushes from the facer motor.

WR00034-11-30-92

WR00080-4-12-93

TX02979-04-02-14

1 - 2

Fusion Equipment Safety

Units With Hydraulics

For hydraulically operated equipment, it is important to remember
that a sudden hydraulic oil leak can cause serious injury, or even
be fatal if the pressure is high enough.

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 oil into eyes.

WR00078-4-8-93

TX03077-2-16-10

Electrical Safety

Always ensure power cords are properly
grounded. It is important to remember that you

are working in a wet environment with electrical
devices. Proper ground connections help to
minimize the chances of an electric shock.

Frequently inspect electrical cords and unit for damage. Have
damaged components replaced and service performed by a
qualified electrician.

Do not carry electrical devices by the cord.
NOTICE: Disconnect the machine from the power source before

attempting any maintenance or adjustment.

WR00055-4-7-93

WR00025-11-30-92

TX 02947- 4-15-09

1 - 3

Fusion Equipment Safety

Crush Points

Hydraulically operated jaws are operated under
pressure. Anything caught in the jaws will be
crushed. Keep all body parts out of the jaw area.
Always check pipe alignment with a pencil or
similar object.

TX03091-4-7-10

Facer Blades Are Sharp

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 when handling the
unit.

NOTICE: Disconnect power from the facer, and remove the facer
blades before attempting any maintenance or adjustment.

NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.

TX02378-1-24-05

WR00012-12-4-92

WR00073-4-6-93

Heater is Hot

The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater stand or
blanket when not in use, and use care when
heating the pipe.

NOTICE: Use only a clean nonsynthetic cloth to clean the heater
plates.

TX04244-10-12-10

Heavy Lifting

Components of the DynaMc® EP fusion machines
may be heavy. Using one person to lift may
result in injury. Two people are required to lift
components.

TX04694-04-07-14

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Fusion Equipment Safety

Fusion Procedures

Obtain a copy of the pipe manufacturer's procedures or
appropriate joining standard for the pipe being fused. Follow the
procedure carefully, and adhere to all specified parameters.

NOTICE: Failure to follow pipe manufacturer's procedure

could result in a bad joint. Always follow pipe
manufacturer's procedures.

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Overview

Theory of Heat Fusion

The principle of heat fusion is to heat two surfaces to a
designated temperature, and then fuse them together by
application of force. This pressure causes flow of the melted
materials, which causes mixing and thus fusion. When the
thermoplastic 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
thermoplastic part mix. As the joint cools, the molecules return to
their crystalline form, the original interfaces are gone, and the
fitting and pipe have become one homogeneous unit. A strong,
fully leak tight connection is the result.

The principal operations include:
Clamping The pipe pieces held axially to allow all subsequent

operations to take place.

Facing The pipe ends must be faced to establish clean,

parallel mating surfaces perpendicular to the
centerline of the pipes.

Aligning The pipe ends must be aligned with each other to

minimize mismatch or high-low of the pipe walls.

Heating A melt pattern that penetrates into the pipe must be

formed around both pipe ends.

Joining The melt patterns must be joined with a specified

force. The force must be constant around the interface
area.

Holding The molten joint must be held immobile with a

specified force until adequately cooled.

Inspecting Visually examine the entire circumference of the joint

for compliance with standards established by your
company, customer, industry, federal, state, or local
regulations.

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Overview

Introduction to the Electric Pump (EP) Fusion
Machines

The McElroy DynaMc® Electric Pump (EP) fusion machines
are hydraulically operated fusion machines designed to fuse
thermoplastic pipe.

When fusing thermoplastic pipe materials, refer to the pipe
manufacturer's fusion procedures or appropriate joining standard.

The 28 model fuses 2" IPS (63mm) through 8" DIPS (225mm)
maximum pipe.

The 412 model fuses 4” IPS (110mm) minimum to 12" DIPS
(340mm) maximum pipe.

The 250 model fuses 63mm (2" IPS) minimum to 250mm (8" DIPS)
maximum pipe.

The 28 Sidewall fuses branch saddles up to 8" DIPS outlet with up to 9 5/8" diameter base on any size main.
All models utilizes the Electric Pump (EP) Hydraulic Power Unit (HPU) to provide hydraulic power to the machines.

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Carriage Assembly

The DynaMc EP carriage assemblies are available in a 4-Jaw,
2-Jaw and sidewall models and are operated by the DynaMc EP
Hydraulic Power Unit (HPU).

The 4-Jaw EP carriage assembly consists of two fixed jaws and
two hydraulically operated movable jaws bolted to a skid.

For fittings, the inner fixed jaw can be connected to the movable
jaws on the carriage for a 3 movable 1 fixed jaw configuration.

The 2-Jaw EP carriage assembly consists of one fixed jaw and one
hydraulically operated movable jaw bolted to a skid.

The 28 Sidewall EP machine can also be used with the EP HPU.
The 28 Sidewall Ep has one movable jaw and a tailstock that

attaches to the main. The carriage attaches to the main by the use
of chain clamps.

CD00829-4-7-10CD00830-4-7-10CD00828-4-7-10

All EP carriage assemblies use an EP HPU to pressure the
hydraulic cylinders to move the jaws.

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Overview

DynaMc EP Hydraulic Power Unit (HPU)

The DynaMc EP HPU consists of three main hydraulic components:

1. Power pack - Consists of a capacitor start electric motor and
gear pump that are submerged in the fluid reservoir to aid in
cooling and reduce noise.

2. Hydraulic accumulator - Allows the power pack to cycle
on and off to meet the demands of the hydraulic system, which
reduces noise and power consumption.

3. Carriage manifold assembly - Standard McElroy design for
familiar operation and common service parts with other McElroy
equipment.

There are two pressure gauges on the HPU. The pressure gauge
above the carriage directional valve displays fusion pressure. The
pressure gauge on the rear left side of the HPU displays main
system pressure, which will fluctuate between approximately 1600
psi - 2900 psi as the power pack cycles on and off.

The main power switch for the HPU is located on the front side of
the electrical box. Next to the power switch is a digital volt meter
that displays incoming voltage to the HPU. On the bottom side of
the electrical box is a motor circuit breaker.

Electric motors are not explosion proof. Operation
of these components in an explosive atmosphere
will result in serious injury or death.

Power Pack Manifold Block

The DynaMc EP HPU's power pack has three factory preset valve
adjustments:

1. Valve "N" is adjusted completely in (clockwise).

2. Valve "DR" is adjusted completely out (counter-clockwise).

3. The non-labeled valve is the main system pressure relief valve that

protects against over-pressurization.

NOTICE: These valves are properly set at McElroy and should never be
re-adjusted.

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2

Hydraulic Fluid Reservoir

The reservoir is incorporated in the HPU. The fluid level is read
from a dipstick and has a notch to indicate the proper fluid level.

Never allow dirt or other foreign matter to enter the open tank.
Refer to the "Hydraulic Fluids" section of this manual for hydraulic

fluid recommendations.

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Overview

Filter

This machine is equipped with a 10 Micron filter on the return
line.

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Hydraulic Manifold Block

Mounted on this block are a carriage directional control valve, a
pressure reducing selector valve, three pressure reducing valves,
and a 1500 psi gauge.

A) The carriage control valve, mounted on the top of the

manifold, determines whether the carriage is moving left, right,

or is in neutral.
B) A 1500 psi gauge is mounted on top of the manifold.
C) The selector valve, mounted on the front of the manifold,

selects a reduced pressure from one of the pressure reducing

valves.
Each pressure reducing valve is labeled with a different function:
D) The top valve adjusts facing pressure to a maximum of 400

psi.
E) The middle valve adjusts heating pressure to a maximum of

400 psi.

F) The bottom valve adjusts fusion pressure to a maximum of

1500 psi.

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Hydraulic Cylinders

The hydraulic cylinders provide the fusion force which is
dependent on the area of the cylinders.

Consult the "Maintenance" section of this manual for the
procedure to follow when bleeding air from system.

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Overview

Facer

The facer is of the McElroy rotating planer-block design. The blade
holders each contain multiple cutter blades. The block rotates on
ball bearings and is chain driven (enclosed in lubricant) by an
electric motor. The facer has a release mechanism for quick and
easy removal from the machine. The facer can be inserted from
either side of the carriage.

NOTICE: Never extend the blade beyond the inner or outer
circumference of the facer.

Electric motors are not explosion proof. Operation
of these components in an explosive atmosphere will
result in serious injury or death.

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Remove brushes on the Milwaukee facer motor:

The armature brushes must be removed from the electric motor when
manually operating in explosive atmospheres. Unscrew the brushes
from both sides of the motor. (Both brushes must be removed).
A 1-1/8" hex shaft allows for manual operation in explosive
atmospheres.

Remove brushes on the Eibenstock facer motor:

The armature brushes must be removed from the electric motor
when manually operating in an explosive atmosphere.

Remove the rear cover of the motor.
Slide the spring clip away from the brush and pull the brush out

(A).
Loosen the brush ground wire (B) and pull the wire loose.
Repeat these steps on the wire on the opposite side.
Store the brushes in a safe location until needed.
A 1-1/8" hex shaft allows for manual operation in an

explosive atmosphere.

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The facer has a handle that latches into place on a guide rod. The
handle must be pulled out to unlatch and remove facer.

The electric facer is symmetrical and can be inserted from either side.
The facer should be stored in the stand when not in use.
NOTICE: Never extend the blade beyond the inner or outer circumference

of the facer.

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B

A

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Overview

Heater

Heater is not explosion proof. Operation of heater
in an explosive atmosphere without necessary safety
precautions will result in serious injury or death.

If operating in an explosive atmosphere, heater should be brought up to
temperature in a safe environment, then unplugged before entering the
explosive atmosphere for fusion.

The heater has a green indicator light which will flash on and off. This
indicates that the controller is operating normally. If the green indicator
is not flashing then the controller may not be operating properly. If this
occurs, disconnect power and have the heater repaired by a McElroy
Authorized Service Center.

The heater temperature is controlled by a microprocessor. It has a red
indicator light on the handle at the bottom of the temperature scale.
When the heater is plugged in and preheating the light glows steadily
until the set temperature is reached. The light then goes off and on slowly
as the heater maintains temperature.

The heater body is not coated. Coated butt fusion heater plates are
available for all butt fusion applications.

NOTICE: The heater should never be used without butt fusion heater plates
installed.

To prevent a build-up of plastic pipe residue from accumulating on the
heater plates (loss of surface temperature and pipe sticking may result),
the heater plates should be cleaned with a nonsynthetic cloth before every
fusion joint.

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Insulated Heater Stand

The heater should always be stored in the insulated heater stand
for protection of the operator and to minimize heat loss and risk of
mechanical damage.

The heater is hot and will burn clothing and skin.
Keep the heater in its insulated heater stand or
blanket when not in use, and use care when
heating the pipe.

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