ISCO Fusion Manual Table of Contents - ISCO …

1 Table of ContentsThis Manual contains accurate and reliable information tothe best of our knowledge as of the publication date. Theresults of using our suggestions and recommendations can-not be guaranteed because the conditions of use arebeyond our control. Failure to follow these procedures inthis Manual may result in damage to or destruction ofproperty and/or serious injury to or death of a person. Theuser of such information assumes all risk connected withthe use thereof. isco Industries, LLC assumes no respon-sibility for the use of information presented herein andhereby disclaims all liability in regard to such Fusion Manual3 Fusion Equipment Safety Information .. Page 4 Tips For Success .. Page 15 Manual Butt Fusion Machine Procedure .. Page 18 Hydraulic Butt Fusion Machine Procedure .. Page 31 Saddle Fusion Machine Procedure .. Page 48 Socket Tooling and Fusion Procedure .. Page 60 Reference Information: McElroy s DataLogger , Pendant/Coach Equipment & Fusion Pressure Charts.

2 Page 69 Copyright 2007 isco Industries, LLC All rights Copyright 2007 isco Industries, LLC All rights EquipmentSafety InformationPlease read theSafety was I suppose toknow?Safety AlertsThis hazard alert sign appears in this you see this sign, carefully read what it SAFETY IS AT will see the hazard alert sign with these words:DANGER, WARNING, and this Manual you should look for two other words:NOTICE and :: Can keep you from doing something that mightdamage the machine or someone s property. It may also be used to alert against unsafe :: Can help you do a better job or make your job easier in some way.! isco Fusion Manual5 Copyright 2007 isco Industries, LLC All rights reserved.!!DANGER!WARNING! CAUTION!DANGERWARNING!CAUTION!Indicates a hazardous situation which,if not avoided, may result in minor ormoderate a potentially hazardoussituation which, if not avoided, couldresult in death or serious an imminently hazardoussituation which, if not avoided, willresult in death or serious And UnderstandDo not operate Fusion equipment until youhave carefully read, and understand the Safety and Operation sections of thismanual, and all other equipment manualsthat will be used with safety and the safety of others dependsupon care and judgement in the operationof this all applicable federal, state, local,and industry specific Equipment Safety InformationISCO Fusion Manual6 Copyright 2007 isco Industries, LLC All rights Industries, LLC cannot anticipate every possible circumstance that may involve a potential hazard.

3 The warnings in this manualand on the machine are therefore not all inclusive. You must satisfy yourself that a procedure, tool,work method, or operating technique is safe foryou and others. You should also ensure that the machine will not be damaged or made unsafe by the method of operation or maintenance you SafetySafety is important. Report anything unusual that you notice during set up or thumps, bumps, rattles, squeals, airleaks, or unusual like burning insulation, hot metal,burning rubber, hot oil, or natural changes in the way the equipment with wiring and cables, hydraulicconnections, or other you see, feel, smell, or hear that is different from what youexpect, or that you think may be Safety EquipmentWear a hard hat, safety shoes, safety glasses,and other applicable personal jewelry and rings, and do not wearloose-fitting clothing or long hair that couldcatch on controls or moving Equipment Safety InformationISCO Fusion Manual7 Copyright 2007 isco Industries, LLC All rights Equipment Safety InformationUnits With HydraulicsAlthough the hydraulic pressures in the machine are low compared to somehydraulically operated equipment.

4 It is important to remember that a sudden hydraulic leak can cause serious injury or even be fatal if the pressure is high fluid under pressurecan penetrate the skin causing serious injury. Keep handsand 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 :: Wear safety glasses, and keep face clear of area when bleeding air fromhydraulic system to avoid spraying into !Heaters Are Not Explosion ProofHeaters are not explosion of a heater in a hazardous envi-ronment without necessary safety precau-tions will result in explosion and operating in a hazardous environment,heater should be brought up to temperaturein a safe environment, then unpluggedbefore entering the hazardous atmospherefor Fusion .!DANGERISCO Fusion Manual8 Copyright 2007 isco Industries, LLC All rights Equipment Safety InformationElectric Motors Are Not Explosion ProofElectric Motors are not explo-sion proof.

5 Operation of these componentsin a hazardous environment without neces-sary safety precautions will result in explo-sion or death. When operating in a haz-ardous environment, keep pump motorand chassis in a safe area by usinghydraulic extension SafetyAlways ensure power cords are properly grounded. It is important to remember that whenyou are working in a wet environment withelectrical devices, proper ground connectionshelp to minimize the chances of an electric inspect electrical cords and unit for damage. Damaged components need to replacedand service performed by a qualified not carry electrical devices by the :: Always connect units to the proper power sourceas listed on the unit, or in the owner s Manual . Onunits with two power cords, plug each cord intoseparate power circuits. Do not plug into both out-lets of one duplex :: Disconnect the machine from the power sourcebefore attempting any maintenance or adjustment.

6 !DANGERWARNING! isco Fusion Manual9 Copyright 2007 isco Industries, LLC All rights Equipment Safety InformationCrush PointsHydraulically operated jaws areoperated under pressure. Anything caught in thejaws will be crushed. Keep fingers, feet, arms,legs, and head out of the jaw area. Always checkpipe alignment with a pencil or similar Blades Are SharpFacer blades are sharp and can attempt to remove shavings while the faceris running, or is in the facing position between thejaws. Use care when operating the facer, and han-dling the : Disconnect power from the facer, and remove thefacer blades before attempting any maintenance or Is HotThe heater is hot and will burn clothingand skin. Keep the heater in its insulated heaterstand or sling blanket when not in use, and use carewhen heating the :Use only a clean non-synthetic cloth such as a cottoncloth to clean the heater ProceduresFollow the procedures carefully, andadhere to all specified to follow procedures could result in a bad weld.

7 Always follow the proper Fusion !WARNING!CAUTION!CAUTION! isco Fusion Manual10 Copyright 2007 isco Industries, LLC All rights Equipment Safety InformationUnits With Gas EnginesHandle fuel with care. Fuel ishighly flammable. Do not refuel the machinewhile smoking or near open flames or sparks. Always stop the engine before refueling machine. Fill fuel tank prevent fires by keeping machine cleanof accumulated trash, grease, debris, and facer shavings. Always clean up spilled exhaust gases can causesickness or death. Always operate machine out-doors in an area with adequate With BatteriesSulfuric acid in battery electrolyte ispoisonous. It is strong enough to burn skin, eatholes in clothing, and cause blindness if splashedinto eyes. Avoid contact with eyes, skin, andclothing. Exploding gases from battery couldcause blindness or serious injury. Keep sparks,flames, and cigarettes Tires Properly ServicedFailure to follow proper procedureswhen mounting a tire on a wheel or rim can pro-duce an explosion which may result in seriousinjury or death.

8 Have tires mounted by someonethat is experienced, and has the equipment toperform the job !CAUTION!WARNING!WARNING! isco Fusion Manual11 Copyright 2007 isco Industries, LLC All rights Equipment Safety InformationPeriodically Check TemperatureNNOOTTIICCEE::Incorrect heating temperature can resultin bad Fusion joints. Check heater plate surface temperature periodically with a pyrometer, and makenecessary adjustments. The thermometer on heatersindicates internal temperature, and should be used as areference Not Tow Fusion Machine At SpeedsGreater Than 8 KM (5 MPH)The chassis is not designed forover-road towing. Towing at speeds greaterthan five miles per hour can result inmachine damage as well as injury. Alwaystransport the machine by flat bed truck orsimilar means, and make sure that unit isproperly Fusion MachinePlace Fusion machine on as level ground as possible, and set the brake on the rear it is necessary to operate machine on unlevelgrade, chock the wheels and block the unit to makeit as stable as Machine Away From Edge Of DitchHeavy equipment too close to a ditch can cause the walls of the ditch to cave-in.

9 Keep the machine far enough away from the edge of the ditch to prevent injury to personneland equipment from a !WARNING! isco Fusion Manual12 Fusion Equipment Safety InformationDo Not Attempt to Tow A TracStar Fusion MachineThe machine is not designed fortowing. Attempting to tow the machine canresult in machine damage. Always transport the machine by flat bed truck or similar means,and make sure that unit is properly TracStar Fusion MachinesPlace Fusion machine on as level groundas 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 operation safety, never operatemachine on a grade steeper than 30%. A 1 M(3 ) elevation change in 3 M(10 ).Positioning Fusion MachinePlace Fusion machine on as levelground as possible. If it is neces-sary to operate machine on unlevel grade, chock the tracksand block the unit to make it asstable as !

10 CAUTION!Hearing Protection Required For TracStar412 and TracStar operating machine for more than four hours per day, wear hearing M (10 )1M (3 )01 0 02 0 03 0 04 0 05 0 06 0 070 08 0 09 0 01 0 0 0D IR E C T IO N A LC O N T R O LVA LV EFA C I N GPR E S S U R EHE A T I N GPR E S S U R EFU S I N GP R E S S U R ESE L E C T O RV A L V E Copyright 2007 isco Industries, LLC All rights Fusion Manual13 Fusion Equipment Safety InformationSafety Precautions For Guarding Against Static Electricity And GaseousIgnitionPolyethylene plastic pipe doesnot readily conduct electricity. A staticelectricity charge can buildup on insideand outside surfaces and stay on the pipesurface until some grounding device, suchas a tool or a person comes close enoughfor the static electricity to discharge to thegrounding one part of the pipe surface will not affect othercharged areas because static electricity does not flow readily from one area toanother.