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ISCO Fusion Manual

ISCO Fusion Manual

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Published by Joel Cristobal
HDPE Fusion Manual
HDPE Fusion Manual

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Published by: Joel Cristobal on Dec 21, 2012
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Sections

  • Manual Butt Fusion Machine Procedure
  • Hydraulic Butt Fusion Machine Procedure
  • Saddle Fusion Machine Procedure
  • Socket Tooling and Fusion Procedure

For HDPE, contractors know.

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

Connecting the Resources You Need

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 Institute’s 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. We’re 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 manufacturer’s fusion equipment manuals. Always read and understand the original manufacturer’s 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 operator’s 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 world’s 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: McElroy’s 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.

3

4790 © Copyright 2012 ISCO Industries. 4 Fusion Hotline 1-800-345-ISCO ext.Fusion Equipment Safety Information How was I suppose to know? Please read the Safety Section first. . LLC All rights reserved.

4790 © Copyright 2012 ISCO Industries. will result in death or serious injury.ISCO Fusion Manual Fusion Equipment Safety Information This hazard alert sign ! appears in this manual. YOUR SAFETY IS AT STAKE. 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. Follow all applicable federal. DANGER Indicates an imminently hazardous situation which. Safety Alerts ! ! ! ! ! DANGER WARNING CAUTION Indicates a potentially hazardous ! WARNING ! CAUTION Indicates a hazardous situation which. WARNING. It may also be used to alert against unsafe practices. if not avoided. may result in minor or moderate injury. In this manual you should look for two other words: NOTICE and IMPORTANT. LLC All rights reserved. if not avoided. Your safety and the safety of others depends upon care and judgement in the operation of this equipment. carefully read what it says. You will see the hazard alert sign with these words: DANGER. if not avoided. When you see this sign. state. and industry specific regulations. 5 . local. and CAUTION. Fusion Hotline 1-800-345-ISCO ext. NOTICE: Can keep you from doing something that might damage the machine or someone’s property. situation which. could result in death or serious injury. and understand the “Safety” and “Operation” sections of this manual. and all other equipment manuals that will be used with it.

or other equipment. 6 Fusion Hotline 1-800-345-ISCO ext. and other applicable personal protection equipment. or natural gas. squeals. rattles. hot metal. safety shoes.ISCO Fusion Manual Fusion Equipment Safety Information ISCO Industries. General Safety Safety is important. 4790 © Copyright 2012 ISCO Industries. and do not wear loose-fitting clothing or long hair that could catch on controls or moving machinery. Listen for thumps. The warnings in this manual and on the machine are therefore not all inclusive. LLC All rights reserved. feel. LLC cannot anticipate every possible circumstance that may involve a potential hazard. Smell odors like burning insulation. Remove jewelry and rings. safety glasses. air leaks. Report anything unusual that you notice during set up or operation. You should also ensure that the machine will not be damaged or made unsafe by the method of operation or maintenance you choose. Sense any changes in the way the equipment operates. burning rubber. See problems with wiring and cables. hot oil. work method. hydraulic connections. or hear that is different from what you expect. smell. tool. . Report anything you see. Wear Safety Equipment Wear a hard hat. or that you think may be unsafe. You must satisfy yourself that a procedure. bumps. or unusual sounds. or operating technique is safe for you and others.

Fusion Hotline 1-800-345-ISCO ext. it must be immediately removed by a doctor familiar with this type of injury.ISCO Fusion Manual Fusion Equipment Safety Information Units With Hydraulics Although the hydraulic pressures in the machine are low compared to some hydraulically operated equipment. If any fluid is injected into the skin. NOTICE: Wear safety glasses. Heaters Are Not Explosion Proof ! DANGER Heaters are not explosion proof. 7 . When operating in a hazardous environment. 4790 © Copyright 2012 ISCO Industries. ! WARNING Escaping fluid under pressure can penetrate the skin causing serious injury. then unplugged before entering the hazardous atmosphere for fusion. Keep hands and body away from pinholes which eject fluid under pressure. Operation of a heater in a hazardous environment without necessary safety precautions will result in explosion and death. and keep face clear of area when bleeding air from hydraulic system to avoid spraying into eyes. Use a piece of cardboard or paper to search for leaks. it is important to remember that a sudden hydraulic leak can cause serious injury or even be fatal if the pressure is high enough. heater should be brought up to temperature in a safe environment. LLC All rights reserved.

Operation of these components in a hazardous environment without necessary safety precautions will result in explosion or death. Damaged components need to replaced and service performed by a qualified electrician. It is important to remember that when you are working in a wet environment with electrical devices. Do not plug into both outlets of one duplex receptacle. NOTICE: Disconnect the machine from the power source before attempting any maintenance or adjustment. keep pump motor and chassis in a safe area by using hydraulic extension hoses. . proper ground connections help to minimize the chances of an electric shock. Do not carry electrical devices by the cord. On units with two power cords. Frequently inspect electrical cords and unit for damage. 4790 © Copyright 2012 ISCO Industries. Electrical Safety ! WARNING Always ensure power cords are properly grounded. When operating in a hazardous environment. 8 Fusion Hotline 1-800-345-ISCO ext. plug each cord into separate power circuits. or in the owner’s manual. NOTICE: Always connect units to the proper power source as listed on the unit. LLC All rights reserved.ISCO Fusion Manual Fusion Equipment Safety Information Electric Motors Are Not Explosion Proof ! DANGER Electric Motors are not explosion proof.

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. 4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Fusion Equipment Safety Information Crush Points ! WARNING Hydraulically operated jaws are operated under pressure. Failure to follow procedures could result in a bad weld. 9 . and handling the unit. LLC All rights reserved. Facer Blades Are Sharp ! WARNING Facer blades are sharp and can cut. legs. Keep fingers. or is in the facing position between the jaws. Use care when operating the facer. Fusion Procedures ! CAUTION Follow the procedures carefully. Keep the heater in its insulated heater stand or sling blanket when not in use. Always follow the proper fusion procedures. and adhere to all specified parameters. Anything caught in the jaws will be crushed. Fusion Hotline 1-800-345-ISCO ext. and use care when heating the pipe. Never attempt to remove shavings while the facer is running. NOTICE: Disconnect power from the facer. NOTICE: Use only a clean non-synthetic cloth such as a cotton cloth to clean the heater plates. and head out of the jaw area. arms. Always check pipe alignment with a pencil or similar object. feet.

skin. ! WARNING Breathing exhaust gases can cause sickness or death. 4790 © Copyright 2012 ISCO Industries. and cause blindness if splashed into eyes. Exploding gases from battery could cause blindness or serious injury. flames and cigarettes away. and clothing. LLC All rights reserved. eat holes in clothing. grease. Units With Batteries ! CAUTION Sulfuric acid in battery electrolyte is poisonous. Always clean up spilled fuel. and has the equipment to perform the job safely.ISCO Fusion Manual Fusion Equipment Safety Information Units With Gas Engines ! WARNING Handle fuel with care. Do not refuel the machine while smoking or near open flames or sparks. and facer shavings. Help prevent fires by keeping machine clean of accumulated trash. Fuel is highly flammable. Have tires mounted by someone that is experienced. Fill fuel tank outdoors. Always operate machine outdoors in an area with adequate ventilation. . debris. Avoid contact with eyes. It is strong enough to burn skin. Keep sparks. 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. 10 Fusion Hotline 1-800-345-ISCO ext. Always stop the engine before refueling machine.

0 7 6 Positioning Fusion Machine Place fusion machine on as level ground as possible. and should be used as a reference only. and make necessary adjustments. Check heater plate surface temperature periodically with a pyrometer. Keep Machine Away From Edge Of Ditch ! WARNING Heavy equipment too close to a ditch can cause the walls of the ditch to cavein. Towing at speeds greater than five miles per hour can result in machine damage as well as injury. and make sure that unit is properly secured. Always transport the machine by flat bed truck or similar means. chock the wheels and block the unit to make it as stable as possible. LLC All rights reserved. Do Not Tow Fusion Machine At Speeds Greater Than 5 MPH ! WARNING The chassis is not designed for over-road towing. and set the brake on the rear wheel. If it is necessary to operate machine on unlevel grade. Fusion Hotline 1-800-345-ISCO ext. 11 . 4790 © Copyright 2012 ISCO Industries. The thermometer on heaters indicates internal temperature.ISCO Fusion Manual Fusion Equipment Safety Information Periodically Check Temperature NOTICE: Incorrect heating temperature can result in bad fusion joints. Keep the machine far enough away from the edge of the ditch to prevent injury to personnel and equipment from a cave-in.

ISCO Fusion Manual Fusion Equipment Safety Information Operating TracStar Fusion Machines Place fusion machine on as level ground as possible. chock the tracks and block the unit to make it as stable as possible. . snow. If it is necessary to operate machine on unlevel grade. 4790 © Copyright 2012 ISCO Industries. Positioning Fusion Machine Place fusion machine on as level ground as possible. make sure that the ground is stable. Attempting to tow the machine can result in machine damage. and loose gravel. wear hearing protection. Always transport the machine by flat bed truck or similar means. Hearing Protection Required For TracStar 412 and TracStar 618. 12 Fusion Hotline 1-800-345-ISCO ext. 3 If it is necessary to operate machine on unlevel grade. LLC All rights reserved. ! WARNING For operation safety.) 10 Do Not Attempt to Tow A TracStar Fusion Machine ! CAUTION The machine is not designed for towing. Some unstable conditions maybe ice. When operating machine for more than four hours per day. (A 3 foot elevation change in 10 feet. and make sure that unit is properly secured. never operate machine on a grade steeper than 30%. mud.

The external covering should be kept wet by occasional re-wetting with anti-static solution. Squeeze-off purging. a tool. squeezing-off an open pipe.. In gas utility applications.. etc. can still result in a static electricity discharge. ! 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. cutting. 4790 © Copyright 2012 ISCO Industries. including procedures for discharging static electricity and requirements for personal protection. etc. Where a flammable gas-air mixture may be encountered and static charges may be present. Static electricity discharge can ignite a flammable gas or combustible dust atmosphere. Observe all procedures for static electricity safety and control.ISCO Fusion Manual Fusion Equipment Safety Information Safety Precautions For Guarding Against Static Electricity And Gaseous Ignition ! DANGER Polyethylene plastic pipe does not readily conduct electricity. electric facers and electric power tools are NOT explosion proof. arc preventing safety precautions are necessary. When appropriate. The covering or tape should be suitably grounded such as to a metal pin driven into the ground. venting. Polyethylene pipe cannot be discharged by attaching grounding wires to the pipe. then covering or wrapping the entire wetted. A static electricity charge can buildup on inside and outside surfaces and stay on the pipe surface until some grounding device. 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. conductive poly film. 13 . such as a tool or a person comes close enough for the static electricity to discharge to the grounding device. A static electricity discharge to a person. exposed pipe surface with grounded wet burlap. Take steps to discharge static electricity from the surface of the polyethylene gas pipe. Steps that discharge the outer surface do not discharge the inner surface of the pipe. such as when repairing a leak. static electricity can be a potential safety hazard. purging. ground tools and remove all potential sources of ignition. LLC All rights reserved. or wet tape conductor. Fusion Hotline 1-800-345-ISCO ext. making a connection. Heaters. Such steps include wetting the entire exposed pipe surface with a conductive anti-static liquid or a dilute soap and water solution.

Set the heater temperature at the maximum allowed for the application. Unplug heater prior to using in a hazardous environment.ISCO Fusion Manual Fusion Equipment Safety Information 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. . Smell. See and Report any unsafe situations you see or see coming to your onsite contact. Use 450° F for butt fusion and 510° F for saddle fusion and socket fusion. Use your senses and good judgment: Listen. 4790 © Copyright 2012 ISCO Industries. When prepping the main pipe for a saddle fusion. When making butt fusions. Use a machine equipped with a hydraulic facer or convert the electric facer to a manual by removing the brushes and turning facer manually. Do not use a butt fusion machine with an electric facer in a gaseous environment. saddle fusions and socket fusions in a hazardous environment. Do not drill hole first prior to making a saddle fusion. do not use an electric grinding tool. Feel. Prepare main pipe manually by use of 50-60 grit utility cloth. 14 Fusion Hotline 1-800-345-ISCO ext. These are surface temperatures. if corrective action is not taken in your opinion. Set the chassis up out of harms way and use extension hoses to operate upper works in hazardous area. set the generator up out of harms way and have the heater plugged into it there. Do not enter into the situation. LLC All rights reserved. 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. Do not use an electric drill for punching hole through after saddle fusion has been made.

4790 © Copyright 2012 ISCO Industries. LLC All rights reserved.Tips For Success What can I learn from others before getting started? Fusion Hotline 1-800-345-ISCO ext. 15 Tips for Success .

When making fusions that involve pipe to fittings. skill saws and chain saws work well. In general. make sure to open the facer valve prior to starting the unit and keep it open until started. When rough cutting pipe. special care should be taken. Look for deep scratches. which is normal. For cutting holes in pipe. needs to be completely removed in the facing process. Gloves protect hands from heater burns and sharp blades on the facer. drills with hole saws and reciprocating saws work well. Adjust stands so that pipes are level to reduce drag. Unplug heater before turning fusion unit off. set the wheel lock or block them. Tips for Success 16 Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries. Position fusion equipment on level ground whenever possible. use a pipe wrap to mark the pipe with a reference line. Load loose pipe joints into movable side of the fusion equipment and pull joints already fused through non-movable side. . If the fusion equipment has wheels. This will keep you from having heater element and circuitry problems with your heater. When using chain saws. Close valve once unit is running. When pulling pipe through the fusion equipment. LLC All rights reserved. Use the 10 percent rule: Any imperfection affecting more than 10 percent of the pipe wall being worked with should not be used. The necking down or toe in at the pipe ends. tooling that works with wood works well with HDPE pipe. When working with McElroy Self-Contained fusion units excluding the T-500 and T-900. cuts and gouges. Always wear a hard hat and protective boots. Position pipe support stands on either side of the fusion equipment approximately 20’ from ends of the fusion equipment.ISCO Fusion Manual Tips for Success Use Personal Safety Equipment. Protective Eye Glasses are also a good idea. Check your pipe before you fuse it. Do not abuse the facer when facing pipes by using too much pressure. elevate pipe in the machine using the pipe lifts so the fusion bead clears all obstructions as it is pulled through. Make sure all equipment is in good working order and power cords are free of cuts with grounding blade on receptacle in tack. This is seen primarily in working with the larger pipe diameters. the cut ends MUST be cleaned with isopropyl alcohol to remove BAR Oil Splash or any other contaminants. Plug heater in on self-contained fusion units only after unit has been started and warmed up. For cutting pipe. This will save the battery and keep you from burning up the starter. this will aid you in making a square and even cut.

No liquid of any kind running through the pipe or fittings is permissiable.12 6 . When removing pipe from the fusing unit and pulling into place. 4790 © Copyright 2012 ISCO Industries.10 4-8 Important: Fusions per day are dependent upon pipe wall thickness. 17 Tips for Success . In inclement weather and especially in windy conditions. Squeeze tools can be used on HDPE Pipe to stop flow in a pipeline while a tie in or repair is made.34” 36” . DO NOT INCREASE HEATING TOOL SURFACE TEMPERATURE.5” .3” 4” .60 24 .48” 51. water or the like.24 10 . Use lower number for estimation and planning.6”. Fusions per 8-10 Hr.8” 10” .16 8 . Capping ends of pipe that are being fused aides heater from being chilled as fusion joint is being made. equipment to move and handle pipe.4”/ 100’/ 10ºF. Day 30 . Chains and rope can slip and cause injury/damage to personnel and pipe. LLC All rights reserved. Always remember – IF IN DOUBT.63” Approx. A common obstacle when working with HDPE pipe in the field is understanding the thermal expansion and contraction. When fusion is done in cold weather.24” 26” . When working with coiled pipe 2” .1. Fusion Hotline 1-800-345-ISCO ext. manpower. CUT IT OUT and redo. the fusion operation should be shielded to avoid precipitation or blowing snow and excessive heat loss from wind chill. then cut it out and re-fuse.18” 20” . Do not try to shorten cooling times of fusions by applying wet cloths. site conditions and weather. Butt Fusion Joining Rates Pipe Sizes IPS/DIPS 3/4” . a McElroy LineTamer™ should be used to straighten and reround coiled pipe to meet or exceed ASTM D2513 Quality Requirements. use proper lifting slings and pulling heads in good condition. Fusion beads can be removed by means of external and internal bead removers without effecting the integrity of the fusion joint.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.48 12 . The joint area and its parts that are being fused must be completely dry. Rule of thumb . Follow manufacturer’s squeeze-off tool instructions.

LLC All rights reserved.Manual Butt Fusion Machine Procedure Manual Butt Fusion Machine Procedure 18 Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries. .

the molecules return to their crystalline form. 19 Manual Butt Fusion Machine Procedure . When the polyethylene material is heated. or 1-1/4” max. As the joint cools. A melt pattern that penetrates into the pipe must be formed around both pipe ends. Fusion Hotline 1-800-345-ISCO ext. • The fusion pressure used to join two different wall thicknesses is always that of the thinner. This pressure causes flow of the melted materials. The melt patterns must be joined with a specified force. The pipe ends must be aligned with each other to minimize mismatch or high-low of the pipe wall. the molecules from each polyethylene part mix. The principle operations include: Clamping The pipe pieces held axially to allow all subsequent operations to take place. and the two pipes become one homogeneous unit. The molten joint must be held immobile with a specified force until adequately cooled. You can weld that pipe to pipes or fittings that have a wall thickness of 3/4” min. When fusion pressure is applied. and then fuse them together by application of force. 4790 © Copyright 2012 ISCO Industries. the molecular structure is transformed from a crystalline state into an amorphous condition. Facing Alignment Heating Joining Holding The pipe ends must be faced to establish clean. Important: • The pipe line is only as strong as its weakest link. 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%. parallel mat ing surfaces perpendicular to the centerline of the pipes.ISCO Fusion Manual Manual Butt Fusion Machine Procedure The principle of heat fusion is to heat two surfaces to a designated temperature. LLC All rights reserved. The force must be constant around the interface area. which causes mixing and thus fusion. Example: You have a pipe or fitting that has a wall thickness of 1”. the original interfaces are gone.

Close upper jaws but do not overtighten.4” DIPS Pipe) 2” Master.2” IPS Pipe) 1-1/2” and smaller inserts are fitted to jaw castings using flat head fasteners. 1-1/2” and smaller inserts are fitted to 2” IPS Master inserts using flat head fasteners. 14 Pitbull Machines (1” IPS . LLC All rights reserved. . Let the ends of the pipe protrude about 1” past the face of the jaws. 2CU machines (1/2” CTS . 20 Fusion Hotline 1-800-345-ISCO ext. No. Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed. 4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused. No. 3” & 4” inserts are held in place by spring pins located on upper and lower jaws. 14 Pitbull Used In the Following Illustrations) Clean the inside and outside of the pipe ends that are to be fused. 2LC & No. Manual Butt Fusion Machine Procedure Loading Pipe Into Machine (No.

ISCO Fusion Manual Manual Butt Fusion Machine Procedure Electric Facer The facer is a McElroy Rotating Planer Block Design. Operation of these components in a hazardous environment will result in explosion and death. When operating in a hazardous environment. 2LC and No. 21 Manual Butt Fusion Machine Procedure . operate the facer manually. Fusion Hotline 1-800-345-ISCO ext. 2CU The manually operated facer has a hand powered crank. (Both brushes must be removed). ! DANGER Electric motors are not explosion proof. The Block rotates on ball bearings and is chain driven (enclosed in lubricant) by a heavy duty electric motor. Manual Facer for No. LLC All rights reserved. The facer has a handle that latches into place on a guide bar. Unscrew the brush covers from both sides of the motor. Turn the crank counterclockwise for facing. The armature brushes must be removed from the electric motor when manually operating in a hazardous condition. The blade holders each contain two cutter blades. A 7/8” hex shaft allows for manual operation in hazardous conditions. The handle must be pulled out to unlatch and remove facer. 4790 © Copyright 2012 ISCO Industries. Cam Lock A semi-automatic cam locking system locks the movable jaw during the cooling cycle.

Continue facing until facer stops have bottomed out against the clamping jaws. Remove shavings from pipe ends and machine. then lower the facer handle end down onto the near guide rod and latch.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Inserting Facer Place the end opposite the handle onto the far guide rod. Move jaws apart. Unlatch and remove facer. If the face off is incomplete. . Do not over-tighten. watching the gap between the facer stops and the pipe clamping jaws. Tighten the pipe clamp knobs by hand until firm resistance is felt. return to Loading Pipe Into Machine on page 20. Positioning Pipe In Machine With facer in position use lever handle to bring pipe ends together against the facer. Inspect both pipe ends for complete face off. LLC All rights reserved. Stop rotation of facer. Facing The Pipe Manually Turn facer handle counterclockwise and apply firm pressure on lever handle. 4790 © Copyright 2012 ISCO Industries. Leave enough gap so that proper face-off will be achieved when the facer stops are bottomed out against the clamps. 22 Fusion Hotline 1-800-345-ISCO ext. Do not touch faced pipe ends. Manual Butt Fusion Machine Procedure Important: Thoroughly clean all dirt and debris from pipe ends before facing.

4790 © Copyright 2012 ISCO Industries. any imperfections are visible. 23 Manual Butt Fusion Machine Procedure . LLC All rights reserved. Any time clamp knobs are tightened. use a clean white nonsynthetic cloth to clean affected area before proceeding. Unlatch and remove the facer taking care not to touch the pipe ends. If faced pipe ends are touched. Turn off the facer while continuing to hold pressure closed on the lever until the facer stops completely. Continue facing until the facer stops are against the jaws.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Electric Facer The electric facer should be started before the pipe is pushed into contact with the blades. Reverse force to the lever handle to move the pipe ends away from the facer. If after facing. Do not touch faced pipe ends as this may contaminate them. Remove shavings from pipe ends and machine. return to Loading Pipe Into Machine on page 20. Fusion Hotline 1-800-345-ISCO ext. pipe ends should be refaced.

ISCO Fusion Manual Manual Butt Fusion Machine Procedure Check Alignment Of Pipe Bring the pipe ends together under sufficient force to overcome any pipe drag or friction in the system. If the two jaws are touching. If slippage occurs. 24 Fusion Hotline 1-800-345-ISCO ext. Check Heater Temperature ! CAUTION Incorrect heating temperature can result in questionable fusion joints. do not over-tighten the clamp knobs because machine damage can result. Manual Butt Fusion Machine Procedure For butt fusion heater surface temperature should be Minimum 400° F. Check heater plates periodically in multiple locations with a pyrometer and make necessary adjustments. The dial thermometer can be used as reference once the surface temperature has been verified. Their should be no more than 10% of the wall thickness in misalignment to maintain full joint strength. do not continue to tighten. Bring the pipe ends together under fusion pressure to check for slippage. Maximum 450° F. 4790 © Copyright 2012 ISCO Industries. Important: The dial thermometer on the heater indicates internal temperature which varies from the actual surface temperature. . Check for alignment and proper face off. LLC All rights reserved. return to Loading Pipe Into Machine section on page 20. Optimum 425° F. If high/low (misalignment) exists. adjust by tightening the clamp on the high side and reface the pipes. Check to see if there is space between the upper and lower jaws. Notice: When clamping.

heater should be brought up to temperature in a safe environment. then unplugged before entering the hazardous atmosphere for fusion. Fusion Hotline 1-800-345-ISCO ext. If operating in a hazardous environment. The stripper bar downward legs should be outside of the jaws. 4790 © Copyright 2012 ISCO Industries. LLC All rights reserved. Raise the locking cam into the engaged position while in the heating cycle. Maintain contact. Insert heater between the pipe ends. Operation of heater in a hazardous environment without necessary safety precautions will result in explosion and death. . Replace them if conditions exist. Verify heater temperature by referencing the reading on the dial thermometer. (not on top) Heating The Pipe With heater in position between the pipe ends.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Inserting Heater ! DANGER Heater Is Not Explosion Proof. while a bead of molten polyethylene develops between the heater and the pipe or fitting ends. without force. These conditions could cause a poor fusion. 25 Manual Butt Fusion Machine Procedure Use a clean white nonsynthetic cloth to clean butt fusion heater adapter surfaces. Check heater adapters for coating damage. plastic buildup rings and surface imperfections. Continue heating the pipe ends until the minimum melt bead size has developed. Do not heat under pressure. (See Minimum Melt Bead Size Chart on page 26). bring the pipe or fitting ends into full contact with the heater to ensure proper seating.

it indicates pressure during heating.5 (89) < 6. immediately and in a continuous motion. Do not continue. 26 Fusion Hotline 1-800-345-ISCO ext. in. If the melted surfaces are acceptable. (mm) < 2. Allow the melted ends to cool and start over. Notice: A concave melt surface is unacceptable. QUICKLY inspect the melted ends. Allow the melted ends to cool and start over. which should be flat. . LLC All rights reserved. it indicates pressure during heating.5 (89) > 3.37 (60) < 3. Do not slam. bring the ends together and apply enough joining force for the beads to touch. and form a double roll back against the pipe wall. and completely melted. Do not continue.37 (60) > 2.5) 3/16” (5) Manual Butt Fusion Machine Procedure Fusing the Pipe Once melt beads are of proper size.62 (160) Minimum Bead Size in. Unacceptable Concave Melt Appearance What Causes This? Answer . remove the heater. A concave melt surface is unacceptable. (mm) 1/32” (1) 1/16” (1. The locking cams will assist by holding force during the cooling cycle.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Minimum Melt Bead Size (Pipe Ends): Pipe (OD). 4790 © Copyright 2012 ISCO Industries.Heating under pressure. smooth.

P/N 410802 No. pressure and cooling time may result in a bad joint. measured by torque wrench. 27 Manual Butt Fusion Machine Procedure . 14 Pitbull. remove the heater and quickly apply fusion force with the lever handle.) (Lb. LLC All rights reserved. ! CAUTION Failure to follow the proper heating time.) 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. Lb. 26 Torque No. 4790 © Copyright 2012 ISCO Industries. Fusion Hotline 1-800-345-ISCO ext. Required 15” torque wrench is required when using the torque wrench adapter.) (Lb. To use a torque wrench with the No. place an adapter in the lever socket.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Optional Use Of Torque Wrench After the heating cycle is completed. 14 No. 2LC Pitbull PitBull Wrench Jaw Axial Jaw Axial Jaw Axial Reading Force Force Force (Ft.1416 x (IFP) 75 +DRAG = Force This value is then read on chart to determine how much torque is needed to apply the force.) (Lb. The locking cams will assist by holding force during the cooling cycle. Drag=Amount of force required to move pipe.

3 9 11 13. . apply closing force on the lever handle and push the locking cams down into the unlocked position. use Trouble Shooting Guides to determine problem and make adjustments before next fusion. (See pages 29 and 30) 28 Fusion Hotline 1-800-345-ISCO ext.5 MCT 4 4 2 2 IPS Pipe 3 3 3 3 3 5 5 5 5 5 7.5 17 MCT 7 6 5 4 3 Manual Butt Fusion Machine Procedure Remove Pipe and Inspect After pipe has cooled sufficiently.3 9 11 13.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Cooling Of The Fusion Joint Hold the molten joint immobile under fusion pressure until sufficiently cooled.3 9 11 13. Unscrew the clamp knobs enough that they can be swiveled outward.5 17 MCT 5 4 4 3 2 10 8 7 5 4 IPS Pipe 4 4 4 4 4 DR 7. 4790 © Copyright 2012 ISCO Industries. Minimum Cooling Time Chart IPS Pipe 2 2 2 2 DR 7. installation or rough for additional 30 min or more after removal from fusion machine. Pull pipe through machine. and prepare for making next fusion. Cooling under pressure before removal from the butt fusion machine is important in achieving joint integrity. LLC All rights reserved. Avoid high stress such as pulling. Maintain fusion pressure against the piping component ends for a minimum of 11 minutes per inch of pipe wall.5 17 8 7 6 5 4 6 6 6 6 6 DR 7.5 17 7.3 9 11 13. Inspect joint and if it has to be redone.3 9 11 13.

When butt fusing pipe to molded fittings. The cleavage between the beads must not be lower than the wall of the pipe as shown in the lower right illustration. LLC All rights reserved. and be uniformly rounded and consistent in size all around the joint. 29 Manual Butt Fusion Machine Procedure . The double bead should be rolled over onto the adjacent surfaces. This is acceptable provided the pipe side bead is correct. Butt Fusion Bead Dimensional Guideline Fusion Hotline 1-800-345-ISCO ext. cut it out and redo.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Butt Fusion Joint Troubleshooting Guide The Inspection Of The Fusion Joint Golden Rule: If in doubt. 4790 © Copyright 2012 ISCO Industries. the fitting side bead may have an irregular appearance. It is not necessary for the internal bead to roll over to the inside surface of the pipe. As illustrated in the Figure below. all beads will not necessarily have equal size.

Excessive joining force Excessive joining force. Insufficient heating. defective heating tool. . LLC All rights reserved. incomplete facing Insufficient heating.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Butt Fusion Joint Troubleshooting Guide 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. Component slipped in clamp. Incomplete facing Misalignment. sandpaper-like. worn equipment. Deep v-groove . Worn equipment.Insufficient heating & excessive joining force Excessive heating time Pressure during heating Manual Butt Fusion Machine Procedure Bead not rolled over to surface Beads too large Squarish outer bead edge Rough. Pressure during heating Excessive joining force. Overheating Misalignment. Insufficient joining force Shallow v-groove . 4790 © Copyright 2012 ISCO Industries.Insufficient heating & insufficient joining force. or pockmarked melt bead surface Hydrocarbon contamination 30 Fusion Hotline 1-800-345-ISCO ext. bubbly. Defective heating tool.

4790 © Copyright 2012 ISCO Industries. After regular procedure for facing. Protective measures with auxiliary heating is recommended when temperatures are below -4°F (-20°C). it will require a longer heating time to develop an indication of melt and the final bead size. so that melt heat loss is minimized. frost.232°C) setting. Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. 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. dirt.ISCO Fusion Manual Manual Butt Fusion Machine Procedure Cold Weather and Inclement Weather Procedure • Wind and Precipitation . depending on the pipe size and wall. Pre-Heating – When the ambient temperature is below 3°F (-16°C).Heating tool shall be shielded in insulated container to prevent excessive heat loss. and other contamination. • Fusion Hotline 1-800-345-ISCO ext.4-12. 31 Manual Butt Fusion Machine Procedure • 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. With pipe mounted in the fusion machine.50 inches (6. snow. Shield the pipe fusion area and fusion tools from wind. When the ambient temperature becomes colder.25-. but still take time (no more than 3 seconds) to inspect both melt patterns. an alternate method of pre-heating is to stop the pipe ends within . Do not increase heating tool temperature above the specified temperature (450°F . Work quickly once pipe and fittings have been separated from the heating tool. blowing dust and rain by using a canopy or similar device. snow.7mm) of the heater plate face to allow the pipe ends to warm for 30 seconds to 2 minutes. 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. LLC All rights reserved.

LLC All rights reserved. 4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Hydraulic Butt Fusion Machine Procedure 32 Fusion Hotline 1-800-345-ISCO ext. .

The melt patterns must be joined with a specified force. the molecules return to their crystalline form. 4790 © Copyright 2012 ISCO Industries. Important: • The pipe line is only as strong as its weakest link. As the joint cools. the molecular structure is transformed from a crystalline state into an amorphous condition. When fusion pressure is applied. Fusion Hotline 1-800-345-ISCO ext. The molten joint must be held immobile with a specified force until adequately cooled. the original interfaces are gone. Example: You have a pipe or fitting that has a wall thickness of 1”. 33 Fusion Equipment Safety Information . 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 molecules from each polyethylene part mix. The principle operations include: Clamping Facing The pipe pieces held axially to allow all subsequent operations to take place.ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure The principle of heat fusion is to heat two surfaces to a designated temperature. You can weld that pipe to pipes or fittings that have a wall thickness of 3/4” min. This pressure causes flow of the melted materials. 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%. LLC All rights reserved. • The fusion pressure used to join two different wall thicknesses is always that of the thinner. parallel mating surfaces perpendicular to the centerline of the pipes. which causes mixing and thus fusion. The force must be constant around the interface area. The pipe ends must be faced to establish clean. or 1-1/4” max. and then fuse them together by application of force. and the two pipes have become one homogeneous unit. When the polyethylene material is heated.

LLC All rights reserved. a selector valve. Note: Example of heavy wall pipe is (14” & up. Each pressure reducing valve is labeled with a different function. three pressure reducing valves. 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. FACING ISCO Fusion Manual B C A Hydraulic Butt Fusion Machine Procedure D E F D) The top valve adjusts facing pressure. determines whether the carriage is moving left. always 0 psi/drag or backed all the way out turning knob counterclockwise.Hydraulic Butt Fusion Machine Procedure Hydraulic Manifold Block Mounted on this block are a carriage directional control valve. normally 50-100 psi gauge pressure. this pressure must be determined. B) A pressure gauge is mounted on top of the manifold. mounted on the front of the manifold. . mounted on the top of the manifold. 4790 © Copyright 2012 ISCO Industries. 34 Fusion Hotline 1-800-345-ISCO ext. A) The carriage control value. C) The selector valve. and a pressure gauge.5 & Thicker) F) The bottom valve adjusts fusion pressure. HEATING FUSING Install Clamping Inserts Select and install appropriate clamping inserts for the pipe that is being fused. right. or in neutral. selects a pressure from one of the pressure reducing valves. DR 13. E) The middle valve adjusts heating pressure.

If fusion pressures are used from the reference section. . Shift the selector valve to the center position.) An approximate 30 psi drag factor should compensate for seal. and add the actual measured drag pressure. Shift the carriage control valve to the middle (neutral) position. This will be the actual fusion pressure to set with the bottom pressure reducing valve. select the heating mode. and adjust the middle pressure reducing valve to its lowest pressure by turning the valve counterclockwise. Fusion Hotline 1-800-345-ISCO ext. whichever is higher. Record this actual drag pressure. with the top pressurereducing valve to control facing speed. With the selector valve up. or the drag pressure. How much pressure depends on the position of the selector valve and the pressure set on the specific pressure reducing valve. Increase the pressure until the carriage moves. the actual drag pressure should be determined using the following procedure: After facing the pipe. and set the pressure reducing valve at its lowest setting. heating. the facing pressure can be set. 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. you must subtract 30 psi drag. determined from the Fusion Pressure Calculator. Adjust the middle heating valve to show recorded drag so that pipe ends will stay in contact with heater during heating phase. 4790 © Copyright 2012 ISCO Industries. Gradually increase the pressure by turning the heating valve clockwise.Hydraulic Butt Fusion Machine Procedure Check Hydraulic Pressure The pressure gauge on the manifold block indicates the pressure of the carriage valve. which is already figured in and then add the actual drag pressure back. 35 Hydraulic Butt Fusion Machine Procedure With the selector valve in the down position. Take the pressure. the fusion pressure can be set. It may be necessary to adjust the carriage speed. Quickly reduce the heating pressure valve counterclockwise until the carriage is just barely moving. while facing. Shift the carriage control valve to the left. move the carriage so that the pipe ends are approximately 2” apart. LLC All rights reserved. If additional lengths of pipe or heavy wall pipe are being moved by the movable jaws. and pipe drag with one joint of pipe on a pipe stand. or they can be found in the reference section.

inch of the surface area of the pipe end.625 DR of Pipe = 11 Recommended Interfacial Pressure = 75 PSI Measured Drag 30 PSI Formula: Wall Thickness t= TEPA = 4.) Pipe Size = 8” IPS OD of Pipe = 8. .Hydraulic Butt Fusion Machine Procedure Fusion Pressure Calculator Interfacial Pressure (IFP) Minimum 60 psi Optimum 75 psi Maximum 90 psi Interfacial Pressure (IFP) = amount of force per sq. Step 4: Add Drag Pressure to gauge pressure. Step 3: Read Gauge Pressure at red arrow.1416 DR = Dimensional Ratio IFP = Recommended Interfacial Pressure (Shown Above) TEPA = Total Effective Piston Area DRAG = Force Required to Move Pipe ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Example: Using a McElroy No. LLC All rights reserved.710 (chosen from the table on page 37) + Gauge Pressure = Gauge Pressure = + 36 Fusion Hotline 1-800-345-ISCO ext. How to Use the Fusion Pressure Calculator Step 1: Set DR at Pipe Size. Determining Fusion Pressure Variable Definitions OD = Outside Diameter t = Wall Thickness π = 3. 4790 © Copyright 2012 ISCO Industries. Green Cyl. 28 Standard Fusion Machine (High Force. Interfacial Pressure (IFP) and Fusion machine gauge pressure are not the same. Step 2: Align McElroy Fusion Machine with IFP.

44 29.44 29.01 15.78 11. LLC All rights reserved.32 15. 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. 37 Hydraulic Butt Fusion Machine Procedure . * This distance changes with fusion machine type.14 NA 9.78 NA 29.45 9. 412 and No.Hydraulic Butt Fusion Machine Procedure Notice: See Reference Section.71 11.32 14. for fusion pressure charts showing pressures precalculated to include 30 psi for system drag. 618 Used In the Following Illustrations) Clean the inside and outside of pipe ends that are to be fused.01 6.45 NA NA Loading Pipe Into Machine (No. 4790 © Copyright 2012 ISCO Industries. Fusion Hotline 1-800-345-ISCO ext.14 3.67 3.42 NA 6. Open the upper jaws and insert pipe in each pair of jaws with applicable inserts installed.01 6.42 31. Tighten the clamp knobs on the outer jaws to prevent pipe slippage and lightly tighten inner clamp knobs for possible later alignment adjustments.45 9. pages 86-91.32 15.14 NA 1.44 31. Let the ends of the pipe protrude more than 1” * past the face of the jaws.

adjust the facing pressure so the facer continues to cut. it may be necessary to increase the system pressure. .Hydraulic Butt Fusion Machine Procedure Facing The Pipe Pivot the facer into place and secure. 4790 © Copyright 2012 ISCO Industries. If the facer stalls. Move the carriage to the right so the facer can be removed. LLC All rights reserved. Assure the selector valve handle is up in the facing position. Important: When facing heavy wall pipe. Move the carriage to the right. Let the carriage bottom out at the facer stops. Turn the facer off. Open the ball valve on the facer motor. 38 Fusion Hotline 1-800-345-ISCO ext. 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. ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Move the carriage to the left.

If slippage occurs. careful not to touch faced pipe ends. Check pipe joint for proper alignment. Do not use finger to check for hi/low (misalignment). 39 Hydraulic Butt Fusion Machine Procedure . The unit is under pressure. and slippage could result in crushed fingers. If faced pipe ends are touched. When the pipe is properly aligned tighten outside clamps to insure against slippage. Remove pipe shavings from lower side of pipe ends. Move the carriage to the left until ends of pipe butt together. use clean non-synthetic cloth to clean affected area before proceeding. return to Loading Pipe Into Machine on page 37.ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Remove Facer Pivot the facer out to the storage position. tighten the inner high side jaw to bring into alignment. If pipe is not lined up. 4790 © Copyright 2012 ISCO Industries. Always keep hands clear of the jaw area. Turn facer off. LLC All rights reserved. If clamp knob adjustment has been made. Bring the pipe ends together under fusion pressure to check for slippage. Important: Always tighten the side that is higher. reinstall facer and begin facing procedure again. never loosen the low side. Let the carriage bottom out on facer stops. ! WARNING Fusion Hotline 1-800-345-ISCO ext. Notice: Their should be no more than 10% of the wall thickness in misalignment to maintain full joint strength. Move the carriage to the right so the facer can be removed. Remove shavings from pipe ends careful not to touch faced pipe ends.

FACING HEATING FUSING Hydraulic Butt Fusion Machine Procedure Check Heater Temperature ! CAUTION Incorrect heating temperature can result in questionable fusion joints. Use fusion pressure required from Fusion Pressure Calculator or the formula on page 36 . LLC All rights reserved. For butt fusion heater surface temperature should be Minimum 400° F. Select the Fusion Position Move selector valve handle down to the fusing position. The dial thermometer can be used as reference once the surface temperature has been verified. 4790 © Copyright 2012 ISCO Industries. Optimum 425° F. FACING HEATING FUSING 40 Fusion Hotline 1-800-345-ISCO ext. . Also see Reference Section.ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Position Carriage For Heater Insertion Move carriage to the right to open a gap large enough to insert the heater. Maximum 450° F. Important: The dial thermometer on the heater indicates internal temperature. Check heater plates periodically in multiple locations on both sides of plates with a pyrometer and make necessary adjustments. page 86-91.

When fusing more than one pipe length on the movable side of the fusion unit. FACING HEATING ISCO Fusion Manual ! DANGER A FUSING B FACING HEATING FUSING B) Move selector valve to center position. Check heater plates for coating damage. 4790 © Copyright 2012 ISCO Industries. Insert heater between the pipe ends. 41 Hydraulic Butt Fusion Machine Procedure . Use a clean white non-synthetic cloth to clean the butt fusion heater adapter surfaces. and larger) maintain the fusion pressure until a slight melt is observed around the circumference of the pipe or fitting before reducing pressure. LLC All rights reserved. Once the indication of melt is observed around the circumference of each pipe then move to step B. C FACING HEATING FUSING Fusion Hotline 1-800-345-ISCO ext. Briefly ensure full contact between piping component ends and heating tool and then reduce the pressure to drag without breaking contact. seating pipe ends against heater. If operating in a hazardous environ ment.then unplugged before entering the hazardous atmosphere for fusion. Replace them if conditions exist. Verify heater temperature noting the reading on the dial thermometer. Operation of heater in a hazardous environment without necessary safety precautions could result in explosion and death. bringing the heater into full contact with both pipe ends. (14in. On Larger pipe sizes. drag must be compensated for as described on pg 35.Hydraulic Butt Fusion Machine Procedure Inserting Heater Heater is Not Explosion Proof. plastic buildup rings and surface imperfections. These conditions could cause a poor fusion. Heating The Pipe A) Move the carriage to the left under the fusion pressure. heater should be brought up to temperature in a safe environment. allowing the pressure to drop but maintaining contact without force.

FACING HEATING

FUSING

ISCO Fusion Manual

B

Hydraulic Butt Fusion Machine Procedure
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

Hydraulic Butt Fusion Machine Procedure

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"

42

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

Hydraulic Butt Fusion Machine Procedure
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

A

B

D
Hydraulic Butt Fusion Machine Procedure

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.

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

43

Hydraulic Butt Fusion Machine Procedure
Approximate Dwell/Transfer Times

ISCO Fusion Manual

Pipe Wall Thickness, in (mm) ½ CTS to 1 ½” 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

Hydraulic Butt Fusion Machine Procedure

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.

44

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

3 9 11 13.5 17 9 11 13.3 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 7.ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure 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 7.5 17 21 11 13.3 9 11 13.5 7.3 9 11 13.3 9 11 13.3 9 11 13.3 9 11 13. 45 Hydraulic Butt Fusion Machine Procedure 28 .5 9 11 13. 4790 © Copyright 2012 ISCO Industries.5 17 11 13.3 9 11 13.5 7.5 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 Fusion Hotline 1-800-345-ISCO ext.5 17 21 13.5 7.5 7.3 9 11 13.5 7.5 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 7.5 7.5 7.5 7. LLC All rights reserved.5 7.5 7.5 17 9 11 13.5 17 21 11 13.5 17 9 11 13.3 9 11 13.3 9 11 13.3 9 11 13.3 9 11 13.5 17 21 11 13.

Loosen all clamp knobs.Hydraulic Butt Fusion Machine Procedure Opening Movable Jaws After the joint has cooled for the recommended time. 46 Fusion Hotline 1-800-345-ISCO ext. and prepare for making next fusion. Pull Pipe through machine. and move carriage to the right far enough to open the jaw nearest the facer. use Trouble Shooting Guides on page 47 and 48 to determine problem and make adjustments before next fusion. Inspect joint and if it has to be redone. ISCO Fusion Manual Hydraulic Butt Fusion Machine Procedure Opening Fixed Jaws Open the fixed jaws Raise Pipe Raise the joined pipe using the pipe lift(s). 4790 © Copyright 2012 ISCO Industries. Open the movable jaws. shift the carriage control valve to the neutral position. LLC All rights reserved. .

When butt fusing pipe to molded fittings. all beads will not necessarily have equal size. the fitting side bead may have an irregular appearance. The double bead should be rolled over onto the adjacent surfaces. 4790 © Copyright 2012 ISCO Industries. cut it out and redo. The cleavage between the beads must not be lower than the wall of the pipe as shown in the lower right illustration. As illustrated in the Figure below. It is not necessary for the internal bead to roll over to the inside surface of the pipe. Butt Fusion Bead Dimensional Guideline Fusion Hotline 1-800-345-ISCO ext. 47 Hydraulic Butt Fusion Machine Procedure . and be uniformly rounded and consistent in size all around the joint.Hydraulic Butt Fusion Machine Procedure Butt Fusion Joint Troubleshooting Guide The Inspection Of The Fusion Joint ISCO Fusion Manual Golden Rule: If in doubt. This is acceptable provided the pipe side bead is correct. LLC All rights reserved.

insufficient heating & insufficient joining Bead not rolled over to surface force. 4790 © Copyright 2012 ISCO Industries. incompipe plete facing A third bead Excessive joining force 48 Fusion Hotline 1-800-345-ISCO ext. overheating Insufficient heating or joining force Excessive heating time Hydrocarbon contamination Hydraulic Butt Fusion Machine Procedure Excessive joining force. worn equipment.insufficient heating & excessive joining force Squarish outer bead edge Excessive double bead width Flat top on bead Beads too small Beads too large Rough.Hydraulic Butt Fusion Machine Procedure Butt Fusion Joint Troubleshooting Guide What Is Present One bead larger than the other ISCO Fusion Manual Attributing Factors Misalignment. . excessive joining force Excessive joining force. deep v-groove . defective heating Non-uniform bead size around tool. worn equipment. component slipped in clamp. bubbly. or pockmarked melt bead surface Double v-groove too deep Pressure during heating Overheating. LLC All rights reserved. pressure during heating Misalignment. incomplete facing Shallow v-groove . sand-paper like. insufficient heating.

4790 © Copyright 2012 ISCO Industries. 49 Hydraulic Butt Fusion Machine Procedure . 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.Hydraulic Butt Fusion Machine Procedure Position Pipe For Next Joint Move the fusion machine to the end of pipe. Install Next Piece Of Pipe Insert a new piece of pipe in the movable jaws and repeat all previous procedures. * This distance changes with fusion machine type. ISCO Fusion Manual Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved.

dirt. • Hydraulic Butt Fusion Machine Procedure • • 50 Fusion Hotline 1-800-345-ISCO ext. blowing dust and rain by using a canopy or similar device. When the ambient temperature becomes colder. Pre-Heating – When the ambient temperature is below 3°F (-16°C).Heating tool shall be shielded in insulated container to prevent excessive heat loss. Work quickly once pipe and fittings have been separated from the heating tool. but still take time (no more than 3 seconds) to inspect both melt patterns. After regular procedure for facing. . With pipe mounted in the fusion machine. 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. it will require a longer heating time to develop an indication of melt and the final bead size. 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 (450°F . snow.Hydraulic Butt Fusion Machine Procedure Cold Weather and Inclement Weather Procedure • ISCO Fusion Manual Wind and Precipitation . Shield the pipe fusion area and fusion tools from wind. depending on the pipe size and wall. Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. snow.50 inches (6. and other contamination.7mm) of the heater plate face to allow the pipe ends to warm for 30 seconds to 2 minutes. frost. 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.232°C) setting. so that melt heat loss is minimized.4-12. an alternate method of pre-heating is to stop the pipe ends within .25-. LLC All rights reserved. 4790 © Copyright 2012 ISCO Industries. Protective measures with auxiliary heating is recommended when temperatures are below -4°F (-20°C).

LLC All rights reserved.Saddle Fusion Machine Procedure Fusion Hotline 1-800-345-ISCO ext. 51 Saddle Fusion Machine Procedure . 4790 © Copyright 2012 ISCO Industries.

the original interfaces are gone. LLC All rights reserved. The area of pipe that the fitting will come in contact with must be cleaned and roughed up. and the fitting and pipe have become one homogeneous unit. When the polyethylene material is heated. and then fuse them together by application of force. The fitting must be properly seated on the pipe and then clamped in the machine for proper alignment.ISCO Fusion Manual Saddle Fusion Machine Procedure The theory of heat fusion is to heat two surfaces to a designated temperature. A melt pattern must be formed that penetrates into the pipe and into the fitting. When fusion pressure is applied. the molecules return to their crystalline form. The melt patterns must be joined with a specified force. 4790 © Copyright 2012 ISCO Industries. the molecular structure is transformed from a crystalline state into an amorphous condition. The force must be constant around the interface area. This pressure causes flow of the melted materials. . as well as the base of the fitting. which causes mixing and thus fusion. 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. Saddle Fusion Machine Procedure 52 Fusion Hotline 1-800-345-ISCO ext. The molten joint must be held immobile with a specified force until adequately cooled. As the joint cools. the molecule from each polyethylene part mix.

1416). 4790 © Copyright 2012 ISCO Industries. Fusion Hotline 1-800-345-ISCO ext. and the Fusion Force may be listed in the lower right corner of the fitting label for all saddle fusion fittings. Interfacial Area for Round Base Fittings: The radius of the saddle base squared times π (3. 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. Fitting Label: The Initial Heat Force.²). The Heat Soak Force is the minimum force (essentially zero pounds) that ensures that the fitting.ISCO Fusion Manual Saddle Fusion Procedures Definitions Initial Heat (Bead-up): The heating step used to develop a melt bead on the main pipe. This will eliminate the need to calculate the fusion forces in the field (example 80/0/40). 30 (Lb/in. The fusion force must be maintained for five minutes on 1-1/4 IPS or ten minutes for all other main sizes. The Initial Heat Force is determined by multiplying the fitting base (in. Fusion Force: The force (pounds) applied to establish the fusion bond between the fitting base and the pipe. This force is twice the fusion force. Initial Heat Force (Bead-up force): The force (pound) applied to establish a melt pattern on the main pipe.²) area by the initial heat interfacial pressure 60 (LB/ in. Some manufacturers have this information on fitting labels but not all. 53 Saddle Fusion Machine Procedure . The Fusion Force is determined by multiplying the fitting base area (in. without taking into account the curvature of the base or sides. heater. 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.²). and main stay in contact with each other. The joint must be allowed to cool undisturbed for an additional thirty minutes before tapping the main or joining to the branch outlet. Heat Soak Force: The force (pound) applied after an initial melt pattern is established on the main pipe. Cool Time: The time required to cool the joint to approximately 120° F (49° C). without taking into account the curvature of the base or sides. LLC All rights reserved.²) by the fusion interfacial pressure 30 (LB/in. Interfacial Area for Rectangular Base Fittings: The major width times the major length of the saddle base. minus the area of the hole in the center of the base. Heat Soak Force. minus the area of the hole in the center of the base. after which the saddle fusion equipment can be removed.²).

. .7 in² TEPA 54 Fusion Hotline 1-800-345-ISCO ext.d²) X 30 or FF =(D-wt) X wt X 3. 4790 © Copyright 2012 ISCO Industries. Base End OD Saddle Fusion Machine Procedure Base End d L W 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 (in²) * Add 30 Psi to your fusion pressure to compensate for drag when using hydraulic pump powered fusion equipment.e.785 X (D² .785 X d²) 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.14 x 30 Rectangular Base FF = L X W – (0.Saddle Fusion Procedures How To Figure Out Fusion Pressures Round Base FF = 0. LLC All rights reserved. ** Initial Heating Force is twice the heating force (i. 28 Combo have 4. twice the Fusion Gauge Pressure) Examples: Sidewinders have 1 in² TEPA No.

55 Saddle Fusion Machine Procedure . Secure the tool to the main. The tool should be centered over a clean. holding the fitting. dry location where the fitting will be fused. After abrading. brush residue away with a clean. dry cloth. LLC All rights reserved. to remove oxidation layer and contaminants. 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. Fusion Hotline 1-800-345-ISCO ext. Install the Saddle Fusion Tool on the main according to the manufacturer’s instructions. rounding the main for good alignment between the pipe and fitting. This tool must be capable of holding and supporting the main.ISCO Fusion Manual Saddle Fusion Procedures Prepare Fusion Machine This procedure requires the use of a Saddle Fusion Tool like the examples shown on the cover page of this procedure. applying and indicating the proper force during the fusion process. 4790 © Copyright 2012 ISCO Industries.

Abrade the fusion surface of the main with a 50-60 grit utility cloth to remove oxidation layer and contaminates. ! CAUTION 56 Fusion Hotline 1-800-345-ISCO ext. The non-stick coating on the heater adapters should be in good condition. Check heater plates periodically in multiple locations with a pyrometer and make necessary adjustments. Heating ! DANGER Heater is Not Explosion Proof. Important: The dial thermometer on the heater indicates internal temperature. Serrated heater adapters are recommended to allow for maximum heat penetration. dry cloth. After abrading. LLC All rights reserved. The abraded area must be larger than the area covered by the fitting base. The dial thermometer can be used as reference once the surface temperature has been verified. Saddle Fusion Machine Procedure Using the Saddle Fusion Tool. . move the fitting base and apply about 100 pounds force to seat the fitting. The heater must be fitted with the correct heater adapters. 13 and 14 in Safety Section. If working in a hazardous environment review pages 7. The temperature of the heater adapter fusion surfaces must be 490-510º F. 4790 © Copyright 2012 ISCO Industries. Incorrect heating temperature can result in questionable fusion joints. brush residue away with a clean.ISCO Fusion Manual Saddle Fusion Procedures Insert the fitting in the Saddle Fusion Tool loosely. with 500ºF being Optimum. Secure the fitting in the Saddle Fusion Tool.

Coated heater adapters are available for all fusion applications. apply the Initial Heat Force. and start the heat time.IPS) Place the heating tool on the main centered beneath the fitting base. Care should be taken to assure that the heater adapters are seated on the heater body. Saddle Fusion Machine Procedure Heating Procedure For Small Fittings (<2in. Important: Do not over-tighten the bolts. (see fitting label or use twice the calculated fusion pressure). Quickly check the melt pattern on the main pipe and fitting base for even melt patterns (no unheated areas).) At the end of the Total Heat Time (See Maximum Heating Time and Minimum Cooling Time Table. During Heating. and that there is no foreign matter trapped between these surfaces. Apply the Initial Heat Force until melt is first observed on the crown of the pipe main. the heating tool can slip out of position or displace the main or fitting melt and result in a poor joint. The surface of the heater adapters are coated with an anti-stick coating. Immediately move the fitting against the heater faces. Page 59). remove the fitting from the heater and the heater from the main with a quick snapping action. Heater adapters are installed with Stainless Steel Cap Screws. LLC All rights reserved.ISCO Fusion Manual Saddle Fusion Procedures Installing Fusion Heater Adapters The heater body of this assembly is not coated. 4790 © Copyright 2012 ISCO Industries. Hold the heating tool in position by lightly supporting the heating tool handle. (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. 57 . Fusion Hotline 1-800-345-ISCO ext. If not supported.

apply Initial Heat Force and start the heat time. Quickly check the melt pattern on the main pipe and fitting base for even melt patterns (no unheated areas). remove the Flexible Heat Shield. 4790 © Copyright 2012 ISCO Industries. and then place the flexible Shield between the heating tool and the fitting base. remove the fitting from the heater and the heater from the main with a quick snapping action. release the Initial Heat Force. apply Initial Heat Force. LLC All rights reserved. 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). move the fitting against the heating tool face. (This step could require an assistant to handle the Flexible Heat Shield). Maintain the Heat Soak Force until the Total Heat Time ends (See Maximum Heating Time And Minimum Cooling Time Table. Saddle Fusion Machine Procedure 58 Fusion Hotline 1-800-345-ISCO ext. When a melt is first visible on the main all around the heating tool faces. Page 59). in a quick continuous motion.) Place the heating tool on the main centered beneath the fitting base while supporting the heating tool handle. Move the fitting against the Flexible Heat Shield. and observe melt bead formation on the main all around the heating tool faces. raise the fitting slightly. .ISCO Fusion Manual Saddle Fusion Procedures Heating Procedure For Large Fittings (>IPS 3in) and Large Mains (>IPS 6in. At the end of the Total Heat Time.

4790 © Copyright 2012 ISCO Industries. Fusion Hotline 1-800-345-ISCO ext. Stop heating when about 1/16”-1/8” bead is visible all around fitting base.ISCO Fusion Manual Saddle Fusion Procedures 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. 1-1/4 .) Stop heating when about 1/16” bead is visible all around fitting base. 59 Saddle Fusion Machine Procedure 2” IPS all DR’s Pressurized . LLC All rights reserved.2” IPS all DR’s Non-Pressurized 3” IPS all DR’s Non-Pressurized 10 min. 4” IPS and Larger Stop heating when about 1/8”-1/4” bead is all DR’s 10 min. + 30 min. + 30 min. Do not exceed 15 sec. visible all around fitting base. Minimum Cooling Time 1-1/4” IPS all DR’s Pressurized 5 min. 10 min. 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. + 30 min. when hot tapping (blowout may occur if main line is pressurized. Do not exceed 25 to 35 sec. + 30 min. + 30 min.) Stop heating when about 1/16” bead is visible all around fitting base. when hot tapping (blowout may occur if main line is pressurized. 10 min.

Environmental conditions on a job site could affect heating and cooling times. Important: Visually check the fusion bead around the entire fitting base at the main pipe. The assembly should cool for an additional 30 minutes before rough handling or tapping the main. Do not increase or decrease the heating tool temperature. Saddle Fusion Machine Procedure 60 Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved. The first bead is the fitting base melt bead. The fusion bead should be uniformly sized all around the fitting base. Important: These procedures are based on tests conducted under controlled ambient temperature conditions. cut off the saddle fitting above the base to prevent use and relocate to a new section of main. and should have a characteristic “threebead” shape. 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). The second or outermost bead is produced by the edge of the heating tool face on the main. .ISCO Fusion Manual Saddle Fusion Procedures Fusion and Cooling Whether or not the melt patterns are satisfactory. The second bead is usually smaller. Then make a new saddle fusion using a new fitting. Maintain the Fusion Force on the assembly for 5 minutes on 1-1/4” IPS mains and for 10 minutes on all larger sizes . (Fusion Force adjustment may be required during Cooling Time. the prescribed heating tool temperature is required. Inspect fusion using the troubleshooting guide on page 61 for proper melt patterns. The third or center bead is the main pipe melt bead. but should also be uniformly sized around the fitting base. 4790 © Copyright 2012 ISCO Industries. but never reduce the Fusion Force during the cooling). The first and third beads should be about the same 1/8” .1/4” size all around the fitting base. Regardless of job site conditions or ambient temperature. If melt patterns are not satisfactory or if the fusion bead is unacceptable. after which the saddle fusion equipment may be removed.

61 Saddle Fusion Machine Procedure . Incorrect heating tool faces. Component slipped in clamp. Fitting not secured in application tool. or pockmarked melt bead surface Hydrocarbon contamination Fusion Hotline 1-800-345-ISCO ext. Defective heating tool. Worn equipment. Insufficient joining force Excessive heating time. 4790 © Copyright 2012 ISCO Industries. Loose or contaminated heating tool saddle faces. LLC All rights reserved. Loose or contaminated heating tool saddle faces. Heating tool faces not within specified temperature Misalignment. 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. Defective heating tool. Heating tool faces not within specified temperature. Heating tool faces not within specified temperature Insufficient heating.ISCO Fusion Manual Saddle Fusion Procedures Troubleshooting Guide Observed Condition Non-uniform bead size around fitting base Possible Cause Misalignment. sandpaper-like. bubbly. Worn equipment. 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. 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.

When the ambient temperature becomes colder. LLC All rights reserved.266°C) setting. Shield the pipe fusion area and fusion tools from wind. . frost. dirt. After regular procedure for facing. Work quickly once pipe and fittings have been separated from the heating tool. Do not increase heating tool temperature above the specified temperature (510°F .Heating tool shall be shielded in insulated container to prevent excessive heat loss.Saddle Fusion Procedures Cold Weather and Incement Weather Procedure • ISCO Fusion Manual Wind and Precipitation . Protective measures with auxiliary heating is recommended when temperatures are below -4°F (-20°C). 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. blowing dust and rain by using a canopy or similar device. and other contamination. 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. 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. so that melt heat loss is minimized. snow. it will require a longer heating time to develop an indication of melt and the final bead size. snow. Pre-Heating – When the ambient temperature is below 3°F (-16°C). Open pipe ends should be covered with plugs or covers to protect the heater from unacceptable temperature variations. • Saddle Fusion Machine Procedure • • 62 Fusion Hotline 1-800-345-ISCO ext. but still take time (no more than 3 seconds) to inspect both melt patterns. 4790 © Copyright 2012 ISCO Industries.

Convex (Large Round Base) 5 .Convex (Small Round Base) Fusion Width 2 .e.e.Convex (Large Round Base) Fusion Hotline 1-800-345-ISCO ext.00”) Adapter Fusion Width 0 . 2.Concave (Rectangular Base) Serrated Face 5-Concave (Large Round Base) (Drop for Smooth Face) 4 .e.Convex (Rectangular Base) Fusion Width 4 .00”) (i. 4790 © Copyright 2012 ISCO Industries.37”) Fusion Width 3.Convex (Small Round Base) 2-Convex (Rectangular Base) 1 . LLC All rights reserved.Convex (Rectangular Base) 4-Convex (Large Round Base) 3 .Concave (Small Round Base) 3-Concave (Rectangular Base) 2 .e. Fusion Width 2.37”) Heater Size (2”or 4”) Code System Serrated Face (Drop for Smooth Face) 1-Concave (Small Round Base) 0 . 63 Saddle Fusion Machine Procedure .ISCO Fusion Manual Saddle Fusion Procedures Heater Adapter Code System Heater Adapter Heater Size (2” or 4”) Pipe OD (i. 3.Concave (Large Round Base) S 2 0 S 2 0 0 2 3 7 30-Convex (Small Round Base) 00 Pipe OD (i. 0237 300 ofof Adapter (i.

4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Saddle Fusion Procedures Fusion Width 1 .Concave (Small Round Base) Saddle Fusion Machine Procedure 64 Fusion Width 3 . .Concave (Large Round Base) Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved.Concave (Rectangular Base) Fusion Width 5 .

LLC All rights reserved. . 4790 © Copyright 2012 ISCO Industries.Socket Tooling and Fusion Procedure 1 2 4 5 3 6 Socket Tooling and Fusion Procedure 65 8 7 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 Fusion Hotline 1-800-345-ISCO ext.

When fusion pressure is applied. The molten joint must be held immobile until adequately cooled. As the joint cools. the original interfaces are gone. The fitting must be properly seated on the pipe for proper alignment. The melt patterns must be joined with pressure. This pressure causes flow of the melted materials. the molecule from each polyethylene part mix.Socket Tooling and Fusion Procedure The theory of heat fusion is to heat two surfaces to a designed temperature. . the molecules return to their crystalline form. and then fuse them together by application of force. A melt pattern must be formed that penetrates into the pipe and into the fitting. 4790 © Copyright 2012 ISCO Industries. The principle operations include: Clamping Cleaning Alignment Heating Joining Holding ISCO Fusion Manual Socket Tooling and Fusion Procedure 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 pressure must be constant around the interface area. and the fitting and pipe have become one homogeneous unit. the molecular structure is transformed from a crystalline state into an amorphous condition. 66 Fusion Hotline 1-800-345-ISCO ext. When the polyethylene material is heated. LLC All rights reserved. which causes mixing and thus fusion.

Remove shavings and burrs inside pipe end.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. oil-free. Secure 2” And Larger Fittings Place fitting in socket fitting holder. LLC All rights reserved. 67 Socket Tooling and Fusion Procedure . by wiping with a white clean. Place chamfering tool on end of pipe. Remove chamfering tool. both inside and outside. Clean the pipe end and fitting. Fusion Hotline 1-800-345-ISCO ext. lint-free cloth. 4790 © Copyright 2012 ISCO Industries. Depth Gauge The chamfering tool is also a depth gauge for measuring the length of pipe that will go into the fitting. Tighten socket fitting holder around fitting. Place the chamfering tool on end of pipe and turn to cut off sharp edge on top end of pipe. dry. Place cold ring clamp on pipe at the bottom of the chamfering tool.

then unplugged before entering the haz arduous atmosphere for fusion. If operating in a hazarduous environment the heater should be brought up to tem perature in a safe environment. Operation of heater in a hazardous environment without nec essary safety precautions will result in explosion and death. The dial thermometer can be used as reference once the surface temperature has been verified. Minimum 490° F. Optimum 500° Maximum 510° F. Check socket faces periodically in multiple locations with a pyrometer and make necessary adjustments. Use a clean white cloth to wipe the mating surfaces. ! DANGER Socket Tooling and Fusion Procedure Old Style Heater New Style Heater Heater Temperature ! CAUTION Incorrect heating temperature can result in questionable fusion joints. Important: The dial thermometer on the heater indicates internal temperature. The socket faces of the heater must be at the correct temperature. 4790 © Copyright 2012 ISCO Industries. 68 Fusion Hotline 1-800-345-ISCO ext. Notice: Do not touch with hands.Socket Fusion Tooling and Fusion Procedure Clean Fitting And Pipe Fitting and pipe must be clean and dry. ISCO Fusion Manual Heater Is Not Explosive Proof This heater is not explo sion proof. The non-stick coating on the heater adapters should be in good condition. LLC All rights reserved. non-synthetic cloth to clean the heater adapter surfaces. . Use a clean white.

Heat the pipe end and the fitting socket for the time required. See chart on page 72 for proper heating time. 4790 © Copyright 2012 ISCO Industries. Use a new fitting and repeat preparation and heating process over again. . If melt is not complete. Fusion Hotline 1-800-345-ISCO ext.Socket Fusion Tooling and Fusion Procedure Heating The Pipe And Fittings Firmly seat the socket fitting on the male adapter on the heater. LLC All rights reserved. Inspect Melt Quickly inspect the heated parts to make sure all surfaces have been melted properly. firmly against the cold ring clamp. cut off melted pipe end. ISCO Fusion Manual Remove Heater At the end of the heating time. 69 Socket Tooling and Fusion Procedure Notice: Do not twist fitting. using a snap action. pipe or heater. Place the female adapter of the heater over the end of the pipe. simultaneously remove the pipe and fitting straight out from the tool.

70 Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved. backfilling.Socket Fusion Tooling and Fusion Procedure Fusion And Cooling Immediately after the heater has been removed. Notice: Do not twist or rotate the fitting. ISCO Fusion Manual Socket Tooling and Fusion Procedure Inspecting Fusion Joint After completing the specified cooling and waiting time. Inspect the joint. There should be no gaps. See chart on page 72 for proper cooling time. the Cold Ring Clamp can be removed. . 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. or stressing the joint. firmly push the melted fitting squarely onto the pipe until it makes firm contact with the cold ring clamp. Total Cooling Time equals time shown on chart (page 72) plus an additional 5 minutes. 4790 © Copyright 2012 ISCO Industries. Hold the fitting firmly in place for the total cooling time. After an additional 3 minutes undisturbed cooling time. remove the cold ring clamp and the socket fitting holder. Allow an additional 10 minutes undisturbed cooling time before testing. Pipe and fitting should be aligned straight with each other. A good joint will have a uniform melt ring that is flat against the socket fitting and perpendicular to the pipe. Holding force may be relaxed when the cooling time ends.

or pockmarked melt bead surface Cold ring set too shallow Hydrocarbon contamination Fusion Hotline 1-800-345-ISCO ext. Insufficient heat time Pipe or fitting removed straight from heater face (twisting or removing from heater face at an angle). Cold ring not used. bubbly. 71 Socket Tooling and Fusion Procedure . joining together at an angle. Cold ring not used Pipe or fitting not removed straight from heater face (twisting or removing from heater face at an angle). Twisting while joining pipe and fitting together. LLC All rights reserved. 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. Twisting while joining pipe and fitting together. 4790 © Copyright 2012 ISCO Industries. sandpaper-like. Pipe or fitting not inserted straight into each other when fusing. Pipe or fitting not inserted straight into each other when fusing. or fitting melt bead set at incorrect depth. 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. joining together at an angle.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. 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.

Care should be taken to assure that the heater adapters are seated on the heater body.) (Sec. Important: Do not over-tighten the bolts. The surface of the heater adapters are coated with an anti-stick coating. backfilling. 4790 © Copyright 2012 ISCO Industries.)* (Sec. Coated heater adapters are available for all fusion applications. or stressing the joint. LLC All rights reserved.)* 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 3”IPS 4”IPS 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 Socket Tooling and Fusion Procedure * After an additional 3 minutes of undisturbed cooling time.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. Installing Socket Fusion Heater Adapters The heater body of this assembly is not coated. Heater adapters are installed with Stainless Steel Cap Screws. After removing the Cold Ring Clamp allow an additional 10 minutes of undisturbed cooling time before testing. and that there is no foreign matter trapped between these surfaces. . 72 Fusion Hotline 1-800-345-ISCO ext.) (Sec. the Cold Ring Clamp can be removed.

the surface of the heater adapters must be wiped with a clean. Follow these instructions carefully.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. Turn the adjustment shaft clockwise to lower temperature. One full turn equals approximately 100° F. (Old Style Heater) Old Style Heater New Style Heater Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved. 4790 © Copyright 2012 ISCO Industries. Allow sufficient amount of time for unit to stabilize at the new temperature (5 to 10 minutes) after each adjustment. The heater thermoswitch adjustment shaft protrudes through the heater handle base. Adjusting Heater Temperature ! CAUTION Incorrect adjustment can result in injuries as well as machine damage. counter clockwise to raise temperature. ! CAUTION Before and after each fusion is made. 73 Socket Tooling and Fusion Procedure . non-synthetic cloth.

the surface shall be protected from contamination until joined. Work quickly once pipe and fittings have been separated from the heating tool. • • Socket Tooling and Fusion Procedure • • Fusion Hotline 1-800-345-ISCO ext. After cleaning. This results in loose or slipping cold rings. dirt. it will require a longer heating time to develop an indication of melt and the final bead size. frost. Protective measures with auxiliary heating is recommended when temperatures are below -4°F (-20°C). The first cold ring clamp allows the pipe adjacent to heated pipe to expand to its normal diameter. Shield the pipe fusion area and fusion tools from wind. 3” and 4in. blowing dust and rain by using a canopy or similar device. but still take time (no more than 3 seconds) to inspect both melt patterns. If set (2) cold ring clamps are available.266°C) setting. so that melt heat loss is minimized. Place shim material (sand paper/emery cloth) in second set and clamp this set directly behind the first cold ring clamp. 4790 © Copyright 2012 ISCO Industries. 74 .Heating tool shall be shielded in insulated container to prevent excessive heat loss.pipe) using recommended times. Pre-Heating – When the ambient temperature is below 3°F (-16°C). LLC All rights reserved. When the ambient temperature becomes colder. snow..ISCO Fusion Manual Cold Weather and Inclement Weather Procedure • Wind and Precipitation . increase the soak time 3 seconds in cycles and observe the melt pattern till acceptable. such as in a truck cab. 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. Make sample welds on scrape pipe to develop melt patterns (particularly for IPS 2”. Fittings shall be stored at a warm temperature. Heating – Check the temperature of the heating tool regularly with a pyrometer or other surface temperature measuring devise. Cold Ring Clamps – Pipe outside diameter contracts when colder. clamp 1st set in normal position in loose fit. 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. snow. When melt pattern is incomplete. and other contamination. Do not increase heating tool temperature above the specified temperature (510°F .

Pendant/ Coach™ Equipment & Fusion Pressure Charts More helpful Information! Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved.Reference Information: McElroy DataLogger™. 75 Reference . 4790 © Copyright 2012 ISCO Industries.

200 Watt @ 120 VAC.270 Watt @ 240 VAC 1. 4790 © Copyright 2012 ISCO Industries. 28 No.750 Watt @ 120 VAC. 1Ph 10.38.800 Watt @ 120 VAC.5 KVA @ 240 VAC 60Hz Self-Contained Diesel Self-Contained Gasoline 6. 3Ph 35. 1Ph 3.35.5 KW / 7. 1Ph 4” . 412 No.000 Watt @ 240 VAC. 3Ph @ 240 VAC SelfContained 10 HP. 3Ph @ 240 VAC 10 HP.8 KW @120 VAC 2” .2. 1236 No.000 Watt @ 240 VAC. 2CU Socket Fusion Heater Power 300 Watt @ 120 VAC. 3Ph 65”. 2065 2” . 3Ph @ 240 VAC 10 HP.000 Watt @ 240 VAC. at sea Level 0. 28 No.200 Watt @ 120 VAC. 1Ph 1.0. 618E TracStar 500 No. 1Ph 4” .5 KW @120 VAC Self-Contained Diesel Self-Contained Gasoline 5.000 Watt @ 240 VAC.8 KW @120 VAC 4” . 1Ph 2” .000 Watt @ 240 VAC.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. 1648 No. 1Ph 4.5 KW @120 VAC 2” . 412E TracStar No. 1Ph @ 120 VAC 1 1/2HP.2. 1Ph 1.8 KW @ 120 VAC 0.750 Watt @ 120 VAC.950 Watt @ 240 VAC.ISCO Fusion Manual Reference Power Requirements Machine MiniMc No.800 Watt @ 120 VAC.000 Watt @ 240 VAC.437 Watt @ 240 VAC. 1Ph Saddle.3 KW @ 120 VAC 0.Heater .200 Watt @ 120 VAC. 1Ph Saddle. 824 TracStar 900 No.461 Watt @ 240 VAC.1.5 KW / 6. 3Ph 20.5 KVA @ 240 VAC 60Hz Self-Contained Diesel 17. 3Ph @ 240 VAC SelfContained 7. 28 CU Mc.Heater . 1Ph 3. 1Ph @ 120 VAC 1 1/2HP. 618 No.5 HP. 1Ph 1.Heater .2. 1Ph 3. 3Ph @ 240 VAC Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Reference 76 Fusion Hotline 1-800-345-ISCO ext. 3Ph None SelfContained 1 1/2HP.5 KW @120 VAC 2. 1Ph None Sidewinder TracStar No.000 Watt @ 240 VAC. 3Ph 20. 618 No.5 KW @120 VAC 4 KW @120 VAC 3.Heater .000 Watt @ 240 VAC. 1Ph 3.8 KW @120 VAC 4” .5 KW @120 VAC Self-Contained Gasoline 3. LLC All rights reserved.0. 3Ph @ 240 VAC SelfContained SelfContained 5 HP. 1Ph 3.461 Watt @ 240 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.750 Watt @ 120 VAC.2.1. 14 1. 1Ph 800 Watt @ 120 VAC. 1Ph @ 120 VAC SelfContained SelfContained 3 HP. 2LC No. 3Ph 48”.000 Watt @ 240 VAC. 1Ph 3. 412 No. 1Ph 800 Watt @ 120 VAC.270 Watt @ 240 VAC. .750 Watt @ 120 VAC. Req. 28 Pitbull TracStar No.

50” 21.43” 34.84” 1.13” 5.80” 32.32” CTS Pipe Sizes Pipe 1/2” 3/4” 1” 1 1/4” 1 1/2” 2” OD 0.00” 18.60” 25.64” Circumference 12.50” 5.00” 20.87” 41.00” 34.66” 61.00” 63.00” 28.55” 206.98” 50.30” 4.00” 32.06” 43.90” 2.00” 30.83” 69.50” 50.56” 6.30” 44. 4790 © Copyright 2012 ISCO Industries.11” 6.80” 57.68” 87.37” 2.13” Circumference 1.55” 62.53” 4.68” 28.05” 100.03” 11.00” 42.77” 40.50” 4.63” 8.Reference 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 0.00” 22.98” 2.66” 1.40” 81.75” 3.14” 17.10” 131.44” 15.63” 10.00” 24.96” 94.00” 38.87” 3.05” 1.92” Pipe 3” 4” 6” 8” 10” 12” 14” 16” 18” 20” 24” 30” 36” 42” 48” 54” 60” 64” DIPS Pipe Sizes OD 3.13” 1.88” 1.95” 150.46” 9. LLC All rights reserved.00” 36.59” 179.97” 7.75” 14.10” 13.08” 21.81” 113.47” 48.90” 9.21” 120.80” 159.00” 48.86” 81.69” 4.05” 11.25” 100.53” 106.22” 5.80” 6.00” Circumference 2.63” 0.32” 5.10” 33.30” 17.32” 1.81” 27.40” 19.12” 75.20” 15.38” 1.68” Fusion Hotline 1-800-345-ISCO ext.38” 193.64” 3.63” 2.27” 56.10” 61.80” 163.47” 20.00” 54.26” 67.00” 14.00” 52. 77 Reference .61” 65.07” 54.53” 139.36” 169.00” 16.00” 26.75” 12.65” 197.

92” 11.82” 31.10” 17.57” 16.27” 7 1/8” 21 1/2” OD 2.51” 12.13” 3.05” 13.68” 47.55” 6.90” ISCO Fusion Manual Pipe Size Reference Charts Metric JIS-1.91” 15.75” 49.50” 98.98” 3.48” 8.27” 7.89” 2.80” 77.99” 197.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 0.47” 17.30” 19.50” 4.46” 5. .49” 5.48” 0.95” 35.02” 39.33” 13.39” 42.61” 4.63” 12.50” 26.33” 45.54” Circumference 5.94” 12.69” 61.62” 4.48” 7.92” 15.52” 14.32” 39.54” 11.51” 6.98” 43.54” 78 Fusion Hotline 1-800-345-ISCO ext. 1U.95” 87.43” 111.95” 9.26” 7.86” 27.00” 14.96” What DR (or SDR) Pipe are we working with? DR (Dimension Ratio) = O.25” 6.92” 27.37” 4.66” 19.26” 3.31” 20. LLC All rights reserved. 2.25” 13.26” 24.05” 69.72” 55.37” 123. ÷ Wall Thickness Reference OD Pipe Sizes Pipe 2 5/8” 4 1/4” 6.40” 38.39” 23.87” 24.12” 173.12” 21.D.79” 7.50” Circumference 8.35” 19.02” 34.42” 55.83” 9.49” 7.96” 13.70” 22. 4790 © Copyright 2012 ISCO Industries.97” 6.96” 1.94” 7.79” 2.24” 148.84” 22.77” 51.16” 62.36” 3.09” 22.74” 8.70” 33.38” 67.84” 30.18” 2.41” 11.28” 3.91” 18.79” 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 1.50” 10.09” 1.

Note: Temperatures shown are fluid temperatures .Not ambient temperatures. The oil must meet 150 SSU at 100ºF. Note: This chart is based on pump manufacturer recommendations of 100 to 4000 SSU limits. For use in extremely cold ambient temperatures. Temperature rise of the hydraulic oil can vary from 30ºF to about 70ºF over the ambient temperature depending on the pressure setting. Mobile DTE 15M multi-grade hydraulic oil is installed at the factory. this oil should not be used for continuous operation below 20ºF. we suggest Mobile DTE 11. The following table specifies the oil temperature at various viscosities. wind.ISCO Fusion Manual Reference Hydraulic Fluid Characteristic Chart The use of proper hydraulic oil is mandatory to achieve maximum performance and machine life. The advantage of this oil is a wider temperature range. with the exception of a cold weather operation. LLC All rights reserved. age of the pump. etc. Hydraulic oil should have anti-wear and other special additives. This oil should not be used for continuous operation above 100ºF (oil temperature). 79 Reference . which can be used to -16ºF. 4790 © Copyright 2012 ISCO Industries. however. Fusion Hotline 1-800-345-ISCO ext.

ISCO Fusion Manual Reference Hydraulic Fluid Characteristic Chart 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. 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 Fusion Hotline 1-800-345-ISCO ext. . 4790 © Copyright 2012 ISCO Industries. LLC All rights reserved.I.

LLC All rights reserved. 4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Reference Hydraulic Fluid Characteristic Chart -20ºF -10ºF 0ºF 10ºF 30ºF 50ºF 70ºF 90ºF 110ºF 130ºF 150ºF 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 Fusion Hotline 1-800-345-ISCO ext. 81 Reference .

Fuse with pressure in center of screen.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. Navigate using numeric keys.key to scroll Type in parameter selected. then screen below will appear.to scroll up or down Type in pipe size press = SO18 Pipe Wall Thickness Select DR. let pressure stabilized press + and then = to set drag pressure NOTE: Drag automatically added to Heat and Fuse pressure 82 Fusion Hotline 1-800-345-ISCO ext. D112 Select Pipe Material List of pipe manufacturers in programmed into Coach. 15. Reference Fusion Equipment Safety Information Follow instructions on each screen for navigation instructions.71 for Pit Bull carriage. 4790 © Copyright 2012 ISCO Industries. or enter 4. then press =. Select setup. Password as shipped from McElroy. DIPS. OD. 1 Setup. enter password. Soak. <=> key.ISCO Fusion Manual Reference TracStar® Pendant/ Coach Setup To turn pendant on.to skip C092 Parameter Screen To allow you to review parameters entered. and <c> key. raise pressure until carriage starts to move slowly. mmOD using + or .010. shift carriage to neutral. mmWT using + or .to skip D126 Fuse (IFP) Type in pipe manufacturers recommended IFP usually 75 and press = D128 Cool (IFP) Press . 2 Pressure.44 (Green Cylinders) for T900 SO14 Pipe Size Select IPS. <+> and <-> keys. turn key to right. for T900) Enter -. WT. press 1 on the keyboard. LLC All rights reserved. Using facer pressure valve. Setup Fusion Parameters When starting a job the screen should read time in upper left hand corner. . press = D122 Heat (IFP) Type in 0. CO92 Parameters Screen Press + use parameters on screen Press . type in temperature and press = Heater off set (-10 for T500.32 (Orange Cylinders) or 29. 3 Menu on left side of screen and Face.enter new parameters If selected. 123. turn key to off. To turn pendant off. make selection and press = key SO3O Heater Temperature Use Pipe manufacturers recommend temperature. -60. press + if ok or . and enter 10 for T500 or 60 for T900 D140 Piston Area Press = to default to 6. or enter pipe manufacturers IFP if required D124 Soak (IFP) Press . Scroll through list using + or key.

to continue D170 Log another joint Press + to Log another joint or . press = C090 Indentifications Press + if correct data or . LLC All rights reserved.Stop logging before opening carriage or unclamping pipe D150 Datalogging Stopped Press + to view report or . 4790 © Copyright 2012 ISCO Industries. press = C106 Joint No. Fusion Hotline 1-800-345-ISCO ext. Type in joint No.to enter new data (Refer to Setup Fusion Parameters if .Logging will flash on screen during fusion operation D Screen Press 6 to stop Datalogging . C092. Type in Job No.pressed above) Type in machine ID press = C102 Employees No.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 . and C134 above.selected) D134 Drag Pressure Refer to Drag Pressure Setup in Setup Fusion Parameters Fusion Operation D Screen Press 4 to start Logging . 83 Reference .to enter new data C100 Machine ID (if .to continue D160 Print Report Press + to print or . Type in employee ID press = C104 Job No.to stop *** If + pressed then refer to C090.to change C092 Pipe Parameters + to use data or .

. it does not have an OFF switch. For as long as this switch is held. Stops logging is the Datalogger® is in data logging mode. Every time this switch is presses. refer to the Setting Time and Date section in the operator’s manual to check and set the correct date and time. LLC All rights reserved. hold down the Power button for 5 seconds. especially while logging data. Holding the Datalogger® button for 3 seconds stops logging. Note: it is best to disconnect (or stop communications) between the Recon and Datalogger® before turning off the Recon. Otherwise.ISCO Fusion Manual Reference DataLogger™ Operation Datalogger® DL3 Connect Pressure Transducer to Fusion Machine with a proper hydraulic quick disconnect. Takes temperature reading if the Datalogger® is on but not in the data log in mode. Tap Clock & Alarms. Turn off the Recon by pressing the Power button if it is on. Turns on the Datalogger®® if it is off (both LEDs off). LEDs Solid Orange LED on Datalogger® indicates it is initializing. For example to change the hour field. Tap the System tab. tap on it and then use the up and down arrow keys to adjust the number up or down. 3. Reference 84 Fusion Hotline 1-800-345-ISCO ext. 2. the Datalogger®® will remain on for 2 minutes is there is no communication activity. the Datalogger®® will stay on as long as there is communication between it and a Recon. Turn on the Datalogger® by pushing the multifunction switch. Flashing Green LED on the Datalogger® indicates it is operating normally. The Datalogger® cannot be turned off. Once turned on. Multifunction Switch 1. therefore. Recon Turn on the Recon by pressing the Power button. [For more details. Note: The Datalogger® turns itself off. It is very important to set the correct time and date because joint reports are time stamped using the Recon’s clock]. Select the respective time and date field by tapping on it and adjust the values accordingly. Date and Time: To set date and time: Tap Start> Settings. Flashing Blue LED on the Datalogger® indicates Bluetooth® radio in standby mode. 4790 © Copyright 2012 ISCO Industries. Reset: To reset a TDS Recon. The Datalogger® will automatically turn itself off if it is not logging data and 2 minutes elapsed since the Recon last communicated with it. Solid Blue LED indicates Datalogger® is communicating with Recon. the temperature will be displayed on the Recon screen. Flashing Red LED on the Datalogger® indicates it is logging data. This switch must be held for longer than 3 seconds to turn off logging. it adds another 2 minutes to the on time.

Recommended Precautions Fully charge the Recon before each use for optimal battery performance. If SDR or DR is unknown. you may exit the Log/Status dialog box by tapping the X at the top right hang corner and then turn off the Recon. A series of dialog boxes will prompt you to enter the information one step at a time. You may turn on the Recon and reconnect to the Datalogger® at any time or near the end of the fusion process. Tab the Start button and wait till the stopwatch appears at the bottom of the Recon screen. stop logging before opening the carriage or changing pressures. Close the carriage to bring the pipe ends against the heater and follow the proper shift sequence on the fusion unit and the pipe manufacturer’s recommendations for fusing pipe. The temperature box flashes *Log xxxoF to indicate the recorded temperature. Adjust the distance between the Datalogger® and the heater plate until the two laser beams converge to a single point. Make copies of the reports on a PC or print our hard copied to prevent data loss. the default drag value of 30 psi will be added by the Datalogger®®. pointing the temperature sensor at the heater plate. If you tab Next without entering a value. Set the carriage pressures according to the recommended gauge pressures. For more complete details of the Datalogger® see the operator’s manual. To conserve Recon battery. LLC All rights reserved.ISCO Fusion Manual Reference DataLogger™ Operation Set up to Log Data Tap Start > Programs > McElroy DL3-PCC. See fusion machines operations manual for measuring drag. release the Dtaalogger multifunction switch to record the temperature. 85 Reference . The recording joint report will transfer to the Recon automatically at the end of each joint when the Recon is connected to the Datalogger®. 4790 © Copyright 2012 ISCO Industries. In the Log/Status dialog box. Use the Recon screen to read the temperature. measure the actual wall thickness and select WT. Drag pressure must be entered for each fusion cycle. At the end of the fusion process. tap Setup…to begin entering information for the next joint. Enter the measured drag pressure and tab Next. Press and hold the Datalogger® multifunction switch to turn on the guidance lasers. Log Data The pipes should be faced off and aligned. press and hold the Datalogger® multifunction switch for over 3 seconds or from the Recon. Fusion Hotline 1-800-345-ISCO ext. The latest report appears on the screen for review. Stop communications and then turn off the Recon whenever monitoring is not necessary. Measure the heater temperature by holding the top of the Datalogger® about 4 inches from the heater plate and perpendicular to the heater plate. Open the carriage and place the heater on the guide rods between the faced pipe ends. To stop logging. Enter interfacial pressures and the Recon automatically calculates the corresponding carriage pressures. then Menu > Log/Status. Once the temperature is stable.

5 17 19 21 26 32.71 in2 Piston Area Heater Surface Temperature: 425ºF Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.5 84 109 193 311 17 73 94 162 257 21 82 138 216 26 73 118 182 Fusion Hotline 1-800-345-ISCO ext.5 15. 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 13.28 Cylinders: Green (High Force) . LLC All rights reserved. 4790 © Copyright 2012 ISCO Industries. 86 .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. 28 and McElroy TracStar No.ISCO Fusion Manual Reference If your cylinders are green Machines: McElroy No.4.

McElroy TracStar No.ISCO Fusion Manual Reference If your cylinders are green Machines: McElroy No.78 in2 Piston Area Heater Surface Temperature: 425ºF Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.5 15. McElroy No.5 17 19 21 26 32. 412. 618 Cylinders: Green (High Force) . McElroy TracStar No.11. 618. 4790 © Copyright 2012 ISCO Industries. LLC All rights reserved.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 Fusion Hotline 1-800-345-ISCO ext. 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 13.412. 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 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: 425ºF 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

88

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

ISCO Fusion Manual

Reference

If your cylinders are green

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: 425ºF 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

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

89

Reference

ISCO Fusion Manual

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: 425ºF 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

Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries, LLC All rights reserved.

101 21 133 159 189 256 455 529 703 908 26 114 135 159 215 413 437 579 746 DIPS Fusion Hotline 1-800-345-ISCO ext.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 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 1.5” 22” 24” 26” 28” 30” 32” 34” 36” 40” 42” 48” 51. 1648 and McElroy No. 4790 © Copyright 2012 ISCO Industries.5 101 120 141 158 164 190 217 247 280 314 351 389 460 519 669 766 839 1. 2065 Cylinders: Green (High Force) .022 21 117 140 166 187 195 226 260 297 336 378 423 471 557 630 814 932 1.5 15.380 26 32. Pipe Size 16” 18” 20” 21. 91 Reference .049 17 156 188 224 306 493 639 852 1. LLC All rights reserved.ISCO Fusion Manual Reference If your cylinders are green Machines: McElroy No.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 13.31.42 in2 Piston Area Heater Surface Temperature: 425ºF Interfacial pressure: 75 psi Note: Fusion pressure shown includes 30 psi for system drag.022 1.5 186 226 270 372 557 784 1.

4536 2.00155 0.003280839 645. 4790 © Copyright 2012 ISCO Industries.223 = = = = = = = = = = = = = = = = Millimeters Inches Millimeters Feet SQ. Inches SQ.02957 0.03 14. 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 25.785 0. Millimeters SQ. Inches Liters Liters Quarts Liters Gallons(fluid) US Kilograms Pounds Psi Psi Psi Fusion Hotline 1-800-345-ISCO ext.503 145.2642 0.03937 304.16 .057 3. LLC All rights reserved. .ISCO Fusion Manual 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.8 .205 14.9463 1.40 0.

Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fittings. Baltimore. Volume 8. 2002 3.04.04. ASTM D2657-97. Baltimore. 5. 2001 2. Polyethylene Joining Procedures. Washington. 4. 2002. 93 Reference . March 1998. U. Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe. 4790 © Copyright 2012 ISCO Industries. American Society of Testing and Materials.ISCO Fusion Manual Reference References 1. Pipeline Safety Regulations. Volume 8. 2002. LLC All rights reserved. CFR 49. 2002.S. Plastics Pipe Institute Technical Report-41. ASTM F1056-97. Department of Transportation. American Society of Testing and Materials. 6. Generic Saddle Fusion Joining Procedure for Polyethylene Gas Pipe. Standard Specification for Socket Fusion Tools for Use in Socket Fusion Joining Polyethylene Pipe or Tubing and Fittings. Plastics Pipe Institute. Fusion Hotline 1-800-345-ISCO ext. Plastics Pipe Institute Technical Report-33.

4790 © Copyright 2012 ISCO Industries.ISCO Fusion Manual Notes 94 Fusion Hotline 1-800-345-ISCO ext. LLC All rights reserved. .

4790 © Copyright 2012 ISCO Industries. LLC All rights reserved. 95 .ISCO Fusion Manual Notes Fusion Hotline 1-800-345-ISCO ext.

Inc. Plastic Pipe Institute Acknowledgements Brand Names and product names are trademarks of their respective owners. .McElroy Manufacturing. 96 Fusion Hotline 1-800-345-ISCO ext. 4790 © Copyright 2012 ISCO Industries. LLC All rights reserved.

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