McElroy Talon 2000, Operator'S Manual

Page 1: ...Manual 7848101 Revision C 9 20 Operator s Manual Original Language English Talon 2000 Fusion Machine ...

Page 2: ...This product and other products could be protected by patents or have patents pending All the latest patent information is available at patent mcelroy com ...

Page 3: ...Introduction McElroy University For more than 30 years McElroy has been the only pipe fusion machine manufacturer to continuously offer advanced training Course offerings are meant to enhance your efficiency productivity and safety in the proper use of McElroy machines McElroy University classes are structured so that the skills learned and the machines used in each class closely match the machine...

Page 4: ... Fulton Street Tulsa Oklahoma 74158 0550 PHONE 918 836 861 1 FAX 918 831 9285 EMAIL fusion McElroy com Note Certain repairs warranty work and inquiries may be directed at McElroy s discretion to an authorized service center or distributor TX02486 1 1 4 13 DISCLAIMER OF LIABILITY McElroy accepts no responsibility of liability for fusion joints Operation and maintenance of the product is the respons...

Page 5: ... 9 Safety Label Locations 1 10 Emergency Stop Locations 1 1 1 Overview Theory of Heat Fusion 2 1 Talon 2000 2 2 Talon 2000 Radio Remote 2 6 Heater 2 8 Facer 2 8 Hydraulic Fluid Reservior 2 9 Fuel Tank and Filler Cap 2 9 Power and Data Cables 2 10 Heater Stripper Cylinders 2 10 Indexer Skid 2 1 1 HMI Navigation Map 2 12 Talon 2000 Interface Main Screen 2 14 Machine Control Screen 2 16 COPYRIGHT 202...

Page 6: ... Configuration 3 4 Remove Facer from Storage Configuration 3 6 Remove Indexer from Indexer Skid 3 7 Lifting and Installing the Indexer Assembly 3 8 Install Upper Jaw Inserts 3 10 Calibrate Indexer Position 3 12 Install SIM Card for DataLogger Vault 3 13 Operation Prepare Heater 4 1 Load Pipe 4 2 Talon 2000 Fusion Operation 4 3 DataLogger Operation Joint Information 4 4 Machine Information 4 5 Pipe...

Page 7: ...b End Fusion 6 1 Transport Talon Remove Quarter Jaws 7 1 Attach the Indexer Assembly to Indexer Skid 7 3 Store Facer on Indexer Skid 7 4 Store Heater on Indexer Skid 7 5 Lifting Vehicle 7 7 Diagnostics Hardware Diagnostics Screen 8 1 Current Alarms 8 3 Chassis Settings Screen 8 5 Indexer Drive Settings Screen 8 7 Facer Drive Settings Screen 8 9 Heater Drive Settings Screen 8 1 1 Heater Temperature...

Page 8: ... Fusion Heater Plates 9 3 Clean Heater Surfaces 9 4 Facer Cutters 9 4 Clean Jaw and Inserts 9 4 Grease 9 4 Track Tension 9 5 Track Brake 9 5 Engine Oil 9 6 Air Filters 9 6 Pump Drive 9 7 Heater Facer Chain Tension 9 7 Remote Batteries 9 8 Fasteners Must Be Tight 9 8 Maintenance Checklist Talon 2000 Fusion Machine 10 1 Determining Fusion Pressure Determining Fusion Pressure 1 1 1 Hydraulic Fluids H...

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Page 10: ... job easier in some way PELIGRO PELIGRO ADVERTENCIA PRECAUCIÓN ОСТОРОЖНО ATTENTION Read and Understand Do not operate this equipment until you have carefully read and understand all the sections of this manual and all other equipment manuals that will be used with it Your safety and the safety of others depends upon care and judgment in the operation of this equipment Follow all applicable federal...

Page 11: ...expect or that you think may be unsafe ДУМАЙТЕ О БЕЗОПАСНОСТИ В ПЕРВУЮ ОЧЕРЕДЬ PENSEZ Sécurité en 1er SAFE1ST 12 22 92 Wear Safety Equipment Wear a hard hat safety shoes safety glasses and other applicable personal protective equipment Remove jewelry and rings do not wear loose fitting clothing and tie back long hair that could catch on controls or moving machinery WR00053 12 2 92 TX001 14 4 22 93...

Page 12: ... stored Do not start the engine near spilled fuel Wipe up spills immediately Make sure the fuel tank cap is closed tightly and properly secured Avoid repeated or prolonged fuel contact with skin or breathing of fuel vapor TX00953 04 18 16 FUEL CD00365 2 19 97 PELIGRO PELIGRO Carbon Monoxide Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide can cause severe nausea fainting and ...

Page 13: ...when the pipe and handling equipment are in motion When in motion all persons involved in handling pipe should be able to see all other persons at all times If any handling person is not in sight immediately stop moving equipment and pipe and locate that person Do not continue until all persons are accounted for and in sight Never push roll dump or drop pipe lengths bundles or coils off the delive...

Page 14: ...nt to remember that a sudden hydraulic oil leak can cause serious injury or even be fatal if the pressure or oil temperature is high enough Escaping fluid under pressure can penetrate the skin causing serious injury Keep hands and body away from pinholes which eject fluid under pressure Use a piece of cardboard or paper to search for leaks If any fluid is injected into the skin it must be immediat...

Page 15: ...oad unattended 6 Do not remove or obscure warning labels 7 Read and understand the lifting device operator s manual before use 8 Stay clear of the suspended load 9 Lift loads only as high as necessary 10 Do not alter or modify the lifting device 1 1 Employ generally accepted safe lifting practices 12 Do not shock or impact load the lifting device 13 Inspect all lifting pins for damage See lifting ...

Page 16: ... TX04756 1 1 20 14 WR00108 1 1 17 14 ADVERTENCIA Battery Do not expose the battery to flames or electrical sparks Hydrogen gas generated by the battery is explosive Serious injury can result from an exploding battery The battery contains acid that can cause burns Do not allow battery fluid to contact your skin eyes fabrics or painted surfaces After touching a battery or battery cap do not touch or...

Page 17: ... 1 1 17 14 WR00109 1 1 17 14 WR001 10 1 1 17 14 Safety 1 8 Facer Cutters Are Sharp Facer cutters are sharp and can cut Never attempt to remove shavings while the facer is running or is in the facing position between the jaws NOTICE De energize the machine before attempting any maintenance or adjustment to facer NOTICE Use only the cutters specified in the Maintenance section of this manual TX04993...

Page 18: ...o all specified parameters NOTICE Failure to follow the pipe manufacturer s fusion procedures or appropriate joining standard could result in a bad fusion joint TX02984 04 18 16 WR00079 2 7 96 Inside of Pipe is Slippery Inside of pipe is slippery and you could fall resulting in minor to moderate injury Use caution by using arms to stabilize yourself while moving inside the pipe TX04762 12 02 14 WR...

Page 19: ...G Part Number 8163261 WARNING Part Number 8163260 WARNING Part Number 8163275 CD01305 04 15 16 CD01306 04 15 16 PH05389 04 15 16 PH05391 04 15 16 PH05390 04 15 16 PH05388 04 15 16 CD01307 04 15 16 CD01308 04 15 16 Safety 1 10 A A A A A C C D D D C B B B C B ...

Page 20: ...rgency stop on top of the housing of the HMI display 2 PLC Box Emergency stop the front of the PLC box 3 Engine Control Box Emergency stop near bottom of engine control panel 4 Battery Compartment Emergency stop near battery compartment on the end of the power pack 5 Catwalk Emergency stop on catwalk handrail on top of the machine TX04996 05 03 16 Safety 1 1 1 1 2 3 4 5 CD01305 04 15 16 CD01306 04...

Page 21: ...leak tight connection is the result The principal operations include Clamping The pipe pieces are held axially and radially to allow all subsequent operations to take place Facing The pipe ends are faced to establish clean parallel mating surfaces perpendicular to the centerline of the pipes Aligning The pipe ends are aligned with each other to minimize mismatch of the pipe walls Heating A melt pa...

Page 22: ...two pipe ends There is a catwalk on the indexer assembly that allows operators to cross up and over the pipe that is clamped into the carriage The catwalk also allows access to the indexer electrical box for any maintenance or troubleshooting The vehicle has two hydraulically driven tracks that allow the machine to be driven and placed in the exact location it needs to be in for the fusion It can ...

Page 23: ...eater for melting the ends of the pipe for fusion 4 Indexer Contains the heater with heat shield and facer unit The indexer can move along the frame to be positioned over the fusion area 5 Facer The facer has a long boom with rotating cutters on the end to face the end of both pipes at the same time 6 Heat Shield Shield for insulating the heater and protecting nearby components and personnel from ...

Page 24: ...per jaws of the machine that encircle the pipe Inserts are available for different pipe sizes 9 Tracks Hydraulically driven tracks for machine movement 10 Lower Quarter Jaws Each jaw has two quarter jaws which open and close They are used to lift the pipe into the upper jaws and secure the pipe from the bottom There are different sized quarter jaws available for different pipe sizes 7 9 10 8 Fusio...

Page 25: ...SIM card 14 Engine Control Box Key start and instruments for the engine 15 Battery Disconnect and Fuel Shutoff Battery disconnect switch to shut off battery power to the power pack Fuel shutoff valve to shut off the supply of fuel to the engine 16 Battery Drawer Stores the batteries to power the power pack Holds two 12V batteries 17 Catwalk Ladder Removable ladder for access to the catwalk The lad...

Page 26: ... the tracks are disabled the carriage movements are enabled 7 Open Close Outer Fixed Quarter Jaws Open or close the quarter jaws 8 Open Close Inner Fixed Quarter Jaws Open or close the quarter jaws 9 Machine Elevation Up Down Raise or lower the elevation of the machine 10 Drive Power Pack Side Track Drives the track located underneath the power pack side of the machine 11 Drive HMI Side Track Driv...

Page 27: ... the machine 16 Radio Remote Power Rotate to switch the remote on or off Radio Remote Start Up A Power on the radio remote 16 B Release the Radio Disable button 1 C Wait a few seconds and press the Radio Remote Pairing button to pair the remote to the receiver on the machine TX04998 05 03 16 15 16 PH05503 04 15 16 ...

Page 28: ...th sides of the heater TX04999 05 03 16 Facer The facer assembly has a cutting disc on either side of a telescoping boom that moves in a 2 axis plane on a facer frame The facer will cut along the pipe ends moving around the pipe according to the size of pipe given in the Talon control application The facer frame can be raised and lowered between the carriage jaws and has facer stops on the frame t...

Page 29: ...filled by removing the cap A and the filter Reference the maintenance section of this manual for instruction on filling the hydraulic reservoir TX05001 05 03 16 Fuel Tank and Filler Cap Open the engine compartment door The filler cap A is located just inside the door of the engine compartment Only fill the tank with ultra low sulfur diesel fuel The tank has a breather B next to the filler cap TX05...

Page 30: ... to the indexer assembly at the electrical box adjacent to the power pack These 4 cables must be connected for the machine to operate TX05003 05 03 16 2 10 Overview Heater Stripper Cylinders The carriage jaws are equipped with heater stripper cylinders that push the heater away from the pipe so the heater can be raised out of the carriage after the heating operation The machine is equipped with st...

Page 31: ...tions for the heater and facer A toolbox is mounted for the storage of tools required for machine operation and hardware from the fusion machine The catwalk ladders have a storage location and the ladders are stacked and strapped down during shipping TX05005 05 03 16 CD01316 04 12 16 Toolbox Ladders Facer Shipping Rest Overview 2 1 1 ...

Page 32: ...ain Screen Settings Control Panel Machine Settings Hardware Diagnostics Alarm Buffer Current Alarms Shipping Process Read ings Program Information HMI Settings DataLogger Fusion Manual Fusion Machine Con trols MAIN SCREEN CONTROL PANEL ...

Page 33: ... Facer Calibration Heater Calibration Indexer Drive Settings Facer Drive Settings Heater Drive Settings Heater Temperature Control Chassis Settings On Screen Keyboard Task Manager Operator Panel CPU WEB Server User Administration User Logoff HMI SETTINGS MACHINE SETTINGS ...

Page 34: ...creen which has the controls to drive the machine and operate the carriage and jaws Manual Fusion Control Enables access to the following two options Facer Controls Opens the Manual Facer Control screen which has controls for operating the facer Fusion Controls Opens the Manual Fusion Control screen which has controls for operating the heater and hydraulic pressures Overview 2 14 PH05343 04 15 16 ...

Page 35: ...tank remaining and should be filled before the next fusion joint Heater Temperature Warning Indicates that the heater temperature exceeds the normal operating range Insulation Resistance Warning Indicates low insulation resistance in the AC system Alarm Indicates a module or sensor error Date and Time Displays the date and time Touching this area will open the HMI settings page This page has butto...

Page 36: ...se the fixed set of jaws Open and Close Movable Jaws Open and close the movable set of jaws Individual Jaw Open and Close Open and close an individual jaw on the carriage and also indicates the clamping cylinder pressure of the jaw below the each set of buttons Close Carriage Close the fusion carriage Open Carriage Open the fusion carriage Carriage Actual Close Pressure Set the pressure to allow t...

Page 37: ... Up Pitch the machine up with indication of the degree of pitch Pitch Machine Down Pitch the machine down with indication of the degree of pitch Headlights On Off Toggle the headlights on and off Work Lights On Off Toggle the work lights on and off Far Track Forward Backward Drive the far track forward or backwards The brake is released when driven and applied once drive is released Both Tracks Fo...

Page 38: ...t direction by yellow light Move Facer Up Down Move the facer frame position up and down The end of travel of the facer is indicated in that direction by yellow light Start Facer Start the facer and moves the facer along the circumference of the pipe Pressing the button again will pause the facer operation Facer Start Position Move the facer frame down and move the facer to the start position Abor...

Page 39: ...or for opening and closing the carriage The positions are open and close with neutral in the middle Between open close and neutral is a momentary movement position Pressure Adjustments 3 pressure adjustors for Facing Heating and Fusing pressures Touch the adjustor to bring up a keypad to enter the pressure value or close the keypad and use the up and down arrows to adjust the selected pressure Hol...

Page 40: ...pletely up or down The end of travel of the heater is indicated in that direction by a yellow light Heater On Off Switch Turn the heater on or off Heater Temperature Monitor Displays the current temperature of the heater The red indicator will be lit when the heater is powered on The green indicator will flash while the heater is coming up to the set point and will stay solid once the temperature ...

Page 41: ...or opening and closing the carriage The positions are open and close with neutral in the middle Between open close and neutral is a momentary movement position Pressure Adjustments 3 pressure adjustors for Facing Heating and Fusing pressures Touch the adjustor to bring up a keypad to enter the pressure value or close the keypad and use the up and down arrows to adjust the selected pressure Holding...

Page 42: ...ine Alarm Buffer Opens the Alarm Buffer screen This screen shows a log of activated alarms This is a log and can not reset Current Alarms Opens the Current Alarms screen This screen shows all of the current alarms active on the machine Process Readings Opens the Process Readings screen This screen shows the heater current hydraulic system pressure gauge pressure and carriage close pressure HMI Set...

Page 43: ...ware Diagnostic Opens the diagnostic information for the electronic hardware Shipping Opens the Shipping controls screen This screen has controls and settings for the shipping storage operation Machine Settings Opens the Machine Settings screen Heater Power Red light indicates the heater is powered on TX05009 05 03 16 Overview 2 23 ...

Page 44: ...iguration Change between 2 2 jaw configuration and 3 1 jaw configuration NOTICE Ensure the jaw braces are in the proper position for the jaw configuration being selected If not using the machine controls may cause damage to the machine Indexer Calibration Opens the Indexer Calibration screen Facer Calibration Opens the Facer Calibration screen Heater Calibration Opens the Heater Calibration screen...

Page 45: ...he Facer Drive settings screen Chassis Settings Opens the Chassis settings screen Heater Temperature Control Opens the Heater Temperature Control screen Heater Drive Settings Opens the Heater Drive settings screen Heater Power Red light indicates the heater is powered on TX05010 05 03 16 Overview 2 25 ...

Page 46: ...d of travel of the indexer is indicated in that direction by yellow light Facer Controls Controls to raise and lower facer The end of travel of the facer is indicated in that direction by yellow light Facer Start Position Move the facer frame down and move the facer to the start position Abort Facer Operation Aborts facer operation stops the cutters and stops facer movement Facer Home Moves the fa...

Page 47: ...ndicate the direction of the carriage movement If the carriage does not move the carriage target pressure can be adjusted Calibration Interlock Disables the interlocks to allow the indexer and carriage to be moved Indexer Calibration Calibrates the indexer and carriage Program Status Messages Displays messages about the operation of this screen TX0501 1 05 03 16 Overview 2 27 ...

Page 48: ...Controls to move the indexer The end of travel of the indexer is indicated in that direction by yellow light Facer Controls Controls to raise and lower facer The end of travel of the facer is indicated in that direction by yellow light Facer Start Position Move the facer frame down and move the facer to the start position Abort Facer Operation Aborts facer operation stops the cutters and stops fac...

Page 49: ...carriage movement If the carriage does not move the carriage target pressure can be adjusted Facer Controls Buttons indicate the direction the facer will move A enable jog mode button is in the center Facer Y Axis Calibration Calibrates the facers Y axis position Facer X Axis Calibration Calibrates the facers X axis position Program Status Messages Displays messages about the operation of this scr...

Page 50: ... Home Opens the Main Screen Previous Screen Opens the previous screen Indexer Controls Controls to move the indexer The end of travel of the indexer is indicated in that direction by yellow light Heater Controls Controls to raise and lower heater The end of travel of the heater is indicated in that direction by yellow light PH05481 04 15 16 ...

Page 51: ...icator will be lit when the heater is powered on The green indicator will flash while the heater is coming up to the set point and will stay solid once the temperature has reached the set point Heater Temperature Offset Enter the heater surface temperature readings to calculate the heater temperature offset Store Data Store the entered heater values TX05013 05 03 16 ...

Page 52: ...he home position Abort Facer Operation Aborts facer operation stops the cutters and stops facer movement Facer Shipping Position Moves the facer close to the shipping position It will then need to be positioned into the box on the indexer skid manually using the facer controls Facer Controls Move the facer using the directional arrow buttons Press the Facer X Y movement button to toggle the facer ...

Page 53: ...ravel of the heater is indicated in that direction by yellow light Radio Remote Disable Disable and enables the radio remote control to allow the operator to move the vehicle to connect the umbilical cables Message Screen Displays information during the operation of this screen TX05014 05 03 16 Overview 2 33 ...

Page 54: ...ns the McElroy Panel screen This screen allows changes to the operating system McElroy password protected Open Screen Keyboard Opens the On Screen Keyboard and the size and position of the keyboard can be adjusted Once closed the changes are saved for use on other screens Task Manager Opens the Windows task manager McElroy password protected Units Change the units the machine uses from US to Metri...

Page 55: ...ge users and user passwords User Logoff Log off the current user from the software Data Time Make changes to the date and time used by the software Store Data Stores the entered data to the PLC Time Zone Set the time zone Heater Power Red light indicates the heater is powered on TX05015 05 03 16 Overview 2 35 ...

Page 56: ...n Opens the previous screen User Administration Displays the list of authorized users for the software The password can be changed by touching an existing user but will require administrator authorization To create a new user double touch a new field and type the user name password and group Heater Power Red light indicates the heater is powered on TX05016 05 03 16 PH0541 1 04 15 16 ...

Page 57: ...ppropriately rated piece of overhead lifting equipment Lift and off load the vehicle to the ground If the vehicle can be driven off of the transport vehicle use the instruction on the next page to start the vehicle and use the remote control to drive the vehicle off of the transport vehicle ADVERTENCIA Long Legs of Lifting Sling Read Before Operating Before operating this machine please read this ...

Page 58: ...the vehicle This jumper will bypass the emergency stop from the indexer assembly and allow the vehicle to drive Å Ensure all emergency stops are not activated Å Turn on the battery disconnect switch Å Open the fuel shutoff valve Ensure personnel are clear of the machine before starting Failure to do so could result in serious injury or death to personnel Å Start the machine using the Engine Contro...

Page 59: ... Move the vehicle close enough for the vehicle to indexer umbilical cable to reach between the two assemblies Å Touch the Home button Touch the Settings button to open the Control Panel screen Å Touch the close application button Å Shut off the vehicle Å Remove the data jumper connector Connect the vehicle to the indexer using the included umbilical cable Å Restart the vehicle and log into the app...

Page 60: ...eld locks are above the heat shield stop When the heat shield lock is above the heat shield stop toggle all 4 locks on the heat shield assembly Lower the heater until the heat shield locks rest on the heat shield stops Heat Shield Stop Heat Shield Lock Toggle Heat Shield Lock CD01295 04 1 1 16 CD01296 04 1 1 16 CD01297 04 1 1 16 CD01298 04 1 1 16 ...

Page 61: ...rest The heater shield will stay in place as it is resting on the heat shield stops Remove the heater rest pin and stow in the provided location to prevent loss of pins Raise the heater fully TX05018 05 03 16 Set Up Talon 3 5 Heat Shield Rest Heater Rest Pin Heater Rest Pin Storage Location CD01300 04 1 1 16 CD01301 04 1 1 16 CD01619 04 1 1 16 CD01302 04 1 1 16 CD01302 04 1 1 16 ...

Page 62: ...he facer boom is accessible Å Touch the close application button Å Shut off the vehicle Å Install the facer cutters to the end of the facer boom Å Start the machine Å Send the facer to the home position by pressing the Facer Home button on the screen Å Navigate to the Control Panel screen and touch the close application button Å Shut off the vehicle Å Disconnect the vehicle to indexer umbilical Se...

Page 63: ...Set Up Talon 3 7 Remove Indexer from Indexer Skid The indexer is attached to the skid with 4 bolts Unbolt all 4 corners of the indexer using the supplied tools included in the toolbox CD01319 04 15 16 ...

Page 64: ...ng legs Blue of the sling connected to the two lift points away from the catwalk and the other legs Yellow connected to the points close to the catwalk Connect the sling to an appropriately rated piece of overhead lifting equipment Follow all applicable federal state local and industry specific regulations including the lifting safety warnings in the General Safety section of this manual when lift...

Page 65: ...locks to the locked position and tighten the locking nuts on the twist locks and pin the nuts in place Disconnect the lifting sling from the 4 lifting points and lift and move the lifting sling away from the machine Lower the lifting sling to ground and detach the lifting sling from the overhead lifting equipment Connect the 2 power plugs and 2 data cables for the indexer assembly to the vehicle a...

Page 66: ...nd place the insert against the upper jaw B and rotate B to secure the insert on the upper jaw insert bracket A The quarter jaws and inserts are heavy Using one person to lift the jaws and inserts may result in an injury Two people are required to lift the jaws and inserts Ensure the insert is rotated all the way until the bracket of the insert rests behind the upper jaw insert bracket Å Rotate th...

Page 67: ... jaw using two people and place the jaw on the lower jaw pivot Rotate the quarter jaw down into place The quarter jaws and inserts are heavy Using one person to lift the jaws and inserts may result in an injury Two people are required to lift the jaws and inserts Ensure the quarter jaw is rotated all the way until the jaw stops against the lower jaw pivot Å Install the two bolts and washers to sec...

Page 68: ...ve when attempting to move the facer an interlock is preventing the movement based on the indexers current calibration The facer interlock can be disabled to allow the facer to move in between the jaws NOTICE Disabling machine interlocks will not prevent crashing of components while moving the indexer and its components Use care when moving indexer components to prevent accidental crashing and dam...

Page 69: ...mber APN Access Point Name Provided by the cellular company Static IP address Provided by the cellular company Router overview 1 LEDs DC5V VPN IN OUT 2 2 port switch with the ports X2P1 and X2P2 for connection to the local area network RJ 45 jacks each with 2 LEDs 3 Terminals for in port and out port on the underside of the device 4 X1 USB connector currently without function 5 Antenna socket A2 t...

Page 70: ...ailable Ethernet port X2P1 or X2P2 in the router by using a standard Ethernet cable Å The network adapter of the PC must have the TCP IPv4 configured per below Å Go to Windows Start Menu and type Network and Sharing Center Å Make sure the PC is connected with the router through a Ethernet standard cable Å Click on Local area connection Set Up Talon 3 14 PH05484 04 15 16 PH05485 04 15 16 PH05486 04...

Page 71: ...inued Settings on the PC Å Click on Properties Å Select Internet Protocol Version 4 and click on Properties Å Check Use the following IP Address radio button Å Enter IP address and subnet mask shown in the image PH05487 04 15 16 PH05488 04 15 16 PH05489 04 15 16 ...

Page 72: ...192 168 1 1 Å A message related to the security certificate appears Å In Internet explorer select the red X Continue to this website Å For Mozilla Firefox select Add Exceptions check Permanently store this exception and then press Confirm Security Exception Å You will be prompted to enter the user name and the password Å Enter User Name admin and Password FRupha3t sensitive case Set Up Talon 3 16 ...

Page 73: ...reen is shown Å Go to External Network then UMTS EDGE Å IMPORTANT Do not change any settings otherwise indicated as follow Å If required enter the PIN number and save Å Enter the correct APN for the data plan provided by the cellular company and press Save Å Username guest Password guest PH05493 04 15 16 PH05494 04 15 16 ...

Page 74: ...l Place the SIM card in the tray so that the card audibly locks in place and so that its gold plated contacts remain visible Then push the tray with the SIM card completely back into the housing Å After installing the SIM card go back to the Network and Sharing Center and go to the Internet Protocol Version 4 TCP IPv4 Properties In the general tab click the radio button for Obtain an IP address au...

Page 75: ... for a few minutes before shutting off the machine to take heater temperature readings Incorrect temperature readings will affect the temperature offset of the heater The surface temperature of the heater may be out of range of the fusion standard Å Shut the machine down Å Measure temperature on the heater using a pyrometer at 4 points on each side of the heater If the measurements are not within ...

Page 76: ...pe should be able to see all other persons at all times If any handling person is not in sight immediately stop moving equipment and pipe and locate that person Do not continue until all persons are accounted for and in sight Å Position pipe support stands at each end of the machine to support and align pipe Å Use the Machine Controls screen to load the pipe into jaws of the carriage Allow 3 to 4 ...

Page 77: ...a data activated SIM card The DataLogger Vault is a software application from McElroy that provides joint data storage and analysis at no cost to users The DataLogger Vault is a secure online application that allows users to view and analyze their joint data from almost any device from almost any location All that is needed is a device such as a PC Mac smartphone tablet etc that has a browser and ...

Page 78: ...fusion joint is being performed Å Project Enter the name for the project the fusion joint is attached to Å Operator ID Number Enter the identification number for the operator Å Job Number Enter the job number for the project Å Joint Number The number of the current fusion joint The number will automatically increment as fusion joints with the same information are performed Å Notes Enter informatio...

Page 79: ...Å Machine ID The machine ID is displayed Å Fusion Type The type of fusion is displayed Å Machine Model The model of the fusion machine is displayed Å Specification Select the fusion standard to be used from a list of pre loaded fusion standards Å Interfacial Pressure Displays the interfacial pressure range used for the selected fusion standard The operator can type in a specific interfacial pressu...

Page 80: ...plays the fusion standard selected from the machine information screen Å Material Enter the pipe material of the pipe being fused Å Pipe Size Enter the size of the pipe being fused A drop down menu is available to select the appropriate unit of measurement for the pipe size Å Wall Thickness Enter the wall thickness of the pipe being fused A drop down menu is available to select the appropriate uni...

Page 81: ...he radio remote Use these controls to load pipe into the machine NOTICE Ensure the jaw braces are in the proper position for the jaw configuration being selected If not using the machine controls may cause damage to the machine To change the jaw configuration refer to the Special Operation Jaw Configuration section of this manual Press Next to go to the next screen 4 7 Operation PH05344 04 15 16 ...

Page 82: ...d the facer is in the start position If the facer is not in the start position open the carriage and touch the facer start position button to send the facer cutter to the start position Close the carriage against the facer stops Å Touch the facer start button to start the facer operation Touch the facer start button again to pause the facing operation Pausing the facing operation will stop the cut...

Page 83: ...nment Check the alignment of the pipe using the following procedure Å With the pipe ends together under facing pressure observe the outside diameter of the pipe ends for alignment Å If the pipe ends are not in alignment increase the pressure of the jaw clamps of the pipe on the low side using the Machine Controls screen Slip Check Perform a slip check using the following procedure Å Touch the fusi...

Page 84: ...uuming close to the ground so not to introduce dirt dust onto the pipe ends IMPORTANT A tarp can be used under the fusion area to remove shavings Inside of pipe is slippery and you could fall resulting in minor to moderate injury Use caution by using arms to balance while moving inside the pipe NOTICE Do not touch the ends of the pipe Contamination of the pipe ends could effect the fusion joint Å ...

Page 85: ...eration DataLogger Operation Fusion Parameters On this screen the fusion standard selected and the calculated fusion values are displayed When you are ready to start the fusion touch Start Log PH05418 04 15 16 ...

Page 86: ...essure Allow pressure to decrease to drag pressure Å If heating pressure is not required shift the carriage control valve to neutral position Å Allow the pipe to soak according to the fusion standard Å When the soak cycle is complete touch the Fusion Button to complete the fusion The Fusion Button will not appear until the minimum soak time has elapsed per fusion standard Å Allow the fusion joint ...

Page 87: ...touching the Fusion Joint Report Storage button If you receive this message box you do not have a USB device connected Ensure you have a valid USB device connected to the HMI and touch the Fusion Joint Report Storage button again If you receive this message box the joint report was not stored correctly If you receive this message box the credentials used to log into DataLogger Vault 4 13 Operation...

Page 88: ...t report was successfully stored and sent to the DataLogger Vault A new fusion joint can be performed To perform another fusion joint touch Start a New Fusion Joint The Joint Report Summary screen will be displayed Operation 4 14 PH05497 04 15 16 PH05501 04 15 16 ...

Page 89: ... and touch No to enter new parameters for the next fusion joint Touching Yes will display the Machine Controls screen so that fused pipe can be removed and new pipe can be loaded into the machine Touching No will display the screens for entering new parameters After new parameters are entered the Machine Controls screen will display allowing for pipe removal and loading Remove Fused Pipe Å The pip...

Page 90: ...er The hydraulic pressure controls are available to operate the carriage and have the ability to select between the 3 hydraulic pressures NOTICE The indexer must be calibrated before the first fusion of the work day to ensure the interlock s location is set to prevent accidental crashing of the indexer components against the components of the vehicle To calibrate the indexer position refer to the ...

Page 91: ...send the facer cutter to the start position Close the carriage against the facer stops Å Touch the facer start button to start the facer operation Touch the facer start button again to pause the facing operation Pausing the facing operation will stop the cutter in its current location The cutter will still rotate while paused If there are any issues with the facing operation touch the facer abort ...

Page 92: ... the fusion pressure to that value Check Alignment Check the alignment of the pipe using the following procedure Å With the pipe ends together under facing pressure observe the outside diameter of the pipe ends for alignment Å If the pipe ends are not in alignment increase the pressure of the jaw clamps of the pipe on the low side using Machine Controls screen Slip Check Perform a slip check using...

Page 93: ...isk of contamination If using a vacuum use caution while vacuuming close to the ground so not to introduce dirt dust onto the pipe ends IMPORTANT A tarp can be used under the fusion area to remove shavings Inside of pipe is slippery and you could fall resulting in minor to moderate injury Use caution by using arms to balance while moving inside the pipe NOTICE Do not touch the ends of the pipe Con...

Page 94: ... carriage control valve to neutral position Å The Fusion Button will appear after pressure has reached drag pressure Å Allow the pipe to soak according to the fusion procedure The stopwatch can be used to keep track of time Å When the soak cycle is complete touch The Fusion Button to remove the heater The machine will move on its own in order to complete the fusion The machine will remove the heat...

Page 95: ...in the positions that match the selected configuration When removing the jaw brace the inner fixed jaw will need to be moved slightly to allow the brace to be removed once it has been unbolted When changing configurations the movable jaws will need to be moved to close the distance between the two jaws so that the jaw braces will connect between the two jaws TX05027 05 03 16 Install Jaw Brace in t...

Page 96: ... 14 35 15 1 2 6 88 12 13 13 35 14 1 2 7 88 1 1 12 12 35 13 1 2 8 88 10 1 1 1 1 35 12 1 2 9 88 9 10 10 35 1 1 1 2 10 88 8 9 9 35 10 1 2 1 1 88 7 8 8 35 9 1 2 12 88 6 7 7 35 8 1 2 13 88 Remove the fixed jaw braces from between the 1 and 2 jaws on both sides CD02106 10 23 17 Some machine assemblies may be hidden in these illustrations for visibility of components in the procedure A B C 1 2 3 4 3 1 Ja...

Page 97: ...riate for the length stub end being fused Remove the stripper cylinder pushers from the outer fixed jaw 1 jaw Install the stripper cylinder pusher extensions B appropriate for the length stub end being fused CD02106 10 23 17 CD02106 10 23 17 CD02109 10 23 17 CD02504 05 13 20 Jaw Facer Rest Button Extension Stripper Cylinder Pusher Stripper Cylinder Pusher Extension Carriage Facer Rest Buttons ...

Page 98: ...pting to move the facer an interlock is preventing the movement based on the indexers current calibration The facer interlock can be disabled to allow the facer to move in between the jaws NOTICE Disabling machine interlocks will not prevent crashing of components while moving the indexer and its components Use care when moving indexer components to prevent accidental crashing and damage Å Press t...

Page 99: ... end holder Position the indexer towards the movable jaw end of the machine Lift the stub end holder above the machine and position it between the 1 and 2 jaws Open the quarter jaws of the 1 jaw Lower the stub end holder and place the holder in the 1 jaw Ensure the stops of the holder rest on the inner surface of the 1 jaw Close the quarter jaws of jaw 1 and secure the holder in the jaw Remove and...

Page 100: ...rks on each side of the top spoke of the holder Drive the holder into position below the upper jaw of jaw 1 Lift the holder up and ensure the stops of the holder rest on the inner surface of jaw 1 Close the quarter jaws of jaw 1 and secure the holder in the jaw Lower the forks enough to drive the forklift away from the machine CD021 12 10 23 17 ...

Page 101: ...ositioned Doing this will minimize the amount of alignment adjustments that will need to be done once the stub end is installed in the holder Tighten down the bolts on the slide clamp assemblies Remove the upper 3 over clamp plates A from the upper slide clamp assemblies Loosen the bottom 3 over clamp plates B from the lower slide clamp assemblies Loosen the holder alignment bolts roughly the same...

Page 102: ...er the stub end Tighten the over clamp plates Load pipe into the carriage Confirm the alignment between the stub end and the pipe Make adjustments to the alignment if needed and reconfirm the alignment Perform a fusion of the stub end and pipe using the appropriate fusion standard TX05407 06 1 1 20 CD021 16 10 23 17 CD021 17 10 23 17 CD021 12 10 23 17 ...

Page 103: ...achine up using the Machine Elevation button on the Machine Controls screen Å Close all four sets of jaws so the lower jaw pivot is in the proper position for quarter jaw removal Å Shut down the machine Å Remove the two bolts and washers that secure the quarter jaw to the lower jaw pivot Å Lift the quarter jaw using two people and rotate the jaw up on the pivot Å Lift the jaw up and away from the ...

Page 104: ...all applicable federal state local and industry specific regulations including the lifting safety warnings in the General Safety section of this manual when lifting Connect the lifting sling to the indexer assembly with the two long legs Blue of the sling connected to the two lift points away from the catwalk and the short legs Yellow connected near the catwalk Connect the sling to an appropriatel...

Page 105: ...xer Skid Å Position the catwalk over the extension ladders Lower the indexer assembly on the indexer skid Ensure the legs of the indexer assembly fit into the four corners of the indexer skid Å Bolt the indexer assembly to the indexer skid CD01322 04 15 16 ...

Page 106: ...ropriate interlocks and enable shipping controls to complete the shipping configuration NOTICE When lowering indexer components on to the indexer skid do not run components into the skid Damage to components could occur Å Touch the Facer Shipping Position button to send the facer near the shipping position Å Shut down the machine Å Remove both facer cutters from the indexer assembly Store the cutt...

Page 107: ...ter rest pins from the provided storage location and install the pins into hole below the Heat Shield Rest on both ends of the heater Å Raise the heater until the Heater Rest Pin is in contact with the Heater Shield Rest Heat Shield Rest Heat Shield Rest Heater Rest Pin Heater Rest Pin Storage Location CD01301 04 15 16 CD01301 04 15 16 CD01300 04 15 16 CD01619 04 15 16 ...

Page 108: ...at shield down until the heater rest on the cross member of the indexer skid NOTICE When lowering indexer components on to the indexer skid do not run components into the skid Damage to components could occur Å Close the application Å Shut down machine Å Disconnect the umbilical cable from the indexer assembly and from the vehicle Toggle Heat Shield Lock Heat Shield Stop CD01297 04 15 16 CD01296 0...

Page 109: ...fting sling to the vehicle with the two long legs White of the sling connected to the two lift points on the operator side and the short legs Yellow connected near the power pack Connect the sling to an appropriately rated piece of overhead lifting equipment Lift and load the vehicle onto the transport vehicle TX05028 05 03 16 7 7 Transport Talon ADVERTENCIA Long Legs of Lifting Sling CD01323 04 1...

Page 110: ...uttons may not be present unless certain selections or conditions are met Home Opens the Main Screen Previous Page Opens the previous page Manifold Rack Displays the I O modules on the manifold rack Chassis Rack Displays the I O modules on the chassis rack PH05402 04 15 16 ...

Page 111: ... fault it will display the module in red Touch the red module to see the error description Acknowledge Error Resets the errors to green Press this after the errors have been corrected It is suggested to scan for errors and correct those errors and then scan again to verify that the errors are corrected TX05029 05 03 16 Diagnostics 8 2 ...

Page 112: ...nt unless certain selections or conditions are met Home Opens the Main Screen Previous Page Opens the previous page Alarm Window Displays information about all of the alarms currently activated Alarm Status IO has been corrected I not corrected AI acknowledged error PH05404 04 15 16 ...

Page 113: ...Alarm The button will show all alarms as viewed and acknowledged Pressing this button will clear all alarms with status IO and add an A to alarms with a status I Alarms with a status I are not corrected TX05030 05 03 16 Diagnostics 8 4 ...

Page 114: ...ch Sets the values of the pitch and roll to zero This will set the values as if the machine is level Hydraulic Load Sensing On Off actuation On sends full pressure to the carriage cylinders only Off no pressure to carriage cylinders Machine Interlock Toggles the Machine Interlock on off This button is administrator password protected Machine Elevation Interlock Toggles the Machine Elevation Interl...

Page 115: ...and heater strippers Administrator password protected Track Drive Settings Input fields for adjusting the parameters of the track drive settings Loop time field is not adjustable Administrator password protected Elevation Cylinders Displays the height of each of the elevation cylinders on the chassis TX05031 05 03 16 Diagnostics 8 6 ...

Page 116: ... or conditions are met Home Opens the Main Screen Previous Page Opens the previous page Indexer Servo drive Bank of 4 indexer switches for the indexer Administrator password protected Operating status Displays a bank of status blocks The green blocks are active The gray blocks are inactive and red blocks are alarms Touch the red alarms to reset them PH05407 04 15 16 ...

Page 117: ...led the indexer will have to be moved manually Indexer Drive Parameters Displays fields for speed position and left and right end of travel set points for the indexer Administrator password protected The display on the right shows the current values of the speed current position torque and motor temperature Indexer Current Messages Displays the current number of alarm and fault messages for the in...

Page 118: ...tons may not be present unless certain selections or conditions are met Home Opens the Main Screen Previous Screen Opens the previous screen Operation Mode Contains facer controls facing direction CW CCW and facer interlocks Administrator password protected PH05408 04 15 16 ...

Page 119: ...status blocks The green blocks are active The gray blocks are inactive and red blocks are alarms Touch the red alarms in an attempt to reset it Servo motor Axis X Y Parameters Displays fields for speed position and left and right end of travel setpoints for the indexer The display on the right shows the current values of the speed current position torque and temperature Chip Guard Controls and fie...

Page 120: ...reen Previous Screen Opens the previous screen Control Word 1 Displays a bank of status blocks The green blocks are active The gray blocks are inactive and red blocks are alarms Status Word 1 Displays a bank of status blocks The green blocks are active The gray blocks are inactive and red blocks are alarms Touch the red alarms in an attempt to reset it PH05409 04 15 16 ...

Page 121: ...ater Speed Set points Adjust values for the heater speed McElroy password protected Heater Current Values Displays current values for speed current torque temperature and voltage for the heater Heater Elevation Control Controls for jogging the heater up and down There is a heater elevation interlock which can be enabled disabled Administrator password protected TX05034 05 03 16 Diagnostics 8 12 ...

Page 122: ...tions are met Home Opens the Main Screen Previous Screen Opens the previous screen Heater Temperature Control Settings Adjustable fields for heater control These fields are administrator password protected Heater RTD Display Displays the temperature of both RTD s and has a button for each to enable disable the heater RTD interlock PH05410 04 15 16 ...

Page 123: ...ature Control Error Difference between the target temperature and current temperature Heater Element Failure Detector Displays the amperage of two phases of the heater and if the amperage is out of range the heater will shut down There is a button to enable disable the heater failure interlock TX05035 05 03 16 Diagnostics 8 14 ...

Page 124: ...tion Some buttons may not be present unless certain selections or conditions are met Home Opens the Main Screen Previous Page Opens the previous page PLC and HMI Program Information Displays the information about the PLC and HMI programs PH05413 04 15 16 ...

Page 125: ...Talon 2000 Interface Heater Power Red light indicates the heater is powered on TX05036 05 03 16 Diagnostics 8 16 ...

Page 126: ...age Opens the previous page Hydraulic Supply Displays the system pressure of the machine Gauge Pressure Displays the pressure that would be seen on the gauge of the hydraulic manifold block on a McElroy fusion machine Carriage Close Displays the pressure that would be seen on the DataLogger port of the hydraulic manifold block on a McElroy fusion machine PH05482 04 15 16 ...

Page 127: ... CT1 Displays the amperage of one of the two phases of the heater Heater CT2 Displays the amperage of one of the two phases of the heater Heater Power Red light indicates the heater is powered on TX05037 05 03 16 Diagnostics 8 18 ...

Page 128: ...he top of the sight gauge when the oil is cool Ensure fluid is clear with no air bubbles present Refer to the Hydraulic Fluids section of this manual for hydraulic oil recommendations TX04965 04 1 1 16 Preventative Maintenance The machine must be kept clean and well maintained With reasonable care this machine will give years of service Therefore it is important that a regular schedule of preventi...

Page 129: ...ove the top reservoir cover of the reservoir to access the suction filters Use compressed air to remove contamination from the magnetic elements Hydraulic fluid should be changed to a different viscosity as weather conditions dictate Refer to the Hydraulic Fluids section of this manual for hydraulic oil recommendations TX04966 04 1 1 16 A Reservoir Cover Bleeding Air From Hydraulic System If there...

Page 130: ...tt Fusion Heater Plates Butt fusion heater plates are installed with stainless steel cap screws Always disconnect unit from electrical power source before beginning any maintenance to avoid the risk of electric shock De energize the machine by turning the battery switch to disconnected Install butt fusion heater plates while the heater is cool Care should be taken to assure that the butt fusion he...

Page 131: ... heater faces must be kept clean and free of any plastic build up or contamination Before each fusion joint the heater surfaces must be wiped with a clean non synthetic cloth NOTICE Do not use an abrasive pad or steel wool Use a non synthetic cloth that won t damage surfaces Refer to Prepare Heater in the Operation section of this manual for instructions for cleaning the heater TX04970 04 1 1 16 C...

Page 132: ...o the track Correct track tension is approximately 1 25 32mm Due to the track on the HMI side of the machine being covered with a guard the correct track measurement from the power pack side track can be used to set the HMI side track Measure the distance from the track weldment to the bottom of the track and use that distance to set the tension of the HMI side track To adjust track tension Remove...

Page 133: ...ter maintenance instructions TX04976 09 15 20 9 6 Maintenance CD01590 04 1 1 16 Engine Oil Check engine oil according to engine manual maintenance instructions Change engine oil after the first 50 hours of operation Following that change the oil and filter every 500 hours of operation Refer to the engine manual for engine maintenance instructions TX04975 09 15 20 Engine Oil Dipstick Engine Oil Fil...

Page 134: ...il level is to the MAX oil level on the dipstick It is recommended to change oil after the first 500 hours or 3 months of service which ever occurs first Under normal operating conditions it is recommends that the oil be changed every 1000 hours or 6 months of service The drain plug B is located on the bottom of the pump drive Inspect and clean magnetic drain plug for contamination or metal partic...

Page 135: ...remote to the bottom Push the battery away from the tabs holding the battery and lift the battery out of the remote Use the battery charger to recharge the battery Replace with a fully charged battery There is also a battery pack which uses standard batteries Place the 3 AA batteries into the battery pack and insert the battery pack into the remote TX04979 04 1 1 16 PH05474 03 31 16 PH05504 04 15 ...

Page 136: ...ed properly 1 1 Inserts fit and mounted properly 12 Facer works properly 13 Heater in good condition no nicks or gouges 14 Surface temperature check with a pyrometer 15 Switches and buttons work properly 16 HMI and software working properly 17 All hardware is with unit inserts and pins etc 18 System pressure 3000 psi 19 Power cords and plugs in good condition 20 All rest buttons in place 21 Stripp...

Page 137: ...IPS SDR 1 1 O D 8 625 inch DRAG as measured in PSI for this example use 30 PSI Recommended IFP 75 PSI Using a Model 28 High Force Fusion Unit O D 8 625 t 0 784 SDR 1 1 TEPA 4 71 From Table O D t t π IFP GAUGE PRESSURE DRAG TEPA 8 625 784 784 3 14 75 GAUGE PRESSURE 30 PSI 338 PSI 4 71 TX02893 04 18 16 Fusion High Force Medium Low Force Model A160 A250 0 895 28 4 71 3 24 1 66 250 4 71 3 24 1 66 412 ...

Page 138: ...80 F over the ambient temperature depending on the pressure setting age of the pump wind etc Mobil Univis N46 hydraulic fluid is installed at our factory The advantage of this fluid is a wider temperature range however this fluid should not be used for continuous operation below 24 F TX03082 04 18 16 NOTE This chart is based on pump manufacturer recommendations of 13 to 500 cSt NOTE Temperatures s...

Page 139: ...Specifications Talon 2000 Fusion Machine 13 1 193 4902mm 257 5 6540 5mm 148 5 3772mm STANDARD DIMENSIONS SHIPPING DIMENSIONS MINIMUM HOOK HEIGHT Maximum Height ...

Page 140: ... Fixture Assembly 225 lbs 102 kg Hydraulics System Pressure 3 000 PSI 206 8 BAR Max Hydraulic Reservoir Capacity 60 gal 227 liters Engine Engine 173 5 SHP 129 4 kW 4 4L 268 5 in3 displacement 4 cylinders twin turbo US EPA Tier 4i EU Stage III B Fuel Type Ultra Low Sulfur Diesel 15 PPM Fuel Tank Capacity 100 gallons 378L Operational Tank Capacity 12 Hours Heater Heater Power 70 500 W Facer Facer Cu...

Page 141: ...This manual is waterproof tear resistant grease resistant abrasion resistant and the bonding quality of the printing ensures a readable durable product The material does not contain any cellulose based materials and does not contribute to the harvesting of our forests or ozone depleting constituents This manual can be safely disposed of in a landfill and will not leach into ground water TX001660 8...

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