In the coming months, production is set to begin on two of the latest additions to McElroy’s machine lineup.

Building off the strong legacy of McElroy’s three existing TracStar iSeries machines, the TracStar 412i and TracStar 618i are designed to boost operator confidence and efficiency while also ensuring that joints are performed accurately and according to standard.

Figure 1: The TracStar 618i and TracStar 412i build from the strong legacy of McElroy's existing TracStar iSeries machines and are designed to boost both operator confidence and efficiency in the field. Source: McElroy Manufacturing

Like their current series 2 counterparts, the TracStar 412i is designed to fuse pipe sizes from 4 inch IPS to 12 inch DIPS (110 mm to 340 mm), and the TracStar 618i fuses pipe sizes from 6 inch IPS to 18 inch OD (180 mm to 450 mm).

“We’re excited to see production start on this line of machines,” said TracStar iSeries product manager Brett Stone. “Many of the improvements you see on these two new machines are direct results of feedback from our channel partners and operators who use these machines day in and day out.”

The power of FusionGuide Control

The TracStar 412i and 618i will incorporate the FusionGuide Control System seen on other TracStar iSeries models, providing operators with three levels of control during the fusion process. Each level has varying degrees of assistance, from manual control to fully automatic fusion.

FusionGuide Control implements an integrated software that guides the user through every step of the fusion process, including machine pressures, carriage, heater actions and the shift sequence.

The FusionGuide Control levels are as follows:

• Level 1 (manual control) — Allows the operator to control the carriage position and times during the fusion process.
• Level 2 (enhanced guided workflow) — This level provides a software-controlled shift sequence; however, the heating and fusion times have on-screen prompts.
• Level 3 (automatic fusion) — When fusing with this level, the entire fusion process is software controlled.

“In the four years since the launch of our large-diameter TracStar iSeries line, we’ve consistently heard from our partners and operators that the FusionGuide Control System has translated into countless hours and dollars saved in the field,” Stone said. “As we’ve continued to see more HDPE projects that utilize medium-diameter pipe, we knew that incorporating iSeries technology into our medium-diameter line of machines would provide an extra layer of value, both in terms of efficiency and quality control.”

What’s new

Figure 2: The DataLogger 7 is the most valuable tool on any fusion jobsite. In addition to recording all pertinent fusion parameters, the DataLogger can be used for inspections, rental fleet maintenance checklists and more. Source: McElroy Manufacturing

In addition to the incorporation of the FusionGuide Control System, the TracStar 412i and TracStar 618i include several new key features. These new machines include a DataLogger 7, which operates the machine as well as records fusion parameters. The DataLogger also provides a platform for firmware updates to the machines.

A new, seven-blade fan was added to the machine’s design to combat the extreme heat experienced at job sites around the world. For a machine fusing in 120° ˚F (49° C) conditions like those experienced in the American southwest or the Australian Outback, that additional fan power helps keep the fusion machine running at peak performance while also protecting the components from potential damage.

But there’s more. A new indexer keeps the heater and facer attached to the four jaw carriage, condensing the heater, facer and jaws into a single unit. Operators will be able to move the indexer side to side along a set of rails, allowing them to position the heater and facer between the carriage’s movable jaws as needed.

The indexer also includes a built-in stripping and release mechanism. Once the heat soak phase of the fusion process has been completed and the operator opens the carriage, the mechanism will automatically strip the heater from the ends of the pipe. As the carriage continues to move, the indexer will then retract the heater out of the fusion zone.

These new machines feature an improved design that represents its inclusion into the TracStar iSeries family. The new look allows for a new, larger-volume hydraulic tank that is secured beneath the machine’s dome. In addition to providing additional cooling, the new design also reduces the risk of accidentally adding the wrong fluid to the hydraulic tank.

“One of the many benefits to our channel partner network is the ability to have a dialog that lets us know exactly what challenges operators face with our machines,” Stone said. “That, in turn, gives us the opportunity to use that feedback and turn it into quality-of-life improvements for folks out in the field.”

Data driven

All fusion functions for the TracStar 412i and TracStar 618i — including setting machine pressures, carriage open/close and shift sequence — are performed using the DataLogger, a ruggedized tablet tailored to pipe fusion. In addition to controlling machine functions, the DataLogger records fusion parameters and other pertinent data during the fusion process.

Working in tandem with the DataLogger is the Vault, McElroy’s powerful cloud-based data storage platform. Operators can share reports with supervisors, owners and inspectors for closer evaluation to ensure each fused joint conforms to industry standards and is ready for service.

For inspectors or pipeline owners, the Vault is a valuable tool for inspection and archival. The Vault allows storage of photos for each fusion joint on a job, allowing for closer inspection and review to ensure a quality joint, every time.

And McElroy is consistently improving Vault functionality. In mid 2024, McElroy introduced Vault notifications, which let inspectors, contractors and operators know if a fusion is not performed according to the standard being used. Tailored to exception reporting, these notifications are sent directly to the user’s Vault dashboard, but can also be sent to inboxes as well.

An exception report highlights events that deviate from normal or expected results. For example, if the heat soak phase was terminated prematurely, or an incorrect pressure used during the fusion itself, then an exception report would be created.

“Exception reports are invaluable from a quality control standpoint,” said McElroy digital strategy director Chris Zenthoefer. “On our end, we wanted to make sure there was a way to highlight what exactly was done that didn’t line up with accepted best practices, and to make sure that information is delivered quickly to the correct person.”

Guided Firmware Updates

Figure 3: Recently, McElroy added Guided Firmware Updates to the DataLogger's functionality. This option easily guides users through each step of the firmware update process. Source: McElroy Manufacturing

As machines like the TracStar 412i and 618i become more integrated with technology, it’s important to ensure that equipment is using the latest software. In summer 2024, McElroy introduced Guided Firmware Updates to provide an easy, step-by-step guide for users needing to download and install new software to their machines. Updating firmware is essential to ensure the machine is running the latest version for continued enhancements and new features.

The Guided Firmware Updates process allows users to update components that are controlled by firmware for operation. This process, presented on the DataLogger, can be used as a step-by-step guide for updating machine components as new releases become available.

Equipment inspection

A fused joint is only as good as the machine performing the fusion. To provide yet another layer of quality control, McElroy recently introduced the McElroy Equipment Inspection App, which is best viewed using the DataLogger 7. It is also available for all Android and iOS devices. The inspection app allows machine owners to manage and maintain their fusion equipment, ensuring each machine is ready to perform.

Tailored to rental fleets, the app seamlessly guides users through the inspection process using pre-populated checklists for both machines and components. The app allows users to create customized inspection surveys for not just McElroy machines, but for any piece of equipment they own. As an added feature, the app provides easy access to replacement part numbers, allowing owners and distributors to quickly create a list of replacement parts if repairs need to be made.

Since it was first announced in late 2023, more than 13,000 inspections have been completed through the app.

“Much like Vault notifications, the numbers show us that users are finding value in this functionality,” Zenthoefer said.

Through the app, owners and technicians can share jobs and create detailed reports at the push of a button. Inspection reports that include statuses, images and comments can be downloaded from any device worldwide, giving operators the added assurance that their machines have been inspected and maintained according to McElroy’s industry-leading standards.

Figure 4: Another recent addition to the DataLogger 7 is Training Mode. In Trainer Mode, users can simulate the fusion process without the need for a fusion machine. Source: McElroy Manufacturing

Technology and McElroy

Since its inception in 1954, McElroy has remained committed to staying at the forefront of technological advances. And as the world becomes more technology-driven, McElroy has continuously worked alongside their distributors to realize their philosophy of improving the world through better infrastructure.

Like its larger TracStar iSeries counterparts, the TracStar 412i and 618i will include the ability to remotely diagnose machine issues. If an operator or contractor is encountering a problem with their TracStar iSeries, after obtaining permission to access the machine, McElroy technicians can log in to the machine remotely and access the machine’s full CAN traffic. Essentially “seeing what the fusion machine sees,” McElroy tech support can then provide help more quickly. This capability can greatly reduce the time spent waiting for answers.

Coming soon

The TracStar 412i and TracStar 618i are expected to begin shipping in late September 2024.

During the summer months of 2024, several channel partners traveled to Tulsa to work with these two new machines and provide feedback on the experience.

“It’s just amazing. I want to take three home,” said Jose Briones with Austin, Texas-based C. C. Carlton Industries, referring to the TracStar 618i that he worked with during his time in Tulsa.

Watch this video for more information on the TracStar 412i and TracStar618i.

About McElroy

Founded in 1954, McElroy Manufacturing has grown from a two-person start-up in an Oklahoma garage to the industry leader in fintube and pipe fusion machines. The name McElroy is recognized worldwide as the most reliable, efficient, rugged and technically advanced equipment in the world. McElroy credits its leadership to an unyielding focus on excellence that lies at the heart of the design, engineering and manufacturing of its products. For additional information, please visit the McElroy website. To place an order, contact McElroy Customer Care at customercare@mcelroy.com or call 918-831-9236.