The Evolution of Fusion

The TracStar iSeries brings a new level of performance and reliability to the pipe fusion industry. A new family of fusion machines builds on the TracStar's historically rugged, self-contained tracked vehicle while adding industry-changing technology for an improved user experience across these new models. Numerous improvements have advanced the level of technology available while simultaneously hardening that technology to make the entire fusion experience more reliable. The TracStar iSeries features new emission-compliant engines along with many hydraulic, mechanical and electrical upgrades. Integrated, software-controlled machine options from manual to automatic improves operator consistency and adherence to standards.

Built-in DataLogger records fusion process and serves as operator input

An integrated DataLogger tablet serves as an operator input device for the TracStar iSeries machines and simultaneously documents the entire fusion process. Archive essential details related to the fusion operation and jobsite including operator information, machine information, GPS locations and more while assuring your fusion joint is in adherence with industry standards.

Learn more about DataLogger

Large-diameter TracStar iSeries pictured

FusionGuide™ Control System
Transforms Operator Experience

McElroy TracStar iSeries machines are powered by the FusionGuide Control System. Integrated software guides the user through every step of the fusion process via an easy-to-use ruggedized tablet. After the operator prepares the pipe and enters all joint details, the enhanced guided workflow manages machine pressures, carriage, heater actions, shift sequence, and more to ensure standards compliance and a successful fusion.

Choose Your Level of Machine Control

TracStar iSeries machines offer three levels of operator interaction and FusionGuide assistance to fit your jobsite requirements.

Level 1

Manual Control

Allows the operator to manually control carriage position and times during the fusion process.

Level 2

Enhanced Guided Workflow

Software-controlled shift sequence and heating / fusion times with on-screen prompts.

Level 3

Automatic Fusion

Fully automatic, software-controlled process

How does FusionGuide affect each step of the fusion process?

The FusionGuide Control System allows varying levels of control to fit your jobsite requirements and operator demands. Use the chart below to compare each of the three levels.

Manual operator-controlled operation
Automatic, software-controlled operation
Level 1 Level 2 Level 3
Pipe Alignment
Facing
Carriage position control
Level 1 Level 2 Level 3
Automatic drag pressure management
Drag adjustment
Calibrated pipe interface meet point
Level 1 Level 2 Level 3
Bead up time
Bead up carriage position
Heat Soak time
Heat Soak carriage position
Open/Close time
Open/Close carriage position
Fuse/Cool times
Fuse/Cool carriage position
An operator uses the DataLogger to interact with the TracStar fusion machine

Operator Interfaces Designed for greater control

Large-diameter TracStar iSeries machines replace manual hydraulic valves with smart keypads, providing better feedback to operators. Keypads help guide users through the fusion process by changing colors when certain actions are necessary. Additionally, the hydraulic valves and knobs have been replaced by new paddle levers which provide more precise control of the indexer and carriage.

TracStar 412i and 618i machines are operated through the DataLogger tablet. Easy-to-use, touch controls provide a simple interface for setting pressures, indexing the carriage, and more.

Indexer-mounted heater & facer improves efficiency

All TracStar iSeries machines include indexer-mounted heater and facers to reduce operator fatigue and increase productivity in the field. Large-diameter machines electronically pivot in and out of position with easy toggle buttons. A new mechanical release, featured on TracStar 412i and 618i machines, automatically removes the heater from the fusion zone as the carriage opens once the heat soak is completed.

An operator uses buttons and controls to operate a TracStar fusion machine in the field

Can Bus System & Touchscreen Allow Better Machine Diagnostics & Troubleshooting

A new Controller Area Network (CAN) bus system and Power Control Module (PCM) allows communication between the machine systems from heater control, carriage pressure and positions, and more. A seven-inch touchscreen vehicle display provides service and diagnostic information through the new systems for real-time machine information.*

* not available on TracStar 412i and 618i machines

Additional Features

  28 250 412i 618i 500 630i 900i 1200i
Self-contained, self-propelled, all-terrain ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Removable 3- or 4-jaw carriage for close quarter use ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Patented Centerline Guidance System for equal distribution of force around the joint ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Serrated jaws and inserts keep pipe from slipping during fusion ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Powerful hydraulic facer for facing the toughest pipe with ease ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Industry standard semi-automatic hydraulic control system ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Self-locking brakes ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
DataLogger® compatible ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
On-board generator for powering heater ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Dual hydraulic pipe lifts ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Operational fuel tank capacity (hours) 8+ 8+ 8+ 8+ 11+ 18 18 12+
Cylinder force options (H=High force, M=Medium force, L=Low force) HL HL HML HML M HM HM HM
Dual speed tracks ✓ ✓ ✓ ✓ ✓      
Variable speed tracks           ✓ ✓ ✓
Hydraulic clamping available (standard on 500 and 1200)     ✓ ✓ ✓ ✓ ✓ ✓
Battery disconnect for easy lockout ✓ ✓ ✓ ✓   ✓ ✓ ✓
Thrust-bearing-equipped clamp knobs to minimize force required to clamp and round pipe ✓ ✓ ✓ ✓ ✓      
Auto machine option ✓ ✓     ✓      
Combination unit (CU) available for sidewall fusion ✓ ✓            
Indexer-mounted, hydraulic pivoting heater and facer     ✓ ✓ ✓ ✓ ✓ ✓
Fuel-saving auto throttle         ✓ ✓ ✓ ✓
Wireless Remote Control ensures safe and precise machine placement           ✓ ✓ ✓
Ergonomic operator platform               ✓
Removable cowling design allows easy access for machine maintenance ✓ ✓ ✓ ✓   ✓ ✓ ✓
Remote engine stop/start     ✓ ✓   ✓ ✓ ✓
Outriggers for machine stability and leveling               ✓
Collision- avoidance sensors to prevent damage to heater and facer     ✓ ✓   ✓ ✓ ✓
FusionGuide™ Control System controls pressure calculation and guides operator through fusion process     ✓ ✓   ✓ ✓ ✓
Built-in DataLogger records fusion process and serves as operator input     ✓ ✓   ✓ ✓ ✓
Pipe lifts moved to the vehicle chassis allows for common hydraulic and electrical platform           ✓ ✓ ✓
Stage V- and Stage IIIA- compliant Perkins engine meets environmental requirements, generates less noise, offers greater torque for load response     ✓ ✓   ✓ ✓ ✓
ISO-compliant industrial Teflon-coated heater plates ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

Models

Select a machine below for more detailed specifications and model-specific features.

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