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 three 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, a CAN bus control system, along with many hydraulic, mechanical and electrical upgrades. Integrated, software-controlled machine options from manual to fully automatic improves operator consistency and adherence to standards.

FusionGuide™ Control System
Transforms Operator Experience

McElroy TracStar iSeries machines are powered by the new 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
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

Built-In DataLogger® Records Fusion Process

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

New Cowling Design Accommodates Fusion of Fittings & Tees

The TracStar iSeries machines feature a redesigned cowling to address a common request from the field — fusing of large tees and elbows without removing the carriage from the vehicle. The new two-step design of the vehicle now gives the operator that ability while also being reinforced to handle the weight of heavy fittings.

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.

Electronic Keypads & Paddles Provide Better Control

On all TracStar iSeries machines the manual hydraulic valves are replaced with smart keypads, which provide better feedback to operators. These smart 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.

Additional Features

Self-contained, self-propelled, all-terrain
Pipe lifts moved to the vehicle chassis allows for common hydraulic and electrical platform
New common indexer design across 630i, 900i and 1200i with collision-avoidance sensors to prevent damage to heater and facer
New braided wiring harness and sealed connectors for improved robustness in outdoor environments
Stage V- and Stage IIIA- compliant Perkins engine meets environmental requirements, generates less noise, offers greater torque for load response
System pressure raised to 3,250 psi for more power when you need it for ground drive, pipe lifts and other functions that use higher levels of pressure
Hydraulic hardline or hard tubing replaces hydraulic hoses, where possible, for reduced leak points; defined start/end points for easier assembly and rebuilds
GFCI has been replaced with a PCM (Power Control Module) to reduce false trips
New hardened controllers for vehicle and carriage
Wireless Remote Control ensures safe efficient working environment and precise machine placement
On-board generator for powering heater
Self-locking brakes
ISO-compliant industrial Teflon-coated heater plates
Powerful hydraulic facer for facing the toughest pipe with ease
Serrated jaws and inserts keep pipe from slipping during fusion
Patented Centerline Guidance System for equal distribution of force around the joint
Variable Speed Tracks


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

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