TracStar® iSeries Software Release Notes

Current Public Releases

Carriage Control Module (CCM) 1.037
DataLogger Version 148, 1.31
Vehicle Control Module (VCM) 1.017
Operator Display Console v1.1.17

Previous Public Releases

Carriage Control Module (CCM) 1.036
DataLogger Version 140, 1.31
Vehicle Control Module (VCM) 1.016
Operator Display Console v1.1.14

January 25, 2024 Release Summary

DataLogger® Version 149, 1.31

Bug Fix

  • Bug fix related to a previous release.

January 12, 2024 Release Summary

Carriage Control Module (CCM) 1.037

  • Changes were made to adjust the cushion (flow) as the facer/heater approach the guide rod during fusion operation. This change will address variability in cushion settings.

January 10, 2024 Release Summary

This release includes changes to the facing process as well as increasing pressure limits for high drag environments and support of heaters with thick butt plates.  The vehicle release includes enhancements such as fault code updates, a gate lock feature and a change to hydraulic fan behavior.

Carriage Control Module (CCM) 1.036

What’s New?

  • High drag maximum pressure increase
    The drag pressure limit has been increased from 400psi to ~899psi to accommodate high drag environments. This change will affect drag, facing, alignment check and soak pressure, now all set to a limit of ~899psi.
  • Facing behavior (feed forward)
    The pressure limit has been increased to ~899psi as part of the changes for high drag environments with changes to logic to accommodate the higher pressures.
  • Gate lock (Hydraulic Lock)
    The gate lock function can be enabled on the vehicle screen. The carriage will automatically enable the hydraulic lockout for all vehicle and carriage functions when the gate is opened. When the gate is closed, the hydraulic lock can be turned off from the keypads.
  • Radial heater detection
    When the radial heater is selected on the vehicle screen, the carriage will adjust the heater thickness dimension for carriage travel calculations to accommodate the thicker butt plates.

Vehicle Control Module (VCM) 1.0017

What’s New?

  • Hydraulic fan changes
    • Increased the temperature threshold for hydraulic fan turn on and temperature difference between hydraulic fan turn on and turn off.
  • Revised or added the following faults
    • Revised to use carriage disconnected instead of in-ditch as logic for whether to report certain heater related faults
    • Added Bypass filter 1 disconnected fault
    • Added Bypass filter 2 disconnected fault
    • Added Facer Pressure input too high or disconnected fault
    • Revised threshold for Hyd Temp 1 & Hyd Temp 2 fault down slightly

Operator Display Console v1.1.17

  • Added required settings for enabling or disabling the gate lock feature based on the update to the carriage.

DataLogger® Version 148, 1.31

  • Minor updates for background items

June 22nd, 2023 Release Summary

This DataLogger release includes a new integration with the Highland VORTEX and Supercell electrofusion machines. The DataLogger provides real-time feedback and data collection during the user process and stores data in the Vault™. In addition, smaller-scale improvements include additional CAN log support for field diagnostic needs, machine/pipe selection additions and specification setting changes.

DataLogger® Version 140, 1.30

What’s New?

  • The DataLogger® 7 is now compatible with the Highland VORTEX and Supercell electrofusion machines as both a machine controller and data recorder. This integration allows the fusion process to be monitored through a live graphical interface and fusion data is saved both locally and to the McElroy Vault™ for future access and analyzation.

Additions and Improvements

  • For iSeries machines, improved CAN log support for field diagnostics (update from January 13, 2023 release, v. 134, 1.28.)
  • The Polygon HF and LT have been added as machine selections.
  • Nupi Niron All Pro has been added as a material selection.
  • The Profuse specification has been added, including the functionality to create “dummy” welds.
  • Minor change has been applied to the ISO low fusion specification.
  • New “flag” has been added to the ASTM specification in the Vault™ for reporting purposes.

December 9, 2022 Release Summary

Vehicle Control Module (VCM) 1.016

Bug Fixes

  • In cold weather, it was possible to see a false trip for the filter bypass and high-pressure filter due to the lower viscosity of hydraulic fluid. For fluid temperatures above 30F, fault trip time has been increased from 5 seconds to 30 seconds to reduce nuisance faults. For fluid temperatures less than 30F the same logic is in place (see VCM 1.013).
  • The following faults have been affected by the update:
    • Filter Bypass Warn SPN 520301 FMI 15
    • Filter Bypass Severe SPN 520301 FMI 16
    • Filter Bypass 2 Warn SPN 520339 FMI 15
    • Filter Bypass 2 Severe SPN 520339 FMI 16
    • High Pressure Filter Switch SPN 520334 FMI 31

September 20th, 2022 Release Summary

Additions and refinements in this release affect the DataLogger® and TracStar® iSeries™. This includes the additions of remote CAN logging as a diagnostic tool, fusion specifications, and Swedish translation for selection in the DataLogger®. For the TracStar® iSeries™, additional intelligence in the FusionGuide™ Control System has been added for an improved operator experience during fusion. These improvements include the marker/transition points for Fusions Levels 2 and 3. In addition, the Vault™ has been updated with an additional marker to improve exception reporting and minimize actual open/close time during fusion operation. Lastly, improvements have been made to the manual fusion process (Level 1) and electro fusion detection and reporting for select saddle fittings.

DataLogger® Version 131, 1.27

  • Remote CAN Logging – The CAN log records/sends messages from a TracStar® iSeries™ machine remotely. These records can be accessed and analyzed for use in high-level troubleshooting. The recording/sending of the data is optional according to user preference and can be enabled/disabled.
  • Improvement of manual fusion process (Level 1 Fusions) including reporting and recommended times.
  • Swedish translation – The additional language has been added as a selection in the setting preferences.
  • Norwegian (NS-Insta) fusion specification has been added for selection.
    • TracStar® iSeries™ improvements/additions:
      • Improvement of marker/fusion transition points for Fusion Levels 2 and 3. Level 1 improvements will be included in an upcoming release.
      • Marker added at the “end of open/close” which will be used by The Vault™ to improve exception reporting (which will minimize actual open/close time).
    • Refinement of electrofusion detection and reporting for select saddle fittings.

July 14th, 2022 Release Summary

The changes in this release added an option to restrict facer operation to only function when down in the fusion zone. Position control of the indexer during the open/close cycle was improved, usage of high engine throttle in Level 1 was reduced, and improvements were made to reduce the amount of noise the carriage makes when closing for some lower pressure operations. Finally, descriptions of a few vehicle fault codes were updated and a settings issue was corrected on the vehicle display.

Carriage Control Module (CCM) 1.035

What’s New?

  • Heater out is turned on when the carriage is moving, the heater is already up, and the operator isn’t requesting heater movement to keep the heater from drifting into the collision avoidance zone.
  • Engine throttle during Level 1 fusion changed to only be at high when carriage is moving or heater is on to provide additional fuel economy and less load on system.

Bug Fixes

  • Enhancements were made to improve positional control of the indexer during open/close cycle. In some cases, heater would contact pipe in movable jaws during open/close of a Level 2 or Level 3 fusion. Indexer position was increased by 10 mm and accuracy of target position was changed to 5 mm before heater out function is activated.
  • Improved the operation of carriage to reduce the amount of noise made when closing for the meet point check in manual drag and during alignment check or facing.

Vehicle Control Module (VCM) 1.015

What’s New?

  • Provides ability to restrict operation of the facer to only function when down in the fusion zone. Requires Carriage Control Module v1.035 and Vehicle Display Console v1.1.14 for option to function correctly.
  • Suppresses the PCM temperature fault code for PCM boards with v1.1.5 software.

Bug Fixes

  • None

Vehicle Display Console v1.1.14

What’s New?

  • Adds the option to restrict operation of the facer to only function when down in the fusion zone. Needs Vehicle Control Module v1.015 for option to work.
  • Changed default for beacon mode to operate when tracks are being used to reduce the amount of time the beacon is used.

Bug Fixes

  • Corrected description of several fault codes including SPN 520326 and SPN 3653.
  • Fixed security settings issue with facer alarm and RTD calibration where they couldn’t be changed if another advanced settings field had been changed by using a password.

May 17th, 2022 Release Summary

CCM 1.033 was found to have an issue with the incorrect auto-drag process released and assessing values higher than expected in some cases. This has been reverted back to the 1.031 version. Heater Offset Limit setting widened for increased range.

Carriage Control Module (CCM) 1.034

What’s New?

  • Previously the Heater Offset Limit range was -50°C to 20°C. This setting has been widened to -200°C to 200°C to allow more range between RTD and heater plate measurement.

Bug Fix

  • An incorrect auto drag method was released in CCM v.1033. For some users this resulted in higher than expected drag values. This was reverted back to the previous methodology.

DataLogger Version 120, 1.26

Bug Fix

  • For some users, the application would not open after update. This change in software update process handles updating from old application versions to latest version.

May 3rd, 2022 Release Summary 

The features and updates included with this release were to give the user an additional method to measure drag through a manual process. This method is intended for measuring high drag or when carriage movement is limited due to setup. An additional update has been included in this release to address some observations of brief overpressure when the pipe is brought together under pressure.

Carriage Control Module (CCM) 1.033 

What’s New?

  • Added the ability for the user to measure drag manually in a similar method to legacy machines. The operator will manually increase power until carriage movement is observed. Once the operator is ready they will select a confirm drag button and an automated process will run to determine the pipe meet point, check pipe slip, and set fusion pressures. This feature must be enabled in the iSeries Management Menu accessed by selecting the iSeries logo on the start screen.

Bug Fixes Some users observed a brief overpressure situation when closing pipe together. More dampening was added to this process for better pressure control during transition to higher pressure. Typically this would not cause an issue, but depending on the situation pipe slipping issues could cause problems completing the fusion.

April 18th, 2022 Release Summary 

The changes in this release were primarily to address an incorrect heater temperature display value. This display value is used in the WIS/GIS fusion specification and stops the user from starting the fusion if not within the proper temperature range.

DataLogger Version 119, 1.26 

What’s New?

  • Added a preference in the iSeries Management menu to enable or disable a manual drag measurement procedure. This feature is in the off position by default and will require a version of the Carriage Control Module (CCM) that has not been released yet. The CCM version is currently in closed testing and will be released at a later date.

Bug Fixes

  • A correction was made to the conversion of the heater offset. The displayed heater temperature should now match the Operator Display Console. This does not have any effect on the heater control as that process is fully functional, just ensures the heater temperature is displayed properly with the correctly converted heater offset. Requires Vehicle Control Module (VCM) 1.014.
  • Corrected certain text wrapping issues when user selected Portuguese in the language preference. Some of the text wrapping made certain buttons unreadable when the user had selected high contrast text and larger font sizes.
  • Corrected an issue when reading electrofusion fitting barcode for ISO manufacturers barcode standard. The fitting manufacturer indicated the fitting was multiple sizes however the barcode failed to list the additional sizes in the barcode itself. We have now made a change to accommodate this exception to the barcode standard.

Vehicle Control Module (VCM) 1.014 

Bug Fixes

  • A correction was made to calculation of the heater offset for the displayed heater temperature regardless of the temperature unit chosen.

April 1st, 2022 Release Summary 

The updates in this release were to correct a display issue that only affected the 1200i.

Operator Display Console v1.1.13 

Bug Fixes

  • Corrected issue of “Stop Facer to Track” dialog box shown on the Operator Display Console when using the remote to track and facer off. This only impacts the TracStar 1200i model.

February 14th, 2022 Release Summary

The changes in this release address the issues that stopped users from performing fusions in 3-jaw mode. Low-pressure control was improved for the TracStar 900i High Force and aligned with the logic in the other iSeries machine lineup. Finally, carriage stalling issues were addressed when using an in-ditch kit with low fusion pressures.

Carriage Control Module (CCM) 1.031

What’s New?

  • Enhancements were made to improve low-pressure control on the TracStar 900i HF and align with the pressure control logic of the other TracStar iSeries lineup.

Bug Fixes

  • Addressed issue that stopped users in 3-Jaw mode. 3-Jaw mode in this case is defined as when the carriage is removed from the 4-Jaw skid and the extensions kit is connected at the operator console. Level 1 Manual Fusion is the only selection option when in 3-Jaw mode due to the heater and facer arc sensors not being present.
  • For Levels 2 & 3 only, on low pressures when in in-ditch mode, during the open­ close sequence changes were made to prevent stalling issues and pipe not being able to close against the heater.

DataLogger® Version 107, 1.25

What’s New?

  • Improved the display of capture points of the various fusion stages (open/close start, open/close end, fuse start, cool start). This helps users when analyzing reports later in the McElroy Vault.
  • Added description to each FusionGuide Level as well as a “Help Me Decide” selection that presents an article to the operator with more details describing best use cases for each level.
  • Level 2 and 3 will not be a selection option when fusing in 3-Jaw mode.

Bug Fixes

  • Retain user selection of fusion type from fusion to fusion. Previously, this would reset to Butt Fusion as a default.

Vehicle Control Module {VCM) 1.013

What’s New?

  • Transmitting 3-Jaw mode active to the operator display for notification in the 1/0

screen. Needs vehicle display 1.1.12 to be seen.

Bug Fixes

  • In cold weather, there was a possible false trip for the filter bypass and high-pressure filter due to the lower viscosity of the hydraulic fluid. Adjustments were made to reduce the chance of this occurring.

Operator Display Console v1.1.12

What’s New?

  • Made various cosmetic changes to the display.
  • Added additional description when clearing fault codes to better indicate status to the user.
  • Included 3-jaw mode indication to carriage 10 screen. Requires VCM 1.013.

Bug Fixes

  • None

November 17th, 2021 Release Summary

The efforts for this release were primarily focused on the TracStar 1200i and TracStar 900i MF to coincide with the first production builds. The TracStar 900i MF built at this time was to be used to gain certification to operate in the UK under the GIS fusion standard. Several   enhancements were included for both WIS and GIS to serve those markets.

Carriage Control Module {CCM) 1.026

What’s New?

  • Enhancements were made to the open/close process to reduce the overall time open.
  • Added an alarm when the cool cycle is completed to alert the user that the process has been completed.
  • Enhancements were made to allow for the Dummy Joint process for the GIS fusion standard.

Bug Fixes

  • We observed that when the heater/facer was in the stowed position it could float towards the inner fixed jaw and put the machine into a collision-avoidance state and not operate. Now the indexer stays locked in the stowed position.
  • Sometimes at low pressure the reduced flow would not allow the heater to move at the start of the bead up, so we increased the flow so this would not happen.
  • The indexer lock solenoid coil current fault (SPN 520435 FMI 4) would falsely trip occasionally. Adjustments were made to eliminate this false alert.
  • Sometimes when the operator would use thee-stop to shut the machine down instead of the engine start/stop, output faults would appear. Adjustments were made to eliminate those false alerts.

Vehicle Control Module {VCM) 1.012

What’s New?

  • Added RTD calibration mode for GIS 2-3 fusion specification. Matches TracStar Auto capabilities.
  • Adjusted logic for new alarms being shipped by the manufacturer. At key on case only, the GCM detects as a fault.
  • Removed logic that shut the heater off during facer on operation
  • Removed ability to track if facer is on

Bug Fixes

  • Raised limit for RTD alignment fault to reduce nuisance alarms.

Operator Display Console 1.1.11

What’s New?

  • Added RTD calibration mode for GIS 2-3 fusion specification. Matches TracStar Auto capabilities.
  • Added pipe lifts to output page
  • Won’t allow track movement if facer is on indication

Bug Fixes

  • None

Datalogger Version 101, 1.24

What’s New?

  • Added Dummy Joint selection for WIS, GIS, and DVS standards. The process will run as normal through the heat soak and stop when the heater is removed. This record will be saved, and Dummy Joint will be noted on the report.
  • Added stop in the process if the heater is not in the proper range for WIS, GIS, and DVS standards
  • Added heater temp display to heater temperatures screen
  • Added heater temp display to logging screen for levels 2 & 3 only

Bug Fixes

  • Fixed issue of desired heater set point not converting properly to Celsius on selection screen
  • Fixed issue with “use previous drag” function not running the shortened process but instead running the full drag measurement
  • Fixed issue scanning barcodes for sidewall fittings

October 14, 2021 Release Summary

The efforts for this release were primarily focused on the TracStar 1200i and TracStar 900i MF to coincide with the first production builds. The TracStar 900i MF built at this time was to be used to gain certification to operate in the UK under the GIS fusion standard. Several enhancements were included for both WIS and GIS to serve those markets. The vehicle control module update was released earlier than the other components to address an issue in the field with the RTD alignment fault causing confusion for a non-WIS/GIS user.

Vehicle Control Module {VCM) 1.011

What’s New?

  • Added new default max values on the TracStar 1200i tracking switches to ensure straight tracking
  • New fault (SPN 520344) introduced for excessive amperage load to help protect the generator in an overcurrent situation. Normal overcurrent is caught by the GFCl/circuit breaker. This logic would be a backup as well as checking for an overcurrent due to an excessive load.
  • Prevent operation of a 630/900 heater when plugged into a TracStar 1200i vehicle and vice versa, mismatch for a 630/900 should not allow the heater to be turned on if connected to TracStar 1200i and vice versa. Protecting equipment from misuse.

Bug Fixes

  • Fixed buzzer quick beeping during fault
  • Improved RTD filtering to reduce fault indicating the contactor was not responding
  • RTDs out of alignment fault changed to only apply to WIS and GIS standards
  • Hydraulic level fault threshold raised to lessen annoyance if on a hill or loading

October 1, 2021 Release Summary

The efforts for this release were primarily focused on the TracStar 1200i and TracStar 900i MF to coincide with the first production builds. The TracStar 900i MF built at this time was to be used to gain certification to operate in the UK under the GIS fusion standard. Several  enhancements were included for both WIS and GIS to serve those markets. The operator display console update was validated and released earlier than the other components to support production efforts.

Operator Display Console v1.1.10

What’s New?

  • Added additional popup on home screen and remote pages for putting outriggers up before tracking to make the error more apparent to the user
  • Added new default max values on the TracStar 1200i tracking switches to ensure straight tracking
  • New fault (SPN 520344) introduced for excessive amperage load to help protect the generator in an overcurrent situation. Normal overcurrent is caught by the GFCl/circuit breaker. This logic would be a backup as well as checking for an overcurrent due to an excessive load.

Bug Fixes

  • Corrected touch area issue with outrigger movement for TracStar 1200i