Caldertech Uniprep 4 XL, Uniprep 1, Uniprep 2 Operating Instructions Manual

Uniprep 4 XL
Rotary Scraping Tool

Operating Instructions

Product Code: 01-05-010

Revision: 2

Designed and Manufactured in the UK

Helping you
make the right
connections.

© Copyright Caldervale Technology Ltd.

The copyright for this product and instruction manual is held by Caldervale Technology Ltd.
Any technical specifications, or illustrations part of this manual cannot be reproduced, used
illicitly or distributed in any form for competitive purposes.

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

Contents

Contents

Page

01. Introduction 02

02. Safety Instructions 03

03. Operation 04

04. Removal After Completion 06

05. Specifications 07

06. Parts Diagram 08

07. Warranty Information 10

08. Certificate of Conformity 12

09. Service and Repair

13

10. Decommissioning and Disposal 13

01

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

01. Introduction

01.

Introduction

General Description

The pipe preparation tool is designed to provide a fusible surface
on any polyethylene pipe material (new, weathered or previously
installed). In accordance with Gas Industry Standards GIS/PL2-5 Part 5
Electrofusion ancillary tools.

This product (Uniprep 4 XL) have been manufactured, inspected and
tested in accordance with the ISO9001 quality control systems
procedures in place at Caldervale Technology Ltd, Dewsbury.

Important!

This tool should be used in accordance with the pipe manufacturers’
recommendations and in line with local codes of practice.

This manual outlines the operation of the pipe surface preparation
tooling for the scraping of polyethylene (PE) pipe and forms a part
of the product to which it relates. It should be kept for the life of the
product. Any amendments issued by Caldervale Technology Ltd should
be incorporated in the text. The manual should be passed to any
subsequent holder or user of this product.

and

02

Before Using

It is important to ensure all component parts are present and in
serviceable condition. In addition, the condition of the cutting / peeling
tip should be checked for damage or excessive wearing.

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

02. Safety Instructions

02.

Safety Instructions

1. Read and understand the whole instruction booklet before using
the tool.

2. It is imperative that all possible precautions are made to avoid
unexpected pipe movement when the tool is being used.

3. Never use the tool on pipes that are not within the specified
dimensions.

4. The tool tip holder spring tension is factory set and MUST NOT be
tampered with, without adequate training or instruction.

5. Operatives should wear eye protection, gloves, safety headwear and
footwear when using the equipment.

6. A single scrape / pass cannot be guaranteed to provide 100%
preparation, where this is required users are advised to consider
making 2 scrapes around the pipe.

03

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

03. Operation

03.

Operation

1

5

9

8

7 11

Instructions for use

1. Ensure that the pipe end is cut square (No more than 2° out of
square), is free of burrs and the section to be prepared does not
have any deep scores.

2

3

4

12

10

6

13

04

2. Mark the pipe outer wall at the required point (usually 50% of the
length of the coupler plus 10mm or 7/16 inch).

3. Release the tool post cartridge by loosening the tool post
adjustment nut (5), position the tool post cartridge (3) to its highest
position and temporarily retighten (5).

4. Lower the underarm slide block (8) by turning the undercarriage
adjustment & clamping thumbscrew (1).

5. Position the tool onto the pipe with the tool resting on the axle
wheels and with the undercarriage (7) inside the bore of the pipe.
The end of the pipe should touch the pipe stop (9).

6. Fix the tool in its operating position by adjusting the under-arm
adjustment clamping screw (1) until the undercarriage wheels are
firmly against the inner wall of the pipe.

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

7. Attach the supplied chain firstly to the stationary chain anchor point
(13) then at the adjustable chain anchor point (11) and tighten the
adjustment handle (12) until firm against the pipe ensuring the chain
is straight all the way around the pipe.

8. Pull and twist a quarter turn the quick release thumb nut (4) to allow
the tool post carriage to move freely along the feed screw (10).

9. Slowly rotate the tool around the pipe 2 or 3 times to ensure that it is
positioned correctly adjusting the underarm clamping screw (1) and
adjustment handle (12) to ensure a secure rotation but at the same
time for the ease of rotation.

10. Remove the protection cap from the cutter (6) and position the
cutter (6) above the mark previously made on the pipe indicating
length of peel required, a further quarter turn of the thumb nut (4)
will engage the feed screw-drive nut with the feed screw (10).

11. Pull & twist a quarter turn the cutter lifting thumb nut (2) to lift the
cutter tip. Release the tool post adjustment nut (5) and slide the

tool post down until the cutter is approximately 1mm from the
pipe wall, now retighten the tool post adjustment nut (5) to fix the

tool post in its correct operating position.

03. Operation

12. A further quarter turn of the cutter lifting thumb nut (2) will lower the
cutter on to the pipe wall surface and the correct pressure will be
applied to the tip (6) via the tool tip spring.

13. Rotate the tool around the pipe in a steady clockwise direction, the
cutter will travel towards the pipe end removing a continuous strip
of PE. The process may be halted from time to time to remove
surplus peel.

05

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

04. Removal After Completion

04.

Removal After Completion

1. The scraped section should be inspected for areas of un-scraped
pipe. If necessary, the pipe can be scraped again.

2. To remove the scraper, loosen the tool post locking screw (5) and
raise the tool post clear of the pipe and retighten (5).

3. Loosen the chain adjustment handle (12) to release the chain and
remove it from the tool.

4. Loosen the underarm pressure screw (1) to remove the scraper from
the pipe.

5. Refit the protective cover to the cutter tip when not in use.

Storage

IMPORTANT! When not in use always:

1. Store the tool in the tool box.

2. Ensure the tool tip tension is released.

3. Ensure the tool is clean and dry before storage.

Routine Maintenance

1. Check for correct movement and operation and lubricate moving
parts at regular intervals before using.

06

2. It is important to ensure all component parts are present and in
serviceable condition. In addition, the condition of the cutting /
peeling tip should be checked for damage or excessive wearing.

3. The cutter tip can be replaced. Spares are indicated in the parts
diagram.

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

05. Specifications

05.

Specifications

Materials: Mild Steel EN3A, Stainless Steel, Aluminum,

Brass and Tungsten Carbide

Finish: Natural / Zinc passivate to mild steel

Dimensions: Tool Only: L560 (22”) x W175 (7”) x

H225mm (9”)
Tool Box: L590 (23¼”) x W200 (8”) x
H280mm (11”)

Depth of Cut: 0.3mm

Max Scrape Length:

Min - Max Pipe Size: 63mm (3”) - 315mm (12”) All SDR Ratings

Weight: 4.8kg (10.6lbs) (Excluding tool box & chains)

Product Code: 01-05-010

This unit is design and manufactured to meet the requirements of
National Grid Gas Industry Standards GIS/PL2-5 Part 5 Electrofusion
ancillary tooling.

Caldervale Technology Ltd has a policy of continuous improvement
in product quality and design. Caldervale Technology Ltd therefore
reserves the right to change the specification of its models at any time,
without prior notice.

355mm (14“), feed per rotation 4.5mm (1¾“)

13kg (28.7lbs) (Including tool box & chains)

It is the responsibility of the operator to ensure that the PE pipe
is suitable for pipe preparation if in doubt contact the PE pipe
manufacturer for confirmation.

07

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

06. Parts Diagram

06.

Parts Diagram

10

3

1

5

13

8

9

2

16

6

11

17

14

7

15

12

08

4

20

18

19

21

Part Product Code Description

1 TBC Under Arm Clamping Screw Repair Kit

2 TBC Under Arm Slide Shaft Repair Kit

3 01-02-053 Handle Repair Kit

4 TBC Undercarriage Repair Kit

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

Part Product Code Description

5 TBC Axle Repair Kit

6 01-02-056 Tool-post Carriage Repair Kit

7 01-02-057 Quick Release Button Repair Kit

8 01-02-058 Cutting Tip & Holder Repair Kit

9 TBC Tool-post Carriage

10 01-02-060 Upper Body Repair Kit

11 TBC Under Arm Body Repair Kit

12 TBC Axle End Plate (Boomerang) Repair Kit

13 TBC Stabilizer Shaft

14 TBC Feed Screw

15 TBC Chain Tensioning Screw kit

16 Z01-02-011 ‘V ’ Button

17 01-02-067 Axle Bearing Repair Kit

18 01-02-068 Undercarriage Bearing Repair kit

19 TBC Under Arm Pivot Point Repair Kit

20 TBC Short Length Roller Chain

21 TBC Long Length Roller Chain

06. Parts Diagram

09

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

07. Warranty Information

07.

Warranty Information

1. Extent of Warranty

a) Subject to clauses 2 and 3, Caldervale Technology Ltd warrants to

the end-user customer that its products will be free from defects in
materials and workmanship, for six months after the date of purchase
by the end-user customer, subject to providing proof of purchase.

b) If Caldervale Technology Ltd receives, during the warranty period,

notice of a defect in product which is covered by this warranty;
Caldervale Technology Ltd shall either repair or replace the product,
at its option. Any replacement product may be either new or like­new, provided that it has functionality at least equal to that of the
product being replaced.

c) All warranty work will be carried out by Caldervale Technology

Ltd unless otherwise agreed. On-site warranty and repair or
replacement services are available from authorised Caldervale
Technology Ltd service facilities world-wide.

d) Customers shall prepay shipping charges for products returned

to Caldervale Technology Ltd for warranty service, and Caldervale
Technology Ltd will charge for return of the products back to the
customer.

e) This warranty statement gives the customer specific legal rights.

The customer may also have other rights which vary from country to
country in the world.

10

2. Pre-conditions for Warranty Application

Caldervale Technology Ltd’s warranty covers only those defects which
arise as a result of normal use of the product, and this warranty shall
only apply in the following circumstances:

a) All the instructions contained in the operating manual have been

complied with; and

b) None of the following apply:

i) Improper or inadequate maintenance;

ii) Physical abuse;

iii) Unauthorised modification, misuse or any use not in accordance

with the operating manual and good industry practice;

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

iv) Operation outside the products specifications;

v) Improper site preparation or maintenance;

vi) Faulty pipes.

3. Limitations of Warranty

a) Caldervale Technology Ltd does not warrant the operation of any

product to be uninterrupted or error free.

b) Caldervale Technology Ltd makes no other warranty of any kind,

whether express or implied, with respect to its products. Caldervale
Technology Ltd specifically disclaims the implied warranties of
satisfactory quality and fitness for a particular purpose.

c) To the extent that this warranty statement is inconsistent with

the law of the locality where the customer uses the product, this
warranty statement shall be deemed modified by the minimum
necessary to be consistent with such local law.

d) To the extent allowed by local law, the remedies provided in this

warranty statement are the customer’s sole and exclusive remedies.

e) This tool has been designed for the range of pipes available at the

time of its design and development. Caldervale Technology Ltd can
accept NO liability for the unit’s ability or otherwise to work with
new or dierent pipes that subsequently appear in the market place.

07. Warranty Information

Please complete this information and keep it safely with your proof
of purchase receipt. You will require it for any warranty claim.

Where purchased:

Date of purchase:

Name of purchaser:

Address of purchaser:

Type of tool:

Serial number:

11

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

08. Certificate of Conformity

08.

Certificate of Conformity

12

Operating Instructions Uniprep 4 XL Rotary Scraping Tool

Service and Repair

9.

0

09.

10.

Service and Repair

This product has no specific calibration period, however periodic
safety inspections should be carried out by the operator as specified
in this manual, if in any doubt please contact the manufacturer for
further information.

For service and repair please contact:

INTERNATIONAL

Caldervale Technology Ltd

Bretfield Court, Dewsbury,
West Yorkshire WF12 9BG, UK

T. [phone]
E. [e-mail]
W. caldertech.com

AUSTRALIA / NZ

Caldertech Australia Pty Ltd

Unit 3/30 Juna Drive,
Malaga WA 6090, Australia

T. [phone]
E. [e-mail]
W. caldertech.com.au

Decommissioning and Disposal

These give the instructions for decommissioning and disposal of the
equipment and confirm how it is to be taken out of service safely, in
respect of the Essential Environmental, Health and Safety Requirements.

• If a Caldertech pipe preparation tool has reached the end of its
useful working life and cannot be refurbished it must be sent to a
licensed recycling facility for treatment. That will ensure the waste
hierarchy requirements are met.

• End of life treatment is the responsibility of the Customer. This can
also be achieved by returning the product back to the manufacturer
if required.

13

INTERNATIONAL

Caldervale Technology Ltd

Bretfield Court, Dewsbury,
West Yorkshire WF12 9BG, UK

T. [phone]
E. [e-mail]
W. caldertech.com

AUSTRALIA / NZ

Caldertech Australia Pty Ltd

Unit 3/30 Juna Drive,
Malaga WA 6090, Australia

T. [phone]
E. [e-mail]
W. caldertech.com.au