Victaulic End Caps Installation Instructions Manual

I-ENDCAP

I-ENDCAPINSTALLATION INSTRUCTIONS

REV_ A

Victaulic® End Caps

VICTAULIC END CAP INSTALLATION SAFETY INSTRUCTIONS

WARNING

• Read and understand all instructions before attempting to install, remove, adjust, or maintain the coupling/end cap, any end cap
connections, and any other Victaulic piping products.

• Always depressurize and drain the piping system completely before attempting to install, remove, adjust, or maintain the coupling/end cap,
any end cap connections, and any other Victaulic piping products.

• Always verify that the piping system has been completely depressurized and drained immediately prior to installation, removal, adjustment,
or maintenance of the coupling/end cap, any end cap connections, and any other Victaulic piping products.

• Under no circumstances should coupling hardware or any other system component be loosened to check if the system is pressurized or to
depressurize the system.

• Wear safety glasses, hardhat, and foot protection.

Failure to follow these instructions could result in death or serious personal injury and property damage.

This document provides safety instructions for the installation, use, and removal of Victaulic-manufactured end caps with Victaulic-manufactured
couplings in all size ranges and groove profiles, along with other important information that is critical for proper use of Victaulic end caps.

For Installation-Ready™ Couplings, refer to the “NOTICE” on the opposite side of this page for important Victaulic end cap marking information.

Always verify that the Victaulic end cap being used is designed for the specific groove profile. For example, the Victaulic No. W60 End Cap shall be
used only with Victaulic Advanced Groove System (AGS) products.

When installing, using, or removing a Victaulic end cap, always reference the specific installation instructions for the Victaulic coupling that is being
used with the Victaulic end cap. For the Victaulic No. T-60 Test Caps, always refer to the additional instructions provided with the kit. Installation
instructions for couplings and the No. T-60 Test Caps may be downloaded at victaulic.com.

After installation, always inspect the assembly to verify proper installation.

GOOD

GOOD

GOOD ASSEMBLY
(END CAP IS SEATED WITHIN THE COUPLING WITH THE
CORRECT SIDE FACING OUT AND COUPLING BOLT PADS

ARE IN METAL-TO-METAL CONTACT)

GOOD BOLT ENGAGEMENT

(OVAL NECK OF EACH BOLT

IS SEATED PROPERLY

IN THE BOLT HOLE)

The following conditions are not acceptable and shall be corrected before any system pressure testing occurs.

BAD

BAD

BAD

BAD ASSEMBLY

(INCORRECT SIDE OF END CAP IS FACING OUT –

HARDWARE WILL NOT BE ABLE TO BE TIGHTENED TO

BRING THE BOLT PADS INTO METAL-TO-METAL CONTACT)

BAD ASSEMBLY

(BOLT PADS ARE NOT IN

META L-TO -ME TAL C ONTA CT)

BAD BOLT ENGAGEMENT

(OVAL NECK IS NOT SEATED PROPERLY

IN THE BOLT HOLE)

I-ENDCAPINSTALLATION INSTRUCTIONS

Victaulic® End Caps

For complete contact information, visit victaulic.com

I-ENDCAP 11978 REV A UPDATED 07/2018 Z000ENDCAP

VICTAULIC AND INSTALLATION-READY ARE REGISTERED TRADEMARKS OR TRADEMARKS OF VICTAULIC COMPANY AND/OR ITS
AFFILIATED ENTITIES IN THE UNITED STATES AND/OR OTHER COUNTRIES. © 2018 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

NOTICE

For Installation of Victaulic End Caps with Victaulic Installation-Ready Couplings:

• Victaulic Installation-Ready couplings shall be used with specific types of Victaulic end caps. These end caps are identified by markings
that are listed below. Always verify that the proper Victaulic end cap is being used.

• When assembling a Victaulic Installation-Ready coupling onto a Victaulic end cap, verify that the end cap is seated fully against the
center leg of the gasket. Always refer to the specific instructions for the Victaulic coupling for full installation requirements. Installation
instructions may be downloaded at victaulic.com.

For Victaulic Style 009N Couplings

• Use only Victaulic FireLock™ No. 006 End Caps containing the “EZ” marking on the inside face or Victaulic No. 60 End Caps containing
the “EZ QV” marking on the inside face.

For Victaulic Style 607 Couplings

• Use only Victaulic No. 660 End Caps with the “QV” marking on the inside face.

For All Other Styles of Victaulic Installation-Ready Couplings for the Original Groove System (OGS)

• Use only Victaulic No. 60 End Caps containing the “EZ QV” marking on the inside face.

SAFETY INSTRUCTIONS FOR NO. T-60 TEST CAPS OR END CAPS INSTALLED FOR SYSTEM PRESSURE TESTING

• Victaulic end caps that are installed for system pressure testing shall be equipped with a ball valve that can be opened to verify if the system is
depressurized.

• The Victaulic No. T-60 Test Cap should be used whenever possible for purposes of system pressure testing. If a Victaulic No. T-60 Test Cap is not
available in the applicable size, contact Victaulic about ordering a tapped end cap that the customer can fit with an appropriately-rated ball valve
for the system conditions. Under no circumstances should coupling hardware or any other system component be loosened to check if the
system is pressurized or to depressurize the system.

• Before system pressure testing, verify that no valves within the tested system (or portion of the system being tested) are closed in order to prevent
pressure from being trapped inadvertently.

• Immediately after completing the system pressure test, the system pressure shall be relieved through an appropriate valve.

NOTICE

• A pressure gauge alone is not an acceptable method of verifying system pressure. Always use a secondary means of verification, such as a
second pressure gauge or valve, to confirm that the system is depressurized in accordance with national and local codes and standards for
the jobsite.

VICTAULIC END CAP REMOVAL SAFETY INSTRUCTIONS

WARNING

• COUPLING/END CAP MAY BE PRESSURIZED.

• Always depressurize and drain the piping system completely before attempting to install, remove, adjust, or maintain the coupling/end cap,
any end cap connections, and any other Victaulic piping products.

• Always verify that the piping system has been completely depressurized and drained immediately prior to installation, removal, adjustment,
or maintenance of the coupling/end cap, any end cap connections, and any other Victaulic piping products.

• Under no circumstances should coupling hardware or any other system component be loosened to check if the system is pressurized or to
depressurize the system.

• Wear safety glasses, hardhat, and foot protection.

Failure to follow these instructions could result in death or serious personal injury and property damage.

1. Depressurize and drain the piping system completely, and verify that there is no residual pressure.

2. Loosen the nuts of the coupling slowly and, depending on the orientation of the coupling and end cap, be prepared to support the end cap as it

releases from the coupling.

VICTAULIC RECOMMENDS:

• Hydrostatic (water) testing instead of pneumatic (air) testing whenever possible

• Use of a tapped end cap with a pressure-relieving device at each test point location (the No. T-60 Test Cap Kit and made-to-order tapped end
caps are available for order through Victaulic)

• Removal of pressure immediately after completing a test (follow all applicable national and local codes and standards for the specific jobsite)

• Lockout/tagout procedures approved by the installing contractor

• Following the testing procedures recommended by technical experts, such as those found in the “Guide to Pressure Testing Safety” published by
the Mechanical Contractors Association of America, Inc. (MCAA)