Victaulic VE270FSD Operating And Maintenance Instructions Manual

TM-VE270FSD.2469 Rev.B Page 1 Sunday, October 28, 2001 4:10 PM
R
Operating and
Maintenance
Instructions
Manual
VE270FSD
Failure to follow Instructions and warnings can result in serious personal injury.
• Before installing, operating or servicing the VE270FSD tool, read this Manual and all warning labels on the tool.
• Always wear safety glasses and foot protection.
If you need additional copies of the manual or have any questions about the safe operation of this tool, contact Victaulic Tool Company, P.O. Box 31, Easton, PA 18044-0031, Phone: 610-559-3300.
TM-VE270FSD.2469 Rev.B Page 2 Sunday, October 28, 2001 4:10 PM
VE270FSD
INDEX
Hazard Identification . . . . . . . . . . . . . . . . . . . . . 2
Operator Safety Instructions. . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tool Setup . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operating Tool . . . . . . . . . . . . . . . . . . . . . . .3
Tool Maintenance. . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Power Requirements . . . . . . . . . . . . . . . . . .4
Extension Cord Requirements . . . . . . . . . .4
Tool Nomenclature. . . . . . . . . . . . . . . . . . . . . . . 5
Receiving Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Container Contents . . . . . . . . . . . . . . . . . . .6
Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pre-Operation Adjustments . . . . . . . . . . . . . . . 7
Grooving Rolls. . . . . . . . . . . . . . . . . . . . . . . .7
Pipe Preparation . . . . . . . . . . . . . . . . . . . . . .7
Groovable Pipe Lengths. . . . . . . . . . . . . . . . 7
Roll Guard Adjustment. . . . . . . . . . . . . . . . . 9
Pipe Stabilizer Adjustment . . . . . . . . . . . .11
Groove Diameter Stop Adjustment. . . . . . 12
Grooving Operation . . . . . . . . . . . . . . . . . . . . . 14
Roll Changing. . . . . . . . . . . . . . . . . . . . . . . . . .16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .21
General . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .21
Hydraulic Systems . . . . . . . . . . . . . . . . . . . 22
Parts Ordering Information . . . . . . . . . . . . . . .23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Victaulic Adjustable Pipe Stands . . . . . . . 24
Stabilizer Assembly . . . . . . . . . . . . . . . . . . 24
Optional Rolls . . . . . . . . . . . . . . . . . . . . . . .24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 25
Tool Rating and Roll Selection . . . . . . . . . . . .27
Standard and “ES” Rolls. . . . . . . . . . . . . . .27
Rolls for Stainless Steel (RX Rolls) . . . . . . .28
Rolls for Copper Tubing . . . . . . . . . . . . . . .28
Roll Groove Specifications. . . . . . . . . . . . . . . . 29
Steel Pipe and All Materials Grooved
with Standard and RX Rolls . . . . . . . . . .29
Drawn Copper Tubing . . . . . . . . . . . . . . . . 31
Steel Pipe and All Materials Grooved
with “ES” Rolls. . . . . . . . . . . . . . . . . . . . . 32
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Seamless and Welded Steel Pipe. . . . . . . .33
Drawn Copper Tubing . . . . . . . . . . . . . . . . 33
Read this First – Hazard Identification
Definitions for identifying the various hazard levels shown on warning labels or to indicate proper safety procedures in this Manual are provided below.
This safety alert symbol indicates important safety messages on warning labels and in this manual. When you see this symbol be alert to the possibility of personal injury and carefully read and fully understand the message that follows.
The use of the word “DANGER” always signifies an immediate hazard with a likelihood of serious personal injury or death if instructions, including recommended precautions, are not followed.
The use of the word “WARNING” signifies the presence of hazards or unsafe practices which could result in serious personal injury or death if instructions, including recommended precautions, are not followed.
NOTICE
The use of the word “CAUTION” signifies possible hazards or unsafe practices which could result in personal injury, product or property damage if instructions, including precautions, are not followed.
The use of the word “NOTICE” signifies special instructions which are important but not related to hazards.
2
TM-VE270FSD.2469 Rev.B Page 3 Sunday, October 28, 2001 4:10 PM
VE270FSD
OPERATOR SAFETY INSTRUCTIONS
This tool is designed only for roll grooving pipe. To accomplish this function requires some dexterity and mechanical skills, as well as sound safety habits. Although this tool is manufactured for safe dependable operation, it is impossible to anticipate those combinations of circumstances which could result in an accident. The following instructions are recommended for safe operation of the tool. The operator is cautioned to always practice “Safety First” during each phase of use, including setup and maintenance of this unit. It is the responsibility of the owner, lessee or user to
ensure that all operators receive, read and understand this manual and are fully trained to operate this tool.
GENERAL
1.
Read and understand this Manual before operating or performing maintenance on this tool.
Become familiar with the tool’s operations, applications and limitations. Be particularly aware of its specific hazards. Store this manual in a clean area and always at a readily available location. Additional copies at no charge are available upon request by writing or phoning the Victaulic Tool Company.
2.
Use only recommended accessories. Use of improper accessories may be hazardous. See Accessories on
page 24.
3.
This tool is designed ONLY for roll grooving of pipe sizes, materials and wall thicknesses outlined under Tool Rating and Roll Selection, pages 27 and 28.
TOOL SETUP
1.
Ground the drive motor. Be sure the drive motor is connected to an internally grounded electrical system. Avoid dangerous environments. Don’t use the machine in damp or wet locations. Don’t use the tool on
2.
sloped or uneven ground or floor. Keep work area well illuminated. Allow sufficient space to operate tool and accessories properly and for others to pass safely.
3.
Prevent back injury. During tool setup, a lift must be used to handle and position tool.
OPERATING TOOL
1.
Inspect the equipment. Prior to starting the tool, check the movable parts for any obstructions. Be sure that
guards and tool parts are properly installed and adjusted.
2.
Prevent accidental startings.
3.
Operate with foot switch only. The VE270FSD must be operated with a safety foot switch, located for easy
operator access. The switch should always be accessible to the operator.
4.
Keep hands away from grooving rolls and stabilizer wheel during grooving operation. Grooving
rolls can crush or cut fingers and hands.
5.
Never reach inside pipe ends during operation. Do not over-reach. Keep your proper footing and balance at all times. Be sure you can reach foot switch
6.
safely at all times. Do not reach across tool or pipe. Keep hands and loose tools away from moving parts.
7.
Wear safety glasses and footwear.
8.
Keep work area clean. Cluttered areas, benches and slippery floors invite accidents.
9.
Wear ear protection if exposed to long periods of very noisy shop operations.
10.
Keep visitors away. All visitors should be kept a safe distance from the work area.
11.
Keep alert. Do not operate tool if ill or drowsy from medication or fatigue. Avoid horseplay around tool and
keep bystanders a safe distance from tool and pipe being grooved.
Wear proper apparel. Never wear loose clothing (unbuttoned jackets or loose sleeve cuffs) loose gloves or
12.
jewelry that can get caught in moving parts.
13.
Do not force tool. It will do the job better and safer at the rate for which it was designed. Secure work, tool and accessories. Make sure tool is stable. See “Tool Setup” for securing to floor or
14.
platform.
Support work. Support long pipe with a pipe stand secured to the floor or ground.
15.
16.
Do not misuse tool. Perform only the functions for which the tool is designed. Do not overload the tool.
TOOL MAINTENANCE
Unplug power cord prior to servicing. Repair should be attempted only by authorized personnel. Always
1.
unplug the tool before servicing.
2.
Maintain tool in top condition. Keep tool clean for best and safest performance. Follow lubricating
instructions.
Use only genuine Victaulic replacement parts to ensure proper and safe function of the tool.
3.
3
TM-VE270FSD.2469 Rev.B Page 4 Sunday, October 28, 2001 4:10 PM
NOTICE
Drawings and/or pictures in this manual may be exaggerated for clarity.
VE270FSD
INTRODUCTION
All Victaulic Vic-Easy of pipe to prepare it to receive Victaulic grooved pipe couplings. The VE270FSD is a completely self­contained unit with a gear motor, safety foot switch and power cord/plug. The VE270FSD is designed to roll groove pipe of various materials and wall thicknesses (see Tool Rating and Roll Selection charts on pages 27 and 28.)
This tool and manual contains trademarks, copyrights and/or patented features which are the exclu­sive property of Victaulic Company of America.
• This tool should be used only for roll grooving pipe designated in the Tool Rating and Roll Selection charts on pages 27 and 28.
• Use of the tool for other purposes or exceeding the pipe thickness maximums will overload the tool, shorten tool life and may cause tool damage.
POWER REQUIREMENTS
Power must be supplied through a safety foot switch to ensure safe operation. Be sure the tool is properly grounded in accordance with Article 250 of the National Electrical Code. If an extension cord is to be used, see Extension Cord Requirements for cord size recommendations.
®
Series 270FSD tools are semi-automated hydraulic feed tools for roll grooving
• To reduce the risk of electric shock, check the electrical source for proper grounding and follow the instructions below.
• Before performing any repair or maintenance, disconnect the tool from the electrical source.
Failure to do so could result in death or serious personal injury.
EXTENSION CORD REQUIREMENTS
When pre-wired outlets are not available and an extension cord must be used, it is important to use the proper cord size (e.g., conductor size American Wire gauge). Cord size selection is based upon tool rating (amps) and cord length (feet). Use of a cord size (gauge) thinner than required will cause a significant voltage drop at the gear motor while the tool is operating. The voltage drop may cause damage to the gear motor and can result in failure of the tool to operate properly. Use of a heavier than necessary cord size (gauge) is acceptable.
Listed in the chart below are recommended cord size (gauge) for cord lengths up to and including 100 feet. Use of extension cords beyond 100 feet in length should be avoided.
Tool
VE270FSD 115/15 12 12 10
Tool Rating
Volt/Amps
Cord Lengths
25' 50' 100'
4
TM-VE270FSD.2469 Rev.B Page 5 Sunday, October 28, 2001 4:10 PM
VE270FSD
TOOL NOMENCLATURE
Hydraulic Pump
Guard Setting Pad
Foot Switch
Hydraulic Cylinder
Lower Roll
Pipe Size Indicator Depth Adjuster Depth Adjuster Lock
Upper Roll
Motor/Drive
Guards
Stabilizer Assembly
Stabilizer Handwheel
Legs
ALWAYS KEEP THIS PAD WITH THE TOOL. USE IT TO SET THE GUARDS IN ACCORDANCE WITH THE TOOL OPERATION AND MAINTENANCE MANUAL.
R068272LAB
Failure to follow instructions and warnings can result in serious injury, property damage, or faulty installation.
• Before installing, operating, or servicing this tool, read and understand the Operating Instructions and all warning labels on this tool.
• Always wear safety glasses and foot protection.
If you have any questions about the safe operation of this tool, contact Victaulic Tool Company, P.O. Box 31, Easton, PA 18044-0031,
0567 Rev.A R031272LAB 3/99
5
610-559-3300.
Grooving rolls can crush or cut fingers and hands.
Always unplug the power cord before adjusting guard.
Be sure guard is properly adjusted before grooving pipe.
Keep hands away from grooving rolls and stabilizer wheel.
Never reach inside pipe end or across the tool or pipe during operation.
Never groove pipe shorter than what is recommended.
Never wear loose clothing, loose gloves or jewelry while operating tool.
2244 Rev.B 3/98 R007276LBL
TM-VE270FSD.2469 Rev.B Page 6 Sunday, October 28, 2001 4:10 PM
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
a.
b.
c.
3.
4.
VE270FSD
RECEIVING TOOL
VE270FSD tools are palletized individually and covered with a cardboard sleeve designed for use in re-shipping tools.
NOTE: Be sure to save original shipping con-
tainer for return shipment of rental tools.
VE270FSD CONTAINER CONTENTS
Upon receipt of tool, make sure all necessary parts are included. If any parts are missing, notify your Victaulic distributor or Victaulic representative.
TOOL SETUP
Do not plug in tool until instructed otherwise. Accidental start up of tool may result in serious
personal injury.
Remove all components and check to be sure all necessary items are included. See list under Receiving Tool.
Select location for tool and pipe stand. Choose a location that has:
The required power. Consult Power Requirements on page 4.
The space necessary to adequately
handle the pipe to be grooved.
A level and even surface for tool, pipe
stand and footing.
During tool setup, one person cannot safely handle the tool because it weighs 375 lbs. If a hoist is available, use it to lift the tool head assembly into position.
Failure to follow this instruction may result in serious personal injury.
Place tool on level floor or platform. Using holes provided in feet, secure tool to the plat­form or floor. The tool’s legs are adjustable in length to compensate for uneven surfaces. Adjust as necessary to maintain tool levelness.
Tool head with mounting table and gear motor, (4) legs and foot switch with cord and pump/pump support assembly.
Rolls for 1 - 1 ¹⁄₂ ", 2 - 3 ¹⁄₂ ", 4 - 6" and 8 - 12" steel pipe. The 8 - 12" rolls are mounted on the head assembly.
Two (2) VE270FSD Operating and Maintenance Instructions Manuals.
Guard setting pad.
Lower roller removal wedge.
Stabilizer with mounting hardware, if ordered.
Spare Woodruff keys.
One (1) 11 oz. can of Dow Corning G-n
Mechanical Assembly Spray. The standard Series VE270FSD tools are supplied
with grooving rolls for 1 - 12" carbon steel pipe. Rolls are marked with the size and part number and color coded for pipe material, for your conve­nience. For grooving to other specifications and other materials, see Tool Rating and Roll Selection charts on pages 27 and 28. Grooving rolls for other specifications, sizes and other materials must be purchased separately.
Level the tool front to back. The top of the hydraulic ram is a good location to measure “level”.
6
TM-VE270FSD.2469 Rev.B Page 7 Sunday, October 28, 2001 4:10 PM
VE270FSD
GROOVING ROLLS
Make sure the proper roll set is on the tool for the pipe size and material to be grooved. They are marked with the pipe size, part number and color coded for the pipe material to be grooved. See Tool Rating and Roll Selection charts on pages 26 and 27. If proper rolls are not on tool, refer to Roll Changing on page 16.
Make sure roll retaining bolts and nuts are tight. Loose retaining bolts or nuts could seriously damage
Insert the hand pump handle into lever arm of the pump. Position handle with handle grip down. Lock handle in this position with set screw or nut and bolt provided.
Connect the hydraulic line from the pump to the power cylinder using connectors pro­vided.
VE270FSD tool setup is complete.
both the tool and rolls.
PIPE PREPARATION
For proper tool operation, and production of proper pipe grooves, carefully observe the fol­lowing pipe preparation tips.
Pipe ends should be cut squarely in accor­dance with Column 2 note on appropriate Roll Groove Specification chart, pages 29 - 32.
Internal or external weld bead or seams must be ground flush with the pipe surface extending 2" back from the pipe end.
The end of the pipe, both inside and out, must be cleaned of loose rust, coarse scale, dirt and other foreign material.
5.
6.
1.
2.
3.
4.
PRE-OPERATION ADJUSTMENTS
Every Vic-Easy tool is checked, adjusted and tested at the factory prior to shipment. Before grooving, however, the following adjustments must be made in sequence to make sure of proper tool operation.
Always unplug power cord before making any tool adjustments, unless instructed otherwise.
Accidental start up of tool may result in serious personal injury.
7
For maximum grooving roll life, remove foreign material and loose rust.
Foreign material such as coarse scale or dirt might interfere with or damage the grooving rolls or distort the groove. Rust is an abrasive material and will tend to wear out the surface of grooving rolls.
Victaulic recommends that pipe shall be square ended. When using beveled pipe, stan­dard wall or less, the bevel should not exceed 37 ¹⁄₂ °. Square ended pipe must be used with FlushSeal pipe walls, square ended pipe is required.
®
and EndSeal
®
gaskets. For heavier
GROOVABLE PIPE LENGTHS
The VE270FSD is capable of grooving short pipe lengths without the use of a pipe stand (see Table 1 on page 8), or long pipe lengths up to double randoms (approximately 40 ft.), with the use of appropriate stands.
TM-VE270FSD.2469 Rev.B Page 8 Sunday, October 28, 2001 4:10 PM
VE270FSD
SHORT PIPE LENGTHS
Table 1 shows minimum and maximum pipe lengths that can be grooved hands-off without the need for a pipe stand. You do not have to manually guide the pipe while grooving. For pipe longer than shown in Table 1, refer to Long Pipe Lengths at right.
Grooving rolls can crush or cut fingers and hands.
Loading and unloading pipe will place your hands close to the rollers.
Never groove pipe shorter than what is recommended in Table 1 below.
TABLE 1
VE270FSD GROOVABLE PIPE LENGTHS
2468-1A
DIMENSIONS – (Inches/mm)
Nom.
Min.
Max.
Nom.
Min.
Size
Length
Length
³⁄₄ 8364¹⁄₂ 832
20 203.2 914.4 115 203.2 812.8
18 3658 32
25 203.2 914.4 125 203.2 812.8
1¹⁄₄ 836
32 203.2 914.4 254.0 762.0
1¹⁄₂ 8 36 6 10 28
40 203.2 914.4 150 254.0 711.2
28 36
50 203.2 914.4 254.0 609.6
2¹⁄₂ 8 36 8 10 24
65 203.2 914.4 200 254.0 609.6
3 8 36 10 10 20
80 203.2 914.4 250 254.0 508.0
3¹⁄₂ 836121218
90 203.2 914.4 300 304.8 457.2
48 36
100 203.2 914.4
Size
6 O.D.
8 O.D.
Length
Max.
Length
10 30
10 24
If a pipe shorter than the minimum shown in Table 1 is needed, if possible, shorten the next to last piece of pipe enough so that the last piece of pipe is as long or longer than the mini­mum length specified in Table 1. See example at right.
NOTICE
Pipe nipples shorter than those shown in Table 1 are available from Victaulic.
Example: A 20' 4" length of 10" diameter pipe is needed to finish a section and you only have 20' lengths available. Instead of roll grooving a 20' piece of pipe and a 4" piece of pipe, follow these steps:
1. Refer to Table 1 and note that for 10" diame­ter pipe, the minimum length that should be grooved is 10".
2. Roll groove a 19' 6" piece of pipe and a 10" piece of pipe. Refer to Long Pipe Lengths below.
LONG PIPE LENGTHS
With pipe in excess of the maximum length shown in Table 1, a roller type pipe stand must be used.
NOTICE
Figure 1 shows the Victaulic adjustable pipe stand (VAPS 112). VAPS 112 is suitable for ³⁄₄" to 12" pipe. Also available is Victaulic model VAPS 224 suitable for sizes 2" to 24". See Accessories on page 24.
1. Position pipe and pipe stand in accordance with Figures 1 and 2.
Tool
Pipe angle
Pipe Centerline
Centerline
(Level)
Centerline
0° to ¹⁄₂° Max.
¹⁄₂° to 1°
(2 to 4")
Pipe
(0 to 2")
Pipe angle
exaggerated for clarity
10' +1' -0
SUPPORT OF PIPE
Tool Centerline
20 Ft. Length of Pipe
Figure 1
exaggerated for clarity
20 Ft. Length of Pipe
TRACKING ANGLE
Figure 2
8
TM-VE270FSD.2469 Rev.B Page 9 Sunday, October 28, 2001 4:10 PM
VE270FSD
Pipe stand location will affect pipe tracking.
Incorrect pipe stand position may result in pipe
being pushed out of rolls and falling.
Failure to position pipe and pipe stand in accordance with Figures 1 and 2 (shown on page 8) may result in serious personal injury or property damage.
Pipe position will affect pipe are.
When pipe end are is excessive, right-to-left tracking must be kept to a minimum. It may be necessary to use less than ¹⁄₂ degree.
Make sure tool is level (see Tool Setup).
If pipe is grooved with back end of pipe (end of pipe which is not in tool) higher than the end being grooved, pipe may not track and excessive pipe end
are may result.
Assembly of couplings on pipe exceeding Maximum
Allowable Flare, Column 8 in the Roll Groove Specications charts, pages 29 - 32, may prevent closure of couplings pad-to-pad, allowing possible pipe separation, and result in property damage.
Also, joint leakage may result due to excessive gasket distortion/damage.
NOTICE
For additional information about pipe stands, refer to the Operating Instructions included with your pipe stand.
ROLL GUARD ADJUSTMENT
The VE270FSD guards must be adjusted every time rolls are changed or pipe size or wall thickness is different from previous pipe grooved.
1. Make sure the proper roll set is on the tool for the pipe size and material to be grooved. Rolls are marked with the pipe size, part num­ber and are color coded for pipe material for your convenience. See Tool Rating and Roll Selection charts pages 27 and 28. If the proper rolls are not on the tool, refer to Roll Changing on page 16.
2. Loosen wing nuts and move the adjustable guards to the full up position. Tighten wing nuts.
Always unplug the power cord before making any roll guard adjustments.
Accidental start up of tool may result in serious personal injury.
9
3. Set groove diameter stop to pipe size and schedule/thickness to be grooved. To do this, back off the depth adjuster lock, align the depth adjuster with the proper diameter and thickness. Lock the depth adjuster in position with the depth adjuster lock.
TM-VE270FSD.2469 Rev.B Page 10 Sunday, October 28, 2001 4:10 PM
VE270FSD
4. If so equipped, retract stabilizer, if neces-
sary, to insert pipe. To do this, loosen locking handle and retract stabilizer roller with the hand wheel to clear pipe when inserted onto lower roll.
Grooving rolls can crush or cut
ngers and hands.
Loading and unloading pipe
will place your hands close to the rollers.
Never groove pipe shorter than what is recommended in Table 1 on page 8.
5. Insert a piece of pipe of the correct size and schedule/thickness to be grooved over the lower roll with the pipe end against the lower roll backstop flange. See Pipe Preparation on page 7.
6. Close hand pump valve.
7. Pump upper roll down into firm contact
with pipe.
8. Remove the guard setting pad from its stor­age hook beneath the pump support. Hold the guard setting pad firmly down against the pipe and push it under the adjustable guards flush against the red plate.
10
TM-VE270FSD.2469 Rev.B Page 11 Sunday, October 28, 2001 4:10 PM
VE270FSD
1. Make sure proper roll set is on the tool for
the pipe size and material to be grooved. Rolls are marked with pipe size, part number and are color coded for pipe material for your conve­nience. See Tool Rating and Roll Selection charts on pages 27 and 28.
2. Loosen locking handle. With the hand wheel, retract stabilizer roller to clear pipe when inserted onto lower roll.
9. Loosen the wing nuts and adjust each guard to conform to and lightly pinch the pad against the pipe. Tighten wing nuts to secure guards in position.
10. Remove the guard setting pad. Store the pad back on the hook provided under pump base.
PIPE STABILIZER ADJUSTMENT
(Applies only to tools equipped with the optional stabilizer.)
The Series VE270FSD Pipe Stabilizer (Optional) is designed to prevent pipe sway on 8" through 12" nominal IPS pipe sizes. This applies to short as well as long pipes. Once the stabilizer is adjusted for a selected pipe size and wall thickness, it does not require further adjust­ment on that size and thickness. Pipe of the same size and thickness may be moved in and out of the tool without retracting stabilizer.
Unplug power cord until instructed otherwise. Accidental start up of tool may result in serious
personal injury.
3. Insert a piece of pipe of the correct size and schedule to be grooved over the lower roll with the pipe end against the lower roll backstop flange.
4. Close hand pump valve and pump upper roll down into firm contact with pipe.
5. Make sure guards are properly adjusted per the Roll Guard Adjustment Procedure, page 9.
11
Loading...
+ 23 hidden pages