Operating instructions and
Specification’s for
Large Diameter
Re-Rounding
Clamps
Products by innovation not imitation
Helping you make the right connections™
Models covered by this manual:
01-08-100 Power assisted re rounding clamp + pump 400mm
01-08-103 Power assisted re rounding clamp + pump 500mm
01-08-106 Power assisted re rounding clamp + pump 630mm
01-08-109 Power assisted re rounding clamp + pump 710mm
1
INDEX.
Schematic parts drawing............................ 3
Parts list and product codes ....................... 4
Pictorial representation .............................. 5
Specifications ............................................ 6
General description ................................... 7
Safety instructions ..................................... 8
Instructions for use .................................. 9
Certificate of conformity ............................ 12
Certificate of calibration ............................. 13
Warranty information ................................ 16
2
Product diagram
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13
8
12
15
9
5
7
14
6
11
2
3
4
10
3
Product description
Product code Quantity
Power assisted re rounding clamp + pump 400mm
Power assisted re rounding clamp + pump 500mm
Power assisted re rounding clamp + pump 630mm
Power assisted re rounding clamp + pump 710mm
01-08-200
01-08-300
01-08-400
01-08-500
1
1
1
1
1. NIKE cylinder c/w eye bolt (universal)
2. Support bar cam c/w spacers and screws (universal)
3. Support bar location profiles (universal)
4. Segment location pins (universal)
5. Middle segment 400mm
5. Middle segment 500mm
5. Middle segment 630mm
5. Middle segment 710mm
6. Eye bolt location segment 400mm
6. Eye bolt location segment 500mm
6. Eye bolt location segment 630mm
6. Eye bolt location segment 710mm
7. Hydraulic cylinder segment 400mm
7. Hydraulic cylinder segment 500mm
7. Hydraulic cylinder segment 630mm
7. Hydraulic cylinder segment 710mm
8. Eye bolt (universal)
9. Eye bolt location pin (universal)
10. Set of reducing shells (3 pc’s) 400 to 355mm
10. Set of reducing shells (3 pc’s) 400 to 315mm
10. Set of reducing shells (3 pc’s) 500 to 450mm
10. Set of reducing shells (3 pc’s) 500 to 400mm
10. Set of reducing shells (3 pc’s) 630 to 560mm
10. Set of reducing shells (3 pc’s) 630 to 500mm
10. Set of reducing shells (3 pc’s) 710 to 630mm
11.Spare hydraulic pump (universal)
12. Hydraulic connector (universal)
13. NIKE cylinder (universal)
14. Spare hydraulic hose complete (universal)
15. Safety security chain
01-08-209
01-08-210
01-08-211
01-08-212
01-08-213
01-08-214
01-08-215
01-08-216
01-08-217
01-08-218
01-08-219
01-08-220
01-08-221
01-08-222
01-08-223
01-08-224
01-08-225
01-08-226
01-08-101
01-08-102
01-08-104
01-08-105
01-08-107
01-08-108
01-08-110
01-08-205
01-08-207
01-08-208
01-08-206
01-08-227
1
2
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
1
1
1
1
1
4
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Specifications.
Materials:
Finish:
Mild Steel EN3A Chrome Plated Tube
Powder coating / zinc plated (Steel)
Dimensions:
400mm Re-rounding clamp
(H x W x D)
Liners/inserts 400mm x 315mm
Liners/inserts 400mm x 355mm
500mm Re-rounding clamp
(H x W x D)
Liners/inserts 500mm x 450mm
Liners/inserts 500mm x 400mm
630mm Re-rounding clamp
(H x W x D)
Liners/inserts 630mm x 560mm
Liners/inserts 630mm x 500mm
710mm Re-rounding clamp
(H x W x D)
530mm x 200mm x 530mm
200mm x 120mm x 340mm
200mm x 120mm x 340mm
630mm x 200mm x 630mm
200mm x 150mm x 425mm
200mm x 150mm x 425mm
825mm x 200mm x 825mm
200mm x 200mm x 540mm
200mm x 200mm x 540mm
1100mm x 200mm x 960mm
Weight:
400mm Re-rounding clamp
500mm Re-rounding clamp
630mm Re-rounding clamp
710mm Re-rounding clamp
Liners/inserts 400mm x 315mm
Liners/inserts 400mm x 355mm
Liners/inserts 500mm x 450mm
Liners/inserts 500mm x 400mm
Liners/inserts 630mm x 560mm
Liners/inserts 630mm x 500mm
Hydraulic hand pump
Oil Volume:
Oil Type:
60 Kg
66 Kg
75 Kg
90 Kg
7 Kg
5 Kg
7.2 Kg
9.2 Kg
11.2 Kg
13.8 Kg
per
per
per
per
per
per
per
per
per
per
segment
segment
segment
segment
segment
segment
segment
segment
segment
segment
NIKE PH70-500
600cm
ISO VG 10 or equivalent
6
This unit is design and manufactured to meet the requirements of
National Grid Gas Industry Standards GIS/PL2-5:2006 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.
Important!
This manual outlines the operation of the hydraulic large diameter
pipe re-rounding clamps.
This manual 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.
General description.
The equipment has been designed to re-round the P.E. pipe from
315mm to 710mm (dependant on model) prior to carrying out the
electrofusion jointing process on SDR11 and SDR17 pipe work in
accordance with Gas Industry Standards GIS/PL2-5:2006 Part 5
Electrofusion ancillary tooling.
Pipe is re-rounded by using a hydraulic unit, and can then be
locked off in position, whilst the pipe is re-rounded.
The units have been manufactured so that inserts can be fitted and
used on various pipe dimensions.
These clamps will not cure flattening in previously
squeezed off pipe, where the clamp comes into contact
with scraped pipe, the area must be re-scraped before
fitting into the electrofusion coupler
7
First Use
Before operating the clamp for the first time, the rerounder must have its hydraulic circuit ‘purged’ to
eliminate any possible air in the system.
Air can collect in the hydraulic system when hoses or tools are
connected and this can lead to problems in operation. To bleed
the system run the tool or ram through 3-4 cycles (pumping to full
extension then releasing) without any load. At the same time
make sure that the tool or ram is kept lower than the pump so that
the air can travel back to the oil reservoir in the pump. Then bleed
the pump oil reservoir. Top up the pump with oil if necessary.
Before using
It is important to ensure all component parts are present and in
serviceable condition. Check the pump, hose and connectors for
damage. Ensure the reducing inserts are fitted with the correct
screws
Safety
Instructions
1. Read FIRST USE procedure before using the tool.
2. It is imperative that all possible precautions are made to
avoid unexpected movement of the tool during use.
3. Never operate the hydraulic cylinder beyond its maximum
stroke.
4. The pump is fitted with a safety valve to stop overloading.
This is factory set and MUST NOT be tampered with.
8
5. The clamps are heavy between 60Kg & 90Kg dependant on
model care should be taken when in use.
6. To avoid injury the re-rounder should be closed and secured
and the safety chains latched in position with the hydraulic
cylinder extended for transportation, lifting must be by 2
persons.
7. Operatives should wear eye protection, gloves, safety
headwear & footwear when using the equipment.
Instructions for use.
1. The tool consists of a steel 3 segment body with hinges and
transportation eyes, a hydraulic pump and optional liner shells to
increase the operating range of the tool.
2. The tool should ideally be positioned onto the pipe using a
suitable powered lifting device. Chains and shackles or webbing
slings should be connected through the eyebolts or lifting handles
to allow ease of movement. The tool should never be opened more
that the length of the safety chain, neither should the safety chain
ever be removed or left disconnected.
3. When the tool is correctly positioned, the cylinder eyebolt should
be positioned so that the clevis pin can be passed through the first
clevis plate, the eyebolt and the second clevis plate easily.
4. The hose connector from the pump can then be fitted to the
coupler on the hydraulic cylinder, to do this, ensure the coupling
locknut is free to rotate and at the base of the stem nearest the
cylinder.
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5. After wiping to remove loose dirt etc. firmly insert the probe on
the hose into the cavity in the cylinder coupler and fully lock in
position with the locknut.
6. To close the segmented body together and initiate the re
rounding effect, ensure the open/close valve on the pump is shut
prior to operating the pump handle in a regular motion.
7. Pressure will build up inside the cylinder forcing the piston to
move in the direction of the arrow in picture 1 and thereby close
the segments together.
8. Allow sufficient time for the re-rounding effect to take place
prior to releasing the cylinder pressure by opening the open/close
valve on the pump.
Instructions for removal after
pipe re-rounding.
Care must be taken on removing the clamp to ensure
injury to operatives is avoided.
Transport and Storage
1. Release the pressure in the circuit by opening the valve on
the pump unit.
2. Release the hydraulic couplers/hose between the pump and
cylinder.
3. Remove the eye bolt pin this will allow the re-rounder to
relax around the pipe.
4. It should be possible to now lift the re-rounder clear of the
pipe.
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5. Care should be taken not to cause damage to the already
re-rounded pipe end.
Storage
IMPORTANT: When hydraulic equipment is not in use:
1.
2.
3.
4.
Store the tool in an upright position.
Clean the equipment.
Store in a clean damp free environment
Make sure the store is not subject to extreme temperature
changes
5. Ensure the pressure in the cylinder is released.
Maintenance
Hydraulic cylinder cleaned and dirt free
Lubricate all moving parts at regular intervals.
Use only OEM spare parts (NIKE)
NOTE: AN EXCESS OF OIL WILL RENDER THE PUMP INOPERATIVE
Use only hydraulic oil type HL or HM (30cSt at 40°C)
Tool
Grease and check screw threads at regular intervals.
Inspect and replace damaged security chains.
Inspect and lubricate all moving components if necessary.
11
EC DECLARATION OF CONFORMITY
MACHINERY SUPPLIER:
Caldervale Technology Limited
SUPPLIER’S ADDRESS:
Bretfield Court,
Dewsbury,
WF12 9DB,
UK
Declares that the Machinery described below:
Make:
CTL
Product:
Maxifuse™ Hydraulically Powered Re- rounding clamps
Type:
400mm c/w pump.
500mm c/w pump.
630mm c/w pump.
710mm c/w pump.
Reference No:
01-08-100, 01-08-103, 01-08-106 & 01-08-109
Conforms to the following Directives:
98/37/EC
Machinery (Safety) Regulations (as amended)
Meets the following standards:
Safety of Machinery
BS EN 12100: 2003, BS EN 982: 1996
Gas Industry Standard
GIS/PL2-5: 2006 Part 5 Electrofusion ancillary tooling
Complies with, or is designed and constructed so far as is possible to comply with the relevant essential
health and safety requirements, taking into account the state of the art.
Modifications to the equipment without prior approval by the undersigned will render this Declaration null
& void
For and on behalf of the Manufacturer:
Signature: ……G L Lilley…………
Gordon Lilley – Managing Director (CE Responsible Person)
Signed at: ……DEWSBURY………………….. on: 5th February 2007…….(date)
Signature of this Declaration of Conformity authorises the manufacturer or his authorised representative in the
community to affix the CE Mark to the equipment
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Certificate of calibration.
• This product has been inspected and tested in accordance with the
ISO9001 quality control systems and procedures in place at Caldervale
Technology Ltd, Dewsbury.
• This product has no calibration period, periodic, safety inspections
should be carried out by the operator if in any doubt please contact
the manufacturer for further information
Decommissioning & Disposal Instructions
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 Health and Safety Requirements.
• If a Maxifuse™ Hydraulically Powered Re-rounding tool has reached
the end of its useful working life and cannot be refurbished it must
be disposed of through a licensed scrap or waste disposal facility.
Alternatively, a reverse engineering company could be used to strip
the equipment for recycling purposes.
• Waste hydraulic oil, similarly, must be disposed of via a licensed
waste disposal route.
• Disposal is the responsibility of the Customer this can also be
achieved by returning the product back to the manufacturer
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.
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 like-new,
(b)
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(c)
(d)
(e)
2.
provided that it has functionality at least equal to that of the product
being replaced.
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.
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.
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.
Pre-conditions for Warranty Application.
Caldervale Technology Ltd’ 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;
(iv)
Operation outside the products specifications;
(v)
Improper site preparation or maintenance;
(vi)
Faulty pipe.
3.
Limitations of Warranty.
(a)
Caldervale Technology Ltd does not warrant the operation of any
product to be uninterrupted or error free.
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.
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.
(b)
(c)
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(d)
(e)
To the extent allowed by local law, the remedies provided in this
warranty statement are the customer’s sole and exclusive remedies.
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
different pipes that subsequently appear in the market place.
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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 & address
of purchaser
...............................................................
...............................................................
...............................................................
...............................................................
...............................................................
...............................................................
Type of tool
...............................................................
Serial number
...............................................................
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For Service and repair please contact:
Caldervale Technology Ltd
Bretfield Court
Dewsbury
West Yorkshire
WF12 9DB
United Kingdom
Tel: +44 (0)1924 469571
Fax: +44 (0)1924 460951
sales@caldertech.com
http://www.caldertech.com
© February 2007 Revision G
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