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Climax VM1900S Operating Manual

Gate valve grinding and lapping machine
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VM1700S-
1900S
GATE VALVE GRINDING AND LAPPING
MACHINE
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 90075
July 2017
Revision 1

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  • Page 1 VM1700S- 1900S GATE VALVE GRINDING AND LAPPING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 90075 July 2017 Revision 1...
  • Page 3 CLIMAX. CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-...
  • Page 4 CLIMAX GLOBAL LOCATIONS Page B VM1700S-1900S Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 90075, Rev. 1 Page C...
  • Page 6 CLIMAX will, at its option, either repair or replace the defective part and/ or correct any defect in the labor performed, both at no charge, and return the part or repaired machine shipping prepaid.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS HAPTER ECTION 1 INTRODUCTION ............1 .
  • Page 8 TABLE OF CONTENTS (CONTINUED) HAPTER ECTION 5.4.2 Pneumatic equipment tasks ..........39 .
  • Page 9 3-2 Accessory case (VM1900S shown) ........
  • Page 10 LIST OF FIGURES (CONTINUED) IGURE A-19 List of abrasives ..............71 A-20 470-70S-N01-00 tooling .
  • Page 11 LIST OF TABLES ABLE 1-1 Sound levels ..............3 1-2 Risk assessment checklist before set-up .
  • Page 12 This page intentionally left blank Page 2 VM1700S-1900S Operating Manual...

  • Page 13: Introduction

    INTRODUCTION IN THIS CHAPTER: 1.1 H - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OW TO USE THIS MANUAL 1.2 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...

  • Page 14: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS CLIMAX leads the way in promoting the safe use of portable machine tools and valve testers. Safety is a joint effort. You, the end user, must do your part by being aware of your work environment and closely following the operating procedures and safety precautions contained in this manual, as well as your employer’s safety...

  • Page 15: Machine - Specific Safety Precautions

    Moving parts – CLIMAX machines have numerous exposed moving parts and interfaces that can cause severe impact, pinching, cutting, and other injuries. Except for stationary operating controls, avoid contact with mov- ing parts by hands or tools during machine operation. Remove gloves and secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts.

  • Page 16: Risk Assessment And Hazard Mitigation

    ISK ASSESSMENT AND HAZARD MITIGATION The Gate Valve Grinder Model VM 1700(S) respectively VM1900(S) was designed and built on the basis of a risk analysis and under consideration of all rel- evant harmonised standards as well as further national standards and technical specifications.

  • Page 17: Risk Assessment Checklist

    ISK ASSESSMENT CHECKLIST The following checklist is not intended to be an all inclusive list of things to watch out for when setting up and operating this Portable Machine Tool. However, these checklists are typical of the types of risks the assembler and operator should con- sider.
  • Page 18 This page intentionally left blank Page 6 VM1700S-1900S Operating Manual...

  • Page 19: Overview

    37 must be followed to ensure a safe operation of the Gate Valve Grinder. Any faults during the warranty period will be recovered according to CLIMAX’s terms of warranty. Excluded are damages due to dismantling the machine by cus- tomer’s maintenance personnel.
  • Page 20 Principle components are shown in Fig- ure 2-1 and identified in Table 2-1: 2-1. C ABLE OMPONENTS Position Component Drive Motor Gear box Machine arm Drive shaft with ball joint Tools (grinding and lapping tools) Tilting adapter The Gate Valve Grinder is driven by an electric or a pneumatic motor, which is mounted to the upper gear housing.
  • Page 21 The abrasives are put onto the grinding discs which are mounted to the planet arms. This system ensures a quick change from grinding with abrasives to CBN- grinding discs or to lapping discs. Prior to the machining operation, the Gate Valve Grinder has to be mounted to the gate valve body by means of a tilting adapter with clamping elements (included in the basic scope of supply).

  • Page 22: Specifications

    PECIFICATIONS 2-2. S ABLE PECIFICATIONS Unit Specification Machining Data Machining range VM1700 DN 200 – DN 700 (VM1700) Machining range VM1900 DN 200 – DN 1000 (optional DN 1200) Submerging depth VM1700 1000 mm Submerging depth VM1900 1400 mm Maximum speed (electric / pneumatic) 370 U/min / 250 U/min Power requirements Connection (electric/pneumatic)

  • Page 23: Setup

    Keep the shipping container and all packing materials for future storage and shipping of the machine. The machine ships from CLIMAX with a heavy coating of LPS 3. The recom- mended cleaner is LPS PreSolve Orange Degreaser. All parts must be cleaned before use.
  • Page 24 CAUTION Do not put your hand through the holes of the Planet Wheels when putting a Planet Wheel into the Case. There is the danger of shearing or injuring the Hand. 3-1. M (VM1900S IGURE ACHINE CASE SHOWN Page 12...

  • Page 25: Selecting Tools And Preparation

    3-2. A (VM1900S IGURE CCESSORY CASE SHOWN ELECTING TOOLS AND PREPARATION For all screws being used as connecting elements, the following maximum torque must be observed: Socket head screw according to DIN 912, Quality 8.8: • M4, wrench size 3 mm: 1,8 Nm •...

  • Page 26: Selecting Tools

    • 5 pcs. lapping discs, diameter 50 mm (5 mm thick, cast iron) • 5 pcs. lapping discs, diameter 80 mm (7 mm thick, cast iron) Additionally for machine VM1900S • 2 pcs. CBN-grinding discs • 2 pcs. grinding discs diameter 80 mm (6 mm thick, black colour) Additionally for machines with the optionally Lapping Accessories (VM1900): •...
  • Page 27 3-1. M DN 80–DN 600 ABLE ACHINING DIAMETERS FOR PLANET WHEELS The diameters mentioned above are valid for recommended combinations and ranges. However, in some cases it is possible to extend the grinding range. P/N 90075, Rev. 1 Page 15...
  • Page 28 3-3. T . 220) IGURE OOL COMPONENTS FOR PLANET GRINDING WHEEL AS SHOWN WITH PLANET WHEEL DIA 3-4. T . X540) IGURE OOL COMPONENTS FOR PLANET GRINDING WHEEL AS SHOWN DIA Page 16 VM1700S-1900S Operating Manual...

  • Page 29: Preparing Tools

    3.2.2 Preparing tools If necessary, cleaning of grinding discs with oil-free cleaning fluid (i.e. lacquer thinner) Putting abrasives onto grinding discs (not applicable for lapping operation and grinding with CBN-grinding discs) Assembly of selected tool components (according to Figure 3-5), observe applica- ble torque for screws (if too low, components get loose, if too high, screw might be damaged): •...

  • Page 30: Mounting The Tilting Adapter Onto A Valve Body

    3-6. P X540, IGURE LANET GRINDING WHEEL DIAMETER COMPLETELY ASSEMBLED OUNTING THE TILTING ADAPTER ONTO A VALVE BODY Select all clamping elements for mounting the base plate: • tilting adapter • base plate • forged steel C-clamps (4 pieces) • clamping pads L=100 mm (2 pieces) •...
  • Page 31 If the top flange of the valve body has a raised sealing surface, use clamping pads with 90° countersunk hole at the end to avoid any damage to the sealing during clamping (according to Figure 3-8). 3-8. C IGURE LAMPING PADS WITH SPACERS 1.

  • Page 32: Machine Assembly

    2. Connect the base plate to the flange of the gate valve body. 3. Connecting tilting adapter onto base plate using 4 socket head screws M10 x 20-8.8-Zn according to DIN 912 with washers Ø 10,5- 140HV-Zn according to DIN 433. Make sure that the location for the machine arm is approximately in 3-10.

  • Page 33: Mounting The Drive Shaft With Ball Joint

    Assemble the bracket and locate the bracket on the machine arm according to the submerging depth required. The machine spindle has to be on centre with the valve seat. Prior to locating the bracket measure the distance from the center of the seat to top of tilting adapter.

  • Page 34: Adapting The Planet Wheel

    3-13. M IGURE OUNTING THE DRIVE SHAFT WITH BALL JOINT In some cases it might be required to mount the machinearm with the drive system in opposite direction. In this case just turn the bracket 180° and locate the drive shaft accordingly.

  • Page 35: Locating And Aligning The Machine In The Tilting Adapter

    3.4.4 Locating and aligning the machine in the tilting adapter 1. Open the flap of the tilting adapter. 2. Place the machine arm with the bracket and the two ball locations into the tilting adapter. 3-15. L IGURE OCATING THE MACHINE ARM INTO THE TILT- ING ADAPTER P/N 90075, Rev.
  • Page 36 3. Close the flap and clamp the machine arm. If additional height adjustment of the machine arm is required take the machine arm out of the tilt- ing adapter, readjust the bracket and replace the machine arm again. 3-16. M IGURE ACHINE ARM IN CLAMPED POSITION To avoid any backlash in the...
  • Page 37 CAUTION When placing the machine arm into the tilting adapter, hold it by hand to avoid slipping. The machine arm is protected against slipping when the bracket is locked and resting in the ball locations. The machine can be centred hori- zontally by means of the adjust- ment mechanism of the tilting adapter.
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  • Page 39: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 OPERATION CHECKS 4.2 O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27...
  • Page 40 CAUTION Make sure that always proper grinding discs are being used, otherwise the machine or the valve body can be damaged: If grinding discs are used for lapping operation, they will be damaged. If already used lapping discs are utilised for grinding operation, the required accuracy cannot be guaranteed and the valve seat might be damaged.
  • Page 41 applied to the star knob of the tilting adapter. The different lines are standing for the submerging depth. The diagram gives the values for pre-setting the pressure and it shows that the torque at the star knob is fairly low since the ratio of the tilt- ing table is very high.
  • Page 42 (“R” means clockwise). The electric drive motor is equipped with an additional 2- stage mechanically switching gear. The switch for the mechanical gear is located on the bottom side of the electric drive motor. The switch is marked with a turtle and a rabbit.
  • Page 43 4-4. M IGURE AINTENANCE UNIT WITH OPERATING BUTTONS FOR PNEUMATIC DRIVE OPTIONAL CAUTION Never operate the pneumatic drive without maintenance unit with lubricator and filter. The lubricator must always be filled with oil. The air supply line must always offer an air pressure of 6,3 bar to the maintenance unit.

  • Page 44: Change Of Abrasives

    • Overproportional heat creation: shearing off the abrasives and damag- ing the valve seat HANGE OF ABRASIVES CAUTION Stop the machine with trigger button (electric drive) or with red safety button on maintenance unit (pneumatic drive) and interrupt the power supply. 1.

  • Page 45: Change Of Mounted Drive Motor

    4.4.1 Change of mounted drive motor After release of the clamping screw, the drive can be pulled off. With the electric drive motor, there is an additional adapter bushing in the drive flange bore (dia. 43 mm / 48 mm). This bushing has to be removed for mounting the pneu- matic drive motor.

  • Page 46: Mounting Of New Drive Motor

    4.4.2 Mounting of new drive motor To mount a new drive motor, the coupling has to be connected to the ½" – 20 UNF- 2A thread of the motor spindle. Due to the fact that the electric drive motor offers spindle rotation in both directions, the coupling has to be secured with a left-hand threaded screw (see Figure 4-6 on page 33).
  • Page 47 To change the abrasives, the grinding pressure has to be released and after unclamping the 3-jaw centring chuck, the machine including chuck can be taken out of the valve body. After changing the abrasives, the machine can be relocated as described before. P/N 90075, Rev.

  • Page 48: Conical Seats ( Optional )

    ONICAL SEATS OPTIONAL Page 36 VM1700S-1900S Operating Manual...

  • Page 49: Maintenance

    MAINTENANCE IN THIS CHAPTER: 5.1 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37 AINTENANCE CHECKLIST 5.2 L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38...

  • Page 50: Lubricating The Machine Modules

    Alternatively, the machine can be sent to CLIMAX for proper maintenance. Under normal circumstances and proper handling the maintenance as described in Table 5-1 is sufficient. Under unfavourable circumstances, such as rough operation or operation under harmful environmental conditions (high temperature, high humidity, etc.) the inspection period should be shorter.

  • Page 51: Lubricating The Pneumatic Drive Motor

    In case of a rattling noise coming out of the machine arm, most likely the drive chain is not sufficient anymore. To adjust the tension of the drive chain, untie the screws of the machine arm clamping plate 20T-004 and adjust the tension by means of the adjusting screw 20N-023.

  • Page 52: Troubleshooting

    5.4.2 Pneumatic equipment tasks CAUTION All work on the machine’s pneumatic equipment must be carried out by trained pneumatic specialists! Before any service and maintenance work, the pressure has to be released. Disconnection of lines under pressure should only be done with adequate tooling and according to all safety regulations that apply.
  • Page 53 To solve mechanical faults, a complete part list and assembly drawing is supplied with the operator's manual in Appendix A. 5-2. T ABLE ROUBLESHOOTING FOR POSSIBLE FAULTS Possible fault Operating or maintenance error Recovery of fault Make sure that power supply line is Power supply line is not connected plugged in.
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  • Page 55: Storage And Shipping

    STORAGE AND SHIPPING IN THIS CHAPTER: 6.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43 TORAGE 6.1.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43...

  • Page 56: Shipping

    HIPPING The gate valve grinding and lapping machine can be shipped in its original ship- ping container. ECOMMISSIONING To decommission the gate valve grinding and lapping machine before disposal, remove the drive assembly from the RDU and dispose of the drive assembly sepa- rately from the rest of the machine components.

  • Page 57: Appendix Aassembly Drawings

    APPENDIX A ASSEMBLY DRAWINGS The general design of the machine is shown in the assembly drawings as enclosed. For ordering any spare part, please always mention position and part number. Also for the universal clamping device and the tooling, you will find part lists as enclosed.
  • Page 58 A-1. A IGURE SSEMBLY Page 46 VM1700S-1900S Operating Manual...
  • Page 59 P/N 90075, Rev. 1 Page 47...
  • Page 60 Page 48 VM1700S-1900S Operating Manual...
  • Page 61 P/N 90075, Rev. 1 Page 49...
  • Page 62 A-2. 470-10S-N01-00 IGURE DRIVE MOTOR Page 50 VM1700S-1900S Operating Manual...
  • Page 63 A-3. 240-11S-N01-00 220V IGURE ELECTRIC DRIVE P/N 90075, Rev. 1 Page 51...
  • Page 64 A-4. 240-13S-N01-00 IGURE PNEUMATIC DRIVE Page 52 VM1700S-1900S Operating Manual...
  • Page 65 A-5. 240-15S-N01-00 110V IGURE ELECTRIC DRIVE P/N 90075, Rev. 1 Page 53...
  • Page 66 A-6. 470-16S-N01-00 A IGURE IR DRIVE WITH EX CERTIFICATE Page 54 VM1700S-1900S Operating Manual...
  • Page 67 A-7. 470-20S-N01-00 IGURE UPPER GEAR BOX P/N 90075, Rev. 1 Page 55...
  • Page 68 A-8. 470-30S-N01-00 IGURE MACHINE ARM Page 56 VM1700S-1900S Operating Manual...
  • Page 69 A-9. 470-31S-N01-00 M IGURE ACHINE ARM GENERAL PARTS P/N 90075, Rev. 1 Page 57...
  • Page 70 A-10. 470-33S-N01-00 T=1400 IGURE MACHINE ARM Page 58 VM1700S-1900S Operating Manual...
  • Page 71 A-11. 470-40S-N01-00 IGURE BALL JOINT COUPLING P/N 90075, Rev. 1 Page 59...
  • Page 72 A-12. 470-41S-N01-00 IGURE Page 60 VM1700S-1900S Operating Manual...
  • Page 73 A-13. 170-10S-N01-00 IGURE P/N 90075, Rev. 1 Page 61...
  • Page 74 A-14. 470-42S-N01-00 IGURE Page 62 VM1700S-1900S Operating Manual...
  • Page 75 A-15. 170-40S-N01-00 IGURE P/N 90075, Rev. 1 Page 63...
  • Page 76 Mounting system Page 64 VM1700S-1900S Operating Manual...
  • Page 77 P/N 90075, Rev. 1 Page 65...
  • Page 78 Page 66 VM1700S-1900S Operating Manual...
  • Page 79 P/N 90075, Rev. 1 Page 67...
  • Page 80 A-16. 470-50S-N01-00 IGURE MOUNTING SYSTEM Page 68 VM1700S-1900S Operating Manual...
  • Page 81 A-17. 470-51S-N01-00 IGURE TILTING ADAPTER P/N 90075, Rev. 1 Page 69...
  • Page 82 A-18. 470-52S-N01-00 IGURE FLANGE SETUP Page 70 VM1700S-1900S Operating Manual...
  • Page 83 Tooling A-19. L IGURE IST OF ABRASIVES P/N 90075, Rev. 1 Page 71...
  • Page 84 A-20. 470-70S-N01-00 IGURE TOOLING Page 72 VM1700S-1900S Operating Manual...
  • Page 85 A-21. 470-71S-N01-00 DN 200 … DN 500 IGURE PLANET WHEELS P/N 90075, Rev. 1 Page 73...
  • Page 86 A-22. 470-72S-N01-00 DN 500 … DN 700 IGURE PLANET WHEELS Page 74 VM1700S-1900S Operating Manual...
  • Page 87 A-23. 470-76S-N01-00 DN1000 DN1200 IGURE EXTENSION FROM P/N 90075, Rev. 1 Page 75...
  • Page 88 A-24. 470-78S-N01-00 DN1000 DN1200 IGURE EXTENSION FROM Page 76 VM1700S-1900S Operating Manual...
  • Page 89 A-25. 470-80S-N01-00 IGURE ABRASIVES P/N 90075, Rev. 1 Page 77...
  • Page 90 A-26. 240-81S-N01-00 VM 2350 IGURE ABRASIVES Page 78 VM1700S-1900S Operating Manual...
  • Page 91 A-27. 240-84S-N01-00 VM 2500 IGURE ABRASIVES P/N 90075, Rev. 1 Page 79...
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