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Climax VM2150 Series Operating Manual

Globe valve grinding machine
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VM2150
GLOBE VALVE GRINDING MACHINE
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 90418
October 2017
Revision 1

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  • Page 1 VM2150 GLOBE VALVE GRINDING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 90418 October 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 VM2150 Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 90418, 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: Chapter /Section Page

    TABLE OF CONTENTS (CONTINUED) HAPTER ECTION 6 STORAGE AND SHIPPING ...........45 .
  • Page 9 LIST OF FIGURES IGURE 2-1 Machine with electric drive motor and hand-held operation ........8 2-2 Machine with pneumatic drive system and hand-held operation .
  • Page 10 LIST OF FIGURES (CONTINUED) IGURE A-10 170-10S-N01-00 ..............57 A-11 220-40S-N01-00 mounting device for valves with flange .
  • 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 vi VM2150 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 VM2150 globe valve grinding machine was designed and built on the basis of a risk analysis and under consideration of all relevant harmonised standards as well as further national standards and technical specifications. The machine thus conforms to the current level of technology and guarantees the highest possible degree of safety.

  • 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.
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  • Page 19: Overview

    39 must be followed to ensure a safe operation of the globe valve grinding machine. 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 the customer’s maintenance personnel.
  • Page 20 CAUTION The globe valve grinding machine is only to be used as prescribed. If the globe valve grinding machine is not used accordingly, safe operation is not guaranteed. Any danger to the life and health of people and all damage to the globe valve grinding machine resulting from use not as prescribed will be the customer’s responsibility.
  • Page 21 2-2. M IGURE ACHINE WITH PNEUMATIC DRIVE SYSTEM AND HAND HELD OPERATION 2-3. M IGURE ACHINE WITH ELECTRIC DRIVE MOTOR AND COLUMN SETUP P/N 90418, Rev. 1 Page 9...

  • Page 22: Hand-Held Operation

    2-4. M IGURE ACHINE AS SHOWN WITH PNEUMATIC DRIVE SYSTEM AND COLUMN SETUP The machine spindle of the globe valve grinding machine is driven by an electric or a pneumatic motor. The tool is adapted to the machine spindle by the quick-lock coupling which is located at the bottom end of the machine spindle.

  • Page 23: Specifications

    The trigger button should not be locked during manual operation even though a button is provided. The spindle speed can be adjusted at the trigger button of the electric drive. For the machine with pneumatic drive, the spindle speed is adjusted with the regulating valve at the maintenance unit for air supply.
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  • Page 25: 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 26 CAUTION The weight of the cases should not be underestimated. Secure the cases during transportation to avoid any harm to people or damage to other equipment by parts falling out of the case. Especially during work at high levels, secure all parts against dropping.
  • Page 27 3-2. M VM2150 IGURE ACHINE CASE WITH PNEUMATIC DRIVE 3-3. A VM2150 (VM2150 SVL) IGURE CCESSORY CASE P/N 90418, Rev. 1 Page 15...
  • Page 28 3-4. M VM2150S IGURE ACHINE CASE WITH ELECTRIC DRIVE 3-5. M VM2150S IGURE ACHINE CASE WITH PNEUMATIC DRIVE Page 16 VM2150 Operating Manual...
  • Page 29 3-6. A VM2150S IGURE CCESSORY CASE 3-7. M VM2150SV IGURE ACHINE CASE AS SHOWN INCLUDING ELECTRIC DRIVE P/N 90418, Rev. 1 Page 17...
  • Page 30 3-8. M VM2150SV IGURE ACHINE CASE AS SHOWN INCLUDING PNEUMATIC DRIVE 3-9. A VM2150SV IGURE CCESSORY CASE Page 18 VM2150 Operating Manual...

  • Page 31: Selecting Tools And Preparation

    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 • M5, wrench size 4 mm: 3,5 Nm Countersunk screw according to DIN 7991, Quality 8.8: •...
  • Page 32 3-1. S .39–3.94" (10–100 ABLE OLID GRINDING DISCS WITH GUIDES FOR DIAMETER Diameter Guides Grinding disk Lapping disk range in diameter Ball joint Screw with Screw without diameter in diameter in inches in inches coupling type Guide DIN 912 Guide DIN 912 inches (mm) inches (mm) (mm)
  • Page 33 3-10. T 10 ( IGURE OOL COMPONENTS FOR HAND HELD OPERATION WITH BALL JOINT COUPLING TYPE SOLID GRIND- ING DISC WITH GUIDE 3-11. T 10 ( IGURE OOL COMPONENTS FOR HAND HELD OPERATION WITH BALL JOINT COUPLING TYPE SOLID GRIND- ING DISC WITH GUIDE 3-12.

  • Page 34: Preparing Tools

    3.2.2 Preparing tools If necessary, clean the grinding discs with oil-free cleaning fluid (for example, lac- quer thinner). Put abrasives on the grinding discs (not needed for lapping). Assemble the selected tool components (see Figure 3-10 on page 21, Figure 3-11 on page 21, and Figure 3-12 on page 21): •...
  • Page 35 NOTICE For lapping operation, check that sufficient lapping paste is put onto the surface to be machined. Use low pressure for lapping operations. 7. Connect the machine to energy supply. CAUTION All cables and hoses for the machine power supply must be covered or installed to prevent stumbling.
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  • Page 37: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 OPERATION CHECKS 4.2 O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25...
  • Page 38 3. Adjust grinding (or lap- ping) pressure according to application (see Figure 4- 4-1. I IGURE NDICATOR OF GRINDING PRESSURE 4-2. I VM2150 VM2150S IGURE NDICATOR OF GRINDING PRESSURE AT GRINDING SPINDLE 4-3. I VM2150SV IGURE NDICATOR OF GRINDING PRESSURE AT GRINDING SPINDLE For machines with electric drives, adjust speed at the trigger button.
  • Page 39 • Pressure regulation for speed control • Pressure gauge • Filter with drain screw for condenser water • Safety button for pressure release of the system • Air lubricator If customers are using their own maintenance unit, the operation might be differ- ent, however, the basic functions as described above must be provided.
  • Page 40 4-5. E IGURE LECTRIC DRIVE WITH TRIGGER BUTTON AND DIRECTION OF ROTATION 4-6. M IGURE AINTENANCE UNIT WITH OPERATING BUTTONS FOR PNEUMATIC DRIVE OPTIONAL Page 28 VM2150 Operating Manual...

  • Page 41: Operation With Column Mounting Device (Vm2150 Only )

    (VM2150 PERATION WITH COLUMN MOUNTING DEVICE ONLY 4.3.1 Set-up of column mounting device Do the following: 1. Take the brackets and base plate out of the case. 2. For connecting the brackets and base plate, use screws M10 x 20 DIN 912. Do not tighten the screws, it should still be possible to move the brackets.
  • Page 42 4. After alignment, tighten all screws. Check that the distance from front of base plate to center of valve is still approximately 7.09–7.87" (180–200 mm). 5. Connect the adjustable support of the column mounting device to the base plate using screws M8 x 20 DIN 912 (see Figure 4-3). 4-9.
  • Page 43 6. Locate and clamp column into adjustable support (see Figure 4-10). 4-10. C IGURE OLUMN MOUNTING DEVICE COMPLETELY MOUNTED 7. Locate and clamp the machine into the column mounting device (see Fig- ure 4-11). 4-11. M IGURE ACHINE AND COLUMN MOUNTING DEVICE ASSEMBLY P/N 90418, Rev.

  • Page 44: Selecting Tools

    4.3.2 Selecting tools Select the size of tools according to valve seat outer diameter. Combine the proper tool components according to Figure 3-10 on page 21 and Fig- ure 3-11 on page 21. • Grinding or lapping disc • Ball joint coupling •...
  • Page 45 CAUTION All cables and hoses for the machine power supply must be covered or installed to preve stumble. Before connecting the machine to the power supply, check all cables and hoses for damages. For grinding operation, always wear eye protection glasses. For machines with electric drive motor, check that the trigger button is in unlocked position before connecting to the power supply.
  • Page 46 4-12. A IGURE DJUSTMENT OF VERTICAL GUIDES ON COLUMN WARNING If the set screws of the vertical guides are not tight enough, the self-locking is not guaranteed and the vertical slide will not keep its vertical position. After aligning the machine, tighten all screws carefully. For machines with electric drives, adjust speed at the trigger button.

  • Page 47: Change Of Abrasives

    • Filter with drain screw for condenser water • Safety button for pressure release of the system • Air lubricator If customers are using their own maintenance unit, the operation might be differ- ent, however, the basic functions as described above must be provided. Adjust grinding and lapping pressure according to application.
  • Page 48 Select proper grinding disc according to the outer diameter of the valve plug (see Table 4-1). 4-1. S ABLE ELECTION OF GRINDING DISC FOR GRINDING OF VALVE PLUGS WITH SOLID GRINDING DISCS AND ADJUSTABLE GUIDES Valve plug Grinding disc Guide diameter Ball joint Connecting screws diameter in...
  • Page 49 4-14. S (OD- IGURE OLID GRINDING DISC WITH ADJUSTABLE GUIDES FOR GRINDING OF VALVE PLUGS GUIDED Check manually that the grinding disc with the adjustable guides can rotate easily on the valve plug (play between adjustable guides and valve plug should be approximately .004"...
  • Page 50 CAUTION All cables and hoses for the machine power supply must be covered or installed to prevent stumbling. Before connecting the machine to the power supply, check all cables and hoses for damages. For grinding operation, always wear eye protection glasses. For machines with electric drive motor, check that the trigger button is in unlocked position before connecting to the power supply.

  • Page 51: Maintenance

    Section 5.2 on page 40 and Section 5.3 on page 40 as well as under Section 5.4.1 on page 41 and Section 5.4.2 on page 41. Alternatively, the machine can be sent to CLIMAX for proper maintenance. Under normal circumstances and proper handling the maintenance as described above is sufficient.

  • Page 52: Lubricating The Machine Modules

    The machine is re-assembled in horizontal position. We recommend to have this service done by CLIMAX due to the experience required. Before every machine operation, the ball joint coupling of the machine spindle should be lubricated with grease Molykote or Unimoly GL82 (Klüber).

  • Page 53: Electrical Tasks

    5.4.1 Electrical tasks CAUTION All work on the machine’s electrical equipment must be carried out by trained electrical specialists. Electrical equipment must be checked regularly. Loose connections must be made secure. Damaged wires or cables must be replaced immediately. Never clean electrical apparatus with water or similar liquids. 5.4.2 Pneumatic equipment tasks CAUTION...
  • Page 54 CAUTION The operator must inform the supervisor and should never try to resolve any problem on the electrical equipment on their own. Disregard of safety regulations may result in danger of life and health of persons. CAUTION All work on the machine’s electrical equipment must be carried out by trained electrical specialists.
  • Page 55 To solve mechanical faults, a complete part list and assembly drawing is supplied with the operator's manual in Appendix A. 5-1. 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 57 STORAGE AND SHIPPING TORAGE Proper storage of the globe valve grinding machine will extend its usefulness and prevent undue damage. Before storing, do the following: 1. Clean the machine with solvent to remove grease, metal chips, and mois- ture. 2. Drain all liquids from the pneumatic conditioning unit. Store the globe valve grinding machine in its original shipping container.
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  • Page 59 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 60 A-1. V IGURE ALVE GRINDER ASSEMBLY Page 48 VM2150 Operating Manual...
  • Page 61 A-2. 220-11S-N01-00 IGURE ELECTRIC DRIVE P/N 90418, Rev. 1 Page 49...
  • Page 62 A-3. 220-12S-N01-00 IGURE PNEUMATIC DRIVE Page 50 VM2150 Operating Manual...
  • Page 63 A-4. 220-20S-N01-00 IGURE SPRING SYSTEM P/N 90418, Rev. 1 Page 51...
  • Page 64 A-5. 220-21S-N01-00 IGURE SPRING STANDARD MACHINE Page 52 VM2150 Operating Manual...
  • Page 65 A-6. 220-22S-N01-00 SV-M IGURE SPRING ACHINE P/N 90418, Rev. 1 Page 53...
  • Page 66 A-7. 220-31S-N01-00 IGURE BALL JOINT COUPLING TYPE Page 54 VM2150 Operating Manual...
  • Page 67 A-8. 170-20S-N01-00 IGURE P/N 90418, Rev. 1 Page 55...
  • Page 68 A-9. 220-32S-N01-00 IGURE BALL JOINT COUPLING TYPE Page 56 VM2150 Operating Manual...
  • Page 69 A-10. 170-10S-N01-00 IGURE P/N 90418, Rev. 1 Page 57...
  • Page 70 Column mounting device (not delivered with S and SV machines) A-11. 220-40S-N01-00 IGURE MOUNTING DEVICE FOR VALVES WITH FLANGE Page 58 VM2150 Operating Manual...
  • Page 71 A-12. 220-41S-N01-00 IGURE MOUNTING DEVICE FOR VALVES WITHOUT FLANGE P/N 90418, Rev. 1 Page 59...
  • Page 72 Tools A-13. S .4–2.6" (10–65 IGURE OLID GRINDING AND LAPPING DISCS DIAMETER A-14. S 3.2–3.9" (80–100 IGURE OLID GRINDING AND LAPPING DISCS DIAMETER Page 60 VM2150 Operating Manual...
  • Page 73 A-15. S 3.2–5.9" (80–150 IGURE OLID GRINDING DISCS WITH ADJUSTABLE BEARINGS DIAMETER P/N 90418, Rev. 1 Page 61...
  • Page 74 A-16. L IGURE IST OF ABRASIVES Page 62 VM2150 Operating Manual...

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