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Climax VM1350 Operating Manual

Gate valve grinding and lapping machine
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VM1350-
1500-1600
Gate Valve Grinding and Lapping Machine
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 89800
May 2017
Revision 2

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  • Page 1 VM1350- 1500-1600 Gate Valve Grinding and Lapping Machine OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 89800 May 2017 Revision 2...
  • 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 VM1350-1500-1600 Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 89800, Rev. 2 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 ASSEMBLY DRAWINGS ......... .49 Page ii VM1350-1500-1600 Operating Manual...
  • Page 9 LIST OF FIGURES IGURE 2-1 Valve machine with pneumatic drive motor ..........8 3-1 Machine case (here VM 1350;...
  • Page 10 A-28 440-72S-N01-00 Solid Grinding Discs DN 40 ... DN 65 (VM 1350 only) ..... . 83 Page iv VM1350-1500-1600 Operating Manual...
  • 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 VM1350-1500-1600 Operating Manual...

  • Page 13: Introduction

    The first page of each chapter includes a summary of the chapter contents to help you locate specific information. The appendices contain supplemental product information to aid in setup, operation, and maintenance tasks. Read this entire manual to familiarize yourself with the VM1350-1500-1600 before attempting to set it up or operate it. AFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual.

  • 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

    Due to the unique nature of portable machining applications, identifying one or more hazards that must be addressed is typical. When performing the on-site risk assessment, it is important to consider the Porta- ble Machine Tool and the workpiece as a whole. Page 4 VM1350-1500-1600 Operating Manual...

  • 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 VM1350-1500-1600 Operating Manual...

  • Page 19: Overview

    PECIFICATIONS EATURES AND COMPONENTS The Gate Valve Grinding and Lapping Machine, Models VM1350-1500-1600 (in the following called Gate Valve Grinder or machine) are specifically designed for grinding and lapping of gate valve seats. The VM 1350 for Gate Valves size DN 40 –...
  • Page 20 Each planet grinding wheel covers a wide working range. To adjust the wheel to the machining diameter, the planet arms can be moved into the planet wheel guides. The planet arms are clamped with one screw quick clamping system. Page 8 VM1350-1500-1600 Operating Manual...

  • Page 21: Specifications

    This system ensures a quick change from grinding with abrasives to CBN- grinding discs or to lapping discs. For smaller gate valve seats (DN 40, 50 ,65), solid grinding discs are provided (model VM1350(S) only). The solid grinding discs consist of: •...
  • Page 22 Drive power (electric / pneumatic) 685 W (at 1000 W Pauf)/ 550 W Weights Basic machine without tools (VM1350) 11 kg Weight of machine case VM1350, VM1500 33 kg Weight of machine case VM1600 45 kg Weight of accessory case VM1350...

  • 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 TIP: case should always be closed and secured against dropping. After transportation, check all parts for visible damages before connecting the machine to power supply again. 3-1. M VM 1350; IGURE ACHINE CASE HERE INCLUDING SOME OPTIONS Page 12 VM1350-1500-1600 Operating Manual...
  • Page 25 3-2. A VM 1350) IGURE CCESSORY CASE HERE 3-3. M VM 1500; IGURE ACHINE CASE HERE INCLUDING SOME OPTIONS P/N 89800, Rev. 2 Page 13...

  • Page 26: Selecting And Preparing Tools

    5 pcs. grinding discs, diameter 50 mm (4 mm thick, steel) • 5 pcs. CBN-grinding discs, diameter 50 mm (detectable by CBN-coat- ing) • 5 pcs. lapping discs, diameter 30 mm (5 mm thick, cast iron) Page 14 VM1350-1500-1600 Operating Manual...
  • Page 27 • 5 pcs. lapping discs, diameter 50 mm (5 mm thick, cast iron) Additionally for the VM 1500 and VM1600: • 5 pcs. grinding discs, diameter 80 mm (6 mm thick, steel) • 5 pcs. lapping discs, diameter 80 mm (6 mm thick, cast iron) For machines with the additional “…S”...

  • Page 28: Preparing Tools For Dn 80-Dn 600

    M5 x 8 – 8.8-ZN according to DIN 7991. Make sure that the pin for transmitting the torque is locked. All mating sur- faces have to be cleaned prior to assembly; otherwise the accuracy will be influenced. Page 16 VM1350-1500-1600 Operating Manual...

  • Page 29: Selecting Solid Grinding Discs For Dn 40-Dn 65

    • Move planet arms into the guides on the planet wheel. Also here, all mating surfaces have to be clean. • Planet arms are positioned and clamped onto planet wheel by means of the counter sunk screws mentioned above (planet arm Type I has 2 screws, planet arm Type IV has 2 clamps).

  • Page 30: Mounting The Tilting Adapter On The Valve Body

    The mounting of the tilting adapter onto a valve body depends on the application. The different types of application are: • Gate Valve Bodies with flange (mounting with base plate and standard clamping elements) • Gate Valve Bodies without flange (mounting with collar band system) Page 18 VM1350-1500-1600 Operating Manual...

  • Page 31: Mounting The Tilting Adapter On Valves With Flange

    3.3.1 Mounting the tilting adapter on valves with flange Select all clamping elements for mounting the base plate: • tilting adapter • base plate • forged steel clamps (2 pieces) • socket head screws M8 x 20-8.8-Zn according to DIN 912 (4 pieces) •...
  • Page 32 These offset the tilting adapter above the studs so that the machine can be assembled as described in the following without getting problems with the threaded studs. BASE PLATE EXTENDED CLAMPING 3-11. IGURE OPTIONAL EXTENDED CLAMPING PADS Page 20 VM1350-1500-1600 Operating Manual...

  • Page 33: Collar Band Mounting

    3. Connect the tilting adapter onto base plate using 4 socket head screws M8 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 centreline to the valve seat.
  • Page 34 On the spacers of the mounting plate, a raised surface is provided to avoid the collar band from slip- ping. 3-16. L IGURE OCATING THE COLLAR BAND AND MOUNTING PLATE Page 22 VM1350-1500-1600 Operating Manual...
  • Page 35 6. After positioning of the col- lar band and the mounting plate, the collar band is securely fastened. 3-17. F IGURE ASTENING OF THE COLLAR BAND The collar band locks automati- cally and fixates the mounting plate to the valve body. 7.

  • Page 36: Mounting The Bracket

    3.3.4 Mounting the drive shaft with ball joint For the adaptation of a planet wheel, a drive shaft with ball joint Type 15 G has to be mounted (if not located in machine spindle already). Page 24 VM1350-1500-1600 Operating Manual...
  • Page 37 Put the drive shaft with its splines into the machine spindle. The ball joint points into the direction of the drive system. The drive shaft is secured on the opposite side by using a washer (Ø 19 x Ø 6,6 x 2) and a countersunk screw M5 x 10-8.8-Zn according to DIN 7991.

  • Page 38: Adaptating The Planet Wheel Dia. 100 Or Dia. 135

    Prior to operation, the ball joint of the machine has to be lubri- cated with grease (i.e. Molykote or Uni- moly or similar). 3-24. M IGURE OUNTING OF BALL JOINT COUPLING TO MACHINE SPINDLE Page 26 VM1350-1500-1600 Operating Manual...

  • Page 39: Adaptating The Solid Grinding Discs

    After this, the prepared planet wheel can be adapted to the ball joint coupling with two socket head screws M5 x 12 according to DIN 912. 3-25. A IGURE DAPTATION OF PLANET WHEEL TO BALL JOINT COUPLING 3.3.7 Adaptating the solid grinding discs Remove drive shaft with ball joint Type 15 G from the machine spindle and replace it by the drive shaft and...
  • Page 40 3-27. L IGURE OCATING THE MACHINE ARM INTO THE TILT- ING ADAPTER Page 28 VM1350-1500-1600 Operating Manual...
  • Page 41 4. Lock the bracket and close the flap of the tilting adapter. Clamp the machine arm by tightening the lever of the flap. 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...

  • Page 42: Installation

    After the machine is completely assembled, make sure that all screws and levers are securely tightened. Then connect the machine to the power supply. Page 30 VM1350-1500-1600 Operating Manual...
  • Page 43 To avoid the danger of stumbling: • All cables and hoses for the machine power supply have to be covered or installed in such manner that no person can stumble • Before connecting the machine to the power supply, check all cables and hoses for damages.
  • Page 44 This page intentionally left blank Page 32 VM1350-1500-1600 Operating Manual...

  • Page 45: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 OPERATION CHECKS 4.2 E - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35...
  • Page 46 The diagram gives the KNOB OF TILTING ADAPTER 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 34 VM1350-1500-1600 Operating Manual...

  • Page 47: Electric Drive Motor

    CAUTION If grinding pressure is too high, it might result in damage of the machine. 4-2. G IGURE RINDING PRESSURE IN RELATION TO THE TORQUE APPLIED AT THE STAR KNOB OF THE TILTING ADAPTER LECTRIC DRIVE MOTOR Push the trigger button and adjust the speed on top of the drive motor. For perma- nent speed, the trigger button can be locked at the bottom of the handle.
  • Page 48 The machine should always run in drilling mode (symbol = drill) and never in per- cussion drill function (symbol = hammer). Speed adjustment 4-3. E IGURE LECTRIC DRIVE MOTOR CONTROLS Page 36 VM1350-1500-1600 Operating Manual...

  • Page 49: Pneumatic Drive Motor

    NEUMATIC DRIVE MOTOR (Operating with the optional maintenance unit). The spindle speed is activated by pushing the red safety button of the maintenance unit to its upper position. The speed can be adjusted by the regulating knob on the maintenance unit. The operat- ing pressure is indicated at the gauge on the maintenance unit.

  • Page 50: Change Of Abrasives

    Put the machine arm into a stable position to change the abrasive • Change the abrasive • Put machine back into position, adjust grinding pressure and go on with the grinding operation (steps vice versa as described above) Page 38 VM1350-1500-1600 Operating Manual...

  • Page 51: Change Of Drive Motor

    HANGE OF DRIVE MOTOR CAUTION The Gate Valve Grinder may only be used with the original drive motors delivered with the machine. Otherwise, due to higher speeds and torque or wrong mechanical connections, the machine can be damaged and it may result into harm to the operator.

  • Page 52: Mounting Of New Drive Motor

    Make sure that the coupling of the drive motors engage the drive pin inside the gear. This is achieved when the shaft of the electric drive is completely moved into the drive flange. Page 40 VM1350-1500-1600 Operating Manual...

  • Page 53: Maintenance

    Alternatively, the machine can be sent to CLIMAX for proper maintenance. Under normal circumstances and proper handling the maintenance as described in maintenance is sufficient.

  • Page 54: Approved Lubricants

    5.3.2 After 300 hours Lubricate the drive chain and upper gear. PPROVED LUBRICANTS CLIMAX recommends using the following lubricants at the locations indicated. Failure to use the appropriate lubricants can result in damage and premature machine wear. CAUTION Avoid damage, premature machine wear, and protect your warranty by using only approved lubricants.

  • Page 55: Pneumatic Drive Motor Gear

    The gear of the pneumatic drive motor has to be disassembled and cleaned after 150 working hours and then be lubricated with Bosch-special grease. This proce- dure has to be repeated every 300 working hours. CLIMAX offers this service. 5.3.2...
  • Page 56 Grinding pressure cannot Tilting adapter is not firmly connected to Tighten connecting screws of tilting be activated the base plate adapter Tighten connecting Grinding pressure exceeds 300 N Reduce grinding pressure screws of tilting adapter Page 44 VM1350-1500-1600 Operating Manual...
  • Page 57 5-3. T ABLE ROUBLESHOOTING FOR POSSIBLE FAULTS Possible fault Operating or maintenance error Recovery of fault Unusual noise (rattling in Adjust tension of drive chain (see Pretension of drive chain is insufficient machine arm) chapter “Maintenance”) P/N 89800, Rev. 2 Page 45...
  • Page 58 This page intentionally left blank Page 46 VM1350-1500-1600 Operating Manual...

  • Page 59: Storage And Shipping

    STORAGE AND SHIPPING IN THIS CHAPTER: 6.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47 TORAGE 6.1.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47...

  • Page 60: Shipping

    To decommission the Gate Valve Grinding and Lapping Machine prior to disposal, remove the drive assembly from the RDU and dispose of the drive assembly sepa- rately from the rest of the machine components. Refer to Appendix A for compo- nent assembly information. Page 48 VM1350-1500-1600 Operating Manual...

  • Page 61: Appendix Aassembly Drawings

    APPENDIX A ASSEMBLY DRAWINGS Drawing list A-1. G - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50 IGURE ATE VALVE GRINDING AND LAPPING MACHINE A-2.

  • Page 62: Ate Valve Grinding And Lapping Machine

    A-1. G IGURE ATE VALVE GRINDING AND LAPPING MACHINE Page 50 VM1350-1500-1600 Operating Manual...
  • Page 63 P/N 89800, Rev. 2 Page 51...
  • Page 64 Page 52 VM1350-1500-1600 Operating Manual...

  • Page 65: Igure A-3. 240-11S-N01-00

    A-2. 440-10S-N01-00 IGURE BASIC MACHINE P/N 89800, Rev. 2 Page 53...
  • Page 66 Page 54 VM1350-1500-1600 Operating Manual...

  • Page 67: Electric Drive

    A-3. 240-11S-N01-00 IGURE ELECTRIC DRIVE P/N 89800, Rev. 2 Page 55...

  • Page 68: Pneumatic Drive

    A-4. 240-13S-N01-00 IGURE PNEUMATIC DRIVE Page 56 VM1350-1500-1600 Operating Manual...

  • Page 69: Electric Drive

    A-5. 240-15S-N01-00 115 V IGURE ELECTRIC DRIVE P/N 89800, Rev. 2 Page 57...

  • Page 70: Upper Gear

    A-6. 440-20S-N01-00 IGURE UPPER GEAR Page 58 VM1350-1500-1600 Operating Manual...

  • Page 71: Additional Parts Fort = 1000)

    A-7. 440-21S-N01-00 T = 1000) IGURE UPPER GEAR ADDITIONAL PARTS FOR P/N 89800, Rev. 2 Page 59...
  • Page 72 A-8. 440-32S-N01-00 T=600 IGURE MACHINE ARM WITH SUBMERGING DEPTH Page 60 VM1350-1500-1600 Operating Manual...

  • Page 73: Machine Arm With Submerging Depth

    A-9. 440-33S-N01-00 T=800 IGURE MACHINE ARM WITH SUBMERGING DEPTH P/N 89800, Rev. 2 Page 61...
  • Page 74 A-10. 440-34S-N01-00 IGURE SWING CHECK SPINDLE EXTENSION Page 62 VM1350-1500-1600 Operating Manual...

  • Page 75: Machine Arm With Submerging Depth

    A-11. 440-35S-N01-00 T=1000 IGURE MACHINE ARM WITH SUBMERGING DEPTH P/N 89800, Rev. 2 Page 63...
  • Page 76 A-12. 440-36S-N01-00 IGURE SWING CHECK SPINDLE EXTENSION Page 64 VM1350-1500-1600 Operating Manual...

  • Page 77: Machine Arm General Parts

    A-13. 440-37S-N01-00 IGURE MACHINE ARM GENERAL PARTS P/N 89800, Rev. 2 Page 65...

  • Page 78: Ball Joint

    A-14. 440-40S-N01-00 IGURE BALL JOINT Page 66 VM1350-1500-1600 Operating Manual...

  • Page 79: Ball Joint Type 10

    A-15. 440-41S-N01-00 IGURE BALL JOINT TYPE P/N 89800, Rev. 2 Page 67...
  • Page 80 A-16. 170-30S-N01-00 IGURE Page 68 VM1350-1500-1600 Operating Manual...

  • Page 81: Ball Joint Type

    A-17. 440-42S-N01-00 IGURE BALL JOINT TYPE P/N 89800, Rev. 2 Page 69...
  • Page 82 A-18. 170-10S-N01-00 IGURE Page 70 VM1350-1500-1600 Operating Manual...

  • Page 83: Ounting System

    A-19. M IGURE OUNTING SYSTEM P/N 89800, Rev. 2 Page 71...

  • Page 84: Tilting Adapter

    A-20. 440-51S-N01-00 IGURE TILTING ADAPTER Page 72 VM1350-1500-1600 Operating Manual...
  • Page 85 A-21. 440-52S-N01-00 M IGURE OUNTING FOR VALVE BODIES WITH FLANGES P/N 89800, Rev. 2 Page 73...
  • Page 86 Page 74 VM1350-1500-1600 Operating Manual...
  • Page 87 A-22. 440-53S-N01-00 M IGURE OUNTING FOR VALVE BODIES WITHOUT FLANGES P/N 89800, Rev. 2 Page 75...

  • Page 88: Wing Check Adapter

    A-23. 440-55S-N01-00 S IGURE WING CHECK ADAPTER Page 76 VM1350-1500-1600 Operating Manual...

  • Page 89: Additional Parts Fort = 1000)

    A-24. 440-57S-N01-00 T T = 1000) IGURE ILTING DAPTER ADDITIONAL PARTS FOR P/N 89800, Rev. 2 Page 77...
  • Page 90 Tooling Page 78 VM1350-1500-1600 Operating Manual...
  • Page 91 P/N 89800, Rev. 2 Page 79...

  • Page 92: Ilting Adapter

    A-25. 240-71S-N01-00 P DN 80 ... DN 350 IGURE LANET HEELS Page 80 VM1350-1500-1600 Operating Manual...

  • Page 93: Lanet Heels Dn 400

    A-26. 240-73S-N01-00 P DN 400 ... DN 500 (VM 1500/1600 IGURE LANET HEELS ONLY P/N 89800, Rev. 2 Page 81...
  • Page 94 A-27. 110-20S-N01-02 P IGURE LANET Page 82 VM1350-1500-1600 Operating Manual...

  • Page 95: Only )

    A-28. 440-72S-N01-00 S DN 40 ... DN 65 (VM 1350 IGURE OLID RINDING ISCS ONLY P/N 89800, Rev. 2 Page 83...
  • Page 96 This page intentionally left blank Page 84 VM1350-1500-1600 Operating Manual...

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