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Rausch QuickLock Operator's Manual

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Operator Manual
QuickLock Operator Manual – Version 15.07.01
QuickLock is NSF/ANSI 61 Certified for use in potable water.
QuickLock meets ASTM Standard F3110-14.
Rausch Electronics USA, LLC. 4757 Innovation Way Chambersburg, PA 17201
Service: (717) 263-8093 | Office: (717) 709-1005 | Fax: (717) 709-1009 | www.rauschusa.com | reusa@rauschusa.com

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  • Page 1 Operator Manual QuickLock Operator Manual – Version 15.07.01 QuickLock is NSF/ANSI 61 Certified for use in potable water. QuickLock meets ASTM Standard F3110-14. Rausch Electronics USA, LLC. 4757 Innovation Way Chambersburg, PA 17201 Service: (717) 263-8093 | Office: (717) 709-1005 | Fax: (717) 709-1009 | www.rauschusa.com | reusa@rauschusa.com...

  • Page 2: Important Disclaimer

    7. NEVER inflate the packer outside of a pipe – serious bodily injury or death may occur! 8. QuickLock is designed for and must only be used in municipal sewer, storm sewer and potable water environment. For use in potable water, a special rubber gasket is required. For all other applications, please consult Rausch prior to use.

  • Page 3: Table Of Contents

    Preparation ......................10 2.1.1. Pipe Inspection .......................10 2.1.2. Pipe Preparation .....................10 2.1.3. Space required by the packer .................11 2.2. Equipment, Material and Preparations for the QuickLock Installation ....12 2.2.1. Equipment ......................12 2.2.2. Material ........................12 2.3. Selecting the QuickLock Sleeve ................13 2.3.1.
  • Page 4 2.6.5. Repairing plastic pipes ...................35 2.6.6. QuickLock in non-permeable pipe systems ............36 2.6.7. Using QuickLock to repair holes longer than single sleeve ........37 2.6.8. Removing installed QuickLock sleeves ..............38 2.6.9. Deflating the packer using a vent valve ..............39 3. QuickLock Technical Data Sheet ..............40 4.

  • Page 5: Description Of The Quicklock System

    QuickLock Operator Manual Description of the QuickLock System 1.1. Intended Use QuickLock is an entirely mechanical, seamless assembly system for patch repairs inside pipes ranging from 6” to 32” pipe diameter in any common wastewater, well, or drinking water pipe system.

  • Page 6: Components And Functions

    (when a single sleeve is installed). Projecting Rubber End The projecting rubber end acts as a seals between sleeves installed Cross section of steel sleeve and rubber gasket. in a series. QuickLock Operator Manual – Version 15.07.01...

  • Page 7: Description Of The System And Installation Procedure

    The increments are only 0.65 mm (.025”), which means that the sleeve is almost infinitely adjustable. How it works: The middle gear wheel is on a spring and acts as a ratchet for the others. QuickLock Operator Manual – Version 15.07.01...

  • Page 8: Suitability And Materials Used

    Pipes with joint misalignments of more than 2.5 cm (0.98”) In such cases, please contact us. 1.6.2. 316L Stainless Steel The QuickLock sleeve is made of 316L stainless steel of grade 1.4404. This grade of stainless steel is characterized by its high corrosion resistance. ...

  • Page 9: Types Of Pipe Damages

    Length of damage When installed individually, QuickLock can be used for instances of damage up to the following lengths:  6” – 16”: maximum damage length 10.62”- 11.81” (see Technical Data Sheet, sealed area)  18” – 32”: maximum damage length 11.02” – 13.38” (see Technical Data Sheet, sealed area) Instances of damage that are longer than this can be repaired by installing multiple sleeves in a series.

  • Page 10: How To Install Quicklock

    Notes for Nominal Diameter 28” & 32” When using the QuickLock 28” sleeve, the top rungs in the manhole have to be removed. The QuickLock 32” sleeve will not fit through a 24.5” manhole entrance – rolled up, its diameter is 27.36”. ...

  • Page 11: Space Required By The Packer

    The packer can pass through sleeves that have already been installed The sleeves are designed so that once they have been installed, the packer can pass through them with another rolled-up sleeve, except for the 6” version. QuickLock Operator Manual – Version 15.07.01...

  • Page 12: Equipment, Material And Preparations For The Quicklock Installation

    An air-hose on a reel with a minimum hose length of 350ft.  A milling robot for preparatory jobs 2.2.2. Material The following materials and tools are necessary for the preparation of the QuickLock sleeve  Sharp knife  Talcum powder ...

  • Page 13: Selecting The Quicklock Sleeve

    QuickLock Operator Manual 2.3. Selecting the QuickLock Sleeve Beveled and non-beveled versions of each QuickLock sleeve are available. 2.3.1. With beveled end The beveled QuickLock sleeve improves flow, increases jetting resistances, and makes a better looking fit. It closes the gap between the QuickLock sleeve and the host pipe wall with a beveled end.

  • Page 14: Preparing The Quicklock Sleeve

    2.4.1. Setup & Inspection  Check the QuickLock sleeve and rubber gasket for visible damage.  Set up the QuickLock sleeve so that the lettering on the adhesive tape is upside down. 2.4.2. Lubricating the sleeve  Use biodegradable lubricant.

  • Page 15: Apply Talcum Powder To The Rubber Gasket

    Cut along the marking seam. Serial Installation  When installed in a series, the projecting rubber end is left on so that the join between the sleeves is sealed, except on the last sleeve to be installed. QuickLock Operator Manual – Version 15.07.01...

  • Page 16: Centering The Rubber Gasket

     Note: If the rubber gasket is not properly affixed, there is a risk that it might unfold and bunch up at a constricted point in the pipe without you noticing. QuickLock Operator Manual – Version 15.07.01...

  • Page 17: Quicklock Installation

    The packer is usually connected to the camera or robot using a transfer bar and two ball joints. Using a camera The QuickLock system can be installed most efficiently when the packer is positioning using a camera. Push rods or other insertion apparatus can also be used. However, a camera must be used during installation.

  • Page 18: Positioning The Quicklock Sleeve On The Packer

     Slide the sleeve over the end of the packer without wheels.  Position the QuickLock sleeve forward so that it is flush with the front edge of the packer. 2.5.2.4. Laser alignment ...

  • Page 19: Aligning The Locking Gear Strip

    After installation, the locking gears will be in the 11:00 or 1:00 position.  If the QuickLock sleeve is positioned on the packer with the lock in the 12:00 position, the weight is balanced.  This makes it easier to transport, especially in narrow pipes. It is also reduces the risk of the packer tipping over in the pipe.

  • Page 20: Single Installation Procedure

    The most efficient and reliable way to install a QuickLock sleeve is by pushing the packer with a camera tractor system. However, other means are possible, too: Telescopic rods or pulling the packer through the pipe.

  • Page 21: Positioning The Packer & Sleeve

    QuickLock Operator Manual 2.5.3.2. Positioning the packer & sleeve Positioning the packer with the QuickLock sleeve over the center of the damaged area can be done by three different ways: 1) By sight  Position the sleeve using only the image from the camera.

  • Page 22: Deflating & Aligning In Center

    The customer might think that the sleeve is not properly set – however, this is just an optical illusion that will disappear by changing the camera head position. QuickLock Operator Manual – Version 15.07.01...

  • Page 23: Serial Installation (Standard Procedure)

    Where there is an incipient longitudinal crack, the entire length of the host pipe must be repaired because the crack will continue to the end of the pipe, regardless of the repair. 6” QuickLock sleeves cannot currently be installed in a series. QuickLock Operator Manual – Version 15.07.01...

  • Page 24: Installation

    (1) is at least equal to the distance between the locking gar and the edge of the sleeve (2). (1) ≥ (2)  This ensures that the two circumferential seals form a tight seal within the projecting rubber end. QuickLock Operator Manual – Version 15.07.01...
  • Page 25 0.5 cm between the locking gear & the sleeve edge.  The new sleeve must not touch the lock.  If possible, use the laser as described in section 2.5.6 “Using the Laser Marker” QuickLock Operator Manual – Version 15.07.01...
  • Page 26 Follow the instructions in section 2.5.4.3 below to correct this. Beveled End QL sleeve, beveled end Metal Overlap Installation finished. The sleeves installed have a uniform, consistent appearance. QuickLock Operator Manual – Version 15.07.01...

  • Page 27: Passing Through The Projecting Rubber End

    (0.5-1.5 cm) in front of the locking gear of the previous sleeve. 3/16” – 5/8”  The circumferential seals of the new sleeve form a tight seal with the projecting rubber end of the previous sleeve. QuickLock Operator Manual – Version 15.07.01...

  • Page 28: Serial Installation (Alternative Procedure)

    Because of the beveled end, the diameter of the pipe is 2 to 4 mm less than with the standard method. In narrow pipes and/or if there is any deformation, it may be difficult or impossible for the packer to pass through installed sleeves with the next ones. QuickLock Operator Manual – Version 15.07.01...
  • Page 29 Move the new sleeve through the previously installed sleeves (1) and (2).  Note: Watch out for the projecting rubber end. See section 2.5.4.3.  Install the sleeve (2) with the correct metal overlap as described in 2.5.4.4. QuickLock Operator Manual – Version 15.07.01...

  • Page 30: Using The Laser Marker

    The edge of the next sleeve will be directly behind it. Positioning on the Packer  Position the QuickLock sleeve on the packer so that the laser beam can be seen on both the edge of the sleeve and on the host pipe. ...

  • Page 31: Special Scenarios

    Placed approx. 12” or 16” (30 or 40 cm) into the offset joint, depending on the pipe diameter. Installing the second QuickLock sleeve  Beveled end  Without projecting rubber end  Approx. 5/8” (1.5 cm) metal overlap with the first sleeve. QuickLock Operator Manual – Version 15.07.01...

  • Page 32: Groundwater Infiltration

    Note: The waterstop seals add to the amount of material to Application pressure be compressed. + 7 psi (0.5 bar) Increase the application pressure by approx. 7 psi (0.5 bar) QuickLock Operator Manual – Version 15.07.01...

  • Page 33: Root Penetration

    When there is existing root penetration, a special method can be used.  This prevents the root from growing along the QuickLock sleeve and breaking through the circumferential seals. However, although this method has had positive long-term results, we cannot guarantee its success.

  • Page 34: Corroded Steel In Reinforced Concrete

    Apply a patch of mortar  Apply a patch or mortar large enough to cover the damage area. Note: Never completely coat the rubber gasket with mortar. This would impair the compression of the circumferential seals. QuickLock Operator Manual – Version 15.07.01...

  • Page 35: Repairing Plastic Pipes

    QuickLock Operator Manual 2.6.5. Repairing plastic pipes Plastic pipes (PVC) can be repaired by using QuickLock in accordance with the single and serial offset methods. However, the following issues are to be observed:  In many cases, a given diameter for a plastic pipe does not refer to its ID, but rather to its OD.

  • Page 36: Quicklock In Non-Permeable Pipe Systems

    QuickLock Operator Manual 2.6.6. QuickLock in non-permeable pipe systems The QuickLock sleeve is tightly sealed with the rubber gasket by means of compression. This achieves excellent sealing results.  If QuickLock is used in non-permeable pipe systems or in undamaged and air tight pipes, there is a risk of excess pressure arising in the space between the two pairs of circumferential seals and the host pipe wall.

  • Page 37: Using Quicklock To Repair Holes Longer Than Single Sleeve

    If the damaged section is larger than the width between the circumferential seals, the pipe can be repaired with the aid of a protector tube.  The QuickLock system is based on compressing the circumferential seals against the inner wall of the pipe. ...

  • Page 38: Removing Installed Quicklock Sleeves

    The sleeve collapses  The QuickLock sleeve collapses under its own tension and that of the stretched rubber gasket.  The sleeve can then be picked up on the holder head of the robot cutter and taken out of the pipe.

  • Page 39: Deflating The Packer Using A Vent Valve

    When the pressure is removed via the vent valve, the packer balloon deflates more quickly. This is much faster than deflation via the compressed air unit. Vent valve (1) Air hose connection (2) Vent outlet (3) Packer connection Example installation (1) From the compressed air unit (3) To the packer QuickLock Operator Manual – Version 15.07.01...

  • Page 40: Quicklock Technical Data Sheet

    QuickLock Operator Manual QuickLock Operator Manual QuickLock Technical Data Sheet QuickLock Operator Manual – Version 15.07.01...
  • Page 41 QuickLock Operator Manual QuickLock Operator Manual QuickLock Operator Manual – Version 15.07.01...

  • Page 42: Quicklock Wheel Set Charts

    QuickLock Operator Manual QuickLock Operator Manual QuickLock Wheel Set Charts 4.1. 6-8” QuickLock Packer Wheel/Axel Set Overview (AS1528 / VP 150-200) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Delrin 6” RS150 AS1528 RS150-Q1 * a = Ø58.0 mm...
  • Page 43 QuickLock Operator Manual QuickLock Operator Manual 4.2. 8-12” QuickLock Packer Wheel/Extender Overview (AS1537 / VP 200-300) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Tente 75x25 * a = Ø75.0 mm 8” RS200 AS1537 RS200-Q1.2A...
  • Page 44 QuickLock Operator Manual QuickLock Operator Manual 4.3. 10-12” QuickLock Packer Wheel/Axel Set Overview (AS1552 / VP 250-300) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Tente 75x25 10” RS250 AS1552 RS250-Q2 * a = Ø75.0 mm * b = 53.55 mm...
  • Page 45 QuickLock Operator Manual QuickLock Operator Manual 4.4. 14-20” QuickLock Packer Wheel/Axel Set Overview (AS1563 / VP 350-500) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Tente 75x25 14” RS350 AS1563 RS350-Q3 * a = Ø75.0 mm * b = 79.1 mm...
  • Page 46 QuickLock Operator Manual QuickLock Operator Manual 4.5. 20-24” QuickLock Packer Wheel/Axel Set Overview (AS1531 / VP 500-600) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Spoked 20” RS500 AS1531 RS500-Q4 * a = Ø125.0 mm * b = 73.2 mm...
  • Page 47 QuickLock Operator Manual QuickLock Operator Manual 4.6. 24-28” QuickLock Packer Wheel/Axel Set Overview (AS1553 / VP 600-700) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Spoked 24” RS600 AS1553 RS600-Q5 * a = Ø150.0 mm * b = 73.20 mm...

  • Page 48: Quicklock Adjustable Packer

    QuickLock Operator Manual QuickLock Operator Manual 4.7. 28-32” QuickLock Packer Wheel/Axel Set Overview (VP 700-800) Pipe SIze Wheel Set + Extender For Packer Item No. Image Drawing Dimensions Type – Spoked 28” RS700 VP 700-800 RS700-Q6 * a = Ø150.0 mm * b = 86.40 mm...

  • Page 49: Description

    QuickLock Adjustable Packer 5.1. Description The new 8-12” QuickLock Adjustable Packer uses a single set of wheels and adjustable sliding chassis for application in every Inner Diameter (ID) from 7.48” (190 mm) to 12.60” (320 mm). There are two wheel rod slots to insert the wheel.
  • Page 50 To use the larger of the two pipe ID, use the lower slot by pressing the spring-loaded button to open the latch. 5.2.5. Repeat for other 3 wheels All 4 sliding chassis need to be adjusted to match the QuickLock sleeve size. QuickLock Operator Manual – Version 15.07.01...

  • Page 51: Table Of Application Pressures

    Increase the application pressure gradually, especially when repairing longitudinal cracks and fragmentation. When you notice that despite the gradually increasing pressure, the locks have stopped moving along the toothed strips, the maximum compression pressure has been reached. QuickLock Operator Manual – Version 15.07.01...

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