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Victaulic VE460 Operating And Maintenance Instruction Manual

Roll grooving tool
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OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL
VE460 Roll Grooving Tool
WARNING
If you need additional copies of any literature, or if you have questions concerning the safe
and proper operation of this tool, contact Victaulic, P.O. Box 31, Easton, PA 18044-0031,
Phone: 1-800-PICK VIC, E-Mail: pickvic@victaulic.com.
REV_C
WARNING
Failure to follow instructions and warnings could result in death,
serious personal injury, property damage, and/or product damage.
• Before operating or servicing any roll grooving tools, read all
instructions in this manual and all warning labels on the tool.
• Wear safety glasses, hardhat, foot protection, and hearing
protection while working around this tool.
• Save this operating and maintenance manual in a place
accessible to all operators of the tool.
Original Instructions
TM-VE460
OGS
OGS-200
EndSeal
™
TM-VE460

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  • Page 1 If you need additional copies of any literature, or if you have questions concerning the safe and proper operation of this tool, contact Victaulic, P.O. Box 31, Easton, PA 18044-0031, Phone: 1-800-PICK VIC, E-Mail: pickvic@victaulic.com.

  • Page 3: Table Of Contents

    TM-VE460 / Operating and Maintenance Instructions Manual TABLE OF CONTENTS Maintenance ..... . .51 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 52 Hazard Identification .

  • Page 4: Hazard Identification

    INSTRUCTIONS Definitions for identifying the various hazard levels are provided below . The VE460 Roll Grooving Tool is designed for the sole purpose of roll grooving pipe . These This safety alert symbol indicates instructions must be read and understood important safety messages .
  • Page 5 Disconnect the power cord from the CAUTION electrical source before servicing the tool. Only authorized personnel should The VE460 tool is designed ONLY for roll perform maintenance on the tool . Always grooving pipe sizes, materials, and wall disconnect the power cord from the thicknesses as designated.

  • Page 6: Introduction

    Stabilizer Mounting Hardware (Installed Loose to Advanced Groove Specifications (AGS) . in Mounting Holes for Stabilizer) VE460 rolls are marked with the size and part Pipe Diameter Tape number, and are color coded to identify the pipe Hydraulic System Bleeder Tube material .

  • Page 7: Power Requirements

    TM-VE460 / Operating and Maintenance Instructions Manual POWER REQUIREMENTS POWER HOOKUP Each VE460 Roll Grooving Tool is provided with DANGER a label outside the main electrical enclosure, which identifies voltage ratings for the tool (refer • ONLY QUALIFIED to example below) . Reference shall be made to ELECTRICIANS SHOULD this label to ensure proper tool setup .

  • Page 8: Tool Nomenclature

    R090424LAB If you need additional copies of any literature, or if you have questions concerning the safe and proper operation of any pipe preparation tools, contact Victaulic, P.O. Box 31, Easton, PA 18044-0031, Phone 1-800-PICK VIC, E-Mail: pickvic@victaulic.com. 0567 Rev. D...

  • Page 9: Important Information For Tool Setup

    TM-VE460 / Operating and Maintenance Instructions Manual IMPORTANT INFORMATION FOR TOOL SETUP Support bases are required when using a VE460 Roll Grooving Tool to groove 26-inch/660-mm and larger pipe sizes . Each support base corresponds with a range of pipe sizes; these requirements shall be followed to ensure pipe is grooved properly (refer to table below) .

  • Page 10: Without Support Bases

    TM-VE460 / Operating and Maintenance Instructions Manual TOOL DIMENSIONS AND SPECIFICATIONS – WITHOUT SUPPORT BASES 50.80 inches/ 37.38 inches/ 1290 mm 949 mm 30.30 inches/ 770 mm 71.12 inches/ 1806 mm 48.00 inches/ 1219 mm 37.39 inches/ 950 mm 26.00 inches/660 mm 25.00 inches/635 mm...

  • Page 11: With Support Bases

    660 mm 56.00 inches/ 24.00 inches/ 1422 mm 610 mm The VE460 Roll Grooving Tool by itself weighs approximately 1800 pounds/820 kilograms . • The VE460 Roll Grooving Tool mounted on one support base weighs approximately 1980 pounds/900 kilograms . •...

  • Page 12: Without Support Bases

    TM-VE460 / Operating and Maintenance Instructions Manual LIFTING REQUIREMENTS – WITHOUT SUPPORT BASES WARNING • An overhead crane shall be used to lift/transport the tool to its intended location. • An eye bolt is provided in the top-middle section of the tool, as shown in the drawing to the left.

  • Page 13: With Support Bases

    LIFTING REQUIREMENTS – WITH SUPPORT BASES WARNING • DO NOT attempt to use the eye bolt for lifting a VE460 Roll Grooving Tool that is installed on a support base(s). • When attempting to relocate a VE460 Roll Grooving Tool that is installed on a support base(s), the wedge-type concrete floor anchors shall be removed, and a forklift shall be used to transport the tool assembly.

  • Page 14: Pipe Sizes

    Ambient temperature requirements of 20º F to 104º F/-6 .7ºC to 40º C 3. The VE460 Roll Grooving Tool is designed c. A level concrete floor or base for the tool for use in a permanent location and shall be and pipe stand located on a level concrete floor or base .
  • Page 15 TM-VE460 / Operating and Maintenance Instructions Manual 5. Install the safety foot switch by aligning the pins/tab of the male adapter plug with the receptacle . 4. Remove the stabilizer bolts and lock washers from the front and right side of the tool . Position...

  • Page 16: 26-Inch/660-Mm And Larger

    . Refer to the “Receiving the Tool” section . 2. The VE460 Roll Grooving Tool with support base(s) is designed for use in a permanent location and shall be located on a level concrete floor .
  • Page 17 TM-VE460 / Operating and Maintenance Instructions Manual Handrail (4 Total) Hex-Head Bolt (16 Total) Handrail Base (8 Total) Platform (2 Total) Lock Washer (16 Total) Hex Nut (16 Total) Anchor Flat Washer 5. Wedge-type concrete floor anchors 6. Using a four-point lifting method, as shown...
  • Page 18 TM-VE460 / Operating and Maintenance Instructions Manual 9. Locate the bolt, two flat washers, lock washer, and nut (supplied with the support base kit) . This hardware is required to anchor the support bases to each other . 10. Insert a bolt with flat washer through the holes in the second support base and first support base .
  • Page 19 TM-VE460 / Operating and Maintenance Instructions Manual NOTICE • VE460 tools are equipped with a detachable safety foot switch cord. The safety foot switch can be removed easily for storage in the cabinet when the tool is not is use.
  • Page 20 TM-VE460 / Operating and Maintenance Instructions Manual 17. Install the platform onto the support base . 19a. Install a handrail base onto the platform at Align the holes in the platform with the holes in the eight locations on the platform/tool support .
  • Page 21 TM-VE460 / Operating and Maintenance Instructions Manual 19e. Tighten the two set screws on each handrail base to retain the handrails . 20. Proceed to the “Power Requirements” section . NOTICE 19d. Insert a handrail into each handrail base, • Always use the handrails for support as shown .

  • Page 22: Verification Of Pipe Rotation Direction

    TM-VE460 / Operating and Maintenance Instructions Manual VERIFICATION OF PIPE ROTATION DIRECTION The VE460 Roll Grooving Tool is equipped with a “TEST (JOG)” setting . Operating the tool in the “TEST (JOG)” setting allows for: • Determining rotation of the tool’s lower roll •...
  • Page 23 TM-VE460 / Operating and Maintenance Instructions Manual 5. If rotation of the lower roll is counter- clockwise, turn the main power switch on the side of the tool to the “OFF” position and proceed with the following steps . 7. Open the main enclosure by loosening the screw on the two brackets of the main enclosure .

  • Page 24: Emergency Stop Operation

    TM-VE460 / Operating and Maintenance Instructions Manual EMERGENCY STOP OPERATION Verify that emergency stop function is operational during tool setup . Perform the “PUSH”, “PULL”, and “START” actions to test emergency stop function . 3. Depress the safety foot switch, confirm tool operation, then release the safety foot switch .
  • Page 25 TM-VE460 / Operating and Maintenance Instructions Manual 7. Depress the safety foot switch, confirm tool operation, then release the safety foot switch . 5. Pull the “EMERGENCY STOP” button and confirm that power to the motor remains off . Depressing the foot switch or adjusting the selector switch should have no effect on the state of the tool .

  • Page 26: Preparing Pipe For Grooving

    Rust is an abrasive material that PIPE LENGTH REQUIREMENTS will wear the surface of grooving rolls. VE460 tools are capable of grooving short pipe Foreign material may interfere with or lengths without the use of a pipe stand . Table 1...
  • Page 27 TM-VE460 / Operating and Maintenance Instructions Manual TABLE 1- PIPE LENGTHS SUITABLE FOR Steel, Stainless Steel, GROOVING Aluminum, and PVC Pipe Size Length – inches/mm Nominal Pipe Size Actual Outside Steel, Stainless Steel, inches or Diameter Aluminum, and PVC Pipe Size Length –...

  • Page 28: Checking And Adjusting The Tool Prior To Grooving

    The VE460 tool features a “SET GUARD” control Failure to follow this instruction could result switch setting . With the correct pipe size and in serious personal injury.
  • Page 29 TM-VE460 / Operating and Maintenance Instructions Manual 5. Prior to making tool guard adjustments, push 3. Insert a length of pipe that is the correct size the “EMERGENCY STOP” button on the control and schedule over the lower roll . Ensure that the panel .
  • Page 30 TM-VE460 / Operating and Maintenance Instructions Manual 9. Remove the guard setting pad from the pipe . Store the guard setting pad in a safe location . 7. Hold the correct guard setting pad firmly against the pipe and push it under the roll guards .

  • Page 31: Pipe Stabilizer Adjustment

    Failure to follow these instructions could result in serious personal injury. The pipe stabilizer for the VE460 is designed 2b. Using the stabilizer handwheel, retract to prevent pipe sway of short and long pipe the stabilizer roller to clear the pipe when it is lengths .
  • Page 32 TM-VE460 / Operating and Maintenance Instructions Manual CAUTION • DO NOT adjust the stabilizer roller to push the pipe to the left and off center from the rolls. Increased pipe-end flare and shortened roll life will result if the pipe is pushed to the left and off center.

  • Page 33: Ram Speed Adjustment

    TM-VE460 / Operating and Maintenance Instructions Manual RAM SPEED ADJUSTMENT Ram Speed Pipe Control WARNING Material Valve Setting * Steel • Always turn off the main power supply to the tool before making any tool Steel (Grooved to AGS adjustments.

  • Page 34: Dwell Control Adjustment

    . NOTE: VE460 tools are factory set in the “SEC-10” position . Use only a #0 Phillips head screwdriver to adjust the range screw .

  • Page 35: Pipe Size Adjustment

    TM-VE460 / Operating and Maintenance Instructions Manual PIPE SIZE ADJUSTMENT Rotate the timer dial to the appropriate pipe size . Indicator Barrel • 4–38-inch/114 .3–965-mm pipe sizes are detailed in black . Ensure that the timer range is set to “SEC-10 . ”...
  • Page 36 TM-VE460 / Operating and Maintenance Instructions Manual NOTICE NOTICE • Occasionally during grooving, the groove • Rotating the depth adjusters while locked diameter stop may move up and down will cause premature thread wear of the slightly, making contact and then depth adjusters and cylinder ram.
  • Page 37 TM-VE460 / Operating and Maintenance Instructions Manual CAUTION NOTICE • Rotating the depth adjusters while locked • The “C” dimension (groove diameter) will cause premature thread wear of the shall conform to Victaulic specifications depth adjusters and cylinder ram. to ensure proper joint performance.

  • Page 38: Grooving Long Pipe Lengths

    TM-VE460 / Operating and Maintenance Instructions Manual GROOVING LONG PIPE LENGTHS 2. Place the pipe stand at a distance slightly beyond half the pipe length from the tool . Refer DANGER to the drawing below . • To reduce the risk of...
  • Page 39 TM-VE460 / Operating and Maintenance Instructions Manual 5. Before grooving, ensure that all instructions in the previous sections of this manual have been followed . 6. Turn on the main power supply to the tool (circuit breaker panel, knife switch, etc .) .
  • Page 40 TM-VE460 / Operating and Maintenance Instructions Manual WARNING Grooving rolls can crush or cut fingers and hands. • Always turn off the main power supply to the tool before making any tool adjustments. • Loading/unloading pipe will place your hands close to the rollers. Keep hands away from the grooving rolls and the roller on the pipe stabilizer during operation.
  • Page 41 TM-VE460 / Operating and Maintenance Instructions Manual 14. During the grooving operation, visually NOTICE check the tracking of the pipe as it rotates . Ensure that the pipe remains against the lower- • Occasionally during grooving, the groove roll backstop flange . If the pipe does not stay in...

  • Page 42: Grooving Short Pipe Lengths

    TM-VE460 / Operating and Maintenance Instructions Manual GROOVING SHORT PIPE LENGTHS DANGER • To reduce the risk of electric shock, check the tool for proper grounding and follow all instructions. • Before operating the tool, review the “Operator 4. Ensure that the selector switch on the control Safety Instructions”...
  • Page 43 TM-VE460 / Operating and Maintenance Instructions Manual CAUTION • Pipe shall be supported manually before and after the grooving cycle. Failure to follow this instruction could result in personal injury. 6. Push the “HYDRAULIC PUMP START” button . WARNING Grooving rolls can crush or cut fingers and hands.

  • Page 44: Roll Changing

    TM-VE460 / Operating and Maintenance Instructions Manual ROLL CHANGING VE460 roll grooving tools are designed with rolls to accommodate several pipe sizes and materials, which eliminates the need for frequent roll changes . When a different pipe size or material is required for grooving, the upper and lower rolls shall be changed .
  • Page 45 TM-VE460 / Operating and Maintenance Instructions Manual 5. Push the “HYDRAULIC PUMP START” button . 3. Pull the “EMERGENCY STOP” button on the control panel and the electrical enclosure to the 6. Depress the safety foot switch . When the out position .

  • Page 46: Lower Roll Removal

    TM-VE460 / Operating and Maintenance Instructions Manual LOWER ROLL REMOVAL 8. Push the “HYDRAULIC PUMP START” button to retract (raise) the slide . 1. Using an appropriate wrench, loosen the lower-roll retaining bolt . 9. After the slide is retracted (raised) completely, push the “EMERGENCY STOP”...

  • Page 47: Upper Roll Removal

    TM-VE460 / Operating and Maintenance Instructions Manual UPPER ROLL REMOVAL 3b. Remove the upper roll . Store the upper roll inside the tool cabinet . 1. Adjust the front roll guard, if necessary, to UPPER ROLL INSTALLATION uncover the upper shaft completely .

  • Page 48: Lower Roll Installation

    TM-VE460 / Operating and Maintenance Instructions Manual LOWER ROLL INSTALLATION 3a. While supporting the upper roll, insert the upper shaft into the slide and upper roll . Align 1. Prior to installation, clean the main shaft and the hole in the upper shaft with the locking pin the lower roll to remove any dirt and scale .
  • Page 49 TM-VE460 / Operating and Maintenance Instructions Manual 7. Pull the “EMERGENCY STOP” button on the 4. Install the lower-roll washer and lower-roll control panel to the out position . retaining bolt . 8. Push the “HYDRAULIC PUMP START” 5. Tighten the lower-roll retaining bolt completely button .
  • Page 50 TM-VE460 / Operating and Maintenance Instructions Manual CAUTION • The upper roll is free floating. Ensure that the upper roll is positioned toward the back of the upper shaft. Failure to follow this instruction could result in damage to the flange of the upper and lower rolls.

  • Page 51: Maintenance

    TM-VE460 / Operating and Maintenance Instructions Manual MAINTENANCE DANGER • Always turn off the main power supply to the tool before making any tool adjustments or before performing any maintenance. Failure to follow this instruction could result in death or serious personal injury.

  • Page 52: Lubrication

    TM-VE460 / Operating and Maintenance Instructions Manual LUBRICATION 1. After every 8 hours of operation, lubricate the tool . Always lubricate the upper roll bearings when rolls are changed. 4. Grease the main shaft bearings through the fitting located on the side of the tool .

  • Page 53: Checking And Filling Gear Reducer Oil

    TM-VE460 / Operating and Maintenance Instructions Manual CHECKING AND FILLING GEAR CHECKING AND FILLING HYDRAULIC REDUCER OIL The gear reducer oil level shall be checked 1 . Check the hydraulic oil level on a monthly semi-annually or every 3,000 hours of operation, basis .
  • Page 54 TM-VE460 / Operating and Maintenance Instructions Manual 4. On the other bracket, loosen and remove the screw on top of the hydraulic oil reservoir . It is not necessary to loosen the screw that holds the bracket to the frame .
  • Page 55 TM-VE460 / Operating and Maintenance Instructions Manual NOTICE • Reference local ordinances regarding the proper disposal of hydraulic oil. 11. Lubricate the gasket of the new hydraulic oil filter with new hydraulic oil . Fill the filter with new hydraulic oil, then install it hand-tight into the tool .
  • Page 56 TM-VE460 / Operating and Maintenance Instructions Manual 14. Turn on the main power supply to the tool (circuit breaker panel, knife switch, etc .) . 17. Push the “HYDRAULIC PUMP START” button . Allow the hydraulic pump to run for 3 – 5 15.

  • Page 57: Air Bleeding

    TM-VE460 / Operating and Maintenance Instructions Manual AIR BLEEDING 4. Install the bleeder tube into the tee, as shown 1. Remove the fill/vent plug from the hydraulic above . Insert the other end of the bleeder oil reservoir . tube into the fill/vent hole in the hydraulic oil reservoir .
  • Page 58 TM-VE460 / Operating and Maintenance Instructions Manual 10. Depress the safety foot switch, hold it down for 5 seconds, then release it for 5 seconds . Repeat this step until no air bubbles can be seen through the clear vinyl tube .

  • Page 59: Recommended Lubricants

    Texaco Inc. PARTS ORDERING INFORMATION When ordering parts, the following information is required for Victaulic to process the order and send the correct part(s) . Parts can be ordered 14. Bring the hydraulic oil level up to by calling 1-800-PICK-VIC .

  • Page 60: Troubleshooting

    TM-VE460 / Operating and Maintenance Instructions Manual TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION Pipe will not stay in grooving Incorrect pipe positioning of long pipe Refer to the “Long Pipe Lengths” section. rolls. length. Lower roll and pipe are not rotating Refer to the “Power Hookup and Verification of Pipe Rotation...
  • Page 61 Ensure that pipe is against the lower-roll backstop flange. Refer to or pipe is not tracking properly. the “Long Pipe Lengths” section for proper pipe stand positioning. In the event of tool malfunction outside the scope of the troubleshooting section, contact Victaulic for assistance. REV_C...

  • Page 62: Tool Rating And Roll Selection

    TM-VE460 / Operating and Maintenance Instructions Manual TOOL RATING AND ROLL SELECTION - ORIGINAL GROOVE SYSTEM (OGS) ROLLS FOR STEEL AND SCHEDULE 40 STAINLESS STEEL PIPE - COLOR CODED BLACK (For light-wall stainless steel pipe, refer to separate table) Dimensions...
  • Page 63 Types 304/304L and 316/316L stainless steel pipe The wall thicknesses listed are nominal minimum and maximum The VE460 can groove pipe with yield strength up to 60,000 psi. In addition, the following pipe sizes may be roll grooved: 108.0 mm; 133.0 mm; 139.7 mm; 152.4 mm;...
  • Page 64 139.7 mm; 152.4 mm; 159.0 mm; 165.1 mm; 203.2 mm; 216.3 mm; 254.0 mm; 267.4 mm; 304.8 mm; and 318.5 mm. Contact Victaulic for details. For PVC pipe, the following additional pipe sizes may be roll grooved: 108.0 mm; 133.0 mm; 139.7 mm; 159.0 mm; 165.1 mm; and 216.3 mm. Contact Victaulic for details. REV_C TM-VE460_64...
  • Page 65 TM-VE460 / Operating and Maintenance Instructions Manual TOOL RATING AND ROLL SELECTION - ORIGINAL GROOVE SYSTEM (OGS) ROLLS FOR SCHEDULE 5S AND 10S STAINLESS STEEL PIPE - COLOR CODED SILVER Dimensions Pipe Size inches/millimeters Stainless Steel Pipe Wall Thickness Nominal...
  • Page 66 TM-VE460 / Operating and Maintenance Instructions Manual TOOL RATING AND ROLL SELECTION - ADVANCED GROOVE SYSTEM RW ROLLS FOR GROOVING LIGHT-WALL, STANDARD-WEIGHT, AND EXTRA-STRONG (XS) STEEL PIPE TO ADVANCED GROOVE SYSTEM (AGS) SPECIFICATIONS - COLOR CODED BLACK WITH YELLOW BAND...
  • Page 67 TM-VE460 / Operating and Maintenance Instructions Manual TOOL RATING AND ROLL SELECTION - ADVANCED GROOVE SYSTEM RW ROLLS FOR GROOVING LIGHT-WALL, STANDARD-WEIGHT, AND EXTRA-STRONG (XS) STEEL PIPE TO ADVANCED GROOVE SYSTEM (AGS) SPECIFICATIONS - COLOR CODED BLACK WITH YELLOW BAND...

  • Page 68: Explanation Of Critical Roll Groove Dimensions

    NOTICE FOR OGS COUPLINGS WITH RATINGS ON LIGHT-WALL STAINLESS STEEL PIPE: • Victaulic RX rolls SHALL be used when roll grooving light-wall stainless steel pipe for use with OGS couplings. Pipe Outside Diameter – Nominal NPS Pipe Size (ANSI B36.10) and Basic Metric Pipe Size (ISO 4200) –...
  • Page 69 “T” Dimension – The “T” dimension is the lightest grade (minimum nominal wall thickness) of pipe that is suitable for cut or roll grooving . Pipe that is less than the minimum nominal wall thickness for cut grooving may be suitable for roll grooving or adapted for Victaulic couplings by using Vic-Ring ®...
  • Page 70 TM-VE460 / Operating and Maintenance Instructions Manual EXPLANATION OF CRITICAL ROLL GROOVE DIMENSIONS FOR ADVANCED GROOVE SYSTEM (AGS) PRODUCTS WARNING • Pipe dimensions and groove dimensions shall be within the tolerances specified in the tables on the following pages to ensure proper joint performance.
  • Page 71 OD for proper coupling fit . The groove shall be of uniform depth for the entire pipe circumference . Victaulic RW roll sets shall be used for carbon steel and standard-wall stainless steel pipe . Victaulic RWX roll sets shall be used for light-wall stainless steel pipe .
  • Page 72 24-inch/610-mm minimum nominal wall thickness is 0 .218 inch/5 .5 mm NOTICE • Coatings that are applied to the interior surfaces of Victaulic grooved and plain-end pipe couplings shall not exceed 0.010 inch/0.25 mm. This includes the bolt pad mating surfaces.
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  • Page 74: Roll Groove Specifications

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  • Page 79: Ec Declaration Of Conformity

    Director – Global Regulatory Compliance Machinery Manufacturer Representative Place of Issue: Easton, Pennsylvania, USA Date of Issue: April 24, 2020 MD_DoC_RGT_010_042420_en.docx Victaulic and all other Victaulic marks and logos are registered trademarks of Victaulic Company and/or its affiliates. ©2020 All Rights Reserved...
  • Page 80 OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL VE460 Roll Grooving Tool UPDATED 08/2020 TM-VE460 5855 REV C RM00460000 VICTAULIC IS A REGISTERED TRADEMARK OF VICTAULIC COMPANY AND/OR ITS AFFILIATED ENTITIES IN THE UNITED STATES AND/OR OTHER COUNTRIES. © 2020 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

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