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PICOTE CONNECTION COLLAR 2.0 Operation & Safety Manual

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CONNECTION COLLAR 2.0
OPERATION & SAFETY MANUAL
These instruc ons are for your personal safety. Always ensure that you
have read and understood these instruc ons before using the machinery.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

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Summary of Contents for PICOTE CONNECTION COLLAR 2.0

  • Page 1 CONNECTION COLLAR 2.0 OPERATION & SAFETY MANUAL These instruc ons are for your personal safety. Always ensure that you have read and understood these instruc ons before using the machinery. SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.

  • Page 2: Table Of Contents

    Opera ng Instruc ons Using the Strapping Tool Fastening the Bladder to the Installa on Tool Connec ng the Picote Push Rods Chart 1 and Chart 2—Bladder Installa on Pressures for Ambient Cure Steam Curing Chart 3—Bladder Installa on Pressures for Steam Curing...

  • Page 3: Safety Informa On

    Suitable gloves to help prevent any contact with chemicals. Do not use gloves which can become entangled. Suitable respirator to prevent any dust or fumes being inhaled or consumed, which could cause occupa onal asthma or derma Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 4: General Safety Informa On

    Change damaged parts immediately. 3. Only use this tool with the accessories and spare parts offered by Picote Solu ons. Accessories and spare parts should only be used in the manner intended and as described by Picote Solu ons.

  • Page 5: Environment, Transport, Storage & Disposal

    The two end caps, steel cable es and connectors can be recycled in metal waste collec on points. The Bladders can be disposed of as rubber waste. Always check and follow local waste handling rules and regula ons! Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 6: Declara On Of Incorpora On For A Partly Completed Machine

    DECLARATION OF INCORPORATION FOR A PARTLY COMPLETED MACHINE SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE We Picote Solu ons Oy Ltd as the responsible manufacturer, declare that the following Picote Solu- ons Oy Ltd Equipment: Picote Connec on Collar 2.0 System...

  • Page 7: General Informa On

    Stainless Steel Cable tie 1410000039 Bladder Release Agent 1410000035 Installation Tool 2.0 Accessories Starter Kit (Includes Picote Bladder Release Agent, Hybrid Tape, Sealing Tape, Cover Tape, & Bladder Lubricant Spray in a Picote Tool Bag.) Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 8 Push Rod with Turning Handle Picote’s Push Rods work as a push/turn rod and air or steam supply. Separate air/steam hoses are not needed. There are two versions, the slightly smaller 22mm (0.87”) version for extra flexibility for more bends and smaller pipes, or the 24mm (0.94”) version that has more rigidity for longer runs and larger pipes.
  • Page 9 SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Connec on Collars Picote Solu ons offer a range of connec on collars available in 2 versions (GRP - Glass Reinforced Polymer & Felt), as well as Single & Double Connec on Op ons.
  • Page 10 Installa on Tool Accessories Starter Kit. This Starter Kit includes, Bladder Release Agent, Hybrid Tape, Sealing Tape, Cover Tape, & Bladder Lubricant Spray in a Picote Tool Bag. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 11: Opera Ng Instruc Ons

    OPERATING INSTRUCTIONS SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Before opera on: Always use a pressure regulator when using the Picote Connec on Collar 2.0. Unregulated compressor pressure will burst the bladder. USING THE STRAPPING TOOL This sec on contains important safety informa on. Failure to comply could result in serious injury The Strapping Tool has two tension se ngs: Manual and Controlled.
  • Page 12 OPERATING INSTRUCTIONS SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE Bend strap 90° and cut it. Bend le over strap 90° by hand. Close the strap buckle. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 13: Fastening The Bladder To The Installa On Tool

    3. Open the Bladder and put the Installa on Tool Head inside it. Pay a en on to the lateral direc on when installing Y-connec ons. 4. Before adding the Sealing Tape on the Bladder, make sure it is centralised on the Installa on Tool Head. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 14 The Sealing Tape needs to be wide enough to cover the groove of the Installa on Tool Head sleeve. 6. Make double rounds on the cable e. Add Bladder Release Agent lubricant between the first and second layer to reduce fric on. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 15 You will need to do this around 15 mes un l fully ghtened. 8. Cut the excess cable e and lock it with the strapping tool. (Refer to Page 11 of the manual) Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 16 FAILING TO DO SO WILL DAMAGE THE BLADDER. 10. Add Covering Tape over the cable es 11. Spray Bladder Lubricant inside the Bladder through the coupling (not the steam valve). Spread the lubricant evenly by rubbing the bladder walls together. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 17 SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE 12. Test that the Bladder is properly lubricated by pushing the Bladder lateral inside the main using a rounded s ck. Add lubrica on if necessary. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 18: Connec Ng The Picote Push Rods

    SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE CONNECTING PICOTE PUSH RODS Using Picote Push Rods allows you to push/pull, rotate, fill and extend your tools reach using only one hose/rod- system. Push Rod fi ngs have a hex socket that must be aligned.
  • Page 19 Screw locking ring un l it’s completely turned against the collar to lock it in posi on. Addi onally, you can wrap protec ve tape around each fi ng to prevent resin from going in between the fi ngs. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 20: Chart 1 And Chart 2-Bladder Installa On Pressures For Ambient Cure

    DN70 (3”) DN100 (4”) DN150 (6”) STEAM CURING Picote Push Rods and Connec on Collar Use a flat screwdriver to open or close steam valve. 2.0 can be used with steam to speed up the curing process. To open it, turn the screw counter clockwise un l it stops.

  • Page 21: Chart 3-Bladder Installa On Pressures For Steam Curing

    SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE CHART 3 - BLADDER INSTALLATION PRESSURES FOR STEAM CURING (STEAM PORT OPEN) When using Picote Midi Steamer you need to increase the infla on pressure and set temperature based on the number of Push Rods being used.

  • Page 22: Steam Curing Example

    Therefore, the correct pressure se ng on the Picote Midi Steamer is as follows: Ambient Infla on Pressure + Infla on Pressure for using 10 Picote Push Rods = Total Pressure of 0.45 Bar (6.5 PSI)+ 0.48 Bar (7 PSI) = 0.93 Bar (13.5 PSI) Required curing temperature at the Bladder - 70°C (158°F)

  • Page 23: Maintenance

    2. Clean the Connec on Collar before and a er each use to help increase the Bladder life. Primary cleaning method should be a damp cloth with soap or wet wipes to clean the surfaces. 3. Using Picote Bladder Release Agent prevents resin from s cking to the Bladder and makes cleaning and Bladder removal easier.

  • Page 24: Repairing A Damaged Bladder

    SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE REPAIRING A DAMAGED BLADDER A damaged Bladder can be repaired using Picote Silicone Glue. The Silicone Glue takes approximately 12 hours to cure at room temperature per 1 mm (1/32”) applied thickness.
  • Page 25 3. Throughly clean inside of the Bladder with acetone. 4. Measure the area being repaired. Patch piece should 5. Cut a piece of silicone material (excess Bladder overlap the damaged area around 10mm (1/2”) material) to the appropriate size with scissors. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 26 10. Place a weight on top of the repaired area. The 9. Apply patch over the damaged area. Silicone Glue takes approximately 12 hours to cure at room temperature per 1mm (1/32”) applied thickness. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 27: Appendix 1: A Typical Repair Installa On

    NEVER use resin that has not been properly stored or has expired. Ensure that you have all the necessary equipment available and everything is set up before we ng out to ensure a good end result. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 28: Tool Prepara On

    1. Select correct Bladder based on pipe sizes and configura on. Make sure that the inside of the Bladder is well lubricated, if it feels s cky, add Picote Bladder Lubricant Spray as needed. A ach the Air Adapter and Pressure Regulator to the Installa on Tool assembly.

  • Page 29: Applying Bladder Release Agent

    Bladder Release Agent will prevent adhesion of future coa ng, lining, or point repairs. Any Bladder Release Agent in the pipe will need to be removed before any subsequent rehabilita ons. APPLYING BLADDER RELEASE AGENT 1. Apply Picote Bladder Release Agent and spread evenly over main body area where Connec on Collar will be placed.

  • Page 30: Adding The Connec On Collar

    2. Fold over the end of the Connec on Collar to use as a pulling point. 3. Slide the Connec on Collar onto the Bladder. 4. Line up the Collar & Bladder lateral opening. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 31 Leave approximately 0.2 bar (2.9 PSI) pressure in the bladder. Cau on! Do not over pressurise the Bladder to prevent stretching the Connec on Collar. Over stretching the Connec on Collar may cause wrinkles. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 32: We Ng Out The Connec On Collar

    Be sure to use suitable chemical resistant gloves to prevent resin contact with your skin. 4. Make sure there are no dry spots on the Connec on Collar. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 33 4. Slide the Connec on Collar onto the Bladder and by inspec ng the reverse side and ends for any dry line up the Collar & Bladder lateral opening as spots. shown on page 30. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 34: Inver Ng Wet Out Connec On Collar

    3. Make sure both the Bladder and the lateral por on of the Connec on Collar are inverted ghtly together. This step can be easier to perform while adjus ng the Bladder pressure using the Picote Pocket Vacuum. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 35 4. Release the Pressure Regulator and a ach the Pocket Vacuum. 5. Vacuum down the Bladder Assembly and remove the rounded s ck. Be sure not to pull out the Bladder or Connec on Collar when removing. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 36: Securing The Connec On Collar

    SECURING THE CONNECTION COLLAR 1. If not already a ached, a ach the Pocket Vacuum and fully vacuum down the Bladder while folding as shown. 2. Fold whole assembly together as ghtly as possible. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 37 Connec on Collar System used in this manual is presented for educa onal purposes only to allow you to visualise the general process. SECURING THE CONNECTION COLLAR 4. Secure Connec on Collar. Use blue Picote Hybrid Tape to secure the Connec on Collar to the Bladder assembly 5. The Picote Hybrid Tape is wrapped around each end of the wet-out Connec on Collar overlapping approx.

  • Page 38: Carrying Connec On Collar To Pipeline

    For ambient curing, make sure steam port is fully closed (steam port full closed in clockwise direc on). 3. Place the Connec on Collar Assembly in the pipe and a ach the first Push Rod. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 39: Installing The Connec On Collar

    3. Con nue adding the appropriate number of Push Rods to be able to reach the connec on repair loca on. Alterna vely, you can pre-measure and assemble the complete Push Rod string. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 40 Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 41 8. Push or pull to fine tune the posi on while rota ng the Turning Handle as needed in order to aling the lateral Bladder opening with the connec on opening. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 42 As long as you haven’t added too much air pressure, you should s ll be able to make small adjustments on the alingment by pulling, pushing or turning the Turning Handle at this point. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 43 Bladder! 13. Bladder infla on. 14. Bladder fully inflated. Make sure Bladder is fully opened. When installing double Connec on Collars, make sure to check both lateral connec ons with CCTV. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 44 Push Rod air channel with your finger. Then, add the Installa on Tool Air Adaptor. 18. Simply reconnect the air pressure regulator and air hose. Re-open the air valve and ensure the Bladder has re-pressurised to the correct curing pressure. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 45: Removing The Bladder

    For example, in repair with a 45 degree lateral, you need to push away from the connec on to help release the lateral bladder por on so it will enter main pipe smoothly, otherwise the bladder may be damaged. Picote Solu ons Oy Ltd www.picoteins tute.com...
  • Page 46 Connec on Collar System used in this manual is presented for educa onal purposes only to allow you to visualise the general process. REMOVING THE BLADDER You can use the Turning Handle during the removal process as needed. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 47: Final Inspec On

    Check the cured Connec on Collar with the CCTV camera. The connec on should now be sealed and repaired. Check both from the main and from the lateral. View looking down the Main Line. View looking down the Lateral Line. Picote Solu ons Oy Ltd www.picoteins tute.com...

  • Page 48: Warranty Policy & Procedure

    End User and for a period of one (1) year, except electric motors and ba eries for which the warranty period shall be six (6) months, provided, however, that Picote does not warrant any claim or damage under this Warranty if such claim or damage results from:...
  • Page 49 Revision number: Rev. 3 Date: 1st April 2024 Author: Ville Hukkanen Accepted: Dawn Greig 21/07/23 For More Informa on Please Contact: Your Reseller / Salesperson or Picote www.picotegroup.com Produc on & R&D Interna onal Offices Technical Support Pienteollisuus e 24 Finland.

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