Climax VM1350, Operating Manual

Page 1: ...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 3: ...stions about CLIMAX products or services please call CLIMAX or e mail info cpmt com For quick and accurate service please provide your representative with the following Your name Shipping address Telephone number Machine model Serial number if applicable Date of purchase CLIMAX World Headquarters 2712 East 2nd Street Newberg Oregon 97132 USA Telephone worldwide 1 503 538 2815 Toll free North Ameri...

Page 4: ...Page B VM1350 1500 1600 Operating Manual CLIMAX GLOBAL LOCATIONS ...

Page 5: ...P N 89800 Rev 2 Page C CE DOCUMENTATION ...

Page 6: ...ct its factory representative and return the part or repaired machine shipping pre paid to the factory 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 These warranties do not apply to the following Damage after the date of shipment not caused by defects ...

Page 7: ...or DN 40 DN 65 17 3 3 MOUNTING THE TILTING ADAPTER ON THE VALVE BODY 18 3 3 1 Mounting the tilting adapter on valves with flange 19 3 3 2 Collar band mounting 21 3 3 3 Mounting the bracket 24 3 3 4 Mounting the drive shaft with ball joint 24 3 3 5 Adaptating the planet wheel dia 100 or dia 135 26 3 3 6 Adaptating the planet wheel dia 220 mm or bigger 26 3 3 7 Adaptating the solid grinding discs 27...

Page 8: ...MACHINE MODULES 42 5 3 1 Pneumatic drive motor gear 43 5 3 2 Drive chain 43 5 3 3 Ball joint coupling 43 5 4 LUBRICATING THE PNEUMATIC DRIVE MOTOR 43 5 5 TROUBLESHOOTING 43 6 STORAGE AND SHIPPING 47 6 1 STORAGE 47 6 1 1 Short term storage 47 6 1 2 Long term storage 47 6 2 SHIPPING 48 6 3 DECOMMISSIONING 48 APPENDIX A ASSEMBLY DRAWINGS 49 ...

Page 9: ...r on collar band mounting plate 23 3 20 Unlocking the collar band 24 3 21 Mounting the bracket 24 3 22 Mounting of drive shaft with ball joint Type 15 G 25 3 23 Adaptation of planet wheel dia 100 mm or dia 135 mm 26 3 24 Mounting of ball joint coupling to machine spindle 26 3 25 Adaptation of planet wheel to ball joint coupling 27 3 26 Adaptation of solid grinding disc 27 3 27 Locating the machine...

Page 10: ... joint type 10 67 A 16 170 30S N01 00 68 A 17 440 42S N01 00 ball joint type 15 69 A 18 170 10S N01 00 70 A 19 Mounting system 71 A 20 440 51S N01 00 tilting adapter 72 A 21 440 52S N01 00 Mounting for valve bodies with flanges 73 A 22 440 53S N01 00 Mounting for valve bodies without flanges 75 A 23 440 55S N01 00 Swing check adapter 76 A 24 440 57S N01 00 Tilting Adapter additional parts for T 10...

Page 11: ...assessment checklist before set up 5 1 3 Risk assessment checklist after set up 5 2 1 Components 8 2 2 Sub component mass 9 3 1 Diameters for seats and grinding discs 17 5 1 Maintenance intervals and tasks 42 5 2 Approved lubricants 42 5 3 Troubleshooting for possible faults 44 ...

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Page 13: ... 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 1 2 SAFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual Safety alerts will call your attention to specific hazardous situations that may be encoun tered when operating this machine Examples of safety ale...

Page 14: ...ne poses risks to your safety You the end user are responsible for conducting a risk assess ment of each job site before setting up and operating this machine Intended use Use this machine in accordance with the instructions and precautions in this manual Do not use this machine for any purpose other than its intended use as described in this manual Personal protective equipment Always wear approp...

Page 15: ... SAFETY PRECAUTIONS Eye hazard This machine produces metal chips during operation Always wear eye protection when operating the machine Sound level This machine produces potentially harmful sound levels Hearing protection is required when operating this machine or working around it During testing the machine produced the sound levels1 listed in Table 1 1 Hazardous environments Do not operate the m...

Page 16: ...ally attach directly to the workpiece itself or to an adjacent struc ture and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and the structure to which it is attached become one complete machine during the material removal process To achieve the intended results and to promote safety the operator must under stand and follow the...

Page 17: ...g operations I have taken pre cautions to keep workers away from the identified fall path I considered how this machine operates and identified the best placement for the controls cabling and the operator I evaluated and mitigated any other potential risks specific to my work area TABLE 1 3 RISK ASSESSMENT CHECKLIST AFTER SET UP After set up I checked that the machine is safely installed according...

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Page 19: ...c drive system Optionally the machine can be delivered with electric and pneumatic drive system However both drive systems are described in this operating manual Also the grinding tools are described from DN 40 DN 600 but the different mod els don t include all sizes of tools The lapping is also described however the S models grinding only don t include the lapping equipment DANGER The Gate Valve ...

Page 20: ... during machine operation Planet grinding and lapping wheels in the following called planet grinding wheels are used as tools The planet grinding wheels consist of a ball joint coupling for self alignment of planet wheels a planet wheel planet arms with integrated spindle bearing system grinding or lapping discs to put onto planet arms abrasives for grinding for lapping operation a lapping paste i...

Page 21: ...e the abrasives without dismantling the tilting adapter and its clamping elements The machine configuration with electric drive motor is started with the trigger but ton The machine spindle is rotating as long as the trigger button is being pushed For permanent operation the trigger button can be locked The spindle speed can be adjusted at the top of the electric drive motor The machine configurat...

Page 22: ...ctric pneumatic 230 V 50 Hz or 110 V 60 Hz 12 l s 6 3 bar 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 21 kg Weight of accessory case VM1500 32 kg Weight of accessory case VM1600 32 kg TABLE 2 2 SUB COMPONENT MASS Unit Specific...

Page 23: ...is section describes the setup and assembly procedures for the VM1350 1500 1600 Gate Valve Grinding and Lapping Machine 3 1 RECEIPT AND INSPECTION Your CLIMAX product was inspected and tested prior to shipment and packaged for normal shipment conditions CLIMAX does not guarantee the condition of your machine upon delivery When you receive your CLIMAX product perform the following receipt checks 1 ...

Page 24: ...ted The cases are to be secured 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 all parts are to be secured against dropping This is also important for parts that are not directly used for the operation TIP case should always be closed and secured against dropping After transportation check all pa...

Page 25: ...P N 89800 Rev 2 Page 13 FIGURE 3 2 ACCESSORY CASE HERE VM 1350 FIGURE 3 3 MACHINE CASE HERE VM 1500 INCLUDING SOME OPTIONS ...

Page 26: ...r of the valve seat to be ground Selection of proper tool components according to the maximum machine diameter table that follows Planet wheel of applicable size Planet arms of applicable size Grinding discs no need if spindle diameter 30 mm is sufficient abrasives size and grain according to application no need for lap ping operation and grinding operation with CBN grinding discs proper screws Th...

Page 27: ...hines with the additional S only grinding there are no lapping disks included in the scope of supply CAUTION Make sure that always proper grinding discs are being used otherwise the machine or the valve body can be damaged If grinding discs are used for lapping operation they will be damaged If already used lapping discs are utilised for grinding operation the required accuracy cannot be guarantee...

Page 28: ...ols for DN 80 DN 600 If necessary clean the grinding discs with oil free cleaning fluid i e lacquer thin ner Put abrasives onto grinding discs not applicable for lapping operation and grind ing with CBN grinding discs During assembly of selected tool components observethe applicable torque for screws If too low components get loose if too high screw might be damaged Do the following Put grinding d...

Page 29: ...ing discs the pitch circle of the discs should be smaller than the inner diameter of the seat to be ground FIGURE 3 6 PLANET GRINDING WHEEL COMPLETELY ASSEMBLED 3 2 3 Selecting solid grinding discs for DN 40 DN 65 For grinding of seats DN 40 to DN 65 only VM 1350 solid grinding discs are provided The standard scope of supply includes the following solid grinding discs The solid grinding discs cons...

Page 30: ...the bottom surface of the solid grinding discs is covered with self adhesive abrasives 3 3 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 ba...

Page 31: ...HV Zn according to DIN 433 4 pieces clamping pads 2 pieces socket head screws M10 x 20 8 8 Zn according to DIN 912 2 pieces washers Ø 10 5 140HV Zn according to DIN 433 2 pieces Do the following 1 Connect the clamping pads to the base plate by using socket head screws M10x20 8 8 Zn according to DIN 912 and washers Ø 10 5 140HV Zn according to DIN 433 FIGURE 3 8 TILTING ADAPTER WITH BASE PLATE AND ...

Page 32: ...h room for the tilting adapter As an option there are extended clamping pads available 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 FIGURE 3 11 OPTIONAL EXTENDED CLAMPING PADS FIGURE 3 10 MOUNTING OF BASE PLATE TO FLANGE BY MEANS OF FORGED STEEL CLAMPS BASE PLATE EXTENDED CLAMPIN...

Page 33: ...tween the machine arm and the rotating tool to avoid any collision 4 After mounting the tilting adapter onto the valve body make sure that all screws are securely tightened 3 3 2 Collar band mounting All elements for mounting the tilt ing adapter onto a valve body with out top flange are also included in the scope of supply Do the following 1 Select all components for collar band mounting tilting ...

Page 34: ... and through the lock of the collar band fastening system 4 After the collar band is located around the valve body and the mounting plate it is slightly fastened 5 Move the collar band mounting plate into posi tion On the spacers of the mounting plate a raised surface is provided to avoid the collar band from slip ping FIGURE 3 14 ADJUSTMENT OF COLLAR BAND MOUNTING PLATE FIGURE 3 15 POSITIONING OF...

Page 35: ...cation for the machine arm is approximately in centreline to the valve seat TIP For higher rigidity it is recommended to leave one empty tap hole between the connecting screws CAUTION Make sure that the location for the machine arm is positioned to leave enough space between the machine arm and the rotating tool to avoid any collision 9 After mounting the tilting adapter make sure that all connect...

Page 36: ...unting system are prepared the machine is taken out of the case First the bracket is mounted to the machine arm and locked according to the approximate submerging depth The side with the pocket holes should point to the side of the drive system and they should be in downward direction 3 3 4 Mounting the drive shaft with ball joint For the adaptation of a planet wheel a drive shaft with ball joint ...

Page 37: ...pplications it might be required that the machine drive points into the opposite direction with optional drive shaft In this case the bracket also has to be turned 180 degrees In addition the drive shaft has to be mounted in opposite direction To avoid any collision between machine arm and rotating tooling only use the optional drive shaft Due to the danger of collision this set up should only be ...

Page 38: ...peration the ball joint of the machine spindle has to be lubri cated with grease i e Molykote or Unimoly or similar 3 3 6 Adaptating the planet wheel dia 220 mm or bigger In case a grinding wheel dia 220 mm or bigger is used a ball joint coupling has to be mounted to the machine spindle first After the set screw of the ball joint coupling is released 1 2 rotations the coupling can be engaged to th...

Page 39: ...lid grinding disc should point into the direction of machine s drive system Secure the drive shaft from the opposite side with the washer Ø 19 x Ø 6 6 x 2 and the countersunk screw M5 x 10 8 8 Zn according to DIN 7991 Before operation the ball joint of the machine has to be lubricated with grease i e Molykote or Unimoly or similar 3 4 LOCATING AND ALIGNMENT OF MACHINE IN TILTING ADAPTER Do the fol...

Page 40: ... the bracket and the two ball locations into the tilting adapter 3 Hold the machine arm by hand unlock the bracket and move the machine arm down to its working posi tion until the tool is in cen tre with the valve seat FIGURE 3 27 LOCATING THE MACHINE ARM INTO THE TILT ING ADAPTER ...

Page 41: ... 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 and resting in the ball locations FIGURE 3 28 MACHINE ARM IN CLAMPED POSITION ...

Page 42: ... has to 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 M4 wrench size 2 5 mm 1 8 Nm M5 wrench size 3 mm 3 5 Nm In addition all screws with visible damages must be replaced immediately If dis regarded damaged screws can only be unscrewed with extreme effort and parts of the mach...

Page 43: ... wear eye protection glasses For machines with electric drive motor make sure that the trigger button is in unlocked position before connecting to the power supply WARNING Machines with pneumatic drive may not be used without maintenance unit filter and oil lubricator The air supply line must offer a minimum pressure of 6 3 bar to the maintenance unit The air supply must be free from humidity and ...

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Page 45: ... equipment 3 Check that the machine control observation area will not be in the path of hot flying chips during machine operation 4 Check the machine is securely mounted to the workpiece 5 Check that air hoses are routed and secured to avoid tripping entangle ment damage from hot chips or other damage should an air hose or con nection fail 6 Check the tool condition and sharpness 7 On the PCU chec...

Page 46: ...not be too high or too low If the grinding pressure is too high it might result in heat cre ation at the grinding disc and the abrasive might shear off If grind ing pressure is too low it could result in low performance To get the perfect grinding pres sure please consider diagram 4 5 0 2 This diagram shows the grinding pressure resulting from the torque applied to the star knob of the tilting ada...

Page 47: ...it is possible to select the direction of the rotation cw ccw It is always recommended to use the clockwise direction because only in clockwise direction the machine can reach its max speed white arrow points to the top On top of the electric drive motor the direction of the rotation is indicated by two diodes R means clockwise The electric drive motor is equipped with an addi tional 2 stage mecha...

Page 48: ... figures have to be divided by 3 6 The electric drive motor also has a switch for a percussion drill function This switch is located at the side of the electric drive housing However for the general function of the valve grinder this switch and its function is not required The machine should always run in drilling mode symbol drill and never in per cussion drill function symbol hammer FIGURE 4 3 E...

Page 49: ...he gauge on the maintenance unit If customer is using his own maintenance unit the operation might be different however the basic operating buttons should be provided FIGURE 4 4 MAINTENANCE UNIT WITH OPERATING BUTTONS FOR PNEUMATIC DRIVE OPTIONAL CAUTION The operating pressure of the machine is 6 3 bar Higher pressure can result in damaging the machine and therefore it is not applicable Never oper...

Page 50: ...e abrasives in time otherwise it will result in poor performance Over proportional heat creation of abrasive might result into shearing off and the valve seat might be damaged 4 4 CHANGE OF ABRASIVES Stop the machine with trigger button electric drive or with red safety button on maintenance unit pneumatic drive Release grinding pressure To release grinding pressure use the star knob of the tiltin...

Page 51: ...rew the drive can be pulled off With the electric drive motor there is an additional adapter bushing in the drive flange bore dia 43 mm 48 mm This bushing has to be removed for mounting the pneumatic drive motor After the drive motor is taken out of the machine the coupling can be discon nected This step is unnecessary when the machine is delivered with electric and pneumatic drive motor since bot...

Page 52: ...20 UNF 2A thread of the motor spindle Due to the fact that the electric drive motor offers spindle rotation in both directions the coupling has to be secured with a left hand threaded screw see 4 7 1 2 If the machine is delivered with electric and pneumatic drive this step is unnecessary since both drives are prepared with cou plings After connection of the coupling the electric drive can be moved...

Page 53: ...danger of life and health of persons For all maintenance work the machine has to be disconnected from power supply line All lubrication fluids have to be disposed in suitable containers CAUTION For all work on the machine the electrical power supply line must be disconnected to avoid any danger to the life and health of persons due to uncontrolled rotation of the tools Alternatively the machine ca...

Page 54: ...ck power supply lines for visible damages Check the maintenance unit with pneumatic drive Check the ventilating slots of electric drive motor Before and after each use Clean the machine and check for visible damage After 150 hours Disassemble clamp clean and lubricate the gear of the pneumatic drive motor with Bosch special grease Section 5 3 1 After 300 hours Inspect the drive chain integrated in...

Page 55: ...ost likely the drive chain is not sufficient anymore To adjust the tension of the drive chain untie the screws of the machine arm clamping plate 20T 021 and adjust the tension by means of the adjusting screw 20N 026 After every half rotation of the adjusting screw check if the noise disappears After adjusting the tension of the drive chain tighten the screws of the clamping plate After this proced...

Page 56: ...ne spindle TABLE 5 3 TROUBLESHOOTING FOR POSSIBLE FAULTS Possible fault Operating or maintenance error Recovery of fault Machine does not start Power supply line is not connected Make sure that power supply line is plugged in Default in power source Check energy source fuses plugs connections air pressure etc Only with electric drive Machine overloaded The heat protection is activated Let the mach...

Page 57: ...oise rattling in machine arm Pretension of drive chain is insufficient Adjust tension of drive chain see chapter Maintenance TABLE 5 3 TROUBLESHOOTING FOR POSSIBLE FAULTS Possible fault Operating or maintenance error Recovery of fault ...

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Page 59: ...achine 6 1 1 Short term storage Do the following for short term storage three months or less 1 Retract the tool head from the workpiece 2 Remove the tooling 3 Remove hoses 4 Remove the machine from the workpiece 5 Clean the machine to remove dirt grease metal chips and moisture 6 Spray all unpainted surfaces with LPS 2 to prevent corrosion 7 Store the Gate Valve Grinding and Lapping Machine in its...

Page 60: ... in its original ship ping container 6 3 DECOMMISSIONING 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 61: ...40 36S N01 00 SWING CHECK SPINDLE EXTENSION 150 64 FIGURE A 13 440 37S N01 00 MACHINE ARM GENERAL PARTS 65 FIGURE A 14 440 40S N01 00 BALL JOINT 66 FIGURE A 15 440 41S N01 00 BALL JOINT TYPE 10 67 FIGURE A 16 170 30S N01 00 68 FIGURE A 17 440 42S N01 00 BALL JOINT TYPE 15 69 FIGURE A 18 170 10S N01 00 70 FIGURE A 19 MOUNTING SYSTEM 71 FIGURE A 20 440 51S N01 00 TILTING ADAPTER 72 FIGURE A 21 440 5...

Page 62: ...Page 50 VM1350 1500 1600 Operating Manual FIGURE A 1 GATE VALVE GRINDING AND LAPPING MACHINE ...

Page 63: ...P N 89800 Rev 2 Page 51 ...

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Page 65: ...P N 89800 Rev 2 Page 53 FIGURE A 2 440 10S N01 00 BASIC MACHINE ...

Page 66: ...Page 54 VM1350 1500 1600 Operating Manual ...

Page 67: ...P N 89800 Rev 2 Page 55 FIGURE A 3 240 11S N01 00 ELECTRIC DRIVE ...

Page 68: ...Page 56 VM1350 1500 1600 Operating Manual FIGURE A 4 240 13S N01 00 PNEUMATIC DRIVE ...

Page 69: ...P N 89800 Rev 2 Page 57 FIGURE A 5 240 15S N01 00 ELECTRIC DRIVE 115 V ...

Page 70: ...Page 58 VM1350 1500 1600 Operating Manual FIGURE A 6 440 20S N01 00 UPPER GEAR ...

Page 71: ...P N 89800 Rev 2 Page 59 FIGURE A 7 440 21S N01 00 UPPER GEAR ADDITIONAL PARTS FOR T 1000 ...

Page 72: ...Page 60 VM1350 1500 1600 Operating Manual FIGURE A 8 440 32S N01 00 MACHINE ARM WITH SUBMERGING DEPTH T 600 ...

Page 73: ...P N 89800 Rev 2 Page 61 FIGURE A 9 440 33S N01 00 MACHINE ARM WITH SUBMERGING DEPTH T 800 ...

Page 74: ...Page 62 VM1350 1500 1600 Operating Manual FIGURE A 10 440 34S N01 00 SWING CHECK SPINDLE EXTENSION 100 ...

Page 75: ...P N 89800 Rev 2 Page 63 FIGURE A 11 440 35S N01 00 MACHINE ARM WITH SUBMERGING DEPTH T 1000 ...

Page 76: ...Page 64 VM1350 1500 1600 Operating Manual FIGURE A 12 440 36S N01 00 SWING CHECK SPINDLE EXTENSION 150 ...

Page 77: ...P N 89800 Rev 2 Page 65 FIGURE A 13 440 37S N01 00 MACHINE ARM GENERAL PARTS ...

Page 78: ...Page 66 VM1350 1500 1600 Operating Manual FIGURE A 14 440 40S N01 00 BALL JOINT ...

Page 79: ...P N 89800 Rev 2 Page 67 FIGURE A 15 440 41S N01 00 BALL JOINT TYPE 10 ...

Page 80: ...Page 68 VM1350 1500 1600 Operating Manual FIGURE A 16 170 30S N01 00 ...

Page 81: ...P N 89800 Rev 2 Page 69 FIGURE A 17 440 42S N01 00 BALL JOINT TYPE 15 ...

Page 82: ...Page 70 VM1350 1500 1600 Operating Manual FIGURE A 18 170 10S N01 00 ...

Page 83: ...P N 89800 Rev 2 Page 71 FIGURE A 19 MOUNTING SYSTEM ...

Page 84: ...Page 72 VM1350 1500 1600 Operating Manual FIGURE A 20 440 51S N01 00 TILTING ADAPTER ...

Page 85: ...P N 89800 Rev 2 Page 73 FIGURE A 21 440 52S N01 00 MOUNTING FOR VALVE BODIES WITH FLANGES ...

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Page 87: ...P N 89800 Rev 2 Page 75 FIGURE A 22 440 53S N01 00 MOUNTING FOR VALVE BODIES WITHOUT FLANGES ...

Page 88: ...Page 76 VM1350 1500 1600 Operating Manual FIGURE A 23 440 55S N01 00 SWING CHECK ADAPTER ...

Page 89: ...P N 89800 Rev 2 Page 77 FIGURE A 24 440 57S N01 00 TILTING ADAPTER ADDITIONAL PARTS FOR T 1000 ...

Page 90: ...Page 78 VM1350 1500 1600 Operating Manual Tooling ...

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Page 92: ...Page 80 VM1350 1500 1600 Operating Manual FIGURE A 25 240 71S N01 00 PLANET WHEELS DN 80 DN 350 ...

Page 93: ...P N 89800 Rev 2 Page 81 FIGURE A 26 240 73S N01 00 PLANET WHEELS DN 400 DN 500 VM 1500 1600 ONLY ...

Page 94: ...Page 82 VM1350 1500 1600 Operating Manual FIGURE A 27 110 20S N01 02 PLANET ARMS ...

Page 95: ...P N 89800 Rev 2 Page 83 FIGURE A 28 440 72S N01 00 SOLID GRINDING DISCS DN 40 DN 65 VM 1350 ONLY ...

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