Quick-Lock LEM >700 User Manual 1st release, version 03/2015 [English] Sold by: Kanaltechnik GmbH
Published by: Uhrig Kanaltechnik GmbH Am Roten Kreuz 2 78187 Geisingen, Germany Tel. +49 (0) 7704 / 806-0 Fax +49 (0) 7704 / 806-50 Internet www.uhrig-bau.de E-mail info@uhrig-bau.de 2
Contents 1. About this document... 4 1.1 Regulations... 4 1.2 Certifications... 4 2. Description of the Quick Lock LEM >700...5 2.1 Intended use... 5 2.2 Suitability and materials used... 5 2.3 Components and functions... 6 2.4 Description of the system and procedure... 6 2.5 Suitability and materials used... 6 3. How to use the system...7 3.1 Preparation... 7 3.1.1 Inspecting the pipe...7 3.1.2 Preparing the pipe...7 3.2 Equipment and materials... 8 3.3 Preparation: Trimming the liner... 10 3.4 Installing the Quick-Lock LEM>700... 11 3.5 Tool maintenance... 18 4. Appendix... 19 4.1 Pneumatic cutter for liner end sleeves... 19 4.2 Maintenance instructions for the pneumatic cutter... 20 4.3 Data sheet... 21 3
1. About this document These instructions supplement the basic Quick-Lock user manual. They specifically describe how to use the Quick-Lock liner end sleeve > 700. Please observe the aforementioned user manual with its general instructions on using the Quick-Lock system. 1.1 Regulations The basis and general specification for pipe repairs using the Quick-Lock system is DWA data sheet M143 Part 3 Repairing wastewater pipes and sewers with internal sleeves See the main user manual. 1.2 Certifications An application for technical approval will be submitted shortly. 4
2. Description of the Quick Lock LEM >700 2.1 Intended use Cross-section The Quick-Lock liner end sleeve > 700 is a product for permanently and tightly sealing liner systems to the host pipes or manhole pipe connections in the range of diameters from DN 700-DN 1200. 2.2 Suitability and materials used The system is made from V4A stainless steel of grade 1.4404 (AISI 316L) a nd an EPDM compression seal. The materials used are permanently resistant in municipal wastewater systems. The suitability of the materials must be ascertained for use in industrial or polluted wastewater. The Quick-Lock liner end sleeve may only be installed in cured, stress-free liner systems. Hydrophilic waterstop tape does not need to be used around the liner. The basis for selecting a suitable liner end sleeve is the technical data sheet (appendix 1). Observe the instructions in section 1.6 of the main user manual. 5
2.3 Components and functions System components Two-piece stainless steel sleeve Locking screws (4x) Sliding blocks (4x) Rubber jacket (1x) Compensating rubber (1 or 2, if needed) 2.4 Description of the system and procedure See the main usermanual. 2.5 Suitability and materials used See the main usermanual. 6
3. How to use the system 3.1 Preparation 3.1.1 Inspecting the pipe Before using the Quick-Lock liner end sleeve, check the area where the liner is connected to the host pipe or the manhole pipe connection to see whether the liner end sleeve is suitable. 3.1.2 Preparing the pipe Repairing the contact surfaces A reliable compression seal is only possible if the quality of the surface is suitable for sealing. Repair any irregularities or holes in the host pipe or the manhole pipe connection. Only used mineral or epoxy-based materials. Let the material cure. 7
3.2 Equipment and materials Installation tools (Supplied by Uhrig) Four-piece clamping tool set 2x with screw unit 2x with seat (1) Spindle For pre-tensioning the sleeve (2) Clamping screws For clamping the sleeve and pressing it in place (3) Retaining lug For attaching the tool to the sleeve Pneumatic cutter A pneumatic cutter is required for cutting back the liner. Uhrig supplies pneumatic cutters that are specially designed for cutting liners. They are lowmaintenance and have an adjustable cut depth. Observe the operation and maintenance instructions in the appendix. 8
Required accessories Make sure you have the necessary tools. If necessary we can provide the tools for sale or hire. Lubricant Ruler or tape measure 8 mm Allen key 17 mm socket Crayon Interchangeable socket wrench (or 17 mm ratchet wrench) Open-end spanner with 17 mm ring ratchet Plastic or rubber mallet Talcum powder Laser for measuring the damaged area (optional, not shown) Gauge Pneumatic socket wrench (optional for rapid installation) 9
3.3 Preparation: Trimming the liner Fitting the depthstop Measure the thickness of the liner. Fit the appropriate depth stop onthe pneumatic cutter. Trimming the liner Using the pneumatic cutter, make a radial cut around the entire sleeve circumference. Liner trimlength: DN 700 DN 1200: 265 mm Measure from the position where the front edge of the sleeve will be. Make a longitudinal cut with a pneumatic angle grinder. Do not damage the host pipe. Remove the liner offcut. Deburr the new end of the liner with the angle grinder. Clean the area where the liner will be connected with a high-pressure jet. Longitudinal cut Make a longitudinal cut with a pneumatic angle grinder. Do not damage the host pipe. Remove the liner offcut. Deburr the new end of the liner with the angle grinder. Clean the area where the liner will be connected with a high-pressure jet 10
3.4 Installing the Quick-Lock LEM >700 Installation Bringing in thesleeve Do not assemble the sleeve. Bring in the sleeve via the manhole entrance. Remove the edge protection on the metal rim. Putting the sleeve together Join the sleeve sections together so that their respective engraved tracks are on the outside. Place the sliding blocks in the tracks. Secure the sliding blocks with the locking screws. Adjust the sleeve to the smallest diameter and tighten the locking screws. Applying talcum powder to the rubber jacket Apply talcum powder to the inside of the rubber jacket. 11
Fitting the rubberjacket Pull the jacket over the sleeve and center it on the 300 mm wide (without rims) steel sleeve. The preassembled sleeve is rolled so tightly that it can be taken into the pipe and turned around there. Fitting compensating rubbers (if necessary) For greater liner thicknesses, one or two compensating rubbers must be mounted (see data sheet). Peel back the rubber jacket. Pull on one or two compensating rubbers over the sleeve (on the side with the larger border). Fold the rubber jacket back over the compensating rubbers. Check for correct seating. Aligning the rubber jacket Check and correct the fit of the rubber jacket: Position the compensating rubbers so thatthe edges lie under each other (see figure). 12
Positioning the liner end sleeve in the host pipe Depending on the type ofconnection: Alternative A (standard method): Connecting to liner in host pipe Rubber jacket is seated in the center around the steel sleeve. Alternative B: Connecting to liner in manhole pipe connection Rubber jacket is seated in the center around the steel sleeve. This requires that the surface of the manhole pipe connection be suitable for sealing and that there are no significant bends in the connection from the host pipe to the manhole. Maximum bend 1.0. For a tight seal, the sealed area of the manhole wall (pipe connection) must be at least 110 mm. Alternative C: Edge of the sleeve as repair bead Rubber jacket is seated in the center around the steel sleeve. The flared end of the sleeve protrudes 10-15 mm inside the manhole and acts as a bead for repairs around the pipe connection. 13
Positioning and aligning thesleeve Align the sleeve inside the pipe. Turn the sleeve so that the locking screws are roughly level on the left and right sides of the pipe. The sleeve must always be installed perpendicular to the axis of the pipe. When using a spirit level, the pipe slope must be adjustable. Attaching and securing the clampingtools The clamping tools on the left and right sides are identical. However, the clamping tools are aligned differently on the left and right: oneclamping screw points up and the other points down. Attach the two parts of each clamping tool as close together as possible. Tighten the spindles to hold the clamping tools in place. Expanding the sleeve Start on one side. Loosen the locking screws. Tighten the spindle to about half way until the sleeve is pressed against the pipe. When expanding the sleeve, make sure it opens up evenly. The easiest way to do this is to look at the holes on the left and right. Continue on the other side: Loosen the locking screws here too. Tighten the spindle to about half way. 14
Checking the alignment in the pipe Before the sleeve is on the pipe, check the alignment once more and correct it, if necessary. Repositioning the clamping tools Tighten the locking screws. Loosen the spindles. Reposition the two parts of each clamping tool as close together as possible. Fasten them with the clamping screws. Clamping Keep working on both sides of the sleeve alternately: Tapping in Note Loosen the locking screw. Tighten the two clamping screws evenly. Use the holes as a guide. While you are doing this, occasionally tap all the way round the sleeve with the mallet so that the tension is evenly distributed. The spindle is only designed for expanding the sleeve. The sleeve is clamped using the two clamping screws on the left and right of the tool. 15
Reaching the maximum compressionof the seal nubs Keep clamping until the added material (non-compressible rubber jacket + metal thickness) is less than: Measured in liner: 8-9 mm Measured in host pipe: 18-19 mm with no compensating rubber 22-23 mm with 1 compensating rubber 26-27 mm with 2 compensating rubbers You can use the gauge from the accessories as an aid. Set this to the value with or without compensating rubbers and lay it over the sleeve. If the measuring instrument lies against it, the maximum compression has been reached. Eccentric expansion of the sleeve To compens ate for differing liner thic knesses, the sleeve can be expanded eccentrically up to 8 mm by tightening the inner and outer clamping screws by different amounts. Note: If the sleeve is expanded too eccentric ally, the tools can become jammed. Use the holes as a guide. 16
Tightening the locking screws Make sure that the sleeve has reached its final state. Tighten the locking screws using the ratchet. Removing the clampingtools Loosen the clamping screws of the tools. Remove the tools. The Quick-Lock LEM >700 now forms a tight and reliable seal. 17
3.5 Tool maintenance Maintenance The spindles and clamping screws must be treated with high-pressure lubricant (Metaflux lubricating metal) after each use. Conversion of the clampingtools The clamping tool set can be used for both the Quick-Lock BIG an Quick-Lock LEM >700. For this reason, there are side pieces in two widths. Side piece for Quic k-lock BIG (approx. 20 cm wide) Side piece for Quic k-lock LEM >700 (approx. 30 cm wide) Mount the plates on the corresponding side pieces. Screw the clamping screws into the corresponding side piece. 18
4. Appendix 4.1 Pneumatic cutter for liner end sleeves Observe the operating instructions: Safety: Always wear face, ear and mouth protection. Only use the tool for its intended purpose. The tool may only be used by qualified personnel. Pneumatic system requirements: Minimum compressor output 1.1 m³/min. Recommended operating pressure 6.2 bar at the tool (maximum operating pressure at the tool 8 bar) Air hose 13 mm ID, maximum length 20 m. Only use the pneumatic cutter with the oil and oiler supplied, oil quantity: approx. 1 drop/min. Air consumption approx. 1000 1500 l/min. Always observe the operating manual supplied with the equipment. 19
4.2 Maintenance instructions for the pneumatic cutter Clamp the holder for the pneumatic cutter in a vice. Clamp the tool in theholder. Using the wrench provided, unscrew the pneumatic cutterin a clockwise direction Remove the pneumatic motor and the spacer bushing. Take the blades out of the pneumatic motor. Blow out the housing and motor with compressedair. Spray the pneumatic motor with WD 40 anti-corrosion spray or a similar product. Put the blades back in, with the tapered side on the inside. Reassemble the pneumatic cutter and tighten it hand-tight with the wrench. 20
- V4A : da/da - Min/max pipe ID Technical data sheet Liner trim length: RS Liner Liner thickness: S Liner Rubber thickness: S Rubber Sleeve length L Metal thickness V4A: S V4A Liner end sleeve DN 700-1600 Hn1 : Seal height: Hn2 Liner end sleeve Sleeve length Suitable for pipes from / to Pipe ID min. Pipe ID max. Liner thickness 1 max Liner trim length Metal thickness Stainless steel sleeve V4A pipe rolled Max. expanded diameter Rubber thickness Rubber jacket Height of seals mm mm mm mm mm mm mm mm mm mm mm mm x- parts DN: L DN min DN max S Liner RS Liner S V4A da DA S Rubber Hn1 Hn2 700 365 670 730 15 265 3 600 700 3 16 6 2 800 365 770 830 15 265 3 700 800 3 16 6 2 900 365 870 930 15 265 3 800 900 3 16 6 2 1000 365 970 1030 15 265 3 900 1000 3 16 6 2 1100 365 1070 1130 15 265 3 1000 1100 3 16 6 2 1200 365 1170 1230 15 265 3 1100 1200 3 16 6 2 1300 365 1270 1330 15 265 4 1200 1300 3 16 6 2 1400 365 1370 1430 15 265 4 1300 1400 3 16 6 3 1500 365 1470 1530 15 265 4 1400 1500 3 16 6 3 1600 365 1570 1630 15 265 4 1500 1600 3 16 6 3 Version: 01/2017 21