Conversion System USER GUIDE: OVERVIEW The Swivelpole Conversion Tool clamps onto the existing non-lowering pole and safely supports the pole during a cold cut with the Ratchet Pipe Cutter, eliminating the need for Hot Work Permits. USER GUIDE The safety pin is then removed from the mid-hinge. This allows lowering of the pole top without the need to disturb the integrity of the existing wiring system. PCT-RPC-01 (c/w 1 x Fitted Blade & 1 x Spare Blade) The Safe Swivel Joint then simply slips onto the existing pole base. The new or existing pole top, along with the fixture is inserted back into the Safe Swivel Joint, and the Swivelpole conversion is complete. All work takes place at platform level, eliminating the risks of working at heights. PCT-01 PCT-MG-01 PCT-SKWR OIL* Conversion Tool Kit (PCTK- 01) Tools recommended for converting poles on Brownfield sites. Product and Ordering Information All Kits include 1 x Conversion Tool PCT-01 PCT Clamps suit pole sizes: NPS DN OD 11/4 32 42.2 11/2 40 48.3 2 50 60.3 PCTK Product Code Page 1 (c/w 1 PCT-RGB-01 PCT-RPC-01-SB 1 x Marking Gauge PCT-MG-01 1 x Ratchet Pipe Cutter PCT-RPC-01 3 x Spare Blades PCT-RPC-01-SB 1 x Socket Wrench PCT-SKWR 1 x Riggers Bag PCT-RGB-01 Note: Tools are available for conversion of PVC coated poles. PCT-01 Conversion Tool is structurally Certified (Reference Number: T-16-102) for use with a maximum luminaire weight of 44lb (10 pole). *Multipurpose oil supplied as a consumable in Kit only, not to be supplied separately. Product Warranty: All equipment and goods are warranted by the seller to be free from defects in material and workmanship for five (5) years from the date of shipment. This warranty does not apply to equipment or goods which are misused, or abused, or damaged from installation, or not used in accordance with seller s instructions. Normal wear of equipment or goods is not included in this warranty. No responsibility will be taken for any modifications, alterations or additions to the standard product design. This includes exceeding recommended maximum weights for any fittings or exceeding the installed height.
Conversion System USER GUIDE: NOTES The Swivelpole Conversion System incorporates the use of: Conversion Tool Kit Safe Swivel Joint Copyright and Patent Pending Swivelpole Group Pty Ltd 2016. General Notes: POLE CONVERSION SYSTEM Certification: The Conversion Tool (PCT-01) is structurally Certified for use with a maximum fixture weight of 44lb (10 pole). R PCTK Lanyards are provided for your safety. Isolation of Power: Onsite safe working procedures should be followed to locate and isolate power circuits at the switchboard. Drawings: Copies of Assembly Drawings are available online at swivelpole.com. R1 Conversion (Re-using existing pole) R2 Conversion (Renewing pole top) Marking Gauge Conversion Tool Copyright and Patent: The Swivelpole Product range is protected by patents and registered designs worldwide. Socket Wrench Ordering Information: Please email sales@swivelpole.com Ratchet Pipe Cutter R- SERIES CONVERSIONS POLE CONVERSION TOOL KIT 1.0 Conversion Tool Notes: 1.1 The Conversion Tool Kit (PCTK) includes a Conversion Tool, Marking Gauge, Socket Wrench, Ratchet Pipe Cutter, two spare Ratchet Cutter Blades, Oil, Riggers Bag and Instructions. 1.2 The Conversion Tool (PCT) has been designed with a 4 offset mid hinge. This is to allow flexibility around mounting brackets. 1.3 The PCT can be attached either inside or outside of the guardrail. If the PCT will not align correctly on the RIGHT (due to the mounting brackets), rotate the PCT 180-degrees and attach it to the LEFT of the stanchion. 1.4 The PCT identification labels must always face the operator. The Marking Gauge must be used on the same side as the PCT will be used. 1.5 For an R1 conversion, use the R1 indicators on the Marking Gauge. 1.6 For an R2 conversion, use the R2 indicators on the Marking Gauge. Page 2
Conversion System USER GUIDE: R1 and R2 Conversions 2.0 Attaching the PCT and Cutting the 2.1 Decide which direction you will need the PCT to face see note 1.3. 2.2 Place the Marking Gauge on top of the guard rail, against the fixed pole. 2.3 Use the Marking Gauge indicators to mark the pole depending on whether completing an R1 or R2 conversion. Note: The R1 conversion requires three marks, one for the PCT Clamp Location and two for cutting the pole. Whereas an R2 conversion will require only two marks, one for the PCT Clamp Location and one for cutting. 2.4 Attach the PCT safety lanyard to the guardrail. Align the top edge of the upper PCT Clamp with the top mark on the pole and hand tighten the Clamp Bolts. 2.5 Use the Socket Wrench to tighten clamp bolts firmly. 2.6 Align the Ratchet Pipe Cutter to the top mark, place a drop of Oil on the blade and cut the pole according to the Ratchet Pipe Cutter Instructions. Note: Cut only the top mark at this stage of the conversion. Be sure to hold Ratchet Pipe Cutter horizontally, and avoid any downward pressure when cutting. 2.7 While holding the Top, remove the the Safety Pin from the PCT s Mid Hinge. Gently lower the Top while ensuring there is no tension on the cable. 2.8 Cut through the Plastic Inserts and fit them into the cut ends of the pole sections. 2.9 Disconnect the cable at the Fixture. Loosen the top PCT Clamp and remove the Top. Loosen the bottom PCT Clamp and remove the PCT. Note: The second cut for the R1 conversion, ensures that the pole s original installed height is maintained and enables the existing cable length to be re-used. Top R1 Clamp R1 Cut #1 Marking Gauge Rachet Pipe Cutter PCT Clamp 2.10 Align the Ratchet Pipe Cutter to the bottom cut mark on the pole. Cut according to the Ratchet Pipe Cutter Instructions. 2.11 Remove and discard the offcut BUT keep the Plastic Inserts and fit to the newly cut pole end. Clamp Bolts R1 Cut #2 Base Section Fixture Conversion Tool Safety Pin Plastic Inserts Page 3
Conversion System USER GUIDE: R1 and R2 Conversions 3.0 Installation of the (Safe Swivel Joint) 3.1 Remove the tape from around bottom Locking Collar of the Safe Swivel Joint. 3.2 While routing the cable through, place the Safe Swivel Joint onto the Base Section. 3.3 Loosen but do not remove the Joint Bolts. Remove the Safety Pin and swivel the Joint 90-degrees downwards and re-insert the Safety Pin. 3.4 Orientate the Safe Swivel Joint correctly (see Orientation Guide overleaf). Tighten the bottom Grub Screws firmly. (Recommended torque setting 22lb/ft to 25lb/ft). 3.5 Fit Plastic Inserts into the end of the Top Section and feed the cable through it. While holding the Top horizontally, slide it through the R1 Seal into the Safe Swivel Joint. 3.6 Slide the R1 Seal onto Top to reveal the Grub Screws. These should now be tightened firmly. Attach the Fixture as per the manufacturer s instructions. 3.7 Raise the Top while checking for obstructions. Adjust if necessary. Insert Safety Pin and tighten the Joint Bolts evenly and firmly. (Recommended torque setting 30lb/ft to 60 lb/ft). 3.8 The Fixture can be re-orientated by loosening the top Grub Screws and rotating the Top to the desired direction. Adjust orientation, tighten the Grub Screws and slide the R1 Seal back over the Locking Collar. (Recommended torque setting 22lb/ft to 25lb/ft). R1 R1 R1 -- - NEC Top Locking Collar Safe Swivel Joint Joint Bolts Safety Pin R1 Seal Grub Screws Plastic Insert Fixture Base Section Page 4
Safe Swivel Joint: Orientation & Motion Path Safe Swivel Joint Orientation and Motion Path IMPORTANT: Safe Swivel Joint allows clockwise or counter-clockwise orientation at any degree from the guardrail, with lowering operation to either side to clear any obstruction. Stanchion mounted 0 orientation Stanchion mounted 45 counter-clockwise Structure mounted 90 counter-clockwise Column mounted 90 clockwise orientation 0 Safe Swivel Joint orientation Orientation clearing obstruction behind the guardrail and to the right side. 0 30 Safe Swivel Joint orientation Clockwise orientation clearing obstruction to the left side. 30 Clockwise 75 Safe Swivel Joint orientation Clockwise orientation clearing obstruction behind the guardrail and to either side. 75 Clockwise 90 Safe Swivel Joint orientation Counter-clockwise orientation clearing obstruction behind the guardrail and to the right side. 90 Counter-clockwise Page 5
Ratchet Pipe Cutter (PCT-RPC- 01) For safe and efficient conversion of non-lowering light poles. OPERATING INSTRUCTIONS The Ratchet Cutter is designed to allow easy cutting in tight spaces. Cutting is possible with just an 8 swing of the handle. As the handle grip is moved forward and backward the rotary head turns and automatically feeds the cutting blade until pipe is cut. Important Notes: Ensure you have read and understood the step by step directions on using the Conversion Tools. CAUTION: Ensure safety lanyard is connected to guardrail and PCT clamps are tight. For technical enquiries, email info@swivelpole.com. Moving angle 8 How to use Ratchet Pipe Cutter 1. Before use, ensure any PVC coating is removed before cutting. 2. Turn the rotary head to fit the main body and the opening section of rotary head. Cog Rotary Head 2. 62 135 Radius gyration 90 How to change Cutter 335 3. If cutter interferes with inserting pipe in the opening, turn the Cog and move the cutter until pipe can be inserted. 4. Fit the pipe on the roller, turn the Cog until it gets a little tight, and pinch the pipe with the cutter. Do not over tighten. 5. If you move the grip forward and backward, rotary head turns and with automatic cutter feeding mechanism, pipe is cut. CAUTION Clockwise Cutter To avoid blade failure: Ensure that the tool is cutting straight. Apply cutting oil to blade prior to each cut. Do not exceed 90 movement of handle grip in each backward and forward stroke. Counterclockwise Roller 3. 4. 5. 1. Turn Cog until attachment Cog can be seen. 2. Remove clip ring. 3. Remove attachment pin. 4. Remove cutter. 5. Replace cutter and follow reverse order for securing pin and clip ring. Be sure to apply grease (molybdenum grease) to attachment pin when cutter is changed. Important Notes: Max. diameter cut: 2.6 Max. wall thickness: Carbon Steel - 0.15 Stainless Steel - 0.06 Ratchet Pipe Cutter is supplied with three spare blades. If used in accordance with instructions and cutting lubricant, blades can last in excess of 50 cuts. 1. Attachment pin 2. 3. 4. Clip ring Page 6