Caldertech Uniprep 7 User manual

Designed and Manufactured in the UK
Uniprep 7
Rotary Scraping Tool
Operating Instructions
Product Code: 01-06-201
Revision: 2

Operating Instructions Uniprep 7 Rotary Scraping Tool
01
Page
Contents
Contents
01. Introduction 02
02. Safety Instructions 03
03. Operation 04
04. Removal After Completion 07
05. Specifications 08
06. Cutter Arm Parts Diagram 09
07. Mandrel Parts Diagram 10
08. Warranty Information 11
09. Certificate of Conformity 13
10. Service and Repair 14
11. Decommissioning and Disposal 14
© Copyright Caldervale Technology Ltd.
The copyright for this product and instruction manual is held by Caldervale Technology Ltd.
Any technical specifications, or illustrations part of this manual cannot be reproduced, used
illicitly or distributed in any form for competitive purposes.
Helping you
make the right
connections.

Operating Instructions Uniprep 7 Rotary Scraping Tool
02
01. Introduction
Introduction
General Description
The pipe preparation tool is designed to provide a fusible surface
on any polyethylene pipe material (new, weathered or previously
installed) in accordance with Gas Industry Standards GIS/PL2-5 Part 5
Electrofusion Ancillary Tools.
A small layer is removed from the pipe with each pass of this tool, this
provides a suitable, fusible surface from which pipe welding can occur
more easily.
The unit has rotating pre-set spring tension load indicator that
is used to apply the correct load to the cutting tip around the
whole pipe.
Important!
This tool should be used in accordance with the pipe manufacturers’
recommendations and in line with local codes of practice.
This manual outlines the operation of the pipe surface preparation
tooling for the scraping of polyethylene pipe and forms a part of the
product to which it relates. It should be kept for the life of the product.
Any amendments issued by Caldervale Technology Ltd should
be incorporated in the text. The manual should be passed to any
subsequent holder or user of this product.
Before Using
It is important to ensure all component parts are present and in
serviceable condition. In addition, the condition of the cutting / peeling
tip should be checked for damage or excessive wearing.
01.
This product (Caldertech Uniprep 7) has been manufactured,
inspected and tested in accordance with the ISO9001 quality control
systems and procedures in place at Caldervale Technology Ltd,
Dewsbury.

Operating Instructions Uniprep 7 Rotary Scraping Tool
03
02. Safety Instructions
Safety Instructions
1. Read and understand the whole instruction booklet before using
the tool.
2. It is imperative that all possible precautions are made to avoid
unexpected pipe movement when the tool is being used.
3. Never use the tool on pipes that are not within the specified
dimensions.
4. The tool tip holder spring tension is factory set and MUST NOT be
tampered with, without adequate training or instruction.
5. Operatives should wear eye protection, gloves, safety headwear and
footwear when using the equipment.
6. A single scrape / pass cannot be guaranteed to provide 100%
preparation, where this is required users are advised to consider
making 2 scrapes around the pipe.
02.

Operating Instructions Uniprep 7 Rotary Scraping Tool
04
Familiarisation with the Tool
The tool is made up of 4 main parts:
1. A spring-loaded scraper arm which holds the blade within a
load indicator.
2. A threaded shaft with crank handle for traversing the scraper;
3. A spanner to expand the body;
4. An expanding body to fix the tool axially in the pipe;
03. Operation
Operation
03.
Feed Screw
Collet
Feed Screw
Drive Knob Expanding
Mandrel Shaft
Foot Pads
Arm Extension
Wing Nuts
Cutting Tip
Cutting Tip Angle
Relief Wingnut
Cutting Arm
T Screw
Cutting Arm
Release Knob
Crank Arm
Crank Arm
T Screw
Feed Screw Hex Spanner

Operating Instructions Uniprep 7 Rotary Scraping Tool
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Pipe Preparation
1. Inspect the end of the pipe to be scraped to ensure it has no
damage or deep scores and that it is externally clean.
2. Check that the pipe is round. Ovality should be reduced where
possible. (Re-round with re-rounding tool if required).
3. Check that the end has been cut reasonably square.
4. Measure the insertion depth of the fitting and add on a minimum of
25mm (35mm recommended) to give a scraping witness. Mark the
distance (from furthest protruding face of pipe end) and cross hatch
that length of pipe with suitable pen such as white china pencil.
Using the Scraping Tool
Firstly, check the expanding body, ensure all parts are present and
nothing is loose or hanging o the tool.
1. Insert expanding body of the tool into pipe making sure the feet are
past the point of any pipe end regression with the Feed Screw collet
outermost.
2. Using supplied hex spanner locate on Feed Screw Collet expand the
body by turning anti-clockwise until very tight, aiming to leave the
Feed Screw Drive knob uppermost. Once tight, remove the spanner.
3. Quarter turn the feed screw drive knob to raise and disengage the
thread driver (if not already in position). Next fully insert the feed
screw and engage the feed screw driver by turning the feed screw
drive knob a quarter turn. Unscrew the crank arm T screw ready to
receive the scraper arm.
4. Raise the crank handle and insert the scraper arm. (Note it is highly
recommended to have the crank handle and scraper arm together
in the same orientation to prevent injury from rotation of the tool)
Lower the scraper arm until the scraper tip is approximately 6-10mm
from the pipe surface and lock in position with the crank arm T
screw.
5. Mark the position of the blade tip on the pipe to identify the point
when the telescopic scraper arm is retracted. This mark is used to
identify when the feed screw is nearing the end of the thread and to
prevent the scraper arm falling out and/or being damaged.
03. Operation

Operating Instructions Uniprep 7 Rotary Scraping Tool
06
6. Loosen the two arm extension wing nuts, extend the scraper arm
until it reaches the witness marking and lock in position.
7. Ensure the angle relief wing nut is tightened and does not allow the
tool tip cartridge to pivot then release the cutting arm release knob
and lower the spring-loaded scraper arm and blade onto the pipe.
8. Use the cutting arm T screw to adjust the spring tension until the
load indicator is set on top of the cutting tip (top of the cap head
screw is flush with the round boss).
9. Slowly turn the crank handle clockwise to rotate the cutter once
round the pipe whilst continually keeping an eye on the load
indicator, adjust the spring tension if required to apply the correct
load at the pipes lowest spot.
10. Double check the Feed screw driver is engaged on the shaft then
begin scraping until the mark made earlier is reached.
11. At the point where the mark is reached release the blade tension
(with the cutting arm T screw), lift and lock the arm (using the
cutting arm release knob).
12. Disengage the feed screw drive knob and slide the feed screw back
in to the start position. Re-engage the feed screw drive knob.
13. Loosen the two wing nuts, retract the arm to line up with the end of
the scrape and lock in position.
14. Release the arm using the cutting arm release knob and adjust the
spring tension until the load indicator is set. Continue to scrape
keeping an eye on the load indicator on the first rotation; adjust
tension as necessary to set it for any pipe lowest spot.
15. If the pipe being scraped has any pipe end regression the Cutting
Tip Angle Relief Wingnut needs to be loosened to allow the cutting
tip to remain in full contact with the pipe and give a good scrape.
Note: keeping an eye on the load indicator at this stage is
essential to a good scrape
16. Continue until the scrape is complete.cutter on to the pipe wall
surface and the correct pressure will be applied to the tip (6) via the
tool tip spring.
03. Operation

Operating Instructions Uniprep 7 Rotary Scraping Tool
07
Removal After Completion
1. Use the Cutting arm T screw to release blade spring tension.
2. Lift and lock scraper arm using cutter arm release knob.
3. Ensure the angle relief wing nut is tightened and does not allow the
tool tip cartridge to pivot.
4. Release the feed screw drive knob and slide out feed screw and
scraper arm and crank handle.
5. Separate scraper arm from crank handle using Crank Arm T Screw.
6. Use spanner clockwise to remove expanding body.
7. Ensure all parts are clean and dry.
8. Put all parts away in transport cases to protect them.
Storage
IMPORTANT! When not in use always:
1. Store the tool in the transport cases, ensure it is clean and dry
before storage.
2. Ensure cutter tip will not get damaged when transporting or storing
as this can severely limit the quality of the scrape.
Routine Maintenance
1. Check for correct movement and operation and lubricate moving
parts at regular intervals before using.
2. It is important to ensure all component parts are present and in
serviceable condition. In addition, the condition of the cutting /
peeling tip should be checked for damage or excessive wearing.
3. The cutter tip can be replaced. Spares are indicated in the parts
diagram.
04.
04. Removal After Completion

Operating Instructions Uniprep 7 Rotary Scraping Tool
08
05. Specifications
Specifications
Materials: Mild Steel EN3A, Stainless Steel, Nylon,
Brass, Aluminum and Tungsten Carbide
Finish: Natural / Zinc passivate to mild steel
Assembled Dimensions: Max: H1300 x W1360 x D1300mm
Min: H760 x W875 x D1275mm
Depth of Cut: ≤0.2mm
Min - Max Pipe Size: 630 - 1200mm All SDR Ratings
Weight: 23.85kg (Excluding packaging and
transport cases)
Product Code: 01-06-201
This unit is design and manufactured to meet the requirements of
National Grid Gas Industry Standards GIS/PL2-5 Part 5 Electrofusion
and Ancillary Tooling.
Caldervale Technology Ltd has a policy of continuous improvement
in product quality and design. Caldervale Technology Ltd therefore
reserves the right to change the specification of its models at any time,
without prior notice.
It is the responsibility of the operator to ensure that the PE pipe
is suitable for pipe preparation if in doubt contact the PE pipe
manufacturer for confirmation.
05.

Operating Instructions Uniprep 7 Rotary Scraping Tool
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06. Cutter Arm Parts Diagram
Part Product Code Description
1 TBC Feed Screw
2 TBC Arm Slider Box
3 TBC Clamping Pad and Screw
4 TBC Handle Plate
5 TBC Handle Shaft
6 TBC Plastic Handle
7 TBC T-Screw
8 TBC Height Adjusting Arm
9 TBC Load Cell
10 TBC Side Supports
11 TBC Cutter Arm Collet
12 TBC Cutter Arm
13 TBC Cutter Tip
14 TBC Wing Screws for Cutter Arm Collet
15 TBC Angle Relief Wing nut
Cutter Arm Parts Diagram
06.
8
1
6 5
7
4
3 2
14 1512
11 13
10
9

Operating Instructions Uniprep 7 Rotary Scraping Tool
10
Mandrel Parts Diagram
07.
Part Product Code Description
1 TBC Mandrel Shaft Inc Spacers
2 TBC Plain Mandrel Collar
3 TBC Threaded Mandrel Collar
4 TBC Straight Leg
5 TBC Slotted Leg
6 TBC Foot Piece
7 TBC Link Kit (Mandrel - legs,
slotted leg - straight leg, leg - foot pad)
8 TBC Feed Screw Drive (Quick Release)
9 TBC Feed Screw Collet
07. Mandrel Parts Diagram
6
5 7
19 2 3
8
4

Operating Instructions Uniprep 7 Rotary Scraping Tool
11
08. Warranty Information
Warranty Information
1. Extent of Warranty
a) Subject to clauses 2 and 3, Caldervale Technology Ltd warrants to
the end-user customer that its products will be free from defects in
materials and workmanship, for six months after the date of purchase
by the end-user customer, subject to providing proof of purchase.
b) If Caldervale Technology Ltd receives, during the warranty period,
notice of a defect in product which is covered by this warranty;
Caldervale Technology Ltd shall either repair or replace the product,
at its option. Any replacement product may be either new or like-
new, provided that it has functionality at least equal to that of the
product being replaced.
c) All warranty work will be carried out by Caldervale Technology
Ltd unless otherwise agreed. On-site warranty and repair or
replacement services are available from authorised Caldervale
Technology Ltd service facilities world-wide.
d) Customers shall prepay shipping charges for products returned
to Caldervale Technology Ltd for warranty service, and Caldervale
Technology Ltd will charge for return of the products back to the
customer.
e) This warranty statement gives the customer specific legal rights.
The customer may also have other rights which vary from country to
country in the world.
2. Pre-conditions for Warranty Application
Caldervale Technology Ltd’s warranty covers only those defects which
arise as a result of normal use of the product, and this warranty shall
only apply in the following circumstances:
a) All the instructions contained in the operating manual have been
complied with; and
b) None of the following apply:
i) Improper or inadequate maintenance;
ii) Physical abuse;
iii) Unauthorised modification, misuse or any use not in accordance
with the operating manual and good industry practice;
08.

Operating Instructions Uniprep 7 Rotary Scraping Tool
12
iv) Operation outside the products specifications;
v) Improper site preparation or maintenance;
vi) Faulty pipes.
3. Limitations of Warranty
a) Caldervale Technology Ltd does not warrant the operation of any
product to be uninterrupted or error free.
b) Caldervale Technology Ltd makes no other warranty of any kind,
whether express or implied, with respect to its products. Caldervale
Technology Ltd specifically disclaims the implied warranties of
satisfactory quality and fitness for a particular purpose.
c) To the extent that this warranty statement is inconsistent with
the law of the locality where the customer uses the product, this
warranty statement shall be deemed modified by the minimum
necessary to be consistent with such local law.
d) To the extent allowed by local law, the remedies provided in this
warranty statement are the customer’s sole and exclusive remedies.
e) This tool has been designed for the range of pipes available at the
time of its design and development. Caldervale Technology Ltd can
accept NO liability for the unit’s ability or otherwise to work with
new or dierent pipes that subsequently appear in the market place.
Please complete this information and keep it safely with your proof
of purchase receipt. You will require it for any warranty claim.
Where purchased:
Date of purchase:
Name of purchaser:
Address of purchaser:
Type of tool:
Serial number:
08. Warranty Information

Operating Instructions Uniprep 7Rotary Scraping Tool
13
Certificate of Conformity
09.
09. Certificate of Conformity

Operating Instructions Uniprep 7 Rotary Scraping Tool
14
09. Certificate of Conformity
This product has no specific calibration period, however periodic
safety inspections should be carried out by the operator as specified in
this manual, if in any doubt please contact the manufacturer for further
information.
Service and Repair
For service and repair please contact:
INTERNATIONAL AUSTRALIA / NZ
Caldervale Technology Ltd Caldertech Australia Pty Ltd
Bretfield Court, Dewsbury, Unit 3/30 Juna Drive,
West Yorkshire WF12 9BG, UK Malaga WA 6090, Australia
T. [phone] T. [phone]
E. [e-mail] E. [e-mail]
W. caldertech.com W. caldertech.com.au
Decommissioning and Disposal
These give the instructions for decommissioning and disposal of the
equipment and confirm how it is to be taken out of service safely, in
respect of the Essential Environmental, Health and Safety Requirements.
• If a Caldertech pipe preparation tool has reached the end of its
useful working life and cannot be refurbished it must be sent to a
licensed recycling facility for treatment. That will ensure the waste
hierarchy requirements are met.
• End of life treatment is the responsibility of the Customer. This can
also be achieved by returning the product back to the manufacturer
if required.
10.
11.

INTERNATIONAL
Caldervale Technology Ltd
Bretfield Court, Dewsbury,
West Yorkshire WF12 9BG, UK
T. [phone]
E. [e-mail]
W. caldertech.com
AUSTRALIA / NZ
Caldertech Australia Pty Ltd
Unit 3/30 Juna Drive,
Malaga WA 6090, Australia
T. [phone]
E. [e-mail]
W. caldertech.com.au