Caldertech Uniprep 1 User manual

Designed and Manufactured in the UK
Uniprep 1 + 2
Rotary Scraping Tools
Operating Instructions
Product Code: 01-02-001, 01-02-002
01-03-001, 01-03-002
Revision: 2

© 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 1 + 2 Rotary Scraping Tools
01
Page
Contents
Contents
01. Introduction 02
02. Safety Instructions 03
03. Operation 04
04. Removal After Completion 06
05. Specifications 07
06. Parts Diagram 08
07. Warranty Information 10
08. Certificate of Conformity 12
09. Service and Repair 13
10. Decommissioning and Disposal 13

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
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.
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 (PE) 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.
These products (Uniprep 1 + 2 Rotary Scraping Tools) have 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 1 + 2 Rotary Scraping Tools
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 1 + 2 Rotary Scraping Tools
04
03. Operation
Operation
03.
2
34
9
5
7
8
10
6
1
Instructions for use
1. Ensure that the pipe end is cut square (No more than 2° out of
square), is free of burrs and the section to be scraped does not have
any deep scores.
2. Mark the pipe outer wall at a point 50% of the length of the coupler
plus 10mm.
3. Release the tool post cartridge by loosening the tool post
adjustment nut (5), position the tool post cartridge (3) to its highest
position and temporarily retighten (5).
4. Lower the underarm (8) by unscrewing the wing nut (11) which will
allow you to push underarm (8) forward against the spring allowing
you to lower the arm (8) down the ladder rack (1).
11

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
05
03. Operation
5. Position the scraper onto the pipe with the tool resting on the axle
wheels and with the undercarriage (7) inside the bore of the pipe.
The end of the pipe should touch the pipe stop (9).
6. Fix the tool in its operating position by pushing & lifting the under
arm (8) back up the ladder (1) until the undercarriage wheels are
touching against the inner wall of the pipe, now screw in wing nut
(11) until the wheels on the undercarriage (7) are firmly in contact
with the pipe wall.
7. Slowly rotate the scraper around the pipe 2 or 3 times to ensure that
it is positioned correctly adjusting the underarm clamping screw (11)
to ensure a secure but at the same time ease of rotation.
8. Pull and twist a quarter turn the quick release thumb nut (4) to
allow the tool post carriage to move freely along the feed screw
(10). Remove the protection cap from the cutter (6) and position the
cutter (6) above the mark previously made on the pipe indicating the
length or scrape required, a further quarter turn of the thumb nut (4)
will engage the feed screw-drive nut with the feed screw (10).
9. Pull & twist a quarter turn the cutter lifting thumb nut (2) to lift
the cutter tip up, this also applies pressure via the tool tip spring.
Release the tool post adjustment nut (5) and slide the tool post (3)
down until the cutter is approximately 1mm from the pipe wall
surface, now retighten the tool post adjustment nut (5) to fix the
tool post in its correct operating position.
10. A further quarter turn of the cutter lifting thumb nut (2) will lower the
cutter on to the pipe wall surface and the correct pressure will be
applied to the tip (6) via the tool tip spring.
11. Rotate the scraping tool around the pipe in a steady clockwise
direction. The cutter will travel towards the pipe end removing a
continuous strip of PE the process may be halted from time to time
to remove surplus peel.

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
06
04. Removal After Completion
Removal After Completion
1. On completion, the scraped section should be inspected for areas of
un-scraped pipe. If necessary, the pipe can be scraped again.
2. To remove the scraper, loosen the tool post locking screw (5) and
raise the tool post clear of the pipe and retighten (5). Loosen the
underarm pressure screw (11) to release the undercarriage wheels
and remove the scraper from the pipe. Refit the protective cover to
the cutter tip when not in use.
Storage
IMPORTANT! When not in use always:
1. Store the tool in the tool box.
2. Ensure the tool tip tension is released.
3. Ensure the tool is clean and dry before storage.
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.

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
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05. Specifications
Specifications
Materials: Mild Steel EN3A, Stainless Steel,
Aluminum, Brass and Tungsten Carbide
Finish: Natural / Zinc passivate to mild steel
Dimensions: Uniprep 1: L390 x W160 x H260mm
Uniprep 2: L420 x W160 x H270mm
Depth of Cut: 0.3mm
Max Scrape Length:
feed per rotation 4.5mm
Min - Max Pipe Size: Uniprep 1: 90 - 400mm All SDR Ratings
Uniprep 2: 125 - 500mm All SDR Ratings
Weight: Uniprep 1: 3.6kg
Uniprep 2: 3.8kg
Product Codes: Uniprep 1: 01-02-001, 01-02-002
Uniprep 2: 01-03-001, 01-03-002
This unit is design and manufactured to meet the requirements of
National Grid Gas Industry Standards GIS/PL2-5 Part 5 Electrofusion
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.
Uniprep 1: 150mm
Uniprep 2: 175mm

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
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Parts Diagram
06.
Part Product Code Description
1 01-02-071 Body Repair kit
2 01-02-072 Handle Repair Kit
3 01-02-073 Underarm Repair Kit
4 01-02-074 Undercarriage Repair kit
5a 01-02-075 Axel Repair Kit 400 Uniprep 1
5b 01-02-078 Axel Repair Kit 500 Uniprep 2
6 01-02-076 Toolpost Carriage Repair Kit
7 01-02-077 Quick Release Button Repair Kit
06. Parts Diagram

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
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Part Product Code Description
8 01-02-058 Cutting Tip and Holder Repair Kit
9 01-02-079 Toolpost Cartridge
10 01-02-080 Axel End Plate (boomerang) Repair Kit
11a Z01-02-108 Feed Screw 400 Uniprep 1
11b Z01-02-202 Feed Screw 500 Uniprep 2
12 01-02-083 Undercarriage Bearing Repair kit
13 01-02-084 Axel Bearing Repair Kit
14 01-02-023 Cutting Tip and Screw
15 Z01-02-011 ‘V’ button
06. Parts Diagram

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
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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;
07.
07. Warranty Information

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
11
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:
07. Warranty Information

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
12
Certificate of Conformity
08.
08. Certificate of Conformity

Operating Instructions Uniprep 1 + 2 Rotary Scraping Tools
13
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.
10. Decommissioning and Disposal
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
Caldervale Technology Ltd
Bretfield Court, Dewsbury,
West Yorkshire WF12 9BG, UK
AUSTRALIA / NZ
Caldertech Australia Pty Ltd
Unit 3/30 Juna Drive,
Malaga WA 6090, Australia
T. [phone]
E. [e-mail]
W. caldertech.com
T. [phone]
E. [e-mail]
W. caldertech.com.au
09.

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