Vetter 9987076900 Operational manual

Art. no. 9987076900 | © Vetter GmbH I 07/19 I Subject to modications and errors.
Industrial Pneumatics.
Translation of the original
operating manual
VETTER 1bar cone pipe stopper
Keep in a safe place for future use

Vetter 1bar cone pipe stopper
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Contents
1. Introduction ......................................................3
2. Safety ............................................................4
2.1 Symbols in this manual .....................................4
2.2 Personal protective equipment..............................5
2.3 Intended use ...............................................6
2.4 Personnel requirements.....................................7
2.5 General information ........................................7
2.6 Residual risk ................................................7
3. Operating the cone pipe stopper ................................11
3.1 Preparing to insert the cone pipe stopper .................11
3.2 Inserting the cone pipe stopper into a pipe ................ 13
3.3 Shoring ..................................................14
3.4 Shutting o the pipeline ..................................14
3.5 Draining the pipeline .....................................15
3.6 Water and compressed air check .......................... 15
4. Care, maintenance intervals and storage......................... 16
4.1 Care ......................................................16
4.2 Maintenance intervals .................................... 17
4.3 Storage................................................... 18
5. Technical data:..................................................19
6. List of materials and compatibilities .............................19
6.1 Material list ...............................................19
6.2 Temperature resistance ...................................19
6.3 Compatibilities list ........................................19

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1. Introduction
In order to operate the cone pipe stopper safely and without
malfunctions, it is essential to be familiar with and to follow this
operating manual and the safety information contained therein.
In addition, the applicable occupational health and safety regula-
tions and accident prevention regulations must be complied with,
together with the generally recognised rules of technology.
This operating manual is a component of the product and must
be retained throughout the product’s service life. If the product
is transferred or sold to another party, the user manual must also
be transferred to the subsequent user. Knowledge of and compli-
ance with the user manual is a prerequisite for using cone pipe
stoppers.
You can nd the latest version of this operating manual on our
website, “www.vetter.de” under “Support”.

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2. Safety
2.1 Symbols in this manual
Read the operating manual!
The following symbols are used in the text to indicate safety information
and warnings:
DANGER!
This combination of symbol and signal word indicates an imminently
dangerous situation that will result in death or serious injury unless
avoided.
WARNING!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in death or serious injury unless
avoided.
CAUTION!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in minor or light injury unless
avoided.
NOTE!
This combination of symbol and signal word indicates a potentially
dangerous situation that could result in property damage unless
avoided.
This symbol highlights useful tips and recommendations, as
well as information on ecient and trouble-free operation.

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2.2 Personal protective equipment
Safety gloves
Safety gloves protect the wearer’s hands against friction, abrasion,
puncture wounds or deeper injuries.
Safety shoes
Safety shoes protect the wearer’s feet against crushing, falling
objects and slipping on slippery surfaces.
Face, head and ear protection
Face protection protects the wearer’s eyes and face against ames,
sparks or embers, as well as hot particles and waste gases. Head
protection protects the wearer’s head against falling objects, sus-
pended loads and impact with stationary objects. Ear protection
protects the wearer against hearing damage caused by noise.
Protective clothing
Protective clothing is close-tting work clothing with a low tear
strength, with tight-tting sleeves and with no protruding parts.

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2.3 Intended use
Cone pipe stoppers may only be lled with compressed air, and only
using original lling devices. Filling using lling devices procured from
third parties shall be considered contrary to the intended use.
Cone pipe stoppers are used exclusively to shut o pipes that are intend-
ed for that purpose, to test for leaks in pipelines, and to create a bypass.
The intended use also includes the following:
9Observing all the information in this user manual
9Compliance with the maintenance and care intervals specied in the
section “Care, maintenance intervals and storage”
Any use other than that described here shall be considered contrary
to the intended use. Usage of the cone pipe stoppers contrary to the
intended use includes the following:
9Improper operation, handling or maintenance of the cone pipe
stoppers
9Operating the cone pipe stoppers with faulty safety equipment or
improperly attached or non-functioning lling devices
9Failure to observe the information in the user manual regarding stor-
age, operation and maintenance of the cone pipe stoppers
9Inadequate monitoring of accessory parts that are subject to wear
9Improperly performed maintenance work
9Filling the cone pipe stopper system with ammable, hazardous or
aggressive gases and uids
9Operation outside the permissible temperature range or in a tropical
environment
9Operating the system in a potentially explosive atmosphere
9Operating the system in a corrosive or contaminated environment
9Operating the system in the vicinity of strong magnetic elds
9Use by private users or users without technical instruction and training
The entire cone pipe stopper may only be used in a temperature range
from -20°C cold-resistant to +55°C heat-resistant.

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2.4 Personnel requirements
This section describes the qualications required for persons performing
the various tasks:
An instructed person is a person who has veriably been instructed
by the owner about the tasks to which said person has been entrusted,
and who has been informed of the possible dangers associated with
improper behaviour. This instruction was provided by a person trained
and qualied in the relevant discipline.
An expert is a person who, thanks to his or her technical training and
experience, possesses sucient knowledge in the eld of pipe shut-o
devices and is familiar with the applicable national occupational health
and safety regulations, accident prevention regulations and generally
recognised rules of technology (e.g. trade association rules, DIN and
EN standards, technical rules of other EU member states or other states
which are party to the Agreement on the European Economic Area) to
the extent that he or she is able to assess the condition and reliability of
pipe shut-o devices. (Source: BGI 802)
2.5 General information
Compliance with all the applicable occupational health and safety rules,
accident prevention regulations (e.g. safety rules of the civil engineering
trade associations) and the generally recognised rules of technology is
assumed.
2.6 Residual risk
Even when all the safety regulations are complied with, residual risks
remain when operating the cone pipe stopper, as described below.
Asthe owner/operator, make sure that all persons who work on and with
the inatable pipe stopper system are aware of the residual risks. Follow
the instructions that prevent residual risks from causing accidents or
damage.
During operation of the cone pipe stopper, there are various residual
risks and potential hazards that every operator should be aware of:
During operation of the inatable pipe stopper system, risks to
the operator may occur or the pipe stopper system and other
material assets may become damaged in the following cases:
- Operation and handling of the cone pipe stopper by personnel who
are not trained and experienced
- Use contrary to the intended use
- Improper maintenance
No modications or conversions to pipe stoppers, lling devices and
lling hoses are permitted. The cone pipe stopper may only be operated
with genuine Vetter lling devices and lling hoses. If third-party parts
are used, safety may be impaired.

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During a water pressure check, the pipeline to be checked must not be
directly connected to a pressurised line (e.g. hydrant).
Before and after each use, check that the cone pipe stopper and acces-
sories are in perfect working order. During the visual inspection, look out
for the following possible damage:
9Separation
9Cuts
9Punctures
9Eects of heat/acid
9The nipples and couplings must be clean, undamaged and fully
functioning.
Outside pipelines, 1bar cone pipe stoppers may only be lled to a max-
imum of 0.2bar for the visual inspection.
All the control devices are tted with a safety relief valve corresponding
to the maximum permissible operating pressure for the pipe stopper or
test pipe stopper. If the maximum operating pressure of 1bar is exceed-
ed, the safety relief valve vents. The tolerance for opening and closing
the safety relief valves must not exceed ± 10%. The set pressure must
not be altered.
If the lead seal on the valve bonnet has been removed, safe functioning
is no longer guaranteed and the safety relief valve must be replaced. The
permissible inlet pressure to the control devices (labelled on the inlet
coupling) must not be exceeded.
Ejection of the cone pipe stopper
DANGER!
Risk of death due to ejection of cone pipe stopper!
A cone pipe stopper that is ejected from the pipe can cause life-threat-
ening injuries.
– Keep away from the vicinity of the pipe’s opening.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.

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Flooding of the working area
DANGER!
Risk of death due to remaining in the working area in the
event of ooding!
A leak in the cone pipe stopper when there is water trapped in the
pipe can result in death by drowning due to ooding of the pipe.
– After lling and shoring the cone pipe stopper, do not remain in the
danger zone.
– Make sure that there are no persons present in the shaft or pipe
during the lling, testing and draining procedures.
– Before removing the shoring, check that the pipe is depressurised
and completely drained.
Release of gases from shut-o lines
DANGER!
Risk of death due to escaping gases from shut-o lines!
Escaping gases from shut-o lines can lead to life-threatening poison-
ing or asphyxiation.
– Before working in the working area, take precautionary measures
against the release of gases.
Waste gases and lack of oxygen in the pipe
DANGER!
Risk of death due to waste gases and lack of oxygen in the
pipe!
Waste gases and a lack of oxygen can lead to life-threatening poison-
ing or asphyxiation.
– Check the oxygen concentration before and during work in the pipe.
– Wear safety gloves, safety shoes, face, head and ear protection, pro-
tective clothing and respiratory protection.

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Bursting of the cone pipe stopper
WARNING!
Health risk due to bursting of the cone pipe stopper!
The cone pipe stopper may burst while in use. Bursting of the cone
pipe stopper may result in loss of hearing and pressure trauma.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Carry out maintenance and an inspection after any damage to the
cone pipe stopper.
– Immediately put a defective cone pipe stopper out of operation.
– Before inserting the cone pipe stopper, clean the pipe and remove
any sharp and rough materials.
Gases and dusts
WARNING!
Risk of poisoning from gases and dusts!
Inhaling toxic gases and dusts can result in severe or fatal damage to
health.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Make sure that the opening of the pipe is unobstructed.
– Ensure sucient air circulation.
Viruses and bacteria
WARNING!
Risk of infection from viruses and bacteria!
Inhalation of or contact with viruses and bacteria can result in severe
or fatal damage to health.
– Wear safety gloves, safety shoes, face, head and ear protection and
protective clothing.
– Maintain and clean the cone pipe stopper at regular intervals.

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3. Operating the cone pipe stopper
3.1 Preparing to insert the cone pipe stopper
This section describes which sources of compressed air you can use to
operate the cone pipe stoppers.
• Personnel: - Instructed person
• Protective equipment: - Safety shoes
- Protective clothing
- Safety gloves
Cone pipe stopper
9Step 1
Connect the 1bar cone pipe stopper to the lling hose.
Filling hose
9Step 2
Connect the lling hose to the control device.
The lling hose, the pipe stopper and the control device must
be at the same pressure stage.
Control device
9Step 3
Connect the connecting hose for the pressure reducer to the inlet
coupling for the control device. Make sure to comply with the per-
missible inlet pressure for the control device.
Air supply hose, 10m with shut-o valve
The air supply hose with shut-o valve can be used as an extension
between the compressed air source and the control device.
The maximum inlet pressure to the control device from the
compressed air supply must not exceed 2bar.

Truck compressed air connection
Dummy coupling
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Adapter ttings of the adapter set
The adapter set contains adapter ttings for the following com-
pressed air sources:
Truck compressed air connection and dummy coupling
Seal the control line with the dummy coupling.
Stationary compressed air system
Connection to the outlet coupling of a compressed air network
Adapter tting for portable compressor
For lling with a portable compressor
The maximum inlet pressure to the control device from the
compressed air supply must not exceed 2bar.
The lling may only be carried out with oil and dust-free com-
pressed air up to a max. temperature of 55 ° C.
The device can also be lled using the enclosed adapt-
er claw/quick-action coupling. The lling has to be done
with a corresponding control unit 1.0 bar.

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3.2 Inserting the cone pipe stopper into a pipe
This section describes how to insert the cone pipe stopper into a pipe.
• Personnel: - Instructed person
• Protective equipment: - Safety gloves
- Safety shoes
- Face, head and ear protection
- Protective clothing
Before the cone pipe stopper is inserted into a pipe, the pipeline must be
checked for damage. The area for the cone pipe stopper in the pipe must
be free of deposits, contamination and foreign matter, such as shards
and sharp objects. Cone pipe stoppers must be ush with the pipeline
along their entire length at the front, and the sealing surface must be in
contact with the inner wall of the pipe.
All cone pipe stoppers must be inserted and shored in pipe-
lines force-t and form-t.
9Make sure that only authorised persons are present in the working
area and danger zone. Risk of death!
9Choose a suitable pipe stopper and/or test pipe stopper according
to requirements.
9Check the stopper and the accessories to be used to ensure that they
are complete and free of damage.
9Damaged stoppers and accessory parts must not be used.
9Never insert a stopper size into a pipe with a larger diameter.
9The lling hose and control device must be connected to the pipe
stopper before insertion.
9Mark out and clean the working area.
9Insert the stopper into the pipe with the front ush along the entire
length.
9Shore the pipe stopper inside the pipe.
9Exit the shaft and/or pipeline.
DANGER!
Risk of death for persons inside the pipe!
Make sure that there are no persons in the danger zone.
9From a secure position, ll the pipe stopper to the maximum permis-
sible operating pressure.
9When used over a longer period, check the pressure at least once an
hour.

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Once work is complete, relieve the pressure via the lling hose or the con-
trol device (pressure relief via the knurled screw on the safety relief valve).
This action must always be performed from outside the pipeline or shaft.
9Once the water has fully drained from the shaft/pipeline, discharge
the compressed air from the stopper.
9Now remove the shoring and take the stopper out of the shaft/pipeline.
3.3 Shoring
The type of shoring required depends on the struc-
tural conditions in the pipe, on the pipe itself and
on the expected backpressure.
3.4 Shutting o the pipeline
DANGER!
Risk of death for persons in shafts and in pressurised pipe-
lines during a pressure check!
• Personnel: - Instructed person
• Protective equipment: - Safety gloves
- Safety shoes
- Face, head and ear protection
- Protective clothing
Cone pipe stoppers can be used for dierent pipe diameters
(see label on the cone pipe stopper).
9Select a cone pipe stopper, lling hose, control device and com-
pressed air source.
9Make sure that there are no branch pipes, service connections or
similar in the section of pipe to be shut o.
9Connect the cone pipe stopper to the lling hose and control device
and insert it into the pipe.
9From a secure position, ll the cone pipe stopper from above to the
maximum permissible operating pressure.
9If a pipeline is to be shut o with a cone pipe stopper, generally
monitor the operating pressure on the control device (e.g. possible
pressure changes due to temperature uctuation). See separate op-
erating manual for the control device.

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Pressure reducer
Tethering rope
Controller
Due to presentation reasons, the support structure is schematically presented and
simplied.
3.5 Draining the pipeline
• Personnel: - Instructed person
• Protective equipment: - Safety gloves
- Safety shoes
- Face, head and ear protection
- Protective clothing
9Before draining the pipeline, make sure that there are no persons in
the shaft or pipe. Risk of death!
9From the control device or using an industrial suction unit and the vacu-
um adapter, drain the secured pipe stopper until the dammed up liquid
can slowly ow past the pipe stopper and shoring.
9Only remove the shoring or the safeguard for the pipe stopper once
the pipeline has been completely drained.
DANGER!
Risk of death due to removal of the shoring in pressurised
pipelines!
3.6 Water and compressed air check
• Personnel: - Instructed person
• Protective equipment: - Safety gloves
- Safety shoes
- Face, head and ear protection
- Protective clothing
9Always observe the specications of standard EN 1610 for leak
checks on gravity pipelines.
9Always take suitable measures to secure pipe stoppers and test pipe
stoppers against ejection and slipping.
Vacuum adapter Cone pipe stopper
Artikel-Nr. 1700078400

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9Fill the pipelines and vent and measure the test pressure using the
test pipe stopper.
9Shut o the pipeline with the pipe stopper.
4. Care, maintenance intervals and storage
This section describes how to maintain the cone pipe stoppers and
which maintenance intervals to observe.
See also:
9BGR 126
9BGR 117
9BGI 802
9BetrSichV (German
Ordinance on In-
dustrial Safety and
Health)
9ArbSchG (German
Occupational Safe-
ty and Health Act)
4.1 Care
After each use, the pipe stopper equipment must be cleaned. Clean with
lukewarm water and a soapy solution.
NOTE!
Property damage due to cleaning the cone pipe stopper with
chemical cleaning agents, hot water and high-pressure cleaners!
Cleaning the device with chemical cleaning agents, hot water, high
pressure or high-pressure hot water devices can damage the cone
pipe stopper.
– Only use lukewarm water and a soapy solution when cleaning the
cone pipe stopper.
Dry at room temperature.

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4.2 Maintenance intervals
Perform functional checks of the cone pipe stopper at full operating pressure in the maximum permissible pipe
diameter in a resistant pipe only. A weak pipe will be burst by the stopper when it is inated to maximum oper-
ating pressure.
When? What? What action? Who?
Before each use Cone pipe stopper,
control devices and lling
hoses
(safety equipment)
Check for completeness
Visual check of the cone pipe stopper lled to max. 0.2bar
and the safety equipment (e.g. for deformation, cracks,
damage to fabric, porous surfaces etc.)
Functional check of the safety equipment
Expert*
If there are any safety concerns after the visual check of
the cone pipe stopper, the stopper should be sent to the
manufacturer for a more thorough functional check.
Manufacturer
After every use Cone pipe stopper,
control devices and lling
hoses
(safety equipment)
Check for completeness
Visual check of the cone pipe stopper lled to max. 0.2bar
and the safety equipment (e.g. for deformation, cracks,
damage to fabric, porous surfaces etc.)
Functional check of the safety equipment
Expert*
If there are any safety concerns after the visual check of
the cone pipe stopper, the stopper should be sent to the
manufacturer for a more thorough functional check.
Manufacturer
At least
once a year
(otherwise, according
to BGI 802, use of the
stoppers is prohibited)
Cone pipe stopper,
control devices and lling
hoses
(safety equipment)
Check for completeness
Visual check of the cone pipe stopper lled to max. 0.2bar
and the safety equipment (e.g. for deformation, cracks,
damage to fabric, porous surfaces etc.)
Functional check of the safety equipment
Expert*
If there are any safety concerns after the visual check of
the cone pipe stopper, the stopper should be sent to the
manufacturer for a more thorough functional check.
Manufacturer
After every repair Cone pipe stopper,
control devices and lling
hoses
(safety equipment)
Check for completeness
Visual check of the cone pipe stopper lled to max. 0.2bar
and the safety equipment (e.g. for deformation, cracks,
damage to fabric, porous surfaces etc.)
Functional check of the safety equipment
In addition, a functional check of the stoppers must be
carried out at operating pressure in the pipe. The stopper
is pressurised with 1 bar in the maximum permissible pipe
diameter. The stopper remains in the pipe for 60 minutes
following a holding time of 5 minutes. Once these 60 minu-
tes have elapsed, the pressure loss must not exceed 10 %.
Expert*
We recommend having the devices checked by the manufacturer every ve years.
Small cracks or cuts in the material (max. 6cm) can be repaired using the Vetter repair material kit (article no.
1420005500), without problems. See separate operating manual.
Document and le the test results.
If any doubts concerning safety arise during the visual and/or functional check, abort the test and send the
stopper together with the equipment to the manufacturer for further testing.

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4.3 Storage
NOTE!
Property damage due to improper handling and storage!
Improper handling and storage of the cone pipe stoppers alter their
physical characteristics. This can result in damage to the cone pipe
stoppers and a reduced service life.
– Handle the cone pipe stoppers with care.
– Comply with all the storage conditions.
If stored and handled correctly, the characteristics
of rubber products will remain almost unchanged
for a long time.
Note the following storage conditions:
Where possible, store the cone pipe stopper suspended from the towing
eyes (not the couplings).
The storage area must be cool, dry, free of dust and moderately venti-
lated.
The temperature in the storage area must be around 15°C and it must
never exceed 25°C. The temperature must also not fall below -10°C.
If there are radiators and pipelines in the storage area, these must be
insulated accordingly to ensure that the temperature does not exceed
25°C. The minimum distance between radiators and the stored goods
must be 1m.
Rubber products must not be stored in damp storage areas. The humid-
ity must be below 65%.
Protect rubber products against light (direct sunlight, articial light
with a high UV proportion). Windows in the storage area must be
darkened accordingly.
Make sure that there is no ozone-causing equipment in the storage area.
The storage area must be free of solvents, fuels, lubricants, chemicals,
acids etc.
Rubber products must be stored without pressure, tension or similar
deformation as this can cause lasting deformation or the formation of
cracks.
Some metals, e.g. copper and manganese, are also harmful to rubber
products.

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5. Technical data:
1bar cone pipe
stopper Pipe diameter
mm / inch
Length
mm / inch
Nominal content
Litre / cu. ft.
Air requirement
Litre / cu. ft.
Weight, approx.
kg / lbs
250/600 cone pipe
stopper
1420005600
250-600
9.8-23.6
1050
41.3
180
6.4
433.5
15.3
5
11
400/1000 cone
pipe stopper
1420005700
400-1000
15.7-39.4
1900
74.8
860
30.4
2071.2
73.1
13
28.7
600/1600 cone
pipe stopper
1420005000
600 -1600
23.6-63
3180
125.2
3500
123.6
8429.5
297.7
31.8
70.1
Max. operating pressure: 1bar
Max. backpressure: 0.5bar
Safety factor: 2:1
Subject to technical modications as a result of product improvements.
6. List of materials and compatibilities
6.1 Material list
Product Material Carrier material Production
1bar cone pipe stopper CR Polyester Cold vulcanised
Filling hoses and air supply hoses EPDM Polyester -
6.2 Temperature resistance
Product Cold-resistant Cold-exible Heat-resistant
1bar cone pipe stopper -40°C -20°C +55°C
Rubber hoses -40°C -30°C +90°C
Control devices:
Fitting design -20°C -- +55°C
6.3 Compatibilities list
The following compatibilities list shows which of the materials (CR, EPDM) in the 1bar cone pipe stopper, the
lling hoses and the air supply hoses are resistant to, partially resistant to and not resistant to various chemicals.
Contact between the materials of the products and these chemicals could damage the products.
Note!
Property damage due to contact between materials and various chemicals!
Improper use of the 1bar cone pipe stopper, the lling hoses or the air supply hoses could result in damage.
– Avoid contact between the listed chemicals and the 1bar cone pipe stopper, the lling hoses and the air
supply hoses.

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Material
Chemical CR EPDM
Acetone o -
Acetylene + -
Alum, aqueous + -
Aluminium chloride + +
Aniline - n.s.
ASTM No. 1 oil o -
Benzine o n.s.
Benzene - -
Boric acid + +
Bromine (moist) - -
Butyric acid - n.s.
Chlorine gas (moist) - n.s.
Chlorine (wet) o o
Diesel fuel o -
Iron chloride + +
Petroleum o -
Acetic acid o o
Fatty acids + -
Formaldehyde + +
Glucose + +
Heating oil + -
Potassium chloride + +
Calcium chloride + +
Calcium nitrate + +
Carbon dioxide + +
Carbon monoxide + +
Copper sulphate + +
Glue + +
Methyl chloride - o
Seawater + n.s.
Mineral oils + -
Sodium carbonate + -
Ozone + +
Paran + -
Perchloric acid o +
Phenol (aqueous) - +
Phosphoric acid (concentrated) - -
Mercury + +
Nitric acid (fuming) - -
Sulphur oxide (dry) - n.s.
Sulphuric acid (50%) + -
Nitrogen + +
Carbon tetrachloride - -
Animal fats + +
Toluene - -
+ resistant o partially resistant - not resistant
n.s. not specied