Victaulic 809N User manual

I-809N
I-809NINSTALLATION INSTRUCTIONS
REV_A
Style 809N High-Pressure Coupling for Ring Systems
IMPORTANT INFORMATION
WARNING
• Read and understand all instructions before attempting to install, remove, adjust, or maintain any Victaulic piping products.
• Depressurize and drain the piping system before attempting to install, remove, adjust, or maintain any Victaulic piping products.
• Wear required personal protective equipment during the welding process, and follow all jobsite regulations regarding welding safety.
• Wear safety glasses, hardhat, and foot protection during the coupling installation process.
• DO NOT attempt to install this product on pipe that is grooved (roll or cut) or that contains a weld bevel. Pipe ends shall be square cut.
• DO NOT attempt to install this product with rings supplied by other manufacturers.
Failure to follow these instructions could result in death or serious personal injury and property damage.
The Style 809N High-Pressure Coupling for Ring Systems is designed for installation on pipe that is prepared with rings supplied by Victaulic. Refer to
Victaulic publication 15.03 for allowable pipe materials and joint performance.
PIPE PREPARATION/RING ATTACHMENT
"S" Max.
1a. SQUARE CUT THE PIPE ENDS: The
maximum allowable tolerance from square-
cut pipe ends (“S” dimension shown) is
⁄ inch/1.6 mm. This is measured from
the true square line.
1b. INSPECT PIPE ENDS PRIOR TO
RING ATTACHMENT: The outside
surface of the pipe ends (approximately
2 inches/51 mm back from the ends) shall
be smooth and free from indentations and
projections. All oil, grease, loose paint, dirt,
and cutting particles shall be removed.
2a. INSTALL RING ON PIPE: Spread the ring apart using appropriate
tooling at the ring opening (refer to the ring detail on page 2). Slide the
ring over the pipe end.
2b. POSITION RING: Remove the tooling and position the ring at the
required distance (refer to page 2 for the “B” dimension, which is the
required distance from the edge of the ring to the pipe end).
NOTICE
• Use Victaulic ring clamps to hold the rings at the appropriate
location on the pipe during tack welding.
Ring Clamp for
4-inch/114.3-mm Pipe
Ring Clamp for
6-inch/168.3-mm and
8-inch/219.1-mm Pipe
Ring Clamp for
10-inch/273.0-mm Pipe
2c. CLAMP RING IN POSITION: Hold the ring in position by applying
a ring clamp at three locations around the pipe circumference. DO NOT
cover the butt ends of the ring with a ring clamp.
2d. TACK WELD THE RING: Tack weld the ring to the pipe in enough
locations so that the ring does not shift out of position when the ring
clamps are removed.
2e. REMOVE RING CLAMPS AND COMPLETE WELD PROCEDURE:
Remove ring clamps. Weld around the entire circumference on both
sides of the ring. Refer to page 2 for complete weld requirements.
3a. INSPECT RING: The ring shall not contain any weld splatter or arc
strikes.
3b. INSPECT WELDS: Weld size and geometry shall meet the
requirements on page 2.

I-809N_2
REV_A
I-809N / Style 809N High-Pressure Coupling for Ring Systems / Installation Instructions
RING DETAIL
RING WELD DETAIL
MECHANICAL JOINT DETAIL
Style 809N Coupling
Ring
("Ø A")
SEE NOTE 4
"X" MIN
"B"
"T"
SEE NOTE 6
(”S”)
"E1"
("S")
"E2"
SEE NOTE 9
S(E1)
G
S(E2)
SEE NOTES 3 AND 8
Ring Opening
WELD SIZE TABLE
Nominal Pipe
Size inches/
Actual mm
Dimensions - inches/millimeters
Ring "B"
"S"
Weld Size
"X" Minimum("Ø A") Basic Maximum Minimum "E1" "E2"
4⁄ 1.00 1.03 0.97 ⁄ ⁄ ⁄ 0.91
114 . 3 9.5 25.4 26.2 24.6 4.8 4.8 4.8 23.0
6 ½ 1.22 1. 25 1.19 ¼ ¼ ¼ 1.10
168.3 12 .7 31.0 31.8 30.2 6.4 6.4 6.4 27. 8
8⁄ 1.22 1.25 1.19 ⁄ ⁄ ⁄ 1.10
219.1 15.9 31.0 31.8 30.2 7. 9 7. 9 7. 9 27. 8
10 ¾1.22 1. 25 1.19 ⁄ ⁄ ⁄ 1.10
273.0 19.1 31.0 31. 8 30.2 9.5 9.5 9.5 27. 8
NOTES:
1. Victaulic ring to be supplied unpainted with a rust-inhibiting coating applied. Check rings to verify that all oil, grease, and dirt is
removed prior to welding.
2. Victaulic ring material: ASTM A108 Grade 1018, cold-rolled carbon steel
3. Weld metal: E70XX or greater
4. This area shall be free from indentations, projections, and weld splatter to ensure a leak-tight seal for the gasket. All oil, grease,
and dirt shall be removed.
5. Pipe material: Refer to Victaulic publication 15.03, which can be downloaded at victaulic.com
6. Pipe thickness: Refer to Victaulic publication 15.03, which can be downloaded at victaulic.com
7. Weld procedure by others
8. Take precautions during welding to keep heat buildup low. Excessive heat buildup can result in ring diameter shrinkage after
cooling to ambient temperature.
9. Final weld shall not extend past the edge of the ring. Excess weld material will compromise the joint.

I-809N_3
REV_A
I-809N / Style 809N High-Pressure Coupling for Ring Systems / Installation Instructions
COUPLING INSTALLATION
CAUTION
• A thin coat of Victaulic Lubricant shall
be used on the gasket sealing lips and
exterior to prevent the gasket from
pinching/tearing during installation.
Failure to use a compatible lubricant will
cause gasket damage, resulting in joint
leakage and property damage.
1. CHECK GASKET AND LUBRICATE: Check
the gasket to verify that it is suitable for the
intended service. The color code identifies the
material grade. Refer to Victaulic publication
05.01 for the color code chart, which can be
downloaded at victaulic.com. Apply a thin coat
of Victaulic Lubricant or silicone lubricant to the
gasket sealing lips and exterior.
2. POSITION GASKET: Position the gasket
over one pipe end until the gasket’s center leg
contacts the pipe end.
3. JOIN PIPE ENDS: Align and bring the other
pipe end into position until contact with the
gasket’s center leg occurs.
4. LUBRICATE BOLT THREADS: Lubricate
the bolt threads with a thin coat of Victaulic
Lubricant or silicone lubricant.
WARNING
• Verify that the gasket does not become
rolled or pinched while installing the
housings.
• Verify that the housings’ tongue and
recess features are mated properly
(tongue in recess), as shown below.
Failure to follow these instructions will
cause joint failure, resulting in death
or serious personal injury and property
damage.
Tongue
Recess
Housing
Ribs
Recess
Tongue
Recess
Tongue
5a. INSTALL HOUSINGS: Install the housings
over the gasket and rings with the tongue and
recess features mated properly (tongue in
recess). Verify that the housings’ ribs engage
the rings completely on both pipe ends without
interference from the applied welds. Grind
welds, if necessary, in accordance with the
specifications on page 2.
5b. INSTALL BOLTS/NUTS: Install the bolts.
Thread a nut finger-tight onto each bolt. Verify
that the oval neck of each bolt seats properly in
the bolt hole.
1
3
4
2
6. TIGHTEN NUTS: Tighten all nuts evenly by
alternating sides (follow the sequence shown
above) until the gaps are equal at the bolt pads.
Apply torque to each nut with a torque wrench.
Refer to the “Style 809N Required Assembly
Torques and Helpful Information” table on the
following page for the torque requirement.
NOTE: It is important to tighten all nuts evenly
to prevent gasket pinching.

I-809NINSTALLATION INSTRUCTIONS
Style 809N High-Pressure Coupling for Ring Systems
For complete contact information, visit victaulic.com
I-809N 11252 REV A UPDATED 10/2017 Z000809N00
VICTAULIC IS A REGISTERED TRADEMARK OF VICTAULIC COMPANY AND/OR ITS AFFILIATED ENTITIES IN THE UNITED STATES AND/OR OTHER COUNTRIES.
© 2017 VICTAULIC COMPANY. ALL RIGHTS RESERVED.
GOOD GOOD
7. INSPECT BOLT PADS: Before pressurizing the system, inspect the bolt pads at each joint to verify that proper assembly is achieved. If
the installation requirements in step 6 on the previous page cannot be achieved, the coupling shall be removed so that the welds can be
inspected. Any weld interference shall be corrected to ensure proper coupling assembly.
STYLE 809N REQUIRED ASSEMBLY TORQUES AND HELPFUL INFORMATION
Nominal Size
inches
DN
Required Torque
ft-lbs/N•m
Bolt Size
inches/Metric
Socket Size
inches/mm
4250 ¾1 ¼
DN100 339 M20 30
6450 11 ⁄
DN150 610 M24 36
8500 1 ⁄ 1 ⁄
DN200 678 M27 41
10 750 1 ¼ 2
DN250 1017 M30 46
BAD
Tongue not
engaged
with recess
BAD
One Side
Tightened
Too Far
BAD
Housings
Not Mated
Tongue-to-
Recess