Victaulic AGS TM-RG5200i Manual

TM-RG5200iOPERATING AND MAINTENANCE INSTRUCTIONS MANUAL
RG5200i Pipe Roll Grooving Tool
WARNING
Failure to follow instructions and warnings could result in death or serious personal injury, property damage, and product damage.
• Before operating or servicing any pipe preparation tools, read all instructions in the operating and maintenance manual and all warning
labels on the tool.
• Wear safety glasses, hardhat, foot protection, and hearing protection while working around pipe preparation tools.
• Save the operating and maintenance manual in a place accessible to all operators of the tool.
If you need additional copies of any literature, or if you have questions concerning the safe and proper operation of any pipe preparation tools,
contact Victaulic, P.O. Box 31, Easton, PA 18044-0031, Phone: 1-800-PICK VIC, E-Mail: [email protected]
Original Instructions
OGS
TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
TABLE OF CONTENTS
Hazard Identification ......................................1
Operator Safety Instructions.................................2
Tool Safety Features ......................................2
Introduction .............................................3
Receiving the Tool ........................................3
SECTION I
Tool Nomenclature........................................5
SECTION II
Tool Dimensions and Weights ...............................7
Lifting Requirements ......................................7
Tool Setup ..............................................8
Workspace Requirements ..................................8
Placement of Tracks for the VAP131R Hydraulic,
Adjustable Pipe Stand ...................................9
VAP131R Hydraulic, Adjustable Pipe Stand Placement ...........10
Control Station Placement .................................11
Proximity Scanner Typical Range ............................11
SECTION III
Power Requirements and Hookup ...........................13
SECTION IV
Preparing Pipe for Grooving ................................15
Minimum Pipe Length Requirements .........................15
SECTION V
Checking and Adjusting the Tool Prior to Operation ..............17
Adjusting the Roll Guards..................................17
Pipe Stabilizer Adjustment .................................19
SECTION VI
Fully-Automated Grooving Operation for 4 - 12-inch/
114.3 - 323.9-mm Pipe (OGS Specifications) and
14 - 16-inch/355.6 - 406.4-mm Pipe (AGS Specifications) ......21
Explanation of Readings Within Victaulic Specifications . . . . . . . . . . . 24
Explanation of Readings Not Within Victaulic Specifications ........24
Grooving a Partially-Grooved Pipe End........................25
Semi-Automated Grooving Operation for 18 - 24-inch/
457 - 610-mm Pipe (AGS Specifications)....................26
Groove Diameter Within Specification ......................27
Groove Diameter Within Specification -
Adjustment May be Needed .............................28
Groove Diameter Too Shallow.............................29
Groove Diameter Too Deep (Reject Pipe End Immediately).......31
SECTION VII
Extracting Data Via the USB Connection ......................33
SECTION VIII
Roll Changing ..........................................35
Lower Roll Removal ......................................36
Upper Roll Removal......................................36
Upper Roll Installation ....................................37
Lower Roll Installation ....................................38
SECTION IX
Maintenance ...........................................41
Recommended Lubricants.................................42
SECTION X
Troubleshooting .........................................45
SECTION XI
RG5200i Ratings - Maximum Pipe Size and Wall Thickness Capacity
(OGS and AGS) .......................................49
Roll Part Numbers .......................................49
Links to Groove Specifications and Additional Resources ..........49
EC Declaration of Conformity ...........................50
UK Declaration of Conformity ........................... 51
HAZARD IDENTIFICATION
Definitions for identifying the various hazard levels are provided below.
This safety alert symbol indicates important safety
messages. When you see this symbol, be alert to the
possibility of personal injury. Carefully read and fully
understand the message that follows.
DANGER
• The use of the word “DANGER” identifies an immediate
hazard with a likelihood of death or serious personal injury if
instructions are not followed.
WARNING
• The use of the word “WARNING” identifies the presence of
hazards or unsafe practices that could result in death or serious
personal injury if instructions are not followed.
CAUTION
• The use of the word “CAUTION” identifies possible hazards or
unsafe practices that could result in personal injury and product
or property damage if instructions are not followed.
NOTICE
• The use of the word “NOTICE” identifies special instructions
that are important but not related to hazards.
1
TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
OPERATOR SAFETY INSTRUCTIONS
These instructions must be read and understood by each operator
PRIOR to working with the RG5200i. These instructions describe
safe operation of the tool, including setup and maintenance. Each
operator must become familiar with the tool’s operations, applications,
and limitations. Particular care should be given to reading and
understanding the dangers, warnings, and cautions described
throughout these operating instructions.
Use of these tools requires dexterity and mechanical skills, as well as
sound safety habits. Although these tools are manufactured for safe,
dependable operation, it is impossible to anticipate all combinations
of circumstances that could result in an accident. The following
instructions are recommended for safe operation of these tools. The
operator is cautioned to always practice “safety first” during each
phase of use, including setup and maintenance. It is the responsibility
of the lessee or user of these tools to ensure that all operators read this
manual and fully understand the operation of these tools.
Read this manual before operating or servicing these tools. Become
familiar with the tool’s operations, applications, and limitations. Be
particularly aware of its specific hazards. Store this manual in a clean
area where it is always readily available. Additional copies of this manual
are available upon request through Victaulic.
DANGER
1. Avoid using the tool in dangerous environments. Do not expose
the tool to rain, and do not use the tool in damp or wet locations.
Do not use the tool on sloped or uneven surfaces. Keep the work
area well lit. Allow sufficient space to operate the tool properly.
2. Ground the tool to protect the operator from electric shock. Tool
components are grounded to the frame of the tool. Verify that the
frame is grounded properly.
3. Always turn off the main power supply to the tool before making
any tool adjustments or before performing maintenance on
the tool. Only authorized personnel should attempt to perform
maintenance on the tool.
WARNING
1. Prevent back injury. DO NOT attempt to lift tool components
without the use of mechanical lifting equipment.
2. Wear proper apparel. Do not wear loose clothing, jewelry, or
anything that can become entangled in moving parts.
3. Wear protective items when working with tools. Always wear
safety glasses, hardhat, foot protection, and hearing protection.
4. Do not stare directly into the profile laser (Class 2 Laser
Product) or pipe revolution sensor (Class 1 Laser Product).
Staring directly into the profile laser or pipe revolution sensor can
result in eye damage.
5. Keep hands and tools away from grooving rolls and stabilizer
roller during the grooving operation. Grooving rolls can crush or
cut fingers and hands.
6. Do not reach inside the pipe ends during tool operation. Pipe
edges can be sharp and can snag gloves, hands, and shirt sleeves.
Fingers and hands can be crushed between the pipe and lower
roll.
7. Do not over-reach. Maintain proper footing and balance at all
times. Verify that the red “EMERGENCY STOP” button on the
control station is easily accessible at all times.
CAUTION
1. The RG5200i tool is designed ONLY for roll grooving pipe sizes,
materials, and wall thicknesses listed in Section XI.
2. Inspect the equipment. Before using the tool, check all moveable
parts for any obstructions. Verify that the guards and tool
components are installed and adjusted properly. Verify that roll
sets are in good condition and that a properly-matched roll set is
installed on the tool.
3. Stay alert. Do not operate the tool if you are drowsy from
medication or fatigue. Avoid horseplay around the equipment.
4. Keep visitors away from the immediate work area. All visitors
should be kept away from the proximity scanner zone at all times.
5. Keep work areas clean. Keep the work area around the tool clear
of any obstructions that could limit the movement of the operator.
Clean up any oil or other spills.
6. Secure the work, tool, and accessories. Verify that the tool is
stable. Refer to Section II of this manual.
7. Support the work. Support pipe lengths in accordance with the
requirements listed in Section II of this manual.
8. Do not force the tool. Do not force the tool or accessories to
perform any functions beyond their capabilities. Do not overload
the tool.
9. Maintain tools with care. Keep tools clean at all times to
ensure proper and safe performance. Follow the instructions for
lubricating tool components.
10. Use only Victaulic replacement parts and accessories. Use of any
other parts may result in a voided warranty, improper operation,
and hazardous situations.
11. Do not remove any labels from the tool. Replace any damaged or
worn labels.
Tool Safety Features
The RG5200i Roll Grooving
Tool is equipped with multiple
safety features, including a red
“EMERGENCY STOP” button
on the control station. NOTE:
To activate the emergency
stop, press in the red button.
Activation of the emergency
stop halts the machine process
and prevents machine startup.
If additional roll grooving will not
be performed, the tool will shut
off the hydraulic system after
15 minutes of inactivity.
The RG5200i Roll Grooving
Tool’s support base contains
a proximity scanner that emits
an invisible 9-foot/2.7-meter
light curtain that automatically
detects and shuts down the
tool if anything crosses within
its programmed range (front,
left, and right sides of the tool).
Refer to page 11 for additional
information.
2TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
INTRODUCTION
NOTICE
• Photos/graphics in this manual may be exaggerated for clarity.
• The tool, along with this operating and maintenance instructions
manual, contains trademarks, copyrights, and/or patented
features that are the exclusive property of Victaulic Company.
The RG5200i is designed for roll grooving carbon steel pipe in sizes
4 - 12-inch/114.3 - 323.9 mm to Original Groove System (OGS)
specifications and 14 - 16-inch/355.6 - 406.4-mm to Advanced Groove
System (AGS) specifications in fully-automated mode. In addition, the
RG5200i is capable of roll grooving carbon steel pipe in sizes
18 - 24-inch/457 - 610-mm to AGS specifications in semi-automated
mode. Grooving roll sets are marked with the size and part number,
and they are color coded to identify the pipe material. Always verify that
a properly-matched roll set is installed on the tool. For roll grooving to
other specifications and materials, refer to Section XI. Grooving rolls for
other specifications, sizes, and materials must be purchased separately.
CAUTION
• The RG5200i must be used ONLY for roll grooving pipe
designated in Section XI of this manual.
• Always verify that a properly-matched roll set is installed on the
tool.
Failure to follow these instructions may cause grooves that are not
within Victaulic specifications, resulting in joint failure, personal
injury, and property damage.
RECEIVING THE TOOL
The RG5200i Roll Grooving Tool is mounted on a pallet and enclosed in
a wooden crate, which is designed for use in shipping the tool back to
Victaulic upon completion of the lease.
Upon receipt of the tool, verify that all necessary parts are included. If
any parts are missing, contact Victaulic.
RG5200i Container Contents
Qty. Description
1RG5200i Pipe Roll Grooving Tool with Stabilizer
Assembly and Support Base/Handrails
1Control Station
1VAP131R Hydraulic, Adjustable Pipe Stand with Tracks
1TM-RG5200i Operating and Maintenance Instructions
Manual
1
Roll Set for 8 – 12-inch/219.1 – 323.9-mm Steel Pipe
Mounted on the Tool (Unless Specified Otherwise on
the Order) - Original Groove System Specifications
1Roll Set for 4 – 6-inch/114.3 – 168.3-mm Steel Pipe -
Original Groove System Specifications
1Roll Set for 14 – 24-inch/355.6 – 610-mm Steel Pipe -
AGS Specifications
1Guard Setting Pad (OGS)
1Guard Setting Pad (AGS)
1Electrical Cable (10-foot/3-meter Length)
75 Reflective Target
3
TM-RG5200I REV_C

SECTION I
• Tool Nomenclature
4TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
TOOL NOMENCLATURE
NOTICE
• Drawings and/or pictures in this manual may be exaggerated for clarity.
• The tool, along with this operating and maintenance instructions manual, contains trademarks, copyrights, and/or patented features that are
the exclusive property of Victaulic.
Located on Electrical Enclosure Located on Front of Tool Above Roll Guards
Located on Side of Tool Head
Located on Mounting Bracket that
Houses Prole Laser
Center Reective Target
Between Lines
Located on Front of Support Base
Located on Side of Roll Guard System
Upper Shaft and
Upper Roll
Stabilizer Roller Guard
and Stabilizer Roller
Lower
Roll
Stabilizer
Assembly
Roll Guard
System
Electrical
Enclosure
Emergency
Stop
Main Power
Switch
Hydraulic
Cylinder
Control
Station
Proximity
Scanner
Adjustable Feet
Mounting
Bracket (Houses
Prole Laser)
Actuation
Palm
Switches
Stabilizer
Handwheel
Slide (Houses
Pipe Revolution
Sensor)
DO NOT stare directly into the prole laser or pipe revolution sensor. Staring directly
into the prole laser or pipe revolution sensor can result in eye damage.
Support Base
Handrails
• DO NOT use a forklift to move
or stack the tool support bases.
Failure to follow this instruction
could result in serious personal
injury, property damage, and
product damage.
5890 Rev. A R556460LBL
VAP131R Hydraulic,
Adjustable Pipe Stand
5
TM-RG5200I REV_C

SECTION II
• Tool Dimensions and
Weights
• Lifting Requirements
• Tool Setup
• Workspace Requirements
• Placement of Tracks for the
VAP131R Hydraulic,
Adjustable Pipe Stand
• VAP131R Hydraulic,
Adjustable Pipe Stand
Placement
• Control Station Placement
• Proximity Scanner Typical
Range
6TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
TOOL DIMENSIONS AND WEIGHTS
76 inches
1930 mm
24 inches
610 mm
18 inches
457 mm
29 inches
737 mm
74 inches
1880 mm
37 inches
940 mm
31 inches
787 mm
43 inches
1092 mm
12 inches
305 mm
45 inches
1143 mm
18 inches
457 mm
• An overhead crane must be used to lift/transport
the tool to its intended location.
• An eye bolt is provided in the top-middle section of
the tool, as shown in the drawing below.
• Minimum capacity rating of the overhead crane
shall be 2000 pounds/910 kilograms.
Failure to follow these instructions could result in
death or serious personal injury.
LIFTING REQUIREMENTS
The RG5200i Roll Grooving Tool with suport base, as shown, weighs
approximately 1300 pounds/590 kilograms.
The control station weighs approximately 54 pounds/24 kilograms.
7
TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
TOOL SETUP
WARNING
• DO NOT turn on the main power supply to the tool until
instructed otherwise.
• The tool MUST be leveled and anchored securely to a concrete
floor.
Failure to follow these instructions could result in serious personal
injury and/or property damage, including damage to the tool.
An overhead crane must be used to lift/transport the tool to its intended
location. An eye bolt is provided in the top-middle section of the tool.
Verify that the minimum capacity rating of the overhead crane is
2000 pounds/910 kilograms. Refer to the “Tool Dimensions and
Weights” and “Lifting Requirements” sections on the previous page for
additional information.
1. Remove all components from the packaging, and verify that all
items are included. Refer to the “Receiving the Tool” section.
2. Select a location for the tool, control station, and pipe stand by
taking into consideration the following factors:
•A permanent indoor location with a level concrete floor.
The location must remain at a temperature from
+20º F to +104º F/-6º C to +40º C.
•The required power supply (refer to the “Power
Requirements” section)
•Adequate space to accommodate pipe lengths and clearance
for adjustment and maintenance (refer to graphic below)
3. Level the tool from front-to-back and side-to-side. Anchor the tool
to the concrete floor. NOTE: A non-level tool can severely affect
grooving operation.
Exaggerated for Clarity
Allow Approximately
10 feet/3.0 meters
of Space for the Width
of the Tool and
Control Station
Allow Approximately
16 feet/5.0 meters of Space for
the Depth of the Tool and
Length of the VAP131R Tracks
Allow a Minimum of
3 feet/0.9 meter of Space
Behind the Tool for
Maintenance
Workspace Requirements
8TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
PLACEMENT OF TRACKS FOR THE VAP131R HYDRAULIC, ADJUSTABLE PIPE STAND
CAUTION
• The VAP131R Hydraulic, Adjustable Pipe Stand and tracks must be used to support pipe and are critical to proper tool operation.
• Verify that the VAP131R is positioned properly to minimize pipe-end flare.
• DO NOT install couplings on pipe that exceeds the maximum allowable flare.
• This tool must be used ONLY for roll grooving pipe designated in Section XI of this manual.
Failure to follow these instructions could cause product failure, resulting in personal injury and property damage.
Exaggerated for Clarity
Overhead View
of RG5200i
Stop Bolt
Anchor Location
45.50 inches/1156 mm
14 inches/356 mm
Centerline of
Lower Shaft/Roll 22.75 inches/
578 mm
22.75 inches/
578 mm
45.50 inches/
1156 mm
Stop Bolt
Anchor Location
9
TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
VAP131R HYDRAULIC, ADJUSTABLE PIPE STAND PLACEMENT
1. Place the centerline of the VAP131R approximately 6 inches/152 mm back from the middle of the pipe length. Refer to the drawing shown
below. NOTE: If the tool is set up properly in a level position, but the back end of the pipe is higher than the end being grooved, the pipe may
not track. In addition, excessive flare may occur on the pipe end. Refer to the “Tool Setup” section.
Tool Centerline
(Level)
Centerline of VAP131R should be
placed 6 inches/152 mm back from
the middle of the pipe length
Middle of Pipe Length
Centerline of VAPS131R
+ 6 inches/152 mm
Pipe Centerline
0 to 1°
VAP131R
Right-Side View
of RG5200i
2. Position the VAP131R so that the pipe centerline is square to the lower roll. Refer to the drawing shown below. NOTE: When pipe flare is
excessive, right-to-left tracking must be kept to a minimum.
Pipe Centerline
Square to Lower Roll
Overhead View
of RG5200i
Illustrations are Exaggerated for Clarity
10 TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
CONTROL STATION PLACEMENT
The control station must be located on a level concrete floor or base
and contains adjustable feet to accommodate for variations in the floor’s
surface.
The RG5200i Roll Grooving Tool’s support base contains a proximity
scanner that emits an invisible light curtain, which automatically detects
and shuts down the tool if anything crosses within its programmed
range. The typical range is shown in the graphic below and can be
adjusted by a Victaulic representative, as required, during setup and
commissioning. The control station must be placed outside this range in
order for the tool to operate.
Proximity Scanner Typical Range
Exaggerated for Clarity
Detectable Space
(Can be programmed
to accommodate
specic jobsite
conditions)
Detectable Space
(Can be programmed
to accommodate
specic jobsite
conditions)
11
TM-RG5200I REV_C

SECTION III
• Power Requirements and
Hookup
12 TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
POWER REQUIREMENTS AND HOOKUP
DANGER
• ONLY QUALIFIED ELECTRICIANS SHALL CONNECT INCOMING
POWER TO THE TOOL, IN ACCORDANCE WITH NATIONAL AND
LOCAL ELECTRICAL CODE REQUIREMENTS.
• To reduce the risk of electric shock, check the tool and electrical
source for proper grounding.
• DO NOT alter connections in any way.
Failure to follow these instructions could result in death or serious
personal injury.
The RG5200i is designed and wired to operate on a 220-volt, 3-phase,
50/60-Hz power supply.
Each RG5200i Roll Grooving Tool is provided with a label inside the
main electrical enclosure, which identifies proper wiring for the tool.
Reference must be made to this label to ensure proper tool setup.
The RG5200i Roll Grooving Tool is supplied with a ¾-inch nominal
conduit opening for wiring incoming power. The conduit opening is
located at the back of the tool near the main electrical enclosure.
Incoming electrical connections must be made inside the main
electrical enclosure (10-gauge wire minimum). The incoming, three-
phase power must be connected at the top of the main breaker at the
upper-right side within the main electrical enclosure.
1. Make the ground connection inside the main electrical enclosure
2. Make 3-phase electrical connections to the circuit breaker of the
tool
13
TM-RG5200I REV_C

SECTION IV
• Preparing Pipe for Grooving
• Minimum Pipe Length
Requirements
14 TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
PREPARING PIPE FOR GROOVING
CAUTION
• For maximum grooving roll life, remove foreign material and
loose rust from the interior and exterior surfaces of the pipe
ends. Rust is an abrasive material that will wear the surface of
grooving rolls.
Foreign material may interfere with or damage grooving rolls,
resulting in distorted grooves and grooves that are out of Victaulic
specifications.
For proper tool operation and production of grooves that are within
Victaulic specifications, the following pipe preparation steps must be
followed.
Victaulic recommends square-cut pipe for use with
grooved-end pipe products. Square-cut pipe MUST
be used with Victaulic FlushSeal®and EndSeal®
gaskets. The maximum allowable tolerance from
square-cut pipe ends (“S” dimension shown) is
⁄ inch/1.6 mm for 4 – 24-inch/114.3 – 610-mm
sizes.
"S" Max.
For 12-inch/323.9-mm and smaller pipe sizes, beveled-end pipe may
be used with Victaulic standard and Vic-Flange gaskets, provided that
the wall thickness is standard wall (ANSI B36.10) or less and that the
bevel meets ANSI B16.25 (37½°) or ASTM A-53 (30°).
NOTE: Roll grooving beveled-end pipe may result in unacceptable
pipe flare. Beveled steel pipe in 14 - 24-inch/355.6 - 610-mm sizes is
acceptable with Victaulic Advanced Grooving System (AGS) standard or
FlushSeal gaskets, including AGS Vic-Flanges.
•For 12-inch/323.9-mm and smaller pipe sizes, raised internal and
external weld beads and seams must be ground flush with the
pipe surface 2 inches/50 mm back from the pipe ends.
•For 14 - 24-inch/355.6 - 610-mm pipe sizes, raised internal and
external weld beads and seams must be ground flush with the
pipe surface 4 inches/100 mm back from the pipe ends.
•The inside diameter of the pipe end must be cleaned to remove
coarse scale, dirt, and other foreign material that might interfere
with or damage grooving rolls. The front edge of the pipe end shall
be uniform with no concave/convex surface features that will cause
improper grooving roll tracking and result in difficulties during
coupling assembly.
MINIMUM PIPE LENGTH REQUIREMENTS
RG5200i Roll Grooving Tools are capable of grooving short pipe lengths. Refer to the following table, which identifies the minimum pipe length
requirement per pipe size. NOTE: Grooved pipe nipples, shorter than those listed in the following table, are available from Victaulic.
Pipe lengths, from 20 feet/6 meters up to double-random lengths (approximately 40 feet/12 meters), will require additional lengths for the VAP131R
track system. Refer to Section II, along with the TM-VAP131 Operating and Maintenance Instructions Manual provided with the VAP131R, for
complete setup instructions.
If pipe is required that is shorter than the minimum length listed in the following table, shorten the next-to-last piece so that the last piece is as long
(or longer) than the minimum length specified.
EXAMPLE: A 20-foot, 4-inch/6.2-m length of 10-inch diameter steel pipe is required to finish a section, and only 20-foot/6.1-m lengths are available.
Instead of using a 20-foot/6.1-m length of carbon steel pipe and a 4-inch/102-mm length of carbon steel pipe, follow these steps:
• For 10-inch/273.0-mm diameter carbon steel pipe, the minimum length that should be roll grooved is 10inches/255 mm.
• Roll groove a 19-foot, 6-inch/5.9-m length of pipe and a 10-inch/255-mm length of pipe.
Nominal Pipe
Size inches
Actual Pipe
Outside Diameter
inches/mm
Minimum Pipe
Length
inches/mm
Nominal Pipe
Size inches
Actual Pipe
Outside Diameter
inches/mm
Minimum Pipe
Length
inches/mm
44.500 814 14.000 12
114 . 3 205 355.6 305
4½ 5.000 816 16.000 12
127. 0 205 406.4 305
55.563 818 18.000 18
141.3 205 457 460
66.625 10 20 20.000 18
168.3 255 508 460
88.625 10 22 22.000 18
219.1 255 559 460
10 10.750 10 24 24.000 18
273.0 255 610 460
12 12.750 12
323.9 305
15
TM-RG5200I REV_C

SECTION V
• Checking and Adjusting the
Tool Prior to Operation
• Adjusting the Roll Guards
• Pipe Stabilizer Adjustment
16 TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
CHECKING AND ADJUSTING THE TOOL PRIOR
TO OPERATION
Every Victaulic RG5200i Roll Grooving Tool is checked, adjusted, and
tested at the factory prior to shipment. However, before attempting to
operate the tool, the following checks and adjustments must be made to
ensure proper tool operation:
Verify that the proper roll set is installed and aligned properly on the tool
for the pipe size that will be grooved. Roll sets are marked with the pipe
size, part number, and they are color coded for the pipe material. Refer
to Section XI and the “Roll Changing” section.
• Verify that the roll guards are adjusted.
• Verify that the pipe stabilizer is adjusted.
NOTICE
• Upper and lower rolls are matched components and must not be
intermixed with other roll sets.
• If roll sets are ordered as replacements for the ones that were
shipped with the tool, the value etched on the back of the roll
set must be entered in the “Calibrate Roll” section of the control
station’s maintenance screen. Contact Victaulic for details.
Adjusting the Roll Guards
CAUTION
• The “Adjusting the Roll Guards” section must be completed with
every roll change.
Failure to adjust the roll guards properly could result in personal
injury.
1. Loosen the stabilizer locking handle and the stabilizer-roller-guard
wing nut.
2. Using the stabilizer handwheel, retract the stabilizer roller to clear
the pipe when it is inserted onto the lower roll.
Loosen
3. Insert a length of pipe that is the correct size and schedule over
the lower roll. Verify that the pipe end contacts the lower-roll
backstop flange. The pipe must rest directly on top of the roll and
must not be skewed to one side or the other. Refer to Section II for
complete setup instructions.
4. With the correct pipe size and schedule inserted onto the lower
roll, press the “MAINTENANCE” button on the control station’s
home screen.
5. Press the “MOVE RAM TO PIPE” button. NOTE: The “MOVE
RAM TO PIPE” button allows the user to move the ram from the
park position to the pipe at a reduced force in order to set the
roll guards or adjust the pipe stabilizer. If the red “EMERGENCY
STOP” button was activated, two touches of the “MOVE RAM TO
PIPE” button will be necessary to activate the hydraulic motor and
execute movement of the ram.
17
TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
WARNING
• Always turn off the main power supply to the tool before making
any tool adjustments.
Failure to follow this instruction could result in serious personal
injury.
6. Prior to making tool guard adjustments, press the red
“EMERGENCY STOP” button located on the control station.
7. Loosen the knob on the front of the roll guards to raise the plate to
its highest position. Tighten the knob.
CAUTION
• The roll guards must be spaced properly by using the
appropriate guard setting pad.
• DO NOT attempt to use damaged roll sets. Contact Victaulic for
replacement parts.
• Verify that the lower-roll retaining bolt is tight and that the
upper shaft is locked in position.
Failure to follow these instructions could result in damage to the
tool and roll set.
Two guard setting pads are included with the tool. For 12-inch/
323.9-mm and smaller pipe sizes, use the ¼-inch/6.4-mm thick guard
setting pad. For 14-inch/355.6-mm and larger pipe being grooved
with AGS roll sets, use the ⁄-inch/9.5-mm thick guard setting pad
containing a “FOR AGS ONLY” label.
8. Hold the correct guard setting pad firmly against the pipe and
push it under the roll guards. Loosen the knob on the front of the
roll guards to drop the plate onto the guard setting pad. Tighten
the knob.
9. Loosen the knob on the left side of the roll guards to drop the
side sliding guard onto the guard setting pad. Tighten the knob.
10. Remove the guard setting pad from the pipe. Store the guard
setting pad in a safe location. The roll guard adjustment
procedure is now complete.
18 TM-RG5200I REV_C

TM-RG5200i / RG5200i Pipe Roll Grooving Tool / Operating and Maintenance Instructions Manual
Pipe Stabilizer Adjustment
WARNING
• Always turn off the main power supply to the tool before making
any tool adjustments.
Failure to follow this instruction could result in serious personal
injury.
The pipe stabilizer for the RG5200i is designed to prevent pipe sway
of short and long pipe lengths. When the stabilizer is adjusted for
a selected pipe size and wall thickness, it does not require further
adjustment unless pipe of a different size and wall thickness will be
grooved. Pipe of the same size and wall thickness can be moved in and
out of the tool without retracting the stabilizer.
CAUTION
• DO NOT adjust the stabilizer roller to push the pipe to the left
and off center from the rolls. Increased pipe-end flare and
shortened roll life will result if the pipe is pushed to the left and
off center.
Assembly of couplings on pipe that exceeds the maximum
allowable flare dimension may prevent proper pad-to-pad assembly
of coupling housings and gasket distortion/damage, resulting in
joint failure, personal injury, and property damage.
1. Press the red “EMERGENCY STOP” button located on the control
station. Using the stabilizer handwheel, adjust the stabilizer roller
toward the pipe. Position the roller guard so that the roller opening
faces the pipe directly. Verify that the guard does not rub the pipe.
Stabilizer
Handwheel
NOTE: DO NOT adjust the stabilizer roller too far inward, since it will
skew the pipe to the left and off center, resulting in excessive pipe-end
flare. Refer to the drawing shown below for proper positioning.
INCORRECT
CORRECT
2. Tighten the stabilizer locking handle and the stabilizer-roller-
guard wing nut. The pipe stabilizer adjustment procedure is now
complete.
Tighten
19
TM-RG5200I REV_C