Victaulic 809N Bedienungsanleitung

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)

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.

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.

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

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

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