MU-41-15 Drilling Machine ACUDRILL Plus
Contents
1. ACUSTER USER MANUAL DRILLING MACHINE FOR UNDER PRESSURE MAINS MODEL AcuDrill Plus Revision N9 3 November 2010 Publication MU 41 15E NOTES The modifications carried out against the previous revision of this publication are indicated with on the right margin USER MANUAL Plus DRILLING MACHINE CONTENTS Page CHAPTER 1 INTRODUCTION 4 1 1 NEN E 4 1 2 General 5 CE declaration Of 6 1 4 db end e A 7 CHAPTER 2 MACHINE DESCRIPTION sesessee HH 8 2 1 Components of the drilling machine 8 2 2 Machine 10 2 3 Hole saws diameters and characteristics 11 CHAPTER 3 MODE OF ee 12 3 1 Machine application 12 3 2 Drilling under pressure over flanged branch connections 13 3 2 1 Initial 13 3 2 2 Branch connection installation 13 3 2 3 Assembly of the 13 3 2 4 Assembly of drilling machine 14 32 9 Pr2. WARNING It is recommended to avoid excess of feed especially in the pilot drill work phase given that the drill could break specially at low revolutions Figure 18 Edition November 2010 20 MODE OF USE Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE 3 3 7 ACUSTER Once perforated with the drill remember that distance a will be increased by the internal mains pressure for under pressure drilling operation only If due to an excess of compression feed internal pressure the drilling resistance increases turn slightly in the opposite direction to release that increase of drilling resistance WARNING In case of using an electric threading machine as drilling actuator take in mind that an excess of feed results in a high increase of torque which might lead to a potential risk of accident for the operator Depending on the working conditions the under pressure drilling operation could be carried out with the venting valve open to remove chip residues produced during the drilling Ensure that the drilling is complete by making one or two additional turns Close the venting valve in case it was in the open position Disassembly of the machine and accessories Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwise until the end travel mechanism is activated In case of being installed an intermediate valve and the chuckshaft would not be up enoug
3. retention tool UI Edition November 2010 10 MACHINE DESCRIPTION Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE 2 3 ACUSTER HOLE SAW DIAMETERS AND CHARACTERISTICS FOR ACUDRILL amp ACUDRILL PLUS AcuDrill Acudrill Plus AcuDrill Plus AcuDrill Plus 76 76 AcuDrill Plus Bi metal HSS Hole saw made of speed steel type M3 Sizes from 14 to 210 mm cutting depth of 35 mm Long series request information cutting depth of 48 mm Application standard pipelines made of ductile iron steel and asbestos cement Tungsten carbide grit Hole saw made of tungsten carbide dust Sizes from 19 to 152 mm cutting depth of 38 mm Application pipelines made of ductile iron Tungsten carbide Hole saw made from tungsten carbide tooth welded on a solid body of special steel Sizes from 19 to 152 mm cutting depth of 38 mm Application pipelines made of ductile iron and steel For plastic pipes Hole saw made of tungsten carbide tooth welded on a sheet body Sizes from 16 to 210 mm cutting depth of 50 55 mm Application plastic pipelines such as PE PP PVC etc MAX The indicated hole saw diameter is the one recommended based on Available diameters according to the hole saw supplier Maximum diameter depending on the drilling machine adapter used Maximum diameter depending on the saddle T clamp valve full bore connecting accessories etc of the DN used Editio
4. through an electric actuator this fastening mechanism should be replaced by an adapter Edition November 2010 Revision No 3 ACUSTER nmm m za a RN OR JIEN i kr Ja 7777 777777 inn PAPA REREAD yd NN Figure 2 MACHINE DESCRIPTION 7 lia 9 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER 2 2 MACHINE ACCESSORIES The AcubDrill Plus drilling machine also features the following accessories N aSHNEEHENEKO Figure 3 1 Saddle adapter kit on three different sizes 2 212 y 3 la Saddle adapter lb Gasket metal rubber washer for 2 adapter and o ring for 2 and 3 adapters lc Variable pitch hole saws of 46 60 and 76 mm respectively In addition to the hole saws sizes indicated above other optional sizes can be ordered There are special hole saws for drilling PE pipes For additional information refer to clause 2 3 of this Manual 2 80 120 mm hinged pin key 3 Hole saw transmission discs For hole saws from 76 to 105 mm For hole saws from 108 to 152 mm 4 Flange adapters of PN10 PN16 4a DN65 DN80 gt Threaded connection to the 3 dome 4b DN100 DN125 DN150 and DN200 gt Screwed in the machine flange Plug carrier 19 mm squared size Adapter for electric actuator Chuckshaft extension it provides an additional length of 100 mm Shaft
5. ADAPTADOR ROOM RESERVED FOR PROPULSOR PLUG CARRIER ROOM RESERVED FOR FLECTRIC ACTUATOR ADAPTOR NOTA CUANDO SE INCORPORE EL ACOPLAMIENTO BRIDA DN65 80 ROSCARLO A LA CAMPANA 3 SCREW IN THE DN65 80 FLANGE ADAPTOR TO THE 3 DOME WHEN SUPPIED Figure 1 Carrying case with die cut foam Drilling machine Modified universal hole saw arbor 232 mm with pilot drill with coupon retainer 3 dome 3 4 ratchet wrench Ul Edition November 2010 8 MACHINE DESCRIPTION Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE Main parts of the AcuDrill Plus drilling machine 1 Connecting flange with spindle Includes four lossless screws and a front o ring for the 3 dome and flange adapters tightness 2 Venting valve PN16 valve for depressurizing and pressurizing test operations 3 Machine body Includes end travel mechanism and absorbing mechanism to optimize drilling power 4 CE identification plate Marking pursuant to Machinery Safety Directive 5 End travel mechanism Blocks the machine s end travel but allows a manual release through the retractable handle 6 Chuckshaft Features four fastening openings to select the most appropriate length for drilling 7 Absorbing mechanism Assembly which includes the absorbing mechanism 8 Chuckshaft fastening mechanism This allows quick and safe fastening of the chuckshaft to the fastening bush In case of carrying out an automatic drilling
6. Shaft 496 mm Total adding range travel fastening shaft and shaft extension 16 bar for water mains Manual by means of a 3 4 ratchet wrench Optionally by means of an electric Swivel gear threading machine 20 kg including carrying case Carrying case Length 915 mm Width 390 mm Height 165 mm 24 TECHNICAL CHARACTERISTICS DN200 PN10 PN16 Figure 21 Edition November 2010 Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE Weight of optional items 80 120 mm hinged pin key 2 threaded saddle adapter 2 1 2 threaded saddle adapter 3 threaded saddle adapter DN65 DN80 flange adapter DN100 DN125 flange adapter DN150 flange adapter DN200 flange adapter Transmission disc 76 105 mm hole saws Transmission disc 108 152 mm hole Plug carrier 19 mm squared size Adapter for electric actuator Electric actuator threading machine Shaft retaining tool Edition November 2010 Revision No 3 ACUSTER 0 685 Kg 0 990 Kg 0 810 Kg 0 670 Kg 3 920 Kg 7 735 Kg 10 355 Kg 15 330 Kg 0 230 Kg 0 615 Kg 0 220 Kg 0 425 Kg 8 515 Kg with carrying case 1 290 Kg TECHNICAL CHARACTERISTICS 25 wd USER MANUAL AcuD rill PIUS DRILLING MACHINE ACUSTER RESERVED FOR NOTES Edition November 2010 26 TECHNICAL CHARACTERISTICS Revision No 3
7. and in the knurled area until the pilot drill makes contact with the pipe the chuckshaft will have risen depending on the contact force see dimension a of Figure 10 At this point withdraw the tip of drill from the pipe by approximately one turn Now begin drilling the mains by activating the chuckshaft using the ratchet wrench if drilling is manual or through the electrical swivel gear SWIVEL GEAR If an electrical actuation swivel gear threading machine is used the following considerations must be taken into account The adapter components may be supplied Acuster S L The usage and safety recommendation given by the manufacturer must be followed Edition November 2010 Revision No 3 MODE OF USE 15 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER Feed is achieved by making the machine body rotate with the hand placed in the knurled area Do not exceed the feed increasing of dimension a see Figure 10 WARNING It is recommended to avoid excess of feed especially in the pilot drill work phase given that the drill could break specially at low revolutions Once perforated with the drill remember that distance a will be increased by the internal mains pressure If due to an excess of compression feed internal pressure the drilling resistance increases turn slightly in the opposite direction to release that increase of drilling resistance Figure 10 WARNING In case of using a
8. ars If the product proves defective during this period due to the materials or its assembly it will be repaired free of charge including the cost of materials and labour at Acuster S L s Technical Service The Guarantee is not valid in the following cases When the fault in the product is a result of Usual wear and tear due to usage Abuse or incorrect use of the unit Repairs carried out without authority from Acuster S L Accidents natural disasters including lightning water action etc as well as any cause beyond Acuster S L s control In all claims against this guarantee information relating to the model date of purchase Serial number and any other additional information must at all times be stated Edition November 2010 Revision No 3 INTRODUCTION 7 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER CHAPTER 2 MACHINE DESCRIPTION 2 1 COMPONENTS OF THE DRILLING MACHINE The AcubDrill Plus drilling machine assembly is made of the following components eee a EE E EER SSS e SSS E uk Wesel ws e Cmca nd fie 0o o uu mI ii PARA LA LLAVE DE GANCHO NT ROOM RESERVED FOR A PIN SPANNER 3 ESPACIOS RESERVADOS ESPACIO RESERVADO AERE ose PARA EL UTIL DE INSER 4 3 ROOMS RESERVED FOR TAR TAPON ESPACIO RESERVADO THREADED ADAPTERS PARA EL
9. der pressure the maximum allowable pressure is 16 bar for water mains It is specially designed to be used over All kind of DIN flanged branch connections T clamps with flange connection such as the Acuster s ARH branch T clamp or any clamp or fitting with flange connection The available flange adapters for the drilling machine go from DN65 up to DN200 PN10 PN16 This option allows holes of up to 185 mm diameter to be drilled using standard hole saws of high speed steel tungsten carbide etc long series hole saws according to the pipe wall thickness to be drilled or hole saws for plastics PE PVC PP and coupon retainer equipped pilot dill Threaded outlet saddles Also it is used to drill over any saddle or ferrule with threaded outlets of 2 212 and 3 BSP It allows holes from 32 up to 76 mm diameter to be drilled using standard hole saws of high speed steel tungsten carbide etc long series hole saws according to the pipe wall thickness to be drilled or hole saws for plastics PE PVC PP and coupon retainer equipped pilot dill The assembly of the different drilling accessories to the drilling machine is done by means of a flange which is provided with lossless anchoring screws and a venting valve for depressurizing and pressurizing test operations The assembly to the threaded outlet saddles is achieved by a 3 threaded dome on which the three possible thread adapters 2 212 and 3 BSP are fit
10. e chuckshaft the optional shaft extension the spindle threads and machine dome is sufficient Monitor the cutting condition of the drill and hole saws before usage It is recommended they be replaced in case of fault On a regular basis and especially when the equipment is used over a prolonged period we recommend it be sent to the ACUSTER S L After Sales Service Department for a complete inspection generally with time and use the O rings and gaskets need to be changed Edition November 2010 Revision No 3 MAINTENANCE 23 ACUSTER AcuDrill Plus USER MANUAL LLI NG MACHI NE CHAPTER 5 TECHNICAL CHARACTERISTICS Usage Flanged branch connections Threaded outlet saddles Maximum drilling capacity Maximum range Service pressure Operation Total equipment weight Outer dimensions Drilling of mains made of steel gray cast iron ductile casting asbestos cement clay polyester PVC PE PP etc T clamps with flange connection such as the Acuster s ARH branch T clamp or any clamp or fitting with DIN flange connection sizes from DN65 up to both included Any saddle or ferrule with threaded outlets of 2 21 2 and 3 BSP Up to 76mm threaded connections Up to 185 mm connections flanged 141 mm from the machine body 255 mm from the chuckshaft moving the fastening openings 100 mm Optional shaft extension 396 mm Total adding range travel and fastening
11. e drilling operation was under pressure carefully open the venting valve to remove chip residues Next close the valve again Then switch the intermediate valve to the CLOSED position Open again the venting valve to depressurise the drilling machine and to be sure that the intermediate valve is fully closed as well Disassemble the saddle adapter and drilling machine using the 80 120 mm hinged pin key The coupon resulting from drilling the mains will have remained trapped by the pilot drill s coupon mechanism To extract the coupon disassemble the drill by loosening the fastening stud Remove the coupon through the upper part of the drill and fit it to the hole Saw arbor again place correctly the drill s slot aligned with the fastening stud position See Figure 20 Connecting the branch connection Connect the branch connection to the appropriate outlet for the intermediate valve or saddle according to the layout Retighten the saddle branch connection fasteners Edition November 2010 22 MODE OF USE Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE ACUSTER CHAPTER 4 MAINTENANCE 4 1 GENERAL INFORMATION As a general principle we recommend maintaining the drilling machine and all components and accessories in perfect conditions of cleanliness and lubrication ready for use and stored in their original carrying case The preventive maintenance for the equipment is minimal cleaning and lubricating th
12. ed Flat gaskets for DN80 or DN100 according to the valve to be installed Full bore flange connection gate valve of DN80 or DN100 according to branch Shaft retaining tool if required Tools flat screwdriver open end spanners of 19 and 24 mm 3 4 ratchet wrench manual drilling and electric actuator with its chuckshaft adapter if applicable 3 2 2 Branch connection installation The installation of the Acuster s ARH clamp or equivalent is performed placing the saddle with its rubber gasket on the pipe on ARH s the gasket is factory glued to the saddle Next fasten the clamp between the saddle and mains the hinge joints should remain above the saddle equally tightening the fastening bolts to ensure tightness For more information refer to Fitting Instructions included with the accessory 3 2 3 Assembly of the valve Install the full bore flange connection gate valve Screw it over the flange branch connection previously installed on the line Use the flat gasket of the proper size Leave the gate valve in the fully OPEN position Figure 5 Edition November 2010 Revision No 3 MODE OF USE 13 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER INFORMATION ABOUT VALVE INSTALLATION Saddle of flanged T clamp Depending on the dimension H of the saddle the shaft extension shall be necessary to be used H lt 120 mm without shaft extension H gt 120 lt 220 mm with shaft exten
13. essure 15 3 2 6 Drilling the 5 15 3 2 7 Disassembly of the machine and accessories 16 3 2 8 Connecting the branch connection 17 3 3 Drilling over threaded outlet saddles 18 3 3 1 Initial 18 3 3 2 Saddle installation eere 18 3 3 3 Assembly of the 18 3 3 4 Assembly of drilling machine 18 3 3 5 Pressure esci va acia ka a e ncc d er eaa es 20 3 3 0 CEP 20 3 3 7 Disassembly of the machine and accessories 21 3 3 8 Connecting the branch connection 22 CHAPTER 4 E 23 4 1 General information esci aee nnn e 23 CHAPTER 5 TECHNICAL 5 5 nnn 24 Edition November 2010 Revision No 3 GENERAL CONTENTS 3 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER CHAPTER 1 INTRODUCTION 1 1 4 INTRODUCTION The AcuDrill Plus drilling machine is especially designed to drill on mains under pressure or pressureless on any type of material gray iron casting ductile casting PVC PE PP asbestos cement polyester clay steel etc For drilling mains un
14. h continue withdrawing the chuckshaft proceeding with following steps Conventional method Figure 19a Continue withdrawing the chuckshaft by pulling the retention mechanism out of the opening where it is located on the shaft To do so first place the ratchet wrench on the end shaft 3 4 square and push down to facilitate the retention mechanism removal Then take control with the ratchet wrench of the moving up of the chuckshaft due to pipeline pressure The chuckshaft will fully rise until the hole saw is positioned on the upper part of the dome Using the shaft retention tool Figure 19b Install the shaft retention tool Fix the anchorage plate screwing the knob 1 inside the existing hole on the drilling machine Assembly the upper plate in the shaft square end 2 Slide the nut 3 until it fits in the plate orifice Turn the handle 4 slightly clockwise to be able to remove the bolt of the adapter 5 Once the adapter bolt removed turn the handle 4 on the opposite direction to allow the Shaft to go up until the hole saw is positioned on the upper part of the flange adapter dome WARNING Due to internal mains pressure the chuckshaft will pop up by itself Take the necessary safety precautions to avoid any sort of accident during the operation Edition November 2010 Revision No 3 MODE OF USE 21 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER 3 2 8 Figure 19a Figure 19b Figure 20 If th
15. il the hole saw is positioned on the upper part of the dome Using the shaft retention tool Figure 11b Install the shaft retention tool Fix the anchorage plate screwing the knob 1 inside the existing hole on the drilling machine Assembly the upper plate in the shaft square end 2 Slide the nut 3 until it fits in the plate orifice Edition November 2010 16 MODE OF USE Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE 3 2 8 ACUSTER Turn the handle 4 slightly clockwise to be able to remove the bolt of the adapter 5 Once the adapter bolt removed turn the handle 4 on the opposite direction to allow the Shaft to go up until the hole saw is positioned on the upper part of the flange adapter dome Figure lla Figure 11b Figure 12 WARNING Due to internal mains pressure the chuckshaft will pop up by itself Take the necessary safety precautions to avoid any sort of accident during the operation Carefully open the venting valve to remove chip residues Next close the valve again Then switch the gate valve to the CLOSED position Open again the venting valve to depressurize the drilling machine and to be sure that the gate valve is fully closed as well Disassemble the drilling machine and flange adapter set from the gate valve The coupon resulting from drilling the mains will have remained trapped by the pilot drill s coupon mechanism To extract the coupon disassemble the dril
16. ion and use careful treatment and compliance with the pre established regular maintenance Edition November 2010 Revision No 3 INTRODUCTION 5 6 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER 1 3 CE DECLARATION OF CONFORMITY ACUSTER S L Juan de la Cierva 1 Pol gono Industrial N9 1 08960 Sant Just Desvern we declare under our sole responsibility that the AcuDrill Plus drilling machine has been manufactured in compliance with the following specifications Directive Related specification 2006 42 CE EN ISO 12100 1 Acubrill Plus Machine safety Directive EN ISO 12100 2 Sant Just Desvern 3rd September 2007 Ya Ramon Garcia Sol Edition November 2010 Revision No 3 INTRODUCTION USER MANUAL AcuD rill Plus DRILLING MACHINE ACUSTER 1 4 GUARANTEE Guarantee declaration All AcuDrill Plus drilling machines are manufactured from high quality material and have been subjected to rigorous tests for resistance and working order as well as passing all the quality control tests required by the applicable normative see CE Declaration of conformity Regardless of whether an incident might occur during the period of guarantee we recommend a careful reading of the following general guarantee conditions General conditions of Guarantee 1 ACUSTER S L guarantees that this product has no manufacturing defect at the time of its purchase and extends this guarantee for the period of TWO ye
17. ith its chuckshaft a 3 dome a modified universal hole saw arbor with pilot drill with coupon retainer system a 3 4 ratchet wrench in addition to carrying case with User Manual The rest of components and accessories are supplied separately although on the carrying case foam the necessary rooms to locate the 80 120 mm hinged pin key the three threaded adapters the DN65 DN80 flange adapter the plug carrier and the adapter for the electric actuator are already prepared The remaining three flange adapters are supplied with its own package The technical information provided in this Manual is purely informative and subject to change without prior notification ACUSTER S L shall not be responsible for any claims derived from misuse of this publication or any errors and or omissions that could be detected it following its publication GENERAL INFORMATION The development documentation production testing and shipping of the products described have been performed 9 in compliance with the applicable safety rules and 9 in accordance with the Acuster S L quality assurance requirements WARNING Only qualified personnel are authorized to perform drilling work with the Acubrill Plus drilling machine Qualified personnel must be familiar with all safety measures potential hazards and maintenance rules described in this Manual The safe usage of the products described herein requires appropriate transport storage installat
18. l by loosening the fastening stud Remove the coupon through the upper part of the drill and fit it to the hole Saw arbor again place correctly the drill s slot aligned with the fastening stud position See Figure 12 Connecting the branch connection Make the necessary branch connection to the gate valve flange If required make a pressure test of the new connection before opening the valve Retighten the saddle branch connection fasteners Edition November 2010 Revision No 3 MODE OF USE 17 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER 3 3 DRILLING OVER THREADED OUTLET SADDLES 3 3 1 Initial operations Before performing the drilling operations ensure that you have all the necessary material and that it is in good condition Complete drilling machine Modified universal hole saw arbor with pilot drill installed Hole saw of diameter to be used 9 Threaded adapter with gasket included of the diameter of the thread matching the saddle to be installed If the drilling operation is under pressure intermediate full bore valve of the size corresponding to the saddle s threaded outlet Adapter fitting if necessary Shaft retaining tool if required Tools flat screwdriver open end spanner of 19 mm 80 120 mm hinged pin key 3 4 ratchet wrench manual drilling and electric actuator with its chuckshaft adapter if applicable 3 3 2 Branch connection installation The installatio
19. n November 2010 Revision No 3 MACHINE DESCRIPTION 11 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER CHAPTER 3 MODE OF OPERATION 3 1 MACHINE APPLICATION LAYOUT The AcuDrill Plus drilling machine can be operated in accordance with the following combinations M QUINA DE PERFORAR UNVERSAL ACUDRILL PLUS l L UNIVERSAL MACHINE I E CAMPANA m 3 DOME E EA ADAPTADOR BRIDA ADAPTADOR BRIDA 0100 7 DN125 DN150 DN200 PN10 PN16 FLANGE ADAPTOR FLANGE ADAPTOR FLANGE ADAPTOR i 1 EE Es Ee ADAPTADOR ADAPTADOR ADAPTADOR ADAPTADOR BRIDA 3 1 1 2 P DNES DN80 ADAPTOR ADAPTOR ADAPTOR FLANGE ADAPTOR Figure 4 Edition November 2010 12 MODE OF USE Revision No 3 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER 3 2 DRILLING UNDER PRESSURE OVER FLANGED T CLAMP APPLICATION EXAMPLE USING AN ACUSTER S ARH FLANGE CONNECTION DIN DN80 amp DN100 FLANGE 3 2 1 Initial operations Before performing the drilling operations ensure that you have all the necessary material and that it is in good condition Complete drilling machine Modified universal hole saw arbor with pilot drill installed Chuckshaft extension only for very long T clamps neck see information below 9 Hole saw of diameter to be used plus transmission disc for diameter gt 76 mm Flange adapter DN80 or DN100 for ARH DN according to the valve to be install
20. n electric threading machine as drilling actuator take in mind that an excess of feed results in a high increase of torque which might lead to a potential risk of accident for the operator Depending on the working conditions the drilling operation could be carried out with the venting valve open to remove chip residues produced during the drilling Ensure that the drilling is complete by making one or two additional turns Close the venting valve in case it was in the open position If a length longer than the machine s travel is necessary the drilling can be continued by moving the retention mechanism to the opening above the one it was fastened to on the shaft unless the highest anchoring has been in use See Figure 8 3 2 7 Disassembly of the machine and accessories Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwise until the end travel mechanism is activated Because the chuckshaft has not rose enough to close the valve proceed with the following steps Conventional method Figure 11a Continue withdrawing the chuckshaft by pulling the retention mechanism out of the opening where it is located on the shaft To do so first place the ratchet wrench on the end shaft 3 4 square and push down to facilitate the retention mechanism removal Then take control with the ratchet wrench of the moving up of the chuckshaft due to pipeline pressure The chuckshaft will fully rise unt
21. n of the threaded outlet saddle is performed placing the saddle and gasket on the pipe Next fasten the clamp between the E saddle and mains equally tightening the fastening bolts to ensure T tightness 2 For more information refer to Fitting Instructions included with the accessory a a Figure 13 3 3 3 Assembly of the valve for under pressure drilling only Install the full bore intermediate valve not supplied with the equipment Screw it directly or through an adapter fitting over the branch connection previously installed on the line Put the valve actuation lever in OPEN position 3 3 4 Assembly of the drilling machine Fit the 3 dome on the drilling machine flange Choose the threaded adapter that matches the thread of the saddle and screw it into the installed dome adapters of 2 21 and 3 See Figure 14 This assembly can be done manually If necessary use the 80 120 mm hinged pin key Edition November 2010 18 MODE OF USE Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE ACUSTER Set up the modified universal hole saw arbor with the pilot drill in the chuckshaft This step is carried out just the first time Normally the hole saw arbor keeps always installed in the chuckshaft it is not necessary to disassembly it when the drilling is completed So for normal routine applications the assembly of the hole saw corresponding to the diameter to be drilled w
22. ould be the standard procedure Screw the hole saw matching the size outlet of the branch connection into the hole Saw arbor See Figure 15 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Figure 14 Figure 15 Figure 16 With the installed valve actuation lever in the open position for under pressure drilling operations now assemble the AcubDrill Plus drilling machine screwing it onto the valve or over the saddle installed on the pipe depending on the situation The adapter must have the gasket installed See Figure 13 WARNING Select the position of the chuckshaft depending on the distance it will have to travel during drilling under pressure or pressureless drilling operation placing the retention mechanism in the most appropriate opening of the four located on the shaft locking pin or actuator s adapter according to the operation mode used See Figure 16 Edition November 2010 Revision No 3 MODE OF USE 19 USER MANUAL AcuDrill Plus DRILLING MACHINE ACUSTER WARNING Be sure that the retention mechanism is placed in the correct shaft opening the hole saw arbor with its hole saw and pilot drill must be located inside the threaded adapter dome Modify accordingly 3 3 5 Pressure test for under pressure drilling only 3 3 6 Once the drilling machine set and accessories are installed on the valve pe
23. rform a pressure test To do so apply compressed air through the venting valve to check tightness of the assembly see Figure 17 Once the interior is pressurized and with the venting valve closed check for leaks in the connected parts and their gaskets using a spray detector or soapy water Correct in case of leaks Once the check is complete open the venting valve to depressurize then leaving it the closed position Figure 17 Drilling the mains Once the pressure test is complete for under pressure drilling only lower the chuckshaft by rotating the machine body with your hand in the knurled area until the pilot drill makes contact with the pipe the chuckshaft will have risen depending on the contact force see dimension a of Figure 18 At this point withdraw the tip of drill from the pipe by approximately one turn Now begin drilling the mains by activating the chuckshaft using the ratchet wrench if drilling is manual or through the electrical swivel gear SWIVEL GEAR If an electrical actuation swivel gear threading machine is used the following considerations must be taken into account The adapter components may be supplied Acuster S L The usage and safety recommendation given by the manufacturer must be followed Feed is achieved by making the machine body rotate with the hand placed in the knurled area Do not exceed the feed increasing of dimension a see Figure 18
24. sion Gate valve Depending on the DN used the dimension L could be different Side to side flange dimension according to EN 1092 1 for a gate valve VAG EKO PLUS or equivalent DN SHORT SERIES F4 65 170 mm 80 180 mm 100 190 mm 125 200 mm 150 210 mm 200 230 mm 3 2 4 Assembly of the drilling machine Choose the flange adapter which matches the valve flange size installed on the branch connection Refer to Figure 6 gt Valve with DN80 flange install the 3 dome and the DN65 DN80 flange adapter gt Valve with DN100 flange install the DN100 DN125 flange adapter directly on the drilling machine flange Set up the modified universal hole saw arbor with the pilot drill in the chuckshaft This step is carried out just the first time of machine operation or when using the shaft extension Normally the hole saw arbor keeps always installed in the chuckshaft it is not necessary to disassembly it when the drilling is completed So for normal routine applications the assembly of the hole saw corresponding to the diameter to be drilled would be the standard procedure Screw the hole saw matching the size outlet of the branch connection into the hole saw arbor For hole saws from 76 mm diameter a transmission disc must be used See Figure 7 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Now assemble the Plus drilling machine onto the valve Ins
25. tall the gasket of the corresponding size See Figure 5 Select the position of the chuckshaft depending on the distance it will have to travel during drilling on the current example ARH clamp gate valve placing the retention mechanism in the most appropriate opening of the four located on the shaft locking pin or actuator s adapter according to the operation mode used See Figure 8 Slid the chuckshaft downwards till the pilot drill touches the pipe Then move the chuckshaft upwards to fit the retention mechanism in the closest shaft opening Edition November 2010 14 MODE OF USE Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE ACUSTER f _ DN100 DNi25 DN65 DN80 Figure 6 Figure 7 Figure 8 3 2 5 Pressure test Once the drilling machine set and accessories are installed on the valve perform a pressure test To do so apply compressed air through the venting valve to check tightness of the assembly see Figure 9 Once the interior is pressurized and with the venting valve closed check for leaks in the connected parts and their gaskets using a spray detector or soapy water Correct in case of leaks AIRE Once the check is complete open the venting valve to prs depressurize then leaving it in the closed position Figure 9 3 2 6 Drilling the mains Once the pressure test is complete lower the chuckshaft by rotating the machine body with your h
26. ted to In case of fitting the flange adapters to the drilling machine the smallest flange adapter of DN65 DN80O is directly screwed in the 3 dome whereas the rest of flange adapters DN100 DN125 DN150 and DN200 are directly fitted on the drilling machine mounting flange The size range of hole saws are mounted on a modified universal arbor which is installed and removed from the chuckshaft without any threaded connection just using an anchoring locking pin The hole saw arbor is provided with a 9 mm pilot drill with coupon retainer Depending on the hole saw diameter a transmission disc must be used which is supplied separately The chuckshaft can be fixed in four different positions according to the position of the accessories to be drilled Its length allows it to drill through valves of sizes up to DN200 short series assembled on the corresponding pipeline flanged T clamp Edition November 2010 INTRODUCTION Revision No 3 USER MANUAL AcuD rill Plus DRILLING MACHINE 1 2 ACUSTER The machine is equipped with an absorbing mechanism that ensures a soft and regular operation system of the drill and hole saw over the pipe during drilling absorbing excessive feed that could lead to blocking of the hole saw allowing continuous drilling It can be operated manually by means of a ratchet wrench although it is designed to be used through a swivel gear with an electric actuator The basic set includes the machine body w
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