MU-41-14 Drilling Machine ACUDRILL
Contents
1. Ensure that the drilling is complete by making one or two additional turns WARNING It is recommended to avoid excess feed especially in the pilot drill work ohase given that the drill could break specially at low revolutions Figure 40 Figure 41 Edition November 2010 Revision No 3 MODE OF USE 29 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER 9 9647 3 5 8 3 5 9 Plugging the fitting Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwise until the hole saw is positioned in the upper part of the dome On that position the chuckshaft does not allow the sandwich valve to be closed Continue withdrawing the chuckshaft by pulling the retention mechanism out of the opening where it is located To do so first place the ratchet wrench on the end shaft 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 refer to Figure 41 The chuckshaft will fully rise until the hole saw is positioned on the upper part of the dome WARNING Due to pipeline internal pressure the chuckshaft will be moved upwards Take the necessary safety cautions to avoid any sort of accident during this operation Put in the close position the sandwich valve to allow the disassembling of the drilling machine and later internal plug installation Carefully o2. 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER Page 3 4 Pressureless drilling over ACUFLEX branch connections 24 3 4 1 Initial 24 3 4 2 Branch connection 24 3 4 3 Assembly of the drilling machine 24 3 4 4 Drilling the mains 25 3 4 5 Disassembly of the machine and accessories 26 3 4 6 Connecting the branch 26 3 5 Drilling under pressure fittings for gas 27 SoA druttal DDeretiODISosssssrsdiund vuifbuxwsDUEUEUTQ RE EUN RUD FU d da d 27 3 5 2 Fitting mains 27 3 5 3 Sandwich valve 27 3 5 4 Assembly of the drilling machine 27 3 9 9 Pressure E A i UR EQ NA 28 3 5 0 Dring 29 3 5 Plugging the Fr wid Pt a 30 3 5 8 Disassembly of the machine and accessories 30 3 5 9 Installation of the fitting internal plug 30 CHAPTER 45 MAINTENANCE 103993099 EE Pe TE Ta 32 4 1 General Dari su Mi
3. 3 INTRODUCTION 5 6 USER MANUAL a AcuD rill DRILLING MACHINE ACUSTER 123 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 drilling machine has been manufactured in compliance with the following specifications Directive Related specification 2006 42 CE EN ISO 12100 1 AcuDrill Machine safety Directive EN ISO 12100 2 Sant J ust Desvern 13 May 2005 Ramon Garcia Sol Edition November 2010 Revision No 3 INTRODUCTION USER MANUAL AcuDrill DRILLING MACHINE 1 4 GUARANTEE ACUSTER Guarantee declaration All AcuDrill 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 Edition November 2010 Revision No 3 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 years If the product proves defective during this period due to the materials or its assembly it will be repaired
4. See Figure 30 Choose the adapter that matches the thread of the saddle and screw it into the machine dome See Figure 31 This can be performed manually If necessary use the dome adapter spanner included with the equipment Edition November 2010 24 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE Figure 30 Figure 31 Figure 32 For this type of branch connection and intervention position the retention mechanism in the first lowest of the three anchoring openings on the chuckshaft See Figure 32 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Now install the AcuDrill drilling machine screwing it onto the saddle of the branch connection The adapter must have the washer installed WARNING If the support face of the saddle is not flat enough apply Teflon tape to the adapter thread to achieve tightness Manually tighten the machine body If necessary retighten using the dome adapter spanner included with the equipment 3 4 4 Drilling the mains Once the machine set and saddle accessories are assembled 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 measurement a of Figure 33 At this point withdraw the tip of the drill from the pipe by approximately one turn Now
5. 152 152 160 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 e Maximum diameter depending on the saddle T clamp valve full bore connecting accessories etc of the DN used Edition November 2010 Revision No 3 MACHINE DESCRIPTION 11 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SECTION 3 MODE OF OPERATION 3 1 DRILLING UNDER PRESSURE OVER ACUSTOP R BRANCH CONNECTIONS 3 1 1 Initial operations Before performing the drilling operations ensure that you have all th
6. 3 2 3 Assembly of the drilling machine Set up the arbor hole saws with the pilot drill in the chuckshaft Screw the hole saw matching the threaded outlet of the branch connection into the arbor hole Saw See Figure 15 Choose the adapter that matches the thread of the saddle and screw it into the machine dome See Figure 16 This operation can be performed manually If necessary use the dome adapter spanner included with the equipment Edition November 2010 Revision No 3 MODE OF USE 17 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER Figure 15 Figure 16 Figure 17 For this type of branch connection and intervention position the retention mechanism in the lowest of the three anchoring openings on the chuckshaft See Figure 17 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Now install the AcuDrill drilling machine screwing it onto the saddle of the branch connection The adapter must have the washer installed WARNING If the support face of the saddle is not flat enough apply Teflon tape to the adapter thread to achieve tightness Manually tighten the machine body If necessary retighten using the dome adapter spanner included with the equipment 3 2 4 Drilling the mains Once the machine set and saddle accessories are assembled lower the chuckshaft by rotating the machine body with your hand in the knurled area until the pi
7. 3 3 4 Assembly of the drilling machine Set up the arbor hole saws with the pilot drill in the chuckshaft Screw the hole saw matching the threaded outlet of the branch connection into the arbor hole saw See Figure 22 Choose the adapter that matches the thread of the saddle and screw it into the machine dome See Figure 23 This operation can be performed manually If necessary use the dome adapter spanner included with the equipment Select the position of the chuckshaft depending on the distance it will have to travel during drilling placing the retention mechanism in the most appropriate opening of the three located on the shaft See Figure 24 Figure 22 Figure 23 Figure 24 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released With the control mechanism of the intermediate valve in open position now assemble the AcubDrill drilling machine screwing it onto the valve installed over the saddle of the branch connection The adapter must have the washer installed WARNING If the support face of the intermediate valve is not flat enough apply Teflon tape to the adapter thread to achieve tightness Manually tighten the machine body If necessary retighten using the dome adapter spanner included with the equipment Edition November 2010 Revision No 3 MODE OF USE 21 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER 3 3 5 Pressure te
8. free of charge including the cost of materials and labour at Acuster SL 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 INTRODUCTION 7 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SECTION 2 MACHINE DESCRIPTION 2 1 COMPONENTS OF THE DRILLING MACHINE The AcubDiill drilling machine assembly is made of the following components L XKX XX SISIN X Nut NOU X lt gt X e SN Vs e DIN IS IS LS INS S ZR SESE S2 QU aa Va ta IN UN aN a S SU NS A OO OCOWCOWC EEK KE EE YY S SS S CD XC bv N ON N N ESPACIO RESERVADO PARA EL ADAPTADOR 1 2 H AL 5 1 o 3 6 EJE PERFORADOR ROOM RESERVED FOR 1 2 SHAFT ADAPTER 5 ESPACIOS RESERVADOS PARA LOS ADAPTADORES CABEZAL 9 ROOMS RESERVED FOR THE DOME ADAPTERS Figure 1 C
9. mains Once the pressure test is complete 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 measurement a of Figure 9 At this point withdraw the tip of the 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 or pneumatic swivel gear SWIVEL GEAR If an electrical actuation swivel gear drilling machine or pneumatic swivel gear pneumatic non impact tool is used the following considerations must be taken into account e The rotation speed must be that indicated by the hole saw manufacturer The adapter components may be supplied by Acuster SL e The usage and safety recommendations given by the manufacturer must be followed The feed is achieved by making the machine body rotate with the hand placed in the knurled area The recommended distance produced by the feed is a 1 or 2 mm see Figure 9 when drilling with the pilot drill Once perforated with the drill remember that distance a will be increased by the internal driving pressure The feed limit Is indicated by a mechanized line on the fastening bush shaft If due to an excess of compression feed internal pressure this line becomes visible see Figure 9 turn Slightly in the opp
10. the drill and hole saw over the tube during drilling absorbing excessive feed that could lead to blocking of the hole saw allowing continuous drilling The set includes a dome with built in spindle a machine body chuckshaft two arbor hole saws with pilot drill with coupon retainer system a spanner for the dome adapters a 3 mm Allen key gt ratchet wrench with revolving handle in addition to a carrying case and User Manual The technical information provided in this Manual is purely informative and subject to change without prior notification ACUSTER SL shall not be responsible for any claims derived from misuse of this publication or any errors and or omissions that could be detected in it following its publication GENERAL I NFORMATI ON The development documentation production testing and shipping of the products described have been performed in compliance with the applicable safety rules and in accordance with the Acuster SL quality assurance requirements Only qualified personnel are authorized to perform drilling work with the drilling machine Qualified personnel must be familiar with all safety measures potential hazards and maintenance rules described in this Manual he safe usage of the products described herein requires appropriate transport storage installation and use careful treatment and compliance with the pre established regular maintenance Edition November 2010 Revision No
11. 3 5 6 Drilling the mains Once the pressure test is complete 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 measurement a of Figure 40 At this point withdraw the tip of the 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 pneumatic swivel gear SWIVEL GEAR If a pneumatic swivel gear pneumatic non impact tool is used the following considerations must be taken into account e The rotation speed must be that indicated by the hole saw manufacturer e The adapter components may be supplied by Acuster SL e The usage and safety recommendations given by the manufacturer must be followed Feed is achieved by making the machine body rotate with the hand placed in the knurled area The recommended distance produced by the feed is a 1 or 2 mm see Figure 40 when drilling with the pilot drill Once perforated with the drill remember that distance a will be increased by the internal driving pressure The feed limit is indicated by a mechanized line on the fastening bush shaft If due to an excess of compression feed internal pressure this line becomes visible see Figure 40 turn slightly in the opposite direction to return to the previously recommended distance
12. ACUSTER 2 2 MACHINE ACCESSORIES The AcubDiill drilling machine also features the following accessories 1a 1b 2 max 1c Figure 3 Saddle adapter kit of 3 4 1 1 1 4 1 1 2 and 2 la Saddle adapter lb Metal rubber washer lc Variable pitch hole saws of 19 22 30 33 and 46 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 15 Arbor hole saw with drill for hole saws of 14 to 30 mm and arbor hole saws of 5 8 with drill for hole saws of 32 to 46 mm 2a Arbor hole saws without drill 2b Pilot drill of 6 5 mm diameter with coupon retainer Chuckshaft adapter to an electric drilling machine Two options 1 female square drive of 1 x Ya thread and 2 female square drive of x 5 8 thread Chuckshaft adapter to pneumatic machine Female square drive of 21 sandwich valve with 11 and 2 adapters for 3 way tees and TOR threaded O rings 2 2 drilling machine dome sandwich valve adapter Tool for inside plug installation Edition November 2010 10 MACHINE DESCRIPTION Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE 2 3 ACUSTER HOLE SAW DIAMETERS AND CHARACTERISTICS FOR ACUDRILL amp ACUDRILL PLUS iy 375 33 32 33 35 AcuDrill 2 65 60 60 60 60 AcuDrill Plus 184 7 177
13. CUSTER Figure 42 Figure 43 Figure 44 Once the plug and fitting are in contact turn the shaft clockwise by means of a 3 4 ratchet wrench open end spanner etc to screw in the plug into its fitting location After several turns the torque resistance will dramatically increase indicating that the plug has completed its screwing travel See Figure 44 Move the shaft upwards pull up without turning Disassembly the plug installation tool and the sandwich valve Install the fitting exterior plug following the Gas Company established procedure Edition November 2010 Revision No 3 MODE OF USE 31 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SECTION 4 MAINTENANCE 4 1 32 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 the chuckshaft 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 SL After Sales Service Department for a complete inspection generally with time and use the O rings and
14. Q3 ACUSTER USER MANUAL DRILLING MACHINE FOR UNDER PRESSURE MAINS MODEL AcuDrill Revision No 3 November 2010 Publication MU 41 14E NOTES The modifications carried out against the previous revision of this publication are indicated with on the right margin USER MANUAL AcuDrill NG MACHINE ACUSTER CONTENTS Page CHAPTER 1 1 airi 5 1 1 TETTE TUTTI 5 1 2 General informatio Nrs io Rd 5 1 3 CE declaration of conformity eexevexaues e eor ER aaron veins 6 1 4 UN ote ac va REM Sai RT aca ce 7 CHAPTER 2 MACHINE DESCRIPTION vesciasecte rine exa vai da ada er a xs CFR 8 2 1 Components of the drilling 8 2 2 Machine dccessorleS eseusesveasisussuds 10 2 3 Hole saws diameters and 11 CHAPTER 3 MODE OF OPERA OWN veces abun 12 3 1 Drilling under pressure over AcuStop R branch connections 12 Obl TnitlaloDerattoDS oes pic mr Es apa i tcn RO Nan ERA 12 3 1 2 Branch connection 12 3 1 3 Assembly of the drilling machine 12 Solve Pressure TOSDussecinkertaha bela deer ntc doc aV 13 3 1 5 Drilling the TslfiSseoenpnecereaaprede COO Es 14 3 1 6 Plugging the branc
15. anch connections with 2 threaded outlet Insert the spatula all the way to the bottom through the slot of the saddle See Figure 11 Disassembly of the machine and accessories Before carrying out the disassembly of the drilling machine check the tightness of the Spatula by opening the venting valve There should not be any fluid overflow unless it is the amount remaining in the interior before fitting the spatula Correct the position of the spatula in case of leak or determine the causes of any possible loss Once the check is complete return the venting valve to the closed position Disassemble the saddle adapter and drilling machine using the spanner designed for this purpose Edition November 2010 Revision No 3 MODE OF USE 15 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER The coupon resulting from drilling the main will have remained trapped by the pilot drill s coupon retainer mechanism To extract the coupon disassemble the drill by loosening the Allen fastening stud Remove the coupon through the upper part of the drill and fit it to the arbor hole saw again See Figure 12 Figure 12 Figure 13 3 1 8 Connecting the branch connection Make the proper connections at the threaded outlet of the saddle If necessary perform a pressure test on the new section Completely withdraw the spatula to allow fluid flow Next slide the exterior clamp gasket assembly all the way down Tighten the fastening bolt of the e
16. arrying case with die cut foam Drilling machine Dome adapter spanner Ratchet wrench with revolving handle 3mm Allen key Arbor hole saws 14 to 30 mm featuring pilot drill with coupon retainer Arbor hole saws 32 to 46 mm featuring pilot drill with coupon retainer NO Ul 3 UJ N Edition November 2010 8 MACHINE DESCRIPTION Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE Main parts of the drilling machine Dome with spindle 2 BSP threaded with inner O ring to screw threaded adapters of the saddle or accessory to be drilled Venting valve PN16 valve for depressurizing and pressurizing test operations Machine body Includes end travel mechanism and absorbing mechanism to optimize drilling power CE identification plate Marking pursuant to Machinery Safety Directive End travel mechanism Blocks the machine s end travel but allows a manual release through the retractable handle Chuckshaft Features three fastening openings to select the most appropriate length for drilling Chuckshaft fastening bush This is the element that joins the chuckshaft with the absorbing mechanism It features a mark indicating the maximum feed limit Chuckshaft fastening mechanism This allows quick and safe fastening of the chuckshaft to the fastening bush Edition November 2010 Revision No 3 ACUSTER Figure 2 MACHINE DESCRIPTION 9 USER MANUAL AcuDrill DRILLING MACHINE
17. avel mechanism is activated Continue withdrawing the chuckshaft by pulling the retention mechanism out of the opening where it is located To do so first place the ratchet wrench on the end shaft 12 square and push down to f facilitate the retention mechanism removal Then take control with P ASAN the ratchet wrench of the moving up of the chuckshaft due to the oA ye pipeline pressure refer to Figure 27 The chuckshaft will fully rise until the hole saw is positioned on the upper part of the dome WARNING Due to pipeline internal pressure the chuckshaft will be moved upwards Take the necessary safety cautions to avoid any sort of accident during this operation Carefully open the venting valve to remove chip residues Next close the valve again Then switch the intermediate valve to the CLOSED position Disassemble the saddle adapter and drilling machine using the spanner designed for this purpose The coupon resulting from drilling the mains will have remained trapped by the pilot drill s coupon retainer mechanism To extract the coupon disassemble the drill by loosening the Allen fastening stud Remove the coupon through the upper part of the drill and fit it to the arbor hole saw again See Figure 28 Figure 28 3 3 8 Connecting the branch connection Connect the branch connection to the appropriate outlet for the intermediate valve Retighten the branch connection fasteners Edition November 2010 Revis
18. begin drilling the mains by activating the chuckshaft using the ratchet wrench if drilling is manual or through the electrical or pneumatic swivel gear Edition November 2010 Revision No 3 MODE OF USE 25 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SWIVEL GEAR If an electrical actuation swivel gear drilling machine or pneumatic swivel gear pneumatic non impact tool is used the following considerations must be taken into account e The rotation speed must be that indicated by the hole saw manufacturer e The adapter components may be supplied by Acuster S L e The usage and safety recommendations given by the manufacturer must be followed The feed is achieved by making the machine body rotate with the hand placed in the knurled area The recommended distance produced by the feed is a 1 or 2 mm see Figure 33 The feed limit is indicated by a mechanized line on the fastening bush shaft If due to an excess of compression feed internal pressure this line becomes visible see Figure 33 turn slightly in the opposite direction to return to the previously recommended distance WARNING It is recommended to avoid excess feed especially in the pilot drill work phase given that the drill could break specially at low revolutions Figure 33 3 4 5 Disassembly of the machine and accessories Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwi
19. e necessary material and that it is in good condition Complete drilling machine Arbor hole saw with pilot drill installed matching the size of the hole saw to be used Hole saw of the diameter to be used Adapter with washer of the diameter of the thread matching the saddle to be installed Tools 3 mm Allen key adapter spanner 17 mm open end Spanner 72 ratchet wrench manual drilling and electrical or pneumatic swivel gear with chuckshaft adaptation elements if applicable 3 1 2 Branch connection installation The installation of the AcuStop R branch connection is performed placing the saddle and sealing gasket on the pipe Next fasten the clamp between the saddle and mains the hinge joints should remain above the saddle equally tightening the two fastening bolts to ensure tightness For more information refer to the Fitting Instructions included with the accessory Figure 4 3 1 3 Assembly of the drilling machine Set up the arbor hole saws with the pilot drill in the chuckshaft Screw the hole Saw matching the threaded outlet of the branch connection into the arbor hole Saw See Figure 5 Choose the adapter that matches the thread of the saddle and screw it into the machine dome See Figure 6 This operation can be performed manually If necessary use the dome adapter spanner included with the equipment For this type of branch connection position the retention mechanism in the lowest of the
20. essary use the dome adapter spanner included with the equipment Figure 36 Figure 37 Figure 38 Select the position of the chuckshaft depending on the distance it will have to travel during drilling placing the retention mechanism in the most appropriate opening of the three located on the shaft middle orifice for 2 TOR and upper orifice for 1 and 2 3 way tees See Figure 38 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Now assemble the AcuDrill drilling machine screwing it onto the sandwich valve installed over the fitting WARNING Manually tighten the machine body If necessary retighten using the dome adapter spanner included with the equipment 3 5 5 Pressure test Once the drilling machine set and accessories are installed on the sandwich valve perform a pressure test To do so apply compressed air through the venting valve to check tightness of the assembly see Figure 39 Once the interior is pressurized and with the venting valve closed check for leaks in the threaded connections or the gasket at the mains head seat gasket 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 in the closed position Figure 39 Edition November 2010 28 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER
21. ete 32 CHAPTER 5 TECHNICAL CHARACTERISTICS cccccccceeeeeeeeeeeeeeeeeeeeeeeeeneneneneees 33 4 GENERAL CONTENTS Edition November 2010 Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SECTION 1 INTRODUCTION 1 1 1 2 INTRODUCTION The AcuDrill 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 It is especially designed to be used on branch connections or threaded accessories The machine dome is connected to the threaded outlets of saddles through threaded adapters The sizes of the available adapters are 3 4 1 1 1 and 2 BSP It allows holes of up to 48 mm diameter to be drilled using standard hole saws of high speed steel or tungsten carbide tipped hole saws with coupon retainer equipped pilot drill The chuckshaft can be fixed in three different positions according to the position of the accessories to be drilled It can be operated manually by means of a ratchet wrench provided with a revolving handle although it is designed to be used through a swivel gear with either an electric or pneumatic actuator For drilling mains under pressure the maximum allowable pressure is 16 bar for water mains and 5 bar for gas mains The machine is equipped with an absorbing mechanism that ensures a soft and regular operation system of
22. gaskets need to be changed Edition November 2010 MAINTENANCE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER SECTION 5 TECHNICAL CHARACTERISTICS Usage Acuster branch connections Other brands Fittings for gas Maximum drilling capacity Maximum range Service pressure Operation Total equipment weight Outer dimensions Edition November 2010 Revision No 3 Drilling of mains made of steel gray cast iron ductile casting asbestos cement clay polyester PVC PE PP etc ACUSTOP R CA R and ACUFLEX All types of saddles with threaded outlets 3 4 1 1 1 4 1 1 2 and 2 BSP 3 way tees and TORs of 1 2 and 2 Up to 48 mm 117 mm from the machine body 124 mm from the chuckshaft moving the fastening openings 241 mm Total adding range travel and fastening shaft 16 bar for water mains 5 bar for gas mains Manual by means of a ratchet wrench provided with a revolving handle Optionally by means of an electric or pneumatic actuated swivel gear 6 9 kg with carrying case and without adapters Carrying case Length 700 mm Width 260 mm Height 105 mm TECHNICAL CHARACTERISTICS 33 ACUSTER Weight of optional components Kit 3 4 saddle adapter Kit 1 saddle adapter Kit 1 saddle adapter Kit 172 saddle adapter Kit 2 saddle adapter Dome sandwich valve adapter 2V2 sandwich valve w o adapter 12 sandwich val
23. ge and safety recommendations given by the manufacturer must be followed Feed is achieved by making the machine body rotate with the hand placed in the knurled area The recommended distance produced by the feed is a 1 or 2 mm see Figure 26 when drilling with the pilot drill Once perforated with the drill remember that distance a will be increased by the internal driving pressure The feed limit is indicated by a mechanized line on the fastening bush shaft If due to an excess of compression feed internal pressure this line becomes visible see Figure 26 turn slightly in the opposite direction to return to the previously recommended distance Ensure that the drilling is complete by making one or two additional turns Figure 26 Edition November 2010 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER WARNING It is recommended to avoid excess feed especially in the pilot drill work ohase given that the drill could break specially at low revolutions If a length longer than the machine s travel is necessary the drilling can be continued by moving the retention mechanism to the next opening above the one it was fastened to on the shaft unless the highest anchoring has been in use See Figure 24 3 3 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 tr
24. h 15 3 1 7 Disassembly of the machine and accessories 15 3 1 8 Connecting the branch 16 3 2 Pressureless drilling over CA R branch connections 17 3 2 1 Initial nnn 17 3 2 2 Branch connection 17 3 2 3 Assembly of the drilling machine 17 3 2 4 DEMING exta Es 18 3 2 5 Disassembly of the machine and accessories 19 3 2 6 Connecting the branch 19 3 3 Drilling under pressure over CA R branch connections 20 TInital oDeratioDS oves dvor ses qn e tI 20 3 3 2 Branch connection 20 3 3 3 Assembly of the cutoff 20 3 3 4 Assembly of the drilling machine 21 3 3 9 PPISSSUFIG TOS ei RAE RERO ede a wa Sb RE an us 22 3 3 6 Drilling the 22 3 3 7 Disassembly of the machine and accessories 23 3 3 8 Connecting the branch 23 Edition November 2010 Revision No 3 GENERAL CONTENTS
25. ion No 3 MODE OF USE 23 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER 3 4 PRESSURELESS DRILLING OVER ACUFLEX BRANCH CONNECTIONS 3 4 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 Arbor hole saw with pilot drill installed matching the size of the hole saw to be used Hole saw of the diameter to be used Adapter with washer of the diameter of the thread matching the saddle to be installed Tools 3 mm Allen key adapter spanner 17 mm open end ped Spanner 12 ratchet wrench manual drilling and electrical or pneumatic swivel gear with chuckshaft adaptation elements if applicable 3 4 2 Branch connection installation Installation of the ACUFLEX branch connection is performed by L24 placing the threaded outlet in the opening of the upper sector Next set the upper sector and inferior sector through the hinge mechanism they are equipped with and place them over the mains in the desired position and orientation Tighten the two fastening bolts to ensure tightness For more information refer to the Fitting Instructions ji included with the accessory s t Figure 29 3 4 3 Drilling machine assembly Set up the arbor hole saws with the pilot drill in the chuckshaft Screw the hole saw matching the threaded outlet of the branch connection into the arbor hole Saw
26. lot drill makes contact with the pipe the chuckshaft will have risen depending on the contact force see measurement a of Figure 18 At this point withdraw the tip of the 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 or pneumatic swivel gear Edition November 2010 18 MODE OF USE Revision No 3 USER MANUAL ACUDrill DRILLING MACHINE ACUSTER SWIVEL GEAR If an electrical actuation swivel gear drilling machine or pneumatic Swivel gear pneumatic non impact tool is used the following considerations must be taken into account e The rotation speed must be that indicated by the hole saw manufacturer The adapter components may be supplied by Acuster S L e The usage and safety recommendations given by the manufacturer must be followed The feed is achieved by making the machine body rotate with the hand placed in the knurled area The recommended distance produced by the feed is a 1 or 2 mm see Figure 18 The feed limit is indicated by a mechanized line on the fastening bush shaft If due to an excess of compression feed internal pressure this line becomes visible see Figure 18 turn slightly in the opposite direction to return to the previously recommended distance WARNING It is recommended to avoid excess feed especially in the pilot drill work phase give
27. m open end Spanner 12 ratchet wrench manual drilling and pneumatic swivel gear with chuckshaft adaptation elements if applicable 3 5 2 Fitting installation Install the steel fitting 3 way tee or TOR threaded O ring following the procedure established by the Gas Company It is recommended to remove the exterior plug but keep the internal plug without o ring fitted in position during the fitting preparation and welding Once the welds cool remove the internal plug and install its O ring a 3 5 3 Sandwich valve installation Figure 35 Remove the grease from the fitting internal thread WARNING Use Teflon tape of equivalent to the sandwich valve adapter thread to achieve tightness Check good condition of the upper and lower sandwich valve O rings Install the 212 sandwich valve with the adapter corresponding the fitting thread size 1 or 2 See Figure 35 The sandwich valve gate shall be in OPEN position 3 5 4 Assembly of the drilling machine Set up the arbor hole saws with the pilot drill in the chuckshaft Screw the hole saw matching the threaded outlet of the branch connection into the arbor hole saw See Figure 36 Edition November 2010 Revision No 3 MODE OF USE 27 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER Screw in the sandwich valve adapter to the drilling machine dome See Figure 37 This operation can be performed manually If nec
28. n that the drill could break specially at low revolutions Figure 18 3 2 5 Disassembly of the machine and accessories Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwise Disassemble the saddle adapter and drilling machine using the spanner designed for this purpose The coupon resulting from drilling the main will have remained trapped by the pilot drill s coupon retainer mechanism To extract the coupon disassemble the drill by loosening the Allen fastening stud Remove the coupon through the upper part of the drill and fit it to the arbor hole saw again See Figure 19 WARNING Do not touch the coupon following drilling especially if an electrical or pneumatic swivel gear has been used Hot surfaces Figure 19 3 2 6 Connecting the branch connection Connect the branch connection to the threaded outlet of the saddle Retighten the branch connection fasteners Edition November 2010 Revision No 3 MODE OF USE 19 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER 3 3 3 3 1 3 3 2 3 3 3 DRILLING UNDER PRESSURE OVER CA R BRANCH CONNECTIONS 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 Arbor hole saw with pilot drill installed matching the size of the hole saw to be used Hole saw of the diame
29. osite direction to return to the previously recommended distance Ensure that the drilling is complete by making one or two additional turns Figure 9 WARNING It is recommended to avoid excess feed especially in the pilot drill work ohase given that the drill could break specially at low revolutions Edition November 2010 14 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE 3 1 6 3 1 7 ca ACUSTER Plugging the branch connection Once the mains has been perforated move the chuckshaft up by turning the machine body counterclockwise until the hole saw is positioned in the upper part of the dome Carefully open the venting valve to remove chip residues Next close the valve again Now carry out the plugging to facilitate disassembly of the machine and the subsequent connection to the branch connection Figure 10 Figure 11 To do so the slot in the saddle for the introduction of the spatula must be fully accessible Slightly raise the clamp gasket assembly of the saddle closure to keep it from interfering with the handle of the spatula during the introduction See Figure 10 The clamp gasket assembly is delivered flush with the upper face of the saddle and with the fastening bolt untightened Place the pivoting shaft of the spatula in the opening of the saddle use the small spatula to plug branch connections with threaded outlets of 3 4 to 1 and the large spatula for br
30. pen the venting valve to remove chip residues and depressurize Disassembly of the machine and accessories Before disassembling the drilling machine check sandwich valve tightness opening the venting valve No fluid must flow out except the one which remains inside before the Sandwich valve closing Investigate the reason of any suspicious leakage Once carried out the above check close again the venting valve Disassemble the drilling machine and its sandwich valve adapter using the spanner designed for this purpose The coupon resulting from drilling the mains will have remained trapped by the pilot drill s coupon retainer mechanism To extract the coupon disassemble the drill by loosening the Allen fastening stud Remove the coupon through the upper part of the drill and fit it to the arbor hole saw again See Figure 42 Installation of the fitting internal plug Fit the fitting internal plug ensure that the O ring is fitted in the plug installation tool Assembly the plug installation tool with the plug on it over the sandwich valve See Figure 43 This operation can be carried out by hand If necessary use the dome adapter spanner included with the equipment Open the sandwich valve Move downwards the installation plug tool shaft as far the plug makes contact with the fitting 3 way tee or TOR Edition November 2010 30 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE A
31. se Disassemble the saddle adapter and drilling machine using the spanner designed for this purpose The coupon resulting from drilling the mains will have remained trapped by the pilot drill s coupon retainer mechanism To extract the coupon disassemble the drill by loosening the Allen fastening stud Remove the coupon through the upper part of the drill and fit it to the arbor hole saw again See Figure 34 WARNING Do not touch the coupon following drilling especially if an electrical or pneumatic swivel gear has been used Hot surfaces Figure 34 3 4 06 Connecting the branch connection Connect the branch connection to the threaded outlet of the saddle Retighten the fasteners Edition November 2010 26 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER Ia DRILLING UNDER PRESSURE OVER STEEL FITTINGS FOR GAS PIPELINES 3 WAY TEES AND THREADED O RINGS OF 117 2 3 5 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 pe Arbor hole saw with pilot drill installed matching the size of the hole saw to be used Hole saw of the diameter to be used Drilling machine dome sandwich valve adapter Sandwich valve with adapter to the fitting thread 1 2 or 2 Tool for internal plug installation HD Tools 3 mm Allen key adapter spanner 17 m
32. st Once the drilling machine set and accessories are installed on the intermediate valve perform a pressure test To do so apply compressed air through the venting valve to check tightness of the assembly see Figure 25 Once the interior is pressurized and with the venting valve closed check for leaks in the threaded connections or the gasket at the mains head seat gasket 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 in the closed position Figure 25 3 3 6 Drilling the mains 22 Once the pressure test is complete 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 measurement a of Figure 26 At this point withdraw the tip of the 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 or pneumatic swivel gear SWIVEL GEAR If an electrical actuation swivel gear drilling machine or pneumatic swivel gear pneumatic non impact tool is used the following considerations must be taken into account e The rotation speed must be that indicated by the hole saw manufacturer The adapter components may be supplied by Acuster S L e The usa
33. ter to be used Adapter with washer of the diameter of the thread matching the saddle to be installed Intermediate full bore valve of the size corresponding to the saddle s threaded outlet Adapter fitting if necessary Tools 3 mm Allen key adapter spanner 17 mm open end spanner 5 ratchet wrench manual drilling and electrical or pneumatic swivel gear with chuckshaft adaptation elements if applicable Branch connection installation The installation of the CA R branch connection is performed placing the saddle and gasket on the pipe Next fasten the clamp between the saddle and mains the hinge joints should remain above the saddle equally tightening the two fastening bolts to ensure tightness For more information refer to the Fitting Instructions included with the accessory Assembly of the cutoff valve Figure 20 WI Install an intermediate valve not supplied with the equipment u Screw it directly or through an adapter fitting over the CA R tie branch connection previously installed on the line Put the valve N actuation lever in OPEN position rr h WARNING wl M The total height h of the branch connection saddle A Z selected intermediate valve and fitting once y ce assembled must not exceed 210 mm See Figure 21 LEON H Figure 21 Edition November 2010 20 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER
34. three anchoring openings on the chuckshaft See Figure 7 Edition November 2010 12 MODE OF USE Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER Figure 5 Figure 6 Figure 7 Place the body of the machine in its upper position unscrew it until the end travel mechanism is released Now install the AcuDrill drilling machine by screwing it onto the saddle of the branch connection The adapter must have the washer installed WARNING If the support face of the saddle is not flat enough apply Teflon tape to the adapter thread to achieve tightness Manually tighten the machine body If necessary retighten using the dome adapter spanner included with the equipment 3 1 4 Pressure test Once the drilling machine set and accessories are installed on the saddle of the branch connection perform a pressure test To do so apply compressed air through the venting valve to check tightness of the assembly see Figure 8 Once the interior is pressurized and with the venting valve closed check for leaks in the threaded connections or the gasket at the mains head seat gasket 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 in the closed position Figure 8 Edition November 2010 Revision No 3 MODE OF USE 13 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER 3 1 5 Drilling the
35. ve adapter 2 sandwich valve adapter Plug installation tool Electric propeller rotary machine 34 TECHNICAL CHARACTERI STI CS USER MANUAL AcuDrill DRILLING MACHINE 0 590 Kg 0 555 Kg 0 575 Kg 0 575 Kg 0 640 Kg 1 110 Kg 7 395 kg 0 910 Kg 0 835 Kg 2 075 Kg 6 690 Kg with shaft adapter and transport case Edition November 2010 Revision No 3 USER MANUAL AcuDrill DRILLING MACHINE ACUSTER RESERVED FOR NOTES Edition November 2010 Revision No 3 TECHNICAL CHARACTERISTICS 35
36. xterior clamp gasket assembly to its end travel See Figure 13 The tightening bolt must remain positioned on the opposite side from the Spatula insertion slot as it is delivered stock Retighten the fastening bolts of the branch connection Edition November 2010 16 MODE OF USE Revision No 3 USER MANUAL ACUDrill DRILLING MACHINE ACUSTER 3 2 PRESSURELESS DRILLING OVER CA R BRANCH CONNECTIONS 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 Arbor hole saw with pilot drill installed matching the size of n the hole saw to be used Hole saw of the diameter to be used Adapter with washer of the diameter of the thread matching the saddle to be installed auus Tools 3 mm Allen key adapter spanner 17mm open end Spanner 1 ratchet wrench manual drilling and electrical or pneumatic swivel gear with chuckshaft adaptation elements if applicable 3 2 2 Branch connection installation The installation of the CA R branch connection is performed placing the saddle and gasket on the pipe Next fasten the clamp between the saddle and mains the hinge joints should remain above the saddle equally tightening the two fastening bolts to ensure tightness For more information refer to the Fitting Instructions T Lr included with the accessory Figure 14
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