Hy-Ram No1 Drilling Machine · 7. Position the drilling machine on the top of the Saddle ensuring...

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OPERATING INSTRUCTIONS

FOR

Hy-Ram No1

Drilling Machine

1. Machine to be operated by trained personnel.

2. Instructions to be read before use.

Hy-Ram Mansfield Pelham Street Mansfield Nottinghamshire NG18 2EY Tel: 01623 422982 Fax: 01623 661022

Hy-Ram Bury 9 Portland Industrial Estate Portland Street Bury Lancashire BL9 6EY Tel: 0161 7641721 Fax: 0161 7620577

Hy-Ram Enfield Unit 2, Riverwalk Business Park Riverwalk Road Enfield EN3 7QN Tel: 0208 805 8010 Fax: 0208 805 6010

Hy-Ram Livingston 18 Napier Square Houstoun Road Trading Estate Livingston West Lothian EH54 5DG TEL: 01506 440233 Fax: 01506 440266

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This unit is design and manufactured by Hyram Engineering Co Ltd. Hy-Ram Engineering Co Ltd has a policy of continuous improvement in product quality and design. Hy-Ram Engineering Co Ltd therefore reserves the right to change the specification of its models at any time, without prior notice.

Important! This manual forms a part of the product to which it relates. It should be kept for the life of the product. Any amendments issued by Hy-Ram Engineering Co Ltd should be incorporated in the text. The manual should be passed to any subsequent holder or user of this product.

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Safety Information The Hy-Ram No1 Drilling Machine should only be used by trained and competent operators. As an operator, always ensure that you fully understand how the equipment functions and that you are fully aware of the dangers. Always wear the necessary protective clothing including adequate eye protection, hard hat, gloves, overalls, protective boots etc.

Prior to commencing work, always ensure that the drill kit is complete and fully serviceable. If in doubt replace.

The Machine operation:

Ensure that the Saddle Ring and Felt/Leather Pad are correctly positioned and that the machine is securely fastened to the main. It is often necessary to prepare /clean the pipe with a cleaning strap prior to mounting the machine. When tapping the thread or inserting the Ferrule do not use excessive force. After inserting the Ferrule/Plug, ensure that the Bleedscrew is used to check that the Ferrule/Plug are correctly inserted and pressure tight.

Extreme Caution should be exercised when retracting the Drill Tap/Drill Spindle assembly after drilling and tapping. Under the pressure of the water, the drill spindle can suddenly force upwards. Always ensure that the Feedscrew is engaged in the Drill Spindle centre and use the Feedscrew to resist the force. When inserting the Ferrule, never overtighten into the main or saddle. If the threads are stripped, the water pressure may suddenly blow the Ferrule out. If in doubt – reduce the water pressure to zero before removing the machine and check the connection.

Mounting the drilling machine for tapping directly into metallic mains

1. Prepare the area of pipe where machine is to be mounted by removing dirt, scale etc. Hy-Ram recommends the use of a Cleaning Strap for this operation.

2. Place the Felt Pad underneath the Leather Pad on the main.

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3. Select the Machine Saddle for the size of main to be tapped and if required a

saddle ring extension. Ensure the Saddle Ring is located in the recess of the saddle and position the saddle centrally on top of the Leather Pad. Ensure the slot in the saddle corresponds to the hole in the Felt/Leather Pad to enable the Drill Tap and ferrule to be able to pass through.

4. Select the appropriate Drill Tap (½", ¾" or 1" BSP) for the application and place the

Drill Tap into the Drill Spindle ensuring that the Drill Tap tang locates into the slot in the spindle bore. Using a soft hammer knock in the Drill Tap and lock in position with the Grubscrew on the side of the Drill Spindle. Position the Drill Tap/Spindle assembly into either of the holes in the Machine Piston.

Felt Pad

Leather Pad

Saddle Extension

Saddle

Rubber Saddle Ring

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5. Select the appropriate Ferrule (½", ¾" or 1" BSP) for the application ensuring it is

compatible with the Drill Tap. Using the Ferrule Key, tightly screw the Ferrule Inner Plug to the closed position. For ½" and ¾" BSP Ferrules, screw the Ferrule tightly into the Ferrule Spindle using the Ferrule Spanner. For 1" BSP Ferrules the Ferrule Adaptor should be used between the Ferrule and Ferrule Spindle. Once the Ferrule is inserted into the Ferrule Spindle, use PTFE tape on the end of the Ferrule in preparation for insertion into the main. Position the Ferrule/ Ferrule Spindle assembly into the other hole in the Machine Piston.

6. Ensure both Drill Tap and Ferrule are pushed up inside the machine body and do not protrude from the base.

Ferrule Stem

PTFE Tape PTFE Here

Ferrule Adaptor

Ferrule Stem

Ferrule Spindle

No1 Drill

Drill Spindle Ferrule Spindle

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7. Position the drilling machine on the top of the Saddle ensuring that the chain lugs are at 90º to the length of the main.

8. To secure the machine to the main.

Mounting The Drilling Machine For Tapping Through A Tapping Saddle (For use on metallic, PVC and Asbestos Cement Mains)

1. Prepare the area of pipe where machine is to be mounted by removing dirt, scale

etc. Hy-Ram recommends the use of a Cleaning Strap for this operation.

2. Select the correct Tapping Saddle for the size of main and bolt the Tapping Saddle around the main with the Boss positioned upwards.

Tapping Saddle

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3. Place the Universal Undercarriage on the Saddle Boss ensuring that the sealing washer is positioned centrally between Undercarriage and Boss. Set level with the Adjusting Screw resting on the crown of the pipe. Position sealing ring in the recess of the Universal Undercarriage.

4. Load Drill Tap and Ferrule into the Drill and Ferrule Spindles by carrying out steps (4) to (6), section above.

5. Position the drilling machine on the top of the Universal Undercarriage ensuring that the chain lugs are at 90º to the length of the main.

6. To secure the machine to the main carry out the procedure detailed in section 2.3.

Securing The Machine To The Main In Preparation For Tapping

1. Position the chain evenly around the pipe and loosely assemble into the Pull Up Hooks. Tighten the Pull Up Hooks against the lugs by spanner until the machine is firmly positioned onto the main.

Universal Undercarriage

Tapping Saddle

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2. Place the Ratchet Spanner on the Drill Spindle and position the Bridle/Feedscrew

above the Drill Spindle.

3. Insert the Stop Pin into the hole in the side of the upper body of the machine and ensure it is engaged in the hole in the Piston.

4. Engage the Feedscrew into the centre of the Drill Spindle. Turn the Feedscrew clockwise until it is felt that the drill tap is just touching the pipe (in the case of direct tapping) or just touching the Saddle Strap Boss (in the case of tapping through a saddle strap).

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5. Open the Bleedscrew on the side of the machine body by turning it anti-clockwise two turns.

Drilling, Tapping And Insertion Of Ferrule

1. To drill, rotate the Drill Spindle clockwise using the Ratchet Spanner and gradually turn the Feedscrew to apply and maintain drilling pressure. The ‘feel’ of the

required pressure is down to the experience of the operator – AVOID EXCESSIVE

PRESSURE

2. When the Drill Tap penetrates through the main, air and then water will be expelled

from the Bleedscrew. When this happens, retighten the Bleedscrew.

3. When drilling is complete, the tapping operation will begin. The operator will notice a difference in the ‘feel’ of the cut as the thread begins to form. Less pressure is required on the Drill Spindle by the Feedscrew as the tap will naturally be drawn down by the tapping procedure. The Feedscrew should still be operated to

maintain contact with the Drill Spindle and ‘follow’ it. DO NOT USE EXCESSIVE

PRESSURE.

4. When the tapping is complete, the Drill Tap will reach a positive stop as the outside diameter of the main contacts the shoulder of the Drill Tap. Do not attempt to continue tapping at this point.

5. To disengage the Drill Tap, reverse the Ratchet Spanner and unscrew the tap from the hole. Simultaneously, gradually raise the Feedscrew ensuring that it is always engaged in the centre of the Drill Spindle. (ie. Raise the Feedscrew at the same rate as the tap is unscrewing).

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6. When the Drill Tap completely disengages, the Drill Spindle, under the pressure of the water, will be forced upwards. For safety, it is crucial that the Feedscrew is engaged in the centre of the Drill Spindle and regulates this force. Continue to turn the Feedscrew anti-clockwise until the Drill Spindle is fully withdrawn and the Feedscrew is disengaged.

7. Remove the Stop Pin from the side of the machine. Use the Piston Spanner to rotate the Piston through 180º, then replace the Stop Pin. The Ferrule Spindle will now be directly below the Feedscrew.

8. Turn the Feedscrew clockwise and engage into the centre of the Ferrule Spindle. Use the Ratchet Spanner and Feedscrew simultaneously to screw the ferrule into the tapped hole.

9. When the ferrule is screwed in, open the Bleedscrew to release pressure from the

machine body. [If at this point water continues to be expelled, there is a problem and the tapping is incomplete. Carefully try to retighten the ferrule. Should this fail, for safety reasons the connection should be condemned, the main shut down and the machine removed for examination of the problem]. Remove the Morse Chain in order to release the machine. (Note! The machine body will contain water). Remove the machine off of the main by sliding it up and off of the ferrule spindle. This will then just leave the Ferrule/Ferrule Spindle connected to the main.

10. Ensure that the Ferrule is tightly secured in the main and then remove the Ferrule Spindle.

11. Assemble the Ferrule and connect the service pipe.

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12. When the service pipe is ready for use, remove the top plug of the Ferrule and

raise the Plug using the Ferrule Key. Rotate anti-clockwise until the Plug seals against the inside of the Top Cap. Refit the Top Plug. The procedure is now complete.

13. Take care to clean and lubricate the machine after use and store safely in the steel carry case.

Certificate of Calibration.

• This product has been inspected and tested in accordance with the ISO9001 quality

control systems and procedures in place at Hyram Engineering Co Ltd.

• This product has no calibration period, periodic, safety inspections should be carried out by the operator if in any doubt please contact the manufacturer for further information

Decommissioning & Disposal Instructions

These give the instructions for decommissioning and disposal of the equipment and confirm how it is to be taken out of service safely, in respect of the Essential Health

and Safety Requirements.

• If a Hyram tool has reached the end of its useful working life and cannot be

refurbished it must be disposed of through a licensed scrap or waste disposal facility. Alternatively, a reverse engineering company could be used to strip the equipment for recycling purposes.

• Disposal is the responsibility of the Customer this can also be achieved by returning the product back to the manufacturer.

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Warranty Information. 1. Extent of Warranty. (a) Hy-Ram Engineering Co Ltd warrants to the end-user customer that its products will

be free from defects in materials and workmanship, for six months after the date of purchase by the end-user customer, subject to providing proof of purchase.

(b) If Hy-Ram Engineering Co Ltd receives, during the warranty period, notice of a defect in product which is covered by this warranty, Hy-Ram Engineering Co Ltd shall either repair or replace the product, at its option. Any replacement product may be either new or like-new, provided that it has functionality at least equal to that of the product being replaced.

(c) All warranty work will be carried out by Hy-Ram Engineering Co Ltd unless otherwise agreed. On-site warranty and repair or replacement services are available from authorised Hy-Ram Engineering Co Ltd service facilities world-wide.

(d) Customers shall prepay shipping charges for products returned to Hy-Ram Engineering Co Ltd for warranty service, and Hy-Ram Engineering Co Ltd will charge for return of the products back to the customer.

(e) This warranty statement gives the customer specific legal rights. The customer may also have other rights which vary from country to country in the world.

Pre-conditions for Warranty Application. Hy-Ram Engineering Co Ltd’ warranty covers only those defects which arise as a result of normal use of the product, and this warranty shall only apply in the following circumstances:

(a) All the instructions contained in the operating manual have been complied with (b) And none of the following apply:

(i) Improper or inadequate maintenance; (ii) Physical abuse; (iii) Unauthorised modification, misuse or any use not in accordance with the

operating manual and good industry practice; (iv) Operation outside the products specifications; (v) Improper site preparation or maintenance; and (vi) Faulty pipe or fittings.

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Limitations of Warranty. (a) Hy-Ram Engineering Co Ltd does not warrant the operation of any product to be uninterrupted or error free. (b) Hy-Ram Engineering Co Ltd makes no other warranty of any kind, whether express or implied, with respect to its products. Hy-Ram Engineering Co Ltd specifically disclaims the implied warranties of satisfactory quality and fitness for a particular purpose. (c) To the extent that this warranty statement is inconsistent with the law of the locality where the customer uses the product, this warranty statement shall be deemed modified by the minimum necessary to be consistent with such local law. (d) To the extent allowed by local law, the remedies provided in this warranty statement are the customer’s sole and exclusive remedies. (e) This tool has been designed for the range of fittings available at the time of its design and development. Hy-Ram Engineering Co Ltd can accept NO liability for the unit’s ability or otherwise to work with new or different fittings that subsequently appear in the market place.

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Please complete this information and keep it safely with your proof of purchase receipt. You will require it for any warranty claim.

Where purchased ...................................................................................

Date of purchase ................................................................................... Name & address ................................................................................... Of purchaser ................................................................................... ................................................................................... Type of tool ...................................................................................

Serial number ...................................................................................

For Service and repair please contact:

Hy-Ram Mansfield Pelham Street Mansfield

Nottinghamshire NG18 2EY

Tel: 01623 422982 Fax: 01623 661022

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