Live Insertion Valve

1. Installation of fitting housings

► Attach the drain valve to the fitting housing B, and apply grease to the housing gaskets of fitting housing A and B and the pipe where the gaskets come into contact with (Silicone grease is advised).

► Place the fitting housings on the pipe and connect them by using T-bolts and nut.

• In order to prevent uneven tightening, tighten the bolts alternately.
• Tighten fitting housing A and B evenly so that the edge face of both corners are aligned.

The clearance between fitting housings should be DN200:4mm DN250,300:6mm for standard JIS OD. Please adjust the clearance depending on the actual pipe OD. 

► Attach the chain device.

• Attach the body of chain device to the fitting housing B on the side where the rotating feed apparatus is located with using a special bolt.

► Set the fitting housings in horizontal position by using level gauge. Attach the end ring so that it comes into contact to the edge of fitting housings. Make sure the positioning pin (with red knob) touches to the pin of the end rings.

• If it is misaligned or loosened. improper drilling is caused.
• Make sure to fix with 4 bolts at top and bottom tightly after tightening the T-Bolts and nuts.

4. Mount the EM machine

► Remove the blind flange.

► Mount the EM machine on the fitting housing A.

• Check the tip of the cutter before attaching the EM machine. (Change the chips by using a special tool if broken or worn out)
• Check if the cutter is attached properly to the EM machine.
• Only for DN250. replace 2 bolts with the red marked bolts (classified as tool).

Caution! The shaft and tip of cutter are sticking out from the EM machine.

► Connect the electrical cables (there are 2 cables) to the motor of the EM machine

► Connect the power cable to the controller (AC200V)

► Connect the drain hose to the drain valve (drain valve should be closed).

► Operation check

• Relocate the positioning pin (with red knob) and attach the handle to the rotating feed apparatus. By turning the handle, rotate the fitting housings round within the given angular range (the end ring limits the range).
• Make sure to relocate the positioning pin. It may cause the damage of component.
• Check for the smooth rotation, no interference, no misalignment of the rotating feed apparatus and the end ring, no looseness of the chain.
• Make sure to check the operation until fitting housings touch the positioning pin.

► Set the fitting housings back to the horizontal position and adjust the stroke gauge, and it is ready to conduct drilling operation.

5. Drilling Operation

► Turn the main power switch on of the controller. After 30 seconds, turn the power switch of the EM machine on. (The shaft starts to rotate.)

► Turn the handle of the EM machine and feed the shaft until the tip of the cutter touches the surface of the pipe.

► Start the vertical drilling. Open the drain valve when the cutter feed halfway. After penetration, set the feeding gauge on the final position. This would be the end of the vertical drilling.

• Make sure to check the feeding gauge of cutter. If not, it may cause improper drilling or damage to the pipe or cutter.

► Start the sideways cutting by turning the handle of the rotating feed apparatus to rotate the fitting housings.

• Rotate the fitting housings to cut right and left from the center position

► The sideways cutting is done by rotating the fitting housings within the predetermined angular range (check by using the positioning pin)

► After the sideways cutting Is finished, put back the cutter while the shaft of EM machine is still rotating. Rotate the fitting housings to the horizontal position.

• Check if the cutting chips are coming out of the drain port during cutting operation. (If the drain hose is bent, it causes an impediment for the cutting chips coming out.)
• Make sure to confirm the position of start and finish of cutting by checking the positioning pin. If not, it may cause improper drilling.
• Pay special attention to the drilling sound. If the drilling sound is not normal or there is resistance, shut the power off and stop cutting.
• When putting back the fitting housings to the horizontal position, relocate the positioning pin (with red knob) to the original position to touch the pin of the end ring.

6. Removal of the EM machine

► Remove the chain and the rotating feed apparatus, and mount the sliding device.

• There are 2 kinds of sliding device; one is for DN200 only, the other is for DN250 & 300. (For DN250 and 300, use the common spacers on the side which is going to touch the pipe, and use the spacers inside out for DN250 and DN300 on the side which is going to connect with the fitting housings.)
• For the DN250, fit the (A) marks each other for the part which is going to touch the pipe .
• Mount the sliding device so that the spacer (yellow) touches to the side wall.
• Connect the sliding device and the fitting housings with bolts. There are 2 holes for the bolts. Use the front hole this time. Make sure not to interfere the tips of bolts on the pipe.
• Tighten the bolts and nuts and make sure to fix with 4 bolts at top and bottom tightly.

► After confirming water stops by checking with the drain valve, remove the drain valve and attach the plug. After filling the fitting housings with water, remove the EM machine and attach the valve bonnet

► Switch the direction control valve to Free and open the operation valve (turn left).

► Switch the direction control valve to PUSH.

► Turn the operation valve to SHUT (turn right).

► Move the lever up and down and extend the cylinder to slide back the body to the original position.

• Make sure the horizontal position by checking the pins touch each other.

Caution! Remove the spacer and slide the body back if it is impossible to move it to original position due to lack of stoke.

7. Mount of the stopper bolts

► Operate the valve to the halfway of its number of turns to check the position (valve disc and opening) is correct

• Make sure that do not move the body until all stopper bolts are tightened. If body weight or some force is applied, the horizontal level of the body may be affected.

► Attach the stopper bolts on both sides of the fitting housings. Then tighten them so that the clearance between the fitting housings and the pipe become almost equal.

• Make sure to tighten all the stopper bolts. If the bolts are loosened. the body may move.

Tightening torque of stopper bolts …(M20) 60N*m

► Remove the rotating feed apparatus and the end ring.

► Fully open the valve that was half way closed. Operate halfway down again and fully open it again.

• Operate the valve and check for smooth operation without interference in the

► Re-tighten the screw of wrench nut.

8. Cleaning the body and cover the polyethylene sleeve

► Clean the body and the pipe around it.

► After covering the body with the polyethylene sleeve, the job is done.