Compressed Air Alliance HTD User manual

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User Manual
Hot Tap Drill Kit
Model: HTD

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Hot Tap Drill Kit User Manual v1
Table of Contents
Notices............................................................................................................................................................... 3
Safety and Warnings.......................................................................................................................................... 3
About Hot Tapping ............................................................................................................................................ 4
Hot Tap Drill Kit.................................................................................................................................................. 5
Specifications..................................................................................................................................................... 6
Installation......................................................................................................................................................... 7
Warranty.......................................................................................................................................................... 10
Need help?....................................................................................................................................................... 10

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Hot Tap Drill Kit User Manual v1
Notices
Please check that this user manual and the
product type match. If you do not have the
correct user manual, contact Compressed Air
Alliance.
Please read this user manual in full and carefully
observe the notes and instructions before and
during assembly, installation, operation, and
maintenance. The manufacturer cannot be held
liable for any damage which occurs as a result of
non-observance or noncompliance with this user
manual.
Do not tamper with device. Should the device be
tampered with in any manner other than a
procedure which is described and specified in this
manual, the warranty is cancelled, and the
manufacturer is exempt from liability.
The device is designed exclusively for the
described application. Usage of this product in
conditions not specified in this manual or in
contrary to the instructions hereby provided is
considered improper handling of the product and
will void your warranty. The manufacturer will
not be held liable for any damages resulting from
improper use of the product.
This user manual should be read carefully by the
technician / qualified personnel and the end user.
Once you install, use or maintain this product,
you accept that you have read, understood and
complied with this manual. This manual should
be kept with the product and made available to
relevant personnel as needed. In case of any
obscurities or questions, regarding this manual or
the product, please contact Compressed Air
Alliance.
Compressed Air Alliance accepts no liability for
the integrity of the item that this equipment is
used on or applied to. Use of this equipment, its
safe application and its suitability for the job are
at the sole discretion of the user.
Compressed Air Alliance endeavors to make the
content of this manual correct and well stated,
but is not responsible for omissions or errors and
the consequences caused thereby.
Safety and Warnings
Ignoring the warnings can lead to serious injury
and/or cause damage!
Hot tapping on a pressurized system is a highly
dangerous operation. When handling, operating
or carrying out maintenance on this product,
personnel must employ safe working practices
and observe all local health & safety
requirements and regulations. Improper
operation or maintenance of this product could
be dangerous and result in an accident causing
damage to machinery or injury or death.
The manufacturer cannot anticipate every
possible circumstance which may represent a
potential hazard. The warnings in this manual
cover the most common potential hazards and
are therefore not all-inclusive. If the user employs
an operating procedure, an item of equipment or
a method of working which is not specifically
recommended by the manufacturer he or she
must ensure that the product will not be
damaged or made unsafe and that there is no risk
to persons or property.
NEVER CHANGE ORIGINAL COMPONENTS WITH
ALTERNATIVES.
Compressed Air Safety
Any contact with quickly escaping air or bursting
parts of the compressed air system can lead to
serious injuries or even death.
•Do not exceed the maximum permitted
pressure.
•Wear face/eye and hearing protection
•Only use pressure tight installation material.
•Avoid getting hit by escaping air or bursting
parts.
•Do not use this product in explosive areas

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Hot Tap Drill Kit User Manual v1
About Hot Tapping
A hot tap drill is a universal tool that allows you
to manually install a connection point on
pressurized or unpressurised pipes.
A typical hot tap requires a:
•the hot tapping drill
•tapping saddle / clamp,
•ball valve.
Hot tapping takes approximately 30-60 minutes,
depending on the size of the hole and the pipe
material.
Note: Hot tapping can be dangerous and should
be performed by experienced technicians only.
Care should be taken when using the hot tap drill
and appropriate personal protection equipment
should be worn.
Compressed Air Alliance’s hot tap drill is designed
to prevent contamination from the drilling
process entering into the pipework when used on
pressurized pipework. As the drill bit starts to
pierce the pipe, air pressure forces loose particles
back through an exhaust chamber in the drill’s
body where they are captured. This process
ensures that no contamination enters the
pipework when working on pressurized pipes.
Key Features of the Hot Tap Drill
•Can be operated under pressure
•Maximum operating pressure up to 20 bar
(290 psi)
•Innovative structural design to avoid the bit
getting stuck or broken
•Maximum drilling depth up to 200 mm
(7.87”)
•4 interchangeable drill bit sizes:
o8.5 & 14.5 & 19.5 & 24.5 mm
o0.33” & 0.57” & 0.77” & 0.96”
Socket Wrench
Drill
Chip collector
Adaptor
Drill Bit

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Hot Tap Drill Kit User Manual v1
Hot Tap Drill Kit
Each hot tap drill kit comes with:
✓Hard Case
✓Drill, Chip collector and wrench
✓Your choice of drill bits and adaptors
Optional Accessories
The following accessories are available for the hot tap drill kit. Talk to your local dealer for pricing and other
accessories. Note: The pressure rating clamps and valves should be matched to the system being hot
tapped.
Measurement Sensors
Clamps
Ball Valve
PLUS
PLUS
Hot tap tool
PLUS Your choice of drill
bits and adaptors
Wrench
Chip collector
PLUS

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Hot Tap Drill Kit User Manual v1
Specifications
Technical Data
Hot Tap Drill Kit
Drill Depth
Up to 200 mm
Up to 7.87”
Drill Diameters
8.5 & 14.5 & 19.5 & 24.5 mm (interchangeable)
0.33” & 0.57” & 0.77” & 0.96” (interchangeable)
Corresponding Ball Valves
1/4” & 1/2” & 3/4” & 1”
Operating Pressure
20 bar
290 psi
Operating Temperature
-50°C to +200°C
-58°F to +392°F
Drill Bit Material
Cobalt-containing high-performance high-speed steel HSS / E
Main Body Shell Material
Aluminium
Dimensions
Drill and Adapter
380 mm x 47 mm x 47 mm
15” x 2” x 2”
Drill Bit
170 mm long
6.7” long
Socket Wrench
250 mm x 60 mm x 45 mm
9.8” x 2.4” x 1.8”
Weight
2.6 kg
5.7 pounds
Warranty Period
12 Months
Dimensions
Drill and Adapter
380 mm
15”
Drill Bit
170 mm
6.7”
47 mm
2”
Interchangeable Drill Bit
8.5 & 14.5 & 19.5 & 24.5 mm
0.33” & 0.57” & 0.77” & 0.96”
Interchangeable Adapter
DN8, DN15, DN20, DN25
1/4” & 1/2” & 3/4” & 1”

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Hot Tap Drill Kit User Manual v1
Installation
WARNING! Hot tapping can be dangerous.
Notes:
•Do not use this product in explosive areas.
•Use only pressure-resistant installation materials when using the product.
•Please observe national regulations before/during installation and operation.
Tools and Equipment required
Step 1 –Install a connection point
•Find a suitable location with enough space to install, use and remove the hot tap drill.
oAlso make sure the location has enough space to install the sensor, pipe or other item you will
connect to the new connection (after drilling the hole). Refer to the relevant user manual for your
installation requirements.
•Attach a hot tap saddle / clamp / hoop with a 1/4" or 1/2" or 3/4" or 1" threaded head directly on the
pipe.
•Attach a ball valve to the clamp. Use thread tape to ensure that the seal is intact.
oFour ball valves 1/4" & 1/2" & 3/4" & 1" correspond to 8.5 & 14.5 & 19.5 & 24.5 mm drill bits
respectively. Alternatively, you can use a reducing bush to fit a smaller drill bit to a larger valve.
•Close the ball valve.
Hot tap saddle / clamp
with a 1/4" or 1/2" or 3/4"
or 1" threaded head
Ball valve
Thread Tape
Ball Valve
Hot tap saddle / clamp
NOTE: Hot tap saddle / clamp and ball valve
are not included with the hot tap kit. These
items are available for purchase separately

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Hot Tap Drill Kit User Manual v1
Step 2 –Attach hot tap device
•Assemble the hot tap drill:
1. Select the appropriate drill bit size and corresponding adaptor
2. Screw the drill bit into the tool
3. Slide the adaptor over the drill bit and screw it onto the tool
4. Screw the chip collector to the adapter. If necessary, pour out the metal shavings inside the chip
collector before attaching.
•Hold the adaptor and unwind the body of the tool to retract the drill bit far enough to allow it to be
mounted on the ball valve.
•Screw the drill onto the ball valve. To ensure a good seal, using a gasket or sealing tape.
•Open the ball valve
•Open the chip collector valve
Step 3 –Slide Adapter over drill
bit and screw Adapter to Drill
Step 2 - Screw drill bit into drill
Step 4 - Screw Chip
Collector to Adapter
Open ball valve and chip collector
Screw drill into ball valve

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Hot Tap Drill Kit User Manual v1
Step 3 –Drill Hole
1. Turn the housing clockwise until the drill bit touches the outer wall of the pipe, you will feel a slight
resistance. Ensure there is only slight pressure on the drill bit.
2. Attach the wrench to the top of the tool
3. While holding the body of the tool, turn the wrench in a clockwise direction to start drilling.
4. Turn the wrench between two and three complete turns before adjusting the body of the tool.
5. Turn the body of the tool clockwise very slightly (no more than 1/8 of a turn). This increases the
pressure on the drill bit. Repeat the previous step.
6. Continue repeating the previous two steps until the hole is drilled through the wall of the pipe.
•As the drill tip begins to pierce the pipe, you will begin to hear a hissing sound from the chip
collector. NOTE: this does not mean the hole is completed, you will need to continue until the drill
bit is completely through the wall of the pipe. When this has occurred, you will notice lower
resistance when adjusting the body of the tool clockwise.
7. Turn the body of the tool counter-clockwise to retract the drill bit from the pipe and the ball valve.
•Ensure the drill bit is kept stationary during this operation. Do not allow it to turn counter-
clockwise as this may result in damage to the drill bit or allow it to unscrew from the tool.
8. Once the drill bit has been extracted far enough, you will be able to close the ball valve.
9. Remove the entire tool from the valve
10. Blast the valve by opening and closing it two or three times quickly. This will ensure no chips are left
under the valve.
•Ensure you are wearing eye/face and hearing protection when doing this. Warn anyone in the
area of the sudden noise.
11. Unscrew the sintered cap filter on the side of the dismantled drill and pour out the metal shavings.
12. Dismantle the drill and adaptor from the tool and clean out any chips within the tool body.
Turn wrench clockwise
to drill hole
Hold drill
Occasionally adjust body of the tool
to increase pressure on drill bit

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Hot Tap Drill Kit User Manual v1
Warranty
Compressed Air Alliance provides a 12-month
warranty for the hot tap drill kit. The warranty
covers material and workmanship under the
stated operating conditions from the date of
delivery. Please report any findings immediately
and within the warranty time.
If faults occur during the warranty period
Compressed Air Alliance will repair or replace the
defective unit, without charge for repair labour
and material costs but there is a charge for other
services such as labour to remove or reinstall the
instrument, transport, and packing. Warranty
repairs do not extend the period of warranty.
The following damage is excluded from this
warranty:
•Improper use and non-adherence to the user
manual.
•Use of unsuitable accessories.
•External influences (e.g. damage caused by
vibration, damage during transportation,
excess heat or moisture).
The warranty is cancelled when one of the
following situations occurs:
•The user opens the hot tap drill without a
direct request written in this manual.
•Repairs or modifications are undertaken by
third parties or unauthorized persons.
•The serial number has been changed,
damaged or removed.
Other claims, especially damage occurring on the
outside of the instrument (eg dents, marks), are
not included unless responsibility is legally
binding.
Need help?
Contact your local dealer.
Alternatively, contact Compressed Air Alliance
via:
Phone (Australia): 1300 558 526
E-mail: [e-mail]
Website: www.compressedairalliance.com