Compressed Air Alliance HTD User manual

www.compressedairalliance.com 1
User Manual
Hot Tap Drill
Model: HTD

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 2
Table of Contents
Notices...........................................................................................................................................3
Warnings .......................................................................................................................................4
About Hot Tapping.......................................................................................................................5
Specifications................................................................................................................................6
Hot Tap Drill Kit ............................................................................................................................7
Using the Hot Tap Drill ................................................................................................................8
Warranty......................................................................................................................................14
Need help? ..................................................................................................................................14

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 3
Notices
Please read this manual in full and
carefully observe the notes and
instructions before and during
installation, operation and
maintenance. The manufacturer
cannot be held liable for any damage
which occurs as a result of
noncompliance with this 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 product is designed exclusively
for the described application. Use
of this product in conditions not
specified in this manual or, contrary
to the instructions provided by the
manufacturer, 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 manual should be read carefully
by relevant personnel and the end
user. This manual should be kept
with the product and be made
available as needed. Once you
install or use the product, you
accept that you have read,
understood and complied with this
manual.
Compressed Air Alliance endeavours
to make the content of this manual
correct, but is not responsible for
omissions or errors and the
consequences caused. In case of any
doubts or questions regarding this
manual or the product, please
contact Compressed Air Alliance.

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 4
Warnings
Ignoring the warnings can lead to
serious injury and/or cause
damage!
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 they 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 operating pressure.
•Wear suitable PPE including
face/eye and hearing protection
•Only use pressure rated
installation materials and parts.
•Avoid getting hit by escaping air
or bursting parts.
•Do not use this product in
explosive areas.

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 5
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”
Drill and Adapter
Height
380 mm
15”
Interchangeable
Drill Bit Height
170 mm
6.7”
Drill Width
47 mm
2”

www.compressedairalliance.com 6
Hot Tap Drill Kit User Manual v1
Specifications
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

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 7
Hot Tap Drill Kit
Each hot tap drill kit comes with:
✓Carry Case
✓Drill, Chip collector and wrench
✓Your choice of drill bits and adaptors
Hot tap tool
Chip collector
PLUS
Your choice of drill bits
and adaptors
Wrench
PLUS
PLUS

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 8
Using the Hot Tap Drill
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.
•Wear suitable PPE including face/eye and hearing protection when using the
hot tap drill
Hot Tapping Steps
Step 1 –Assemble hot tap drill
Step 2 –Attach hot tap saddle / clamp / hoop and ball valve to pipe
Step 3 –Attach hot tap drill to ball valve
Step 4 –Drill hole
Step 5 –Remove and clean hot tap drill
Tools and Equipment needed
(not included with Hot Tap Drill kit)
Hot tap saddle / clamp
with a 1/4" or 1/2" or 3/4"
or 1" threaded head
Ball valve
Thread Tape
Reducing Bush
(Optional)

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 9
Step 1 - Assemble hot tap drill
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.
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
Socket Wrench
Drill
Chip collector
Adaptor
Drill Bit
Assembled Hot Tap Drill

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 10
Step 2 –Attach hot tap saddle and ball valve to pipe
•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.
oClean pipe first to provide a better seal.
•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 (0.33” & 0.57” & 0.77” & 0.96”) drill bits respectively. If needed, use
a reducing bush to fit the ball valve to the clamp.
•Close the ball valve.
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. Refer to
the Compressed Air Alliance website:
https://www.compressedairalliance.com/product-category/hot-tapping/

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 11
Step 3 –Attach hot tap drill to ball valve
•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, use a gasket or thread
tape.
•Open the ball valve
•Open the chip collector valve
Open ball valve and chip collector
Screw drill into ball valve

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 12
Step 4 –Drill hole
•Wear suitable PPE including face/eye and hearing protection when using the
hot tap drill
•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.
•Attach the wrench to the top of the tool
•While holding the body of the tool, turn the wrench in a clockwise direction to
start drilling.
•Turn the wrench between two and three complete turns before adjusting the
body of the tool.
•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.
•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.
Turn wrench clockwise
to drill hole
Hold drill
Occasionally adjust body of the tool
to increase pressure on drill bit

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 13
Step 5 –Remove drill and clean
•When the drill bit is completely through the wall of the pipe: 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.
•Once the drill bit has been extracted far enough, you will be able to close the
ball valve.
•Remove the entire tool from the valve
•Blast the ball valve by opening and closing it two or three times quickly. This will
ensure no chips are left under the valve.
oEnsure you are wearing eye/face and hearing protection when doing this.
Warn anyone in the area of the sudden noise.
•Dismantle the drill and adaptor from the tool and clean out any chips within the
tool body.
•Unscrew the sintered cap filter on the side of the dismantled drill and pour out
the metal shavings.
Cleaning
To clean the drill it is recommended to use a clean, dry cloth. For stubborn marks,
use distilled water or isopropyl alcohol only.
The chip collector should be emptied before and after using the hot tap drill.
Metal shavings / chips

www.compressedairalliance.com 14
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:
[email protected]
Website:
www.compressedairalliance.com

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 15
This page is left blank intentionally

Hot Tap Drill Kit User Manual v1
www.compressedairalliance.com 16
Compressed Air Alliance Pty Ltd
Phone (Australia): 1300 558 526
E-mail: [email protected]
Website: www.compressedairalliance.com