Hydra-Stop Insta-Valve 250 Patriot User manual

Insta-Valve 250 PatriotTM
4”-12” Nominal Size Installation Instructions
for use with the Hydra-Q.I.K. Ouick Install Kit
IV250MAN 4”-12” IV 250 QK v2.0 Revised 09/19/2017

blank
is is supposed to be on the 2nd page

Table of Contents
SECTION ONE Page
1.00 General Safety Precautions 3
SECTION TWO - 4-8” IV 250 Installation
2.2.0 Mount Valve Body on Pipe 7
2.3.0 Installing the Temporary Gate Valve 7
2.4.0 Setting up the Hydra-Tapper for valve insertion 7
2.5.0 Installing the Hydra-Tapper for 4”-8” IV 250’s 8
2.6.0 Performing the Line Tap 9
2.7.0 Removing the Hydra-Tapper 10
2.8.0 Setting up the Hydra-Tapper for Valve Insertion 4”-8” 10
2.9.0 Install IV 250 Insertion Equipment 11
2.10.0 Set up the IV 250 Insertion Equipment for Equalization 12
2.11.0 Install the IV 250 Valve Cartridge 12
SECTION THREE - 10 - 12” IV 250 Installation
3.2.0 Mount Valve Body on Pipe 16
3.3.0 Installing the Temporary Gate Valve 16
3.4.0 Setting up the Hydra-Tapper for valve insertion 16
3.5.0 Installing the Hydra-Tapper for 10”-12” IV 250’s 17
3.6.0 Performing the Line Tap 18
3.7.0 Removing the Hydra-Tapper 19
3.8.0 Setting up the Hydra-Tapper for Valve Insertion 10”-12” 19
3.9.0 Install IV 250 Insertion Equipment 20
3.10.0 Set up the IV 250 Insertion Equipment for Equalization 21
3.11.0 Install the IV 250 Valve Cartridge 21
SECTION FOUR - APPENDICES
Appendix A Technician Tool List 23
Appendix B Manual Measuring for Valve Cartridge Installation 24
Appendix C IV 250 Valve Body Installation Instructions 26
INSTA-VALVE 250 PatriotTM
4”-12” Insertion Valve Installation Instructions
for use with the Hydra-Q.I.K. Quick Install Kit

SECTION 1.00
GENERAL SAFETY PRECAUTIONS - READ
AND FOLLOW INSTRUCTIONS
Carefully read and understand all safety messages in this
manual before using the equipment. The manuals provided
with the equalization pump must also be read for safety.
The maintenance procedures are to be
followed to keep the equipment in good working condition.
PERSONAL PROTECTION
Hydra-Stop recommends that installers wear required per-
sonal protective equipment including but not limited to:
• Hard Hat
• Safety Shoes
• Safety Glasses
• Ear Protection
• Gloves
Avoid wearing jewelry, such as rings, wristwatches, neck-
laces, or bracelets. If working near traffic, select ear protec-
tion that allows you to hear the traffic for safety.
KEEP SPECTATORS AWAY FROM INSTALLATION
AREA
Keep all spectators and other workers away from machines
and work area(s) while in operation.
CLEAR WORK AREA
Clear the work area of all objects that might interfere with
the proper operation of any tools. Avoid placing tools or
other objects where they can fall into the pit.
DO NOT WORK IN AN UNSUPPORTED TRENCH
Do not work in trench with unstable sides, which could
cave in. Specific requirements for shoring or sloping trench
walls are available from several sources including federal
and state offices. Be sure to contact suitable authorities for
these requirements before working in the trench. A mini-
mum 5’x 5’excavation is recommended.
Locate the existing pipe joints or fittings in the area and use
the appropriate restraint methods if necessary.
CHECK LAWS AND REGULATIONS
Know and obey all Federal, State, and local laws and regu-
lations that apply to your work situation.
HANDLING THE EQUIPMENT
To avoid back injury, use proper lifting techniques. Follow
all equipment instructions when lifting heavy loads.
CHECK HARDWARE AND EQUIPMENT
Make sure that all air or hydraulic line couplings are tight-
ened and secured to eliminate the chance of
accidental uncoupling. Use hose connection retaining
devices such as locking rings, clips, pins, chains, or cables.
Identify all equipment and tools necessary for the size of IV
250 you intend to install. Please refer to the attached tool
list (See Appendix A). Inspect equipment to verify it is in
good working condition and free of wear and damage prior
to use. Never start an operation if the equipment is not in
proper working order. Contact Hydra-Stop if equipment is
not in working order.
DO NOT EXCEED LOAD RATING ON ANY LIFT-
ING EQUIPMENT
This includes but is not limited to lifting magnets, eyebolts
and straps. Lifting magnets provided with Hydra-Stop
equipment are labeled with a load rating. 12” knife gate
lifting assists and ¾” eye bolts should ONLY be used for
lifting 12” and 8” temporary gate valves respectively.
WARNING: Failure to follow any of the above safety
instructions or those that follow in this manual, could result
in serious injury. Any operation involving work on pipe
containing liquids or gases under pressure is potentially
hazardous. It is necessary, therefore, that correct proce-
dures be followed in the use and maintenance of this equip-
ment to maintain a safe working environment.
No person should use this equipment who is not fully
trained in the procedures stated in this manual, and who
is not fully aware of the potential hazards connected with
work on pipe containing liquids or gases under
pressure.
The purchaser of this equipment is responsible for the
manner in which this equipment is used, maintained and the
training, competence and safety of the operators.
Should any difficulty arise at any time in the use of this
equipment, please contact HYDRA-STOP at 708-389-5111
immediately.
GENERAL SAFETY WARNINGS

Section 2
4 - 8” IV 250 Installation
Instructions

Insta-Valve 250 Patriot Installation Instructions 7 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
2.2.0 Mount & Pressure Test Valve Body on
Pipe
2.2.1) Select the proper IV 250 for installation. Identify the type
of pipe the IV 250 will be installed on.Accurately measure the
outside diameter of the pipe.
2.2.2) Refer to the attached IV 250 Valve Body Installation In-
structions. See Appendix C.
2.3.0 Installing the Temporary Gate Valve
2.3.1) Install the temporary gate valve. 4”, 6” and 8” IV 250’s use
the 8” temporary gate valve. If possible avoid positioning the
valve at the true 3, 6, 9 or 12 o’clock position to allow access to
the completion plug pins.
Temporary gate valves are single direction valves and must
be positioned top up. The 8” gate temporary valve must be
installed with the o-ring groove facing up.
2.3.2) Bolt the temporary gate
valve to the top of the IV 250
flange using the bolts, nuts and
washers provided with the instal-
lation equipment. We recommend
using a cross-tightening pattern.
2.3.3) Install the o-ring in the
groove of the 8” temporary gate
valve. (See Figure 1)
2.3.4) Fully open the temporary
gate valve.
If you own an Aluminum
Temporary Gate Valve: Fully
close the temporary gate valve and
count the number of turns to open.
This is important to know in order
to check clearance issues later.
2.4.0 Setting up the Rising Stem
Hydra-Tapper
2.4.1) Select proper size saw mandrel. Tapping of the 4”-8” IV
250 requires the 41” long saw mandrel.
2.4.2) Select proper size shell cutter. Hydra-Stop valve insertion
shell cutters are shipped painted black. If you repaint valve inser-
tion shell cutters in the future, Hydra-Stop recommends painting
them black.
Installation of 4 inch IV 250 - requires 3.8 inch cutter
Installation of 6 inch IV 250 - requires 5.8 inch cutter
Installation of 8 inch IV 250 - requires 7.9 inch cutter
Do not use red painted shell cutters to install the IV 250.
Hydra-Stop side tap shell cutters are shipped painted red.
Red painted side tap shell cutters are ½” undersized for
side tapping.
2.4.3) Select proper size pilot drill.
Installation of 4” & 6” IV 250’s require the 5/8” X 6” long pilot
drill.
Installation of 8” IV 250’s require the 5/8” X 7-1/4” length pilot
drill.
Tapping PVC or steel pipe will require a twist style pilot
drill.
Failure to use the proper sized or type of pilot drill will
result in a failed installation.
2.4.4) Loosen and remove the allen head pilot drill retaining set
screw located on the side of the saw mandrel flange base.
2.4.5) Visually locate the tapered relief on the base of the pilot
drill. Notice the stop or ledge at the base of the taper. (See Fig. 2)
2.4.6) Mark the flat of the taper with a visible marking agent.
(See Figure 3)
2.4.7) Align the pilot drill flat with the allen head set screw and
insert the pilot drill through the center of the saw mandrel stud.
(See Figure 4)
Figure 1
Figure 3
Figure 2
Figure 4

Insta-Valve 250 Patriot Installation Instructions 8 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
2.4.8) Confirm you have completely inserted the pilot drill and
engaged the tapered flat. Look into set screw hole for the mark-
ing on the pilot drill. Adjust the pilot drill until you can see the
marking. (See Figure 5)
2.4.9) Once aligned, insert and tighten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely. (See Figure 6 )
Wear gloves when pulling on the pilot drill. Edges may be
sharp.
2.4.10) Loosen and back out the 2 allen head cap screws on the
flange of the saw mandrel until flush with the face of the flange.
2.4.11) Thread the appropriate shell cutter all the way onto the
threaded stud of the saw mandrel flanged end.
2.4.12) Back off to align the holes in the base of the shell cutter
with the allen head cap screws and thread them through the holes.
Tighten allen head cap screws.
2.4.13) Make sure the saw mandrel is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
2.4.14) Lubricate the end of the saw mandrel with the spray-on
food-grade lubricant provided with the Quick Install Kit to help it
slide freely through the packing nut assembly.
2.4.15) Slide the assembled shell cutter and saw mandrel into the
Rising Stem Hydra-Tapper until the saw mandrel flange bottoms
out in the Hydra-Tapper.
2.4.17) Hand tighten the clamp lever on the packing nut assembly
to keep the assembled shell cutter and saw mandrel in place.
Do not use tools to tighten the clamp lever.
2.5.0 Installing the Rising Stem
Hydra-Tapper for 4”-8” IV 250 Installation
2.5.1) Using a strap or sling install the assembled Rising Stem
Hydra-Tapper on to the 8” temporary gate valve and align the
bolt slots.
Do not lift the assembled Rising Stem Hydra-Tapper by
the OS&Y spokes.
Use extreme caution not to damage the shell cutter or pilot
drill as the unit is raised and positioned on to the tempo-
rary valve. Note the position of the fully retracted
cutting assembly.
2.5.2) Install and cross tighten the bolts, nuts and washers to
secure the assembly. Thread the ¼” nipple and ball valve into the
tap housing and wrench tighten. Teflon tape or thread sealant
can be used.
2.5.3) Hold and control the exposed saw mandrel, loosen the
packing nut assembly clamp lever and slowly lower the saw
mandrel down until the pilot drill is resting on the center top
of the pipe. Ensure the shell cutter spins freely in a clock-wise
direction.
2.5.4) Slide the stop collar over the saw mandrel.
2.5.5) Set the cutting depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
• 4” pipe = 3” cutting depth
• 6” pipe = 4” cutting depth
• 8” pipe = 5” cutting depth
NOTE: These measurements are based on usage of standard
Hydra-Stop pilot bits specified in step 2.4.3
2.5.6) Tighten the stop collar to the correct measurement. (See
Figure 7)
Figure 7
Figure 5
Figure 6

Insta-Valve 250 Patriot Installation Instructions 9 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
2.5.7) Install the drive unit by lifting it above the saw mandrel
and slide it into the three guide bars.
2.5.8) Lower the drive unit onto the machined hex of the saw
mandrel. Confirm the drive unit is fully seated onto the machined
hex of the saw mandrel. (See Figure 8)
2.5.9) Align the thru hole of the restrained motor hex adaptor
with the thru hole of the saw mandrel and tighten the lower 3/8
shoulder bolt and locking nut.
Do not apply downward force as it can damage the pilot
drill.
2.5.10) Install the Rising Stem feed screw provided with the
Quick Install Kit by threading it through the OS&Y Fitting on the
top plate of the Rising Stem Hydra-Tapper until the machined end
of the feed screw seats into the restrained motor assembly top.
2.5.11) Align the feed screw thru hole with the restrained motor
top thru hole and tighten the upper 3/8 shoulder bolt and locking
nut
2.6.0 Performing the Line Tap
2.6.1) Ensure ball valve on the Rising Stem Hydra-Tapper P2
housing is open.
2.6.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
requires 9 GPM at 1800 PSI.
2.6.3) Ensure the drive unit lever control is in the neutral posi-
tion. Always run the power unit in the clockwise direction.
Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cutter.
2.6.4) Engage the drive unit and confirm the saw mandrel is rotat-
ing in the clockwise direction. Slowly turn the OS&Y feed screw
handles in a clockwise direction keeping slight, constant pressure
until the tap is complete.
2.6.5) Close the ball valve on the P2 housing of the Hydra-Tapper
as water fills the housing and flows from the valve.
2.6.6) The tap is complete when the bottom of the stop collar
makes contact with the top of the packing nut assembly.
Do not overfeed the tap. Overfeeding the tap will cause
the shell cutter to jam.
2.6.7) Return the drive unit lever control to the neutral position.
2.6.8) Loosen stop collar and continue to advance the feed screw
an additional two complete revolutions to ensure the cut is
complete. The shell cutter should spin freely. If it does, discon-
nect the drive unit power source from the drive unit. If the shell
cutter does not spin freely pull the drive unit lever control down
and confirm the saw mandrel is rotating in a clockwise direction.
Slowly turn the handle assembly in a clockwise direction an addi-
tional two complete revolutions. Repeat steps 2.6.6 and 2.6.7
2.6.9) Slowly turn the OS&Y feed screw handles in a counter-
clockwise direction until the stop collar has reached the starting
measurement.
• 4” pipe = 3” cutting depth
• 6” pipe = 4” cutting depth
• 8” pipe = 5” cutting depth
2.6.10) Tighten the packing nut assembly clamp lever to lock
the saw mandrel in place. Remove the 3/8 shoulder bolts. Re-
move feed screw. Remove drive unit. Remove stop collar.
2.6.11) Place handled guide plate over saw mandrel and set
within 1 inch of packing nut.
2.6.12) Slowly loosen the packing nut assembly clamp lever
while holding the saw mandrel in place via the guide plate and
guide plate handles. Allow the cutter and mandrel to rise slowly
and fully into the tapping housing. (See Figure 9).
2.6.13) Confirm the shell cutter and saw mandrel assembly is
fully retracted and lock the saw mandrel in place by tightening
the packing nut assembly clamp lever.
2.6.14) Close the temporary gate valve. If using an aluminum
gate valve: make sure you get the same number of turns to close
as you counted in step 2.3.4.
Figure 9

Insta-Valve 250 Patriot Installation Instructions 10 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
2.7.0 Removing the Rising Stem
Hydra-Tapper
2.7.1) Relieve the pressure from the Hydra-Tapper by opening the
ball valve and discharging the pressure.
2.7.2) Connect the slings or straps to the Hydra-Tapper. Unbolt
and remove the Hydra-Tapper from the temporary gate valve.
Place the Hydra-Tapper in a dry and safe work area.
2.7.3) Remove stop collar.
2.7.4) Remove cutter and saw mandrel assembly.
2.7.5) Remove the coupon by loosening the allen head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
2.7.6) Flip the pilot drill and insert it point end through the hole
in the coupon past the retaining clips and use it to pull the coupon
out of the cutter.
Wear gloves when removing the coupon. Coupon edges
may be sharp.
2.7.7) Inspect the coupon for pipe thickness and condition.
2.7.8) Remove cutter from saw mandrel.
2.8.0 Setting up the Rising Stem
Hydra-Tapper for 4-8” Valve Insertion
2.8.1) Locate the proper valve inserting equipment. Installation of
4”-8” IV 250’s will require the 4”-8” insertion housing, the 48 ½”
long insertion tool, two guide plates, and a stop collar.
2.8.2) Stand the insertion housing on a flat surface with the o-ring
grooved flange facing up. Place the o-ring into the insertion
housing o-ring groove. Install the ¾” nipple and ball valve.
2.8.3) Place the Rising Stem Hydra-Tapper on top of the insertion
housing with the pointed end of the P3 facing the same direction
as the step stand of the housing, Cross tighten with supplied
bolts, nuts and washers.
2.8.4) Tip and lay the insertion housing and Rising Stem Hy-
dra-Tapper assembly on its stand. (See Figure 10)
2.8.5) The IV 250 valve cartridge consists of top section and bot-
tom section. The top section and bottom section must be firmly
tightened together. Prior to removing operating nut hold the base
of the valve cartridge and with a pipe wrench or valve key turn
the valve stem firmly in the opening direction. (See Figure 11)
2.8.6) Remove the operating nut and the white teflon washer off
of the valve stem and place the end of the insertion tool over the
valve stem.
2.8.7) Tighten the IV 250 valve cartridge and insertion tool to-
gether by turning the knurled end of the insertion tool clockwise
until snug. Tighten the 3/4” insertion tool lock nut located at the
base of the knurled handle.
Caution: Ensure there are no gaps between the insertion
tool, valve cartridge and feed screw. The valve cartridge
should remain in tight contact with the insertion tool and
act as a single unit.
2.8.8) Make sure the insertion tool is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
Lubricate the end of the insertion tool with the spray-on food-
grade lubricant provided with the Quick Install Kit to help it slide
freely through the packing nut assembly. Ensure packing nut
assembly clamp lever is loose.
2.8.9) Insert the assembled valve cartridge and insertion tool
through the insertion housing / tapping assembly until the top of
the valve cartridge is approximately 2.5” from the bottom flange
Figure 10
Figure 11
Figure 12

Insta-Valve 250 Patriot Installation Instructions 11 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
of the insertion housing. Make sure the shorter, truncated side
of the valve cartridge marked with a star is facing upwards. (See
Figure 12 on previous page.)
2.8.10) Setup the IV 250 4”-8” alignment gauge for the size being
installed (4”, 6” or 8”). Refer to alignment gauge instructions
shipped with 4”-8” IV 250Alignment Gauge Kit.
2.8.11) Set the curved portion of the alignment gauge within the
lock pin groove of the valve cartridge. Slide the valve cartridge
and alignment gauge towards the insertion housing until the
alignment gauge touches the insertion housing. The two gauge
pins will seat in the top two holes of the insertion housing.(See
Figure 13).
2.8.12) Ensure the flat of the alignment gauge arm remains
aligned with the truncated side of the valve cartridge. (See Fig-
ure 14).
2.8.13) Place the 7.5” IV 250 Insertion Depth Gauge on the
insertion tool. Place one end of the insertion gauge against the
packing nut assembly. Slide the stop collar towards the inser-
tion gauge until the stop collar makes contact with the insertion
gauge. This automatically sets the proper depth for insertion.
Lock the stop collar.
2.8.14) Slide and place the two guide plates to within 2” of the
stop collar and lock the clamp lever. (See Figure 15).
2.8.15) Make a reference mark on the insertion housing aligned
with the centerline of the Alignment Gauge. (See Figure 13.)
2.8.16) Remove the 7.5” IV 250 Insertion Depth Gauge.
2.8.17) Slide the valve cartridge back to the original 2.5” mea-
surement away from the insertion housing. Remove the IV 250
Alignment Gauge.
2.8.18) Lubricate the completion plug o-ring with the spray-
on food grade lubricant provided with the Quick Install Kit.
2.8.19) Slide the valve cartridge assembly fully into the insertion
housing.
2.8.21) Tighten the clamp lever on the packing nut assembly to
keep the assembled valve cartridge and insertion tool in place.
Do not use tools to tighten the clamp lever.
2.9.0 Install IV 250 Insertion Equipment
2.9.1) Make sure the o-ring in the temporary gate valve is still
properly seated in the o-ring groove and safely lift the insertion
equipment on to the temporary valve.
Do not lift the insertion equipment by the OS&Y spokes
on top of the Rising Stem Hydra-Tapper.
2.9.2) Align the insertion housing reference mark made in step
2.8.15 with the point of the pentagon valve body that is in line
with the direction of the pipe. (See Figure 16). You may also
utilize the “star” on the valve as an alignment reference.
Use the pin plug hole that aligns with the valve body star as an
additional alignment reference.
2.9.3) Using the bolts, nuts and washers cross tighten the assem-
bly in place.
Figure 16
Figure 13
Figure 15
Figure 14

Insta-Valve 250 Patriot Installation Instructions 12 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
2.10.0 Set up the IV 250 Insertion Equip-
ment for Equalization
2.10.1) Install the ¼” Male NPT Interchange Plug provided with
the Quick Install Kit on to the tap housing ¼” ball valve. Use
the Quick Equalizer provided with the Quick Install Kit as your
equalization source.
2.11.0 Install the IV 250 Valve Cartridge
2.11.1) Loosen the packing nut clamp lever. Lower the valve
cartridge / insertion tool assembly until it touches the temporary
gate valve. Re-tighten the packing nut assembly clamp lever. It
is critical to install the 30” feed screw over the knurled spindle of
the insertion tool until the feed screw bottoms out on the locking
nut washer.
2.11.2) Thread the 30” Rising Stem Feed
Screw by hand until the smooth end of
the feed screw bottoms out on the 4-8”
insertion spacer, then slide top guide plate
from the insertion tool onto the smooth
section of the Rising Stem Feed Screw. It
is critical to install the 30” Rising Stem
feed screw over the spindle of the 4-8”
insertion spacer until the feed screw
bottoms out on the thicker part of the
insertion spacer. (See Figure 17).
Failure to follow step 2.11.2 could
result in damaged equipment and
failed installation.
2.11.3) Open the tapping housing and
insertion housing ball valves and slow-
ly open the temporary gate valve until
the insertion housing begins to fill. Stop
opening the temporary gate valve.
2.11.4) Close the insertion housing ball valve once fluid reaches
the ball valve. Wait for fluid to reach the tapping housing ball
valve and close ball valve. Allow the insertion / tap housings to
fully pressurize.
2.11.5) Fully open the temporary gate valve. Count your turns to
be sure it is fully open on aluminum gate valves (You do not need
to count turns on steel gate valves).
2.11.6) Loosen the packing nut assembly clamp lever and begin
advancing OS&Y stem and valve cartridge insertion assem-
bly. Advancement will stop when the completion plug o-ring
makes contact with the valve body flange. The stop collar will
be approximately 2” from the top of the packing nut assembly.
Confirm this measurement.
Do not start the next step until the 2 inch measurement has
been confirmed. (See Figure 18).
2.11.7) Connect the Quick Equalizer provided with the Quick
Install Kit and open the insertion housing ball valve.
2.11.8) Use any standard hand-held drill with a 3/8” chuck or
larger to pressurize the insertion housing until the pressure read-
ing on the Quick Equalizer gauge is 5 psi greater than the line
pressure. If properly aligned, valve cartridge should seat itself.
2.11.9) Continue advancing the feed screw until the valve car-
tridge assembly is completely seated. The valve cartridge assem-
bly is completely seated when the bottom of the stop collar makes
contact with the top of the packing nut assembly.
NOTE: Measuring errors may prevent the bottom of the stop
collar from reaching the top of the packing nut assembly. Do not
proceed to step 11 if the distance between the stop collar and
the packing nut assembly is greater than 1/8” of an inch. Fully
retract the valve cartridge from the installation housing. Close
temporary gate valve. Return to 8.0 Setting Up the Hydra-Tapper
for Valve Insertion 4”-8” Step 2.8.11 and repeat all installation
steps.
2.11.10) Remove pin plugs. Store in a clean and safe location.
2.11.11) Lock the valve cartridge assembly in place by cross
tightening the four allen head locking pins. Tighten until the
allen head locking pin makes SLIGHT CONTACT with the
completion plug - approximately 7 1/2 turns. Back off ¼ turn on
each pin. Figure 19 below shows a cross tightening pattern which
starts with Locking Pin #1 followed by Locking Pin #2, #3 and
#4. You may start with any of the locking pins as #1, however, be
sure to follow a cross tightening pattern with remaining pins.
Figure 18
Figure 19
* Note: Temporary Gate
Valve removed for clarity.
Locking Pins are shown
for location purposes only.
b
Figure 17

Insta-Valve 250 Patriot Installation Instructions 13 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
NOTE: If you experience excessive leakage from the locking pin
ports you can immediately re-install the pin plugs (removed in
step 2.11.10) after properly setting the completion plug pins.
Do not start the next step until all completion pins have been
properly set. Failure to properly set completion pins could result
in hard operation and impact valve performance. (See Figure 20
below).
2.11.12) Tighten the packing nut assembly clamp lever and retract
the feed screw three full turns.
2.11.13) Remove the Quick Equalizer. Slowly open the ¾” ball
valve on the insertion housing to relieve the pressure in the inser-
tion / tap housings.
2.11.14) Remove the Rising Stem feed screw.
2.11.15) Loosen the insertion tool lock nut three full turns. Turn
the knurled handle of the insertion tool counterclockwise until the
insertion tool is disengaged from the valve stem.
Ensure the insertion tool does not rotate when turning the
knurled handle of the insertion tool.
2.11.16) Loosen the packing nut assembly clamp lever and fully
retract the insertion tool. Re-tighten the packing nut assembly
clamp lever.
2.11.17) Remove the IV 250 insertion equipment & temporary
gate valve. Confirm o-ring is placed on top of IV 250 flange.
2.11.18) Place white teflon washer onto the valve stem.
2.11.19) Lubricate the o-ring in the bore of the IV 250 bonnet and
install over the valve stem.
2.11.20) Align bolt holes.
2.11.21) Cross tighten the bolts, nuts and washers that came with
the IV 250.
2.11.22) Set the 2” operating nut on the valve stem. Thread the
operating locking nut on to the valve stem.
2.11.23) Locate and install allen head pipe plugs removed during
IV 250 valve body installation. Use teflon tape or thread sealant
to ensure a seal.
2.11.24) Full open/close IV 250 to confirm a successful installa-
tion. IV 250 is three turns per inch plus/minus three turns depend-
ing on the type and condition of the inside diameter of the pipe.
2.11.25) Fully disassemble, clean and store equipment.
2.11.26) Order replacement parts, if necessary, to replace lost,
damaged or worn components.
Figure 20

Insta-Valve 250 Patriot Installation Instructions 14 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
Section 3
10 - 12” IV 250 Installation
Instructions

Insta-Valve 250 Patriot Installation Instructions 16 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
3.2.0 Mount & Pressure Test Valve Body
3.2.1) Select the proper IV 250 for installation. Identify the type
of pipe the IV 250 will be installed on.Accurately measure the
outside diameter of the pipe.
3.2.2) Refer to the attached IV 250 Valve Body Installation In-
structions in Appendix C.
3.3.0 Installing the Temporary Gate Valve
3.3.1) Install the temporary gate valve. 10” and 12” IV 250’s use
the 12” temporary gate valve. If possible avoid positioning the
temporary valve over one of the pin plug ports.
Temporary gate valves are single direction valves and must
be positioned top up. The 12” gate temporary valve must be
installed with the red bar facing up. (See Figure 1)
3.3.2) Install the flange o-ring in the
o-ring channel on the IV 250. Using
the 12” temporary gate valve lifting
assist supplied with the Quick Install
Kit, carefully lower the 12” tempo-
rary gate valve into position. Ensure
the temporary gate valve is centered
on the valve flange.
Failure to center temporary
valve could cause mis-align-
ment resulting in a failed
installation.
3.3.3) Bolt the temporary gate valve to the top of the IV 250
flange using the nuts and washers provided with the installation
equipment.
3.3.4) Install green fiber gasket (without holes) on
the top side of temporary gate valve. (See Figure
1)
3.3.5) Fully open the temporary valve and re-
check that temporary valve is centered.
3.4.0 Setting up the Rising Stem
Hydra-Tapper
3.4.1) Bolt Rising Stem Hydra-Tapper to the
P-20 component using the bolts / nuts included
with Rising Stem Hydra-Tapper equipment. (See
Figure 2)
3.4.2) Select proper size saw mandrel. Tapping
of 10” / 12” IV 250’s require the 55” long saw
mandrel.
3.4.3) Select proper size shell cutter. Hydra-Stop valve insertion
shell cutters are shipped painted black. If you repaint valve inser-
tion shell cutters in the future, Hydra-Stop recommends painting
them black.
Installation of 10 inch IV 250 - requires 9.8 inch cutter.
Installation of 12 inch IV 250 - requires 11.8 inch cutter.
Do not use red painted shell cutters to install IV 250.
Hydra-Stop side tap shell cutters are shipped painted red.
Red painted side tap shell cutters are ½” undersized for
side tapping.
3.4.4) Select proper size pilot drill.
Installation of 10” and 12” IV 250’s require the 3/4” X 10 5/16”
long pilot drill.
Tapping PVC or steel pipe will require a twist style pilot
drill.
Failure to use the proper sized or type of pilot drill will
result in a failed installation.
3.4.5) Loosen and remove the allen head pilot drill retaining set
screw located on the side of the saw mandrel flange base.
3.4.6) Visually locate the tapered relief on the base of the pilot
drill. Notice the stop or ledge at the base of the taper.
(See Figure 3)
3.4.7) Mark the flat of the taper with a visible marking agent.
(See Figure 4)
3.4.8) Align the pilot drill flat with the allen head set screw and
insert the pilot drill through the center of saw mandrel stud. (See
Figure 5)
Figure 1
Figure 4
Figure 3
Figure 5
Figure 2

Insta-Valve 250 Patriot Installation Instructions 17 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
3.4.9) Confirm you have completely inserted the pilot drill and
engaged the tapered flat. Look into set screw hole for the mark-
ing on the pilot bit. Adjust the pilot drill until you can see the
marking. (See Figure 6)
3.4.10) Once aligned, insert and tighten the set screw. Test pull
the pilot drill to ensure the set screw is properly locked in place
against the pilot drill ledge. Check the coupon retaining clips so
they move freely. (See Figure 7 )
Wear gloves when pulling on the pilot bit. Edges may be
sharp.
3.4.11) Thread the appropri-
ate shell cutter all the way
onto the threaded stud of the
saw mandrel flanged end.
3.4.12) Back off cutter to
align the holes in the base of
the shell cutter with the allen
head cap screw holes in the
saw mandrel. Thread screws
from inside the shell cutters
and then into the saw man-
drel holes. (See Figure 8).
3.4.13) Thread nylon lock
nuts onto allen head cap
screws and tighten. (See
Figure 9)
3.4.14) Make sure the saw mandrel is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
3.4.15) Lubricate the end of the saw mandrel with the spray-on
food-grade lubricant provided with the Quick Install Kit to help it
slide freely through the packing nut assembly.
3.4.16) Slide the assembled shell cutter and saw mandrel into the
Rising Stem Hydra-Tapper until the saw mandrel flange bottoms
out in the P-20 component.
3.4.17) Hand tighten the clamp lever on the packing nut assembly
to keep the assembled shell cutter and saw mandrel in place.
Do not use tools to tighten the clamp lever.
3.5.0 Installing the Rising Stem Hydra-Tap-
per for 10” - 12” IV 250 Installation
3.5.1) Using a strap or sling install the assembled Rising Stem
Hydra-Tapper on to the 12” temporary gate valve and align the
bolt slots.
Do not lift the assembled Rising Stem Hydra-Tapper by
the OS&Y Spokes
Use extreme caution not to damage the shell cutter or pilot
drill as the unit is raised and positioned on to the tempo-
rary valve. Note the position of the fully retracted
cutting assembly.
3.5.2) Cross tighten the bolts, nuts and washers to secure the as-
sembly. Thread the ¼” nipple and ball valve into the tap housing
and wrench tighten. Teflon tape or thread sealant can be used.
3.5.3) Hold and control the exposed saw mandrel, loosen the
clamp lever and slowly lower the saw mandrel until the pilot drill
is resting on the top of the pipe. Ensure the shell cutter spins
freely in a clock-wise direction.
3.5.4) Slide the stop collar over the saw mandrel.
3.5.5) Set the cutting depth by measuring from the top of the
packing nut assembly to the lower side of the stop collar.
3.5.6) Tighten the stop collar to the correct measurement. (See
Figure 10)
• 10” pipe = 6” Cutting Depth
• 12” pipe = 7” Cutting Depth
3.5.7) Install the drive unit by
lifting it above the saw mandrel
and slide it into the three guide
bars.
Figure 6
Figure 7
Figure 8
Figure 9 Figure 10

Insta-Valve 250 Patriot Installation Instructions 18 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
3.5.8) Lower the drive unit onto the machined hex of the saw
mandrel. Confirm the drive unit is fully seated onto the machined
hex of the saw mandrel. (See Figure 11)
3.5.9) Install the Rising Stem feed screw provided with the Quick
Install Kit by threading it through the OS&Y fitting on the top
plate of the Rising Stem Hydra-Tapper until the machined end of
the feed screw seats into the restrained motor assembly top.
Do not apply downward force as it can damage the pilot
drill.
3.5.10) Align the feed screw thru hole with the restrained motor
top thru hole and set the 3/8 shoulder bolt and locking nut.
3.6.0 Performing the Line Tap
3.6.1) Ensure ball valves on the Hydra-Tapper P2 housing and the
P20 housing are open.
3.6.2) Connect the drive unit power source to the drive unit. The
air drive unit requires 90 CFM at 90 PSI. The hydraulic drive unit
requires 9 GPM at 1800 PSI.
3.6.3) Ensure the drive unit lever control is in the neutral posi-
tion. Always run the power unit in the clockwise direction.
Avoid reversing as this will damage the carbide on the
pilot drill and carbide teeth on the shell cutter.
3.6.4) Engage the drive unit and confirm the saw mandrel is rotat-
ing in the clockwise direction. Slowly turn the OS&Y feed screw
handles in a clockwise direction keeping slight, constant pressure
until the tap is complete.
3.6.5) Close the ball valves on the P20 housing and the P2
housing of the Hydra-Tapper as water fills the housings and flows
from the valves.
3.6.6) The tap is complete when the bottom of the stop collar
makes contact with the top of the packing nut assembly.
Do not overfeed the tap. Overfeeding the tap will cause
the shell cutter to jam.
3.6.7) Return the drive unit lever control to the neutral position.
3.6.8) Loosen the stop collar and continue to advance the feed
screw an additional two complete revolutions to ensure the cut is
complete. The shell cutter should spin freely. If it does, discon-
nect the drive unit power source from the drive unit. If the shell
cutter does not spin freely engage the drive unit and confirm the
saw mandrel is rotating in a clockwise direction. Slowly turn the
handle assembly in a clockwise direction an additional two com-
plete revolutions. Repeat steps 3.6.6 and 3.6.7.
3.6.9) Slowly turn the OS&Y feed screw handles in a count-
er-clockwise direction until the stop collar has reached the start-
ing measurement.
• 10” pipe = 6” Cutting Depth
• 12” pipe = 7” Cutting Depth
3.6.10) Tighten the packing nut assembly clamp lever to lock the
saw mandrel in place. Remove the 3/8 shoulder bolts. Remove
feed screw. Remove drive unit. Remove stop collar.
3.6.11) Place handled guide plate over saw mandrel and set with-
in 1 inch of packing nut.
3.6.12) Slowly loosen the packing nut assembly clamp lever
while holding the saw mandrel in place via the guide plate and
guide plate handles. Allow the cutter and mandrel to raise slowly
and fully into the tapping housing. (See Figure 12)
3.6.13) Confirm the shell cutter and saw mandrel is fully retracted
and lock the saw mandrel in place by tightening the packing nut
assembly clamp lever.
3.6.14) Close the temporary gate valve.
Figure 11
Figure 12

Insta-Valve 250 Patriot Installation Instructions 19 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
3.7.0 Removing the Rising Stem
Hydra-Tapper
3.7.1) Relieve the pressure from the Rising Stem Hydra-Tapper
by opening the ball valve and discharging the pressure.
3.7.2) Connect the slings or straps to the Rising Stem Hydra-Tap-
per. Unbolt and remove the Rising Stem Hydra-Tapper / P-20
assembly from the temporary gate valve. Place the assembly in a
dry and safe work area.
3.7.3) Remove stop collar.
3.7.4) Remove cutter and saw mandrel assembly.
3.7.5) Remove the coupon by loosening the allen head pilot drill
retaining set screw. Remove the pilot drill from the saw mandrel
stud.
3.7.6) Flip the pilot drill and insert it point end through the hole
in the coupon past the retaining clips and use it to pull the coupon
out of the cutter.
Wear gloves when removing the coupon. Coupon edges
may be sharp.
3.7.7) Inspect the coupon for pipe thickness and condition.
3.7.8) Remove cutter from saw mandrel.
3.8.0 Setting Up the Rising Stem
Hydra-Tapper for 10” - 12” Valve Insertion
3.8.1) Locate the proper valve inserting equipment. Installation of
10”-12” IV 250’s will require the 10”-12” insertion housing, the
59” long insertion tool, two guide plates and a stop collar.
3.8.2) Stand the insertion housing on a flat surface. Place a green
full-faced fiber gasket with holes (included with equipment)
between the insertion housing and the tapping machine / P 20
assembly. Install the ¾” nipple and ball valve.
3.8.3) Place the Hydra-Tapper / P-20 assembly on top of the
insertion housing with the pointed end of the P3 facing the same
direction as the step stand of the housing, Cross tighten with
supplied bolts, nuts and washers.
3.8.4) Tip and lay the insertion housing and Hydra-Tapper / P20
assembly on its stand. (See Figure 13)
3.8.5) The IV 250 valve cartridge consists of top section and bot-
tom section. The top section and bottom section must be firmly
tightened together. Prior to removing operating nut hold the base
of the valve cartridge and with a pipe wrench or valve key turn
the valve stem firmly in the opening direction. (See Figure 14)
3.8.6) Remove the operating nut and the white thrust washer off
of the valve stem and place the end of the insertion tool over the
valve stem.
3.8.7) Tighten the IV 250 valve cartridge and insertion tool to-
gether by turning the knurled end of the insertion tool clockwise
until snug. Tighten the 3/4” insertion tool lock nut located at the
base of the knurled handle.
Caution: Ensure there are no gaps between the insertion
tool, valve cartridge and feed screw. The valve cartridge
should remain in tight contact with the insertion tool and
act as a single unit.
3.8.8) Make sure the insertion tool is clean and free of rust or
grime (steel wool can be used to clean and smooth the surface).
Lubricate the end of the insertion tool with the spray-on good-
grade lubricant provided with the Quick Install Kit to help it slide
freely through the packing nut assembly. Ensure packing nut
assembly clamp lever is loose.
3.8.9) Insert the assembled valve cartridge and insertion tool
through the insertion housing / tapping assembly until the top of
the valve cartridge is approximately 2.5” from the bottom flange
of the insertion housing. Make sure the shorter, truncated side
of the valve cartridge is facing upwards. (See figure 15 on next
page.)
3.8.10) Slide the stop collar over the knurled end of the insertion
tool. Align the 3 slots of the triangular shaped guide plate with
the 3 guide bars and slide it over the knurled end of the insertion
tool.
Figure 13
Figure 14

Insta-Valve 250 Patriot Installation Instructions 20 IV250MAN 4”-12” IV 250 QK v2.0 09/27/2017
3.8.11) Setup the IV 250 10”-12” Alignment Gauge for the size
being installed (10” or 12”). Refer to Alignment Gauge instruc-
tions shipped with 10”-12” IV 250Alignment Gauge Kit.
3.8.12) Set the curved portion of the alignment gauge within the
lock pin groove of the valve cartridge. Slide the valve cartridge
and alignment gauge towards the insertion housing until the
alignment gauge touches the insertion housing. The two gauge
pins will seat in the top two holes of the insertion housing. (See
Figure 17).
3.8.13) Ensure the flat of the alignment gauge arm remains
aligned with the truncated side of the valve cartridge. (See Fig-
ure 16).
3.8.14) Place the 4.25” IV 250 Insertion Gauge on the insertion
tool. Place one end of the insertion gauge against the packing nut
assembly. Slide the stop collar towards the insertion gauge until
the stop collar makes contact with the insertion gauge. This auto-
matically sets the proper depth for insertion. Lock the stop collar.
3.8.15) Make a reference mark on the insertion housing inline
with the alignment gauge centerline. (See Figure 17)
3.8.16) Slide and place the two guide plates to within two
inches of the stop collar and lock the clamp lever. (See Figure
18).
3.8.17) Remove the 4.25” IV 250 Insertion Gauge.
3.8.18) Slide the valve cartridge back to the original 2.5” mea-
surement away from the insertion housing. Remove the IV 250
Alignment Gauge.
3.8.19) Lubricate the completion plug o-ring with spray-on food-
grade lubricant provided with the Quick Install Kit.
3.8.20) Slide the valve cartridge assembly fully into the insertion
housing.
3.8.21) Tighten the clamp lever.
Do not use tools to tighten the clamp lever.
3.9.0 Install IV 250 Insertion Equipment
3.9.1) Place a green fiber ring gasket without holes (included
with equipment) between the insertion housing and the temporary
gate valve. Safely lift the insertion equipment and place on to the
temporary valve.
Do not lift the insertion equipment by the OS&Y spokes
on top the Rising Stem Hydra-Tapper.
3.9.2) Align the insertion housing reference mark made in step
3.8.15 with the point of the pentagon valve body that is in line
with the direction of the pipe. (See Figure 19)
NOTE: Use the pin plug hole that aligns with the valve
body pentagon point as an additional alignment reference.
3.9.3) Thread nuts and washers provided and cross tighten the
Figure 19
Figure 16
Figure 18
Figure 17
Figure 15