JIP Hot Tapping Machine

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Operating GuideHotTappingMachine ToolboxJIPJIPHotTappingMachineDN 20-100 Danfoss 2019.04VI.KD.G2.02 1

Operating GuideJIP Hot Tapping Machine Toolbox1. VI.KD.G2.02ContentSafety InstructionsGeneral Safety RequirementsSafety Requirements at the WorksideSpecial RisksThe Significance of Symbols used SafetyDescription Danfoss Hot Tapping Machine ToolboxArea of UseSpecifications of the Danfoss Drilling DeviceDanfoss JIP Hot Tap Valves with Hot Tapping Machine ToolboxOperational InstructionsBranch Preparations before the Hot TappingRemoving the InsulationAdjusting the Hot Tap ValveWelding of the Hot Tap Valve to the Main LineTesting the ValveAssembly of the Drilling DeviceAssembly of the shaft for hole saws 32 mmAssembly of the shaft for hole saws 32 mmAssembly of the Danfoss JIP Adapter SocketAssembly of the Device to the Hot Tapping ValveInstalling the Feed UnitInstalling the Driving UnitThe Hot Tapping ProcessPressure TestStarting the Driling ProcessAdjusting the FeedReleasing the Feed UnitClosing the Valve and Releasing the PressureDisassembling the MachineCreating the New BranchMaintanance Plan and Spare Part ListUsing the Chain BlockAttachments:Safety Instructions in Regards to the Electrical Driving 81919202324 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox2. Safety InstructionsThe user is well adviced to follow the safety instructions given in this manual. No warranty isgiven for incorrect usage of the equipment or applications outside the scope of the Danfoss usermanuals!If any questions occur or if you are unsure about certain aspects regarding the Danfoss hottapping machine toolbox, please don't hesitate to contact local Danfoss for support. It isrecommended to limit the pressure in the system to 12 bar during the operation.2.1. General Safety RequirementsIn the following chapters, the general and specific saftey instructions for the Danfoss hot tapping machine toolboxare given and explained. The user is well adviced to read, understand and follow these instructions carefully.Only qualified and trained person is allowed to execute hot tapping works with the Danfoss hot tapping tool.Among the operators, there should be a control system to ensure that the skills and knowledge of the rightoperation procedures are known and respected by all the working person taking part in hot tapping works. Thisuser manual has to be always available during the drilling works.It is not allowed to use the device outside the application area described in this user manual without thepermission of hot tapping toolbox device manufacturer Danfoss.Be aware that additional requirements can be given at the specific worksite.For a safe usage of the equipment is essential to take the following general points into account: Never use the machine without being aware of the hazards. Take all the aspects from this usermanual and additional requirments into account. The staff must have the adequate skills and training in all the necessary phases ofthe hot tapping work as well as in handling the equipment in question. Make sure that you always have a copy of this user manual with you which is available during thehot tapping process. The Instruction may be downloaded from the manufacturer'sweb-site (http://www.danfoss.com). The application area for this device is limited to water-based liquid fluids of fluid group 2according to PED 2014/68/EU. The system parameters shall never exceed 200 C and/or 40 bar ofpressure. See chapter 3 regarding the max. temperature and pressure this device can be used.It is recommended to reduce the pressure in the system to 12 bar during the operation. Make sure that the chosen adapter including sealings is suitable for the system pressure, fluid typeand temperature. Always make sure that the equipment is not damaged before starting the hot tapping process.Only equipment in excellent condition shall be used. Only use original Danfoss spare parts for your own safety. Wear ear protection and a helmet. Wear suitable work clothes. Do not wear loose clothing or jewellery as they can be caught in movingparts. For the protection from hot fluid, wear heat resistant clothes, gloves and safety glasses. Danfoss 2019.04VI.KD.G2.02 3

Operating GuideJIP Hot Tapping Machine Toolbox Any technical change at the hot tapping machine is not allowed. Read and follow the instruction manual for using the chain block. Take the general accident prevention regulations into account. Take the instructions for motor driven machines into account. Consider the hazards fromelectric current and rotating parts (attachment A1). The electric drive shall never get wet.2.2. Safety Requirements at the WorksiteThe following aspects have to always be checked at the workside before using the Danfoss drilling device.For drillings in district heating pipelines in Germany, the AGFW directive 432 has to be considered. Always make sure that it is possible to close the chosen Hot Tap valve. If the shuttingmechanism cannot be closed, the only way to remove the drilling device is to empty the main line. Double check the size of the used hole saw and pilot drill. Check that the valve closes after themachine is assembled. Familiarize yourself with the Danfoss data sheet for the chosen valve type Make sure that the technical parameters (pressure, temperature, fluid) in the system are notexceeding the allowed values given in this user manual for the specific application Check that the device is assembled correctly as shown in this user manual Always make a pressure test to discover possible leakages at the shut-off valve and/or the drillingdevice Make sure that all the rotating parts move freely Inspect the device according to the inspection plan given in this user manual Unauthorized persons should not be present at the worksite during hot tapping Check the location of the closest network shut-off valve at the worksite Make sure you know all emergency contacts. This concerns the contact persons on the site, the contactto the device manufacturer TONISCO System Oy (http://www.tonisco.com) and the local emergencyservices Do the visual check of the worksite and take all the necessary measurements. Clean the workenvironment from all unnecessary objects. Consider the space needed for shaft removal after drilling Make sure that all the necessary tools and equipment is available while drilling (e.g. chain block at highpressures)4 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox2.3. Special RisksRelease of Hot Water or SteamHot water or steam may escape the system due to mishandling. Make sure to wear prescribed safetyequipment when working with hot tapping machine.When releasing the pressure from the drilling device, make sure to keep a sufficient distance between youand the release hose. Always wear heat resistant safety gloves when removing the drilling machine from thevalve.Hazards from Rotating PartsNote that the drill shaft and drive components rotate during drilling. Be aware of the changes in the torque atthe shaft due to the varying cutting forces.Take a fixed stand and turn the feed slowly.If the hole saw gets stuck during the drilling, reduce the feeding speed or turn the wheel slightly backwardsuntil the hole saw can be rotated again.Hazards Caused by the Pressure in the PipelineMost of the time, there is pressure present in the pipeline that is being drilled. It is recommended to reducethe pressure in the system to 12 bar during the operation.If the pressure in the mainline is 12 bar it is highly recommended to use the chain block for a safe releaseof the drilling shaft. This part is not included in the toolbox but can be purchased from Danfoss as anaccessory.Requirements for the OperatorThe hot tapping device may only be operated by persons who are trained, instructed and authorized to use it.Operator must know the operating instructions and act accordingly.2.4. The Significance of the Symbols used SafetyWARNING:Warns of possible serious injury or deathif instructions are not monitoredCAUTION:Displays possible personal injury or damage,if the instructions are not monitored.NOTICE:Provides useful informationItalics:Provides important information, which must be observedso that the device will not be damaged Danfoss 2019.04VI.KD.G2.02 5

Operating GuideJIP Hot Tapping Machine Toolbox3. Description Danfoss Hot Tapping Machine Toolbox3.1 Area of UseThe Danfoss hot tapping device is intended toaccomplish new pipeline branches under pressurein water-based heating and cooling systems atbranch dimensions DN15 - DN100.The Danfoss drilling device body is designed formaximum pressure of 40 bar and can be used asdescribed in the table on the right for the classPN40.However, for a pressure 12 bar additionalsafety requirements have to be considered whenreleasing the shaft or adjusting the feed.3.2 Danfoss Hot Tapping Toolbox specificationsDevice body contains the EPDM sealings. For max. temperatures follow the P-T diagram in chapter 3.In Danfoss toolbox, an electric drive unit is included. This user manual focuses on the electric drive unit MetaboBE1100 with following technical specifications:Name of Drilling Device:Body Material:Product Number:Marking:Category acc. PED 97/23/EG:Branch Dimension:Area of Use:Agregate State of the Fluid:Max. Working Pressure:Recommended max. PressureTest Pressure:Max. Working Temperature:Min Working Temperature:Sealings:Drill Shaft:Weight Without Drive:Feed Distance Feed Wheel:Maximum Feed Distance:6 VI.KD.G2.02Metabo BE 110042CrMo41200.0000Bxx xx Id. for Month, Year1DN 15 to DN 100Water Based Heating and Cooling Systemsliquid40 bar12 bar60 bar160 C0 CEPDMhardened steel Ø20 mm5,4 kg50 mm150 mm Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine ToolboxDrive Unit (Drilling Machine Reduction Gearbox):Rotates the drilling shaft.Gear Fastening ScrewFeed Extension SocketFeedChain Block*Recommended forhigh pressures 12bar for a safe relase ofthe drilling shaft afterthe drilling.Drilling Shaft:Transfers the torque fromthe driving unit to the pilotdrill and hole saw.The length can be adjustedby shaft extensions.Locking Screw:Chuck:A connection piece betweenthe rotating shaft and thehole saw and pilot drill.Hole Saw:Creates the actual hole in thepipelinePilot Drill:Cuts first and creates a center holefor the hole saw. Allows the fluid inthe mainline to enter the valve, thedevice body and the adapters to coolthe hole saw. The wire inside catchesthe coupon cut by the hole saw. Danfoss 2019.04Device Body:A part containingthe sealings andbearings.Containslocking grooves toadjust the startingposition of thedrillingFeed Unit:Consists of adjusting socket and theactual feed socket, which togetherare used to adjust the startingposition for the drilling and whilemachining create the movementtowards the main pipe.Control Cock:Necessarry forthe pressure testand the release ofpressure after thedrilling.Magnet:Can be used in ferromagneticpipe materials to catch most ofthe drilling waste.Pressure Gauge:or carrying outthe pressure test.Can be used as apressure monitoringduring the drillingprocess*Chain block on special requestVI.KD.G2.02 7

Operating GuideJIP Hot Tapping Machine Toolbox3.3 Danfoss JIP Hot Tap Valves for Hot tappingThe drilling device should be used to drill Danfoss JIP Hot Tap Ball Valves in a range from DN15 to DN100 and inwater-based heating and cooling systems. A connection between the machine body and the valve is realized bythreaded adapter pieces. Some adapter pieces are used for more than one nominal size by using adapter reductionsocket.All adapters are designed to be used only for Danfoss JIP Hot Tap Valves. Keep in mind to control the allowedpressure and temperature acc. chapter 3.1 and following Danfoss JIP Hot tap ball valves data sheet.JIP Adapter DN50JIP Adapter DN65JIP Adapter SocketDNPNHole saw diameterCode No.mm15/2025mmØ15065N0050Ø24065N0051065N1021Tool box Code 7065N1004065N1002Depending on the valve length the shaft has to be adjusted. The recommended way to find the correct shaftlengths is shown in the pictures below.- At first, push the shaft forward so that the pilot drill touches the pipe surface.- Measure the lengths between the lower shoulder of the shaft and the upper device body.- The measured distance should be between 100 - 170 mm- Adjust the length of the shaft if necessary as shown in chapter 4.2.1 and 4.2.28 VI.KD.G2.02 35mm 40 mm100-170mmThe feeding distance is recommended tobe at least 35 mm. Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4. Operational Instructions4.1 Branch Preparations before the Hot TappingBefore the drilling process can start, the branch of the decided dimension has to be prepared. Keep in mindthat the branch size should be at least one nominal size smaller than the main line.4.1.1 Removing the insulation- If the main line is insulated, remove the insulation andclean the pipe surface.- Remove the insulation far enough in order to havesufficient space for the welding.4.1.2 Adjusting the Hot Tap ValveThread End- Adjust the lower end of Danfoss Hot Tap Valve to the roundof the main line using a grinding machine.- It is important that the valve is handled in a proper way toprevent grind or other foreign particles to get into to valve.It is suggested that you insert a rag to prevent damage ofinternal parts. Before welding, the rag must be removed.- The valve has to be fully open during the adjustment.Lower end to be adjusted4.1.3 Welding of the Hot Tap Valve to the Main Line- The hot tap valve can be welded on to the pipe inevery possible direction, but the angle between thecenter line of the main pipe and the valve axis mustbe 90 - Before welding, check the closing mechanism of thevalve.- During welding the ball valve must be open.- The valve has to be welded on by electric arcwelding.- Make sure that no particles are entering the valve. Danfoss 2019.04VI.KD.G2.02 9

Operating GuideJIP Hot Tapping Machine Toolbox4.1.4 Testing the Valve- Before starting the drilling process it ismandatory to test the closing mechanism ofthe valve.- Use the proper key to close the valve andopen it completely afterwardsWARNING: NEVER start drilling if thevalve doesn't close oropen completely10 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.2 Assembly of the Drilling DeviceDanfoss Hot tapping machine is delivered in a box, including all the items described in chapter 3.2 plusadditional tools for (dis)assembly and pressure tests.4.2.1 Assembly of the Shaft for hole saws 32mm- A proper hole saw ③ for the dimensionaccording to chapter 3.3 shall be chosen.E④③- It shall be connected winding clockwise tothe drill chuck ④.F- When connected, it shall be releasedso much that the closest turning pinsE can be pushed through the holes Fat the bottom of the hole saw.- The drill chip magnet ② can be putaround the pilot drill ① the drill is pushed tothe hole of the chuck aligning the groove Band the screw A.A②B①⑥- Finally, the drill is locked by tightening thescrew A.- The drill chuck shall be connected onthe top of the drilling shaft ⑤ or, if used, theshaft extension ⑦.- If the valve should be so long that the shaftlength would not be long enough to enablethe drilling, the useable shaft length can beextended by the feed extension socket ⑥at the end ot the shaft or by adding shaftextensions ⑦ at lower end of the drillingshaft ⑤.CAUTION: Make sure that thedrilling shaft is screwed incompletely so that chuckpins ⑧ are alining with thechuck bottom.⑤⑦NOTICE: Check that the pilot drill is neither toobig no too small for the used hole saw.A too long pilot drill increases thefeeding distance unnecessarily while atoo short drill doesn't provide theguidance for the hole saw. Danfoss 2019.04⑧ACAUTION: If the pilot drill it too longit might be impossible toclose the valve !VI.KD.G2.02 11

Operating GuideJIP Hot Tapping Machine Toolbox4.2.2 Assembly of the shaft for hole saws 32 mm- For hole saws 32mm and 24mm usethe small chuck ⑧. The smallest chuck ⑨should be used for hole saws 20mm.⑥- Screw the hole saw ③ to the chuck ⑧ or⑨ depending on the hole saw size.- The magnet ② has to be put around thepilot drill ① and pushed into the hole of thechuck ⑧ or ⑨.⑤- The groove in the pilot drill ① has to bealligned to the screw G.⑦- Attach the assembly to the shaft ⑤. Useshaft extensions ⑦ or the feed extensionsocket ⑥ if necessary.③⑧⑨G②①CAUTION: If the pilot drill it too longit might be impossible toclose the valve !4.2.3 Assembly of the Danfoss JIP Adapter SocketThe Danfoss JIP Hot Tapping Adapters are delivered in a tool box including all the sizes from DN 15/20 to DN 100.For the sizes DN 25 as well as for DN40 reduction sockets have to be added to adapter of the next size as shownin the following picture.12 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.2.4 Assembly of the Device to the Hot Tapping Valve- The adapter has to be connected to the thread of the valve byfirst winding with hand and tightening it tenderly using the wrench.Because the tightening O-ring, it is not necessary to use much forcewhile connecting the parts.- Prior connecting the adapter to the valve, a proper central drill,hole saw, chuck and drill shaft have to be assembled together asshown in chapter 4.2.1- 4.2.2.- When all parts have been screwed on, test that it is still possibleclose the valve as shown in the picture below ! Dismantle themachine and adjust it again if the valve cannot be closed !- Remember to FULLY open the valve after that !4.2.5 Installing the Feed Unit- The feed device ⑦ is used to create a feed force for the drillling.⑧- The feed thread has to be winded to back position completely byturning the feed wheel ⑧ counter-clockwise.- The adjusting socket ⑨ shall be connected by first alignig the groovesand the guide screws A and there after slided to the closest lockinggroove B at the machine body.⑦A⑨B- The excessive clearance is removed by turning the feed wheel ⑧clockwise.- Measure the feed distance as described in chapter 3.3 and adjust it byshaft or feed extensions if possible. Danfoss 2019.04VI.KD.G2.02 13

Operating GuideJIP Hot Tapping Machine Toolbox4.2.6 Installing the Driving Unit- The shaft square shall be aligned with thedrive square hole and then connected andlocked using the connecting screw.- The right rotating speed is chosen for thedrilling according the table below.- For the pilot drill the maximum rpm issuitable.- An arrow on the left side of the machinepointing upwards indicates the properclockwise rotating direction.Warning: The drive must never runcounter clockwise since the drill shaftconnecting thread may open and the drill chuckcan be lost causing a severe hazard of hotwater leaking from the shaft opening.Turning Speeds for Drilling in Steel PipesMetabo BE 1100 drilling machine settings shown in the table below. Recommended turning speeds based on themanufacturers long term experience.At the beginning of the drilling operation and at the end of drilling operation the cutting forces may vary highly soone must be prepared to change the settings.Valve sizeDN 15 / 20DN 32 / 25DN 50/40DN 65DN 80DN 100Pilot Drill14 VI.KD.G2.02Turning speedTurning speeddrilling shaft [rpm] electric drive ing9998889Setting1111112 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.3 The Hot Tapping ProcessAfter the machine is assembled, all the connections shall be checked and controlled. The user can continuewith the following steps after that.4.3.1 Pressure TestPrior the actual branching a pressure test must be conducted to ensure the tightness of both the weldingseams of the valve and the drilling equipment.- A hose ① of cold water or pressurized air is connectedto the coupler of the body.- The control cock ② is opened to let the pressure in.- If desired, close the control cock ② and mount thepressure gauge ③ in order to monitor a possible fall ofpressure- After the test, the test fluid is released through thesame control cock ②- In case of an occuring leakage, it is not allowedto start the drilling process until the failure iseliminated②①③ Danfoss 2019.04VI.KD.G2.02 15

Operating GuideJIP Hot Tapping Machine Toolbox4.3.2 Starting the Driling ProcessThe drilling process starts by creating a center hole with thepilot drill :- The maximum rpm is chosen from switchesand.-The feed is started lightly by very slowly turning the feedwheel clockwise.- Feed very slowly in the beginning to ensure a goodcentering of the central drill.- A penetration of the pilot drill through the main pipe wallcan be observed by observing the pressure meter ⑦.Raising of the needle indicates the penetration.- An adequate feed using the max. rpm must be continueduntil the pilot drill gets through the wall of the main line.- After the pilot drill is through, the turning speed for thehole saw has to be adjusted as described in chapter 4.2.6- Start the feeding with the hole saw carefully and keepa fixed stand. Extra caution must be pointed to cope thereaction forces. Pull the machine in the direction shown inthe picture to compensate the force.⑦- When the drilling advances, the feed rate can be slightlyaccelerated until at the end of the drilling.-The final penetration of the main pipe wall can beconfirmed by pushing the shaft forward firmly withoutturning shaft - When it advances, the hole must be free.CAUTION: The drive must never be locked tocontinuous run, since the variations ofmachining forces may cause an unexpectedlost of control of the drive and thus causesevere damage to the operator. Be awareof the reaction forces from the cutting.WARNING: The drive and the shaft must always turnCLOCKWISE. Accidental opening of theconnecting threads of the shaft may causesevere damage to the operator.WARNING: NEVER use lever tools at the feeding wheeland feed very carefully ! When the holesaw gets stucked, stop feeding or turn thesaw a little bit backwards. Continuefeeding slowly !16 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.3.3. Adjusting the Feed- If the feed extent runs out and feed wheel ① cannot be turned anymore, the adjusting socket ②must be released and locked to a lower groove.- If the pressure is 12 bar, use the chain blockfor this operation! The use of the chain block isexplained in chapter 4.6.①②- At first, switch of the driving unit.- Screw the feed wheel ① counter clockwise.- Don't unscrew it too much as the hook of the pilotdrill might break.③B- Grip the adjusting handles ③ and push themfirmly forward.Turn the adjusting socket ② until itcan be released.- Push the adjusting socket down in the direction ofthe next groove.B- Continue to turn the feed wheel ① counterclockwise until the next groove can be reached.- Lock the adjusting socket ② to the next grooveby turning it clockwise.Warning: If you are unsure about the forcesacting on the shaft while releasing it, use the chainblock for this operation. From the manufacturersexperience, it is advisable to use it at a pressure 12 bar. See chapter 4.6 how to use the chainblock. Danfoss 2019.04VI.KD.G2.02 17

Operating GuideJIP Hot Tapping Machine Toolbox4.3.4 Releasing the Feed UnitAfter finishing the drilling, the drive shall be released from top of the assembly. In lower pressures, thiscan be done by hand. For higher pressures 12 bar it is highly recommended to use the chain block.- Both of the the adjusting handles ③ shall be gripped, pushedforward and simultaniously turned counterclockwise to release the adusting socket.- The socket can now be reversed by sliding the power screwscompletely off from the drill body- Release the shaft completely. The chuck inside the drillingchamber stopps the shaft from comming out.Warning: If you are unsure about the forces acting on theshaft while releasing it, use the chain block for this operation.From the manufacturers experience, it is advisable to use it at apressure 12 bar. See chapter 4.6 how to use the chain block.③4.3.5 Closing the Valve and Releasing the Pressure- The valve has to be closed completely by turning theball using proper allen key and turning it 90 degrees.Since the ball in the hot tap valve has no automaticstop, you may have to adjust the positionof the ball until it is in correctly closed position.- The tightness can be controlled by opening thecontrol cock.- Connect the hose to the control cock and open it torelease the pressureCAUTION: Keep enough distance to thehose while releasing thepressure to protect yourself.Make sure the valve iscompletely closed !18 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.3.6 Disasembling of the MachineThe machine is dissasembled in the oposite order as shown in chapter 4.2. At the end, the cut out pieceshall be removed.- The pilot drill is loosened by opening the retainerscrew using the proper allen key- The central drill is pulled out and the coupon isremoved around the drill stem.- The drill chips are cleaned from the gathering magnet4.4 Creating the New BranchFor creating the new branch, follow the valvemanufacturers instructions carefully.- When the Hot Tapping has been acomplished, thenew line can be connected to the Danfoss hot tapvalve by electric arc welding.- During that operation, make sure that the sealingsinside the valve are not overheating.- After the welding and when the line is approved tostart operatiing, open the valve first very slowly.- Open the valve COMPLETELY afterwards.- After the valve is completely open, screw the lockingscrews to the closing mechanism and weld it shut. Danfoss 2019.04VI.KD.G2.02 19

Operating GuideJIP Hot Tapping Machine Toolbox4.5 Maintanance Plan and Spare Part ListBefore and after every hot tapping, the whole device should be visually inspected and maintained. Don'tstart the drilling work without inspecting the device before. Never start the drilling if any damages areobserved. If any technical problems occur don't hesitate to contact the manufacturer Danfoss.The following parts have to be inspected regarding their condition before every drilling:Central DrillSealingsHole SawShaftBearingsThread of thefeed wheelWhole DeviceInspect the central drill regarding its ability to cut .Change the drill if necessary.Clean the sealings and inspect them regarding damages. Change them if necessary. Lubricatethem with sealant before using the device.Inspect the hole saw regarding its ability to cut .Change the hole saw if necessary.Inspect the shaft concerning surface damages. Check the connection threads. Store the shaftproperly and avoid droping it.Visual check the condition of inner bearing surfaceCheck that the feeding wheel is going smoothly.Clean the device after each use and inspect it regarding visual damagesIn case that major damages of the device are observed, please contact the manufacturer Danfoss.20 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine 2246234524442548264743422741282740393829 Danfoss 2019.043031323334353637VI.KD.G2.02 21

Operating GuideJIP Hot Tapping Machine ToolboxPosition1234567891011121314PartElectric motorFeed extension socketBinding ring 43 mmPrimary chockCouplingCoupling casingRetaining ringGear fastening ScrewConnecting screw M6Shaft brake connecting plateConnecting screw M5Worm gear 7:1Secondary chockSecondary 738Lip SealingThrust BearingFeed SocketRetainer ScrewHandleAdjusting SocketPower ScrewBall Point ScrewUpper Bearing Retaining RingUpper Bearing SealingO-ring upper bearingUpper PTFE-BearringShaft SealingBodyLower PTFE BearingBody SealingLower Bearing Retaining RingDouble NippleControl CockQuick Connector, maleQuick Connector, femaleSocket 1/4”Manometer 40 barCentral Drill normal39404142Central Drill shortShaft extension DN20Chuck normalChuck small434445Shaft extension 90 mmBase shaftShaft extension 180 mm464748Chain BlockTONISCO Special WrenchOpening Pin49Allen Key 3 mm50Allen Key 4 mm51Allen Key 5 mm52Magnet22 VI.KD.G2.02 Danfoss 2019.04

Operating GuideJIP Hot Tapping Machine Toolbox4.6 Using the Chain Block①For higher pressures 12 bar it is highly recommendedto use the chain block for adjusting the feed (see chapter4.3.3) or for a safe release of the feed unit (see chapter4.3.4).- First, hang the upper end of the hook in the connectionplate ① . The other hook has to be mounted to a stableelement of at the workside e.g. around the main pipe.- Adjust the switch to the middle position for a freemovement of the chain.- Tighten the chain by first pulling the other end ofthe chain and after that by turning the wheelclockwise.- Adjust the switchto the UP position③- Push down the adjusting socket ③ by moving thelever back and forward- Before releasing the locking screw from the groovein the adjusting socket ③, adjust the switch to thedown position if you want to release the feed unit.- If you want to adjust the feed, leave the switchthe up position.in- Turn the adjusting socket ③ counterclockwise torelase the shaft or adjust the feed.CAUTION: Be careful to not squeezeyour hand in the chain. Readthe instruction manual fromthe chain block manufacturer.WARNING: Do not change the switchto the middle position when thechain is under tension. Danfoss 2019.04VI.KD.G2.02 23

Attachments A1Safety Instructions in Regards to the Electrical Driving Unit- Warning: When using electric tools, basic safety

3.3 Danfoss JIP Hot Tap Valves with Hot Tapping Machine Toolbox 8 4. Operational Instructions 9 4.1 Branch Preparations before the Hot Tapping 9 4.1.1 Removing the Insulation 9 4.1.2 Adjusting the Hot Tap Valve 9 4.1.3 Welding of the Hot Tap

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