Hydra-Stop INSTA-VALVE 250 Installation Instructions Manual
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Hydra-Stop INSTA-VALVE 250 Installation Instructions Manual

Insertion valves
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INSTA-VALVE 250
INSERTION VALVES
4"–12" Installation Instructions — Revised May 2021
Covered by U.S. Patent No. 9,829,141,B2 and U.S. Patent No. 9,644,779,B2. Additional patents pending.

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  • Page 1 INSTA-VALVE 250 INSERTION VALVES 4”–12” Installation Instructions — Revised May 2021 Covered by U.S. Patent No. 9,829,141,B2 and U.S. Patent No. 9,644,779,B2. Additional patents pending.

  • Page 2: Table Of Contents

    3.2.0..I nstall.the.IV.250.Valve.Cartridge ........... 13 Section 6 — APPENDICES Appendix.A.Technician.Tool.List............27 Appendix.B.Using.a.Pressure.Test.Flange.to.Pressure.Test ....28 Appendix.C..Manual.Measuring.for.Valve.Cartridge. Installation ..................29 Appendix.D.IV.250.Valve.Body.Installation.Instructions ....31 Appendix.E.Valve.Cartridge./.Cutter.Selection.Size.Chart ....34 Appendix.F.Installation.without.Auto.Equalization......35 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 3: G Eneral.safety.precautions

    Do Not Work in an Unsupported Trench Do.not.work.in.trench.with.unstable.sides,.which.could.cave.in.. The.purchaser.of.this.equipment.is.responsible.for.the.way.this. Specific.requirements.for.shoring.or.sloping.trench.walls.are. equipment.is.used,.maintained,.and.the.training,.competence. available.from.several.sources.including.federal.and.state.offices.. and.safety.of.the.operators. Be.sure.to.contact.suitable.authorities.for.these.requirements. before.working.in.the.trench..A.minimum.5’x.5’.excavation.is. Should.any.difficulty.arise.at.any.time.in.the.use.of.this. recommended. equipment,.please.contact.Hydra-Stop.at.708-389-5111. Locate.the.existing.pipe.joints.or.fittings.in.the.area.and.use.the. immediately. appropriate.restraint.methods.if.necessary. Check Laws and Regulations Know.and.obey.all.Federal,.State,.and.local.laws.and.regulations. that.apply.to.your.work.situation. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 4 Installation Instructions 4”–12” Insta-Valve 250 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 5 INSTA-VALVE 250 INSERTION VALVES 4”–8” Insta Valve 250 Installation Instructions Covered by U.S. Patent No. 9,829,141,B2 and U.S. Patent No. 9,644,779,B2. Additional patents pending.

  • Page 6: Mount Valve Body On Pipe

    2.2.0 Installing the Temporary Gate Valve 2.2.1).Install.O-ring.into.valve.body.flange.O-ring.groove. 2.2.2).Install.the.temporary.gate.valve..4”,.6”.and.8”.IV.250s.use.the.8”. Figure 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.pins.(see. 2.3.7) Align.the.pilot.drill.flat.with.the. Figure.5). Allen-head.set.screw.and.insert.the. NOTE: Temporary.gate.valves.are.single-direction.valves.and.must.be. pilot.drill.into.41”.saw.mandrel.(see. positioned.top.up..The.8”.temporary.gate.valve.must.be.installed.with. Figure.9). the.O-ring.groove.facing.up.. 2.2.3).Bolt.the.temporary.gate.valve.to.the.top.of.the.IV.250.flange. using.the.bolts,.nuts,.and.washers.provided.with.the.installation. Figure 9 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 7: Installing The Hydra-Tapper

    2.5.10) Loosen.the.packing.nut.assembly. difficult.to.remove.. clamp.lever.and.allow.the.pressure.to.slowly. raise.the.cutter.assembly.fully.into.the. 2.4.4) Slide.a.stop.collar.over.the.saw.mandrel.. tapping.housing.. 2.4.5).Set.the.cutting.depth.by.measuring.from.the.top.of.the.packing. nut.assembly.to.the.lower.side.of.the.stop.collar.. 2.5.11).Confirm.the.shell.cutter.and.saw. mandrel.assembly.is.fully.retracted.and.lock. • 6” core sample: 3.5” the.saw.mandrel.in.place.by.tightening.the. packing.nut.assembly.clamp.lever. • 8” core sample: 3.5” Figure 13 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 8: Removing The Hydra-Tapper

    Figure 14 2.7.3) Lubricate.the.end.of.the.saw. step.2.9.1.. mandrel.with.a.dab.of.the.food-grade. 2.8.16) Install.the.upper.and.lower. lubricant.provided.with.the.equipment.to.help.it.slide.freely.through.the. restraint.pins.and.cotter.clips.to.join. packing.nut.assembly.. the.saw.mandrel,.drive.motor,.and.feed. 2.7.4).Insert.tapping.assembly.completely.into.Hydra-Tapper.tapping. screw.into.a.single.assembly. Early.models. machine.. of.Hydra-Stop.Insta-Valve.installation. equipment.did.not.include.the.drive. Figure 16 2.7.5).Hand.tighten.the.clamp.lever.on.the.packing.nut.assembly.to. motor.restraint.kit.. keep.the.assembled.shell.cutter.and.saw.mandrel.in.place.. NOTE: Do.not.use.tools.to.tighten.the.clamp.lever. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 9: Performing The Line Tap

    2.10.1).Relieve.the.pressure.from.the.Hydra-Tapper.by.opening.the.ball. valves.and.discharging.the.pressure. 2.10.2).Connect.the.slings.or.straps.to.the.Hydra-Tapper..Unbolt.and. Figure 19 remove.the.Hydra-Tapper.from.the.temporary.gate.valve..Place.the. Hydra-Tapper.in.a.dry.and.safe.work.area. 2.11.8) 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. 2.10.3).Loosen.the.packing.nut.assembly.clamp.lever. 20). 2.10.4).Remove.cutter.and.saw.mandrel.assembly.. 2.10.5).Remove.the.coupon.by.loosening.the.Allen-head.retaining.set. screw..Remove.the.centering.tool.from.the.saw.mandrel.stud.. 2.10.6).Flip.the.centering.tool.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.. NOTE: Wear.gloves.when.removing.the.coupon..Coupon.edges.may.be. sharp. 2.10.7).This.completes.performing.a.Core.Sample.prior.to.valve. Figure 20 insertion..Proceed.to.step.3.0.0.—.Preparing.the.Hydra-Tapper.for.4”–8”. Valve.Insertion. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 10: Installing The Hydra-Tapper

    2.12.1) Using.a.strap.or.sling.install.the.assembled.Hydra-Tapper.on.to. the.8”.temporary.gate.valve.and.align.the.bolt.slots.. 2.13.6).The.tap.is.complete.when.the.bottom.of.the.stop.collar.makes. contact.with.the.top.of.the.packing.nut.assembly.. NOTE: Use.extreme.caution.not.to.damage.the.shell.cutter.or.pilot.drill. as.the.unit.is.raised.and.positioned.on.to.the.temporary.valve..Note the NOTE: Do.not.overfeed.the.tap..Overfeeding.the.tap.will.cause.the.shell. position of the fully retracted cutting assembly. cutter.to.jam. 2.12.2) Install.and.cross.tighten.the.bolts,.nuts,.and.washers.to.secure. 2.13.7) Return.the.drive.unit.lever.control.to.the.neutral.position. the.assembly..Thread.the.1/4”.long.nipple.and.ball.valve.into.the.tap. 2.13.8).Loosen.stop.collar.and.continue.to.advance.the.feed.screw.an. housing.and.wrench.tighten..Teflon.tape.or.thread.sealant.can.be.used. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 11: Removing The Hydra-Tapper

    2.14.0 Removing the Hydra-Tapper 2.14.1).Relieve.the.pressure.from.the.Hydra-Tapper.by.opening.the. tapping.machine.ball.valve.and.discharging.the.pressure..Open.the. temporary.gate.valve.ball.valve.to.drain.the.tapping.assembly. 2.14.2).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. 2.14.3).Remove.stop.collar.. 2.14.4) Loosen.the.packing.assembly.clamp.lever. 2.14.5).Remove.cutter.and.saw.mandrel.assembly.. 2.14.6).Remove.the.coupon.by.loosening.the.Allen-head.pilot.drill. retaining.set.screw..Remove.the.pilot.drill.from.the.saw.mandrel.stud.. 2.14.7) 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.. NOTE: Wear.gloves.when.removing.the.coupon..Coupon.edges.may.be. sharp. 2.14.8).Inspect.the.coupon.for.pipe.thickness.and.condition. 2.14.9).Remove.cutter.from.saw.mandrel. 2.14.10).This.completes.performing.a.Non-Core.Sample.prior.to.valve. insertion..Proceed.to.step.3.0.0.–.Preparing.the.Hydra-Tapper.for.4–8”. Valve.Insertion. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 12: Preparing The Hydra-Tapper For 4"-8" Valve Insertion

    Equalization,.leave.the.NPT.plug.in.the. 3.0.12) Setup.the.IV.250.4”-8”.alignment.gauge.for.the.size.being. cartridge.and.refer.to.Appendix.F.. installed.(4”,.6”,.or.8”)..Refer.to.alignment.gauge.instructions.shipped. NOTE: If.you.have.the.Generation.1.Auto. with.4”-8”.IV.250.Alignment.Gauge.Kit. Equalization.tool.(see.Figure.28),.refer.to. Appendix.F. 3.0.13) Set.the.curved.portion.of.the.alignment.gauge.within.the.lock. pin.groove.of.the.valve.cartridge..Slide.the.valve.cartridge..towards. 3.0.8).Hand.tighten.the.Auto-E.pin.into.the. Figure 28 Auto E the.insertion.housing.until.the.alignment.gauge.touches.the.insertion. check.valve..Push.down.the.pin.to.ensure.it.is. Generation 1 Tool housing..The.2.gauge.pins.will.seat.in.the.top.two.holes.of.the.insertion. able.to.actuate.(see.Figures.29.and.30). housing.(see.Figure.33.on.next.page)... © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 13: Install Iv 250 Insertion Equipment

    NOTE: Do.not.use.tools.to.tighten.the.clamp.lever.. 3.2.7) 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. 3.1.0 Install IV 250 Insertion Equipment on.steel.gate.valves).. 3.1.1) Make.sure.the.O-ring.in.the.temporary.gate.valve.is.still.properly. 3.2.8) Loosen.the.packing.nut.assembly.clamp.lever.and.begin. seated.in.the.O-ring.groove.and.safely.lift.the.insertion.equipment.on.to. advancing.the.valve.cartridge.insertion.assembly.. the.temporary.valve.. 3.1.2).Align.the.insertion.housing.reference.mark.made.in.step.3.0.17. 3.2.9) Continue.advancing.the.feed.screw.until.the.valve.cartridge. with.the.point.of.the.pentagon.valve.body.that.is.in.line.with.the. assembly.is.completely.seated..The.valve.cartridge.assembly.is. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 14 Completion Pins are shown removed for location purposes only. 3.2.11) Raise.the.feed.screw.1.inch.to.expose.the.insertion.tool.lock.nut. 3.2.12) Attach.a.10’.hose.to.the.3/4”.ball.valve.on.the.insertion.housing,. then.run.the.opposite.end.to.a.discharge.location.outside.of.the. excavation. 3.2.13) Use.a.3/4”.open-ended.wrench.to.loosen.the.lock.nut.until. the.outer.shaft.of.the.insertion.tool.can.be.raised.to.allow.the.auto. equalizing.check.valve.to.close. 3.2.14) Slowly.open.the.ball.valve..A.light.stream.of.water.will.begin.to. flow.from.the.hose. 3.2.15) Continue.to.turn.the.insertion.tool.lock.nut,.raising.the.feed. screw.1.inch.at.a.time.as.needed,.to.fully.disengage.the.insertion.tool. from.the.valve.cartridge. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 15 INSTA-VALVE 250 INSERTION VALVES 10”—12” Insta Valve 250 Installation Instructions Covered by U.S. Patent No. 9,829,141,B2 and U.S. Patent No. 9,644,779,B2. Additional patents pending.
  • Page 16 Installation Instructions 4”–12” Insta-Valve 250 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 17: Mount.valve.body.on.pipe

    NOTE: Tapping.PVC.or.steel.pipe.will.require.a.twist.style.pilot.drill. Figure 44 re-torque.carriage.bolts.to.recommended. 4.3.5).Visually.locate.the.tapered.relief.on.the.base.of.the.pilot.drill.. torque.before.continuing. Notice.the.stop.or.ledge.at.the.base.of.the.taper.(see.Figure.48). NOTE:.Do.not.exceed.recommended.pressure.test.specifications. • Minimum.Test.Pressure:.1.5.times.the.system.working.pressure. • Maximum.Test.Pressure:.375.psi. 4.2.0 Installing the Temporary Gate Valve Figure 48 4.2.1).Install.the.temporary.gate.valve..10.and.12”.IV.250s.use.the.12”. temporary.gate.valve..If.possible,.avoid.positioning.the.valve.at.the.true. 4.3.6).Mark.the.flat.of.the.taper.with.a.visible.marking.agent.(see.Figure. 3,.6,.9,.or.12.o’clock.position.to.allow.access.to.the.completion.pins. 49.on.next.page). © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 18: Installing.the.hydra-Tapper

    If.tap.is.done.on.PVC.and.material.melts,.centering.tool.in.next. section.will.still.function.properly.to.center.tap,.but.coupon.may.be. difficult.to.remove. 4.4.4) Slide.a.stop.collar.over.the.saw.mandrel.. Figure 53 4.4.5).Set.the.cutting.depth.by.measuring.from.the.top.of.the.packing. nut.assembly.to.the.lower.side.of.the.stop.collar.. 4.3.11).Insert.set.screw.and.cotter.clip.to.lock.adaptor.in.place.(see. • 10” core sample: 4.5” Figure.54). • 12” core sample: 4.75” There.should.be.a.small.amount.of.play.between.the.saw.mandrel. 4.4.6).Install.the.drive.unit.by.lifting.it.above.the.saw.mandrel.and.slide. and.adaptor..This.is.desired.as.it.tells.us.the.adaptor.will.not.tighten.to. it.into.the.3.guide.bars. mandrel. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 19: Performing.the.core.sample

    4.7.5).Insert.tapping.assembly.completely.into.Hydra-Tapper.P-20. brake.to.hold.in.place.(see.Figure.57). Housing. 4.5.10).Loosen.the.packing.nut.assembly.clamp. 4.7.6).Hand.tighten.the.clamp.lever.on.the.packing.nut.assembly.to. lever.and.allow.the.pressure.to.slowly.raise.the. keep.the.assembled.shell.cutter,.centering.tool,.and.saw.mandrel.in. cutter.assembly.fully.into.the.P-20.housing. place. 4.5.11).Confirm.the.shell.cutter.and.saw.mandrel. NOTE: Do.not.use.tools.to.tighten.the.clamp.lever. is.fully.retracted.and.lock.the.saw.mandrel.in. place.by.tightening.the.packing.nut.assembly. 4.8.0 Installing the Hydra-Tapper clamp.lever. 4.8.1).Using.a.strap.or.sling.install.the.assembled.Hydra-Tapper.on.to. 4.5.12) Close.the.temporary.gate.valve. Figure 57 the.8”.temporary.gate.valve.and.align.the.bolt.slots. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 20: Performing.the.line.tap

    4.11.1 Preparing the Hydra-Tapper for a non-core sample drive.unit.requires.90.CFM.at.90.PSI..The.hydraulic.drive.unit.requires.9. Valve Insertion Line Tap GPM at 1800 PSI. 4.11.2).Select.proper.size.saw.mandrel..Tapping.of.the.10”-12”.IV.250. 4.9.3) Ensure.the.drive.unit.lever.control.is.in.the.neutral.position.. requires.the.55”.long.saw.mandrel. Always.run.the.power.unit.in.the.clockwise.direction. 4.11.3).Select.proper.size.shell.cutter...Hydra-Stop.valve.insertion.shell. NOTE: Avoid.reversing.as.this.will.damage.the.carbide.teeth.on.the. cutters.are.shipped.painted.black..If.you.repaint.valve.insertion.shell. cutter. cutters.in.the.future,.Hydra-Stop.recommends.painting.them.black. 4.9.4).Engage.the.drive.unit.and.confirm.the.saw.mandrel.is.rotating.in. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 21: Installing.the.hydra-Tapper

    Figure.65). 4.12.0 Installing the Hydra-Tapper 4.12.1) Using.a.strap.or.sling.install.the.assembled.Hydra-Tapper.on.to. the.12”.temporary.gate.valve.and.align.the.bolt.slots.. NOTE: Use.extreme.caution.not.to.damage.the.shell.cutter.or.pilot.drill. as.the.unit.is.raised.and.positioned.on.to.the.temporary.valve..Note.the. position.of.the.fully.retracted.cutting.assembly. Figure 65 4.12.2) Cross.tighten.the.bolts,.nuts,.and.washers.to.secure.the. assembly..Thread.the.1/4”.nipple.and.ball.valve.into.the.tap.housing.and. 4.11.10).Once.aligned,.insert.and.tighten.the.set.screw..Test.pull.the. wrench.tighten..Teflon tape or thread sealant can be used. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 22: Performing.the.line.tap

    NOTE: Avoid.reversing.as.this.will.damage.the.carbide.on.the.pilot.drill. and.carbide.teeth.on.the.shell.cutter. NOTE: Wear.gloves.when.removing.the.coupon..Coupon.edges.may.be. sharp. 4.13.4) Engage.the.drive.unit.and.confirm.the.saw.mandrel.is.rotating.in. the.clockwise.direction..Slowly.turn.the.handle.assembly.in.a.clockwise. 4.14.7).Inspect.the.coupon.for.pipe.thickness.and.condition. direction.keeping.slight,.constant.pressure.until.the.tap.is.complete.. 4.14.8).Remove.cutter.from.saw.mandrel. 4.13.5) 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. 4.14.9) This.completes.performing.a.non-core.sample.prior.to.valve. insertion..Proceed.to.step.5.1.0.—.Preparing.the.Hydra-Tapper.for. 4.13.6).The.tap.is.complete.when.the.bottom.of.the.stop.collar.contacts. 10”–12”.Valve.Insertion. the.top.of.the.packing.nut.assembly.. NOTE: Do.not.overfeed.the.tap..Overfeeding.the.tap.will.cause.the.shell. cutter.to.jam. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 23: Preparing.the.hydra-Tapper.for.10"-12".Valve. Insertion

    5.1.13) Setup.the.IV.250.10”–12”.Alignment.Gauge.for.the.size.being. NOTE: If.you.have.the.Generation.1.Auto. installed.(10”.or.12”)..Refer.to.Alignment.Gauge.instructions.shipped. Equalization.tool.(see.Figure.75),.refer.to. with.10”–12”.IV.250.Alignment.Gauge.Kit. Appendix.F.. 5.1.14) Set.the.curved.portion.of.the.alignment.gauge.within.the. 5.1.8).Hand.tighten.the.Auto-E.pin.into.the. completion.pin.groove.of.the.valve.cartridge..Slide.the.valve.cartridge. check.valve..Push.down.the.pin.to.ensure.it.is. and.alignment.gauge.towards.the.insertion.housing.until.the.alignment. able.to.actuate.(see.Figure.76.and.77). gauge.touches.the.insertion.housing..The.2.gauge.pins.will.seat.in.the. top.2.holes.of.the.insertion.housing.(see.Figure.80.on.next.page).. 5.1.9) Tighten.the.IV.250.valve.cartridge. and.insertion.tool.together.by.turning.the. Figure 75 Auto-E Generation 1 Tool © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 24: Install.iv.250.Insertion.equipment

    5.3.0 Install the IV 250 Valve Car- sure.to.follow.a.cross.tightening.pattern.with.remaining.pins. tridge NOTE: Do not start the next step until all completion pins have been 5.3.1) Loosen.the.packing.nut.clamp.lever. properly set..Failure.to.properly.set.the.completion.pins.could.result. Lower.the.valve.cartridge.until.in.touches. in.hard.operation.and.impact.valve.performance.(see.Figure.84.on.the. the.temporary.gate.valve..It.is.critical.to. next.page). Figure 83 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 25 5.3.18) Lock.the.clamp.lever. 5.3.19) Remove.the.feed.screw. 5.3.20) Loosen.the.clamp.lever. 5.3.21) Raise.the.insertion.tool.up.to.the.start.position,.where.the. knurled.handle.extends.past.the.P3.of.the.tapping.machine.and.secure. the.insertion.tool.in.place.by.tightening.the.clamp.lever.. 5.3.22) Remove.the.IV.250.insertion.equipment.and.temporary.gate. valve..Confirm.O-ring.is.placed.on.top.of.IV.250.flange.. 5.3.23) Unthread.and.remove.the.Auto.Equalization.Pin.Assembly. 5.3.24).Replace.the.Auto.Equalization.Valve.NPT.plug. 5.3.25).Place.white.thrust.washer.onto.the.valve.stem.. 5.3.26) Lubricate.the.O-ring.in.the.bore.of.the.IV.250.bonnet.and.install. over.the.valve.stem..Install.flange.with.recess.facing.down. 5.3.27) Align.bolt.holes.. 5.3.28).Cross.tighten.the.bolts,.nuts,.and.washers.that.came.with.the.IV. 250. 5.3.29).Set.the.2”.operating.nut.on.the.valve.stem..Thread.the.operating. locking.nut.on.to.the.valve.stem. 5.3.30).Fully.open.and.close.IV.250.to.confirm.a.successful.installation.. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 26: Section 6 - Appendices

    INSTA-VALVE 250 INSERTION VALVES Appendices Covered by U.S. Patent No. 9,829,141,B2 and U.S. Patent No. 9,644,779,B2. Additional patents pending.

  • Page 27: Appendix.a.technician.tool.list

    • 3/16”.T-Handle.Allen.Wrench • 1/4”.T-Handle.Allen.Wrench • 5/16”.T-Handle.Allen.Wrench • 3/8”.T-Handle.Allen.Wrench Other.Equipment • Safety.Equipment • Hard.Hat • Safety.Glasses • Safety.Shoes • Fall.Protection • Hearing.Protection • Work.Gloves • Small.Slings NOTE: Have.two.sets.of.open-end.wrenches.on.hand.to.allow.multiple.people.to.assist.in.installation. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 28: Appendix.b.using.a.pressure.test.flange.to.pressure.test

    B.4).Insert.8.flange.bolts.into.the.8.mounting.holes.of.the.pressure.test.flange..Tighten.a.washer.and.nut.onto.each.of.the. eight.bolts.(see.Figure.B-2). B.5) Connect.a.pressure.test.assembly.to.the.pressure.test.flange.(see.Figure.B-3). B.6).Connect.pressure.test.assembly.to.your.pressure.source.for.pressure.testing..Hydra-Stop.recommends.using.a.hydro- static.method.of.pressurizing.the.valve.body.. Figure B-1 NOTE: DO.NOT.use.a.compressible.medium.such.as.air.. B.7) Follow.local.rules.for.the.recommended.length.of.the.pressure.test. B.8).After.completing.pressure.test,.use.ball.valve.to.blow-off.pressure.before.removing.pressure.test.flange. B.9).Follow.the.tightening.pattern.and.re-torque.carriage.bolts.to.recommended.torque.before.continuing. NOTE: Do.not.exceed.recommended.pressure.test.specifications.. Figure B-2 • Minimum.Test.Pressure:.1.5.times.the.system.working.pressure. • Maximum.Test.Pressure:.375.psi. B.10).For.4”–8”.Insta-Valves,.proceed.to.Section.2.2.0.Installing.the.Temporary.Gate.Valve..For.10”–12”.Insta-Valves,. proceed.to.Section.4.2.0.Installing.the.Temporary.Gate.Valve.. Figure B-3 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 29 Tighten.the.3/4”.insertion.tool.lock.nut.located.at.the.base.of.the. knurled.handle.. Figure C-1 10-12” Hydra-Tapper, P-20, and Insertion Housing Caution: Ensure.there.are.no.gaps.between.the.insertion.tool,.valve. C.5).The.IV.250.valve.cartridge.consists.of.top.section.and.bottom. cartridge.and.feed.screw..The.valve.cartridge.should.remain.in.tight. section..The.top.section.and.bottom.section.must.be.firmly.tightened. contact.with.the.insertion.tool.and.act.as.a.single.unit. together..Prior.to.removing.operating.nut.hold.the.base.of.the.valve. C.11).Make.sure.the.insertion.tool.is.clean.and.free.of.rust.or.grime. cartridge.and.with.a.pipe.wrench.or.valve.key.turn.the.valve.stem.firmly. (steel.wool.can.be.used.to.clean.and.smooth.the.surface)..Lubricate. in.the.opening.direction.(see.Figure.C-2). the.end.of.the.insertion.tool.with.a.dab.of.the.food-grade.lubricant. C.6).Remove.the.operating.nut.and.the.white.Teflon.washer.off.of.the. provided.with.the.equipment.to.help.it.slide.freely.through.the.packing. valve.stem..Set.aside.in.a.safe.place.. nut.assembly..Ensure.packing.nut.assembly.clamp.lever.is.loose. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 30 C.17) Adjust.and.align.the.shorter.side.of. the.valve.cartridge,.which.is.marked.with. a.star,.between.(2).bolt.holes.accordingly.. Make.a.reference.mark.on.the.insertion. housing,.between.the.2.bolt.holes.. Figure C-8 Slide.the.guide.plate.to.the.stop.collar.and. lock.the.guide.plate.clamp.lever.(see.Figure.C-10).. C.18) Lubricate.the.completion.plug.O-ring.with.food-grade.lubricant. provided.with.the.equipment..DO NOT LUBRICATE WIPE SEALS OR PADDLE. C.19) Slide.valve.cartridge.and.insertion.tool.assembly.into.the.insertion. housing.until.it.seats.against.the.top.of.the.insertion.housing.. C.20) Tighten.the.clamp.lever.on.the.packing.nut.assembly.to.keep.the. assembled.valve.gate.and.insertion.tool.in.place..Do.not.use.tools.to. tighten.the.clamp.lever.. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 31: Installation

    Figure 3 no.more.than.25.ft.-lb..increments.until.recommended.torque.is.reached. D.10).Wait.10.minutes.to.allow.the.gasket.to.fully.seat.then.retighten.bolts.to.recommended.torque. three.additional.times.following.the.tightening.pattern. RECOMMENDED.TORQUE: 4”.–8”.Insta-Valve.250.. 10”.–12”.Insta-Valve.250 CI./.DI.Pipe:.115.ft.-lbs. CI./.DI.Pipe:.65.ft.-lbs. PVC.Pipe:.55.ft.-lbs. PVC.Pipe:.55.ft.-lbs. Figure 4 AC.Pipe:..75.ft.-lbs. AC.Pipe:..60.ft.-lbs. Installation instructions and best practices continued on next page. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 32 Figure 9 Completion pins flush with I.D. of flange. This is correct position to begin pressure test and continue with installation procedure. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 33 Black 7.80+ 8IVBULTLH08-250 9.40-9.70 8IVBULTLH10-250-U9.5 10” 9.40-9.70 8IVBULTLH10-250-U9.5-AC Black 9.70+ 8IVBULTLH10-250 11.1 Blue 11.00-11.40 8IVBULTLH12-250-U11.1 11.5 11.40-11.70 8IVBULTLH12-250-U11.5 12” 11.5 11.40-11.70 8IVBULTLH12-250-U11.5-AC Black 11.8 11.70+ 8IVBULTLH12-250 © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

  • Page 34: Appendix.e.valve.cartridge./.Cutter.selection.size.chart

    F.4).Remove.the.operating.nut.and.the.white.Teflon.washer.off.of.the. valve.stem.. F.5).Remove.Auto.Equalization.Valve.NPT.plug..Set.aside.in.a.safe.place.. If.you.elect.to.not.use.Auto.Equalization,.leave.the.NPT.plug.in.the. cartridge. Figure 33 F.6).Place.the.end.of.the.insertion.tool.over.the.valve.stem..Tighten.the. IV.250.valve.cartridge.and.insertion.tool.together.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.. NOTE: 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. F.7).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.a.dab.of.the.food-grade.lubricant.provided.with. the.equipment.to.help.it.slide.freely.through.the.packing.nut.assembly.. Ensure.packing.nut.assembly.clamp.lever.is.loose. F.8).Slide.the.Auto.Equalization.adapter.over.the.top.of.the.knurled. handle.of.the.insertion.tool.and.over.the.larger-OD.bell-like.portion.of. the.insertion.tool.(see.Figures.31A.and.31B). NOTE: Install.Auto.Equalization.adapter.after.insertion.tool.has.been. tightened © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.
  • Page 35 These instructions depict the use of the most up-to-date Hydra-Stop insertion valves, installation equipment, and accessories. Please be certain you are following the instructions for your equipment. © 2021 Hydra-Stop | All Rights Reserved. | Specifications subject to change without notice.

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