Operator’s
Manual
32mm, 40mm, 50mm & 63mm
Polypropylene
Hot Tap Tools
Manual: 247901 Revision: 03/17
This product and other products
could be protected by patents or
have patents pending. All the latest
patent information is available at
patent.mcelroy.com
Introduction
Thank you for choosing McElroy.
McElroy Hot Tap Tools are designed to make 32mm, 40mm,
50mm and 63mm Polypropylene hot taps through a branch
saddle into live mains. The tools may be made-up to be used with
a ball valve.
With reasonable care and maintenance, this tool will give years
of satisfactory service.
Before operating this tool, please read this manual thoroughly,
and keep a copy with the tool for future reference. This manual is
to be considered part of your tool.
TX05265-02-28-17
CD01985-02-16-17
McElroy University
For more than 30 years, McElroy has been the only
pipe fusion machine manufacturer to continuously
offer advanced training. Course offerings are meant to
enhance your efficiency, productivity and safety in the
proper use of McElroy machines. McElroy University
classes are structured so that the skills learned and the
machines used in each class closely match the machines
found on pipelining jobsites. We offer training at
our facility or yours. Our uniquely qualified McElroy
University course instructors offer years of industry
experience.
Tuition for each course includes lunches, course materials
and a certificate of completion. Online registration,
as well as up-to-date course offerings and dates, is
available at www.mcelroy.com/university
This manual is intended as a guide only and does not
take the place of proper training by qualified instructors.
The information in this manual is not all inclusive and
can not encompass all possible situations that can be
encountered during various operations.
MU2-03-13-14
TX04659-03-24-14
Warranty
LIMITED WARRANTY
McElroy Manufacturing, Inc. (McElroy) warrants all
products manufactured, sold and repaired by it to be
free from defects in materials and workmanship, its
obligation under this warranty being limited to repairing
or replacing at its factory and new products, within 5
years after shipment, with the exception of purchased
items (such as electronic devices, pumps, switches, etc.),
in which case that manufacturer’s warranty applies.
Warranty applies when returned freight is prepaid and
which, upon examination, shall disclose to have been
defective. This warranty does not apply to any product
or component which has been repaired or altered by
anyone other than McElroy or has become damaged
due to misuse, negligence or casualty, or has not been
operated or maintained according to McElroy’s printed
instructions and warnings. This warranty is expressly in
lieu of all other warranties expressed or implied. The
remedies of the Buyer are the exclusive and sole remedies
available and Buyer shall not be entitled to receive any
incidental or consequential damages. Buyer waives
the benefit of any rule that disclaimer of warranty shall
be construed against McElroy and agrees that such
disclaimers herein shall be construed liberally in favor of
McElroy.
RETURN OF GOODS
Buyer agrees not to return goods for any reason except
upon the written consent of McElroy obtained in advance
of such return, which consent, if given, shall specify the
terms and conditions and charges upon which any such
return may be made. Materials returned to McElroy, for
warranty work, repair, etc., must have a Return Material
Authorization (RMA) number, and be so noted on the
package at time of shipment. For assistance, inquiry shall
be directed to:
McElroy Manufacturing, Inc.
P.O. Box 580550
833 North Fulton Street Tulsa, Oklahoma 74158-0550
PHONE: (918) 836–8611, FAX: (918) 831–9285.
EMAIL: fusion@McElroy.com
Note: Certain repairs, warranty work, and inquiries may
be directed, at McElroy’s discretion, to an authorized
service center or distributor.
DISCLAIMER OF LIABILITY
McElroy accepts no responsibility of liability for fusion
joints. Operation and maintenance of the product is the
responsibility of others. We recommend qualified joining
procedures be followed when using McElroy fusion
equipment.
McElroy makes no other warranty of any kind whatever,
express or implied; and all implied warranties of
merchantability and fitness for a particular purpose which
exceed the aforestated obligation are hereby disclaimed
by McElroy.
PRODUCT IMPROVEMENT
McElroy reserves the right to make any changes in or
improvements on its products without incurring any
liability or obligation to update or change previously sold
machines and/or the accessories thereto.
INFORMATION DISCLOSED
No information of knowledge heretofore or hereafter
disclosed to McElroy in the performance of or in
connection with the terms hereof, shall be deemed to be
confidential or proprietary, unless otherwise expressly
agreed to in writing by McElroy and any such information
or knowledge shall be free from restrictions, other than a
claim for patent infringement, is part of the consideration
hereof.
PROPRIETARY RIGHTS
All proprietary rights pertaining to the equipment or
the components of the equipment to be delivered by
McElroy hereunder, and all patent rights therein, arising
prior to, or in the course of, or as a result of the design
or fabrication of the said product, are exclusively the
property of McElroy.
LAW APPLICABLE
All sales shall be governed by the Uniform Commercial
Code of Oklahoma, U.S.A.
Register your product online to activate your
warranty:www.McElroy.com/fusion
(Copy information listed on the machine nameplate here
for your records).
TX02486-12-3-13
Model No.
Serial No.
Date Received
Distributor
Table of Contents
Safety
Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Read and Understand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Wear Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Gas and Hot Tap Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Power Tool is Not Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Cutters Are Sharp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Overview
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fusion Machines To Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hot Tap Operation
Read Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tool Make-up Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspect Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mark Insertion Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hot Tap Tool Lanyard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Install Tool on Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Begin Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Retract Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Close Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bleed Off All Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Remove Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Fuse Service Line to Branch Saddle Connection. . . . . . . . . . . . . . . . . . . . . 3-5
Open Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Prepare Tool For Next Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintenance
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Washing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pipe Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Housing Assembly O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Housing Assembly Grip Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintenance Checklist
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Specifications
Hot Tap Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
COPYRIGHT © 2017
McElroy Manufacturing, Inc.
Tulsa, Oklahoma, USA
All rights reserved
All product names or trademarks are property of their respective owners. All information,
illustrations and specifications in this manual are based on the latest information available at the
time of publication. The right is reserved to make changes at any time without notice.
Equipment Safety
Safety Alerts
This hazard alert sign appears in this manual.
When you see this sign, carefully read what it says.
YOUR SAFETY IS AT STAKE.
You will see the hazard alert sign with these words:
DANGER, WARNING, and CAUTION.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, may result in minor or
moderate injury.
In this manual you should look for two other words:
NOTICE and IMPORTANT.
NOTICE: can keep you from doing something that might
damage the machine or someone's property. It may also
be used to alert against unsafe practices.
IMPORTANT: can help you do a better job or make your
job easier in some way.
WR00051-11-30-92
TX00030-12-1-92
Read and Understand
Do not operate this equipment until you have carefully read, and
understand all the sections of this manual, and all other equipment
manuals that will be used with it.
Your safety and the safety of others depends upon care and
judgment in the operation of this equipment.
Follow all applicable federal, state, local, and industry specific
regulations.
McElroy Manufacturing, Inc. cannot anticipate every possible
circumstance that might involve a potential hazard. The warnings
in this manual and on the machine are therefore not all inclusive.
You must satisfy yourself that a procedure, tool, work method, or
operating technique is safe for you and others. You should also
ensure that the machine will not be damaged or made unsafe by
the method of operation or maintenance you choose.
WR00052-12-1-92
TX02946-4-15-09
1 - 1
Equipment Safety
General Safety
Safety is important. Report anything unusual that you notice during
set up or operation.
LISTEN for thumps, bumps, rattles, squeals, air leaks, or unusual
sounds.
SMELL odors like burning insulation, hot metal, burning rubber, hot
oil, or natural gas.
FEEL any changes in the way the equipment operates.
SEE problems with wiring and cables, hydraulic connections, or other
equipment.
REPORT anything you see, feel, smell, or hear that is different from
what you expect, or that you think may be unsafe.
TX00114-4-22-93
SAFE1ST-12-22-92
Wear Safety Equipment
Wear a hard hat, safety shoes, safety glasses, and other
applicable personal protective equipment.
Remove jewelry and rings, and do not wear loose fitting clothing
or long hair that could catch on controls or moving machinery.
TX00032 4 7 93
Gas and Hot Tap Safety
Explosion hazard. Gas can ignite, causing
explosion, death or serious injury. Tapping into
pipe under pressure can cause severe injury if
safety procedures are not followed.
Follow all applicable federal, state, local and industry specific
regulations and procedures. No person should make a hot tap
unless that person has been properly trained and qualified in the
use of this equipment.
WR00053-12-2-92
WR00034-11-30-92
TX01290-3-18-97
1 - 2
Equipment Safety
Power Tool Is Not Explosion Proof
This power tool is not explosion proof.
Operation of power tool in an explosive
atmosphere without necessary safety
precautions will result in serious injury or death.
The explosive atmosphere must be cleared from the tapping
area before tapping begins.
TX05245-02-28-17
Power Tool Safety
Read and understand the all instructions provided
with your power tool. Failure to follow all the
power tool instructions, may result in electric shock,
fire and/or serious personal injury.
WR00034-11-30-92
WR00080-4-12-93WR00055-4-7-93
TX05218-02-22-17
Cutters Are Sharp
Cutter edges are very sharp. Avoid injury by
avoiding direct contact with the cutter.
TX05246-02-28-17
WR00117-03-03-17
1 - 3
Nomenclature
Overview
1 Cutter
2 Cutter Shaft
3 Lanyard Ring
4 Lanyard
5 Grip Plates
6 Housing Assembly
7 Gland
8 Pressure Relief Valve
9 Cutter Shaft Hex
4 7
2
1
3
TX05247-02-28-17
Fusion Machines To Use
The Hornet™ can be used to fuse a saddle outlet onto a main. The
saddle outlet requires the use of the Hornet and pressure adapter.
The Spider™ can be used to fuse the ball valve and branch pipes
to the outlet for 63mm only.
The ball valve and branch pipe fusions can be completed using
socket fusion equipment and all fusions must be done according to
pipe manufacturer's procedure or appropriate joining standard.
9
5 6 8
CD02010-03-03-17 CD01984-02-15-17
TX05248-02-28-17
2 - 1
Read Before Operating
Hot Tap Operation
Before operating this machine, please read this manual
thoroughly, and keep a copy with the machine for future reference.
The fusion procedures in this manual are for use with
polypropylene pipe. If fusing other thermoplastic pipe materials,
refer to the pipe manufacturer's suggested procedures or
appropriate joining standard.
TX02953-4-15-09
Tool Make-up Measurements
Tool make-up consists of a branch fitting, branch pipes and a ball valve and must be fused according to pipe
manufacturer's procedure or appropriate joining standard.
A tool make-up is required to prevent the hot tap tool cutter from cutting through the back of the main pipe during tapping.
The total length is measured from the tangent of the OD of the main pipe to the end of the branch pipe. The minimum
distance is measured from the end of the branch pipe and is the minimum distance required to attach the housing
assembly to the branch pipe.
Refer to the table below for the minimum distance and total length for each branch size to a sized main pipe.
Branch Fitting
Main Pipe
Pup Pipe
Ball Valve
Branch Pipe
Stop-5-6-96
TX05266-03-02-17
2" (63mm)
2.5" (75mm)
3" (90mm)
3.5" (110mm)
4" (125mm)
6" (160mm)
8" (200mm)
10" (250mm)
12" (315mm)
MAIN SIZE
14" (355mm)
16" (400mm)
18" (450mm)
20" (500mm)
22" (560mm)
24" (630mm)
Minimum Distance
Total Length ± 1/2"
BRANCH SIZE
1" (32mm) 1.25" (40mm) 1.5" (50mm) 2" (63mm)
Minimum
Distance
3.875" 18.72"
3.875" 18.62"
3.875" 18.58"
3.875" 18.26"
3.875" 18.06"
3.875" 18.02"
3.875" 17.73"
3.875" 17.39"
Total
Length
Minimum
Distance
4.125" 18.90"
4.125" 18.78"
4.125" 18.63"
4.125" 18.43"
4.125" 18.07"
4.125" 17.97"
4.125" 17.43"
Total
Length
Minimum
Distance
4.125" 18.69"
4.125" 18.49"
4.125" 18.13"
4.125" 17.89"
4.125" 17.49"
Total
Length
Minimum
Distance
4.625" 18.89"
4.625" 18.80"
4.625" 18.06"
4.625" 17.89"
4.625" 17.37"
4.625" 17.18"
4.625" 17.86"
4.625" 17.70"
4.625" 17.36"
4.625" 17.74"
4.625" 17.90"
Total
Length
CD02007-03-02-17CD02006-03-02-17
3 - 1
Hot Tap Operation
Inspect Tooling
Inspect the grip plates in housing assembly. The plates must be clean
to prevent slippage and ensure proper fit. Clean the plates of any dirt
or residual material.
NOTICE: All four Grip Plates and spring must be in place before using
Hot Tap Tool.
Verify that the size marked on the housing assembly matches the size
of the pipe being attached to.
The O-ring is lubricated with silicone lubricant for ease of pipe
installation. It may be necessary to lubricate the O-ring periodically.
Use only Parker Super-O-Lube®. The lubricant is not intended to
provide extra sealing capability.
Lubricating the O-ring:
1. First, remove the plates, one at a time, and then remove the spring.
2. Inspect the O-ring in the housing assembly for signs of damage. If
an O-ring is scored or cut, it must be replaced. Apply the lubrication
sparingly (1 or 2 drops) to the inside circumference of the O-ring, with
your finger or swab (O-ring does not need to be removed).
3. Lastly, re-assemble housing assembly, spring first, then the grip
plates one at a time.
NOTICE: Remove any grease, oil or any other foreign material from
grip plates before use.
CD02003-02-28-17CD02004-02-28-17CD01992-02-28-17
Inspect the cutters for damage or dullness. Dull or chipped cutters must
be replaced.
Cutter edges are very sharp. Avoid injury by
avoiding direct contact with the cutter.
TX05249-02-28-17
Mark Insertion Depth
Holding the housing assembly next to the pipe being attached
to, align the line near the end of the housing assembly with the
end of the pipe. Make a mark that is in-line with the end of the
housing assembly.
Mark Insertion
Depth
TX05250-02-28-17
3 - 2
Hot Tap Operation
Hot Tap Tool Lanyard
This device consists of a cable with a ring on one end and the
other end is attached to the housing assembly. In the event that the
hot tap tool is accidentally dislodged, the lanyard is designed to
minimize the travel of the tool by wedging itself on the pipe. The
lanyard may be required by your local regulations.
Install the lanyard ring over the pipe before installing the housing
assembly on the pipe.
Inspect the lanyard for fraying or wear prior to each use. Replace
if damaged or worn.
TX05251-02-28-17
Install Tool on Pipe
Check the end of the pipe. Make sure the outside of the pipe is
free of dirt and scratches that would prevent an airtight seal.
Pull back the tabs on the grip plates and fully insert the tool (as
straight as possible) onto the pipe until the marked insertion
depth is in-line with the edge of the housing assembly. It may
be necessary to rotate the housing assembly as you install it. It
is important that the housing assembly be inserted completely to
minimize the possibility of leakage.
IMPORTANT: When insertion of the pipe is difficult: Chamfer the
outside edge of the pipe. Never use grease or oil on end of pipe.
If pipe is out-of-round, use a cold ring clamp to re-round the pipe.
Ensure the pressure relief valve on the housing assembly is closed.
Open the ball valve.
Lanyard
Ring
Lanyard
CD01993-02-28-17CD01994-02-28-17CD01995-02-28-17
Housing
Assembly
TX05252-02-28-17
3 - 3
Hot Tap Operation
Begin Tapping
Attach the drill or ratchet wrench to the hex at the end of
the cutter shaft.
IMPORTANT: If using a cordless drill, ensure the battery is
charged and has enough power to the tap into the pipe.
Slowly drive the cutter while turning until the snap ring
on the cutter shaft stops against the back of the housing
assembly.
The cutter shaft can move back with force
when retracting the cutter. Stand clear of
shaft travel to avoid the possibility of injury.
TX05253-02-28-17
CD01996-02-28-17CD01998-02-28-17CD01999-02-28-17
Retract Cutter
Pull the cutter away from the main and back to the housing
assembly.
Stand clear of cutter shaft when retracting the cutter.
Make sure cutter is as far back to the housing assembly as
possible.
TX05254-02-28-17
Close Ball Valve
Close the ball valve.
TX05255-02-28-17
3 - 4
Hot Tap Operation
Bleed Off All Pressure
Open pressure relief valve and bleed off all pressure. A
short hose can be attached to direct pressure away from
personnel. The hose is not included.
TX05256-02-28-17
Remove Tool
Pull back on the tabs of the grip plates.
Remove the housing assembly from the end of the pipe. It may
be necessary to rotate the housing assembly to remove. Slide the
lanyard ring off the pipe.
If housing assembly does not remove easily, there may be pressure
in the line. Make sure all pressure has been bled from line before
removing housing assembly.
CD02000-02-28-17CD02008-03-03-17CD02001-02-28-17
TX05257-02-28-17
Fuse Service Line to Branch Saddle Connection
Using appropriate fusion equipment, fuse the service line to the
branch saddle assembly. Perform the fusion according to pipe
manufacturer's procedure or appropriate joining standard.
Allow the fused service line to cool according to manufacturer's
procedure or appropriate joining standard.
TX05258-02-28-17
Open Ball Valve
Open the ball valve when ready to put line into service.
TX05259-02-28-17
3 - 5
Hot Tap Operation
Prepare Tool For Next Tap
Carefully remove coupon from cutter using a long handled
screwdriver.
Cutter edges are very sharp. Avoid injury by
avoiding direct contact with the cutter.
NOTICE: Use care not to damage cutting edges when removing
coupon.
TX05260-02-28-17
CD02002-02-28-17
3 - 6
Maintenance
Preventative Maintenance
To insure optimum performance, the machine must be kept clean
and well maintained.
With reasonable care, this machine will give years of service.
Therefore, it is important that a regular schedule of preventive
maintenance be kept.
Store machine inside, out of the weather, whenever possible.
TX00428-8-10-95
Washing the Machine
The machine should be cleaned, as needed with a soap and
water wash.
CD00142-11-2-94
CD00178-5-3-96
TX05238-02-22-17
Pipe Cutters
Inspect the cutters for damage and dullness. Dull or chipped
cutters must be replaced.
Cutter edges are very sharp. Avoid injury by
avoiding direct contact with the cutter.
TX05262-02-28-17
Housing Assembly O-ring
Lubricating the O-ring:
1. First, remove the plates, one at a time, and then remove the spring.
2. Inspect the O-ring in the housing assembly for signs of damage. If
an O-ring is scored or cut, it must be replaced. Apply the lubrication
sparingly (1 or 2 drops) to the inside circumference of the O-ring, with
your finger or swab (O-ring does not need to be removed).
3. Lastly, re-assemble housing assembly, spring first, then the grip
plates one at a time.
CD02004-02-28-17
CD02003-02-28-17
O-ring
TX05263-02-28-17
4 - 1
Maintenance
Housing Assembly Grip Plates
Inspect the grip plates in housing assembly. The plates should straight
and free of damage, replace any damaged grip plates. The plates
must be clean to prevent slippage and ensure proper fit. Clean the
plates of any dirt or residual material.
NOTICE: All four Grip Plates and spring must be in place before using
Hot Tap Tool.
TX05264-02-28-17
CD02003-02-28-17
Grip Plates
4 - 2
Maintenance Checklist
Fusion Machine Checklist
Item to Check OK
UNIT
Hot Tap Tool is clean
All screws are tight
All fittings are tight
Cutter Shaft is straight with no damage
All hardware is on the basic machine
Cutters are sharp with no damage
Cutter Shaft moves freely through Housing Assembly
Gland is tight in Housing Assembly
Grip Plates are not bent and free of damage
Housing Assembly O-ring is free of damage
Housing Assembly is free of damage
TX05261-02-28-17
5 - 1
Hot Tap Tools
Length:
21" (533mm)
Weight: (includes housing assembly, cutter shaft, gland with relief valve and lanyard)
32mm Hot Tap Tool 3.9 lbs. (1.8 Kg)
40mm Hot Tap Tool 4.6 lbs. (2.0 Kg)
50mm Hot Tap Tool 4.8 lbs. (2.1 Kg)
63mm Hot Tap Tool 4.9 lbs. (2.2 Kg)
Maximum working pressure: 165 psi ( 11.3 bar)
Specifications
21"
(533mm)
32mm Cutter 40mm Cutter 50mm Cutter 63mm Cutter
2.19"
(55.6mm)
2.56"
(65.0mm)
2.62"
(65.5mm)
3.18"
(80.8mm)
CD02005-02-28-17CD02009-03-03-17
TX05267-03-03-17
6 - 1
About this manual . . .
McElroy Manufacturing continually strives to give customers the best quality products available.
This manual is printed with materials made for durable applications and harsh environments.
This manual is waterproof, tear resistant, grease resistant, abrasion resistant and the bonding
quality of the printing ensures a readable, durable product.
The material does not contain any cellulose based materials and does not contribute to the
harvesting of our forests, or ozone-depleting constituents. This manual can be safely disposed
of in a landfill and will not leach into ground water.
TX001660-8-19-99
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