Installation instructions EF-saddle Topload

The following equipment is required:

1. Checking the assembly area

Objective: Prepare the assembly area

• Expose the main pipe in the designated assembly area all the way around and in a professional manner.
• Prepare the installation area for easier final cleaning.
• Measure the main pipe with a suitable pipe gauge for the
  outer diameter.

Instructions: Guide the control mandrel (6 mm & 14 mm) included in the gauge set underneath the gauge. The gap must be between 6 mm and 14 mm (follow the instructions).

Caution: If the value in the welding area is outside the tolerance range, insert two round clamps to the left and right of the saddle to compensate for the ovality. If the ovality cannot be corrected or if there is flattening, damage, or dented pipe sections in the welding area, the area is unsuitable for installing the EF Saddle.

2. Cleaning the main pipe

Objective: clean surface, no dirt, no grease

Caution: In bad weather, the installation area must be protected, e.g.,
with the recommended welding tent!

• Clean the installation area on the main pipe with PE cleaner.
• Use a lint-free cloth.

• Wear protective gloves and safety goggles!

Instructions: Follow the instructions for use of the cleaner.

3. Mark the assembly & peeling area

Objective: Mark where the saddle should go

• Mark the center point on the main pipe using a highcontrast,
  waterproof marker
• Place the EF Saddle on the previously marked area by hand or using a suitable lifting device (To lift the saddle, use the side screws as handles/attachment points).
• Align with a spirit level and hold in position
• Use the saddle as a template to mark the peeling area inside and outside.

4. Main pipe stripping

Objective: Remove oxide layer for clean surface

• Strip the previously marked area evenly in the direction of the pipe circumference using a saddle stripping tool.

• Remove the oxide layer in the marked area to a depth of at least 0.2 mm.

Instructions: When using the peeling device, follow the operating instructions provided by the respective manufacturer.

Caution: To do this, press the peeling device with the guide rollers and the cutting edge onto the existing pipe and peel on the material in strips. The rollers of the peeling device must point away from the peeled surface.

5. Cleaning the welding surfaces

Objectives: Clean welding surfaces

• Thoroughly clean the welding surface of the EF Saddle and the main pipe with PE cleaner and a lint-free cloth to remove grease, dust, or foreign objects.

• Then wait until the cleaner has completely evaporated.

Info: Use suitable, clean gloves.

Caution: A contaminated weld surface can lead to leaks in the welded joint.

6. Securing the saddle with the flex mounting frame

Ziel: correctly aligned & secured saddle 

• With two people, lift the saddle by hand or with lifting equipment onto the side rails.
• Align again using the spirit level.

• Securely fasten the saddle to the main pipe using a
  two-piece tension strap (hook one end into each of the
  two screws).

Info: Saddle must be level when tightening the tension strap.

• Mount the Flex mounting frame directly on the saddle, with two people if possible, and adjust to the correct departure size. To do this, loosen the bolts by hand and slide the steel struts into the correct position.
• Place mounting frame on saddle and secure it around the pipe with two additional tension straps on the red eyelets.
• Attach one ratchet to the right and one to the left of the pipe.

• Tighten the tension straps simultaneously or alternately in stages.

Info: The required preload force is reached as soon as the claws of the force indicators on the tension strap touch each other.

7. Checking the ring gap

Objective: dichte Schweißverbindung sicherstellen

• Measure the ring gap between the saddle and the main pipe all the way around using a gap gauge. The welded surface of the saddle should lie flat against the main pipe.

Info: If the ring gap is larger than 1 mm after tightening, use round clamps to compensate for the ovality of the main pipe. If the ring gap cannot be suffciently compensated, choose another mounting position on the main pipe that offers suffcient roundness. 

8. Welding

Objective: Connecting the saddle and pipe

Instructions: When using the electrofusion welding machine, observe and follow the operating instructions provided by the manufacturer

• Connect the welding machine to the contacts on the saddle.
• switch on the welding machine.
• Scan the welding barcode on the product label using a handheld scanner.
• Compare the welding parameters on display with product data.

• If the parameters match, welding can be started by pressing the green “Start” button.
• The start and end times of the welding process and the cooling time should be noted on the pipe.
• Observe the cooling time displayed.

• Remove the Flex mounting frame after the cooling time
  has elapsed.

Caution: Removing the mounting frame too early can lead to failure of the welded joint.

Info: To reduce the waiting time for subsequent welds, we recommend using a second mounting frame.

9. Drilling

Objective: to open the outlet by drilling through the EF-saddle

Instructions: The following instructions for drilling the EF Saddle supplement the operating instructions provided by the drill manufacturer. Follow the manufacturer's instructions for all further steps.

• One person controls the lifting equipment, another positions and secures the drilling unit. Three people should be available for drilling from the side.
• Locking wrench: Always keep it engaged when moving the drilling machine to prevent the hole saw from falling.
• Lifting: Lift the drilling machine out of the shipping crate using lifting equipment. Attachment point: Machine holder between the drive and the drill stand.
• Removal: Tilt the drilling unit slightly forward and carefully lift it out.
• Positioning: Place the drill stand on the pipe crest next to the saddle and align it so that the hole saw hangs centered in the saddle outlet.
• Securing: Secure the drill stand to the main pipe with a one-piece tension strap. If necessary, use a second tension strap for stabilization.
• Drilling: For continuous feed, the chip chambers of the hole saw must be vented regularly to reduce friction as soon as the feed noticeably stagnates. To do this, the drill must be switched o. As soon as the hole saw stops rotating, it must be removed and all chips removed.
• If the safety clutch of the drive slips, immediate venting is necessary. If excessive heat develops due to insucient venting, the drilling process must be stopped. If the drive's safety clutch slips, immediate venting is necessary. If excessive heat builds up due to insucient venting, the drilling process must be stopped. In this case, drilling can only be resumed once the hole saw and the cutting area have cooled down to ambient temperature.
• Cooling: Fill a spray bottle with water; direct the spray at the gap between the drill bit and the inner wall. Alternatively, partially flood the drilling area to cool the cutting area and allow the chips to float.
• Vertical drilling (12 o'clock position): If there is no access to the inside of the pipe, use a suitable support rod. This prevents the drilled core from falling into the main pipe.

10. Cleaning

Objective: leave the construction site clean

• Remove chips, used materials, and packaging from the pipe and construction site to ensure that the environment is not polluted after installation.

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