XL
B< PRESS PRESS FIT SYSTEM >
TECHNICAL GUIDE
100 years of innovation Conex Bänninger specialises in providing the best plumbing fittings and accessories across the globe by offering innovative and versatile jointing solutions. Since 1909 Conex Bänninger has produced over 10 billion copper fittings and has built its reputation for quality European manufacturing, backed by first-class customer service and unrivalled expertise. Passionate about excellence, Conex Bänninger is a byword for quality in the domestic, commercial, industrial, air conditioning and refrigeration markets worldwide. Conex Bänninger is an ISO 9001 quality assured company, which assures you the very best in quality.
Contents Product Features
2
Applications
3
Technical Data
4-5
Installation Instructions
6-7
Design Considerations
8-10
Fittings 11-16 Tools 17-19 Critical Operating Instructions Regular Maintenance Instructions Servicing and Warranty
20 21-22 23
Conex Bänninger >B< Press is a versatile press fitting system for use with hard, half hard or annealed copper tube providing a secure, life long, leak-proof joint. >B
B
B< Press press fit copper fittings are: Flame free Flame free installation takes away risk of fire on site. Reliable simplicity Simple, quick and reliable installation provides low installed cost. Fully certified Extensive third party certification offers peace of mind to the client, specifier and installer. Performance Corrosion resistant and with a design life of 50 years, >B< Press can be relied on to perform long after installation. Slimline profile Slimline, unobtrusive design provides aesthetic finish. Permanent joint Secure, permanent joint ensures fitting cannot be tampered with. Practical by design Design protects O-ring from damage or displacement. Leak Indicator Larger internal diameters on the grip ring and O-ring compared to the tube allows for pre press leak indication.
Conex XL 65, 80 and 100mm copper fittings EPDM seal
Conex XL fitting
Stainless steel grip ring
Fitting bead
Copper tubing
Product Features >B< Press XL has only two internal parts, the grip ring and the O-ring. Both parts have an internal diameter larger than the tube, which allows for easy tube insertion and pre press leak indication.
Stainless Steel Grip Ring Complete diameter grip with equally spaced collapse zones ensures all round equal grip on the tube diameter and even seal compression between tube and fitting after pressing.
Unique Seal Design Impossible to displace by tube insertion. Triple point seal on the post pressed fitting body counters any pressing distortion. Greater seal contact area on tube. Self setting seal area for correct function of seal. Seal security and longevity increased as a result.
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Conex Bänninger >B< Press XL Technical Guide
The stainless steel grip rings pressed on top, forcing the grip ring teeth against the tube, making a high strength connection.
Applications >B
B< Press fittings (through excessive pressure, for example) where competitor fittings created non-compliant conditions. All >B< Press fittings must be installed by a licensed plumber.
Conex Bänninger >B< Press XL Technical Guide
3
Technical Data >B< Press is suitable for use with type A and B copper tube complying with AS1432.
Water Supply Systems Application / Medium
Comments
Hot and cold potable water
Australian Watermark approved. Watermark certification for all plumbing products is restricted to 1400kPa at 95°C.
Fire Services
Capable of the required test pressure of 1700kPa or 1.5 times the design pressure as specified by AS2419.1
Rainwater Pump circulated hot water systems Steam
Compliant with EN 12828 Low pressure steam equipment
Conditioned water (partially and fully desalinised water, softened, deionised demineralised distilled)
Anti-Freeze / Corrosion Protection / Inhibitors Comments
Application / Medium Product
Anti-freeze cooling concentration 50%
Manufacturer
Antifrogen N
Clariant
Antifrogen L
Clariant
Antifrogen Sol (solar systems)
Clariant
Ethlene glycol (Ethan-1,2-diol)
Various
Propylene glycol (1,2-Propandiol)
Various
Tyfoxit
Tyforop-Chemie
Tyfocop
Tyforop-Chemie
Special Media Application / Medium
Comments
Acetone
Liquid
Condensate
From gas condenser boiler
Condensate
From steam
Ethanol Urea Methanol Sodium Hydroxide Ammonia
✔ Indicates compatibility. (Consultation required for unlisted mediums) *Note: Installations need to comply to the relevant standards and local regulations.
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Conex Bänninger >B< Press XL Technical Guide
P (kPa)
T (°C) Max
>BBBB< Press XL Technical Guide
5
Installation Instructions To install >B< Press, a Rothenberger Romax 3000 mechanical tool with actuator and compatible sized jaw to fit each size fitting is required. When pressure is exerted through the press tool a permanent joint is made and the fitting cannot be disassembled or re-used.
1. Cut the pipe We recommend you use a Rothenberger pipe cutter. It is important to ensure that the pipe is cut completely square. Tube ends should be clean and free from scratches not less than the socket length.
2. Remove burrs Make sure that the internal and external tube end are free from burrs or sharp edges by using a file or deburring tool. Then wipe the tube end clean to avoid damaging the O-ring on tube insertion.
3. Inspect the fitting Before inserting the tube check seal for correct placement, free of damage or any ingress of debris. To prevent this occurring we recommend the fittings are retained in packaging up to the point of use.
4. Insert the tube and mark insertion depth The tube must be fully inserted into the fitting until it reaches the tube stop in order to make a perfect joint. Marking insertion depth will ensure that any tube movement is detected, which is especially important if the joints are to be pressed at a later time. The depth marking must be visible on the pressed fitting.
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Conex Bänninger >B< Press XL Technical Guide
5. Fit the pressing ring Using the appropriate size pressing ring, open the pressing ring, locate on the fitting bead and close the pressing ring.
6. Engage the actuator and check insertion depth With the actuator fitted in the press tool open the actuator and locate the actuator into the aperture of the pressing ring. Check for any tube movement prior to crimping.
7. Press the joint Depress and hold the trigger of the tool until the press cycle of the tool is automatically completed. Keep hands clear of the press actuator and press ring until the cycle is completed.
8. Joint completion Remove the actuator from the press ring, remove the press ring from the tube and remove the label to indicate the joint is pressed and complete.
Important It is important to keep the fitting free of any dust or dirt and to ensure the O-ring stays lubricated and protected from damage. Select the correct size of tube and fitting for the job. Ensure that both are clean and free from damage and imperfections.
Conex Bänninger >B< Press XL Technical Guide
7
Design Considerations Distance between fittings Due to the reforming of the tube profile when pressed, it is advised that a minimum distance is allowed between each fitting. Tube Size
Minimum Clearance F (mm)
65mm
15
80mm
15
100mm
15
F – Clearance Between Fitting Ends
F
Brazing near >B< Press fittings Caution – Brazing or soldering near to >B< Press joints should be avoided as this may cause the seal to degrade due to heat transfer. The table below states the minimum distance away from the press joint which is acceptable to braze. If this distance cannot be maintained then adequate precautions must be taken such as fabricating the brazed section prior to assembly with the press fittings, wrapping in a wet rag or applying a heat barrier spray, to prevent heat transfer to the press fitting during brazing. Tube Size
Minimum Clearance (mm)
65mm
1600
80mm
2000
100mm
2500
D
C
B
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Conex Bänninger >B< Press XL Technical Guide
Minimum clearance requirements The following minimum clearances are required from 3 2 structural components to allow operation of tool for press fitting.
1
Tube Size
Minimum Clearance (mm)
65-100mm
45
D
35
C
B
45 6
5
Minimum Clearance (mm) D a
Tolerierung ISO8015 65mm 90 Änderungen nur über CAD
80mm
95
b Oberflächen DIN EN ISO 1302
ISO 2768 mK
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte für den Fall der Patent- , Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten. Bearbeitet
100mm
c
110
145
Datum
90
Werkstoff :
95
110
17.10.2013 Rafalski
Geprüft
Halbzeug :
100
165
115
190
Einbauräume PSL V80
Sach-Nr.:
3
150
A
C
5 Index Änderungsauftrag
e Gewicht [ kg ] :
90
Benennung :
Name
165
Genehmigt
d
Maßstab :
Allg.-Toleranzen 130
B
Tube Size
6
4
4
Datum Name Ursprung :
CAD-Nr.: Ersatz für :
2
DIN
45938Y02 3
A \\Npfile10\kdaten\45000\45938\45938Y02 Einbauraum V80.idw Ersetzt durch :
A3 2
Blatt :
1
von :
1
1
B
E
B
D
35
A
A
C 6
5
4
E
45
Conex Bänninger >B< Press XL Technical Guide
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Localised Annealing To ensure proper sealing of both the brazed and >B< Press fitting the following minimum distances must be maintained between the two fittings. Tube Size
Minimum Clearance (mm)
65mm
15
80mm
15
100mm
15
Note: It is important that there is no residual solder or other foreign debris on the tubing to be inserted into the >B< Press fitting. The surface condition on the area of press joint must be clean and free from any defect.
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Conex Bänninger >B< Press XL Technical Guide
Fittings
Conex Bänninger >B< Press XL Technical Guide
11
Range >B
B< Press XL Technical Guide
D1
Size (D1 x D2)
404822
D2
Product Code
FITTING REDUCER Size (D1 x D2)
L
Z
404831
DN65 x DN40
106
75
404832
DN65 x DN50
103
64
404833
DN80 x DN50
122
83
404834
DN80 x DN65
131
87
404835
DN100 x DN50
145
106
404836
DN100 x DN65
139
96
404837
DN100 x DN80
136
86
L
D2
D1
Product Code
Z
COUPLING - MALE Product Code
Size (D1 x R)
L
Z
S
404943
DN65 x 2-1/2
121
78
85
404944
DN80 x 3
126
78
95
404945
DN100 x 4
150
91
125
L
R
D1
S (oct)
Z
COUPLING - FEMALE Product Code
Size (D1 x Rp)
L
Z
S
404946
DN65 x 2-1/2
112
31
85
404947
DN80 x 3
114
33
95
404948
DN100 x 4
138
37
125
L
Rp
D1
S (oct)
Z
Conex Bänninger >B< Press XL Technical Guide
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Range ELBOW - 90 DEG Product Code
Size (D1 x D2)
L
Z
404796
DN65 x DN65
126
82
404797
DN80 x DN80
150
98
404798
DN100 x DN100
192
132 L
L
Z
D1
Z
D1
Elbow - 90 Deg (Male /Female) Product Code
Size (D1)
L
Z
L2
404857
DN65 x DN65
132
88
146
404858
DN80 x DN80
150
98
148
404859
DN100 x DN100
192
132
212 L1
L2
D1
Z
D1
Elbow - 45 Deg Product Code
Size (D1)
L
Z
404838
DN65 x DN65
82
38
404839
DN80 x DN80
95
45
404840
DN100 x DN100
118
57 L
D1
Z
L
Z
D1
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Conex Bänninger >B< Press XL Technical Guide
Elbow - 45 Deg (Male / Female) Product Code
Size (D1)
L
Z
L2
404848
DN65 x DN65
82
38
93
404849
DN80 x DN80
95
45
100
404850
DN100 x DN100
117
57
130 L1
D1
L2
Z
D1
TEE Product Code Size (D1 x D2 x D3) L1
L2
L3
Z1
Z2
Z3
404799
DN65
89
89
104
45
45
46
404800
DN80
101
101
111
50
50
52
404801
DN100
128
128
135
67
67
67
D2
D1
Z3
L3
D3
Z2
Z1
L2
L1
REDUCING TEE Product Code Size (D1 x D2 x D3) L1
L2
L3
Z1
Z2
Z3
404802
DN65 x DN65 x DN50
84
84
90
40
40
44
404803
DN80 x DN80 x DN50
90
90
96
39
39
50
404804
DN80 x DN80 x DN65
93
93
108
42
42
52
404805
DN100 x DN100 x DN50
105
105
108
44
44
63
404806
DN100 x DN100 x DN65
105
105
123
44
44
66
404807
DN100 x DN100 x DN80
112
112
124
51
51
66
D2
D1
Z3
L3
D3
Z2 L2
Z1 L1
Conex Bänninger >B< Press XL Technical Guide
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Range End Cap Product Code
Size (D1)
L
Z
Rp
404841
DN65
86
21
3/4
404842
DN80
98
28
3/4
404843
DN100
115
39
3/4 L
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Conex Bänninger >B< Press XL Technical Guide
D1
Rp
Z
The Tools
Conex Bänninger >B< Press XL Technical Guide
17
Tools The approved tools for the installation of >B< Press XL fittings are: • Rothenberger Romax® 3000 • Viega Picco 4B Conex Bänninger recommends the use of Rothenberger press tools.
Rothenberger Romax® 3000 model
Applications sizes: 15-100mm >B< Press Fittings • Weight balanced ergonomic design – reduces fatigue during extended use • Wide application range • Fast pressing – automatic cycle complete in 5 seconds • Easy to use LED status indication – flashing red when battery charge is low and will lock the machine, remains ON when tool has reached 20,000 cycles of use and requires servicing • Bright white - light LED’s to illuminate work space during pressing cycle • Simple and safe operation design – hold start button – tool automatically stops once press cycle is complete • Safety yellow button – press to release pressure and stop press cycle • Long 20,000 cycle interval between service requirements • Head positioning up to 270° rotation – easy fitting in difficult locations • Li-Ion battery technology – long lasting operation between charges
Specifications Battery voltage – 18 v Battery capacity – 3Ah Rated power consumption – 540 Watts Max piston force – 32kN Pressing time – 5 secs (nominal) Dimensions (LxWxH) – 445x125x79mm
Working range: Copper system 15 – 100mm Typical A-rate noise level – 71dB(A) Battery re-charge time periods – 85 minutes (90% charge) – 2.5hrs (100% charge) Approximate pressings per full charge – 160
Weight (less jaws) – 3.54 kg
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Conex Bänninger >B< Press XL Technical Guide
Rothenberger XL Press Jaws & Actuator For Romax® Press Tools
To press >B< Press XL fittings an actuator and appropriately sized jaw are required. To complete a press the jaw is opened and located on the fitting bead. The actuator is connected to the tool, ensuring the locking pin is fully engaged. With the actuator fitted in the press tool open the actuator and locate the actuator into the aperture of the pressing ring. To perform the press hold the trigger of the tool until the press cycle of the tool is automatically completed.
XL Press Jaws For Romax® Press Tools • Made of forged, highly resilient special steel • Compact design • Long-term corrosion protection • Optimised for minimal space requirements
Actuator For Romax® Press Tools • Precision-manufactured contours for optimum and reliable pressings • Made of forged, highly resilient special steel • Long-term corrosion protection
Conex Bänninger >B< Press XL Technical Guide
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Critical Operating Instructions - Tool & Jaw Only operate the Rothenberger Press Tool and Jaws as per instructions in your ‘User Operating Manual, Instructions for Use’. Proper usage includes compliance with the operating manual, inspection and servicing conditions and adherence to all relevant safety regulations. The equipment must only be used by qualified tradespersons that have a trained understanding on how to use the Press Tool & Jaw System properly. Failure to do so will lead to safety risk, poor workmanship, and incorrect use of the Press & Jaw that is not covered under warranty. • Always start with a safety check, reminding yourself of the yellow emergency stop button to deactivate a press cycle • Charge battery fully before first use for optimal number of ‘presses per charge’ • LED flashes red to indicate when you have a flat battery • Insert battery correctly until it clicks into place and LED light flashes briefly to indicate contact made • Insert Press Jaw and close bolt down correctly. Only use the correct Jaw to Tool to Fitting combination • Open the Jaw by squeezing from the base of the Jaw NOT the front tip • Half engage the start button for the handy LED lights • Fully engage the start button for a full press cycle. Activate the Press Tool & Jaw only on a Fitting • Take the time to ensure the correct Pipe Preparation – cut pipe square, deburr and calibrate pipe edge and mark insertion depth. These pipe prep steps are critical for a correct press and quality workmanship • Follow all installation instructions supplied by the Fitting and Pipe manufacturers. Imperfect pipe joints must only be pressed again using a new fitting, DO NOT re-press the same fitting • During the press cycle, visually check that the Press Jaw fully closes at the end of the press cycle • After pressing, check the installation with appropriate testing equipment and ensure it is leak proof
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Conex Bänninger >B< Press XL Technical Guide
Regular Maintenance Instructions - Tool & Jaw Tool – Always clean and grease and store in case
Your Rothenberger Tool is one of the lightest and most ergonomic designed tools that delivers the most consistent press force (CFT® - Constant Force Technology) with regular maintenance and service it generates up to 3.2 tonnes of force in your hand, so it requires regular care and maintenance. • Clean and grease the piston ram and drive rolls ALWAYS after every use to maintain performance especially the internal guide rail OR all the ‘moving metallic parts’
• Watch heavy water areas. Do not expose power tools to rain or wet conditions. Always store in case • Ensure the Jaw locking bolt is closed correctly by fully inserting the bolt through the Jaw and rotating the bolt arm down 180 degrees
• Please note, the bolt is only secured when fully inserted and rotated into the downward position
Conex Bänninger >B< Press XL Technical Guide
21
Regular Maintenance Instructions - Tool & Jaw • Clean contact points on battery and only store battery in a charged state, plus it’s always ready for use •
• Do not force the Press Tool – it will do the job better and safer at the rate for which it was designed • Accidents are caused by poorly maintained Press Tools & Jaws. Take the time to maintain properly Jaws – Always clean, apply lubricant spray and store in case • Jaws must ALWAYS be cleaned after every use. Keep the inside Jaw profile free of any grease and grit
• Jaws must be maintained with liquid lubricant spray. Always store in case
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Conex Bänninger >B< Press XL Technical Guide
Servicing and Warranty - Tool & Jaw Rothenberger prides itself on leading edge design, the highest quality and leading after-sale service support. With ownership of your Rothenberger Tool comes our commitment to support you. We want to help you ‘look after your tool’, so you don’t compromise your reputation. Only have your Press & Jaws inspected and serviced by a qualified Rothenberger Service Centre for high performance and safety. • Quick Fix™ is the Rothenberger ‘After Sales and Service’ repair process across Australia and New Zealand • Comprehensive Spare parts are readily available locally to support your Rothenberger Tool & Jaws • Jaws will also be checked at the annual service interval for any damage, defects and general wear and tear that could affect the press performance or safety Warranty Coverage • After 1 year or 20,000 (Romax 3000) presses the LED lights up red after each press • A press cycle count will be made as part of your annual Tool & Jaw servicing and report • If a serial number sticker is damaged the warranty will be null and void • The warranty does not cover damage caused by incorrect use of the equipment • Tool 3 years, only with regular 1 year or cycle count servicing • Battery 12 months, Jaws 12 months Service and Warranty Process – Quick Fix™ • Return your Rothenberger Press Tool & Jaw Set to your local Branch or call Rothenberger Customer Service (Toll Free) on 1800 186 657 • Your details and serial number of your Tool will be logged for a Service and pick up quickly arranged • Expect 3-5 days (parts dependant) for your service and Tools returned to you, or your local branch • Live status updates will be emailed and SMS to you and your local branch • Any additional repair work beyond the normal annual service will be quoted prior to commencement Conex Bänninger >B< Press XL Technical Guide
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Conex Bänninger >B< Press XL Technical Guide
For more information visit www.reece.com.au/b-press
Reece. Works for you.™ Call 1800 032 566 or visit www.reece.com.au for your nearest Reece store. The manufacturer/distributor reserves the right to vary specifications or delete models from their range without prior notification. The manufacturer/distributor takes no responsibility for printing errors. All measurement and content details in this brochure are subject to a tolerance of ± 3 %. V1 [BROCHURE CODE 2130220]