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.

4

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.

6

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

9

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.

10

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

13

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

15

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

19

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

20

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

22

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]