TECHNICAL MANUAL PRESS FITTINGS FOR STEEL PIPE. Phone: Fax:

Transcription

1 TECHNICL MNUL Phone: Fax: MKT-24 FSTLOCK fittings are not currently approved for use with gas or fire protection applications.

2 TLE OF CONTENTS FSTLOCK System... 2 FSTLOCK Fittings... 2 FSTLOCK pplications & Operating Parameters.. 3 FSTLOCK Pipe Requirements... 4 FSTLOCK Tool Requirements... 4 FSTLOCK Installation Instructions... 5 FSTLOCK dapters... 8 Installation djustments & Clearances... 8 Corrosion Resistance & Protective Coating... 9 FSTLOCK Dimensions Useful Information Pressure Drop Thermal Expansion Certification Warranty Frequently sked Questions FSTLOCK SYSTEM The FSTLOCK system, which was introduced in Europe in 2002, provides a method of joining schedule 10 through schedule 40 black and galvanized STM 53 compliant steel pipe through a quick and easy press connection. The FSTLOCK system provides a very strong and tight connection. The press connections are made with a press tool fitted with FSTLOCK jaws. Current electro-hydraulic crimping tools with a minimum force of 32kN of force equipped with FSTLOCK approved jaws are required. The FSTLOCK system saves time and money by eliminating the need for threading dies, pipe sealants, and pipe wrenches used in threaded systems, as well as the burn permits, welding rods, flux, sealing compound, and protective gear used when welding. FSTLOCK fittings feature a hot dipped, galvanized coating for added strength and resistance to corrosion and are available in both a black and silver finish. FSTLOCK FITTINGS FSTLOCK press fittings are made from malleable cast iron. The annealing process used in the manufacturing of the fittings provides them with a greater malleability well suited for press connections. During manufacturing, all FSTLOCK fittings are cleaned, washed, and then the galvanized fittings are dipped in 99.99% pure, molten zinc at temperatures over 1,112 F. This process completely coats the fitting s surface inside and outside, giving them additional strength and providing a resistance to oxide corrosion. This corrosion resistant coating makes FSTLOCK fittings excellent for use in drinking water systems. FSTLOCK fittings are NSF-61-4 certified. FSTLOCK fittings ensure a tightly sealed connection utilizing efore Press Connection Pressing rea a sealing gasket and stainless steel gripping ring preassembled into each end of the fitting. Tabs on the fitting s end retain the sealing gasket and stainless steel gripping ring. FSTLOCK EPDM Gasket fittings for gas use are properly identified and include an additional copper ring to prevent leakage and fire risk and a yellow HNR 316 Stainless Steel Ring gasket. FSTLOCK fittings that include a black EPDM gasket and lack a copper ring CNNOT be used for gas applications. STM 53 Steel Pipe The sealing gasket ensures the connection is air and water tight after pressing. The thick sealing gasket provides a wide contact fter Press Connection Pressing rea surface between the fitting and the pipe, ensuring a reliable connection. The ISI 316L stainless steel ring grips the pipe and EPDM Gasket prevents it from pulling out, even in cases of very high pressure. The diagram to the right illustrates how the malleability of the fitting s body together with the sealing gasket and stainless steel 316 Stainless Steel Ring ring provide a strong and secure connection after being pressed. STM 53 Steel Pipe 2

3 EPDM Sealing Gaskets Stainless Steel Gripping Rings The gasket and stainless steel ring are held in place by tabs in the fitting s end. FSTLOCK PPLICTIONS & OPERTING PRMETERS FSTLOCK fittings have an operating temperature range of F and a maximum operating pressure of 200 PSI. FSTLOCK fittings can be used for various applications including: drinking water (NSF-61-4 Certified), sanitary plumbing, HVC, and compressed air. The table below details several applications and whether or not FSTLOCK is suitable for them. Fluids Gases pplication Operating Parameters FSTLOCK EPDM pplication Hot and Cold Potable Water 32 F 250 F; Max. 200 PSI YES Potable Water System Flushing Compliant with Major Plumbing Codes YES Chilled Water with Corrosion Inhibitors 0 F 250 F; Max. 200 PSI YES Ethylene Glycol (50% Max. Concentration) Propylene Glycol (50% Max. Concentration) Hydronic Heating 0 F 250 F; Max. 200 PSI YES Ethylene Glycol (50% Max. Concentration) Propylene Glycol (50% Max. Concentration) Low Pressure Steam (WRNING: pplication must be F; Max. 200 PSI YES within operating parameters of FSTLOCK fittings) Rainwater/Greywater 32 F 250 F; Max. 200 PSI YES Heating Fuel Oil -40 F 180 F mbient; Max.125 PSI NO Diesel Fuel Oil Compliant with NFP 30 and 30 NO Process Piping Propylene Glycol (100% Max. Concentration) F; Max. 200 PSI YES Ethylene Glycol (100% Max. Concentration) F; Max. 200 PSI YES utylene Glycol (100% Max. Concentration) F; Max. 200 PSI YES Compressed ir with Less than 25mg/m 3 oil content 0 F 160 F mbient; Max. 200 PSI YES Compressed ir with Greater than 25mg/m 3 oil content 0 F 160 F mbient; Max. 200 PSI NO Carbon Dioxide CO 2 Dry 0 F 250 F mbient; Max. 140 PSI YES Nitrogen N 2 0 F 250 F mbient; Max. 140 PSI YES rgon, Corgon 0 F 250 F mbient; Max. 140 PSI YES Vacuum Max inches of Mercury YES Natural Gas, Liquid Propane Gas, Mixed Fuel Gases, -40 F 180 F mbient; Max. 125 PSI NO Manufactured Fuel Gases, Liquid utane Gas Oxygen O 2 (Non-Medical) 0 F 160 F mbient; Max. 160 PSI YES 3

4 FSTLOCK PIPE REQUIREMENTS FSTLOCK fittings are designed for use with systems utilizing schedule 10 through schedule 40 STM 53 compliant black or galvanized standard steel pipe. Use the table below to determine if the pipe you are using is STM 53 compliant. e sure to measure the pipe with a gauge to ensure that it is the correct size. Nominal Pipe Size STM 53 ctual Outer Diameter Schedule 10 Schedule 40 Wall Thickness ctual Outer Diameter Wall Thickness ½" 0.840" 0.83" 0.840" 0.109" ¾" 1.050" 0.83" 1.050" 0.113" 1" 1.315" 0.109" 1.315" 0.133" 1" 3/4" Pipe with proper 1¼" 1.660" 0.109" 1.660" 0.140" 1/2" wall thickness will 1½" 1.900" 0.109" 1.900" 0.145" hit the inner stop. Stops 2" 2.375" 0.109" 2.375" 0.154" Permissible Variations in Outside Diameter: ± 0.016" FSTLOCK supplies gauges that quickly determine if a pipe is the correct size. The gauge is sized to STM 53 standards for outer diameter and wall thickness. When pipe is inserted into the slots corresponding with its nominal size, properly sized pipe will hit a visible inner stop or ridge (above). Pipe that is too small will pass this stop and pipe that is too large won t fit in the slot. FSTLOCK TOOL REQUIREMENTS FSTLOCK Jaws (Jaws, ctuators, and Collars): FSTLOCK fittings are for use with FSTLOCK approved jaws only. FSTLOCK jaws are suited for use on most ½" 2" press tools available with a press force of at least 32kN. Jaws must be clean and handled carefully to prevent any damage that could cause malfunction. efore making any connections, make sure that the jaws are properly mounted on the press machine. 3/4" 1/2" 1" Too small Too large Pipe with proper outer dimension will hit the inner stop. Press Tools ½", ¾", 1" Jaws ctuator & 1¼", 1½", 2" Collars Ridgid 100-, RP210- NO NO Ridgid CT-400, 320, 330 YES YES REMS Power-Press (E, 2000, CC) YES YES REMS kku-press, kku-press CC YES YES Rothenberger Romax C ECO YES YES Rothenberger Romax Compact NO NO Stanley Virax P20+ YES YES Stanley Virax M20+ NO NO Press Tool: FSTLOCK jaws must be used with an approved press tool for sizes up to 2" with a press force of at least 32kN ( lbf) and operating either at 110 volts or on battery power. FSTLOCK jaws are compatible with press tools by Ridgid, Rothenberger, REMS, and Stanley VIRX. Use the table above to determine if your press tool is compatible with FSTLOCK jaws. Pipe Cutter: manual or electrical tool can be used to cut the steel pipe. The cut must be made perpendicular to the pipe s axis. (See Installation Instructions) 4

5 Deburrer: deburrer must be used to remove any debris or metal shavings from the pipe before it is inserted into the fitting. Failure to do so could damage the fitting s gasket, preventing a proper seal. Lubricant: To ease inserting the pipe into the fitting, it is recommended that you apply an approved silicone lubricant spray to either the edge of the pipe or the inside of the fitting. Make sure that the lubricant used is approved for use with the fitting s EPDM gasket (the lubricant CNNOT be petroleum based) and the system s intended application. Soapy water may also be used to lubricate the pipe and fittings. FSTLOCK Jaws (½" 1") FSTLOCK ctuator & Collar (1¼" 2") Pipe Cutter Deburrer FSTLOCK INSTLLTION INSTRUCTIONS Correct installation is important to the proper functioning of any plumbing system. The following are detailed instructions on how to correctly use FSTLOCK fittings to connect steel pipe. e sure to read through all of these instructions before completing any connections. 1. Prepare and cut the pipe. FSTLOCK fittings are for use with black and galvanized schedules 10 through 40 STM 53 compliant standard steel pipe. Using the supplied gauge or calipers, verify that the outside diameter and wall thickness of the pipe being used conforms to the STM standards on the previous page. In case of doubt, or if using old or oxidized pipe already installed, position the gauge against the pipe and rotate it at least 90 to ensure the pipe s diameter is consistent to STM standards. The pipe should be free of indentations, pits, and deformations. The pipe must also be clean and free of debris, rust, scale, paint, oil, grease, or excessive coating. If 4 necessary, clean the pipe with a 4 3 8" x 3 1 8" piece of Gr. 100 sandpaper by holding the sandpaper against the pipe and buffing it in a back and forth motion with both hands 40 times (picture 1). Repeat this procedure 3 more times, rotating the sandpaper 90 each time, until the complete circumference of the pipe has been sanded (Picture 3 Pipe 2 1 1). Once cleaned, re-measure the pipe to ensure that its diameter remains consistent with STM standards. If the measurement is good, cut the pipe where it has been cleaned. The cut must be made perpendicular to the pipe axis with either a manual or electrical pipe cutter or hacksaw. The pipe s cut should be within 1 10 of the pipe s diameter. 2. Deburr the pipe. Once properly cut, deburr the pipe s inside and outside edges to avoid damaging the fitting s gasket. Make sure the pipe is clean and free of debris after deburring. 1. Clean the Pipe 1C. Cut the Pipe 1. Clean ll Sides of Pipe 2. Deburr the Pipe 5

6 3. Verify the fitting. efore using a FSTLOCK fitting, verify the presence, integrity and correct positioning of both the gasket and stainless steel gripping ring inside the fitting. Refer to picture 3 to see the correct positioning of the gasket and stainless steel gripping ring. 4. Mark the insertion depth on the pipe. efore inserting the pipe into the fitting, a mark must be made on the pipe indicating the proper insertion depth. If the pipe is not inserted to the proper depth before pressing, the connection could be jeopardized. The table below indicates the proper insertion depths for each size fitting. Note that some fittings such as slip couplings and slip tees do not have a stop and a mark must be used to determine if the pipe has been inserted to the proper depth. Stainless Steel Ring Stop Gasket 3. Verify the Fitting 3. Fitting Parts Fitting Size Min. Pipe Insertion Depth ½" ¾" 1" 1¼" 1½" 2" 0.96" 1.12" 1.23" 1.45" 1.45" 1.45" 4. Mark the Insertion Depth 5. Lubricate the Fitting 5. Insert the pipe. Slide the fitting onto the pipe using a gentle turning motion until the pipe makes contact with the stop. If necessary, lubricate the pipe or fitting with an approved silicone spray. Soapy water may also be used as a lubricant. Once the pipe is inserted into the fitting, verify that the mark made on the pipe in the previous step lines up with the edge of the fitting. 6. Make the press connection. Complete the press connection using FSTLOCK approved jaws in accordance with your press tool s instructions. The connection must be completed using the proper tools: a press tool with a minimum force of 32 kn ( lbf), for sizes up to at least 2", operating either at 110 volts or on battery power, and equipped with FSTLOCK approved jaws. Connections must be made using FSTLOCK aproved jaws. Make sure that the jaws are properly installed on the press tool and that they are free of dirt and debris. efore completing a 5. Insert the Pipe 6. Complete the Connection 6. Position the Jaws 7. Verify the Connection connection, read the section on the following page on how to properly position the jaws when making a connection. If the jaws are not positioned correctly, it will jeopardize the integrity of the connection. With the jaws properly positioned around the mouth of the fitting, complete the press connection following the instructions provided by the press tool s manufacturer. 7. Verify the connection. If you forget to press a fitting or improperly press a fitting, the gasket won t tighten all the way and a leak will occur. If left unpressed, FSTLOCK fittings will leak when pressure tested to a minimum of 45 PSI. FSTLOCK jaws imprint a visible, detectable mark on fittings that have been pressed correctly (circled in picture 7). Look for this mark on all connections to ensure that they have been completed correctly. Often a connection may be re-pressed if not pressed completely. 6

7 Positioning the Jaws for a Proper Press Connection FSTLOCK fittings must be used with FSTLOCK approved jaws only. The diagram below left illustrates how to properly position the jaws to make a connection. The jaws should be perpendicular to the pipe and fitting and centered over the fitting mouth (1). Note that in the wrong illustrations, the jaws are either too far left (2), too far right (3), or not centered over the fitting s mouth (4). FSTLOCK jaws feature a ridge running around both sides of their outer edge. To ensure a proper seal when pressing, the mouth of the fitting being pressed must be completely within the ridges of the jaws. No part of the fitting mouth being pressed should be seen or extend beyond the edges of the jaws. If any part of the fitting mouth extends beyond the jaws, the fitting will not seal correctly and may be damaged when pressed. efore completing any FSTLOCK connections, study the diagram below right and the pictures below for the correct way to position the jaws when making a connection JWS RIDGE RIDGE FITTING PIPE CORRECT WRONG! WRONG! WRONG! RIDGE RIDGE CORRECT No part of the fitting mouth being pressed can be seen beyond the jaws when viewed directly. WRONG! When viewed directly, the fitting mouth being pressed visibly extends to the left beyond the jaws. CORRECT The fitting mouth is securely inside of the ridges on the jaws. WRONG! The fitting mouth extends past the ridges on the jaws. WRONG! While the fitting mouth towards the back is within the ridges on the jaw, the fitting mouth extends past the ridges towards the front of the jaws. WRONG! While the fitting mouth towards the front is within the ridges on the jaw, the fitting mouth extends past the ridges towards the back of the jaws. 7

8 ulging Gasket fter Pressing: Occasionally, a portion of the gasket may bulge past the fitting mouth after the fitting has been pressed. The fitting s gripping ring is designed to accept a range of outer pipe diameters. In some cases, the two ends of the gripping ring do not meet after the fitting has been pressed. In these cases the gasket expands past the ring and fills the gap left by the gripping ring, sometimes extruding past the mouth of the fitting. These bulging gaskets have been examined in depth by the manufacturer and have been found to pose no threat of leaking. Gasket ulge Gripping Ring FSTLOCK DPTERS FSTLOCK fittings utilize two types of adapters: reducing adapters for connecting to different sized pipe and threaded adapters for connecting to threaded components. ll FSTLOCK adapters have a plain end that must be inserted completely into the fitting until the edge of the fitting mouth hits the external hexagon of the adapter. In the case of female threaded adapters, make sure the adapter s plain end fits into the fitting s mouth deep enough to allow the stainless steel ring to crimp onto the machined plain end. The press connection is completed in the same way as for connecting pipe, making sure to press the fiting mouth and not the external hexagon of the adapter. Pictured below are some fittings that can be created utilizing the adapters. Reducing dapter Female Threaded dapter ½" dapter dapter 1" ½" ½" 2" 1" 1" dapter Reducing dapter Used to Create a 1" x 1" x ½" Reducing Tee Reducing dapter Used to Create a 2" x ½" Reducing Coupling Female Threaded dapter Used to Create a 1" Female Thread x ½" Press Elbow INSTLLTION DJUSTMENTS & CLERNCES djustment: In some cases, it is possible to slightly turn and adjust the fitting after making a press connection. The fitting design allows a slight manual adjustment. Clearances: Figures 1 through 4 below and on the following page show the clearances that must be maintained during installation to allow room for the press tool. Figure 1 Figure 2 Size C ½" 2.64" 1.18" 3.35" 1.57" 1.97" ¾" 3.15" 1.38" 3.35" 1.57" 2.16" 1" 3.15" 1.38" 3.54" 1.89" 2.16" 1¼" 2.76" 2.76" 2.76" 2.76" 3.15" 1½" 4.33" 2.76" 5.90" 4.33" 4.33" 2" 4.33" 2.76" 5.90" 4.33" 4.33" Figure 1 Figure 2 8 C

9 Minimum Dimensions for Connections (Figure 3) Size C ½" 0.20" 0.98" 2.17" ¾" 0.20" 1.10" 2.40" 1" 0.20" 1.22" 2.64" 1¼" 0.59" 1.46" 3.39" 1½" 0.32" 1.46" 3.22" 2" 0.32" 1.46" 3.22" C Figure 3 FIgure " CORROSION RESISTNCE & PROTECTIVE COTING There are many kinds of corrosion (chemical, electrochemical, surface, etc.) that effect a metal s mechanical properties. From a chemical point of view, a metal can become corroded if it loses or gains electrons. In fact, corrosion is the transfer of electrons from molecules of low electrochemical potential to those with high electrochemical potential. n element is corroded more or less quickly according to its electrochemical potential and its environment. Corrosive Environments: Wet ir: The presence of water and oxygen can corrode most metals. The more acidic the air, the more aggressive the corrosion. Varying Electrochemical Conductivity: Corrosion can occur when two metals with different electrochemical properties are in contact with one another. ad Insulation: Metals located underground that are not properly insulated may become corroded from natural ground conditions, especially in areas where streams pass through the ground where the metal is buried. FSTLOCK Surface Treatment One of the most widely used methods to protect a metal s surface from corrosion is to give it a galvanized coating. y far, the hot dip zinc technology used in manufacturing FSTLOCK fittings is the best method to protect steel and cast iron from corrosion. Electrochemical Protection: ecause it is highly compatible with oxygen, zinc can be quickly heated to create a coating that, when applied, will prohibit corrosion. inc s low electrochemical conductivity ensures that the cast iron fitting s surface will be protected from corrosion. The coating is thick enough to remain intact even if the fitting is scratched. Mechanical Protection: The hot dip zinc process ensures a highly adhesive coating, providing a robust surface that is smooth, flexible and resistant to abrasion. The FSTLOCK ferric structure of layers of zinc coating cast iron also contributes to the fittings mechanical properties. Hot dip zinc is a unique process that produces an extremely hard and resistant surface coating as evidenced in the table to the right. The hardness of annealed cast iron is 100 rinell. The cast iron with zinc coating (Fe-n) is tougher and reaches a hardness of approximately 165 rinell; and therefore more resistant to abrasion. ecause, the outer layers of zinc are more malleable than cast iron, the coasting is able to absorb hits or strikes. The galvanized surface is tougher than the cast iron itself. Even if the coating appears to be scratched off, it s unlikely that it has been completely removed. In fact, thin layers at the bottom of the alloy layer are melted to the cast iron surface. So even if the entire upper layer has been scratched off, the lower layer would remain and still provide resistance to corrosion. 9 inc Fe-n Cast Iron rinell Hardness Number

10 Toxicity: Unlike other materials (lead, copper, cadmium etc.), pure zinc does not present any toxicity, even in large quantities. Possible toxicity could result from other metals in the zinc alloy, but for the hot dip zinc processing utilized to create FSTLOCK, 99.99% pure zinc is used, making it safe for drinking water. Surface Damage Surface Damage Surface Damage inc Coating inc around the damaged point wears out before the cast iron because of its lower electrochemical conductivity. The corrosion is limited to the upper layer, protecting the lower layer completely. Paint The damaged surface triggers a corrosive reaction that will continue to build up until repaired. Other Metal Coatings Surface damage to chromium, nickel, or copper coatings triggers a corrosive reaction more quickly than on uncoated materials. The corrosion can quickly penetrate the surface, causing critical damage. FSTLOCK DIMENSIONS For pricing and availability of the following items, refer to FSTLOCK List Price ook. Item No. 270: Coupling: Press x Press Size Weight ½" 2.165" 0.197" lbs ¾" 2.520" 0.197" lbs 1" 2.756" 0.197" lbs 1¼" 2.953" 0.197" lbs 1½" 3.150" 0.197" lbs 2" 3.346" 0.197" lbs Item No. 271: Slip Coupling: Press x Press Size Weight ½" 2.165" lbs ¾" 2.520" lbs 1" 2.756" lbs 1¼" 2.953" lbs 1½" 3.150" lbs 2" 3.346" lbs Item No. 276: Reducing Coupling: Press x Reduced Press Size 1 1 Weight ¾" x ½" 2.440" 0.492" 0.413" 1.142" 0.984" lbs 1" x ¾" 2.637" 0.492" 0.492" 1.279" 1.142" lbs 1¼" x 1" 2.952" 0.492" 0.492" 1.457" 1.279" lbs 1½" x 1¼" 3.188" 0.492" 0.492" 1.457" 1.457" lbs 2" x 1½" 3.188" 0.492" 0.492" 1.457" 1.457" lbs

11 Item No. 272: Coupling: Press x FIPT Size Weight ½" 1.890" 0.276" lbs ¾" 2.126" 0.236" lbs 1" 2.362" 0.354" lbs 1¼" 2.598" 0.394" lbs 1½" 2.835" 0.472" lbs 2" 3.071" 0.551" lbs Item No. 274: Coupling: Press x MIPT Size Weight ½" 2.106" 0.984" lbs ¾" 2.441" 1.142" lbs 1" 2.756" 1.279" lbs 1¼" 3.071" 1.457" lbs 1½" 3.071" 1.457" lbs 2" 3.189" 1.457" lbs Item No. 90: 90 Elbow: Press x Press Size Weight ½" 1.772" 0.630" lbs ¾" 2.087" 0.748" lbs 1" 2.441" 0.984" lbs 1¼" 2.717" 1.142" lbs 1½" 2.992" 1.339" lbs 2" 3.268" 1.535" lbs Item No. 91: 90 Elbow: Press x Male Plain End Size Weight ½" 1.772" 1.535" 0.630" lbs ¾" 2.087" 1.654" 0.748" lbs 1" 2.441" 2.008" 0.984" lbs 1¼" 2.717" 2.283" 1.142" lbs 1½" 2.992" 2.638" 1.339" lbs 2" 3.268" 2.992" 1.535" lbs 11

12 2 1 Item No. 93: 90 Elbow: Press x FIPT Size 1 2 Weight ½" 1.772" 1.142" 0.630" 0.551" lbs ¾" 2.087" 1.299" 0.748" 0.669" lbs 1" 2.441" 1.575" 0.984" 0.827" lbs 1¼" 2.717" 1.890" 1.142" 0.945" lbs 1½" 2.992" 2.244" 1.339" 1.063" lbs 2" 3.268" 2.598" 1.535" 1.181" lbs Item No. 92: 90 Elbow: Press x MIPT Size Weight ½" 1.772" 1.535" 0.630" lbs ¾" 2.087" 1.654" 0.748" lbs 1" 2.441" 2.008" 0.984" lbs 1¼" 2.717" 2.283" 1.142" lbs 1½" 2.992" 2.638" 1.339" lbs 2" 3.268" 2.992" 1.535" lbs Item No. 130: Tee: Press x Press x Press Size Weight ½" 1.772" 0.630" lbs ¾" 2.087" 0.748" lbs 1" 2.441" 0.984" lbs 1¼" 2.717" 1.142" lbs 1½" 2.992" 1.339" lbs 2" 3.268" 1.535" lbs Item No. 132: Slip Tee: Press x Press x Press Size Weight ½" 1.772" 0.630" lbs ¾" 2.087" 0.748" lbs 1" 2.441" 0.984" lbs 1¼" 2.717" 1.142" lbs 1½" 2.992" 1.339" lbs 2" 3.268" 1.535" lbs 12

13 Item No. 133: Tee - Reducing: Press Run x Reduced Press ranch Size Weight ½" x ½" 2.283" 2.322" 0.492" 0.413" 1.457" 0.984" lbs 1½" x ¾" 2.381" 2.519" 0.492" 0.492" 1.457" 1.142" lbs 2" x ½" 2.283" 2.952" 0.492" 0.413" 1.457" 0.984" lbs 2" x ¾" 2.381" 3.188" 0.492" 0.492" 1.457" 1.142" lbs Other sizes are available but sold as a pre-assembled 130 Tee and 247 dapter. See FSTLOCK List Price ook. Item No. 131: Tee - Reducing: Press Run x Reduced FIPT ranch Size 1 Weight 1" x ½" 2.106" 1.457" 0.492" 1.122" lbs 1¼" x ½" 2.165" 1.516" 0.492" 1.457" lbs 1½" x ½" 2.283" 1.771" 0.492" 1.457" lbs 1½" x ¾" 2.381" 1.850" 0.492" 1.457" lbs 2" x ½" 2.283" 2.027" 0.492" 1.457" lbs 2" x ¾" 2.381" 2.086" 0.492" 1.457" lbs Other sizes are available but sold as a pre-assembled 130 Tee and 243 dapter. See FSTLOCK List Price ook. 1 Item No. 300: Cap: Press Size Weight ½" 1.457" lbs ¾" 1.654" lbs 1" 1.772" lbs 1¼" 2.008" lbs 1½" 2.008" lbs 2" 2.008" lbs Item No. 331: Union - Flat: FIPT x Male Plain End Item N0. 341: Union - Tapered: FIPT x Male Plain End Size Weight ½" 2.087" lbs ¾" 2.244" lbs 1" 2.480" lbs 1¼" 2.795" lbs 1½" 2.992" lbs 2" 3.228" lbs 13

14 Item No. 242: dapter: Male Plain End x Reduced Male Plain End Size Weight ¾" x ½" 1.870" lbs C Item No. 1270: all Valve: Press x Press Size C Weight ½" " 1.875" " lbs ¾" " " " lbs 1" " 2.25" 5.5" lbs 1¼" " " " 2.68 lbs 1½" " " " lbs 2" " " 7.375" lbs 1" x ½" 2.146" lbs 1" x ¾" 2.146" lbs 1¼" x ½" 2.283" lbs 1¼" x ¾" 2.205" lbs 1¼" x 1" 2.264" lbs 1½" x ¾" 2.342" lbs 1½" x 1" 2.362" lbs 1½" x 1¼" 2.315" lbs 2" x ¾" 2.587" lbs 2" x 1" 2.622" lbs 2" x 1¼" 2.677" lbs 2" x 1½" 2.661" lbs Item No. 247: dapter: Male Plain End x Reduced Press End Size Weight ¾" x ½" 2.185" 1.181" lbs 1" x ½" 2.953" 1.378" lbs 1" x ¾" 2.500" 1.319" lbs 1¼" x ½" 3.150" 1.575" lbs 1¼" x ¾" 3.150" 1.575" lbs 1¼" x 1" 3.150" 1.575" lbs 1½" x ½" 3.150" 1.575" lbs 1½" x ¾" 3.150" 1.575" lbs 1½" x 1" 3.150" 1.575" lbs 1½" x 1¼" 3.150" 1.488" lbs 2" x ½" 3.150" 1.575" lbs 2" x ¾" 3.150" 1.575" lbs 2" x 1" 3.150" 1.575" lbs 2" x 1¼" 3.150" 1.575" lbs 2" x 1½" 3.150" 1.575" lbs Item No. 529: dapter: FIPT x Male Plain End Size Weight ½" 1.614" 1.079" lbs ¾" 1.862" 1.307" lbs 1" 2.142" 1.480" lbs 1¼" 2.350" 1.669" lbs 1½" 2.461" 1.779" lbs 2" 2.736" 2.039" lbs 14

15 Item No. 240: dapter: Male Plain End x MIPT Size Weight ½" 1.732" lbs ¾" 1.850" lbs 1" 2.087" lbs 1¼" 2.244" lbs 1½" lbs 2" 2.677" lbs Item No. 241: dapter: Male Plain End x Reduced MIPT Size Weight ¾" x ½" 1.870" lbs 1" x ½" 2.146" lbs 1" x ¾" 2.146" lbs 1¼" x ½" 2.283" lbs 1¼" x ¾" 2.205" lbs 1¼" x 1" 2.264" lbs 1½" x ¾" 2.342" lbs 1½" x 1" 2.362" lbs 1½" x 1¼" 2.315" lbs 2" x ¾" 2.587" lbs 2" x 1" 2.622" lbs 2" x 1¼" 2.677" lbs 2" x 1½" 2.661" lbs Item No. 246: dapter: FIPT x Reduced Male Plain End Size Weight ¾" x ½" 1.929" 1.374" lbs 1" x ½" 2.205" 1.543" lbs 1" x ¾" 2.205" 1.543" lbs 1¼" x ½" 2.362" 1.681" lbs 1¼" x ¾" 2.362" 1.681" lbs 1¼" x 1" 2.362" 1.681" lbs 1½" x ¾" 2.382" 1.681" lbs 1½" x 1" 2.441" 1.681" lbs 1½" x 1¼" 2.508" 1.681" lbs 2" x 1" 2.795" 2.095" lbs 2" x 1¼" 2.795" 2.095" lbs 2" x 1½" 2.795" 2.095" lbs Item No. 243: dapter: Male Plain End x Reduced FIPT Size Weight ¾" x ½" 1.035" 0.799" lbs 1" x ½" 1.065" 0.909" lbs 1" x ¾" 1.065" 0.909" lbs 1¼" x ½" 1.276" 1.020" lbs 1¼" x ¾" 1.276" 1.020" lbs 1¼" x 1" 1.276" 1.020" lbs 1½" x ½" 1.295" 1.020" lbs 1½" x ¾" 1.295" 1.020" lbs 1½" x 1" 1.295" 1.020" lbs 1½" x 1¼" " 1.024" lbs 2" x ½" 1.457" 1.081" lbs 2" x ¾" 1.457" 1.081" lbs 2" x 1" 1.457" 1.081" lbs 2" x 1¼" 1.457" 1.081" lbs 2" x 1½" 1.457" 1.081" lbs 15

16 Fraction (inches) Decimal (inches) Decimal (mm) PRESS FITTINGS FOR STEEL PIPE Fraction (inches) Water Pressure to Feet of Head PSI Feet of Head PSI Feet of Head USEFUL INFORMTION Decimal (inches) Fractions and Decimal Equivalents Decimal (mm) 16 Fraction (inches) Decimal (inches) Decimal (mm) Fraction (inches) Feet of Head to Water Pressure Decimal (inches) Feet of Head PSI Feet of Head PSI Decimal (mm) 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /

17 PRESSURE DROP Pressure drop refers to the decrease in pressure from one point in a piping system to another point downstream. This is mostly caused by friction between the flowing liquid and the pipe s inner wall. Temperature and turns in the line, such as those created by an elbow, as well as branches in the line that converge or divert water flows, such as those created by a tee, will affect pressure drop. The table below details the pressure drop for water flowing through ½" 2" schedule 40 steel pipe at a temperature of 60 F. The friction losses are calculated using the Hazen-Williams equation with a roughness factor (C) of 125. The same information is plotted on Graph 1 below. Pressure Drop for Water Flowing Through 100 Feet of Schedule 40 Steel Pipe at 60 F Nominal Pipe Size ½" ¾" 1" 1¼" 1½" 2" Flow Rate (ft 3 /s) Flow Rate (GPM) Pressure Drop (PSI/100 ft.) Pressure Drop (PSI/100 ft.) Pressure Drop (PSI/100 ft.) Pressure Drop (PSI/100 ft.) Pressure Drop (PSI/100 ft.) Pressure Drop (PSI/100 ft.) Graph 1: Pressure Drop for Water Flowing Through 100 Feet of Schedule 40 Steel Pipe at 60 F ½" ¾" 1" 1¼" 1½" 2" Pressure Drop (PSI/100 ft.) Flow Rate (GPM) 17

18 PRESS FITTINGS FOR STEEL PIPE Localized Pressure Drop: The pressure drop resulting from an elbow or tee can best be understood as being equivalent to an extra length of pipe in the system. The table below contains the equivalent length of pipe in feet for the pressure drop caused by each use of a FSTLOCK 90 elbow and standard tee. Pressure Drop from FSTLOCK Fittings in Equivalent Feet of Pipe Nominal Size 90 Elbow Standard Tee (ranch) Standard Tee (Run) ½" 1.54 ft ft ft. ¾" 2.03 ft ft ft. 1" 2.59 ft ft ft. 1¼" 3.45 ft ft ft. 1½" 4.04 ft ft ft. 2" 5.15 ft ft ft. THERML EXPNSION Expansion Δ L: Each installation is affected by temperature change. Large changes cause a pipe to increase or decrease in length. The formula for thermal expansion is ΔL = L α ΔT ΔL = Total expansion (in) L = Pipe length (ft) α = coefficient of thermal expansion (8x10-5in/ft-F for steel) ΔT = Temperature change (F) This formula says that there are small changes in the length of the pipe due to temperature change. The longer the pipe and the more the temperature increases, the more the pipe will grow in length. If the pipe gets colder, it will shrink in length by the same amount. The table below shows how much the pipe will expand (or contract) based on its length and the temperature change. Data is given for pipe run lengths from 10' to 100' and temperature changes from 20 F to 200 F. Don t forget to use the temperature CHNGE and not the final temperature. If the pipe is installed in a room at 70 F and it heats up to 170 F in operation, the temperature change is 100 F. Temperature Change ΔT ( F) L (ft) " 0.03" 0.05" 0.06" 0.08" 0.10" 0.11" 0.13" 0.14" 0.16" " 0.06" 0.10" 0.13" 0.16" 0.19" 0.22" 0.26" 0.29" 0.32" " 0.10" 0.14" 0.19" 0.24" 0.29" 0.34" 0.38" 0.43" 0.48" " 0.13" 0.19" 0.26" 0.32" 0.38" 0.45" 0.51" 0.58" 0.64" " 0.16" 0.24" 0.32" 0.40" 0.48" 0.56" 0.64" 0.72" 0.80" " 0.19" 0.29" 0.38" 0.48" 0.58" 0.67" 0.77" 0.86" 0.96" " 0.26" 0.38" 0.51" 0.64" 0.77" 0.90" 1.02" 1.15" 1.28" " 0.32" 0.48" 0.64" 0.80" 0.96" 1.12" 1.28" 1.44" 1.60" Piping Flexibility: In the case of long pipe runs or large temperature changes it is important to include expansion joints, offsets, or loops in the line to reduce stresses induced by thermal expansion. If a pipe is held rigidly at each end and it expands due to a hot fluid, the pipe can be overstressed and fail. In these cases, an elbow is added to create an offset that can flex to take up the thermal expansion in the main line. Figures 5, 6, and 7 on the following pages show how changes in pipe direction can be added to reduce stresses to a safe level. In each case, a minimum offset distance of d is shown as the distance between changes in direction and pipe supports that will compensate for the expansion. 18

19 Figure 5 shows the main horizontal run at the top and a vertical offset including a fixed pipe support. Figure 6 shows a vertical drop from a main horizontal run. In both cases the horizontal run is expanding and the vertical run must be long enough to flex and not be over stressed. In both these cases the minimum offset distance is calculated from: d = K De ΔL Where d = Minimum offset length (inches) K = Material flexibility factor (45 for steel pipe) De = Pipe outside diameter (inches) ΔL = Pipe expansion (inches) Graph 2 below is a graphical representation of this equation for different pipe sizes. Example of calculation of d for setup shown in Figures 5 or 6: Main run: 1" pipe, 40' long. 190 F operating temperature, 70 F ambient. ΔT = 190 F - 70 F = 120 F ΔL = 0.38" from table on previous page d = K De L = = 32" This same result can be obtained from the curve for 1" pipe in Graph 2 below. Graph 2: Minimum Offset Distances for Figures 5 and 6 Fixed Support Fixed Support Figure 5 ΔL ΔL Sliding Support d Figure 6 ΔL d Sliding Support Sliding Support 100 Minimum Length rm Offset d (inches) " 1½" 1¼" 1" ¾" ½" Expansion ΔL (inches) 19

20 dditional flexibility can be obtained by using a U shaped loop as shown in Figure 7. The same formula applies, but in this case: L/2 L/2 K = 25 The results of the calculation for this setup are represented in Graph 3 below. Sliding Support d/2 Sliding Support d Figure 7 Graph 3: Minimum Offset Distances for Figure Minimum Length rm Offset d (inches) " 1½" 1¼" 1" ¾" ½" Expansion ΔL (inches) 20

21 21

22 22

23 23

24 What is the background of FSTLOCK fittings? FSTLOCK fittings are manufactured in Italy under the FL trademark by IMS S.p.., a division of the Casti Group. FSTLOCK fittings have been in use in Europe since 2002 under the name lock Fittings and are now sold in the United States through Cimberio Valve Co. Inc. What applications can FSTLOCK fittings be used for? See the table on page 3 for a complete list of applications. What is the warranty on FSTLOCK fittings? IMS S.p.. guarantees that the fittings will be free from defects in material and workmanship when properly installed and used under normal conditions for a period of fifty years from installation. See page 23. What should I do if the fittings I'm using leak? First, make sure that the fitting was pressed completely and correctly as described in the installation instructions. fterwards, if you suspect the fitting is defective, contact Cimberio Valve Co. at within thirty days and create a warranty claim. You must remove the leaking fitting with at least 6" of pipe on each side (where applicable) and mail it at your expense to Cimberio Valve Company, 100 Quaker Lane, Malvern, P FL S.p.. will inspect and test the returned product and will notify you in writing in a reasonable amount of time of the diagnosis. How do I verify that my pipe conforms to STM 53 standards? e sure to measure the pipe with a gauge before use as described in the installation instructions. Gauges are included in the jaws sets and available on request free of charge. In the event that the gauge is lost or missing, use another pipe gauge and make sure that the measurements equal those listed in the table on page 4. oth the outer diameter and the wall thickness must be measured on the pipe being used to ensure that it conforms to STM 53 standards. Should special steps be taken when using old pipe? Yes. Follow the instructions for preparing the pipe in step 1 of the installation instructions on page 5. Can a press connection be made on curved pipe? s long as the pipe end can be inserted into the fitting to the proper insertion depth, there should be no problem making a connection. Can FSTLOCK be used on oval or out-of-round pipe? The pipe must be measured with a gauge to ensure that it meets STM 53 standards. If the pipe conforms to STM 53 standards and can be inserted into the fitting to the proper insertion depth, it is suitable for use with FSTLOCK. How clean should the pipe be? The pipe should be clean and free of debris, rust, scale, paint, oil, grease, and excessive coating. Will debris on the inside of the pipe affect the press connection? It is important that the interior of the pipe be free of debris. Debris and metal shavings can damage the gasket of the fitting or cause further damage on other parts of the line once the plumbing system is in use. How straight should the pipe be cut? The pipe should be cut perpendicular to its axis. The cut s diameter should be within 1/10 of the pipe s diameter. What should I do if I accidentally cut the EPDM gasket? If the gasket is damaged the FSTLOCK fitting will fail to make a proper connection. If the gasket is damaged you must use another FSTLOCK fitting with an intact gasket. What type of lubricant can I use with FSTLOCK fittings? It is recommended that you apply an approved silicone lubricant spray to FREQUENTLY SKED QUESTIONS either the edge of the pipe or the inside of the fitting. Make sure that the lubricant used is approved for use with the fitting s EPDM gasket (the lubricant CNNOT be petroleum based) and the system s intended application. Soapy water may also be used as a lubricant. Without a stop in the fitting, how much weight can the joint take? The weight should not exceed 2,000 lbs. Does the FSTLOCK system require the use of special valves? No. If you prefer to use threaded valves, FSTLOCK provides threaded adapters that will accommodate them. How do I know if FSTLOCK jaws will work with my press tool? FSTLOCK jaws must be used with a press tool for sizes up to 2" with a press force of at least 32kN and operating either at 110 volts or on battery power. For more information, see the table on page 4. Will the jaws I use for copper and stainless steel press connections work with FSTLOCK fittings? No. Only FSTLOCK approved jaws can be used with FSTLOCK fitting. Can a FSTLOCK fitting be rotated or adjusted after being pressed? In some cases, it is possible to slightly turn and adjust the fitting after making a press connection. The fitting design allows a slight manual adjustment. It is recommended that a fitting be repressed after rotating. How can I detect unpressed connections? Unpressed connections will leak when pressure tested to a minimum of 45 psi. lways increase the pressure gradually when performing any pressure tests. FSTLOCK jaws imprint a visible, detectable mark on fittings that have been pressed correctly. Look for this mark on all connections to ensure that they have been completed correctly. Often a connection may be re-pressed if not pressed completely. Is FSTLOCK approved for underground use? Yes, FSTLOCK can be used in underground installations as long as approval is received from the local plumbing inspector. Is FSTLOCK compatible with the cleaning agents used to disinfect a new plumbing system? Yes, as long as the procedure below is followed: 1. The piping system must be flushed with potable water until the water runs clear from all outlets. 2. The system must be completely sealed off and allowed to stand while filled with either a solution of water and 50 parts per million of chlorine for 24 hours or a solution of water and 200 parts per million of chlorine for 3 hours. 3. fter the system has stood with the water and chlorine solution for the proper amount of time, it must be flushed with water until the chlorine is completely purged from the system How long will the EPDM gasket last? It is guaranteed for 50 years and will last the life of the fitting. What is the flow rate of a FSTLOCK fitting? The flow rate for FSTLOCK fittings is the same as for a comparable malleable cast iron threaded fitting. See pages What is the minimum amount of air or water pressure that would cause an unpressed FSTLOCK fitting to leak? Unpressed FSTLOCK fittings will leak at pressures lower than 45 PSI. During lab tests, unpressed FSTLOCK fittings have leaked at pressures as low as 7 PSI for both air and water. What is the minimum amount of air or water pressure that would blow an unpressed FSTLOCK fitting off of a pipe? Under normal conditions, an unpressed FSTLOCK fitting will blow off of a pipe at 29 PSI for both air and water Cimberio Valve Company Inc.