QuickLINE_96.955_Version_28.Octobre.14. QuickLINE COMPRESSED AIR LINE SYSTEM

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1 QuickLINE_96.955_Version_8.Octobre.4 QuickLINE COMPRESSED AIR LINE SYSTEM

2 COMPRESSED AIR LINE SYSTEM QuickLINE Ready for immediate pressurization QUICK AND EASY TO INSTALL Excellent quality compressed air FLEXIBLE AND EASY TO MODIFY Economical - up to 75% less installation time All components totally reusable LEAK-FREE

3 Typical compressed air distribution network Certification & warranty... 6 Technical specifications...7 features Piping...8 Fittings...9 Table of contents Benefits of a QuickLINE piping system... 0 Piping... - Rigid aluminium pipes... Flexible hoses... Fittings Union connections Elbows...3 Tees...4 ed connections...5 Adapters...6 Water trap tee... 7 Valves & drains... 8 Air treatment... 9 Wall mounted manifolds Composite manifolds Aluminium manifolds...3 Fixing accessories Installation guide Basic information...6 Pre-installation...8 General guideline Assembly instruction

4 Typical compressed air distribtion network 4

5 Typical compressed air distribtion network QuickLINE 5

6 Certification Certification and Warranty ASME B3.3 QuickLINE meets the requirement of ASME B3.3 This code prescribes requirements for material and components, design, fabrication, assembly, erection, examination, inspection, and testing of piping. Canadian Registration Number CRN number valid for all Canadian provinces. CRN CANADIAN REGISTRATION NUMBER QUALICOAT Certification QUALICOAT certification is a guarantee of the quality of the lacquer finish applied to QuickLINE aluminium pipe. ISO 900: 008 QuickLINE is manufactured under ISO quality management system. Warranty warrants its QuickLINE products to This warranty is expressly in lieu of any and be free of defects in material and workmanship all other warranties and representations, for a period of ten (0) years from the date of 0YEAR express or implied, including but not purchase of the products. makes WARRANTY no other warranties, express or implied. This limited to, the warranty of fitness for a limitation explicitly excludes any implied warranty of merchantability of fitness for a particular particular purpose and the warranty of merchantability. makes no warranty purpose. The sole remedy for breach of this warranty of material and workmanship or for negligence in manufacture of design is limited to replacement or repair, at the sole option of, of any defective parts which are returned to (prepaid) within ten (0) years of original purchase. In no event shall be liable for indirect, special, incidental or consequential damages of any kind. allowance will be made for repairs made by the purchaser. that the goods sold hereunder are delivered free of the rightful claim of any third party by way of infringement or otherwise. There are no warranties that extend beyond the description on the face hereof the exclusive remedy for defective products shall be only as stated herein. 6 does not warrant the design, assembly or installation of the system, but only the QuickLINE components as stated herein. is not responsible for improper design, assembly or installation, or for any modifications of the QuickLINE products. The warranty herein is void upon:. Failure to follow any of the assembly or installation guidelines. Installation, repair or relocation of the components by a person other than a trained and qualified installer 3. Alteration, misuse or abuse of, or damage to, any other the QuickLINE products 4. Operation beyond the design range, excessive pressure or stress, or mishandling in any way 5. Improper assembly, installation, service or maintenance

7 Technical specifications Fluids Compressed air (dry, wet, lubricated) Nitrogen Water Maximum working pressure Pipes: 5 BAR (7 PSI) Fittings: 5 BAR (7 PSI) Manifolds: 5 BAR (7 PSI) Resistance to Corrosion Aggressive environments Mechanical shocks Thermal variations U.V. Mineral compressor oils Synthetic compressor oils Compressor oil carry over Technical specifications rmal working pressure 5 BAR (7 PSI) Maximum temperature -4 F to 58 F (-0 C to 70 C) Environment All pipe and fittings are guaranteed silicone free 7

8 Rigid alumium pipes 5 mm features Available in 6 sizes: 5,, 8, 40, 50 & 63mm Tubular extruded aluminium pipe Calibrated aluminium pipes for perfect and leak free assembly with fittings Lightweight Smooth, clean, non-corrosive, rust-proof internal finish Easy to install and adapts to existing metal pipe systems QUALICOAT certified powder-coated blue paint for compressed air identification mm 8 mm Suitable fluids: Compressed Air, Vacuum, Nitrogen Traditional piping corrodes and allows contaminant build-up piping resists corrosion and stays clean over time 40 mm Specifications Material: Aluminium extrusion alloy EN AW-6060 T6 with inside and outside titanium-based, chrome-free and RoHS-complying treating and electrocoated outside surface 50 mm Color: Blue RAL 505 Manufacturing process: Seamless extrusion process Marking: Outside diameter mm Material ion Date week/year Lot Number 63 mm 8

9 Push-in fittings for pipe 5 8 mm Suitable for Aluminium and Nylon pipe For diameters of 5,, and 8 mm Quick assembly with gripping ring push-to-connect fittings Limited fitting expansion under pressure, resulting in dimensionally stable installations features soldering, no threading, no sealing materials required All Brass construction Full flow design Fully reusable Quick and easy to assemble Specifications Body: Brass Release Sleeve: Glass Fibre reinforced Polyamide Composite O-Ring: epdm Rubber Screw-type compression fittings for pipe mm For use with Aluminium pipe For diameters of 40, 50 and 63 mm Quick assembly with screw-type compression fittings Unaffected by vibration soldering, no threading, no sealing materials required All Brass construction Full flow design, with optimal flow characteristics Reusable - only internal ring must be replaced Specifications Body: Brass Tightening Collar: Brass O-Ring: Buna-N/Nitrile Spacer Ring: Stainless Steel Clamp Ring: Nickel plated Brass Quick and easy to assemble 9

10 Features and benefits of QuickLINE System Benefits of a QuickLINE piping system Clean air and optimal efficiency Aluminium pipe ensures a total absence of corrosion Aluminium pipes prevent problems caused by rust common in metal pipe systems The fullbore design and the low friction coefficient of aluminium pipe provide optimal and constant flow throughout and minimize pressure drop due to consistent clean quality air from compressor to equipment, aluminium pipe ensures higher longevity of equipment and avoids frequent changes of filtration elements Easy to install Installation speed: simple push-in and push-in-and-tighten fittings (compression) allow installation to be done much more quickly than conventional systems requiring welding, soldering and threading of heavy components Installation is 50 % to 75 % quicker than with conventional metal pipe systems QuickLINE pipes and fittings are assembled in just a few steps by a single installer, without the need for pipe threading equipment Fast and easy drop installation: twin take-off drop fitting makes drop installation simple and fast. need to plan drops before main line installation, since system need not be depressurized for drop installation. Save money Significant energy savings: calibrated aluminium pipe used with fittings eliminates leaks, saving up to 0 % of power costs. Both pipe and fittings are designed to reduce friction and pressure drop, further reducing power consumption Substantial savings due to lower labour costs Reduced system downtime and lost or delayed production Reduced maintenance cost Easy to modify or extend System can be easily dismantled and reinstalled at a new facility Lightweight: half the weight of conventional Steel or Black Iron systems Completely reusable: components are easy to remove and relocate, making moving an easier task 0

11 RIGID ALUMINIUM PIPE mm inch Length m Length ft Weight lb / / / / Piping PREFORMED DROP BEND mm inch / /4 Special Aluminium alloy Ideal for tapping air off a main line without allowing water to get into the drop D DEVIATION PIPE D mm mm inch / /4 Special Aluminium alloy Ideal for getting around obstacles and correcting minor alignment problems Often used to offset drop legs closer to the mounting surface PRACTICAL TOOLS Tools for the installation and extension of topring air pipe systems CHAMFER TOOL For pipe size mm PIPE CUTTER / 0 to 63 mm Description Pipe cutter Spare blade DEBURRING TOOL PIPE CUTTER / 3 to 30 mm Description Pipe cutter Spare blade

12 FLEXIBLE HOSES Piping Flexible Rubber hose 4" Prod. 48" Prod. Fittings (M) NPT Maximum Pressure PSI Minimum Bend radius inch Hose I.D. inch Hose O.D. inch / / / / 3/ / / -/ Typical installation Features and benefits Designed for bypassing obstacles and/or overcoming misalignment of air lines Ideal for connecting a compressor outlet to an air line system Expansion loops Adaptable to all building configurations Corrosion-proof Rubber hose good for most environments Resists mineral and synthetic oils, heat and weathering Extends compressor and air line system life by reducing stress from vibration and misalignment Construction Cover: Oil resistant synthetic Rubber Inner tube: Oil and heat resistant Rubber Reinforcement: One braid of high tensile Steel wire Specifications Temperature range: -40 F to F (-40 C to 00 C) Flexible Stainless steel anti-vibration hose " Prod. 4" Prod. Fittings (M) NPT Maximum Misalignment in Maximum Working Pressure PSI at 70 F Typical installation / -3/ /4-3/ / /4 4-/ / /8 435 Features and benefits Corrugated flexible Stainless Steel hose is designed to minimize vibration coming from the compressor Protects downstream air line system from vibration and shock Made from corrosion-resistant stainless steel Meets ISO 0380 specifications Extends compressor and air line system life by reducing stress from vibration Construction Hose and Braid: Stainless Steel Fitting: Stainless Steel Specifications Temperature range: -340 F to 50 F (-06 C to 676 C)

13 UNION CONNECTIONS ELBOW UNIONS STRAIGHT union mm O ELBOW union mm Fittings mm mm MALE TUBING REDUCER mm mm NYLON PLUG mm ALUMINIUM PLUG mm

14 Fittings TEES REDUCERS T union mm FEMALE BRANCH T CONNECTOR mm (F) BSPP / / mm mm (F) BSPP / / T REDUCERS UNION 4 mm

15 THREADED CONNECTORS BSPT STraight male connector mm (M) BSPT / / / BSPP STraight FEmale connector mm (F) BSPP / / / Fittings mm (M) BSPT / / mm (F) BSPP / / NPT STraight male connector mm (M) NPT / 07.3 / / BLANKING CAP mm mm (M) NPT / / / NPT STraight FEmale connector mm (F) NPT / / mm mm (F) NPT / /

16 Fittings ADAPTERS threaded reducer /aluminium (M) BSPT (F) BSPT /4 / / / /4 / / / / / / /4 3/ / 3/ /4 BSPT-NPT adapter / ALUMINIUM (M) BSPT (F) NPT / / /4 3/ /4 -/ / -/ NPT-BSPP adapter / ALUMINIUM (M) NPT (F) BSPP 4.90 / / 4.9 3/4 3/ /4 -/ / -/ 4.95 reducer (BSPP) / brass male hexagonal reducer BSPT / BRASS (M) BSPT or BSPP (M) BSPT (F) BSPT BSPT / BSPT 3/ /4 BSPP / /4 BSPP 3/ /4 BSPP 4.034* -/ BSPP / 4.035* -/ BSPP 3/ / BSPT / BSPT -/ BSPP / BSPP 3/ BSPP 4.05 BSPP -/4 *Steel (M) BSPT 4.08 /4 3/ /8 / / 3/ /4 male hexagonal nipple NPT / BRASS (M) NPT 4.05 / /8 4.5 / / * -/4 4.9 * *Steel male hexagonal nipple BSPT / BRASS pipe plug (hex head) / BRASS 6 (M) BSPT (M) BSPT 4.0 /4 / /8 3/ / / male hexagonal nipple reducer NPT / BRASS (M) NPT (M) NPT 4.0 3/8 /4 4.4 / /4 4.6 / 3/ /4 / (M) /8 BSPT /4 BSPT /8 BSPT / BSPP /4 BSPP BSPP /4 BSPP / BSPT BSPP FEMALE BACKPLATE ELBOW mm (F) BSPP /

17 WATER TRAP "T" Typical installation mm mm Features and benefits Makes drop installation fast and easy Prevents water in main line from getting into drops Makes drop installations on new or existing compressed air networks AIR AIR Water trasp T CONDENSATE CONDENSATE CONDENSATE STOP A I R Stops water from getting into drop 7

18 Valves and drains VALVES STANDARD BALL VALVE mm SAFETY EXHAUST/LOCKOUT BALL VALVE mm mm DRAINS MANUAL DRAIN mm HIGH FLOW SAFETY EXHAUST/ LOCKOUT VALVE mm mechanical floatoperated automatic drain mm

19 Clean and dry compressed air Compressed air contains water, dirt, wear particles and degraded lubricating oil, which all mix together to form an unwanted condensate. This condensate rapidly wears tools and pneumatic machinery, blocks valves and orifices and also corrodes piping. This results in high maintenance costs and product spoilage which can bring your production process to an extremely expensive standstill. Air treatment offers an extensive range of condensate management solutions: S49 refrigerated air dryers catalogue page 90 S53 compressed air filters catalogue page 74 S54 desiccant air dryers catalogue page 84 S56 water separators catalogue page 300 S57 oil/water separators catalogue page 304 S59 automatic drains catalogue page 36 compressed air treatment: optimum quality options S53 compressed air filters S53 compressed air filters COMPRESSOR RECEIVER TANK S56 water separator C S59 automatic drains S49 refrigerated air dryers C S57 oil/water separators 9

20 COMPOSITE MANIFOLDS Wall Mounted Manifolds Inlet Outlet (F) BSPP (F) NPT / 3/8 Inlet Outlet (F) BSPP (F) NPT 47.0 / 3/8 mm Quick Coupler QUIKSILVER /4 INDUSTRIAL Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 44 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Quick Coupler TOPQUIK /4 INDUSTRIAL mm Outlet (F) NPT /8 Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed easily at zero pressure Disconnection sound level of only 80 db AIr flow: 36 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Quick Coupler mm Outlet (F) NPT / QUIKSILVER ULTRAFLO Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 80 SCFM at 00 PSIG inlet with 0 PSIG pressure drop 0 SPACERs FOR MANIFOLD Thickness mm Manifold Specifications Material: Polyamide Temperature range: -4 ºF to 40 ºF (-0 ºC to 60 ºC) Maximum working pressure: 45 PSI mm Quick Coupler TOPQUIK ULTRAFLO Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed easily at zero pressure Disconnection sound level of only 80 db AIr flow: 60 SCFM at 00 PSIG inlet with 0 PSIG pressure drop

21 COMPOSITE MANIFOLDS Inlet (F) BSPP Outlet (F) NPT / / (x) /4 / (x) mm Quick Couplers QUIKSILVER /4 INDUSTRIAL (x) Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 44 SCFM at 00 PSIG inlet with 0 PSIG pressure drop Wall Mounted Manifolds Inlet Outlet (F) BSPP (F) NPT / / (x) 47. 3/4 / (x) mm Outlet (F) NPT / (x) / (x) mm Quick Couplers QUIKSILVER ULTRAFLO (x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 80 SCFM at 00 PSIG inlet with 0 PSIG pressure drop SPACERs FOR MANIFOLD Thickness mm mm mm mm Quick Couplers TOPQUIK ULTRAFLO (x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed easily at zero pressure AIr flow: 60 SCFM at 00 PSIG inlet with 0 PSIG pressure drop Manifold Specifications Material: Polyamide Temperature range: -4 ºF to 40 ºF (-0 ºC to 60 ºC) Maximum working pressure: 45 PSI

22 COMPOSITE MANIFOLDS Wall Mounted Manifolds Inlet (F) BSPP Outlet (F) NPT 47.4 / / (3x) 47. 3/4 / (3x) Inlet (F) BSPP mm Outlet (F) NPT / (3x) Outlet (F) NPT 47.5 / / (3x) /4 / (3x) mm Quick Couplers QUIKSILVER /4 INDUSTRIAL (3x) Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 44 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Quick Couplers QUIKSILVER ULTRAFLO (3x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 80 SCFM at 00 PSIG inlet with 0 PSIG pressure drop Inlet (F) BSPP Outlet (F) NPT / / (4x) /4 / (4x) mm Quick Couplers TOPQUIK ULTRAFLO (3x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed easily at zero pressure AIr flow: 60 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Outlet (F) NPT / (4x) / (4x) Manifold Specifications Material: Polyamide Temperature range: -4 ºF to 40 ºF (-0 ºC to 60 ºC) Maximum working pressure: 45 PSI SPACERs FOR MANIFOLD Thickness mm mm mm

23 ALUMINIUM MANIFOLDS Top Inlet (F) BSPP mm Ports Outlet (F) NPT /8 (x) /8 (x) /8 (x) Bottom Outlet Ports Outlet (F) BSPP (F) NPT /4 3/4 3/8 (3x) /4 3/4 / (3x) / (3x) mm Ports Outlet (F) NPT / (3x) / (3x) / (3x) mm Ports Outlet (F) NPT /8 (3x) /8 (3x) / (3x) Wall Mounted Manifolds mm Ports Outlet (F) NPT /8 (x) /8 (x) / (x) mm Ports Outlet (F) NPT /8 (3x) /8 (3x) / (3x) mm Quick Couplers QUIKSILVER /4 INDUSTRIAL (3x) Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 44 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Quick Coupler QUIKSILVER ULTRAFLO (3x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Easy to connect, even under pressure AIr flow: 80 SCFM at 00 PSIG inlet with 0 PSIG pressure drop mm Quick Couplers TOPQUIK 07.4 /4 INDUSTRIAL (3x) Coupler Specifications Accepts /4 INDUSTRIAL type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed Manifold Specifications easily at zero pressure Material: Aluminium Disconnection sound level of only 80 db Temperature range: -4 ºF to 40 ºF AIr flow: 36 SCFM at 00 PSIG inlet with (-0 ºC to 60 ºC) 0 PSIG pressure drop Maximum working pressure: 300 PSI mm Quick Couplers TOPQUIK ULTRAFLO (3x) Coupler Specifications Accepts CEJN 30 type plugs Automatic push-to-connect operation Downstream pressure is automatically vented and disconnection is performed easily at zero pressure AIr flow: 60 SCFM at 00 PSIG inlet with 0 PSIG pressure drop 3

24 FIXING CLIP FOR RIGID PIPE Fixing accessories MOUNTING CLIP / 5--8 mm Hole size 5. mm / 4 screw mm CLIP SPACER / 5--8 mm Thickness mm The clip spacer compensates for the height difference which is created when connecting pipes of a different diameter allowing perfect alignment MOUNTING CLIP / 5--8 mm Hole size 5. mm / 4 screw mm CLIP SPACER / mm Thickness mm The clip spacer compensates for the height difference which is created when connecting pipes of a different diameter allowing perfect alignment epdm insert for fixing pipe clip mm Creating a fixed support To create a fixed support in order to compensate for thermal expansion, add the EPDM insert inside the pipe clip 4 Recommended spacing Create a fix support for thermal expansion compensation Fixing clip should be placed at every meters maximum (for all diameters 0 to 63 mm) Clip must be installed at least 0 cm from of a fitting (downstream or upstream)

25 FIXING ACCESSORIES strut adapter for pipe clips Description For all mounting clip suspension pipe clips mm Nut /8 UNC /8 UNC /8 UNC swivel loop hangers Fixing accessories CANTILEVER ARM / -5/8" x -5/8" Length in mm For threaded rod /8 UNC /8 UNC /8 UNC /8 UNC STRUT CHANNEL / -5/8" x -5/8" Length ft i-beam clamp Beam thickness For threaded rod /4-3/4 3/8 UNC THREADED ROD / 0 ft /8 UNC coupling nut /8 UNC screw /8 UNC i-beam mounting ClipS Beam thickness /8 - / /8 - / / - 3/4 5

26 Basic information Installation guide General Prior to the installation of a QuickLINE compressed air distribution system, the installer should ensure that the installation area complies with any regulations applicable to explosive hazards installed downstream of the compressed air receiver, or after the dryer. A flexible hose can be installed at the start of the system in order to eliminate any sources of vibration and to facilitate maintenance and operations. Before repair or modify the system, the dowstream pressure should be relieved. Installers should only use the components and accessories, including pipe clips and fixture clamps in particular. The technical features of the QuickLINE components, as described in the QuickLINE catalog must be respected. QuickLINE pipes QuickLINE pipes should be protected from mechanical impact, particularly if exposed to collision with fork-lift or when positioned in a environment with moving overhead loads. Similarly rotation of the pipe and pipe supports should be avoided. The pipeline system must not be welded. Component assembly QuickLINE components are provided with assembly instructions for their correct use. Simply follow the methods and RECOMMENDATIONs stated in this document. Pressurizing the system Once the QuickLINE installation has been installed and prior to pressurizing, the installer should complete all tests, inspections and compliance check as stated in any contract and according to sound engineering practice and current local regulations. Expansion / Contraction The system designer and installer should calculate the elongation and retraction of each QuickLINE line according to the recommandations in this installation guide. Situation to be avoided Installation within a solid mass (concrete, foam, etc.) Exposure to chemicals that are incompatible with Quick- LINE components. Use QuickLINE for grounding, or as a support for electrical equipment. The hanging of any external device on QuickLINE. Flexible anti-vibration hose It is recommended to install a flexible anti-vibration hose between the compressor and the air line system. A flexible anti-vibration hose will extend air line system life by reducing stress from vibration coming from the compressor and misalignment. It is not recommended to install fittings directly to the compressor. Reasonable engineering practice for the optimization of an air pipe system The installation should be performed in accordance with good engineering practice. Bends and bypasses cause pressure drop. To avoid pressure loss, use the flexible hose to offset the network and to bypass obstacles. Keep in-line pipe diameter reductions to a minimum. Keep good quality air with adequate filtration at the compressor outlet. T h e d i a m e t e r o f t h e p i p e w i l l i n fl u e n c e p r e s s u r e d r o p at the operation of point-of-use equipment. Select the d i a m e t e r a c c o r d i n g t o t h e r e q u i r e d fl o w r a t e a n d t h e acceptable pressure drop at the point of use. 6

27 The point of highest pressure drop The point of the highest pressure drop is typically the furthest point of use in the system. It takes into account all the pressure drops along the path from the point of generation to the point of use. A high pressure drop requires a higher loading pressure on the compressor compensating for the losses along the network. + PSI = +% energy cost A PSI increase in operating pressure results in a % increase in energy consumption. Pressure drops drastically increase the electric bill. Installation guide The pressure drop is influenced by various factors A properly designed system takes all these factors into account. By sizing the pipe properly, using QuickLINE pipe with its low friction factor, minimizing the length of pipe used, and designing a system that takes advantage of a ring design, the pressure drop throughout the network will be minimized. Pipes' inner diameter: Increasing the pipes' inner diameter reduces the pressure drop but increases the initial investment. Free air delivery: The air demand of all downstream equipment connected to the network. Friction factor: Related to the pipe's material. QuickLINE pipe has a very low friction factor due to its smooth surface as opposed to galvanized pipes. Length of the network: The longer the network, the higher the pressure drop. Design: It is recommended to build a closed loop network in order to reduce your pressure drops. Working pressure: When the working pressure is lower, the pressure drop increases. Fittings: Every direction change, cross manifold, T connection or reduction in line size within the network will cause pressure loss equivalent to adding additional line length. The table below indicates effective lengths added to the network by each of these restrictions and/or connections. FITTINGS DIAMETERS 5 mm mm 8 mm 40 mm 50 mm 63 mm Union 0.43" (3 cm) 0.56" (7 cm) 0.7" ( cm) 0.98" (30 cm).3" (40 cm).64" (50 cm) 90 Elbow.5" (35 cm).4" (43 cm).80" (55 cm).6" (80 cm) 3." (95 cm) 4.0" (5 cm) T Straight Line T Reducer 0.56" (7 cm).80" (55 cm) 0.79" (4 cm).0" (67 cm)." (34 m) 3.08" (94 cm).64" (50 cm) 4.59" (40 cm).30" (70 cm) 5.58" (70 cm) 3." (95 cm) 7.55" (30 cm) 7

28 Installation guide Pre-installation Proper line sizing for an airline network. Identify type of network: closed loop or dead-end. Calculate total length of line (feet) 3. Determine total flow required total flow required Line sizing for a closed loop network Total length of network (feet) SCFM FEET 00' 50' 00' 50' 300' 400' 500' 600' 700' 800' 900' 000' 50' 500' 000' total flow required Line sizing for a linear / dead-ended network Total length of network (feet) SCFM FEET 5' 50' 75' 00' 50' 00' 50' 300' 400' 500' 600' 700' 800' 900' 000' Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for entire network, at F Total flow required takes account of all flows for all compressed air powered tools and equipment te that a typical compressor will produce approximately 4 SCFM per HP

29 RECOMMENDATION Pipe bending is not recommended. Modifying original pipe shape during assembly or non-compliance with the instructions indicated in this guide may alter the air system, cause serious injury and void the warranty. Instructions are valid only for an ambient air temperature of 5-5 C during installation. General guideline Thermal variations (expansion / contraction) To ensure the air line functions properly, you must identify in advance especially on long lines the areas where thermal variations will cause expansion and plan to install rigid or flexible expansion loops in order to absorb this expansion. Expansion loop with rigid configuration Installation guide Rigid option Legend A B L L L DL DT M F Description Spacing (mm) Length (m) Expansion (mm) Thermal range ( C) Sliding mounting bracket Fixed mounting bracket DL = DT x 0.0 x L A = DL x 3 B = 0,7 x A Alternative Example L = 40 m L = 40 m DT = 50 C DL = DT x 0.0 x L DL= 50 x 0.0 x 40 DL = 40 mm A = DL x 3 A = 40 x 3 A = 90 mm B = 0.7 x A B = 0.7 x 90 B = 640 mm FLEXIBLE options NEXT PAGE Examples of proper expansion loop configuration for absorbing the expansion caused by thermal variations Example MS P D M F Description Wall bracket Slope Drop Sliding mounting bracket Fixed mounting bracket RECOMMENDATION To avoid the accumulations of condensate on a downward expansion loop, the installation of a drop with an automatic drain is highly recommended. NO DOWNWARD expansion loop YES YES UPWARD expansion loop FLAT horizontal expansion loop YES 9

30 NO NO RECOMMENDATION When stretching the line, avoid elbows that are either too square or insufficiently rounded. General guideline Installation guide Thermal variations (continued) FLEXIBLE option A Legend Description L L Length (m) DL DL Expansion (mm) DT Thermal range ( C) M Mounting bracket R Radius (mm) A B Spacing (mm) YES Expansion loop with flexible hose DL = DT x 0.0 x L B= ( x R) + DL + DL Radius options R-A Diameter (mm) R (mm) A (mm) Legend L L DL DL M R L FLEXIBLE option B L min = 000 mm Description Length (m) Expansion (mm) Mounting bracket Radius (mm) Length of flexible hose (mm) YES Other flexible configuration Topring Series 09 flexible hoses can be used to allow the air line to expand properly during thermal variations. Details page 30

31 General guideline Slopes All straight lines should have a 5-50 mm slope for every 30 meters of length. These slopes (always in the same direction as the air flow) should lead to drops with manual or automatic drains, installed as low as possible in order to eliminate condensates. Installation guide Example for proper inclination 5 to 50 mm 30 meters Fixed mounting bracket INSTALLATION In order to allow the line to expand and to avoid pressure stress points that can compromise the proper functioning of the system, you must install fixed mounting brackets at a few spots along the line. creating a fixed mounting bracket To create a fixed mounting bracket, add the EPDM insert (product no ) into the pipe clip. EPDM INSERT FOR FIXED MOUNTING BRACKET SLIDING MOUNTING BRACKET F FIXED MOUNTING BRACKET 3

32 Installation guide RECOMMENDATION To eliminate snaking and sagging, it is important to follow spacing recommendations. General guideline Mounting brackets recommended spacing A mounting bracket should be installed at least every meters for all pipe diameters (0-63 mm). A bracket also needs to be installed no more than 0 cm from every fitting along the line (downstream or upstream). Details page 4 recommended screw Pan head screws 4. G M G M NO G YES M G Legend M G Description Bracket Fitting M M M M G Ball valves To facilitate maintenance, it is recommended to install ball valves in order to divide the air line system into sections. BALL VALVE Each section can, therefore, be depressurized without stopping the entire network. Details page 8 3

33 RECOMMENDATION When making a drop, be sure to install a bracket on each side of the ball valve. General guideline Drops Legend Description A Spacing L L Length (m) DL Expansion (mm) DT Thermal range ( C) F Fixed mounting bracket NO YES Installation guide DL = DT x 0.0 x L A = DL x Y Calculation factors Diameter (mm) Y

34 Assembly instruction How to cut PIPES CUT SQUARE If pipe needs to be cut, make sure the finished cut is straight, even and NO perpendicular to the pipe length. DEBURR AND CHAMFER For leak-free sealing, deburr the cut end and chamfer the inside and outside diameter. Make sure the cut is clean of all debris. Installation guide BEVEL YES PIPE CUTTERS For 5-8 mm pipes: For mm pipes: CHAMFER AND DEBURRING TOOLS For 5--8 mm pipes: chamfer tool For mm pipes: deburring tool How to make a connection PIPE CONNECTION PIPE CONNECTION To connect, simply push the pipe into the fitting, with a twisting motion, as far as it can go. Pull on the piping to make sure it is secure before use. STEP INSERT PIPE WITH RINGS Place the compression ring, clamp ring, spacer ring, and o-ring over the pipe and push the pipe into the fitting to the stop. STEP TIGHTEN to secure Tighten the compression ring to ensure a leak-free seal. Fewer than one thread should be visible when tightened properly. INSERTion Pipe diameter 5 8 Insertion length IMPORTANT A misalignment of more than 5 from the horizontal line can compromise the strength of the pneumatic fittings. RECOMMENDATION Pull on the pipe to make sure the connection is secure, it is important to perform this operation before pressurizing the system. 3 How to MAKE A DISconnection PIPE CONNECTION PIPE CONNECTION To disconnect, just push in the ring using the dismantling clip and pull the pipe with a twisting motion. Unscrew the compression ring and pull the pipe out of the fitting. IMPORTANT The internal rings must be replaced before reusing the fitting. 34 CLIP FOR DISMANTLing Pipe diameter mm Spacer ring, clamp ring and O-ring. Spacer ring clamp ring and O-ring For 40 mm: For 50 mm: For 63 mm:

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