TUBE & FITTINGS Mechanical Jointing System for joining Large Diameter Copper Tubing TECHNICAL BULLETIN D41/03
A whole new way to join copper tubing Fast and easy to assemble No gas bottle required No waiting time for cooling Meets existing copper tubing working pressures Water-free pipe not required for jointing Always a leak tight seal Superior vibration attenuation Quick disassembly for retrofitting, renovation or expansion Meets National Plumbing and Drainage Code requirements DN50 to DN150 sizes The Victaulic system is an established concept for joining large diameter tubing. In use since 1925 for steel and cast iron pipes, the grooved piping concept is now available to join Australian Standard (AS1432) copper tubing in DN50 (2 ) to DN150 (6 ) sizes. The system uses a proven pressure-responsive synthetic rubber gasket to seal on the outside diameter of the tubing. The coupling surrounds the gasket gripping into grooves rolled into the tubing or fittings. The housing is isolated from the fluid but provides the gripping strength for pressure ratings up to 2440kPa, depending on the diameter and thickness of the copper tubing. Compatible copper fittings are stocked in 90 and 45 elbows, equal and reducing tees, concentric and eccentric reducers, already grooved for installation. Flange adaptors are also available in Tables D and E, ANSI 150, and DIN 16 to permit easy adaption to flanged products. Pre-grooved AS 1432 copper tubing is available in Type A (6m lengths) and Type B (3m & 6m lengths) for sizes DN50 to DN150. For shop or on-site grooving of cut lengths, two types of roll grooving machines are available, a manual, hand-driven machines and a power-driven machine to suit standard power drives. 2 Application Copper Victaulic couplings used in conjunction with AS1432 copper tube is designed for building hydraulic services systems; Plumbing Domestic hot and cold water Roof water drainage Warm water High temperature water Heating and Ventilation Chilled water Condenser water Hydronic Heating Fire and Industrial Compressed air Storage water Fire hydrants Fire hose reels Fire sprinklers Product Approval Copper fittings are manufactured in accordance with Australian Standards AS3688 Copper and Copper Alloy Fittings. Copper Victaulic jointing methods have been tested and certified by SAI Global Assurance Services, complying with the requirements of SAA MP52 Specification 411 Ductile iron pipe clamp, Specification 412 Valves butterfly bronze,watermark Licence 20030. All Victaulic tube and fittings have been type tested to comply to AS4020- Products for use in Contact with drinking water.
Coupling for Copper Tubing Style 606 Style 606 ductile iron coupling is designed specifically to fit Australian copper tube sizes DN50 to DN150 (2 to 6 ), and is suitable for continuous service up to 110 C. Recommended for cold and hot water services, not recommended for petroleum, gas or steam. The coupling features a unique, patented angle pad design which allows the coupling housing to offset while clamping the tube. By permitting the housings to slide on the angled bold pads, rigidity is obtained. This design also permits removing one bolt/nut and swinging the housing over the gasket to further speed installation. Gasket material - Flush seal EPDM rubber suitable for hot and cold water applications. Couplings are certified with WaterMark Licence no 20030 under Counter Top Specification MP52 Spec 411-Ductile iron pipe clamp. Couplings are available upon request with powder coating finish to meet special applications. Refer to Kembla Tube & Fittings instructions for Assembling a Style 606 Copper Victaulic Coupling. Performance The copper Victaulic system has been thoroughly tested on Types A, B and D copper tubing. Victaulic products are routinely tested to failure in unrestrained hydrostatic and flexure tests. Using a 3 to 1 nominal safety factor, these tests provide regular verification of the product working pressures. The ratings below apply with Victaulic Style 606 couplings, Series 608 butterfly valve, and roll grooved copper fittings with the indicated types of tubing. Copper tube Safe Working Pressures shown are applicable for temperatures up to 50 degrees Celsius and are based on annealed tube. Pressure Ratings for Copper Victaulic System using AS1432 Copper Tubing 3
Copper Fittings All fittings are manufactured in accordance with Australian Standard AS3688, Copper and Copper Alloy Body Compression and Capillary Fittings and are grooved in accordance with WaterMark Licence No. W20030 under Counter Top specification MP52 Spec. 042 Copper and Copper Alloy fittings with Roll-grooved Ends. The whole range of fittings is pre-grooved and ready for installation with hard drawn copper tube to AS1432, Types A, B and D using Style 606 couplings. Sizes DN50 (2 ) through to DN150 (6 ) are currently available in 90 elbow; 45 elbow, equal tee, reducing tee, concentric reducers grooved by grooved and grooved by cup, threaded/grooved tapping bands, grooved/threaded end plug and grooved caps. End Plugs Dezincification resistant Brass End Plugs are available for DN50 and DN65. These plugs, machine grooved from solid brass, contain a w BSP threaded bore with screw-in end nut which is ideally suited for attaching a draining valve or pressure gauge or simply to seal off the end of a tube run by connecting with a Style 606 coupling. Caps Copper caps are available for DN80 to DN150. These caps, produced from Type A copper tube are supplied pre-grooved and are installed with a Style 606 coupling. Reducing Tees Concentric Reducers Reducing Tees and concentric reducers are grooved on all ends DN50 and above. For outlets DN40 and below, they are supplied flared in readiness for silver soldering. 4
Butterfly Valves Series 608 Victaulic Series 608 Butterfly valves are designed to provide bubble-tight shut-off to 2030kPa. The valve features a double-seal disc design with a resilient elastomeric coating bonded to the ductile iron disc core. The disc drive hub is integrally cast as part of the disc and can be actuated by a manual lever or gear, pneumatic, electric or hydraulic operations. Sealing and positive shut-off are accomplished by a double ring seal which is integrally moulded on the disc. The disc coating also acts as the primary seal between the disc, the drive hub and hub beating. O-rings on the upper bearing and lower trunnion provide thread sealing. Valves are certified with WaterMark Licence No. W20030 under the Counter Top Specification MP52 Spec. 412 - Valves - Butterfly Bronze with Grooved Ends to suit Copper Tube to AS1432. Material Specifications Body: Bronze per C83600 (85-5-5-5). Disc: Ductile iron to ASTM A-536. Disc Coating: Grade E EPDM EPDM (green colour code). Temperature range for continuous service up to +110 C. Recommended for cold and hot water service within the specifiied temperature range plus a variety of dilute acids, oil-free air and many chemical services. NOT RECOMMENDED FOR PETROLEUM SERVICES. Tapping Bands Style 630 and 631 Drive Hub Adaptor: Steel black enamel coated. Upper Bearing/Lower Trunnion Seals: Same as Disc Coating. Trim: (Upper Bearing/Lower Runnion) Bronze alloy. Operator Bracket: Steel Black enamel coated. Bracket Bolts/Washers: Steel zinc plated. Operator: DN65-DN150 Manual lever lock/infinitely variable handle with memory stop: Steel black enamel coated. Suitable for adaption to standard electric and pneumatic actuators. Victaulic No. 630 and 631 Gunmetal Tapping Bands are specifically developed for use with copper pipe AS1432. This band is metallurgically compatible with copper pipe being 85% copper as cast. The Victaulic Tapping Band features simultaneous cast studs in lower half of tapping band, complete encirclement of pipe when fitted. The radius on edges and band widths comply with water and gas authority specifications, and the fitting is highly resistant to corrosion. Material Gunmetal C83600 D/R Sealing Nitrile fully contained in top half. Nuts Gunmetal C83600 D/R Pressure rating 2068 kpa (300 PSI) for all sizes, but limited to the published working pressure for the rated type of copper tube in use. 5
Copper Flange Adaptor The Copper Flange Adaptor is designed for directly incorporating flanged components with ANSI class 150, Table D or E, into a grooved copper system. The flange adaptor incorporates a painted steel flange, a rubber gasket and the copper adaptor all in one effective assembly. It is connected to the grooved copper system using a standard STYLE 606 coupling. The Flange adaptor backing flange can be easily rotated to line up bolt holes after tightening the Style 606 coupling. Flange Adaptors should not be used as anchor points for tie rods across nonrestrained joints. Copper Roll Groove Machine The Copper Victaulic system allows tubing preparation with a choice of two light, portable and readily available tools. These are copper coloured, only for use on copper tubing. Never use steel pipe grooving machines. Pre-grooved AS1432 copper tubing in Types A and B is also available from Kembla Tube & Fittings distributors. Victaulic Manual Roll Groover VE-26AC The Victaulic manual roll groover is designed for copper tube in the DN50 to DN150 range. No roll changes are needed, and is operated with a hand crank (supplied). Trial grooving depth is easily set using the supplied set of feeler gauges. Unlike traditional roll groovers, the VE-26AC rotates around a stationary tube making it ideal for grooving on inplace systems. With only 90mm of clearance, the VE- 26AC can be applied in the most confined of spaces which, combined with the lightweight (10kg) construction, makes it perfect for field applications. The tracking enhanced rolls allow bi-directional grooving, making operation easy for both right and left handed users. The VE-26AC has limitless applications and is ideal for new installations, retrofit work, pipeline directional changes or where additions to an existing system are needed. Victaulic Power-Driven Roll Groover VE-226AC The Victaulic power-driven roll groover requires no roll changes and easily mounts to a Ridgid or Rothenburger power drive. Designed for tubing in the DN50 to DN150 range, the tools are operated with a standard 10mm square ratchet drive (not included). The VE-226AC weighs just 17 kg. Trial grooving depth is easily set with feeler gauges supplied with the tool, with the setting locked in with an allen wrench (supplied). The roll groover is protected by an integral overload device which guards against undue load being applied through the ratchet. A unique pivot arm design reduces handle effort. 6 CAUTION These tools are designed for roll grooving copper tube only. For your own safety before assembling and operating these units, read the operator s manual carefully and completely.
Groove Specifications The groove is achieved by an upper male roll being pressed, with manual or hydraulic force, depending upon the tool used, into tubing which rotates on a lower female roll. Use only roll sets for Australian copper tubing. Never use steel goove roll sets on copper tubing. Tubing grooves must be within tolerances listed below to assure proper coupling assembly. The Groove Diameter C is measured with a pi tape, which is wrapped around the circumference of the groove, and shows the actual diameter of the groove. Victaulic measuring tapes are available. Refer to Kembla Tube & Fittings instruction Performing a Copper Roll Groove. Design Data and Specification Copper tubing systems fabricated from DN50 DN150 shall be installed using mechanical pipe couplings of a bolted type with a central cavity design and pressure-responsive gasket, as supplied by Kembla Tube & Fittings. Pipe and Material 1.1 Tube - All copper tubing shall be manufactured and certified in accordance with AS1432 Copper and Copper Alloy Seamless Tube. 1.2 Coupling - Style 606 coupling for copper tube water systems shall consist of cast ductile iron housing, EPDM rubber gasket of a pressure-responsive design, with zinc plated nuts and bolts to secure the coupling together. 1.3 Fittings - Fittings shall be supplied rolled grooved copper manufacture in accordance with AS3688 Copper and Copper Alloy Fittings 1.4 Butterfly Valves - Shall be type 608 copper connection valves and shall have a dual-seal disc coated with EPDM rubber, providing water tightness at 2030kPa. 1.5 Flange Adaptor - The copper flange adaptor shall be designed for directly incorporating flanged components with Table D or E, ANSI Class 150 or DIN pattern having a rubber gasket, bolt set and grooved copper flange adaptor. 1.6 Coupling Assembly - Couplings, flange adaptors, copper tube and fittings shall be assembled in accordance with the latest published instructions from Kembla Tube & Fittings, Performing a Style 606 Coupling Assembly. 1.7 Pipe Supports - Piping joined with grooved type couplings, like all other piping systems, requires support to carry the weight of the pipes, pipe contents and equipment. The support and clipping method must be adequate to eliminate undue stresses on the roll grooved joint and system components. AS3500 National Plumbing and Drainage Code stipulates the minimum supports needed for copper piping for water and fire services. Additional consideration for pipe anchoring, thermal expansion and contraction shall be designed into the Copper Victaulic piping systems. Allowance for sudden hydraulic forces shall be included. Copper Victaulic Underground The National Plumbing and Drainage Code AS3500.1 stipulates the requirements for copper rolled grooved joints when used below ground: Each joint shall be protected against corrosion and External to a building and not under concrete. Each assembled copper joint shall be evenly coated with petrolatum mastic filler and wrapped with petrolatum Petro-40 tape to provide a 55% overlap. Petro 250 overwrap may be used to provide mechanical protection. Refer to Kembla Tube & Fittings instructions Installation Practice for Buried Applications. 7
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