SERIES 06 - · PDF file96.615 installation guide 03/2017 topring series 06 compressed air...

96.615 Installation guide 03/2017

TOPRING

SERIES 06 COMPRESSED AIR

DISTRIBUTION SYSTEM

INSTALLATION GUIDE

TABLE OF CONTENTS

1. BASIC INFORMATION ..............................................................................................................3

2. POINT OF HIGHEST PRESSURE DROP ....................................................................................4

3. PRESSURE DROP INFLUENCE FACTORS ................................................................................4

4. PRE-INSTALLATION .................................................................................................................5

5. TERMS OF USE ........................................................................................................................6

6. SAFETY ADVICE .......................................................................................................................6

7. DESCRIPTION OF COMPONENTS ............................................................................................7

7.1. Components for products with 20, 25, 32 mm pipes ............................................7

7.2. Components for products with 40, 50, 63 mm pipes ...........................................7

8. ASSEMBLY INSTRUCTIONS .....................................................................................................8

8.1. Installation tips .....................................................................................................8

8.2 Preparing the pipe .................................................................................................8

8.3 Assembling pipe – fitting ......................................................................................9

9. TECHNICAL STANDARDS FOR INSTALLATION .......................................................................11

9.1 Preamble ..............................................................................................................11

9.2 Clamping of the pipe ............................................................................................11

9.3 Thermal variations (expansion/contraction) .........................................................11

9.4 Expansion ............................................................................................................12

9.5 Slopes ..................................................................................................................13

9.6 Fixed mounting bracket ........................................................................................13

9.7 Mounting bracket .................................................................................................14

9.8 Ball valve ..............................................................................................................14

9.9 Drop options ........................................................................................................15

9.10 Drops and descents .............................................................................................15

9.11 Line and curve with flexible hose .........................................................................16

10. RESIDUAL RISKS .................................................................................................................17

11. MAINTENANCE .....................................................................................................................17

INSTALLATION GUIDE

TOPRING

1. BASIC INFORMATION

GeneralPrior to the installation of a SicoAIR 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 downstream 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 SicoAIR components, as described in the SicoAIR catalogue must be respected.

SicoAIR pipesSicoAIR pipes should be protected from mechanical impacts, particularly if exposed to a collision with a forklift or when positioned in an environment with moving overhead loads. Similarly rotation of the pipe and pipe supports should be avoided. The pipeline system must not be welded.

Component assemblySicoAIR components are provided with assembly instructions for their correct use. Simply follow the methods and recommendations stated in this document.

Pressurizing the systemOnce the SicoAIR 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 / ContractionThe system designer and installer should calculate the elongation and retraction of each SicoAIR line according to the recommendations in this installation guide.

Situation to be avoided• Installation within a solid mass (concrete, foam, etc.)

• Exposure to chemicals that are incompatible with SicoAIR components.

• Use SicoAIR for grounding, or as a support for electrical equipment.

• The hanging of any external device to SicoAIR.

Flexible anti-vibration hoseIt is recommended to install a flexible anti-vibration hose between the compressor and the airline system. A flexible anti-vibration hose will extend airline 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 drops. 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.

• The diameter of the pipe will influence pressure drops at the operation of point-of-use equipment. Select the diameter according to the required flow rate and the acceptable pressure drop at the point of use.

COMPRESSED AIR DISTRIBUTION SYSTEM 3

2. 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 generation point to the point of use.

• A high pressure drop requires a higher loading pressure on the compressor compensating for the losses along the network.

• A 2 PSI increase in operating pressure results in a 1% increase in energy consumption.

• Pressure drops drastically increase the electric bill.

+ 2 PSI = + 1% energy consumption

3. PRESSURE DROP INFLUENCE FACTORS

A properly designed system takes all these factors into account. By sizing the pipe properly, using SicoAIR pipe with its low friction factor, minimizing the length of the pipe used, and designing a system that takes advantage of a ring design, the pressure drop throughout the network will be minimized.

FITTINGSDIAMETERS

20 mm 25 mm 32 mm 40 mm 50 mm 63 mm

Union 6"(15 cm)

8"(20 cm)

10"(25 cm)

12"(30 cm)

16"(40 cm)

20"(50 cm)

90° Elbow 16"(40 cm)

20"(50 cm)

24"(60 cm)

32"(80 cm)

37"(95 cm)

49"(125 cm)

“T” Straight Line

8"(20 cm)

12"(30 cm)

16"(40 cm)

20"(50 cm)

28"(70 cm)

36"(95 cm)

«T» Deviation 24"(60 cm)

32"(80 cm)

43"(110 cm)

55"(140 cm)

67"(170 cm)

91"(230 cm)

Reducer 8"(20 cm)

10"(25 cm)

14"(35 cm)

18"(45 cm)

24"(60 cm)

30"(75 cm)


Pressure loss to consider when using fittings

• Pipes’ inner diameter: Increasing the pipes’ inner diameter reduces the pressure

drop but increases the initial investment.

• Free air delivery: The air demands of all downstream equipment connected

to the network.

• Friction factor: Related to the pipe’s material. SicoAIR 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 losses equivalent to adding additional line length. The table below indicates effective lengths added to the network by each of these restrictions and/or connections.

4. PRE-INSTALLATION

DIAMETER SIZE CHART FOR A CLOSED LOOP NETWORK

DIAMETER SIZE CHART FOR A LINEAR / DEAD-ENDED NETWORK

Proper line sizing for an airline network 1. Identify type of network: closed loop or dead end 2. Calculate total length of the line (feet) 3. Determine total flow required 4. Refer to the chart below to determine the tube diameter required for a compressed air system that will meets the application requirements

TOTAL LENGTH OF THE NETWORK (FEET)100' 150' 200' 250' 300' 400' 500' 600' 700' 800' 900' 1000' 1250' 1500' 2000'

5 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2010 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2015 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2020 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2530 20 20 20 20 20 20 20 20 20 20 25 25 25 25 2540 20 20 20 20 20 20 25 25 25 25 25 25 25 25 3260 20 20 20 25 25 25 25 25 25 25 32 32 32 32 3280 20 25 25 25 25 25 32 32 32 32 32 32 32 32 32

100 25 25 25 25 25 32 32 32 32 32 32 32 32 40 40125 25 25 32 32 32 32 32 32 32 32 40 40 40 40 40150 25 32 32 32 32 32 32 40 40 40 40 40 40 40 40200 32 32 32 32 32 40 40 40 40 40 40 40 50 50 50300 32 40 40 40 40 40 40 50 50 50 50 50 50 50 63400 40 40 40 40 40 50 50 50 50 50 50 63 63 63 63500 40 40 50 50 50 50 50 50 63 63 63 63 63 63 63750 50 50 50 50 63 63 63 63 63 63 63 63

1000 50 50 63 63 63 63 631500 63 63 63 63

TOTA

L FL

OW R

EQUI

RED

SCFM FEET

TOTAL LENGTH OF THE NETWORK (FEET)25' 50' 75' 100' 150' 200' 250' 300' 400' 500' 600' 700' 800' 900' 1000'

5 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2010 20 20 20 20 20 20 20 20 20 20 20 20 20 20 2515 20 20 20 20 20 20 20 20 20 25 25 25 25 25 2520 20 20 20 20 20 20 25 25 25 25 25 25 25 25 3230 20 20 20 20 25 25 25 25 25 32 32 32 32 32 3240 20 20 25 25 25 25 32 32 32 32 32 32 32 32 3260 20 25 25 25 32 32 32 32 32 40 40 40 40 40 4080 25 25 32 32 32 32 32 40 40 40 40 40 40 40 50

100 25 32 32 32 32 40 40 40 40 40 40 50 50 50 50125 32 32 32 32 40 40 40 40 50 50 50 50 50 50 50150 32 32 40 40 40 40 40 50 50 50 50 50 50 63 63200 32 40 40 40 40 50 50 50 50 63 63 63 63 63 63300 40 40 50 50 50 50 63 63 63 63 63 63 63400 40 50 50 50 63 63 63 63 63500 50 50 50 63 63 63 63750 50 63 63 631000 63 631500 63

TOTA

L FL

OW R

EQUI

RED

SCFM FEET

• Calculations based on total maximum pressure drop ( P) of no more than 3 PSIG for the entire network, at 100 PSIG and 15.5 °C• Total flow required takes account of all flows for all compressed air powered tools and equipment• Note that a typical compressor will produce approximately 4 SCFM per horsepower


5. TERMS OF USE

Allowable temperatures: - 20 °C / + 70 °C Nominal operating pressure: 181 PSI (12.5 BAR) Fluid: Compressed air

Max. Temperature (0C) Max. Operating Pressure (PSI)

30 18150 130.570 72.5


• After removing the packaging, check that all components are present; if in doubt do not use the components and contact TOPRING.• It is essential to follow the instructions contained in this manual.• Any installation carried out in a manner inconsistent with the requirements specified in this manual may impair the safety of the user.• The pipes and fittings shall not be installed in contact with sources of vibration and thermal shock that will lead to exceeding the limits given in the section Terms of Use.• TOPRING declines any responsibility for damage to persons, animals or damage caused by improper installation or resulting from improper and unreasonable use.

6. SAFETY ADVICE

WARNING

Please read this manual carefully as it provides important information and warningsabout the safety, use and maintenance of the system.It will also be appropriate to store it for further consultation.

WARNING

The TOPRING product SicoAIR must never be used for direct assembly on compressors, dryers or tanks.

In these applications, there must always be a flexible hose fitted in between.


7. DESCRIPTION OF COMPONENTS The SicoAir product components vary according to their nominal diameter.

7.1 Components for products with 20, 25, 32 mm pipes:

A. Clamping nut Nylon 6 Blue B. Locking clips smooth stainless steel C. Spacer Nylon 6 Black D. Seal OR - NBR E. Body Nylon 6 Black

7.2 Components for products with 40, 50, 63 mm pipes:

A. Clamping nut Nylon 6 Blue B. Locking clips smooth stainless steel C. Spacer Nylon 6 Black D. Seal OR - NBR E. Body Nylon 6 Black F. Internal compensator

F E


8. ASSEMBLY INSTRUCTIONS

07.570 - Chamfer tool

During cutting and chamfering avoid damaging the painted surface of the sealing area (about 50 mm from the end of the pipe).

07.571 - Deburring tool

• Use pipe cutter 07.566 or 07.568 (depending on the diameter of the pipe), position the tool perpendicular to the pipe to be cut and start cutting.

• Use chamfer tool 07.570 (for pipes 15, 22, 28, 32 mm) and deburring tool 07.571.

• Bevel the pipe as evenly as possible without generating chips which are not completely detached from it as these could affect and damage the seal.

8.2. Preparing the pipe

Check the compatibility of the carrier fluid (if different from compressed air) with Nylon 6, NBR and Aluminum, referring to the “Compatibility Table” obtainable from TOPRING. Consider the thermal expansion by activating the most appropriate technical solutions to run the system.

8.1. Installation tips

WARNING If the pipe must be cut, the cut must be perpendicular to prevent damage to fitting joints. Use the deburring and chamfer tools. Remove chips and curve sharp corners.

BEVELED

YESNO

50 CA.50 CA.


Before inserting the pipe into the fitting, screw the lock nut up against the tooth of the self-locking device and no further. The pipe is inserted into the fitting up against the setback, over the seal. To ensure that this is done you can check by creating a mark on the pipe starting from the end to the measurement shown in the table below.

8.3. ASSEMBLING PIPE / FITTINGWARNINGInstallation in the opposite direction may cause fittings to burst.

1

2

3

Make sure all parts are correctly assembled; pay special attention to the direction of the locking ring.

TIP The wrench can be used as a template to pencil a mark on the appropriate area of the pipe. It is important to insert the fitting all the way to the mark (see measurements according to pipe diameter).

Spacing measurements

Pipe diameter (mm) 20 25 32 40 50 63

Distance (mm) 45 55 60 65 85 95

YESTOOTH RING

THIS SIDE

NO

TOOTH OF THE SELF-LOCKING DEVICE

To facilitate the insertion of the pipe, it is recommended to lubricate the exterior of the pipe and interior of the fitting using Vaseline or neutral grease.

NEUTRAL GREASE OR VASELINE

You can also use spray lubricants, as long as they are neutral or Vaseline.

In the event the absence of any type of lubricant in the system is specifically required, the insertion of the pipe into the fitting can be performed without the help of lubricants.

.

LUBRICATE THE SEAL INSIDE THE FITTING LUBRICATE THE OUTER PART OF THE PIPE PERFORM THE INSERTION

MARKING LINE


Insert the pipe into the fitting until it cannot go any further. When the pipe is properly inserted into the fitting, screw the nut as tight as possible, surpassing the self-locking device.

4

The table below shows, for each fitting, the strength (expressed in Nm) required for the closure of the ring in order to ensure a perfect pneumatic and mechanical seal.

To facilitate the mechanical closing of the connection, use of SicoAir spanner wrenches is recommended.

Clamping strength

Diameter (mm) 20 25 32 40 50 63

lb-ft 6.7/8.2 8.2/9.7 9/11.2 11.2/12.7 12.7/15 13.5/16.5

WARNINGUsing tools such as pipe wrenches, pump pliers or clamping tools other than the spanner wrenches prescribed in this guide, may cause serious damage to components with risk of major breakdowns compromising the safe installation of the compressed air network.

YES

5

NO NO

For proper installation and so as not to endanger the pneumatic seal fittings, offsets of more than 2° from the original are not allowed.

TIP Pull on the pipe to make sure the connection is secure, it is important to perform this operation before pressurizing the system.

ALTERNATIVE


9. TECHNICAL STANDARDS FOR INSTALLATION

WARNINGIn the event that the installation takes place at temperatures outside the range indicated above, nec-essary corrections will have to be made.

9.2. Clamping of the pipe The minimum distance from the fitting of the bracket must be 100/150 mm to allow for the slipping of the pipe due to thermal expansion. When the piping is longer than 30 metres, you must insert the appropriate means of compensation for expansion (expansion coefficient of the aluminum K = 0.000023). When planning the system, you should consider the minimum clearances necessary to ensure the proper expansion of the pipe.

9.3. Thermal variations (expansion/contraction) In order to allow the proper operation of the system, absorption points must be sized and prepared on long sections to take care of expansion caused by temperature changes.

9.1. Preamble All theoretical calculations and considerations contained in this manual are valid at an ambient temperature of installation between 15°C and 25°C.

RANGE DUE TO THERMAL EXPANSION

L1 = 40 mt L2 = 40 mt DT = 50°CDL = DT x 0.02 x L = 50 x 0.02 x 40 = 40 mmA = DL x 23 = 40 x 23 = 920 mmB = 0.7 x A = 0.7 x 920 = 640 mm

DL = DT x 0.02 x LA = DL x 23"B = 0.7 x A

* The B unit is not binding for the operation

EXPANSION SECTION

Keywords Description

A-B* Unit (mm)L-L1-L2 Lengths (mm)

DL Expansion (mm)DT Temperature range (°c)M Mobile bracketF Fixed bracket

9.4. Expansion

Application examples of absorption of expansion:

12

WARNINGIn order to avoid the accumulation of condensate, the downward expansion loop should not be used unless there is a condensate outlet.


MS BracketP GradientD DescentM Mobile bracketF Fixed bracket

NO

YESUPWARD

EXPANSION LOOP

YES

DOWNWARD EXPANSION

LOOP

YES

FLAT HORIZONTALEXPANSION LOOP

COMPRESSED AIR DISTRIBUTION SYSTEM


9.5. Slopes

9.6. Fixed mounting bracket

30 meters

25 to 50 mm

06.548

Example for proper inclination

FIXED MOUNTING BRACKET

EPDM INSERT FOR FIXED MOUNTING

BRACKET

SLIDING MOUNTING BRACKET

F

InstallationIn 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 bracketTo create a fixed mounting bracket, add the EPDM insert (product no 06.548) into the pipe clip.

All straight lines should have a 25-50 mm slope for every 30-metre length.

These slopes (always in the same direction as the airflow) should lead to drops with manual or automatic drains, installed as low as possible in order to eliminate condensates.

14

To facilitate maintenance, it is recommended to install ball valves in order to divide the airline system into sections. Each section can, therefore, be depressurized without stopping the entire network.

BALL VALVE

9.8. Ball valve

9.7. Mounting bracket NO

G

G

G

M MRecommended spacing: A mounting bracket should be in-stalled at least every 2 metres for all pipe diameters (20-63 mm).

A bracket also needs to be installed no more than 20 cm from every fitting along the line (downstream or upstream).

Recommended screw: Pan head screws No. 14.


M BracketG Fitting

YES

GGM M M M

M

TIP To eliminate snaking and sagging, it is important to follow spacing recommendations.

COMPRESSED AIR DISTRIBUTION SYSTEM


9.9. Drop options

9.10. Drops and descents

1. Twin take off drop couplingsIt is EASY to install a drop on a compressed air system—whether pressurized or not—with the twin take-off coupling and proper installation tools. 2. Water trap “T”Ideal for tapping air off a main line without allowing water to set into the drop. 3. Preformed drop bend pipesMade of special Aluminium alloy, ideal for tapping air off a main line without allowing water to get into the drop.

4. Threaded drop connectionMaking drop installations on new or existing compressed air networks without cutting pipe.

1. 2.

3. 4.

Video demonstration at TOPRING.com


A Spacing (mm)L1 • L2 Length (m)

DL Expansion (mm)DT Thermal range (°C)F Fixed mounting bracket

DL = DT x 0,02 x LA = DL x Y

TIP When making a drop, be sure to install a bracket on each side of the ball valve.

YESNO

Calculation factors

Diameter (mm) 20 25 32 40 50 63

Y 20 20 25 28 33 40

9.11. Line and curve with flexible hoseWhen stretching the line, avoid elbows that are either too square or insufficiently rounded.It is possible with the use of the hose to manage the change of direction and simultaneously compensate for the thermal expansion.

NO NO

FLEXIBLE OPTION A


L1 • L2 Length (m)DL1 • DL2 Expansion (mm)

DT Thermal Range (°C)M Mounting bracketR Radius (mm)

A • B Spacing (mm)

FLEXIBLE OPTION B

L min = 1000 mm


L1 • L2 Length (m)DL1 • DL2 Expansion (mm)

M Mounting bracketR Radius (mm)L Length of flexible hose (mm)

Radius option R-A

Diameter (mm) 20 25 32 40 50 63

R (mm) 70 85 100 130 160 200

A (mm) 370 390 500 560 600 800

DL = DT x 0,02 x LB= (2 x R) + DL1 + DL2

EXPANSION LOOP WITH FLEXIBLE HOSE

YES

OTHER FLEXIBLE CONFIGURATION

YES


TOPRING Series 09 flexible hoses can be used to allow the airline to expand properly during thermal variations.

10. RESIDUAL RISKS

Pipes and fittings can generate the following residual risks in case of non-compliance with safety information and requirements provided in these operating instructions: • Risk of fluid ejections under pressure in case of disconnection of connections caused by inadequate tightening. • Risk of ejections of fluids under pressure in the event of damage to the pipe caused by shocks. • Risk of ejections of fluid under pressure caused by operating pressures higher than the maximum allowable pressure of 180 PSI (12.5 BAR).

11. MAINTENANCE

Here is a list of checks and controls recommended by TOPRING: • Annually review the status of the systems • Check the tightening of the nuts • In case of shocks check the status of the pipeline; in case of damage replace the damaged parts.


WARNINGAny type of intervention should be performed on the system when it has been depressurized.

Contact your local distributor

or

TOPRING1020, boulevard Industriel Granby (Quebec) J2J 1A4 Canada • Téléphone 450 375-1828 • Toll free 1 800 263-8677• Fax 450 375-1408

TOPRING.com / [email protected]

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