Imagine Life V.2 Without Brazing - ZoomLock · 2017-07-20 · Air Conditioning and Refrigeration...

Imagine Life Without Brazing

ZoomLock Product guide

Braze-free copper fittings for the Air Conditioning and Refrigeration Industry

V.2

ContentsSection 1

Introduction to ZoomLock 03 Section 2

Features & Benefits of ZoomLock 04Section 3

ZoomLock Product Range ZoomLock Kit 06 ZoomLock Fittings 07 ZoomLock Accessories & Spares 10

Section 4Installation Instructions 11

Section 5CPD’s and Product Demonstrations 13

Section 6Testimonials 14

Section 7Technical

Frequently Asked Questions 15 Specifications 17

Performance Data/Reports 18 Manufacturer Commentaries 19

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Fast, Safe, Clean, Simple

ZoomLock offers a braze-free alternative to using Refrigeration Copper Fittings.With feedback from the many contractors who have already invested in ZoomLock, we confidently guarantee ZoomLock will increase the Speed, Quality, Productivity and Profitability of your installations!

Significant labour savings gives you a quick return on your investment, along with saying goodbye to hassle factors associated with traditional brazing. No more hot works permits, or nitrogen purging, fire wardens, or cooling down time.

A Brilliant Idea. A Simple Solution. The ZoomLock braze-free connecting process is based on exclusive, patented crimping technology. You only need two hands and a few simple tools. No brazing, no experience and practically no time at all.

ZoomLock BRAZE-FREE TUBE FITTINGS CHANGES EVERYTHING ZoomLock fittings are specially designed to work without brazing, which automatically makes your job simpler and faster when joining copper tube. In addition, the one-piece fittings are reliably secure, leak-proof and more repeatable than brazed connections - so there’s no compromise on quality or performance.

MEET ZOOMLOCK THE 10-SECOND FLAME-FREE

REFRIGERANT FITTING.

• Ten-second leak-proof refrigerant fitting.• Reduce labour cost up to 60%• No brazing. No flame. No fire warden.

Gives your company significant time savings

Welcome to ZoomLock!

03Email us at [email protected]

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ZoomLockTM fittings are specially designed to work without brazing, which automatically makes your job simpler and faster when joining refrigeration copper tubes.

Features & Benefits of ZoomLock

The ZoomLock Advantage Increases speed and quality of installations

No hot work permits required

No need to nitrogen-purge

Gives you a clean system

More flexible access to job sites

Less equipment and no gas needed

Safer conditions, no fire hazards

More environment friendly

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Quick. Easy. Clean. Repeatable.

ZoomLock Crimping Tool

Tube cutter

De-burring tool

Depth Gauge

Scotch-Brite

Marker Pen

Time-Consuming. Risky. Dirty. Imperfect.

Torch kit with gas regulators

Gas tanks (3 - Nitrogen, Acetylene, Oxygen)

Tube cutter

De-burring tool

Brazing Rods

Scotch-Brite

Cooling rag

Access to water

Solder and flux

Fire extinguisher

Fire safety equipment

Hot Works Permit

Fire Warden

Goggles

Gloves

Pliers

Expanders

VS ZoomLock Fittings

Brazing

All together in one simple carry case.


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Training provided by Greenmill.Need training on site?Give us a call today on 01206 864467

ZoomLock Product RangeComplete ZoomLock Kit

7 Piece Jaw kit, 1/4” - 1-1/8”

15kN ZoomLock Crimping Tool

Tubing Cutter

Deburring Tool

Crimp Gauge

Stainless Steel Brush

Abrasive Pad

Permanent Marker

Battery Charger

2 Lithium-lon Rechargeable Batteries

Part Number: GMZL7 - TAJ

Kit Includes:

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ZoomLock FittingsZoomLock Braze-Free FittingsConnectors

Dimensions

Part Number

Description Dimensions

A B C D

Inch mm Inch mm Inch mm Inch mm

GMZL501 Connector 1/4” C - C 0.26 6.6 0.34 8.6 0.45 11.5 0.95 24.1






GMZL507 Connector 1 1/8” C - C 1.14 28.8 1.29 32.6 1.44 36.7 1.29 32.8

A

D

B C

DimensionsA

B C

D

E

Part Number


A B C D E

Inch mm Inch mm Inch mm Inch mm Inch mm

GMZL601 90° Long Radius Elbow 1/4” 0.26 6.6 0.34 8.6 0.45 11.5 2.01 51.1 0.50 12.7






GMZL607 90° Long Radius Elbow 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 4.29 108.8 2.85 72.4

90o Long Radius Elbows


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Dimensions

D

D

A B C

Part Number


A B C D


GMZL702 Equal Tee 3/8” 0.39 9.8 0.47 11.8 0.59 14.9 1.63 41.4

GMZL703 Equal Tee 1/2” 0.51 13.0 0.59 15.0 0.72 18.2 2.23 56.6

GMZL704 Equal Tee 5/8” 0.64 16.1 0.74 18.7 0.87 22.0 2.29 58.2

GMZL705 Equal Tee 3/4” 0.76 19.3 0.88 22.4 1.05 26.6 2.37 60.2

GMZL706 Equal Tee 7/8” 0.89 22.5 1.02 25.8 1.19 30.2 2.44 62.0

GMZL707 Equal Tee 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 2.56 65.0

Equal Tees

Part Number


A B C D E F G

Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm

GMZL800 Reducing Coupling 3/8” - 1/4” C x C 0.39 9.8 0.47 11.8 0.59 14.9 0.26 6.6 0.34 8.6 0.45 11.5 2.20 55.9











GMZL813 Reducing Coupling 1 1/8” - 1/2” C x C 1.14 28.8 1.29 32.6 1.44 36.7 0.51 13.0 0.60 15.0 0.72 18.2 3.25 82.6




Reducing CouplingsDimensions

G

A D E FBC

ZoomLock Braze-Free Fittings

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End Caps

Part Number


A B C D


GMZL901 End Cap 1/4” 0.26 6.6 0.34 8.6 0.45 11.5 1.11 28.2

GMZL902 End Cap 3/8” 0.39 9.8 0.47 11.8 0.57 14.5 1.13 28.7

GMZL903 End Cap 1/2” 0.51 13.0 0.59 15.0 0.72 18.2 1.47 37.3

GMZL904 End Cap 5/8” 0.64 16.1 0.74 18.7 0.87 22.0 1.56 39.6

GMZL905 End Cap 3/4” 0.76 19.3 0.88 22.4 1.05 26.6 1.57 39.9

GMZL906 End Cap 7/8” 0.89 22.5 1.02 25.8 1.19 30.2 1.60 40.6

GMZL907 End Cap 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 2.05 52.1

Dimensions

D

AB C

Euro Flare FittingsDimensions

A B

D

C

Part Number


A B C D


GMZL1001 Euro Flare Fitting 1/4” 0.26 6.6 0.45 11.5 1.38 35.1 0.56 14.2




ZoomLock Braze-Free Fittings


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ZoomLock Accessories and SparesReplacement Parts and Accessories

ZoomLock JawSize Part Number1/4” GMZL201

3/8” GMZL202

1/2” GMZL203

5/8” GMZL204

3/4” GMZL205

7/8” GMZL206

11/8” GMZL207

ZoomLock Makita 18V Battery Charger240V battery charger for 18V Li-Ion batteries. Extremely short charging time.

Part Number: GMZLCHAR

ZoomLock Makita 18V 1.5Ah Rechargeable BatteryHigh performance, 1.5 Ah, 18V Li-Ion battery.

Part Number: GMZLBAT15

ZoomLock Insertion Depth ToolMetal depth gauge confirms the proper insertion depth of the tubing.

Part Number: GMZL014

ZoomLock Crimp GaugeConfirms the measurement of the finished crimp band diameter


Tubing CutterZoomLock approved tubing cutter

Part Number: GMTC135

ZoomLock Tube Deburring Tool


ZoomLock Marker Pen Part Number: GMPMP

ZoomLock Scotch Brite Scourer Pad


For illustration purposes only

For illustration purposes only

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Installation Instructions

Step 1Slide battery into charger. Plug charger into a power source. Check to see that the charging light is on. When red lights turns off and green light turns on, battery is fully charged - 20 minutes.

Step 2Press the locking pin, then rotate 45° to release.

Step 3Slide jaws over Crimping Tool head, then depress locking pin until it clicks.

Step 7Use the supplied deburring tool to remove any residual burrs from the outside and inside of the copper tube.

Step 8Use a heavy duty scouring pad to clean the ends of the copper tubes to be joined. Tube ends should be free and clear of oxidation, or debris.

Step 9Inspect the copper tube for imperfections such as deep surface scratches and incise marks within the o-ring sealing area that may provide a leak path for refrigerant. If scratches are present, cut off the affected area or sand thoroughly to remove.

WARNING: COPPER TUBE ENDS SHOULD BE INSPECTED AND ANY SHARP EDGES SHOULD BE ADDRESSED, SHARP EDGES MAY CAUSE DAMAGE TO THE O-RING.

Step 4Slide charged battery into base of Crimping Tool.

Step 5Press and hold trigger and Crimping Tool to calibrate. Calibration is recommended daily, prior to use.

Step 6Cut the copper tube using the supplied tube cutter. Do NOT use a hacksaw or reciprocating saw as this creates a rough surface that may damage the o-ring.

Deep Scratches

Incise Marks


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Step 10Using the depth gauge provided determine the minimum insertion depth. Mark the tubing with a permanent marker to indicate proper insertion depth on every tube.

Step 11Ensure both ‘O’ rings are correctly located in the fittings. Push the fitting onto the tube. Use the mark to assure insertion depth and secure fit.

Step 12Open the jaws of the ZoomLock Crimping Tool.

Step 15Open the jaws of the ZoomLock Crimping Tool and remove from the fitting. If the jaws do not open, the crimping cycle was not completed. For manual override, slide the manual release button down to open the jaw in case of emergency.

Step 16A special “RLS” mark will be displayed on the tube to let you know the connection is crimped properly.

Step 17The supplied RLS CrimpGauge will confirm the measurement of the finished crimp band diameter. See crimp band locations noted in Step 16. It may be necessary to rotate the gauge in order to not interfere with the copper tube flashing left from the crimping process.

Step 14Press and hold the trigger on the ZoomLock Crimping Tool to begin the crimping process. Continue to hold the trigger until the ZoomLock Crimping Tool completes its cycle.

Manual Release Slide

Step 13Properly place the crimping jaws onto the fitting. Grooves in the jaws make it easy to align. See illustration above right for proper crimping alignment.

WARNING: ZOOMLOCK IS DIFFERENT THAN OTHER INDUSTRY CRIMP TECHNOLOGY. DO NOT CRIMP WITH JAW CENTERED ON O-RING.

JAW MUST ALIGN BETWEEN O-RING AND OUTER FLANGE.

Installation Instructions Cont

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Hands On/On-site TrainingBoardroom Training

Training, CPD’s and Demonstrations

If your company is interested in arranging a CPD Session or a product demonstration for your team please contact our sales office on 01206 864467 or by email [email protected]

CPD (Continual Professional Development) Training SessionsGreenmill offer to hold CPD training sessions in your own premises to ensure all your team get the opportunity to get up to date with this innovative, game changing system. Our Zoomlock Product Advisors come equipped with everything to create a stimulating and hands on Zoomlock presentation, from the Zoomlock Tool and Fittings to a great PowerPoint Presentation with a great selection of videos.

On Site Demonstrations & Training SessionsGreenmill also offer to hold Zoomlock Product Demonstration sessions on site or at your office to help you evaluate the product and see for yourself the features and benefits of this incredible system. We appreciate you may want to try the Zoomlock to fully appreciate how quickly this product could be saving you time and money. To organise a Zoomlock Demonstration for you or your team please get in touch today.

Greenmill recognises how important it is for the engineers to install Zoomlock correctly so we provide an online training video, which once completed qualifies the engineers for a Zoomlock Training Certificate

Continuous Professional Development CertificationAwarded to

For attending and completing the programme onZoomLock Braze-free pipework connection

Date: 3rd April 2017

John SmithABC Air Conditioning Company Ltd


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TestimonialsAngus Pearce - Director at EAC Services LtdVery Pleased with our ZoomLock purchases as well, have used on a number of sites now, all where hot works permits may have caused potential difficulties and installs all went in problem free. We haven’t calculated out cost savings as yet but it would suggest in time alone decent savings are made over brazing. Would recommend ZoomLock to all to include as an option for any installation projects.

Mark Williams - Maintenance EngineerWhen I was working at a college, the learners loved using this bit of kit. Obviously they were taught all types of jointing. We always found that the best thing to do if you want to test a new bit of kit, is to give it to an apprentice. They will either break it, steal it or eat it. And they managed neither. They loved the time races we had with ZoomLock, brazing, flares etc. And to be fair ZoomLock was the easiest and fastest to set up and use. Very very good piece of kit.

Lee Tindall - Client Service Manager at Johnson ControlsWe have being using ZoomLock on petrochemical and nuclear sites with great results, just need to expand the fitting range which I believe is in hand.

Raymond Knox - Capital Cooling, EdinburghRaymond Knox – “Great piece of kit, used it in a recent VRV installation with a pipe run of 60m with no leaks what so ever”

Tod Harvey – “Thanks for the feedback Raymond Knox, quite a prestigious project wasn’t it? (Hilton Hotel)

Raymond Knox – “Yeah Tod it allowed us to work for a major customer during working hours with no fuss or need for fire alarm isolation”

Stuart Inglis - Director, Inglis Cooling Services LtdGreat machine, saves us time not only on installation but on getting very Hot Work Permits, no fire watch required, no waiting on pipes cooling down and no nitrogen purging required.

Ben Rabbitt - Refrigeration Engineer at Three Nations LtdThis is the hassle free alternative to brazing. It’s clean, quick and reliable. Good job Greenmill, another great product from a great team.

Josh Graves - Specialist HVACR EngineerThe Future of A/C pipework! Tested a crimp fitting suitable for A/C pipework on soft drawn copper 1/2” at 30 bar. Amazed at how quick it is compared to flare and brazed! Very impressed at just how easy and secure the crimp is.

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Technical - Frequently Asked Questions1. How many crimps can you complete on a complete

battery charge?

On average you can achieve 100-150 crimps per charge depending on the size fittings being crimped. Each kit comes with 2 Makita Lithium-ion batteries and a rapid charge charging system. To prevent any downtime, it is recommended that you have both batteries charged before going to the jobsite and to have one charging while the other is in use.

2. Can you use ZoomLock to crimp to aluminum, steel, or stainless steel?

No, ZoomLock is specifically designed for copper to copper connections. Connecting to dissimilar metals can cause formicary corrosion issues that could cause a failure.

3. What material is the o-ring made of?

The o-ring is a highly engineered HNBR Parker o-ring that has been used in HVAC applications by OEMs and suppliers for many years with no issues.

4. What is the expected life of the o-ring in the system?

The expected life of the o-ring that stays within the product specifications for temperature and pressure should be 30 years.

5. Are there any shelf life concerns?

No, the shelf life of the product is estimated at or above 30 years.

6. Is there a concern about ice building up and then thawing under fitting in a horizontal or vertical configuration?

No, ZoomLock has been thoroughly tested in freeze/ thaw applications with over 10,000 cycles completed in both vertical and horizontal configurations with no leakage concerns.

7. Can you braze the fitting after crimping it?

No. Trying to braze the fitting will very likely melt the o-ring material and thus introduce contaminants into the system that could cause other system issues.

8. Are there any concerns with corrosion due to coastal applications, cleaning agents, or offgassing of produce/vegetables?

No, ZoomLock has gone through a battery of corrosion testing, completing over 2,000 hours of salt spray testing without failure, which proves the resilience of the product.

9. How do you slide insulation over these fittings (the flare will grab insulation?

If the flare of the fitting tends to be a problem, you can smooth the transition over the fitting by adding duct tape around the flared edge of the fitting to the tube.

10. How do you know when the tool needs to be serviced?

The tool has a red LED on the back of the tool that will blink for 20 seconds after a crimp. When this occurs, take the tool back to an authorized dealer to have the tool analyzed. They will be able to verify if the tool needs to be sent in for service.

11. What is the expected life of the jaws?

Each jaw has an expected life of 10,000 to 12,000 crimps.

12. How do you know when the jaw needs to be replaced?

You will know when the jaw needs to be replaced when the contact point between the upper and lower jaw starts to open up/widen. A good indication of failure is when the crimp gauge no longer engages.

13. Do you have a solution for crimping onto flared tubing like that coming out of the condenser and evaporator on residential units?

No, we do not have a specific product designed to crimp over the flared tubing. However, if there is at least 2 inches of straight copper tubing after the flared end and is accessible with the jaws, we suggest that you cut the flared end off and crimp directly to the tube.


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16. Does the o-ring compensate for imperfections in the piping to make a tight seal?Yes, the o-ring does compensate for small/minor scratches on the surface of the tube; however, the tubing needs to be inspected prior to use per ASTM B280 and the Copper Tube Handbook published by the Copper Development Association (CDA) specifications. Imperfections in and adjacent to the crimp area could inhibit the joint integrity. These imperfections may include surface scratches,

incise marks, and tubing out of round.

17. The product specifications state that the application temperature limits are -40°F to +300°F / -40°C to +150°C. What happens if we go beyond that limit?If the application that the fitting is being used in goes beyond the specified limits of the o-ring (-40°F to +300°F / -40°C to +1 50°C) then ZoomLock should not be used in this instance.

18. Can I use ZoomLock in a transportation application where fitting vibration is high?Yes, ZoomLock has gone through extensive vibration testing and results are actually better than that of a braze joint. Please review the vibration testing procedure and conclusion for

more information.

14. How do I know the correct insertion depth whenpushing the ZoomLock fitting onto the copper tube?

Use the depth gauge provided or the chartbelow to determine the minimum insertiondepth. Mark the tubing with a permanentmarker to indicate proper insertion depth onevery tube.

Minimum Insertion Depth

Fitting Size Inches mm

1/4 15/16 23.8

3/8 15/16 23.8

1/2 1-1/4 31.8

5/8 1-1/4 31.8

3/4 1-1/4 31.8

7/8 1-1/4 31.8

1-1/8 1-1/4 31.8

15. How much tolerance can the ZoomLock handle onthe pipe being crimped?

We know that not all copper tubing is thesame, but we have tested ZoomLock withmost EN12735-1 conforming copper tubemanufacturers with no issues. The tolerancefor each tube to ensure a good leak-free jointis +.002/-.007. (Greenmill’s stock of refrigerationcopper tube always conforms to EN 12735-1)

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Technical - SpecificationsZoomLock Braze-Free Fittings

ApplicationsHigh Pressure HVAC/R

Product ParametersContinuous Operating Temperature (COT):250°F / 121°C

O-Ring Temperature Rating:-40°F to +300°F-40°C to +148.9°C

Maximum Rated Pressure (MRP):700 psi / 48 bar

Maximum Burst Pressure:3000 psi / 207 bar+

Vacuum Pressure Capability:20 Microns

External Leak Rate:<0.1 Ounces of Helium per Year at Operating Pressure Range

Vibration Resistance: Conforms to UL109

Size Availability (Inches):1/4, 3/8, 1/2, 5/8, 3/4, 7/8, 1-1/8

Fitting MaterialsFitting Body:Refrigerant Grade Copper, per ASTM-B280

O-Ring: HNBR

Fitting Warranty5 years.

CompatibilityApproved Oils: Mineral Oil, POE, PVE, PAG

Approved Tubing Materials: Copper to Copper Connections

Approved Copper Tubing Types for Use with the ZoomLock Jaws:Half Hard Copper Straights - 3/8” - 1-1/8”

Soft Annealed Copper Coils - 1/4” – 7/8”

R410A

R407C

R32

R404A

R134A

R1234YF

R1234ZE

R125

R143A

R407A

R417A

R422D

R407F

R438A

R447A

R448A

R449A

R450A

R452A

R507A

R513A

R718

R290 (Propane)

R600a (Isobutane)

R600 (Butane)

Not approved for R22

Approved Refrigerants


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Technical - Performance DataPressure Testing of a 'Greenmill-ZoomLock' Sample

Methodology

A time study was conducted in a controlled environment, with two

stations set up for joining refrigeration tube: one by brazing and one

by using ZoomLock braze-free fittings. Two different installers were

used, one very experienced in making brazed connections and one

very experienced in using the ZoomLock press tool.

The two installers were timed independently making connections

using various sized copper tube and fittings. Before timing began,

tube was cut to length and the ends were prepared for connection

(as these procedures are the same for both connection methods).

Three connections were timed for each size of tube/fitting for each

installer, and the three times were averaged. The results are shown

in the table below.

Key Findings and Conclusions

The time savings achieved while joining tube using ZoomLock

brave-free fittings, compared to brazed connections, ranged from 31%

on the smallest fittings timed to 77% on the largest. The average time

savings over the fittings sizes timed was approximately 50%. So, on

average, ZoomLock braze-free fittings were made in roughly half the

time of brazing - and in less than one- quarter the time on the largest

fitting size.

Based on the study, brazed connections take longer to complete

than ZoomLock braze-free fittings. When analysing the installation

techniques for both connections, a brazed connection requires a

period of time to raise the temperature of the fitting and tube to

about 1000°F (538°C). As the tubing and fitting increases in diameter, the

amount of time it takes to heat them also increases. The ZoomLock

braze-free fittings only require the connection of a press control tool,

which takes less than ten seconds to complete the actual pressing

operation (two crimps) - and the time to connect does not increase

significantly as the diameter of tubing and fittings increases in size.

In a controlled environment, such as the work station where the

time study was conducted, the brazing operation takes less than

a similar joint made on a construction or repair project in the field.

The controlled environment is already set up for brazing, with all

necessary equipment and materials close at hand. However, using

the ZoomLock press tool and fitting require approximately the same

amount of time in any environment. Therefore, it can be assumed

that the ZoomLock time savings would be even greater outside of a

controlled environment.

Time and Motion StudyReplacement Parts and AccessoriesConducted by:

Jay Peters, Principal Advisor, Codes and Standards International

Labour Time for Installing a Copper Coupling

Fitting Size 1/4” 5/8” 1-1/8”

Brazed Connection 35 Seconds 42 Seconds 1:15 Minutes

ZoomLock Braze-Free Fitting 24 Seconds 24 Seconds 25 Seconds

% Time Savings 31% 43% 77%

ACR Loss CoefficientACR Pressure Drop (10ft. long)

3/8” ACR Tube Pressure Drop vs. Velocity 3/8” ACR Tube Loss Coefficient vs. Reynolds Number

3/4” ACR Tube Loss Coefficient vs. Reynolds Number

7/8” ACR Tube Loss Coefficient vs. Reynolds Number

3/4” ACR Tube Pressure Drop vs. Velocity

7/8” ACR Tube Pressure Drop vs. Velocity

TECHNICAL BULLETIN

JOINTING METHODS FOR RACHP PIPEWORK

2.1 COPPER

This is still the most common material used in light commercial and residential refrigeration, air

conditioning and split or multi-split/VRF style heat pump units. It is essential that copper tubing

used for this purpose is of refrigeration quality, kept free of moisture or contaminant ingress, and of

sufficient wall thickness for the purpose and gas in use. Copper has a high scrap metal value and has

been known to be stolen from sites and even from working systems resulting in total loss of refrigerant.

Copper is suitable for all jointing methods outlined in the next section.

2.2 ALUMINIUM

As concerns about theft and of availability of copper in the long term have increased, there has

been an increase in the use of aluminium tubing. Aluminium has an insignificant scrap metal value

rendering it virtually worthless to thieves. It is also very lightweight compared to copper and relatively

pliable at room temperature and is, therefore, very easy to work with.

Aluminium is not suitable for all jointing methods outlined in the next section. Particular attention

needs to be given where brazing/welding takes place as the melting point of aluminium is significantly

lower than copper and normal brazing equipment will simply melt the tube. A soft solder propane

flame should be used for brazing aluminium tubing.

2.3 DUAL COPPER/ALUMINIUM

Concerns about long term structural integrity of aluminium tubing led to the availability of dual

tubing which comprises of 1/3 copper and 2/3 aluminium. The inner core is copper for the strength and

integrity, while the outer sheath is aluminium to create the impression the whole pipe is aluminium

and, therefore, of no value to thieves as well as having a significant effect on the weight of a coil of

tubing.

As with the aluminium tubing, particular care should be taken when brazing this tube. A propane soft

solder flame should be used to braze dual material tubing.

2.4 CAUTION

Particular care should be given when jointing dual tubing or if there are instances of different pipe

materials used in a pipe run as there is the potential for galvanic corrosion where two materials of

different galvanic potential come into contact with a common fluid flowing between them. Galvanic

corrosion will compromise the integrity of the tubing over time and cause significant leak potential.

Earth bonding between the different materials can overcome this potential but, where possible, you

should always ensure the same pipe material is used throughout the length of its run.

1 | 2

1 OBJECTIVE

2 MATERIALS IN USE

The objective of this technical bulletin is to inform members of the various methods currently

available in the light commercial and domestic RACHP sector for joining the various different

pipe materials currently available on the market and approved for use by manufacturers. Large

commercial systems using steel pipework are covered in other publications.

TB/012

PLEASE NOTE This technical bulletin is not designed to endorse or approve one or more products or

methods above any other but seeks to impartially provide information for BESA Members to aid them

in deciding which pipe material or joining method to use for different applications. Compatibility

with materials and specific refrigerants should be checked before use as many new refrigerants are

entering the marketplace and there may be issues with oils and/or refrigerant gases. At the time of

publishing there are no known issues with refrigerant compatibility and any of the jointing/material

methods outlined below. This technical bulletin should be seen as a fluid document that may be

amended frequently through time as new technologies, materials and methods become available.

GuidetoGoodCommercial

RefrigerationPractice

Part4SystemInstallation

BritishRefrigerationAssociation

InstituteofRefrigeration

Issue1October2008UpdatedMay2016

PMG-1296CSI: DIVISION: 23 00 00—HEATING,

VENTILATING AND AIR CONDITIONING

(HVAC)

Section: 23 20 00–HVAC Pipe and

Fittings

Product certification system:

The ICC-ES product certification

system includes testing samples

taken from the market or supplier’s

stock, or a combination of both, to

verify compliance with applicable

codes and standards. The system

also involves factory inspections, and

assessment and surveillance of the

supplier’s quality system.

Products: Refrigeration Tubing Connectors

Listee: RLS, LLC

101 S. Douglas Street

Shelbina, MO 63468

www.rlspressfittings.com

Additional Listee: Parker Sporlan

206 Lange Drive

Washington, MO 63090

www.parker.com

Compliance with the following codes: 2015, 2012, 2009 and 2006 International

Mechanical Code® (IMC)

2015, 2012, 2009 and 2006 International

Residential Code® (IRC)

2015, 2012, 2009 and 2006 Uniform

Mechanical Code® (UMC)*

*Copyrighted publication of the

International Association of Plumbing

and Mechanical Officials.

Compliance with the following standards: UL 207 (Edition 8), Standard for

Refrigerant-Containing Components

and Accessories,

Nonelectrical

Identification: The refrigerant tubing connectors

shall be legibly and permanently

marked with the manufacturer’s

name, trade name, trademark,

or identifying symbol or other

descriptive maring by which

the organization responsible for

the product may be identified.

The shipping carton, a separate

instruction sheet included with the

shipping carton or a tag attached

to the component shall include a

distinctive model, part number, or

type designation for the connector

and include information for each

refrigerant type for which the

connector is intended and the ICC-ES

PMG listing mark.

Installation: The refrigerant tubing connectors

must be installed in accordance with

the manufacturer’s

published installation instructions, the

applicable codes and this listing.

Mechanical joints shall not be used

on annealed temper copper tube in

sizes larger than 7/8-inch (22.2 mm)

OD size per IMC and 3/4” of an inch

nominal size per UMC.

Models: The refrigerant tubing connectors

are intended for connection of

copper, aluminum, titanum and

other types of tubing approved by

the manufacturer. The connection

is accomplished by compressing

(solder-free) the fitting to a pipe. The

refrigerant tubing connectors are

only suitable for type A1 refrigerants

(R1234yf, R1234ze, R125, R134a, R143a,

R32, R404a, R407a, R407c, R407f,

R410a, R417a, R422d, R438a, R447a,

R448a, R449a, R450a, R452a, R507a,

R513a, R718).

ICC-ES Evaluation ReportEffective Date: January 2015

Revision Date: January 20, 2016

B.R.ABESA

BSRIA Report ACR Pressure ReportICC-ES Report Helium Leak Test Report

Time and Motion Study

EU Declaration of Conformity

CE Declaration of Conformity

Helium Leak Test Report

page 1 of 2

Customer: Marmon Refrigeration Technologies Project No.: 12866CSL-01

Equipment: Veeco MS-40 Date Reported: January 10, 2013

Project Engineer: Jim Busch Principal Tech: Barb Christel

1250 Arthur E. Adams Drive Columbus OH 43221 (614) 688-5000 FAX: (614) 688-5001 http://www.ewi.org/

1250 Arthur E Adams Dr., Columbus, OH 43221 LAB SERVICES

Scope: To test and report the leak rate of RLS press connections.

Background: Marmon Refrigeration Technologies (MRT) submitted RLSTM press connection samples for

helium leak testing. Six (6) different RLS TM sizes were chosen to connect commercially available ACR

tubing (see Table 1). Thirty (30) union connections were chosen as a sample lot with two (2) connections

per fitting. Each sample connected two pieces of tubing approximately nine (9) inches long. One of the

tubes was brazed shut at one end and the other tube was reduced to a ¼” tube stub.

Table 1. Tube Diameters Tested EWI Leak Testing Approach: Prior to testing each lot of samples, the Veeco MS-40 helium leak tester

was calibrated. After calibration, a solid ¼” dowel was tested to verify the integrity of the seals on the

helium leak test fixture. The ¼” tube stub was wiped down with methanol and connected to the leak detector a via a Swagelok ¼”

Ultra-Torr vacuum fitting (see Figure 1). Each sample was pumped down to a level of approximately 500

millitorr prior to applying helium gas near the RLS TM crimp joint (at atmospheric pressure). The helium leak

rate was measured and recorded for each of the sixty (60) connections in a thirty (30) piece sample lot.

Tube O.D. (in)

# of Samples

Total # of Tested Connections

Notes

0.250 30 60 Samples were made from commercially available ACR tubing (soft) 0.313 30 60

0.375 30 60

0.750 30 60

0.875 30 60

1.125 30 60

For a copy of these reports please contact one

of our Zoomlock Product Advisors on 01206 864467 or email your request to

[email protected]

18 Call us on 01206 864467

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Technical - Manufacturer Commentaries

Also availableThese manufacturer warranties, will not be invalidated when

using ZoomLock as the preferred jointing method.

If you require a copy of these documents, please contact

one of our ZoomLock Product Advisors on 01206 864467 or

email your request to [email protected].

Page 1 of 1

Fujitsu-General Air Conditioning (UK) Ltd, Unit 150, Centennial Park, Centennial Avenue, Elstree, Borehamwood, Hertfordshire, WD6 3SG

’

September 2015

Page 1

Statement regarding alternative pipework materials and jointing methods for use on Daikin UK DX Airconditioning and/or heating systems.

The use of alternative materials for jointing and piping direct expansion systems is growing within the industry. As an equipment manufacturer, we understand that the use of these products can enable the reduction or elimination of hot works on site, which can be a requirement of the customers’ specification.

Our equipment warranty relies on high quality pipework installations being performed to the standards as specified in our installation manuals. Using methods or materials for this purpose that are not described in our installation manuals are the sole responsibility of the installing contractor. We will however continue to maintain our manufacturer warranty on systems using these alternative methods, providing that the following criteria are met:

• Any system piping or jointing materials & methods must meet all local and European legislation, including F-Gas obligations, to minimise or eliminate the possibility of refrigerant leaks, and uphold the safety and environmental requirements of BS-EN378.

• Any damage caused directly or indirectly to the installed Daikin system through installation or use of these methods or materials will not be covered by the Daikin warranty. This includes increased wear and tear on the system caused by a lack of refrigerant.

• All refnet joints used on Daikin systems must be original Daikin supplied parts. This is to ensure correct system pressure, oil and gas distribution. The use of third party refnets, Y or T pieces is not supported and could invalidate the warranty.

• Any materials used should not increase the pressure drop or introduce any foreign substances into the refrigerant circuit when compared to the recommended refrigerant grade copper mentioned in the relevant Daikin installation manuals.

• Any installation using different pipework materials (i.e. Cu to Al) must use a system that prevents any dielectric / bi-metal / galvanic corrosion from occurring through the operational life of the system, including maintenance and service activities.

For further information contact Product Management Richard Green


ZoomLock Product G

uide | Section 7

Greenmill Emerald House, Whitehall Road, Colchester CO2 8HAT 01206 864467 E [email protected] www.greenmillac.com

Imagine Life Without Brazing

Imagine Life V.2 Without Brazing - ZoomLock · 2017-07-20 · Air Conditioning and Refrigeration...

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