INSTALLATION / WARRANTY

Installation Guidelines

Please read and understand the instructions before beginning installation to eliminate safety concerns and reduce risks associated with use and handling of IRONWORKS® products.

It is the responsibility of the installer or any other parties to adhere to all applicable local rules and regulations governing the nature of the installation.

Installer shall be a qualified installer, licensed within the jurisdiction, and familiar with the installation of copper press joint systems.

IRONWORKS® copper press fittings shall be installed using the proper tool, actuator, jaws and rings as instructed by the press fitting manufacturer.

The installation of copper tubing for hot and cold water distribution systems shall conform to the requirements of the ICC International Plumbing Code or IAPMO Uniform Plumbing Code.

The installation of copper tubing in sprinkler or standpipe systems shall conform to NFPA 13, 13D, 13R and 14.

The installation of copper tubing in Hydronic Systems shall conform to the requirements of the ICC International Mechanical Code or the IAPMO Uniform Mechanical Code.

Delivery, Storage and Handling of IRONWORKS® Copper Press Fittings

The copper press fittings to be used in a copper press system, need to be handled carefully so as not to damage them.

Copper press fittings shall be handled with care, and stored in a secure area, elevated from flooring, and maintained in their original packaging which is designed to prevent moisture build-up and discoloration of fittings, to prevent drying out of O-rings, or other contamination from interfering with the O-ring sealing area. Any open fittings should be thoroughly inspected and cleaned immediately prior to use. If the O-ring appears not to be soft and lustrous, replacement of the O-ring may be necessary.

In the event press fittings are dropped, exercise the utmost care in visually inspecting them to assure that fittings have not been damaged or deformed.

A copper press joint connection requires undamaged rounded copper tube, and fittings, to create the sealing surface between the tube and O-ring, O-ring and fitting, and any deformities in either component due to improper handling or storage may result in a defective press joint. Copper tube that is materially under spec may also result in press joints that do not seal properly.

The resistance between tube and fitting compression during the press joint is an engineered calculated combination, which when installed correctly and with the right materials gives a permanent water, air and gas tight seal in the systems for which it has been designed.

 

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EXECUTION

Examination

The installing contractor shall examine the copper tube and press fittings for apparent defects.

Any apparent visible defects should cause rejection of use in installation.

Do not attempt to make repairs to fittings when a visible defect has been noted.

The installing contractor shall ensure that sealing elements are properly in place and free from damage.

For sizes 2-1/2” to 4”, installer should ensure that the stainless steel grip ring is in place.

Preparation

A. Copper tubing shall be cut with a wheeled tubing cutter or an approved copper tubing cutting tool.

The tubing shall be cut square to permit proper joining with the fittings.

B. Remove scale, slag, dirt and debris from inside and outside of tubing and fittings before assembly.

The tubing end shall be wiped clean and dry.

The burrs on the tubing shall be reamed with a deburring or reaming tool.

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Locations

Plans indicate general location and arrangement of piping systems.

Identified locations and arrangements are used to size tubing and calculate friction loss, expansion, pump sizing and other design considerations.

Install piping as indicated, except where deviations to layout are approved.

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Installation

Pressure Rating: Install components having a pressure rating equal to or greater than the system operating pressure.

Install piping free of sags, bends and kinks.

Change in Direction: Install fittings for changes in direction and branch connections. Where approved, changes in direction may also be made by bending of Types K and L tube.

Solder Joints: In a mixed system combining both copper press joint fittings and traditional solder joints shall be made in accordance with ASTM B 828.

The temperature of the joint during soldering shall not be raised above the maximum temperature limitation of the flux.

Threaded Joints: Threaded joints shall have pipe joint compound or Teflon tape applied to the male threads only. Tighten joint with a wrench and backup wrench as required.

Press Connections: Copper and copper alloy press connections shall be made in accordance with the manufacturer’s installation instructions. The tubing shall be fully inserted into the fitting and the tubing marked at the shoulder of the fitting. The fitting alignment shall be checked against the mark on the tubing to assure the tubing is fully engaged (inserted) in the fitting. The joints shall be pressed using the tool(s) approved by the manufacturer.

Pipe Protection: Provide protection against abrasion where copper tubing is in contact with other building members by wrapping with an approved tape, pipe insulation or otherwise suitable method of isolation.

Penetration Protection: Provide allowance for thermal expansion and contraction of copper tubing passing through a wall, floor, ceiling or partition by wrapping with an approved tape or pipe insulation or by installing through an appropriately sized sleeve.

Backfill Materials: When using IRONWORKS® Press fittings protect against contact with cinders, refuse, stone, ash or other materials which can damage or break the tubing or promote corrosive action in any trench or excavation in which tubing is installed.

Install hangers for horizontal piping in accordance with MSS-SP-69 or the following maximum spacing and minimum rod sizes. Vertical copper tubing shall be supported at each floor, unless otherwise specified by local building code. To protect against galvanic corrosion, hangers and supports shall be either copper or vinyl coated, or insulated to prevent galvanic corrosion between the tubing and the supporting member. In seismic areas, copper tubing shall be installed to local code. Copper press joint fittings should be installed to maintain, 2% or less of joint deflection in either a horizontal or vertical direction.

Copper tubing systems shall be identified in accordance with the requirements of ASME A13.1.

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Field Quality Control

The copper tubing system shall be air tested for joint tightness.

The piping system shall be pressurized with air, slowly increasing in increments of 10 PSI up to the maximum pressure of the system, or to the code or standard required minimum. Such testing duration shall be dictated by local code.

The piping system can alternatively be water tested for joint tightness. The piping system shall be filled with water. The system shall be pressurized to 5 PSI, and thereafter increased incrementally up to the maximum pressure and length of time required by the code.

Either test process will allow for the detection of leakage in any press joint, or failure to press, either by emission of water or air which should be audible to the installer. Over-pressuring a joint that has not been tested could result in damage to the system or harm to the installer.

A joint with leaks either air or water, may be re-pressed but must be re-pressed in same location or may cause leakage. Re-pressing will often seal a joint that was not completely pressed (which should be indicated on the press tool) and will press a joint that had otherwise been missed.

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Purging or Cleaning a Copper press Joint System

Disinfection of Piping System:

The copper hot and cold water distribution system shall be disinfected prior to being placed in service. The system shall be disinfected in accordance with AWWA C651 or the following requirements:

The piping system shall be flushed with potable water until discolored water does not appear at any of the outlets.

The system shall then be filled with a water chlorine solution containing at least 50 parts per million of chlorine, and allowed to stand for 24 hours.

Consult local code to ascertain if more stringent cleaning is required.

Following the standing time, the system shall be flushed with potable water.

 

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PREPARATION

Source Quality Control

1. Use a rotary tube cutter to cut the copper tube and achieve a squared end. Ragged cuts from saws are more difficult to prepare correctly.

2. Remove all visible burrs from the end of the tube with a file, tube end deburring tool. Make sure that the tube end is smooth and clean to avoid damaging the O-ring component of the press copper fitting. The smooth clean tube end is critical to the proper use of copper press fittings.

3. Identify the depth, using the size chart included, of the press fitting cup. Measure the tube from the end, marking it clearly at the desired insertion depth.

4. When inserting the tube into the press fitting cup, clearly seat the tube until you have reached the mark on the exterior of the tube. This ensures a proper seal of fitting and tube.

 

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INSTALLATION INSTRUCTIONS

For Types K, L and M Hard Copper Tubing in 1/2” to 4” and Soft Copper Tubing in 1/2” to 1-1/4”.

1. Check seal for correct fit. Do not use oils or lubricants.

2. Mark proper insertion depth as indicated by the Insertion Depth Chart. Improper insertion depth may result in improper seal.

3. Turn the fitting slightly when inserting the tube. Slide press fitting onto tubing to the marked depth. The end of the tubing must contact the stop inside the fitting. If properly marked on the outside of the tube, the marking line will align with the end of the cup.

4. Open the jaw and place at right angles on the fitting, such that the recess in the jaw sits directly on top of the O-ring ridge of the fittings exterior.

5. Start pressing process, continue to hold the trigger until the jaw has engaged the fitting. The tool should have an indicator light to display that the press cycle is completed. If for any reason the indicator light does not show a completed press cycle re-press the fitting without moving tool. Not pressing in same location can cause bad seal and allow leakage.

6. After pressing, the jaw can be opened again, releasing the fitting.

Deformity of both the fitting and the tube will give a visual confirmation that the joint has been pressed. This visual does not replace the need to air or water test the fittings and system joining.

For larger size press joints all of the steps are the same. The main difference is that the jaw sets typically utilize a large diameter pressing ring as well as the pressing jaws themselves.

Installation for 1/2” to 2” Tubing

 

 

 

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WARNING

Read and understand all instructions for installing IRONWORKS® copper press fittings.

Failure to follow all instructions may result in extensive property damage and serious injury.

Distance between Press Joints

Mechanical joint pressing causes some engineered degree of deformity to the tubing. To prevent leaks, minimal distances between press joints are set forth in the accompanying table.

 

 

Minimum Distance between Press Joints

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Space Limitations

Press tool and jaw sets can be difficult to get into some tighter spaces. IRONWORKS® recommends that when spaces are too tight to access easily, preassembly of this section of tube and fittings be done away from these space restrictions, and then installed to minimize potential for bad alignment of the pressing tools and jaws.