Viega Profipress G XL User manual

Year built:
from 08/2005
en_INT
Profipress G XL
Instructions for Use

Profipress G XL 2 from 23

Table of contents
1About these instructions for use 4
1.1 Target groups 4
1.2 Labelling of notes 4
1.3 About this translated version 5
2Product information 6
2.1 Standards and regulations 6
2.2 Intended use 8
2.2.1 Areas of use 8
2.2.2 Media 9
2.3 Product description 9
2.3.1 Overview 9
2.3.2 Pipes 10
2.3.3 Press connectors 11
2.3.4 Sealing elements 12
2.3.5 Markings on components 13
2.4 Information for use 14
2.4.1 Corrosion 14
3Handling 15
3.1 Transport 15
3.2 Storage 15
3.3 Assembly information 15
3.3.1 Mounting instructions 15
3.3.2 Space requirements and intervals 17
3.3.3 Required tools 18
3.4 Assembly 19
3.4.1 Shortening the pipes 19
3.4.2 Deburring the pipes 19
3.4.3 Pressing the connection 20
3.4.4 Leakage test 22
3.5 Maintenance 23
3.6 Disposal 23
Table of contents
Profipress G XL 3 from 23

1 About these instructions for use
Trade mark rights exist for this document, further information can be
found at viega.com/legal .
1.1 Target groups
The information in this instruction manual is directed at the following
groups of people:
ncontract installers registered in the installers' register of a utility com-
pany
nprofessional specialist companies for the construction, maintenance
and alteration of a natural or liquid gas system
Liquid gas systems may only be constructed, maintained or altered by
companies that have the necessary qualification and experience.
It is not permitted for individuals without the abovementioned training or
qualification to mount, install and, if required, maintain this product. This
restriction does not extend to possible operating instructions.
The installation of Viega products must take place in accordance with
the general rules of engineering and the Viega instructions for use.
1.2 Labelling of notes
Warning and advisory texts are set aside from the remainder of the text
and are labelled with the relevant pictographs.
DANGER!
This symbol warns against possible life-threatening injury.
WARNING!
This symbol warns against possible serious injury.
CAUTION!
This symbol warns against possible injury.
NOTICE!
This symbol warns against possible damage to property.
About these instructions for use
Profipress G XL 4 from 23

Notes give you additional helpful tips.
1.3 About this translated version
This instruction for use contains important information about the choice
of product or system, assembly and commissioning as well as intended
use and, if required, maintenance measures. The information about the
products, their properties and application technology are based on the
current standards in Europe (e. g. EN) and/or in Germany
(e. g. DIN/DVGW).
Some passages in the text may refer to technical codes in Europe/
Germany. These should serve as recommendations in the absence of
corresponding national regulations. The relevant national laws, stand-
ards, regulations, directives and other technical provisions take priority
over the German/European directives specified in this manual: The
information herein is not binding for other countries and regions; as said
above, they should be understood as a recommendation.
About these instructions for use
Profipress G XL 5 from 23

2 Product information
2.1 Standards and regulations
The following standards and regulations apply to Germany / Europe.
National regulations can be found on the relevant web site of your
country at viega.com/standards .
Scope / Notice Regulations
Planning, execution, modification
and operation of gas installations
DVGW-TRGI 2008
Gas installations for industrial,
commercial and process plants
DVGW-Arbeitsblatt G 5614
Gas installations for industrial,
commercial and process plants
DVGW-Arbeitsblatt G 462
Gas installations for industrial,
commercial and process plants
DVGW-Arbeitsblatt G 459-1
Gas installations for industrial,
commercial and process plants
DVGW-Fachinformation Nr. 10
Planning, execution, modification
and operation of liquid gas instal-
lations
DVFG-TRF 2012
Scope / Notice Regulations
Suitability for gasses
Liquid gas in the gaseous state
DVGW-Arbeitsblatt G 260
Regulations from section: Fields of application
Regulations from section: Media
Product information
Profipress G XL 6 from 23

Scope / Notice Regulations
Rules of the fixing technology for
gas installations
DVGW-TRGI 2008, Point 5.3.7
Rules of the fixing technology for
gas installations
DVFG-TRF 2012, Point 7.3.6
Approval of press connectors for
use with copper pipes
DVGW G 5614
Approval of press connectors for
use with copper pipes
DIN EN 1057
Approval of press connectors for
use with copper pipes
DVGW-Arbeitsblatt GW 392
Scope / Notice Regulations
(Subsequent) corrosion protection
measures for laying in the ground
DIN 30672
Corrosion protection measures for
external pipelines
DVGW-TRGI 2008, Point 5.2.7.1
Corrosion protection measures for
internal pipelines
DVGW-TRGI 2008, Point 5.2.7.2
Corrosion protection measures for
external pipelines
DVFG-TRF 2012, Point 7.2.7.1
Corrosion protection measures for
internal pipelines
DVFG-TRF 2012, Point 7.2.7.2
Overground pipelines in recesses
in the bare floor or levelling layer
DVGW-TRGI 2008, Point 5.3.7.8.4
Scope / Notice Regulations
Requirements for material storage DIN EN 806-4, Chapter 4.2
Scope / Notice Regulations
The general rules of mounting for
gas installations
DVGW-TRGI 2008, Point 5.3.7
The general rules of mounting for
gas installations
DVFG-TRF 2012, Point 7.3.6
Regulations from section: Pipes
Regulations from section: Corrosion
Regulations from section: Storage
Regulations from section: Notes on mounting
Product information
Profipress G XL 7 from 23

Scope / Notice Regulations applicable in Ger-
many
Leakage test for gas installation DVGW-TRGI 2008, Point 5.6
Testing and initial commissioning
of a liquid gas system
DVFG-TRF 2012, Point 8
Scope / Notice Regulations
Ensuring and maintaining a safe
operating condition of gas instal-
lations
DVGW-TRGI 2008, Appendix 5c
2.2 Intended use
Agree the use of the system for areas of use and media
other than those described with the Viega Service Center.
2.2.1 Areas of use
Use is possible in the following areas among others:
nGas installations
nLiquid gas systems
nCompressed air systems
For planning, execution, modification and operation of gas installations,
observe the applicable regulations, see Ä„Regulations from section:
Fields of application“ on page 6 .
Regulations from section: Leakage test
Regulations from section: Maintenance
Gas installation
Product information
Profipress G XL 8 from 23

Use is possible in the gas installations described below:
nGas installations
– low pressure range ≤100 hPa (100 mbar)
– medium pressure range from 100 hPa (100 mbar) up to 0.1 MPa (1 bar)
– industrial, commercial and process technical systems with the
corresponding directives and technical regulations
nLiquid gas systems
– with liquid gas tank in medium pressure range downstream of
the pressure regulating valve, 1st level on the
liquid gas tank > 100 hPa (100 mbar) up to a permitted operating
pressure of 0.5 MPa (5 bar)
– with liquid gas tank in the low pressure range
≤100 hPa (100 mbar) behind the pressure regulating valve, 2nd
level
– with liquid gas pressurised container (liquid gas bottles) < 16 kg
behind the small bottle pressure regulating valve
– with liquid gas tank (liquid gas bottle) ≥16 kg
behind the large bottle pressure regulating device
The Sanpress Inox G system must be used for liquid gas
installations in areas with requirements of higher thermal
resistance (HTR), with a pick-up pressure of the
SSV > 0.1 MPa (1 bar).
2.2.2 Media
The system is suitable for the following media, amongst others:
For the applicable directives, see Ä„Regulations from section:
Media“ on page 6 .
nGases
nLiquid gases, only in the gaseous state for domestic and commercial
applications
nCompressed air
2.3 Product description
2.3.1 Overview
The piping system consists of press connectors for copper pipes and
the corresponding press tools.
Product information
Profipress G XL 9 from 23

Fig. 1: Profipress G XL press connectors
The system components are available in the following dimension: d 64.
2.3.2 Pipes
Profipress G XL press connectors are tested and certified with the fol-
lowing copper pipes, see ÄChapter 2.1 „Standards and regulations“
on page 6 :
Thinner walls than stated are not permitted.
d x s [mm] Volume per metre of
pipe [l/m]
Pipe weight [kg/m]
64.0 x 2.0 2.83 3.47
Observe the general rules of fixing technology:
nFor gas installations, see
ÄChapter 2.1 „Standards and regula-
tions“ on page 6 .
nOnly fix on components with sufficient stability.
nGas supply lines must not be secured to other pipelines nor should
they be used as support for other pipelines.
nThe system can be secured using commercially available plastic
dowels together with non-flammable pipe clamps (e. g. metallic pipe
clamps).
With gas supply lines, observe the following fixing intervals for pipelines
laid horizontally:
Laying and fixing pipes
Product information
Profipress G XL 10 from 23

Interval between the pipe clamps
d [mm] Fixing interval between
the pipe clamps [m]
64.0 4.00
66.7
2.3.3 Press connectors
Press connectors are available in a number of shapes. An overview of
the press connectors suitable for the system can be found in the cata-
logue.
Fig. 2: Press connectors
On Profipress G XL press connectors, there is a cutting ring, a separator
ring and a sealing element in the bead of the press connector. The cut-
ting ring cuts into the pipe during pressing and ensures a force-fit con-
nection.
During installation, and later during the pressing, the separator ring pro-
tects the sealing element from damage from the cutting ring.
Product information
Profipress G XL 11 from 23

Fig. 3: SC-Contur
Viega press connectors are equipped with the SC-Contur. The SC-
Contur is a safety technology that is certified by the DVGW and ensures
that the connector is guaranteed to be leaky in an unpressed state. In
this way, inadvertently unpressed connections are noticed immediately
during a leakage test.
Viega guarantees that unpressed connections are visible during a
leakage test:
nwith dry leakage test in the pressure range from 22 hPa–0.3 MPa
(22 mbar–3.0 bar)
2.3.4 Sealing elements
The press connectors are factory-fitted with yellow HNBR sealing ele-
ments.
Substitution of sealing elements
The exchange of sealing elements is not permitted.
SC-Contur
Product information
Profipress G XL 12 from 23

Use Gas installation Liquid gas installation Heating oil and diesel
pipelines
Operating temperature -20 °C up to +70 °C -20 °C up to +70 °C ≤40 °C
Operating pressure ≤0.5 MPa (5 bar)
(MOP 5)
≤0.1 MPa (1 bar) (HTR /
GT1)2)
≤0.5 MPa (5 bar)
(MOP 5)1)
≤0.1 MPa (1 bar) (HTR /
GT1)2)
≤0.5 MPa (5 bar)
1) The maximum pressure equates to the pick-up pressure of the SSV in the pressure regulating valve.
2) GT1: Operating pressure at HTR requirement 650 °C / 30 min max. 0.1 MPa (1 bar)
2.3.5 Markings on components
Fig. 4: Marking on the press connector
The press connectors are marked as follows:
nyellow rectangle for gas
n Gas for gas supply lines
n MOP5 for maximum operating pressure 0.5 MPa (5 bar)
n GT1 for operating pressure with HTR requirement 0.1 MPa (1 bar)
nDVGW
Markings on press connectors
Product information
Profipress G XL 13 from 23

2.4 Information for use
2.4.1 Corrosion
Depending on the area of use, corrosion protection measures may have
to be taken into account. One differentiates between external pipelines
(underground and overground external pipelines), as well as internal
pipelines.
Information about the area of use, also see
ÄChapter 2.2.1 „Areas of
use“ on page 8 .
The pertinent guidelines must be observed for corrosion protection, see
Ä„Regulations from section: Corrosion“ on page 7 .
Overground pipes and fittings in rooms do not normally require external
corrosion protection.
There are exceptions in the following cases:
nThere is contact with aggressive building materials such as materials
containing nitrite or ammonium.
nin aggressive surroundings
nIn recesses within bare floors or in the compensating layer, they
must be treated in the same way as buried external pipelines, see
Ä„Regulations from section: Corrosion“ on page 7 .
Product information
Profipress G XL 14 from 23

3 Handling
3.1 Transport
Observe the following when transporting pipes:
nDo not pull the pipes over the sill. The surface could be damaged.
nSecure pipes during transportation. Pipes may become bent due to
shifting.
nDo not damage the protective caps on the pipe ends and do not
remove them until immediately before mounting. Damaged pipe
ends may not be pressed.
In addition, observe the instructions provided by the pipe
manufacturer.
3.2 Storage
For storage, comply with the requirements specified in the applicable
regulations, see Ä„Regulations from section: Storage“ on page 7 :
nStore components in a clean and dry place.
nDo not store the components directly on the floor.
nProvide at least three points of support for the storage of pipes.
nWhere possible, store different sizes separately.
Store small sizes on top of larger sizes if separate storage is not pos-
sible.
In addition, observe the instructions provided by the pipe
manufacturer.
3.3 Assembly information
3.3.1 Mounting instructions
System components may, in some cases, become damaged through
transportation and storage.
nCheck all parts.
nReplace damaged components.
nDo not repair damaged components.
nContaminated components may not be installed.
Checking system components
Handling
Profipress G XL 15 from 23

The system is intended for underground device connection pipelines for
gas devices for use outside. Press connectors are not permitted in
underground liquid gas pipelines.
For gas installations, observe the applicable regulations, see
Ä„Regu-
lations from section: Notes on mounting“ on page 7 .
NOTICE!
Active and possibly passive protection measures are
required to protect a gas installation from tampering by
unauthorised persons, see
Ä„Regulations from section:
Notes on mounting“ on page 7 .
Active protective measures (e. g. gas flow monitor) must
always be taken.
Passive protective measures (e.g. gas safety plugs and
caps) must be selected and employed depending on the
installation.
The following conditions amongst others are valid when laying gas
supply lines:
nLay gas supply lines with clearance from the installation body, con-
cealed without hollow spaces or in ventilated ducts or shafts.
nDo not install gas supply lines with operating pressures > 100 hPa
(100 mbar) concealed in the wall.
nArrange gas supply lines in such a way that condense water or water
dripping from other pipes and components does not affect them.
nDo not lay gas supply lines in screed.
nShut-off systems and detachable connections must be easily acces-
sible.
Requirements on concealed installations:
nLay stress-free.
nApply corrosion protection.
nDo not use any detachable connections (screw fittings).
nDo not use copper pipes together with materials containing nitrite or
ammonium.
Continuous, connection-free gas supply lines may be laid in
hollow spaces (pre-wall constructions) to be connected to a
gas device or a gas socket.
Ventilation is not required.
The general rules of mounting for gas supply lines
Handling
Profipress G XL 16 from 23

3.3.2 Space requirements and intervals
d 64.0
a [mm] 110
b [mm] 185
d 64.0
a [mm] 110
b [mm] 185
c [mm] 130
d 64.0
Minimum interval amin [mm] 20
NOTICE!
Leaky press connections due to pipes being too short
If two press connectors are to be mounted next to one
another onto a pipe without an interval, the pipe must not
be too short. If the pipe is not inserted up to the prescribed
insertion depth in the press connector during pressing, the
connection may become leaky.
Pressing between pipelines
Pressing between pipe and wall
Distance to walls
Interval between the pressings
Handling
Profipress G XL 17 from 23

d 64.0
Minimum interval a [mm] 15
The Z dimensions can be found at www.viega.de .
3.3.3 Required tools
The following tools are required for production of a press connection:
npipe cutter or a fine-toothed hacksaw
ndeburrer and coloured pen for marking
npress machine with constant pressing force of 32 kN
npress ring with corresponding adapter jaw, suitable for the pipe
diameter and suitable profile
Fig. 5: Press rings and adapter jaws
Recommended Viega press machines:
nPressgun 5
nPressgun 4E / 4B
nType PT3-AH
nType PT3-H / EH
nType 2 (PT2)
Z dimensions
Handling
Profipress G XL 18 from 23

3.4 Assembly
3.4.1 Shortening the pipes
NOTICE!
Leaky press connections due to damaged material!
Press connections can become leaky due to damaged
pipes or sealing elements.
Observe the following instructions to avoid damage to pipes
and sealing elements:
– Do not use cutting discs (angle grinders) or flame cutters
when cutting to length.
– Do not use grease or oils (e. g. cutting oil).
For information about tools, also see ÄChapter 3.3.3 „Required
tools“ on page 18 .
Cut the pipe properly using a pipe cutter or fine-toothed hacksaw.
Avoid grooves on the pipe surface.
3.4.2 Deburring the pipes
The pipe ends must be thoroughly deburred internally and externally
after shortening.
Deburring prevents the sealing element being damaged or the that the
press connector cants when mounted. Use of a deburrer (model
2292.4XL) is recommended.
NOTICE!
Damage due to the wrong tool!
Do not use sanding disks or similar tools when deburring.
The pipes could be damaged by these.
Handling
Profipress G XL 19 from 23

Secure the pipe in the vice.
When securing, leave an interval of at least 100 mm (a) to the pipe
end.
The pipe ends must not be bent or damaged.
Deburr the inside and outside of the pipe.
3.4.3 Pressing the connection
Requirements:
nThe pipe end is not bent or damaged.
nThe pipe is deburred.
nThe correct sealing element is in the press connector.
HNBR = yellow
nSealing element, separator ring and cutting ring are undamaged.
nThe complete sealing element, separator ring and cutting ring are in
the bead.
Measure insertion depth.
d [mm] Insertion depth [mm]
64.0 43
Handling
Profipress G XL 20 from 23