Viega Profipress S User manual

Year built:
from 01/2008
en_INT
Profipress S
Instructions for Use

Profipress S 2 from 24

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 7
2.2.1 Areas of use 7
2.2.2 Media 7
2.3 Product description 7
2.3.1 Overview 7
2.3.2 Pipes 8
2.3.3 Press connectors 11
2.3.4 Sealing elements 12
2.3.5 Markings on components 12
2.4 Information for use 13
2.4.1 Corrosion 13
3Handling 14
3.1 Transport 14
3.2 Storage 14
3.3 Assembly information 14
3.3.1 Mounting instructions 14
3.3.2 Potential equalisation 15
3.3.3 Permitted exchange of sealing elements 15
3.3.4 Space requirements and intervals 16
3.3.5 Required tools 18
3.4 Assembly 19
3.4.1 Replacing the sealing element 19
3.4.2 Bending pipes 20
3.4.3 Shortening the pipes 20
3.4.4 Deburring the pipes 20
3.4.5 Pressing the connection 22
3.4.6 Leakage test 23
3.5 Maintenance 23
3.6 Disposal 24
Table of contents
Profipress S 3 from 24

1 About these instructions for use
Trade mark rights exist for this document; for further information, go to
viega.com/legal.
1.1 Target groups
The information in this manual is directed at heating and sanitary pro‐
fessionals and trained personnel.
Individuals without the abovementioned training or qualification are not
permitted 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 of possible life-threatening injury.
WARNING!
This symbol warns of possible serious injury.
CAUTION!
This symbol warns of possible injury.
NOTICE!
This symbol warns of possible damage to property.
This symbol gives additional information and hints.
About these instructions for use
Profipress S 4 from 24

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 S 5 from 24

2 Product information
2.1 Standards and regulations
The following standards and regulations apply to Germany / Europe and
are provided as a support feature.
Scope / Notice Regulations applicable in Ger‐
many
Permitted copper pipes DIN EN 1057
Approval of press connectors for
use with copper pipes
DVGW-Arbeitsblatt GW 392
Scope / Notice Regulations applicable in Ger‐
many
Regulations for external corrosion
protection
DIN EN 806-2
Regulations for external corrosion
protection
DIN 1988-200
Regulations for external corrosion
protection
DKI-Informationsdruck i. 160
Scope / Notice Regulations applicable in Ger‐
many
Requirements for material storage DIN EN 806-4, Chapter 4.2
Scope / Notice Regulations applicable in Ger‐
many
Test on a system that is finished
but not yet covered
DIN EN 12976-1
Test on a system that is finished
but not yet covered
DIN EN 12976-2
Test on a system that is finished
but not yet covered
DKI-Informationsdruck i.160
Regulations from section: Pipes
Regulations from section: Corrosion
Regulations from section: Storage
Regulations from section: Leakage test
Product information
Profipress S 6 from 24

Scope / Notice Regulations applicable in Ger‐
many
Operation and maintenance of
solar installations
DKI-Informationsdruck i.160
2.2 Intended use
Coordinate the use of the system in units with additives (
e. g. anti-freeze or anti-corrosion agents) in heating water or
for fields of application and media other than those
described with the Viega Service Center.
2.2.1 Areas of use
Do not use the piping system in potable water and gas installations.
Use is possible in the following areas among others:
nSolar installations
nDistrict heat supply systems
nLow-pressure steam systems
nCooling water pipelines (closed circuit)
2.2.2 Media
The system is suitable for the following media, amongst others:
nAnti-freeze, cooling brines up to a concentration of 50 %
nSteam in low-pressure steam systems
2.3 Product description
2.3.1 Overview
The piping system consists of press connectors for copper pipes and
the corresponding press tools.
Regulations from section: Maintenance
Product information
Profipress S 7 from 24

Fig. 1: Profipress S press connectors
The system components are available in the following dimensions:
d 12 / 15 / 18 / 22 / 28 / 35.
Profipress connectors can be equipped with FKM sealing
elements for dimensions above 35 mm.
2.3.2 Pipes
Only copper pipes that comply with the pertinent regulations may be
used, see Ä Chapter 2.1 „Standards and regulations“ on page 6:
Copper pipes in solar installations
d x s [mm] Volume per metre of
pipe [l/m]
Pipe weight [kg/m]
12 x 0.7 0.09 0.22
12 x 1.0 0.08 0.31
15 x 0.8 0.14 0.32
15 x 1.0 0.13 0.39
18 x 0.8 0.13 0.39
18 x 1.0 0.20 0.48
22 x 1.0 0.31 0.59
28 x 1.0 0.53 0.76
35 x 1.2 0.84 1.13
Product information
Profipress S 8 from 24

d x s [mm] Volume per metre of
pipe [l/m]
Pipe weight [kg/m]
42 x 1.2 1.23 1.37
54 x 1.5 2.04 2.20
The following instructions amongst others must be observed when
dealing with solar installations:
nThe supply line should be installed in an ascending position and the
return flow should be in a descending position, thus allowing the
system to be drained.
nWhen draining, the heat carrying medium must be collected in a suit‐
able container.
Only pipe clamps with noise insulation inlays should be used.
Observe the general rules of fixing technology:
nFixed pipelines should not be used as support for other pipelines
and components.
nDo not use pipe hooks.
nObserve distance to connectors.
nObserve the expansion direction – plan fixed and gliding points.
Affix the pipelines in such a way as to de-couple them from the installa‐
tion body, so that they cannot transfer any structure-borne sound,
resulting from thermal expansion or possible pressure surges, onto the
installation body or other components.
Observe the following fixing intervals:
Interval between the pipe clamps
d [mm] Fixing interval between
the pipe clamps [m]
12.0 1.25
15.0 1.25
18.0 1.50
22.0 2.00
28.0 2.25
35.0 2.75
Pipelines expand with heat. Heat expansion is dependent on the mate‐
rial. Changes in length lead to tension within the installation. These ten‐
sions must be equalised with suitable measures.
Laying and fixing pipes
Length expansion
Product information
Profipress S 9 from 24

The following are effective:
nFixed and gliding points
nExpansion equalisation joints (expansion bends)
nCompensators
Heat expansion co-efficient of copper
Material Heat expansion co-effi‐
cient ⍺
[mm/mK]
Example:
Length expansion with
pipe lengths = 20 m
and ΔT = 50 K
[mm]
Copper 0.0166 16.6
Fig. 2: Length expansion of copper pipes
1 - Length expansion ΔI [mm]
2 - Pipe length  l0 [m]
3 - Temperature difference Δϑ [K]
The length expansion Δl can be taken from the diagram or can be cal‐
culated using the following formula:
Δl = ⍺ [mm/mK] × L [m] x Δϑ [K]
Product information
Profipress S 10 from 24

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.
The press connectors in the Profipress S system consist of the following
materials:
nCopper
nGunmetal/silicon bronze
Fig. 3: Press connectors
The press connectors have a circumferential bead in which the sealing
element lies. The connector is deformed upstream and downstream of
the bead and permanently connected to the pipe during pressing. The
sealing element is not deformed during pressing.
Fig. 4: 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
when filling the system.
Viega ensures that inadvertently unpressed connections during installa‐
tion become visible when the system is filled.
nwith wet leakage test in the pressure range from 0.1–0.65 MPa (1.0–
6.5 bar)
nwith dry leakage test in the pressure range from 22 hPa–0.3 MPa
(22 mbar–3.0 bar)
SC-Contur
Product information
Profipress S 11 from 24

2.3.4 Sealing elements
The press connectors are factory-fitted with FKM sealing elements.
Area of use District heat supply Solar installations Low-pressure steam sys‐
tems
Use
District heat supply sys‐
tems behind the external
wall lead-in
Solar circuit —
Operating temperature
[Tmax.]140 °C 1) 120 °C
Operating pressure [Pmax]1.6 MPa (16 bar) 0.6 MPa (6 bar) < 0.1 MPa (1 bar)
Comments —Short-term peak temper‐
atures ≤ 280 °C —
1) Consultation with the Viega Service Center required.
2.3.5 Markings on components
The press connectors are marked with a coloured dot. This identifies
the SC-Contur, where the test medium would escape in the case of an
inadvertently unpressed connection.
Fig. 5: Marking
The press connectors are marked as follows:
nwhite dot
nwhite rectangle with FKM inscription
Area of use of the FKM sealing element
Markings on press connectors
Product information
Profipress S 12 from 24

2.4 Information for use
2.4.1 Corrosion
Galvanised components may not be used in solar installa‐
tions.
Overground pipelines and fittings in rooms do not normally require
external corrosion protection.
There are exceptions in the following cases:
nContact with aggressive building materials such as nitrite or mate‐
rials containing ammonium
nin aggressive surroundings
If external corrosion protection is required, observe the pertinent guide‐
lines, see Ä „Regulations from section: Corrosion“ on page 6.
Product information
Profipress S 13 from 24

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 6:
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 S 14 from 24

Do not use Teflon® tape to seal threaded connections in
solar installations, because the change in the creep behav‐
iour of the water glycol mixture may result in gradual leaki‐
ness.
Instead, use properly manufactured hemp packages.
3.3.2 Potential equalisation
DANGER!
Danger due to electrical current
An electric shock can lead to burns and serious injury and
even death.
Because all metallic piping systems conduct electricity,
unintentional contact with a live part can lead to the whole
piping system and components connected to it (e. g. radia‐
tors) becoming energised.
– Only allow electrical work to be carried out by qualified
electricians.
– Always integrate the metallic piping system into the
potential equalisation.
It is the fitter of the electrical system who is responsible for
ensuring that the potential equalisation is tested and
secured.
3.3.3 Permitted exchange of sealing elements
Important instruction
With their material-specific qualities, sealing elements in
press connectors are adapted for use with the corre‐
sponding media and/or the areas of use of the piping sys‐
tems and are generally only certified for them.
The exchange of a sealing element is generally permitted.
The sealing element must be exchanged for a designated
spare part for the intended application Ä Chapter 2.3.4
„Sealing elements“ on page 12. The use of other sealing ele‐
ments is not permitted.
Handling
Profipress S 15 from 24

Exchanging a sealing element is permitted in the following situations:
nif the sealing element in the press connector is obviously damaged
and should be exchanged for a Viega replacement sealing element
made of the same material
nif an EPDM sealing element in Profipress connectors should be
exchanged for an FKM sealing element (higher thermal resistance,
e. g. for industrial use)
3.3.4 Space requirements and intervals
Space requirement PT1, type 2 (PT2), PT3-EH, PT3-AH, Pressgun 4B,
4E, 5
d 12 15 18 22 28 35
a [mm] 20 20 20 25 25 30
b [mm] 50 50 55 60 70 85
Space requirement Picco, Pressgun Picco
d 12 15 18 22 28 35
a [mm] 25 25 25 25 25 25
b [mm] 55 60 60 65 65 65
Space requirement press ring
d 12 15 18 22 28 35
a [mm] 40 40 45 45 50 55
b [mm] 45 50 55 60 70 75
c [mm] 35 35 40 40 45 50
Pressing between pipelines
Handling
Profipress S 16 from 24

Space requirement PT1, type 2 (PT2), PT3-EH, PT3-AH, Pressgun 4B,
4E, 5
d 12 15 18 22 28 35
a [mm] 25 25 25 30 30 50
b [mm] 65 65 75 80 85 95
c [mm] 40 40 40 40 50 50
Space requirement Picco, Pressgun Picco
d 12 15 18 22 28 35
a [mm] 30 30 30 30 30 30
b [mm] 70 70 70 75 80 80
c [mm] 40 40 40 40 40 40
Space requirement press ring
d 12 15 18 22 28 35
a [mm] 40 40 45 45 50 55
b [mm] 45 50 55 60 70 75
c [mm] 35 35 40 40 45 50
Minimum interval with d 12–35
Press machine amin [mm]
PT1 45
Type 2 (PT2)
50
Type PT3-EH
Type PT3-AH
Pressgun 4E / 4B
Pressgun 5
Picco / Pressgun Picco 35
Pressing between pipe and wall
Distance to walls
Handling
Profipress S 17 from 24

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.
d 12 15 18 22 28 35
Min‐
imum
interval
a [mm]
0 0 0 0 0 10
For the Z dimensions, refer to the respective product page in the online
catalogue.
3.3.5 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
nPress jaw or press ring with corresponding hinged adapter jaw, suit‐
able for the pipe diameter and suitable profile
Fig. 6: Press jaws
Interval between the pressings
Z dimensions
Handling
Profipress S 18 from 24

Recommended Viega press machines:
nPressgun 5
nPressgun Picco
nPressgun 4E / 4B
nPicco
nType PT3-AH
nType PT3-H / EH
nType 2 (PT2)
3.4 Assembly
3.4.1 Replacing the sealing element
Do not use pointed or sharp-edged objects to remove the
sealing element. These could damage the sealing element or
bead.
Remove the sealing element from the bead.
Insert a new, undamaged sealing element into the bead.
Ensure that the complete sealing element is in the bead.
Removing the sealing element
Inserting the sealing element
Handling
Profipress S 19 from 24

3.4.2 Bending pipes
Copper pipes in the sizes d 12, 15, 18, 22 and 28 can be bent cold with
commercially available bending equipment (radius at least 3.5 x d).
The pipe ends (a) must be at least 50 mm long so that the press con‐
nectors can be mounted properly.
3.4.3 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 Ä Chapter 3.3.5 „Required
tools“ on page 18.
Cut the pipe properly using a pipe cutter or fine-toothed hacksaw.
Avoid grooves on the pipe surface.
3.4.4 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 2292.2)
is recommended.
Handling
Profipress S 20 from 24