Viega 2648S User manual

for double-pipe gas meters
Model Year built:
2648S from 02/2009
en_INT
Profipress G mounting unit
Instructions for Use

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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 Intended use 6
2.1.1 Areas of use 6
2.1.2 Media 6
2.2 Product description 6
2.2.1 Overview 6
2.2.2 Press connection with SC-Contur 8
2.2.3 Sealing elements 9
2.2.4 Markings on components 9
2.2.5 Compatible components 10
2.2.6 Operating mode 10
2.2.7 Technical data 12
2.3 Information for use 13
2.3.1 Corrosion 13
3Handling 14
3.1 Assembly information 14
3.1.1 Mounting instructions 14
3.1.2 Required tools 14
3.2 Mounting 15
3.2.1 Mounting the wall bracket 15
3.2.2 Shortening the pipes 16
3.2.3 Pressing the connection 16
3.2.4 Leakage test 18
3.3 Maintenance 18
3.4 Disposal 19
Table of contents
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1 About these instructions for use
Trade mark rights exist for this document, further information can be
found at www.viega.com/legal-notices.
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
company
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, service 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
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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 pertinent national laws, stand-
ards, regulations and guidelines, as well as other technical guidelines,
have priority over German/European guidelines in this manual: The
information is not binding for other countries and territories and should,
as mentioned, be considered as support.
About these instructions for use
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2 Product information
2.1 Intended use
The use of the model for areas of use and media other than
those described must be approved by the Viega Service
Center.
2.1.1 Areas of use
Use is possible in the following areas among others:
nGas installations
nLiquid gas systems
The general rules of engineering must be observed for planning, execu-
tion, alteration and operation gas installations.
E. g. the following regulations apply:
nDVGW-TRGI 2008 for gas installations
nDVFG-TRF 2012 for liquid gas systems
2.1.2 Media
The model is suitable for the following media, amongst others:
nGases
in acc. with DVGW Worksheet G 260
nLiquid gases, only in the gaseous state for domestic and commercial
applications
in acc. with DVGW-AB G 260
2.2 Product description
2.2.1 Overview
Viega gas fittings conform with the requirements of
DIN EN 331. The gas fittings are tested and certified in
accordance with the following criteria by the DVGW:
– Leak tightness in acc. with 3537-1
– higher thermal resistance (HTR)
Product information
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The model is equipped as follows:
nInlet side gas ball valve with Profipress G press connection with SC-
Contur, casing made of brass
nOutlet side with Profipress G press connection with SC-Contur
ndual-sided gas ball valve screw fitting with thread G 1¼
nWall bracket with fixing set
nGas flow monitor (GFM)
The gas meter is screwed onto the gas meter screw fittings G 1¼.
The model is lead-sealable and, in addition, can be locked using a com-
mercially available padlock.
The yellow protective sleeve on the actuating lever shows the medium
to be gas.
A gas flow monitor (GFM) type K is integrated into this model. A power
match across the protectable length is not required when a gas flow
monitor type K is installed in metallic pipelines.
You can find more detailed information about the GFM in the technical
data about the GFM ÄChapter 2.2.7 „Technical data“ on page 12 .
The model is available in the dimension d 28 with the following GFM:
VGas 2.5 m3/h / 4.0 m3/h / 6.0 m3/h.
Product information
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2.2.2 Press connection with SC-Contur
Fig. 1: Press connection using a press connector as an example
The press connection has a circumferential bead in which the sealing
element lies. The connector is deformed in front of and behind the bead
and permanently connected to the pipe during pressing. The sealing
element is not deformed during pressing.
Fig. 2: SC-Contur
Viega press connections are equipped with the SC-Contur. The SC-
Contur is a safety technology that is certified by the DVGW and ensures
that the connection is guaranteed to be leaky in an unpressed state. In
this way, unpressed connections are noticed immediately during a
leakage test.
SC-Contur
Product information
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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)
2.2.3 Sealing elements
The gas meter threaded connections are equipped with nyhalit seals.
The seals are higher thermal resistant (HTR).
The nyhalit seals may only be used once. The seals in the
meter threaded connections must be exchanged when
replacing a gas meter (model G2932).
The press connections are factory-fitted with yellow HNBR sealing ele-
ments.
Use Gas installation Liquid gas installation
Operating tempera-
ture
-20 °C up to +70 °C -20 °C up to +70 °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)
1) Maximum pressure – equates to the pick-up pressure of the SAV in
the pressure regulating valve
2) Operating pressure at HTR requirement max. 0.1 MPa (1 bar) (GT1)
In acc. with DIN EN 331 the scope of the operating temperature is
between -20 °C and max. +60 °C.
2.2.4 Markings on components
The press connections 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.
The model is marked as follows:
nMOP5 for maximum operating pressure 0.5 MPa (5 bar)
nGT1 for operating pressure with HTR requirement max. 0.1 MPa
(1 bar)
nFlow direction indicator
nDWGW writing
Product information
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nHTR marking
nyellow dot and yellow rectangle for gas
The protective sleeve on the actuating lever is marked with the following
information about the GFM:
nManufacturer
nGFM Type
nNominal flow
nOperating pressure range
nPosition indicator
nDVGW-G
2.2.5 Compatible components
The model is compatible with the following systems:
nProfipress G
nSanpress Inox G
Profipress G gas fittings are equipped with press connections.
The press connections are tested and certified with the following types
of pipe in accordance with DVGW Worksheet G 5614:
nCopper pipes
– in acc. with DVGW Worksheet GW 392
– in acc. with DIN EN 1057
nStainless steel pipes (material 1.4401)
– in acc. with DVGW Worksheet GW 541
– in acc. with DIN EN 10088
Profipress G gas fittings may only be connected to the San-
press Inox stainless steel pipe (material 1.4401) up to
dimension 28 mm.
Please contact the Viega Service Center for questions on this subject.
2.2.6 Operating mode
A gas flow monitor is an active protective measure in a gas installation.
A GFM interrupts the flow of gas if an unintended release of gas occurs.
The GFM is tested in acc. with DVGW-VP 305-1.
GFM specification plate
Fig. 3: Protective sleeve on the actuating
lever
Gas flow monitor (GFM)
Product information
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The GFM is fully open in normal operation. It is based on the nominal
volume flow VN.
The operating volume flow is stable. The Δp from p1and p2is constant.
In the case of a fault, there is a drop in the pressure in the following
pipes so that the flow rate increases sharply. The shut-off flow VSis
reached due to the pressure loss in the range p2. p1presses against the
valve plate and interrupts the flow.
After the fault has been rectified, pressures p1and p2re-balance, by gas
flowing from the overflow opening.
V0= 30 l/h at 100 hPa (100 mbar).
The valve plate opens with help from p2and the spring force against p1.
The gas flow monitor is back in normal operation.
Fig. 4: Normal operation
Fig. 5: Breakdown: Valve closed
Fig. 6: Breakdown: Valve closed,
overflowing gas
Fig. 7: Fault repaired
Product information
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2.2.7 Technical data
Observe the following operating conditions for the installation of the
model:
Use Gas installation Liquid gas installation
Operating tempera-
ture
-20° C up to +70° C -20° C up to +70° C
Operating pressure ≤0.5 MPa (5 bar)
(MOP 5)
≤0.1 MPa (1 bar)
(HTR / GT1)2)
≤0.5 MPa (5 bar)
(MOP5)1)
≤0.1 MPa (1 bar)
(HTR / GT1)2)
1) Maximum pressure – equates to the pick-up pressure of the SAV in
the pressure regulating valve
2) Operating pressure at HTR requirement max. 0.1 MPa (1 bar) (GT1)
In accordance with DIN EN 331 the scope of the operating temperature
is between -20° C and max. +60° C.
Installation position vertically downwards
Design I
Operating temperature -20° C up to +70° C
Operating pressure 15–100 hPa (15–100 mbar)
Pressure loss ≤0.5 hPa (0.5 mbar)
Closing factor fS1.45
Overflow opening ≤30 l/h at 100 hPa (100 mbar)
The shut-off flow is dependent on the gas volume flow of the integrated
GFM.
Integrated gas flow monitor
Product information
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2.3 Information for use
2.3.1 Corrosion
Depending on the area of use, corrosion protection measures may have
to be taken into account.
One differentiates between external pipelines (underground and over-
ground external pipelines), as well as internal pipelines.
The general rules of engineering must be observed for corrosion protec-
tion.
The following regulations apply, e.g.:
nDIN 30672
nDVGW-TRGI 2008, Point. 5.2.7.1 (for external pipelines)
nDVGW-TRGI 2008, Point. 5.2.7.2 (for internal pipelines)
nDVFG-TRF 2012, Point. 7.2.7.1 (for external pipelines)
nDVFG-TRF 2012, Point 7.2.7.2 (for internal pipelines)
Overground pipes and fittings in rooms do not normally require external
corrosion protection.
There are exceptions in the following cases:
nThere is external contact with materials containing chloride.
nStainless steel pipes must not come into contact with building mate-
rials or mortar containing chloride.
nThere is contact with aggressive building materials such as materials
containing nitrite or ammonium.
nin aggressive surroundings
Product information
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3 Handling
3.1 Assembly information
3.1.1 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.
Observe the following when mounting:
nObserve flow direction indicator.
nObserve required space for the gas meters according to the manu-
facturer's instructions.
nDo not cover or paint the model.
nDo not install the model in heat zones (e. g. with hot emissions or
strong heat radiation.
nUse suitable tools.
Exceptions, selection criteria and order of the components are
described in DVGW-TRGI 2008 and DVFG-TRF 2012.
NOTICE!
Active and possibly passive protection measures are
required to protect a gas installation from tampering by
unauthorised persons
Active protective measures must always be taken.
Passive protective measures must be selected and
employed depending on the installation.
The use of active and passive protective measures is regu-
lated in DVGW-TRGI 2008, Point 5.3.9.
3.1.2 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 adapter jaw, suitable for
the pipe diameter and suitable profile
Checking system components
Mounting conditions
Handling
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Fig. 8: Press jaws
Recommended Viega press machines:
nPressgun 5
nPressgun Picco
nPressgun 4E / 4B
nPicco
nType PT3-AH
nType PT3-H / EH
nType 2 (PT2)
3.2 Mounting
3.2.1 Mounting the wall bracket
Mount the wall bracket first, then the fitting.
The model is equipped with a wall bracket and the required fixing set for
mounting on masonry.
The fixing material must be adapted to the ground and to the ambient
conditions.
Information about the ground and the ambient conditions are to be
found in DVGW-TRGI 2008, Point 5.3.7.
Hold the wall bracket in the correct position and mark the drill holes
on the wall.
Drill holes.
Align the wall bracket horizontally and screw on.
Mount the fitting on the wall bracket.
Handling
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3.2.2 Shortening the pipes
NOTICE!
Leaky press connections due to pipes being too short
If two press connectors are to be mounted 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.
For that reason, the length of the pipe must correspond
exactly with the total insertion depth of both press connec-
tors.
See ÄChapter 3.1.2 „Required tools“ on page 14 for information about
tools.
Cut the pipe properly using a pipe cutter or fine-toothed hacksaw.
Avoid grooves on the pipe surface.
3.2.3 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
Handling
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nThe sealing element is undamaged.
nThe complete sealing element is in the bead.
Push the press connector onto the pipe as far as it will go.
Mark the insertion depth.
Place the press jaw onto the press machine and push the retaining
bolt in until it clicks into place.
INFO! Observe the press tool instruction manual!
Open press jaw and place at a right-angle onto the connector.
Check the insertion depth using the marking.
Ensure that the press jaw is placed centrally on the bead of the
press connector.
Handling
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Complete pressing.
Open and remove press jaw.
ðConnection is pressed.
3.2.4 Leakage test
The installer must perform a leakage test before commissioning.
This test is carried out on a unit that is finished but not yet covered.
The general rules of engineering must be observed.
E. g. the following regulations apply:
nDVGW-TRGI 2008, Point 5.6
nDVFG-TRF 2012, Point 8 (Testing and commissioning of a liquid gas
system)
The result must be documented.
By employing a gas meter connecting piece (y-adaptor
model G2326), the remaining gas installation can be tested
up and downstream from the mounting unit without
mounted gas meters.
3.3 Maintenance
The gas installation must be given a visual inspection, e. g. by the
owner, once a year.
Serviceability and leak tightness must be checked every 12 years by an
installation contractor.
Gas installations must be operated and maintained as intended to
ensure and maintain a safe operating condition. Detailed information on
this topic can be found in DVGW-TRGI 2008 appendix 5c.
Handling
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3.4 Disposal
Separate the product and packaging materials (e. g. paper, metal,
plastic or non-ferrous metals) and dispose of in accordance with valid
national legal requirements.
Handling
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