Alpha innotec expansion joints Owner's manual

Brand: Alpha innotec

Model: expansion joints

Type: Owner's manual

We reserve the right to make changes without notice.

83015700aUK – Translation of the original operating manual

Operating Manual

Expansion joints

for P series

Contents

INFORMATION FOR USERS AND QUALIFIED PERSONNEL

PLEASE READ FIRST ............................................................................ 2

SYMBOLS ........................................................................................................................2

GENERAL INFORMATION .........................................................................................3

DISCLAIMER ...................................................................................................................3

SAFETY .............................................................................................................................3

WARRANTY / GUARANTEE ......................................................................................3

MAINTENANCE ............................................................................................................. 3

INSTRUCTIONS FOR QUALIFIED PERSONNEL

SCOPE OF DELIVERY ...................................................................................................4

Installation package 50/50, 50/65, 65/65 .....................................................4

Size 1: IPFK 50/50: ..................................................................................................4

Size 2: IPFK 65/50: .................................................................................................4

Size 3: IPFK 65/65: ..................................................................................................4

STORAGE.......................................................................................................................4

INSTALLATION .............................................................................................................. 4

INSTALLATION INSTRUCTIONS .............................................................................5

PRODUCT DESCRIPTION: ......................................................................................... 6

DIMENSIONED DRAWINGS .....................................................................................6

TIGHTENING TORQUES NM OF THE FLANGE BOLTS ................................. 7

BOLT TIGHTENING TORQUES ................................................................................. 7

83015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

Please read rst

This operating manual provides important information on handling the

unit. It is an integral part of the product and must be stored so that it is

accessible in the immediate vicinity of the unit. It must remain available

throughout the entire service life of the unit. It must be handed over to

subsequent owners or users of the unit.

Read the operating manual before starting any work on or with the

unit. Especially the chapter on safety. Follow all instructions in full and

unreservedly.

This operating manual may contain descriptions, which seem

incomprehensible or unclear. In the event of any questions or if any

details are unclear, contact the factory customer service department or

the manufacturer's local partner.

As this operating manual has been written for several unit models,

always comply with the parameters that apply to the respective model.

This operating manual is intended only for persons assigned to work

on or with the unit. Treat all its constituent parts condentially. They

are protected by copyright. They may not be reproduced, transmitted,

copied, stored in electronic systems or translated into another language,

either wholly or in part, without the express written permission of the

manufacturer.

Symbols

Information for users.

Information or instructions for qualied personnel.

DANGER!

Risk of fatal electric shock!

DANGER!

Indicates imminent danger, which results in severe injuries or death.

WARNING!

Indicates a potentially dangerous situation, which could result in severe

injuries or death.

CAUTION!

Indicates a potentially dangerous situation that could result in moderate

or slight injuries.

ATTENTION

Indicates a potentially dangerous situation, which could result in

property damage.

NOTICE

Emphasised information.

€

ENERGY SAVING TIP

Indicates advice, which helps to save energy, raw materials and

costs.

Reference to other sections of the operating manual.

Reference to other documents of the manufacturer.

383015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

General information

Rubber expansion joints can only full their function if they are properly

installed and assembled. The life of the joints is not only determined by

the operating conditions, but above all, by correct installation. Expansion

joints are moving parts, which must be subjected to regular checking.

Disclaimer

The manufacturer is not liable for any damage or losses resulting from

use of the unit which is not its intended use. The manufacturer's liability

also expires:

•

if work is carried out on the unit and its components contrary to the

instructions in this operating manual.

•

if work is improperly carried out on the unit and its components.

•

if work is carried out on the unit which is not described in this

operating manual, and this work has not been explicitly approved

by the manufacturer in writing.

•

if the unit or components in the unit have been altered, modied or

removed without the explicit written consent of the manufacturer.

Safety

The unit is safe to operate for its intended use. The construction and

design of the unit conform to current state of the art standards, all

relevant DIN/VDE regulations and all relevant safety regulations.

Every person who carries out work on the unit must have read and

understood the operating manual before starting the work. This also

applies if the person concerned has already worked with such a unit or a

similar unit or has been trained by the manufacturer.

Every person who carries out work on the unit must comply with the

relevant local accident prevention and safety regulations. This especially

applies to the wearing of personal protective clothing.

WARNING!

Only qualied personnel (trained heating, refrigeration engineers

and electricians) may carry out work on the unit and its compo-

nents.

Warranty / Guarantee

For warranty and guarantee provisions, please refer to your purchase

documents.

Contact the responsible dealer regarding all warranty and guarantee

matters.

Maintenance

Clean the expansion joints with soap and hot water only. Sharp-edged

objects, wire brushes or sand paper must not be used as cleaning

materials

Maintenance

The expansion joints must be freely accessible and inspections at regular

intervals must be possible.

Check that the expansion joints are intact. Repairs are not allowed.

Rubber parts should be kept clean (clean with water, soapy water). Keep

parts free from grease and oils!

Rubber parts must not be enclosed by insulation if the temperature

exceeds 50°C. (Heating and hardening of the rubber).

Minimum inspections one week after start-up. Retighten ange bolts

with torque wrench. Inspect after 1, 4 and 12 months, then annually.

Inspection criteria

- Visible damage to the rubber and to the tie rods.

- Deformations in the outer diameter of the rubber ange, between

the bolts (displacement of the ange surfaces).

- Changes to the rubber bellows (bubbles/blistering, brittleness,

cracks, hairline cracks

- Check the tie rods for unacceptable deection and oset.

Assess the corrosion and wear of the whole component

4 83015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

Scope of delivery

INSTALLATION PACKAGE 50/50, 50/65, 65/65

SIZE 1: IPFK 50/50:

Brine/Water H series 29 KW - 56 kW

Brine/Water series 37 KW - 69 kW

Water/Water series 55 KW - 110 kW

4 x rubber expansion joints DN 50

16 x bolts DIN 933 M16x60 8.8 zinc-coated

16 x nuts DIN 934 M16 8.8 zinc-coated

32 x washers DIN 125 A17 zinc-coated

SIZE 2: IPFK 65/50:

Brine/Water H series 70 kW - 100 kW

Brine/Water series 110 kW

2 x rubber expansion joints DN 50

2 x rubber expansion joints DN 65

16 x bolts DIN 933 M16x60 8.8 zinc-coated

16 x nuts DIN 934 M16 8.8 zinc-coated

32 x washers DIN 125 A17 zinc-coated

SIZE 3: IPFK 65/65:

Brine/Water series 125 kW - 160 kW

4 x rubber expansion joints DN 65

16 x bolts DIN 933 M16x60 8.8 zinc-coated

16 x nuts DIN 934 M16 8.8 zinc-coated

32 x washers DIN 125 A17 zinc-coated

STORAGE

See DIN 7716, Guidelines for the storage of rubber parts. Rubber

expansion joints must be stored stress-free, free from deformation and

kinks.

Rubber expansion joints with steel anges must be stored upright on

the anges (otherwise risk of crushing).

STORAGE ROOM

The storage room should be cool, dry, dust-free and moderately

ventilated.

OXYGEN AND OZONE

Protect rubber parts from draughts. Cover if necessary.

Do not operate any ozone-producing equipment such as electric

motors, uorescent light sources, etc. in the storage room.

MATERIALS STORED WITH THE EXPANSION JOINTS

Do not store any solvents, fuels, chemicals or similar materials in the

storage room at the same time as the expansion joints.

Installation

Check the packaging of the rubber expansion joints for damage. Never

install damaged expansion joints.

Check the installation gap allowed for their installation; the mating

ange should be inserted ush.

Maximum dierence in the gap to the pressure joint: + 10 mm minus

appropriate expansion allowance. Lateral deviation of the anges: 5 mm

maximum.

Do not use sharp-edged tools. No additional seals are required. The

rubber ange of the expansion joint seals directly against the pipe

ange.

In the case of expansion joints with through holes, the bolts must be

inserted with the bolt head facing the bellows, to avoid damaging the

bellows body under pressure.

The bolts of the ange must be tightened alternately, uniformly tight.

Further, also ensure that the sealing bead does not cant. The protruding

sealing surface should be uniformly pressed together, all-round. The

bolts must be tightened uniformly tight, cross-wise in 3 to 4 passes.

See tightening torques.

Do not weld near the rubber expansion joints. If necessary, cover the

expansion joint to protect it from welding heat and ying sparks. (Sparks

and temperatures above 90°C damage the rubber parts!)

ATTENTION

In case of welding work on the whole pipe system, steel wire expansion

joints can become irreparably damaged by stray currents ore electrical

earth cable. The anode and cathode of the electric welding connection

must always lie on the same section of the pipe. (Not separated by the

rubber expansion joint!)

ATTENTION:

The bellows may not be coated or insulated (heating and hardening of

the rubber).

583015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

PIPE ROUTING

Anchor points and brackets

Before lling the pipes, check whether all anchor points

and brackets are installed and properly functioning.

The tie bolt anchors must carry the forces uniformly and

are to be adjusted to the current pipe condition.

NOTES

The anges should be clean and burr-free, and t in the gripping section

of the rubber bellows, although depending on the nominal size, the

sealing surface can protrude by approx. 1 - 10 mm. The mating ange

sealing surfaces may be smooth or with a sealing strip, according to EN

1092 - 1: 2001

The expansion joints are supplied with pressure-resistant solid rubber

anges, including one-piece steel lapped anges according to the

standard joint (DIN, ASA, BS, etc.) The mating anges must have a

smooth sealing surface.

Both expansion joints are self-sealing; additional seals are not required.

The installation distance from the pump socket to the expansion joint /

elbow must be 1 to 1.5 x DN. Avoid operating the pump against wholly

or partially closed slide or buttery valves. Equally, avoid cavitation, as

this can quickly result in irreparable damage to the expansion joint.

LATERAL PRESTRESS

When planning the expansion joint arrangement, please note that the

design of the pipe must must ensure that any necessary lateral prestress

should only be applied by means of pipe oset with tightly installed

expansion joint. Only slight lateral prestresses of 5 mm are possible in

the uninstalled condition. However, you must ensure that the rubber

bead is not pulled out of the groove of the steel lapped ange.

SAFETY MEASURES

Suitable measures should be taken to protect the pipes against excessive

overpressure, excessive temperature rise and uncontrolled vacuum.

Please refer to the technical data for the limit values for the relevant

settings.

MATING FLANGE

The mating ange must be designed and made as described in the

installation instructions, to ensure a safe and reliable seal and to protect

the rubber expansion joints.

In the case of expansion joints with rotatable anges, mating anges

with and without projection can be used in accordance with EN 1092-

1:2001 Form A or B. In the case of expansion joints with solid anges,

only smooth mating anges should be used.

Installation instructions

Heat pump

Rear panel of heat pump

Expansion joint

Pipe xed point













6 83015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

Product description:

Rubber expansion joint

Face-to-face dimension 130mm both sides with rotatable anges

AREA OF USE/FLUID QUALITY

For details of the uid (medium) quality required and use limits on the

heat source side and heating water side, please refer to the operating

manual for your heat pump.

Heat pump operating instructions

The expansion joints may not be used outdoors.

The rubber bellows must be protected from UV light. The expansion

joints are not suitable for underpressure (vacuum). Do not allow the

rubber bellows to come into contact with oil and grease. The same

ambient conditions apply as for storage.

“Storage”

SETUP:

Shallow-corrugated rubber bellows with support inserts and integral

sealing beads (therefore self-sealing, additional seals are not

required) for holding the rotatable anges.

CHARACTERISTIC DATA:

Allowable operating data:

bar °C

16 50

13 70

10 90

Dimensioned drawings

Datenblatt_Kompensatoren_Alpha_InnoTec_Kasendorf Seite 4 von 4

Anhang: Massdatenblatt für Pos2 (DN50) und Pos3 (DN65):

19.11.2012 – M. Artinger

CHARACTERISTIC DATA:

DN Bellows

BL Ø A Eective area

mm mm cm²

50 130 96 32

65 130 111 53

DN Flanges PN 16

Ø D Ø LK Ø d n s

mm mm mm

50 165 125 M 18 4 16

65 185 145 M 18 4 16

DN Expansion compensation

ax + ax - lat ± <° ±** Ø C

mm mm mm mm

50 30 30 30 35 74

65 30 30 30 35 86

ALLOWABLE UTILISATION OF THE MOVEMENT AREAS

up to 50°C utilisation ~ 100%

up to 70°C utilisation ~ 80%

up to 90°C utilisation ~ 70%

WEIGHTS:

DN kg

50 3.7

65 5.3

783015700aUK– Translation of the original operating manual – We reserve the right to make changes without notice.

Tightening torques (Nm) of the ange bolts

ASSEMBLY INSTRUCTION

Tools Torque wrench, rubber hammer, aligning punch.

Alltools burr-free (risk of damage to rubber parts).

USE FLANGE BOLTS WITH STRENGTH CLASS 8.8

(Bolts without after-treatment, lubricated)

step a) Insert all bolts and tighten uniformly by hand.

b) Apply step 1 torque cross-wise and uniformly in

approx. 3 passes. Check the gap width at the outer

edge of the ange.

c) Settling time >= 30 minutes

step d) Retighten all bolts cross-wise in 3 passes as given in

above table or 2/3 of the nal torque. Check the gap

width.

e) Settling time >= 60 minutes

III

step f) Apply the nal torque cross-wise in 2 passes.

NO FURTHER TIGHTENING!

Before the test pressure: Check the torque in 1 pass cross-wise with

nal value (step 3).

Tighten ange bolts only up to nal value (step 3).

FLANGE TIGHTENING TORQUE

The tightening torques given in the table for the ange bolts produce a

specic unit pressure of 7 N/mm2 (70 kp/cm2) based on the total area of

the expansion joint ange (use ange without sealing strip). Due to the

settling process over time in the rubber ange zone, under operating

conditions the unit pressure reduces to around 50 % of the applied nal

value (third step). The remaining eective gripping and sealing force is

absolutely sucient and is suitable for test pressures up to 16 bar.

(Tensile stresses from overexpansion are not allowed!)

Attention: The given maximum tightening torques may not be exceeded

signicantly, because under excessive compression the yielding in the

elastomer is progressive and results in irreparable damage (crushing).

TIGHTENING TORQUE:

Rough calculation of the nal torque for special anges.

RULE OF THUMB:

= 0.2 x FVM x d2

= tightening torque of the bolts

= thread anks Ø 1.4

= installation prestress force = *KA x FKL

= tightening factor ~ 1.4 lubricated, against a rm support

= empirical value = 1.0 chosen yielding in the rubber ange

= clamping force, contact force. 7 N/mm2 for total ange area



 

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  

  

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 

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  

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























  

  

  

  

  

  

 

 







 











 





 





 











 

 





 

 





 

 





 













π



   





Bolt tightening torques

DN Step 1 Step 2 Step 3

for all for all PN 16

Nm Nm

50 by hand 50 80

65 by hand 50 80

Made by Alpha-InnoTec GmbH

Alpha innotec expansion joints Owner's manual

Alpha innotec expansion joints Owner's manual

Alpha innotec expansion joints Owner's manual

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