Buy Viega 26505 MegaPress 3" 90-deg Carbon Steel Elbow w/FKM
Installation Manual Viega MegaPress® Systems Table of Contents Table of Contents IM-MP 724992 0120 MegaPress 1 About this Document ______________________________________ 6 1.1 Disclaimers____________________________________________ 6 1.2 Symbols Used _________________________________________ 7 1.3 Audience _____________________________________________ 7 1.4 About this Version ______________________________________ 7 2 Product Information _______________________________________ 8 2.1 MegaPress Systems ____________________________________ 8 2.2 Safety ________________________________________________ 8 2.3 Areas of Use __________________________________________ 8 2.3.1 MegaPress _____________________________________ 9 2.3.2 MegaPress FKM ________________________________ 9 2.3.3 MegaPressG __________________________________ 10 2.3.4 Fire Protection Systems _________________________ 11 2.3.5 Design Services ________________________________ 12 2.4 Standards and Regulations _____________________________ 12 2.4.1 Overview______________________________________ 12 2.4.2 Regulations: Applications ________________________ 12 2.4.3 Standards: Pipes _______________________________ 12 2.4.4 Standards: Sealing Elements _____________________ 12 2.4.5 Standards: Pipe Hangers ________________________ 13 2.4.6 Standards: Pressure Testing _____________________ 13 2.5 Listings and Certifications ______________________________ 13 2.6 Codes and Standards _________________________________ 14 2.7 Product Description ___________________________________ 14 2.7.1 Overview______________________________________ 14 2.7.2 Pipes_________________________________________ 15 2.7.2.1 Schedule 5 Pipe_________________________ 15 2.7.2.2 Schedule 10 Pipe________________________ 15 2.7.2.3 Schedule 40 Pipe________________________ 16 2.7.3 Press Fittings __________________________________ 16 2.7.3.1 Viega MegaPress ½" to 2" Fittings__________ 16 2.7.3.2 Viega MegaPress 2½" to 4" Fittings ________ 16 2.7.3.3 EPDM Sealing Element ___________________ 17 2.7.3.4 FKM Sealing Element ____________________ 17 2.7.3.5 HNBR Sealing Element ___________________ 17 2.7.3.6 Fitting Markings _________________________ 18 2.7.3.7 Viega Smart Connect Technology __________ 19 2.8 General Installation Requirements________________________ 19 2.8.1 Required Tools _________________________________ 19 2.8.2 Expansion_____________________________________ 20 2.8.3 Exposure to Freezing Temperatures _______________ 20 2.8.4 Underground Installations________________________ 20 2.8.5 Concealed Spaces _____________________________ 20 2.8.6 Electrical Bonding ______________________________ 21 3 of 46 Table of Contents Table of Contents, continued 2.8.7 Corrosion Protection ____________________________ 22 2.8.8 Deflection _____________________________________ 22 2.8.8.1 Controlling Deflection ____________________ 23 3 Handling Instructions _____________________________________ 24 3.1 Transport ____________________________________________ 24 3.2 Storage______________________________________________ 24 3.3 Pipe Preparation ______________________________________ 25 4 Installation Instructions ___________________________________ 26 4.1 Check System Components ____________________________ 26 4.2 Installing and Mounting the Pipe _________________________ 26 4.2.1 Pipe Hangers and Supports______________________ 26 4.2.2 Transition Fittings_______________________________ 28 4.2.2.1 Threaded Connections ___________________ 28 4.2.2.2 Flange Connections______________________ 28 4.2.3 No-Stop Couplings _____________________________ 28 4.3 Space Requirements and Intervals _______________________ 29 4.3.1 Minimum Distance Between Fittings _______________ 29 4.3.2 Minimum Space Requirements ___________________ 30 4.3.3 MegaPress Jaws Clearance Requirements _________ 30 4.3.4 MegaPress Rings Clearance Requirements _________ 31 4.3.5 Pressing with Ring and Actuator in Tight Quarters ___ 32 4.4 Welding _____________________________________________ 33 4.4.1 Welding Adjacent to a Fitting _____________________ 33 4.4.2 Welding In Line with a Fitting _____________________ 33 4.4.3 Welding Requirements __________________________ 33 4.5 Cutting the Pipe ______________________________________ 33 4.6 Deburring the Pipe ____________________________________ 34 4.7 Pressing the Fitting ____________________________________ 34 4.7.1 Viega MegaPress ½" to 2" Installation _____________ 35 4.7.2 Viega MegaPress 2½" to 4" Installation ____________ 38 4.8 Pressure Testing ______________________________________ 41 4.9 Disposal _____________________________________________ 41 5 Limited Warranty _________________________________________ 42 5.1 Limited Warranty for Viega MegaPress____________________ 42 5.2 Limited Warranty for Viega Metal Systems for Industrial Applications __________________________________________ 43 4 of 46 IM-MP 724992 0120 MegaPress Table of Contents List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Fluids and water approved for use with MegaPress systems __ 9 Gases approved for use with MegaPress systems __________ 9 Fluids and water approved for use with MegaPress FKM systems ______________________________________________ 9 Gases approved for use with MegaPress FKM systems _____ 10 Fuel, oil, and lubricant approved for use with MegaPress FKM systems _____________________________________________ 10 Fuel, oil, and lubricant approved for use with MegaPressG systems _____________________________________________ 10 Gases approved for use with MegaPressG systems ________ 10 Applications Regulations _______________________________ 12 Pipes Standards______________________________________ 12 Sealing Elements Standards ____________________________ 12 Mounting Standards __________________________________ 13 Pressure Testing Standards ____________________________ 13 Schedule 5 Pipe Sizing ________________________________ 15 Schedule 10 Pipe Sizing _______________________________ 15 Schedule 40 Pipe Sizing _______________________________ 16 Press Tools __________________________________________ 19 Pipe hanger spacing __________________________________ 27 Insertion depths for MegaPress no-stop couplings _________ 28 Insertion depths for MegaPress extended no-stop couplings 29 Minimum distance between press fittings _________________ 29 MegaPress distance requirements for press jaws between pipes and walls_______________________________________ 30 MegaPress standard jaws clearance requirements _________ 30 MegaPress compact jaws clearance requirements _________ 30 MegaPress standard jaws clearance requirements between pipe, wall, and floor ___________________________________ 31 MegaPress compact jaws clearance requirements between pipe, wall, and floor ___________________________________ 31 MegaPress rings dimensions ___________________________ 31 MegaPress rings with V2/V3 actuator clearance requirements_ 31 MegaPress rings with V2/V3 actuator clearance requirements between pipe, wall, and floor ____________________________ 32 Minimum insertion depths for MegaPress ½" to 2" _________ 35 Minimum insertion depths MegaPress 2½" to 4" ___________ 39 IM-MP 724992 0120 MegaPress 5 of 46 About this Document 1 About this Document 1.1 Disclaimers Viega products are designed to be installed by licensed and trained plumbing and mechanical professionals who are familiar with Viega products and their installation. Installation by non-professionals may void Viega LLC's warranty. This document is subject to updates. For the most current Viega technical literature please visit www.viega.us. MegaPress FKM 2½" to 4" formerly MegaPress XL 6 of 46 IM-MP 724992 0120 MegaPress About this Document 1.2 Symbols Used The following symbols may be used within this document: 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. Notes give additional helpful tips. 1.3 Audience The information in this manual is directed at plumbing and mechanical professionals and trained personnel. Individuals without the abovementioned training or qualification are not permitted to mount, install and, if required, maintain this product. 1.4 About this Version This installation manual 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 the United States and Canada. Some passages in the text may refer to technical codes in the United States and Canada. These should serve as recommendations in the absence of corresponding national regulations. The information herein is not binding for other countries and regions; and as mentioned above, should be understood as a recommendation. IM-MP 724992 0120 MegaPress 7 of 46 Product Information 2 Product Information 2.1 MegaPress Systems Viega MegaPress systems are state-of-the-art Iron Pipe Size (IPS) press fitting systems that provides an economical and reliable installation of schedule 5 to schedule 40 carbon steel pipes. The Viega MegaPress fitting system is offered in configurations that allow for the installation of the vast majority of carbon steel piping applications in the residential, commercial, and industrial markets. MegaPress fittings may be used with seamless (S) or longitudinal welded (W) steel pipes. Viega MegaPress fittings and valves are constructed of carbon steel with a corrosion-resistant zinc/nickel coating ranging from ½ inch to 4 inches. MegaPress fittings feature a green dot with an EPDM sealing element while MegaPress FKM fittings have a white dot with an FKM sealing element. MegaPressG fittings feature a yellow dot with an HNBR sealing element. All use Viega's unique, patented Smart Connect® technology to help installers ensure that they have pressed all connections. The Viega MegaPress fitting system requires no welding, soldering, brazing, or threading and poses no fire hazard, which is particularly important in restoration or retrofit work. The fittings are installed with electro-hydraulic press tools (battery-powered or corded press tools). 2.2 Safety Please read and understand the instructions before beginning installation to eliminate safety concerns and reduce risks associated with use and handling of Viega products. 2.3 Areas of Use The system is intended for use in industrial, heating and cooling systems and is a replacement for welded, threaded, and rolled-groove connection in new installations and repairs. The system is not suitable for use in potable water installations. 8 of 46 IM-MP 724992 0120 MegaPress Product Information 2.3.1 MegaPress 2.3.2 MegaPress FKM Type of Service Comments Pressure Fire sprinklers NFPA 13, 13D, 13R 175 psi Chilled water Ethylene glycol / propylene glycol 200 psi Hydronic heating Ethylene glycol / propylene glycol 200 psi Cooling water Up to 50% ethylene glycol or propylene glycol solution 200 psi Low-pressure steam Max 15 psi Isopropyl Alcohol 200 psi Table 1: Fluids and water approved for use with MegaPress systems Temperature Ambient 0° to 250°F 0° to 250°F 0° to 250°F Max 250°F Ambient Type of Service Compressed Air Comments Pressure Temperature Less than 25mg/m3 oil content 200 psi Max 140°F Oxygen medical) O2 (non- Nitrogen - N2 Carbon Dioxide CO2 Acetylene Keep oil and fat free / non-liquid O2 140 psi 200 psi 200 psi 20 psi Max 140°F Max 140°F Max 140°F Ambient Argon Welding Use 200 psi Max 140°F Vacuum 29.2" of Hg Max 140°F Table 2: Gases approved for use with MegaPress systems Type of Service Comments Pressure Temperature Fire sprinklers NFPA 13, 13D, 13R 175 psi Ambient Chilled water Ethylene glycol / propylene glycol 200 psi 14° to 284°F Hydronic heating Ethylene glycol / propylene glycol 200 psi 14° to 284°F Cooling water Up to 50% ethylene glycol or propylene glycol solution 200 psi 14° to 284°F Low-pressure steam Max 15 psi Max 250°F Isopropyl Alcohol 200 psi Ambient Table 3: Fluids and water approved for use with MegaPress FKM systems IM-MP 724992 0120 MegaPress 9 of 46 Product Information 2.3.3 MegaPressG 10 of 46 Type of Service Compressed air Compressed air Oxygen - O2 (non-medical) Nitrogen - N2 Acetylene Argon Vacuum Comments Oil concentrate < 25 mg/m3 Oil concentrate > 25 mg/m3 Keep oil and fat free / nonliquid O2 Welding use Pressure 200 psi 200 psi 140 psi 200 psi 20 psi 200 psi 29.2" of Hg Table 4: Gases approved for use with MegaPress FKM systems Temperature Max 140°F Max 140°F Max 140°F Max 140°F Ambient Max 140°F 0° to 160°F Type of Service Heating Fuel Oil Lube Oil Mineral Oil Comments Petroleum Based Pressure 125 psi 200 psi 200 psi Temperature Max 100°F Max 150°F Ambient Table 5: Fuel, oil, and lubricant approved for use with MegaPress FKM systems The MegaPressG system is intended for use in natural gas, lubricants/oils, fuel oils, and compressed air systems and is a replacement for welded, threaded, and rolled-groove connection in new installations and repairs. The system is not suitable for use in potable water installations. MegaPressG fittings are for use with fuel gases and are intended for the operating pressure 0-125 psi. Type of Service Heating Fuel Oil Diesel Fuel Propane Butane Kerosene Natural Gas Lube Oil Mineral Oil Comments Compliant with CSA LC4 Compliant with CSA LC4 Compliant with CSA LC4 Petroleum Based Pressure 125 psi 125 psi 125 psi 125 psi 125 psi 125 psi 200 psi 200 psi Temperature Max 100°F Max 100°F -40°F to 180°F -40°F to 180°F Max 68°F -40°F to 180°F Max 150°F Ambient Table 6: Fuel, oil, and lubricant approved for use with MegaPressG systems Type of Service Compressed air Compressed air Oxygen - O2 (non-medical) Nitrogen - N2 Carbon dioxide - CO2 Acetylene Argon Vacuum Comments Oil concentrate < 25 mg/m3 Oil concentrate > 25 mg/m3 Keep oil and fat free / non-liquid O2 Welding use Pressure 200 psi 200 psi 140 psi 200 psi 200 psi 20 psi 200 psi 29.2" of Hg Table 7: Gases approved for use with MegaPressG systems Temperature Max 140°F Max 140°F Max 140°F Max 140°F Max 140°F Ambient Max 140°F 0° to 160°F IM-MP 724992 0120 MegaPress Product Information MegaPressG: The installation, inspection, testing, and purging of the fuel gas system shall be in accordance with local codes or, in the absence of local codes, in accordance with the International Fuel Gas Code, NFPA 54/National Fuel Gas Code z223.1, the Uniform Plumbing Code, NFPA 58, or CSA B 149.1, as applicable. CAUTION! MegaPressG fittings are for use with fuel gases and are intended for operating pressures of 0-125 psi. It is recommended that all systems be clearly labeled with the fluid or gas being conveyed. In the absence of local requirements, systems should be identified in accordance with ANSI/ASME A13.1. The use of the system for applications other than those listed or outside of these parameters must be approved by the Viega Technical Services Department. 2.3.4 Fire Protection Systems MegaPress system components may be installed in NFPA 13, 13R, and 13D fire sprinkler systems. They are certified for use in "wet" and "dry" fire protection systems in accordance with UL and FM certifications: UL/ANSI 213: Standard for Rubber Gasketed Fittings for Fire- Protection Services. ULC ORD-C213: Canadian Standard for Rubber Gasketed Fittings for Fire-Protection Services. FM Class 1920: Pipe Couplings and Fittings for Aboveground Fire Protection Systems. Permitted pressure: 175psi Pipe wall thickness: Schedule 5 to Schedule 40 Area of use (pipeline network): Wet sprinkler units: Piping network downstream of the alarm valve station Dry sprinkler units: Piping network downstream of the alarm valve station Firefighting water additive: Generally not permitted; exceptions only with the manufacturer's permission and prior agreement of Viega Technical Support. Only black, galvanized, or powder-coated steel pipes may be used in sprinkler systems in accordance to the approved specifications from Viega Technical Support. IM-MP 724992 0120 MegaPress 11 of 46 Product Information 2.3.5 Design Services Consult Viega's Technical Services Department for information on applications not listed or applications outside listed temperature and pressure ranges. Viega Technical Services Department: Techsupport@viega.us Design Service: For more information on fire protection system design, radiant system design, and plumbing design services: Design@viega.us 2.4 Standards and Regulations 2.4.1 Overview The following standards and regulations apply to the United States and Canada and are provided as a support feature. 2.4.2 Regulations: Applications 2.4.3 Standards: Pipes Scope / Notice Application for fuel gases Application in fire extinguishing systems Hydronic heating and cooling Regulations Applicable in U.S./Canada MegaPressG only - CSA LC-4 NFPA 13, 13D, and 13R ICC LC1002 Table 8: Applications Regulations Standard Definition ASTM A53 Standard specifications for steel, black and hot dipped, zinccoated, welded, or seamless pipe ASTM A106 Standard specification for seamless carbon steel pipe for high-temperature service ASTM A135 Standard specification for electric-resistance-welded steel pipe ASTM A795 Standard specification for black and hot-dipped zinc-coated (galvanized) welded and seamless steel pipe for fire protection ASME B36.10 Welded and seamless wrought steel pipe Table 9: Pipes Standards 2.4.4 Standards: Sealing Elements Standard Definition ASTM D2000 Classification system for rubber products in automotive applications ASTM F1476 Performance of gasketed mechanical couplings for use in piping applications Table 10: Sealing Elements Standards 12 of 46 IM-MP 724992 0120 MegaPress Product Information 2.4.5 Standards: Pipe Hangers Standard Definition MSS SP 58 Pipe hangers and supports materials, design, and manufacturer Table 11: Mounting Standards 2.4.6 Standards: Pressure Testing Standard Definition ASME B31 Pressure piping IAPMO PS 117 Press and nail connections ASTM F3226 Standard specification for metallic press-connect fittings for piping and tubing systems IACS Requirements concerning pipes and pressure vessels Table 12: Pressure Testing Standards 2.5 Listings and Certifications MegaPress, MegaPress FKM, and MegaPress G fittings have the following listings and certifications: ABS: American Bureau of Shipping Type Approval ASME B31.1: Power Piping ASME B31.3: Process Piping ASME B31.9: Building Service Piping BV: Bureau Veritas Type Approval Canadian Registration Number (CRN): 0A14541.5 A/B/C DNV GL: Det Norske Veritas Germanischer Lloyd Type Approval LR: Lloyd's Register Type Approval NKK: Nippon Kaija Kyokai Type Approval MegaPress and MegaPress FKM fittings have the following listings and certifications: FM Class 1920: Pipe Couplings and Fittings for Aboveground Fire Protection Systems IAPMO PS-117: Press and Nail Connections ICC-ES LC1002: Press-Connection Fittings for Potable Water Tube and Radian Heating Systems NFPA 13: Standard for the Installation of Sprinkler Systems NFPA 13D: Standard for the Installation of Sprinkler Systems in One- and Two-Family Dwellings and Manufactured Homes NFPA 13R: Standard for the Installation of Sprinkler Systems in Low- Rise Residential Occupancies UL/ANSI 213: Standard for Rubber Gasketed Fittings for Fire-Protection Service ULC/ANSI ORD-C213: Canadian Standard for Rubber Gasketed Fittings for Fire-Protection Service IM-MP 724992 0120 MegaPress 13 of 46 Product Information MegaPressG fittings have the following listings and certifications: CSA: ANSI LC 4a/CSA 6.32a: Press-Connect Metallic Fittings for Use in Fuel Gas Distribution Systems IAPMO: ANSI LC 4a/CSA 6.32a: Press-Connect Metallic Fittings for Use in Fuel Gas Distribution Systems ICC-ES: ANSI LC 4a/CSA 6.32a: Press-Connect Metallic Fittings for Use in Fuel Gas Distribution Systems 2.6 Codes and Standards 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. MegaPress, MegaPress FKM, and MegaPressG fittings comply with the following codes and standards: ASME B31: Code for Pressure Piping IAPMO Uniform Mechanical Code (UMC) ICC International Mechanical Code (IMC) ICC International Residential Code (IRC) National Building Code of Canada (NBCC) National Plumbing Code of Canada (NPCC) MegaPressG fittings comply with the following codes and standards: CAN/CSA-B149.1: Natural Gas and Propane Installation Code IAPMO National Standard Plumbing Code (NSPC) IAPMO Uniform Plumbing Code (UPC) ICC International Fuel Gas Code (IFGC) NFPA 54/Z223: National Fuel Gas Code NFPA 58: Liquefied Petroleum Gas Code 2.7 Product Description 2.7.1 Overview The MegaPress system consists of press connectors for heavy steel pipes and the corresponding press tools. MegaPress press jaws, actuator, and rings are available for various dimensions. Their constant compression produces a positive, nondetachable, mechanical joint. The system components are available in the following dimensions: ½", ¾", 1", 1¼", 1½", 2", 2½", 3", 4". 14 of 46 IM-MP 724992 0120 MegaPress Product Information 2.7.2 Pipes 2.7.2.1 Schedule 5 Pipe 2.7.2.2 Schedule 10 Pipe IM-MP 724992 0120 MegaPress MegaPress connectors may be used with the following seamless or longitudinal welded steel pipes: Black Galvanized (non-potable applications) Industrially painted Powder coated Viega MegaPress systems are compatible with ASTM A53, A135, A106, and A795 Schedule 5 to Schedule 40 carbon steel pipe. Viega MegaPressG fittings for fuel gas or fuel oil systems shall be used with ASTM A53 schedule 40 carbon steel pipe. If the pipe has been coated, the maximum external diameter listed in the tables on the next page must not be exceeded. Pipe Size (inches) ½ ¾ 1 1¼ 1½ 2 2½ 3 4 Outside diameter (inches) 0.84 1.05 1.32 1.66 1.9 2.375 2.875 3.5 4.5 Table 13: Schedule 5 Pipe Sizing Outside diameter (mm) 21.3 26.7 33.4 42.2 48.3 60.3 73.0 88.9 114.3 Wall thickness Wall thickness (inches) (mm) 0.065 1.65 0.065 1.65 0.065 1.65 0.065 1.65 0.065 1.65 0.065 1.65 0.083 2.11 0.083 2.11 0.083 2.11 Pipe Size (inches) ½ ¾ 1 1¼ 1½ 2 2½ 3 4 Outside diameter (inches) 0.84 1.05 1.32 1.66 1.9 2.375 2.875 3.5 4.5 Table 14: Schedule 10 Pipe Sizing Outside diameter (mm) 21.3 26.7 33.4 42.2 48.3 60.3 73.0 88.9 114.3 Wall thickness Wall thickness (inches) (mm) 0.083 2.11 0.083 2.11 0.109 2.77 0.109 2.77 0.109 2.77 0.109 2.77 0.12 3.05 0.12 3.05 0.12 3.05 15 of 46 Product Information 2.7.2.3 Schedule 40 Pipe Pipe Size (inches) ½ ¾ 1 1¼ 1½ 2 2½ 3 4 Outside diameter (inches) 0.84 1.05 1.32 1.66 1.9 2.375 2.875 3.5 4.5 Table 15: Schedule 40 Pipe Sizing Outside diameter (mm) 21.3 26.7 33.4 42.2 48.3 60.3 73.0 88.9 114.3 Wall thickness Wall thickness (inches) (mm) 0.109 2.77 0.113 2.87 0.133 3.38 0.14 3.56 0.145 3.68 0.154 3.91 0.203 5.16 0.216 5.49 0.237 6.02 2.7.3 Press Fittings Press fittings are available in a number of configurations and sizes. An overview of the press fittings suitable for a system can be found in the catalog. 2.7.3.1 Viega MegaPress ½" to 2" Fittings 1 Each fitting contains an application specific sealing element. 2 The 304 stainless steel separator ring ensures that the sealing element and grip ring perform at maximum capacity by providing a positive physical separation. 3 The grip ring is a 420 stainless steel ring with bidirectional teeth that grip the pipe and ensure that the fitting is locked securely to the piping. 2.7.3.2 Viega MegaPress 2½" to 4" Fittings 1 The 420 stainless steel grip ring's teeth cut into the pipe and lock the fitting securely in place. 2 A PBT (Polybutylene Terephthalate) separator ring for MegaPress and MegaPress FKM fittings and a graphite separator ring for MegaPressG fittings protects the sealing element from damage by creating a positive physical separation during installation and later during pressing. 3 The sealing element ensures water-tight or air-tight connections. 16 of 46 IM-MP 724992 0120 MegaPress Product Information 2.7.3.3 EPDM Sealing Element 2.7.3.4 FKM Sealing Element 2.7.3.5 HNBR Sealing Element IM-MP 724992 0120 MegaPress Viega MegaPress fittings are manufactured with a high-quality, shiny black EPDM (Ethylene Propylene Diene Monomer) sealing element installed at the factory. The molded sealing lips also seal pipe surfaces with slightly uneven surfaces. Sealing elements are inserted into the fitting using a H1 food grade lubricant registered with NSF and the USDA, and is approved for use under FDA 21 CFR. The EPDM sealing element possesses excellent resistance to aging, ozone, sunlight, weathering, environmental influences, and most alkaline solutions and chemicals used in a broad range of applications. The operating temperature of the EPDM sealing element is 0° to 250°F (-18° to 120°C). Viega MegaPress FKM fittings are manufactured with a high-quality, dull black FKM (Fluoroelastomer) sealing element installed at the factory. The molded sealing lips also seal pipe surfaces with slightly uneven surfaces. Sealing elements are inserted into the fitting using a H1 food grade lubricant registered with NSF and the USDA, and is approved for use under FDA 21 CFR. FKM possesses excellent resistance to aging, ozone, sunlight, weathering, environmental influences, and oils and petroleum-based additives. Its superb resistance to high temperatures and petroleum based additives makes it ideal for seals and gaskets in solar, district heating, low-pressure steam, and compressed air system fittings. The operating temperature of the FKM sealing element is 14° to 284°F (-10° to 140°C). It can withstand heat spikes up to 356°F. Viega MegaPressG fittings are manufactured with a yellow HNBR (Hydrogenated Nitrile Butadiene Rubber) sealing element installed at the factory. HNBR is widely known for its physical strength and retention of properties after long-term exposure to heat, oil, and chemicals. The molded sealing lips also seal pipe surfaces with slightly uneven surfaces. The unique properties attributed to HNBR have resulted in wide adoption of HNBR in automotive, industrial, and assorted high-performance applications. Sealing elements are inserted into the fitting using a H1 food grade lubricant registered with NSF and the USDA, and is approved for use under FDA 21 CFR. The operating temperature of the HNBR sealing element is -40°F to 180°F (-40°C to 82°C). 17 of 46 Product Information 2.7.3.6 Fitting Markings QGWEXRYMANY UMC® viega XX STD S58 2(8&93:."/: WJFHB 99 45%4 61$ Each MegaPress fitting is marked with the following: Green dot: EPDM sealing element and Smart Connect technology Size of fitting Manufacturer name Manufacturer date code Country of origin UMC® UL® FM STD S58 Each MegaPress FKM fitting is marked with the following: White dot: FKM sealing element and Smart Connect technology Size of fitting Manufacturer name Manufacturer date code Country of origin UMC® UL® FM STD S58 Each MegaPressG fitting is marked with the following: Yellow dot: HNBR sealing element and Smart Connect technology Yellow rectangle: identifies Viega MegaPressG fitting as a certified gas or fuel oil fitting Size of fitting Manufacturer name Manufacturer date code Country of origin UPC® CSA: indicates certification to ANSI/CSA LC4 125G: identifies the CSA maximum pressure rating of the fitting for fuel oil or gas applications 18 of 46 IM-MP 724992 0120 MegaPress Product Information 2.7.3.7 Viega Smart Connect Technology 1Identify an unpressed connection during pressure testing when water flows past the sealing element. Viega Smart Connect technology provides the installer quick and easy identification of an unpressed fitting during a leak test. When the fitting is pressed, a secure, non-detachable, mechanical connection is created. Smart Connect technology provides the installer with an easy way to see connections that have not been pressed before putting the system into operation. 2Upon identification, use the press tool to press the fitting, making a secure leak-proof connection. Testing for leaks using Viega Smart Connect is not a replacement for testing requirements of local codes and standards. If testing with compressed air, it is necessary to use an approved leak-detect solution. 3 Viega MegaPress connections are fast, flameless, and reliable. 2.8 General Installation Requirements 2.8.1 Required Tools The Viega MegaPress fitting system must be installed while considering the following general industry requirements. The following tools are required for making a press connection: Pipe cutter or a fine-toothed hacksaw Deburring tool Marker for marking insertion depth on pipe Press machine with constant pressing force Press jaw or press ring with corresponding actuator suitable for the pipe diameter and with the proper profile Improper Tool/Material Damage Only use press jaws and rings that are designed for use with MegaPress fittings. IM-MP 724992 0120 MegaPress Press Tool Models Press Jaw Models Press Ring Models Standard RIDGID RP330 RIDGID RP340 Milwaukee M18 Compact RIDGID RP240 RIDGID RP241 XL Use standard tools 37958 - ½" MegaPress jaw 37963 - ¾" MegaPress jaw 37968 - 1" MegaPress jaw 48433 - ½" Compact MegaPress jaw 48438 - ¾" Compact MegaPress jaw 60658 - MegaPress XL PressBooster 21878 - V2 Press Ring Actuator 37973 - 1¼" MegaPress Ring 37978 - 1½" MegaPress Ring 37983 - 2" MegaPress Ring 60643 - 2½" MegaPress ring 60648 - 3" MegaPress ring 60653 - 4" MegaPress ring Table 16: Press Tools 19 of 46 Product Information 2.8.2 Expansion Pipelines expand with heat. Heat expansion is dependent on the material. Thermal expansion in installed systems generates stress on pipes and appliance connectors. Compensation must be allowed for expansion and contraction that may occur within the piping system. Expansion joints or mechanical expansion compensators may be used to alleviate these stresses. The following methods are effective: Fixed and sliding hangers Expansion equalization joints (expansion bends) Expansion compensators 2.8.3 Exposure to Freezing Temperatures Viega MegaPress systems with EPDM sealing elements can be installed in ambient temperatures down to 0° F. Viega MegaPress FKM systems with FKM sealing elements can be installed in ambient temperatures down to 14°F. The HNBR sealing element available with Viega MegaPressG fittings can be installed in ambient temperatures down to -40°F. Piping systems exposed to freezing temperatures must be protected per acceptable engineering practices, codes, and as required by the local authority. 2.8.4 Underground Installations Viega MegaPress fitting systems are all approved for underground installations. However, installations must meet all state and local codes, including those for underground. Proper authorization must be obtained prior to installation from the local authority. 2.8.5 Concealed Spaces The Viega MegaPress fitting system has been approved for use in concealed spaces. Specific performance tests were conducted to evaluate the fittings for use in concealed spaces. Concealed tubing and fittings shall be protected from puncture threats. The Viega MegaPressG fitting system has been examined according to the construction and performance criteria in the CSA requirement LC-4 and was found acceptable. Specific performance tests were conducted to evaluate the fittings for use in concealed locations. 20 of 46 IM-MP 724992 0120 MegaPress Product Information 2.8.6 Electrical Bonding When properly installed, MegaPress fittings comply with Section 1211.15 Electrical Bonding and Grounding of the Uniform Plumbing Code. The mechanical press provides continuous metal-to-metal contact between fitting and pipe. The press ensures the continuity of the bonding through this contact. A qualified electrician is responsible for ensuring electrical bonding is tested and secured. DANGER! Electric Shock An electric shock can cause burns, serious injury, and even death. Because all metallic piping can conduct electricity, unintentional contact with a live wire can lead to the entire system and components connected to it to become energized. Metal piping is not meant to conduct electricity. A properly bonded system creates a safe path for electricity to travel so that the system can't be energized. An unbonded or improperly bonded system can be a shock hazard. Always ensure bonding is in accordance with local codes. CAUTION! Potential explosive hazard MegaPressG The fuel gas system shall not be used as a grounding electrode for an electrical system. CAUTION! Pressure and electrical grounding The fittings are for use with fuel gases and are intended for the operating pressure 0-125 psi. The fuel gas system shall not be used as a grounding electrode for an electrical system. IM-MP 724992 0120 MegaPress 21 of 46 Product Information 2.8.7 Corrosion Protection 2.8.8 Deflection Viega MegaPress fittings exposed to corrosive action, such as soil conditions or moisture, must be protected in an approved manner in accordance with NFPA 54 Section 404.8, NACE Standard RP0169-2002 Section 5, 2009 UPC Chapter 6 Section 609.3.1, 2009 UMC Chapter 13 Section 1312.1.3, or satisfying local code requirements. Care should be taken to select hangers of suitable material that is galvanically compatible with the piping system. In addition, systems should be properly sized to minimize the risk of erosion corrosion resulting from excessive velocities. In some cases the local authority may require pipe and fittings to be painted. Installers should use caution to prevent saturating the fittings with paint and take care to not allow excess paint to accumulate on the fitting hub. Failure to use caution could result in a premature failure. The pressing process can cause deflection (angular misalignment) to occur. When pressing Viega MegaPress fittings in a system, the deformation of the fitting is constant. This allows for a consistent leak-free joint every time and is a result of the pressing technique. Deflection occurs in the same way for every fitting. The fitting being pressed will move in the direction of the jaw or ring opening. Since the fitting will deflect toward the opening of the jaw or ring, the pipe end will deflect in the opposite direction. By counteracting the fitting movement, one can minimize the deflection of the fitting and ultimately the pipe. When using strut and clamps, deflection is minimized and nearly eliminated depending on clamp spacing. 22 of 46 IM-MP 724992 0120 MegaPress Product Information 2.8.8.1 Controlling Deflection Deflection while pressing can be minimized by utilizing the following installation practices. Alternate sides for presses Press one end of fitting. Make second press on other end of fitting from the opposite side. Site conditions permitting. Push-pull method Rings = Push on press tool. Jaws = Pull on press tool. The press tool can be feathered using the trigger as needed to apply pulling or pushing force to control deflection. Re-Press Press the fitting, once on each side (that is, re-press the fitting a second time on the opposite side). Pressing the same connection from the opposite side will usually straighten misalignment between the pipe and fitting. When pressing overhead piping, it may be inconvenient to alternate sides for each press. The natural weight of the piping plus pressing on opposite sides at a 45 degree angle should adequately eliminate deflection. This technique can also be used for any horizontal piping and also when working above the piping. IM-MP 724992 0120 MegaPress As long as the pipe is properly prepped and marked and the fitting is installed according to Viega's MegaPress Product Instructions, if there is any deflection present after the installation of the fitting, the connection is still acceptable and meets Viega's manufacturing specifications for proper installation and warranty. Deflection of a press connection has no effect on the integrity of the system, and it can be pressure tested in accordance with the MegaPress Product Instructions. 23 of 46 Handling Instructions 3 Handling Instructions 3.1 Transport 3.2 Storage All Viega MegaPress components and associated pipe shall be free from dirt, debris, or items that may interfere with the sealing element and the press connection. Viega MegaPress sealing elements, separator rings, and grip rings are to be visually inspected prior to installation to ensure the seal is intact and properly located within the fitting. Viega MegaPress sealing elements, separator rings, and grip rings are not interchangeable between the different MegaPress systems. When transporting fittings: Do not pull or drag the fittings or system components along other surfaces. Secure fittings, piping, and system components during transportation to keep them from shifting. Do not damage the protective cap on components or pipe ends. Do not remove protective caps until immediately before installing. When storing materials: Store fittings, pipe, and system components in a clean and dry place. Do not store components directly on the floor. Provide at least three points of support for the storage of piping. Where possible, store different sizes separately. Store small sizes on top of larger sizes if separate storage is not possible. Store fittings, pipe, and system components of different materials separately to prevent contact corrosion. 24 of 46 IM-MP 724992 0120 MegaPress Handling Instructions 3.3 Pipe Preparation Description Different kinds of Prep necessary Surface after Comments pipe surface Yes / No prepping Clean, bare pipe If the pipe has no lacquer and there is No no rust on the surface and the surface is smooth, no preparing is necessary. Galvanized steel pipe If the surface of the galvanized pipe is Yes uneven, then the pipe surface must be smoothed. Pipe with black shellac or lacquer If the pipe is coated with black shellac or Yes lacquer the coating has to be smoothed. It is not necessary to completely remove the coating. Pipe with rust Epoxy coating Cataphoretic paint (KTL) If the pipe has no lacquer and there is a Yes rust film on the surface, the surface has to be prepped until the rust film is removed and the pipe surface is smooth. The epoxy coating must be reduced to allow the pipe to be inserted into the fitting. No If the pipe has been coated, the maximum external diameter must not exceed the limit in the Insertion Depth table. If the pipe is cataphoretic painted (KTL) and the surface is smooth, it is not No necessary to prep the pipe. If there are scratches on the KTL, the surface has to be smoothed. Pipe surfaces for each type of pipe must be smooth, free of indentations (even and undamaged), pits, and deformations and must be clean and free of dirt, debris, rust, scale, oil, and grease. It is not necessary to completely remove protective coatings or to expose the bare steel material. To avoid leak paths, engraved or stamped pipe shall not be used with the Viega MegaPress fitting system. Engraving or stamping shall not be removed through use of a grinder or other tool. In systems where complete corrosion protection is required (e.g., cooling systems), apply suitable corrosion protection to the previously processed pipe surfaces that are still uncovered after pressing. The Viega MegaPress system does not require lubrication of the pipe or the fitting. IM-MP 724992 0120 MegaPress 25 of 46 Installation Instructions 4 Installation Instructions 4.1 Check System Components System components may, in some cases, become damaged through transportation and storage. Check all parts. Replace damaged components. Do not repair damaged components. Contaminated components may not be installed. 4.2 Installing and Mounting the Pipe Observe the general rules of hanging and mounting: Fixed piping should not be used as support for other piping and components. Do not use pipe hooks. Observe distance between fittings and mounting points. Observe the expansion direction plan fixed and sliding mounts. 4.2.1 Pipe Hangers and Supports Piping supports perform two functions: To provide support for the piping. To guide the pipe during thermal expansion and contraction. Fittings must not be used as support System malfunction may result from additional stress and strain put on the fitting. At no point in the system should a fitting be the sole means of support. For example, when installing a tee, both the branch and the trunk must be properly supported. 26 of 46 IM-MP 724992 0120 MegaPress Installation Instructions Industry standard practices and guidelines shall be used for pipe layout and support. Supports, hangers, and anchors are to be installed in a manner that does not interfere with the free expansion and contraction of the piping. All parts of the support equipment need to be designed and installed to not disengage due to movement of the supported piping. Sliding hangers must be positioned so that they cannot unintentionally become rigid hangers when the system is in use. Do not use fixed pipelines as a support for other pipelines and components. Do not use pipe hooks. Observe the expansion direction: plan fixed and gliding points. Hangers and supports must conform to the local code requirements. In the absence of local code requirements, hangers and supports should conform to ANSI/MSS SP 58 Pipe Hangers and Supports - Materials, Design, Manufacture, Selection, Application and Installation. Only pipe clamps with chloride-free noise insulation inlays should be used to secure the pipes. Pipe Size (inches) Maximum Span (feet) ½ ¾ 1 7 1¼ 1½ 9 2 10 2½ 11 3 12 4 14 Table 17: Pipe hanger spacing Minimum Rod Diameter (inches) ½ ½ ½ IM-MP 724992 0120 MegaPress 27 of 46 Installation Instructions 4.2.2 Transition Fittings 4.2.2.1 Threaded Connections 4.2.2.2 Flange Connections 4.2.3 No-Stop Couplings The Viega MegaPress systems can be joined with off-the-shelf threaded fittings. In this regard: The threaded connection is made first. The press connection is made second. This process avoids unnecessary torsion on the press fitting. When using Viega flanges, bolt the flange end in place prior to pressing the fitting to the pipe. No-stop couplings and extended no-stop couplings are often used to conduct repairs. Without a stop, these couplings can slide completely onto a pipe and allow a connection to be made in tighter spaces. Unlike fittings with an integrated stop that have a minimum insertion depth, no-stop couplings have minimum and maximum allowable insertion depths. Both the minimum and the maximum insertion depths must be marked and a line connecting the two marks. Drawing a line between the minimum and maximum insertion marks distinguishes a good connection on a no-stop fitting from a bad connection on a fitting with a stop. Pipe Diameter (inches) ½ ¾ 1 1¼ 1½ Minimum Insertion Depth (inches) 11/16 13/16 1 113/16 1 Minimum Insertion Depth (mm) 27 29 34 46 48 Maximum Insertion Depth (inches) 1 113/16 115/16 2½ 2¾ 2 2 50 2¾ 2½ 113/16 46 3 3 25/16 59 311/16 4 3 80 4 Table 18: Insertion depths for MegaPress no-stop couplings Maximum Insertion Depth (mm) 41 46 49 63 70 70 79 93 120 28 of 46 IM-MP 724992 0120 MegaPress Installation Instructions Pipe Minimum Diameter Insertion (inches) Depth (inches) Minimum Insertion Depth (mm) Maximum Insertion Depth (inches) Maximum Insertion Depth (mm) ½ 11/16 27 2¾ 70 ¾ 13/16 29 213/16 72 1 1 34 3 77 1¼ 113/16 46 3½ 89 1½ 1 48 39/16 91 2 2 50 311/16 93 Table 19: Insertion depths for MegaPress extended no-stop couplings 4.3 Space Requirements and Intervals Not enough space The connection may leak and/or ring/press gun may not fit around the fitting. Adhere to minimum space requirements. Make sure that the space required for pressing tools is available if fittings will be pressed immediately upstream or downstream from wall or ceiling penetrations. Take the minimum required distances into consideration during the planning phase of the project whenever possible. 4.3.1 Minimum Distance Between Fittings To ensure a correct press, a minimum distance between press fittings must be maintained. Failure to provide this distance may result in an improper seal. minimum distance Pipe Diameter (inches) A minimum (inches) ½ ¾ ¼ 1 1¼ 1½ 2 2½ ½ 3 4 Table 20: Minimum distance between press fittings A minimum (mm) 6 13 IM-MP 724992 0120 MegaPress 29 of 46 Installation Instructions 4.3.2 Minimum Space Requirements Ensure that the space required for Viega system pressing tools is available if press fittings will be executed immediately upstream and downstream from wall or ceiling penetrations. Pipe Size (inches) Minimum space requirement, amin for press tools (inches) RIDGID RP241, RP320, RP330, RP340, and CT400 Press Tools Milwaukee M18 Press Tools ½ to 1 1½ 1¼ to 2 2½ to 4 Table 21: MegaPress distance requirements for press jaws between pipes and walls 4.3.3 MegaPress Jaws Clearance Requirements The minimum distance between pipe, or the pipe and the wall/ceiling construction, must be taken into consideration in the planning phase for a problem free work process. The following illustrate the clearance requirements for the jaws and fittings and the procedure for pressing fittings in tight quarters. Pipe installed too closely together Connection may leak Adhere to minimum intervals between fittings. Insert pipe to full insertion depth before pressing. Pipe Diameter A minimum A minimum B minimum (inches) (inches) (mm) (inches) ½ 1 26 2 ¾ 1¼ 32 3 1 1¾ 45 3 Table 22: MegaPress standard jaws clearance requirements B minimum (mm) 67 79 92 Pipe Diameter A minimum A minimum B minimum (inches) (inches) (mm) (inches) ½ 1¼ 32 2 ¾ 1 29 3 Table 23: MegaPress compact jaws clearance requirements B minimum (mm) 73 76 30 of 46 IM-MP 724992 0120 MegaPress Installation Instructions Pipe Diameter (inches) ½ ¾ 1 A minimum (inches) 1¼ 1½ 2 A minimum (mm) 32 38 51 B minimum (inches) 1 2 2½ B minimum (mm) 48 54 64 C minimum (inches) 3 3½ 4 C minimum (mm) 76 89 101 Table 24: MegaPress standard jaws clearance requirements between pipe, wall, and floor Pipe Diameter (inches) A minimum (inches) A minimum (mm) B minimum (inches) B minimum (mm) C minimum (inches) C minimum (mm) ½ 1½ 38 2 54 3 79 ¾ 1 35 2 54 3 86 Table 25: MegaPress compact jaws clearance requirements between pipe, wall, and floor 4.3.4 MegaPress Rings Clearance Requirements Ensure that the space required for system pressing tools is available if Viega MegaPress fittings will be installed immediately upstream or downstream from ceiling penetrations. Pipe Diameter (inches) A minimum (inches) A minimum (mm) B minimum (inches) 1¼ 6 152 6¼ 1½ 6 152 6¾ 2 6 152 6 2½ 5 168 7 3 7½ 190 8 4 8½ 214 10 Table 26: MegaPress rings dimensions B minimum (mm) 159 171 175 194 225 270 C minimum (inches) 2½ 2 2½ 2½ 2½ 2 C minimum (mm) 64 67 64 64 64 67 Pipe Diameter (inches) A minimum (inches) A minimum (mm) B minimum (inches) B minimum (mm) 1¼ 3¾ 95 4 124 1½ 4 102 5 130 2 4 102 5 137 2½ 4½ 115 5 150 3 4¾ 120 6¾ 170 4 5 135 8¼ 210 Table 27: MegaPress rings with V2/V3 actuator clearance requirements IM-MP 724992 0120 MegaPress 31 of 46 Installation Instructions Pipe Diameter (inches) A minimum (inches) A minimum (mm) B minimum (inches) B minimum (mm) C minimum (inches) C minimum (mm) 1¼ 3¾ 95 3¾ 95 4 124 1½ 4 102 4 102 5 130 2 4 102 4 102 5 137 2½ 4½ 115 5 150 4 100 3 4¾ 120 6¾ 170 4¾ 120 4 5 135 8¼ 210 5½ 140 Table 28: MegaPress rings with V2/V3 actuator clearance requirements between pipe, wall, and floor 4.3.5 Pressing with Ring and Actuator in Tight Quarters Wrap the actuator ring around the press fitting with the opening facing away from you. Close the actuator ring tight around the fitting. Rotate the actuator ring until the press jaw receptacle is facing toward you. Properly insert the press jaw and begin the press fitting procedure. 32 of 46 IM-MP 724992 0120 MegaPress Installation Instructions 4.4 Welding 4.4.1 Welding Adjacent to a Fitting To prevent damage to the sealing element, maintain proper welding distances from the fitting. If welding adjacent to the connection, weld a minimum of four inches away. 4.4.2 Welding In Line with a Fitting 4.4.3 Welding Requirements To prevent damage to the sealing element, maintain proper welding distances from the fitting. If welding in line with the connection, weld a minimum of three feet away from the connection to protect the sealing element. The installer should take precautions to keep the MegaPress connection cool: Wrap the connection with a cold wet rag. Protect the connection with a weld blanket. Prefabricate solder connections/welded fittings prior to installing the press fitting. (Ensure pipe has cooled before installing the press fitting.) Apply heat sink gel or spray or spot freezing. 4.5 Cutting the Pipe Damaged pipe and/or sealing element Press fittings can form improper connections as the result of damaged pipe and/or sealing elements. Do not use flame cutters when cutting the pipe. Do not use grease or oils when cutting the pipe. Note: Cut pipe a minimum of four inches away from the contact area of the vise to prevent possible damage to the pipe in the press area. Avoid cutting through grooves, manufacturer's stamps, or engravings on the pipe's surface. IM-MP 724992 0120 MegaPress 33 of 46 Installation Instructions Cut the pipe square using a displacement-type cutter or fine toothed saw. 4.6 Deburring the Pipe Damage resulting from the wrong deburring tool Connections may leak if they are damaged by improper deburring. Failure to deburr piping will reduce the service life of the system and can cause premature leaks. The pipe ends must be thoroughly deburred after cutting. Damage to or twisting of the sealing element during installation is prevented by deburring. Remove burr from inside and outside of piping and prep to proper insertion depth using a preparation tool or fine grit sandpaper. 4.7 Pressing the Fitting WARNING! Read and understand all instructions for installing Viega MegaPress fittings. Failure to follow all instructions may result in extensive property damage, serious injury, or death. 34 of 46 IM-MP 724992 0120 MegaPress Installation Instructions 4.7.1 Viega MegaPress ½" to 2" Installation Check the sealing element for correct fit: The pipe end is not bent or damaged. The pipe is deburred. The correct sealing element is in the fitting. The sealing element is undamaged. The sealing element is completely in the bead. Illustration demonstrates proper fit of grip ring, separation ring, and sealing element. Measure insertion depth (see table below). Mark the proper insertion depth on the outside of the pipe. Improper insertion depth Improper insertion depth may result in an improper seal. Be sure to mark the correct insertion depth on the pipe before pressing the fitting. Pipe Diameter (inches) ½ ¾ 1 1¼ 1½ 2 Insertion Depth (inches) 11/16 13/16 1 113/16 1 2 Insertion Depth (mm) 27 29 34 46 48 50 Table 29: Minimum insertion depths for MegaPress ½" to 2" IM-MP 724992 0120 MegaPress 35 of 46 Installation Instructions While turning slightly, slide press fitting onto the pipe to the marked insertion depth. Note: End of pipe must contact stop. Viega MegaPress ½" to 1" fitting connections must be performed with MegaPress jaws. See RIDGID Operator's Manual for proper tool instructions. Viega MegaPress 1¼" to 2" fitting connections must be performed with MegaPress rings and V2 actuator. See RIDGID Operator's Manual for proper tool instructions. Use only MegaPress jaws and rings to press MegaPress fittings. See Operator's Manual for proper tool instructions. Use of incompatible jaws or rings will result in an improper connection. Do not use ProPress press jaws or rings. Do not mix actuators and rings from different manufacturers. For ½" to 1" fitting connections, open the MegaPress jaw and place at right angles on the fitting. Visually check insertion depth using mark on piping. 36 of 46 IM-MP 724992 0120 MegaPress Installation Instructions Start the pressing process and hold the trigger until the jaw has engaged the fitting. WARNING! Keep extremities and foreign objects away from press tool during pressing operation to prevent injury or incomplete press. DANGER! High pressure Pressure above the specified range or improper application and use could cause pipes to burst resulting in serious injury or even death. Fittings are for use with fuel gases and are intended for operating pressures 0 to 125 psi. For 1¼" to 2" fitting connections, open MegaPress ring and place at right angles on the fitting. MegaPress ring must be engaged on the fitting bead. Visually check insertion depth using mark on piping. Place V2 actuator onto MegaPress ring and start the pressing process. Hold the trigger until the actuator has engaged the MegaPress ring. WARNING! Keep extremities and foreign objects away from press tool during pressing operation to prevent injury or incomplete press. Once the press is complete, remove MegaPress jaw from fitting or release V2 actuator from RIDGID MegaPress ring. Remove MegaPress ring from the fitting. Remove control label to indicate press has been completed. IM-MP 724992 0120 MegaPress 37 of 46 Installation Instructions 4.7.2 Viega MegaPress 2½" to 4" Installation WARNING! Read and understand all instructions for installing Viega MegaPress 2½" to 4" fittings. Failure to follow all instructions may result in extensive property damage, serious injury, or death. Use only rings that are compatible with MegaPress 2½" to 4" fittings. Viega MegaPress 2½" to 4" fitting connections must be made using MegaPress XL rings and a PressBooster/Z3 actuator. See Operator's Manual for proper tool instructions. Use of incompatible rings will result in an improper connection. Do not mix actuators and rings from different manufacturers. Check the sealing element, separator ring, and grip ring for correct fit: The pipe end is not bent or damaged. The pipe is deburred. The correct sealing element is in the fitting. Illustration demonstrates proper fit of grip ring, separator ring, and sealing element. 38 of 46 IM-MP 724992 0120 MegaPress Installation Instructions Measure insertion depth (see table below). Mark the proper insertion depth on the outside of the pipe. Improper insertion depth Improper insertion depth may result in an improper seal. Be sure to mark the correct insertion depth on the pipe before pressing the fitting. Pipe Diameter (inches) 2½ 3 4 Insertion Depth (inches) 113/16 25/16 3 Table 30: Minimum insertion depths MegaPress 2½" to 4" Insertion Depth (mm) 46 59 80 While turning slightly, slide fitting onto the pipe to marked insertion depth. Note: End of pipe must contact stop. Open the MegaPress ring and place at right angles on the fitting. MegaPress ring must be engaged on the fitting bead. Check insertion depth. Remove the retaining bolt of the press machine. Slide the PressBooster in via the press jaw fixture. Look at insertion depth mark on the pipe to make sure that the pipe is properly inserted into the fitting. IM-MP 724992 0120 MegaPress 39 of 46 Installation Instructions Place PressBooster/Z3 actuator onto MegaPress XL rings and start pressing process. Hold the trigger until the actuator has engaged the MegaPress ring. WARNING! Keep extremities and foreign objects away from press tool during pressing operation to prevent injury or incomplete press. x2-3 The PressBooster requires two presses of the trigger to execute a complete press. A third press may be needed to initiate a release cycle to reset the rollers back to the original position. Once the press is complete, release the PressBooster/Z3 actuator from MegaPress XL ring. Remove the MegaPress XL ring from fitting. Remove control label to indicate press has been completed. 40 of 46 IM-MP 724992 0120 MegaPress Installation Instructions 4.8 Pressure Testing Viega Smart Connect technology provides a quick and easy way for installers to identify connections that need to be pressed. Unpressed connections are located by pressurizing the system with air or water. Pressure test all installed pipe in accordance with local codes or, in the absence of local codes, in accordance with NFPA 54 or NFPA 58. Smart Connect Testing Testing for unpressed connections using Smart Connect is not a replacement for pressure testing requirements of local codes and standards. If testing with compressed air, use an approved leakdetect solution. Water testing with Viega Smart Connect: Use a range of 15 to 85 psi. If an unpressed fitting is found, make sure the pipe is fully inserted before completing the press. If the initial test is successful, system may be pressure tested as required up to 600 psi. Testing with air can be dangerous at high pressures. When air testing with Viega Smart Connect: Use a range of ½ psi to 45 psi. If an unpressed fitting is found, make sure the pipe is fully inserted before completing the press. If the initial test is successful, system may be pressure tested as required up to 200 psi. Viega recommends air testing of gas systems at a minimum of ½ psi. The installation, inspection, testing, and purging of the fuel gas system shall be in accordance with local codes or, in the absence of local codes, tested in accordance with the International Fuel Gas Code, NFPA 54/National Fuel Gas Code z223.1, the Uniform Plumbing Code, NFPA 58 or CSA B 149.1 as applicable. 4.9 Disposal Separate the product and packaging materials (e.g. paper, metal, plastic, non-ferrous metals) and dispose in accordance with all national, state, and regional requirements. IM-MP 724992 0120 MegaPress 41 of 46 Limited Warranty 5 Limited Warranty 5.1 Limited Warranty for Viega MegaPress Subject to the conditions and limitations in this Limited Warranty, Viega LLC (Viega) warrants to end users, installers, and distribution houses that its Viega MegaPress metal press fittings (Viega Product) with application appropriate sealing element when properly installed in non-industrial and non-marine applications and under normal conditions of use shall be free from failure caused by manufacturing defects for a period of ten (10) years from date of installation in Viega MegaPress Approved Applications for fluids/water, oil and lubricant, and gases under Viega specified system operating conditions. MegaPress Valves, when properly installed and under normal conditions of use, will be free of failure from manufacturing defects for a period of two (2) years from date of installation. Under this Limited Warranty, you only have a right to a remedy if the failure or leak resulted from a manufacturing defect in the Viega Product and the failure or leak occurs during the warranty period. You do not have a remedy under this warranty and the warranty remedy does not apply if the failure or any resulting damage is caused by (1) components other than those manufactured or sold by Viega, such as black iron pipe; (2) not designing, installing, inspecting, testing, or maintaining the Viega Product in accordance with Viega's installation and product instructions in effect at the time of installation and other specifications and approvals applicable to the installation; (3) use of Viega Product under non recommended system operating conditions, improper handling and protection of the Viega Product prior to, during and after installation, inadequate freeze protection, or exposure to environmental conditions not recommended for the application; or (4) acts of nature, such as, but not limited to, earthquakes, fire, or weather damage. In the event of a leak or other failure of the Viega Product covered by this warranty, it is the responsibility of the end user to take appropriate measures to mitigate any damage, to include making timely repairs. Only if the warranty applies will Viega be responsible for the remedy under this warranty. The part or parts which you claim failed should be kept and Viega contacted by writing to the address below or telephoning 1-800-976-9819 within thirty (30) calendar days after the leak or other failure and identifying yourself as having a warranty claim. You should be prepared to ship, at your expense, the product which you claim failed due to a manufacturing defect, document the date of installation, and the amount of the repair or replacement if performed by you. Within a reasonable time after receiving the product, Viega will investigate the reasons for the failure, which includes the right to inspect the product at a Viega location and reasonable access to the site of damage. Viega will notify you in writing as to the results of its review. In the event that Viega determines that the failure or leak was the result of a manufacturing defect in the Viega Product covered by this warranty and this warranty applies, the EXCLUSIVE AND ONLY REMEDY under this 42 of 46 IM-MP 724992 0120 MegaPress Limited Warranty warranty shall be the reimbursement for reasonable charges for repair or replacement of the Viega Product itself. VIEGA SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR OTHER DAMAGE (FOR EXAMPLE, ECONOMIC LOSS, WATER OR PROPERTY OR MOLD REMEDIATION) UNDER ANY LEGAL THEORY AND WHETHER ASSERTED BY DIRECT ACTION, FOR CONTRIBUTION OR INDEMNITY OR OTHERWISE. THE ABOVE WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OR ANY STATUTE OF LIMITATIONS RELATING TO SUCH WARRANTIES. Other than this Limited Warranty, Viega does not authorize any person or firm to create for it any other obligation or liability in connection with its products. This Limited Warranty gives you specific legal rights and you also may have other rights which may vary from state to state. This warranty shall be interpreted and applied under the law of the state in which the product is installed and is intended as a COMMERCIAL WARRANTY. 5.2 Limited Warranty for Viega Metal Systems for Industrial Applications Industrial applications are defined as non-residential and noncommercial applications not normally accessible to the general public, including manufacturing, mining, process or fabrication environments. Subject to the terms and conditions of this Limited Warranty, Viega LLC (Viega) warrants to end users, installers and distribution houses that its Viega metal press products (Viega product) when properly installed in industrial applications shall be free from failure caused by manufacturing defects for a period of two (2) years from date of installation. Under this Limited Warranty, you only have a right to a remedy if the failure or leak resulted from a manufacturing defect in the Viega product and the failure or leak occurs during the warranty period. You do not have a remedy under this warranty and the warranty remedy does not apply if the failure or any resulting damage is caused by (1) components other than those sold by Viega; (2) not designing, installing, inspecting, testing, or maintaining the Viega product in accordance with Viega's installation and product instructions in effect at the time of installation and other specifications and approvals applicable to the installation; (3) improper handling and protection of the Viega product prior to, during and after installation, inadequate freeze protection, or exposure to environmental or operating conditions not recommended for the application; or (4) acts of nature, such as, but not limited to earthquakes, fire, or weather damage. Final approval as to use compatibility to a specific process or fluid application is the responsibility of the engineer of record or responsible design/facilities personnel and this Limited Warranty only applies to manufacturing defects in the Viega Product. In the event of a leak or other failure in the Viega product covered by this warranty, it is the responsibility of the end user to take appropriate measures to diminish any damage, to include making timely repairs. Only if the warranty IM-MP 724992 0120 MegaPress 43 of 46 Limited Warranty applies will Viega be responsible for the remedy under this warranty. The part or parts which you claim failed should be kept and Viega contacted by writing to the address below or telephoning 1-800-976-9819 within thirty (30) calendar days after the leak or other failure and identifying yourself as having a warranty claim. You should be prepared to ship, at your expense, the product which you claim failed due to a manufacturing defect, document the date of installation, and the amount of the repair or replacement if performed by you. Within a reasonable time after receiving the product, Viega will investigate the reasons for the failure, which includes the right to inspect the product at a Viega location and reasonable access to the site of damage. Viega will notify you in writing as to the results of its review. In the event that Viega determines that the failure or leak was the result of a manufacturing defect in the Viega Product covered by this warranty and to which this warranty applies, the EXCLUSIVE AND ONLY REMEDY under this warranty shall be the reimbursement for reasonable charges for repair or replacement of the Viega Product itself. VIEGA SHALL NOT BE LIABLE FOR CONSEQUENTIAL OR OTHER DAMAGE (FOR EXAMPLE, ECONOMIC LOSS, WATER OR PROPERTY OR MOLD REMEDIATION) UNDER ANY LEGAL THEORY AND WHETHER ASSERTED BY DIRECT ACTION, FOR CONTRIBUTION OR INDEMNITY OR OTHERWISE. THE ABOVE WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OR ANY STATUTE OF LIMITATIONS RELATING TO SUCH WARRANTIES. Other than this Limited Warranty, Viega does not authorize any person or firm to create for it any other obligation or liability in connection with its products. This Limited Warranty gives you specific legal rights and you also may have other rights which may vary from state to state. This warranty shall be interpreted and applied under the law of the state in which the product is installed and is intended as a Commercial Warranty. 44 of 46 IM-MP 724992 0120 MegaPress Viega LLC 585 Interlocken Blvd. Broomfield, CO 80021 Phone (800) 976-9819 www.viega.us IM-MP 724992 0120 MegaPress ©2019, Viega®, MegaPress®, Smart Connect®, and XL® are registered trademarks of Viega GmbH & Co. KG. Viega: Connected in quality® is a trademark of Viega Holding GmbH & Co. KG. RIDGID® is a registered trademark of RIDGID, Inc.GPL Ghostscript 9.50 Adobe InDesign 15.0 (Windows)