Aircom Installation
Table of Contents
Aircom Installation Overview
The AIRCOM system allows reducing installation, maintenance and system management costs. However, the installation shall be optimally executed by authorized, qualified and specialized personnel, accurately following the provided instructions to obtain the expected reliability, security and performance results. The lines shall always be slightly slanting towards a condensate collection and discharge point. In order to guarantee constant maintenance of the system or a general intervention, it is advisable not to install the system underground. Provide inspection wells in case of underground installation.
Avoid conditions that may lead to excessive misalignment of the pipes. Lacking pipes alignment with the respective fittings may involve an incorrect position of the pipe end inside of the fitting and hence incorrect working conditions for the o-ring seal, and consequently possible untightness situations.
Support the heavier accessories and equipment of a given weight mounted installed on the piping system (e.g. valves, flex some flexible hoses, flanged expansion compensators, filters etc.) using dedicated, suitable supports, to be installed arranged directly upstream and downstream of the same such accessories or equipment. If not properly supported, the static weight of such additional components or accessories may involve over the time negative consequences on the correct alignment of the piping-fitting connections and hence lead e.g. to untightness conditions.
For the same reason, direct hanging of heavier objects to parts of the piping, as e.g. hose reels or similar items hanging at droplets, should be strictly avoided too.
Provide good sealing of the threads using appropriate products in the proper quantity required. and at the right amounts. In case of doubts, we recommend to contact our Technical Service for suggestions about possible sealing solutions.
For flanged connections it is recommended to always refer to our installation instructions and to make sure availability of a correctly trimmed torque wrench to ensure the proper tightening of the bolts (please be aware that flange-to-flange connections and flanged-fitting–to–flange connections require bolt tightening at different torque
values!).
All supply system maintenance or modifications shall be carried out with the system empty. Always provide for the possibility of disconnecting parts of the system that may be subject of maintenance, expansion or modifications thus avoiding total shutdown.
Within the Quick Line System, various options are available to this purpose thus offering high flexibility in layout: “Sliding fittings” – similar to the usual straight fittings but without internal stop for the pipe (to be used in pairs, one sliding fitting at each end of the pipe section(s) that may require to be temporarily removed / disconnected); by proper operation they can be unscrewed and carefully slide onto the opposite pipe end, thus enabling easy removal from the side of the pipe section on which they were mounted. Reverse procedure to be followed for re-installation of the removed pipe section(s). Flanged fittings – on larger piping sizes, pairs of flanged fittings coupled together flange-to-flange on both ends of a pipe section enable easy removal from the side of such section of pipe, after careful unscrewing of the bolts connecting the flange pairs. Please take care of respecting proper assembly procedure for flanged fittings, when reassembling together the removed part of piping.
Ball Valves and Butterfly Valves – such devices enable safe and reliable shut-off of branches of a piping network, to enable easy and safe disassembly of a part of it, so that their installation at “strategic” layout-specific places is also strongly recommended, e.g. upstream and downstream of a section or branch of piping subject to possible removal for maintenance/expansion/changes on the piping network.
Recommended Tools for Aircom Installation
Tools for Aircom Installation
For the correct installation of Aircom systems it is advisable to use the following tools.
Chamfering Cone – for the correct external and internal de-burring of the pipe
Specified Wrenches (Aluminum Body & Nut or Poly Body & Nut) – for Aircom wrench; allows efficient tightening.
Pipe Insertion Meter – allows marking the correct insertion of the pipes of any diameter
Drill Screwdriver – during bracketing and during the installation of the rapid diversions.
D.16-24mm Hole Saw – which, being crucial during the assembly of rapid diversions, allows drilling which will allow the passage of the ideal about of air required by the opening.
Screwdriver – during the bracketing for opening the pipe holder
Allen Wrench – for tightening rapid diversions
Pipe Wrench – blocks the body of the sleeve during installation
Gasket Lubricant – allows the correct lubrication of the gaskets allowing an easier insertion of the pipe hence avoiding the risk of cutting thereof. Without oils and mineral fats, it keeps the system clean
Marker – for mounting fittings and accessories
Tape Measure – for measuring heights, depths, inclinations, heights etc…
Pipe Cutter (Multi-layer or Aluminum) – for correct vertical cutting of the pipe without forming burs
Deburring Tool – for de-burring the hole created during
Polymer Install Accessories
ACCESSORIES AIRCOM: NUT WRENCH
FOR HR-POLYMER FITTINGS
The AIRCOM wrench allows suitably tightening the nut wrench of the fittings without causing any damage, as it usually occurs with metal pipe wrenches. It is specifically designed for AIRCOM fittings made of plastic or aluminum material.
The Aircom fittings wrenches allow an accurate tightening of the fitting. The perfect fitting of the wrenches on the ferule shall allow tightening the component and activating the safety system. Using the right tools makes for an easy Aircom installation.
Depth Insertion
ACCESSORIES: PIPE INSERTION METER
The AIRCOM “spline gauge” is an accessory required for the execution of safe mounting operations. It allows marking on the pipe, as indicated in figures 1 and 2, the exact splining depth for all pipe measurements. Once inserted into the fitting, it will be easy to check the correct insertion depth of the pipe thus marked.
HR Polymer Fittings Specifications
HR Polymer 16 mm – 63 mm Fittings Installation
The “QUICK LINE” Aircom system is extremely easy, quick and does not require the use of expensive and complex equipment. Just a few operations and the joint is ready for use.
ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THERE OF
1)
After checking the condition of the surface of the pipe (there should be no evident scratches, abrasions, dents that could lead to leakages), perform a precise and straight cut at the desired measurement.
The cut shall be cut closest to a right angle (90° with respect to the axis of the pipe) as possible.
2)
De-bur the previously executed cut at the external surface of the pipe and eliminate possible chippings and/or cut residue along the edge of the internal diameter. Eliminate the cut residue, dust, and impurities possibly present in the pipe with the aim of avoiding future problems to the pneumatic apparatus is important
3)
Untighten the ferule, by turning it by half rotation anticlockwise: the distance between the body and the ferule shall increase. Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting. This will allow avoiding incomplete insertions.
4)
Lubricate the end of the pipe and/or contact surface of the O-ring gasket using our AIRCOM lubricant so as to facilitate the operation.
5)
Insert the pipe into the fitting and push up to the stop of the pipe at the abutment at the bottom of the splining.
AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF.
IF NOT SURE, PLEASE CONTACT US!
6)
Tightening shall be carried out by hand tightening up to the stop point and subsequently 180°, using a sector
wrench.
7)
A correct tightening of the fitting shall position the nut wrench halfway the tightening marking point.
Joints executed using the “QUICK LINE” AIRCOM systems do not require waiting times after completion; pressurisation is instantaneous.
Aluminum Aircom Installation Accessories
The AIRCOM wrench allows suitably tightening the ferule of the fittings without causing any damage, as it usually occurs with metal pipe wrenches.
It is specifically designed for AIRCOM fittings made of plastic or aluminum material.
The AIRCOM fittings wrenches allow an accurate tightening of the fitting. The perfect fitting of the wrenches on the ferule shall allow tightening the component and activating the safety
system.
Aircom Quick Body Holder
The quick grip wrenches allow an accurate and safe installation of the aluminum fittings with the following diameters: 20 mm – 25 mm – 32 mm – 50 mm. Created specifically to hold the body of the fitting during the tightening of the ferule so as to avoid the use of inappropriate accessories that could ruin the fitting, such as the pipe wrench or pliers.
Quick grip holder for holding the aluminum fitting body
Nut wrench
Using the Quick Body Holder
Using the QLCLE wrench, clamp the screw nut and then, using the QLCPR quick grip holder, hold the body of the fitting ensuring the holder cavity coincides with the cylindrical insert of the body. Holding the body still, tighten the ferule making sure that the fitting is tightly tightened.
HOLDING THE BODY USING QLCPR
HOLDER CAVITY ON CYLINDRICAL PART OF THE FITTING
Pipe Insertion Meter
The AIRCOM “spline gauge” is an accessory required for the execution of safe mounting operations. It allows marking on the pipe, as indicated in figures 1 and 2, the exact splining depth for all pipe measurements. Once inserted into the fitting, it will be easy to check the correct insertion depth of the pipe thus marked.
The marking, which can be carried out using a normal marker, shall be at least flushed with respect to the ferule as indicated in the figure.
The Quick Line Aluminum spline gauge line bears the AIRCOM ALUMINIUM indication on the side, thus making the product identifiable.
Aluminum Fittings Specifications
Aluminum Fittings Installation 20-80 mm
The “QUICK LINE” Aircom system is extremely easy, quick and does not require the use of expensive and complex equipment. Just a few operations and the joint is ready for use.
ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THERE OF
1)
After checking the condition of the surface of the pipe (there should be no evident scratches, abrasions, dents that could lead to leakages), perform a precise and straight cut at the desired measurement.
The cut shall be cut closest to a right angle (90° with respect to the axis of the pipe) as possible.
2)
De-bur the previously executed cut at the external surface of the pipe and eliminate possible chippings and/or cut residue along the edge of the internal diameter. Eliminate the cut residue, dust, and impurities possibly present in the pipe with the aim of avoiding future problems to the pneumatic apparatus is important
3)
Untighten the ferule, by turning it by half rotation anticlockwise: the distance between the body and the ferule shall increase. Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting. This will allow avoiding incomplete insertions.
4)
Lubricate the end of the pipe and/or contact surface of the O-ring gasket using our AIRCOM lubricant so as to facilitate the operation.
5)
Insert the pipe into the fitting and push up to the stop of the pipe at the abutment at the bottom of the splining.
AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF.
IF NOT SURE, PLEASE CONTACT US!
6)
Tightening shall be carried out by hand tightening up to the stop point and subsequently 180°, using a sector
wrench.
7)
A correct tightening of the fitting shall position the nut wrench halfway the tightening marking point.
Joints executed using the “QUICK LINE” AIRCOM systems do not require waiting times after completion; pressurisation is instantaneous.
110mm Fitting Specifications
110mm Aluminum Fitting Installation
The “QUICK LINE” Aircom system is extremely easy, quick and does not require the use of expensive and complex equipment. Just a few operations and the joint is ready for use. Below is the process for the installation of a sleeve, valid for all components of the 110 mm line.
ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THEREOF
1)
After checking the condition of the surface of the pipe (there should be no evident scratches, abrasions, dents that could lead to leakages), perform a precise and straight cut at the desired measurement. The cut shall be cut closest to a right angle (90° with respect to the axis of the pipe) as possible.
2)
De-bur the previously executed cut at the external surface of the pipe and eliminate possible chippings and/or cut residue along the edge of the internal diameter. Eliminate the cut residue, dust, and impurities possibly present in the pipe with the aim of avoiding future problems to the pneumatic apparatus is important
3)
Untighten the ferule, by turning it by half rotation anticlockwise: the distance between the body and the ferule shall increase. Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting. This will allow avoiding incomplete insertions.
4)
Lubricate the end of the pipe and/or contact surface of the O-ring gasket using our AIRCOM lubricant so as to facilitate the operation.
5)
Insert the pipe into the fitting and push up to the stop of the pipe at the abutment at the bottom of the splining.
AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF.
IF NOT SURE, PLEASE CONTACT US!
6)
Use a torque wrench to tighten the screws of the ferules at 30 Nm, so as to tighten the ferule correctly. Correctly tighten the 3 screws arranged on both ferules so as to have perfect joining with the body. Use a wrench to hold the nut, so as to quicken the work and have greater tightening safety.
7)
A correct tightening of the fitting shall position the nut wrench halfway the tightening marking point.
Joints executed using the “QUICK LINE” AIRCOM systems do not require waiting times after completion; pressurisation is instantaneous.
Caution’s 110mm Install
On any Aircom Installation, follow the suggested methods and procedures. Failure to do so may result in damage or injury.
168mm & 220mm Aircom Installation
PREPARATORY STEP FOR COUPLING INSTALLATION
1 – Check Pipe Ends
The outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections (including weld seams), and roll marks to ensure a leak-tight seal.
2 – Check Gasket & Lubricate
Check the gasket to make sure it is suitable for the intended service. Apply a thin coat of AIRCOM lubricant to the gasket sealing lips and exterior.
3 – Position Gasket
Position the gasket over the pipe end. Make sure the gasket does not overhang
the pipe end.
4 – Join Pipe Ends
Align and bring the two pipe ends together. Slide the gasket into position and center it between the groove in each pipe end. Make sure no portion of the gasket extends into the
groove in either pipe end.
5 – Assemble Housing
Insert one bolt into the housings, and thread the nut loosely onto the bolt to allow for the “swing-over” feature, as shown above. The nut should be backed off no further than flush with the end of the bolt.
6 – Install Housing
Using the “swing-over” feature, install the housings over the gasket. Make sure the housings’ keys engage the grooves completely on both pipe ends.
6 – Install Remaining Nuts & Bolts
Install the remaining bolt, and thread the nut finger-tight onto the bolt. Make sure the oval neck of each bolt seats properly in the bolt hole.
6 – Tighten Bolts
Tighten all nuts evenly by alternating sides until metal to-metal contact occurs at the angle bolt pads. Make sure the housings’ keys engage the grooves completely on both pipe ends and that the offsets are equal at the bolt pads. Equal, positive offsets are necessary to ensure a rigid joint (refer to the example above). It is important to tighten all nuts evenly to prevent gasket pinching.
Visually inspect the bolt pads at each joint to ensure metal-to-metal contact is achieved.
Flange Adaptor for Aircom Installation 168 & 220mm
Flange Adapters require a smooth, hard surface at the mating flange face for proper sealing. Some applications, for which the Flange Adapter is otherwise well suited, do not provide an adequate mating surface. In such cases, a metal Flange Washer is recommended for insertion between the Flange Adapter and the mating flange to provide the necessary sealing surface.
- When mating a flange to a serrated flange – a flange gasket shall be used against the serrated flange. The Flange Washer should then be inserted between the Flange Adapter and the flange gasket.
- When mating a flange adapter to a wafer type valve – – the Flange Washer shall be placed between the valve and the Flange Adapter.
- When Mating a flange adapter to rubber faced flange valve – the Flange Washer must be placed between the Flange Adapter and the rubber-faced flange
- Mating to components when component has an insert – follow the same arrangement as if the Flange Adapter was being mated to a serrated flange.
- Adapters – the Flange Washer must be placed between the two Flange Adapters with the hinge points oriented 90° to each other. If one flange is not a AIRCOM Flange Adapter (i.e. Flanged valve), a flange gasket must be placed against the non-AIRCOM Flange. The Flange Washer must then be inserted between the flange gasket and the Flange gasket.
1 – Check Pipe Ends
The outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections (including weld seams), and roll marks to ensure a leak-tight seal.
2 – Check Gasket & Lubricate
Check the gasket to make sure it is suitable for the intended service. Apply a thin coat of AIRCOM lubricant to the gasket sealing lips and exterior.
3 – Position Gasket
Position the gasket over the pipe end. Make sure the gasket does not overhang
the pipe end.
4 – Install Flange Adapter
Open the hinged flange adapter fully, and install the flange over the gasket. Make sure the flange key section engages the pipe groove properly.
5 – Insert Mating Bolts
Insert a standard, full-shank diameter assembly bolt through each of the two mating hole in the flange adapter. This will maintain the position of the flange in the pipe groove.
5a – Make Sure Gasket is Seated
Make sure the gasket is seated properly in the flange adapter
Closure lugs are provided for ease of installation. If necessary, use an adjustable wrench to bring the flange holes intovalignment. This will ease insertion of the
6 – Join Flange Adapter and Mating Flange
Join the flange adapter with the mating flange by aligning the bolt holes.
6a – Thread standard Flange nuts Finger-tight onto the two mating bolts.
7 – Install Remaining Bolt and Nuts
Insert a standard, full-shank diameter assembly bolt through each remaining hole in the flange adapter/mating flange. Thread standard flange nuts finger-tight onto all bolts.
8 – Tighten Nuts and Bolts
Tighten the nuts evenly, as with a regular flange assembly. Continue tightening until the flange faces come into firm, metal-to-metal contact or the standard, flange-bolt torque requirement is achieved.
Quick Brach 168-220mm Installation
- Proper preparation of the hole is essential for sealing and performance. Make sure the correct hole saw size is being used. Refer to the Pipe Preparation Requirements” table.
- Holes MUST be drilled on the centerline of the pipe.
- Ensure that a 5/8 inch – 16-mm area around the hole is clean, smooth, and free from indentations and/or projections that could effect gasket sealing (refer to the sketch below). Remove any burrs and sharp or rough edges from the hole. Burrs and sharp edges might effect assembly, proper seating of the locating collar, flow from the outlet, or gasket sealing.
- The pipe around the entire circumference, within the “A” dimension shown in the sketch below, must be free from any dirt, scale, or projections that might prevent the housing from seating fully on the pipe. Refer to the Pipe Preparation Requirements” table.
DO NOT USE STYLE BOLTED BRANCH OULTELS ON PVC PLASTIC PIPE.
Assemble Housing
Insert a bolt into the two housings. Thread a nut loosely onto the end of the bolt.
Check Gasket & Lubricate
Inspect the sealing surface of the gasket to make sure no debris is present.
The Correct Gasket is Shipped Depending on Branch Drop
Install Housing
Rotate the lower housing so that it is positioned approximately 90° to the upper (outlet) housing, as shown above. Place the upper (outlet) housing onto the face of the pipe in line with the outlet hole cut into the pipe. Rotate the lower housing around the pipe.
Install Housing Continued
Make sure the locating collar engages the outlet hole properly. Check this engagement by rocking the upper (outlet) housing in the hole.
Install Remaining Bolts
Insert the remaining bolt. Thread a nut onto the bolt finger-tight. Make sure the oval neck of each bolt seats properly in the bolt hole.
Tighten Nuts
Make sure the locating collar is still positioned properly in the outlet hole. Tighten the nuts evenly by alternating sides until the upper (outlet) housing contacts the pipe completely.
Multi-layer Aircom Installation – Instruction to use the flexible pipe
Owing to its bendability, with Aircom’s multilayer pipe you will be able to easily overcome or bypass obstacles in your compressed air piping such as pillars or corners without needing to use elbows.
Cut the pipe with the special shear
Use the calibrator tool to chamfer the pipe end and restore the correct shape after cutting.
Insert the internal bending spring into the multilayer pipe to start bending the pipe.
Fix the bending spring with a lanyard, that will help pulling out the spring from the pipe after bending.
Bend the pipe by applying an uniform force across the whole length of the pipe section
Pull the bending spring out of the pipe: you will obtain the required curve with an uniform bend. NB – With the outside bending spring you should proceed in a similar way
(slide the bending spring over the pipe!).
TO BE STRICTLY AVOIDED:
A) Avoid repeated bending of the multilayer pipe at the same point (risk of damage!): for this function you should use QLFLEX.
B) Avoid bending the pipe with sharp edges (risk of damage of the pipe structure!): use the appropriate bending springs.
C) Do not weld, glue, punch or drill the multilayer pipe; use only dedicated mounting accessories.
Threaded: Valves, Nipples, Connectors
The item normally comes assembled, so as to be directly inserted into the system. In case one intends to insert a valve or threaded element, on the system or on an aluminum connectors, proceed as follows
Flexible Pipes: QLFLEX
Dilatation / Contraction Compensation
Flanged Dilation Compensators
When using DIRDIL as a flanged dilation and contraction compensator it is recommended to follow the following instructions so as to avoid malfunctions and damages deriving from the erroneous use of the component.
Bracketing System for Aircom Installation
The bracketing of the aluminum pipe shall be carried out solely using special DIRFEM8 pipe wrench designed to allow the pipe to slide in case of possible dilations or contractions.
Quick Branch Installation: Aluminum & Polymer
The AIRCOM diversion intakes are designed to allow the end user to obtain a quick branch plug without having to cut the bearing pipe. In addition, due to the particular design of the component the opening air intake is arranged above the condensate formation level thus guaranteeing an optimal quality of air in the opening.
Wall Mounted Manifold Installation
The array of aluminum connectors is available in a wide range of models designed to meet all application needs and all compressed air supply needs.
In compliance with the safety philosophy which distinguishes the AIRCOM products, the aluminum connectors have conventional 1/2” outputs at 45° with respect to the fixing plane, so as to reduce the risk of direct ejection towards the operator.
Spigot Installation
The male threaded spigot is a special hollow cylinder block in aluminum alloy with a male conic gas thread for airtight couplings according ISO 7-1 at one end and a plain pipe segment of size identical to QLTUAL pipe on the other end.
Always check with the manufacturer for the latest information. Aluminum Pipe Now provides this information from Aircom the manufacturer of Aircom Piping Systems.