Megapress
INTInstructions for UseMegapressPress connector system made of non-alloy steel for thick-walledsteel pipesSystemMegapressYear built (from)10/2014
Table of contentsTable of contents123MegapressAbout these instructions for use31.1 Target groups1.2 Labelling of notes1.3 About this translated version334Product information52.1 Standards and regulations2.2 Intended use2.2.1Areas of use2.2.2Media57772.3 Product description2.3.1Overview2.3.2Pipes2.3.3Press connectors2.3.4Sealing elements2.3.5Technical data2.3.6Markings on components888141516162.4 Information for use2.4.1Corrosion1717Handling183.1 Transport3.2 Storage3.3 Assembly information3.3.1Mounting instructions3.3.2Potential equalisation3.3.3Space requirements and intervals3.3.4Required tools181818182323263.4 Assembly3.4.1Replacing the sealing element3.4.2Shortening the pipes3.4.3Deburring the pipes3.4.4Pressing the connection3.4.5Leakage test2829303031343.5 Disposal352
About these instructions for use1About these instructions for useTrade mark rights exist for this document; for further information, go toviega.com/legal.1.1Target groupsThe information in this manual is directed at heating and sanitary pro‐fessionals and trained personnel.Individuals without the abovementioned training or qualification are notpermitted to mount, install and, if required, maintain this product. Thisrestriction does not extend to possible operating instructions.The installation of Viega products must take place in accordance withthe general rules of engineering and the Viega instructions for use.1.2Labelling of notesWarning and advisory texts are set aside from the remainder of the textand are labelled with the relevant pictographs.DANGER!This symbol warns of possible life-threatening injury.WARNING!This symbol warns of possible serious injury.CAUTION!This symbol warns of possible injury.NOTICE!This symbol warns of possible damage to property.This symbol gives additional information and hints.Megapress3
About these instructions for use1.3About this translated versionThis instruction for use contains important information about the choiceof product or system, assembly and commissioning as well as intendeduse and, if required, maintenance measures. The information about theproducts, their properties and application technology are based on thecurrent standards in Europe (e.g. EN) and/or in Germany(e.g. DIN/DVGW).Some passages in the text may refer to technical codes in Europe/Germany. These should serve as recommendations in the absence ofcorresponding national regulations. The relevant national laws, stand‐ards, regulations, directives and other technical provisions take priorityover the German/European directives specified in this manual: Theinformation herein is not binding for other countries and regions; as saidabove, they should be understood as a recommendation.Megapress4
Product information2Product information2.1Standards and regulationsThe following standards and regulations apply to Germany / Europe andare provided as a support feature.Regulations from section: Fields of applicationScope / NoticeRegulations applicable in Ger‐manyNo application for fuel gasesDVGW G 260Application in fire extinguishingsystemsDIN 14462Scope / NoticeRegulations applicable in Ger‐manySuitability for heating water forpump hot water heating systemsVDI-Richtlinie 2035, Sheet 1 andSheet 2Scope / NoticeRegulations applicable in Ger‐manyDifferentiation of pipe types andpipe seriesDIN EN 10255Requirements in steel pipes Boiler pipe qualityDIN EN 10220Requirements in steel pipes Boiler pipe qualityDIN EN 10216–1Requirements in steel pipes Boiler pipe qualityDIN EN 10217–1Fixing interval between the pipeclampsVdS CEA 4001Regulations from section: MediaRegulations from section: PipesMegapress5
Product informationRegulations from section: Sealing elementsScope / NoticeRegulations applicable in Ger‐manyArea of use of the EPDM sealingelementDIN EN 12828n HeatingRegulations from section: StorageScope / NoticeRegulations applicable in Ger‐manyRequirements for material storage DIN EN 806-4, Chapter 4.2Regulations from section: Notes on mountingScope / NoticeRegulations applicable in Ger‐manyRequirements and notes for fireextinguisher and sprinkler sys‐temsVdS-Anerkennung G 414021Permissible pressures, nominalwidths and application conditionsVdS 2100-26-2: 2012-04, Table A.1Distances and layout (bracket dis‐ VdS CEA 4001, Section 15.2tances) for steel pipesFire risk classesMinimum pipe wall thickness fornominal widths up to andincluding DN 50VdS CEA 4001, Table 15.02Regulations from section: Leakage testMegapressScope / NoticeRegulations applicable in Ger‐manyTest on a system that is finishedbut not yet coveredDIN EN 806–4Leakage test for water gen von Trink‐wasserinstallationen mit Druckluft,Inertgas oder Wasser"Pressure test in sprinkler systemsVdS CEA 4001, Chapter 17Requirements in filling and top-upwaterVDI 20356
Product information2.2Intended useCoordinate the use of the system for areas of use andmedia other than those described with the Viega ServiceCenter.2.2.1Areas of useThe system is intended for use in industrial, heating and cooling sys‐tems and is a replacement for welded, threaded, and rolled-groove con‐nections in new installations and repairs. The system is not suitable foruse in potable water installations. For this reason, the press connectorsare labelled with a black symbol "Not potable water".Do not use the piping system for fuel gas, see Ä „Regulations from sec‐tion: Fields of application“ on page 5.Fig. 1: "Non-potable water"Use is possible in the following areas among others:Closed heating and cooling circuitsIndustrial unitsSprinkler systemsFire extinguishing systems, see Ä „Regulations from section: Fieldsof application“ on page 5n Compressed air systemsn Systems for technical gases (on request)nnnn2.2.2MediaThe system is suitable for the following media, amongst others:For the applicable directives, see Ä „Regulations from section: Media“on page 5.n Heating water for closed pump hot water heating systemsn Compressed air (dry) in compliance with the specification of thesealing elements being usedn EPDM at oil concentration 25 mg/m3n Anti-freeze, cooling brines up to a concentration of 50 %n technical gases (on request)Megapress7
Product information2.3Product description2.3.1OverviewThe piping system consists of press connectors for thick-walled steelpipes and the corresponding press tools.Fig. 2: Megapress press connectorsThe system components are available in the following dimensions:D⅜ (DN10), D½ (DN15), D¾ (DN20), D1 (DN25), D1¼ (DN32),D1½ (DN40), D2 (DN50), 38.0 mm, 44.5 mm, 57.0 mm.2.3.2PipesMegapress press connectors may be used with the following seam‐less (S) or longitudinal welded (W) steel pipes:nnnnblackgalvanisedindustrially paintedpowder coatedThe steel pipes must correspond to the applicable regulations, seeÄ „Regulations from section: Pipes“ on page 5If the pipe has been coated, the maximum external diam‐eter mentioned in the table must not be exceeded.Pipe overview – threaded pipe qualityThe standard differentiates between heavy pipe series H and mediumpipe series M or between pipe type L, L 1 and L 2. Seamless pipes andpipes welded along the longitudinal seam belong to the different pipeseries and pipe types, see Ä „Regulations from section: Pipes“on page 5.Megapress8
Product informationThreaded pipe quality – heavy series H and Medium series MThreadsize[inch]Nominal widthNominal[DN]external diam‐eter [mm]Min. externaldiameter incl.coating [mm]Max. externaldiameter incl.coating [mm]Wall thickness Wall thicknessheavy series H medium series[mm]M 0.84.53.6Threaded pipe quality – pipe type L and pipe type L 1Thread size[inch]Nominal width[DN]Nominal externaldiameter [mm]Min. externaldiameter incl.coating [mm]Max. externaldiameter incl.coating [mm]Wall eaded pipe quality – pipe type L 2Thread size[inch]Nominal width[DN]Nominal externaldiameter [mm]Min. externaldiameter incl.coating [mm]Max. externaldiameter incl.coating [mm]Wall apress9
Product informationPipe overview – boiler pipe qualityThe standards differentiate between pipe series 1, 2 and 3. They recom‐mend using installation pipe series 1 as pipe series 2 and 3 are eithernot or not always available in practice. Pipe series 1 includes seamlesspipes and pipes welded along the longitudinal seam, see Ä „Regula‐tions from section: Pipes“ on page 5.Boiler pipe quality – pipe series 1, 2 and incl. coating incl. coating[mm][mm]Possiblepipe wallthicknessfor seam‐less pipes1)[mm]1)Possible pipe wall thick‐ness for pipes weldedalong the 9–16.01.4–10.0see Ä „Regulations from section: Pipes“ on page 5Laying and fixing pipesOnly pipe clamps with chloride-free sound insulating inlays should beused to secure the pipes.Observe the general rules of fixing technology:n Do not use fixed pipelines as a support for other pipelines and com‐ponents.n Do not use pipe hooks.n Observe the expansion direction: Plan fixed and gliding points.Megapress10
Product informationInterval between the pipe clamps1)D [mm]Nominal width[inch]Fixing intervalFixing distancebetweenbetweenthe pipe clamps the pipe .324.754.00see Ä „Regulations from section: Pipes“ on page 5Length expansionPipelines expand with heat. Heat expansion is dependent on the mate‐rial. Changes in length lead to tension within the installation. These ten‐sions must be equalised with suitable measures.The following are effective:n Fixed and gliding pointsn Expansion equalisation joints (expansion bends)n CompensatorsHeat expansion co-efficients of various pipe materialsMaterialSteelMegapressHeat expansion co-effi‐cient [mm/mK]0.0120Example:Length expansion withpipe lengths L 20 mand ΔT 50 K[mm]12.011
Product information Fig. 3: Length expansion steel pipes1 - Length expansion ⃗ΔI [mm]2 - Pipe length ⃗ l0 [m]3 - Temperature difference ⃗Δϑ [K]The length expansion Δl can be taken from the diagram or can be cal‐culated using the following formula:Δl [mm/mK] L [m] x Δϑ [K]-#;-#; M M MFig. 4: Z-shaped and T-shaped expansion bendsMegapress12
Product information Fig. 5: Z- and T-shaped expansion bends for Megapress ⅜ to 2 inches1 - Expansion compensation ⃗ΔI [mm]2 - Pipe leg length ⃗ LBZ [m]-#6 -#6 M M Fig. 6: U-shaped expansion bendMegapress13
Product information Fig. 7: U-shaped expansion bend for Megapress ⅜ to 2 inches1 - Expansion compensation ⃗ΔI [mm]2 - Pipe leg length ⃗ LBZ [m]2.3.3Press connectorsPress connectors are available in a number of shapes. An overview ofthe press connectors suitable for the system can be found in the cata‐logue.The Megapress press connectors consist of non-alloy steel (mate‐rial 1.0308) and have an external 3–5 µm zinc-nickel coating. There is acutting ring, a separator ring and a profile sealing element in the bead ofthe press connector. The cutting ring cuts into the pipe during pressingand ensures a force-fit connection.During installation, and later during the pressing, the separator ring pro‐tects the sealing element from damage from the cutting ring.Fig. 8: Megapress press connectorsMegapress14
Product informationSC-ConturViega press connectors are equipped with the SC-Contur. The SCContur is a safety technology that is certified by the DVGW and ensuresthat the press connector is guaranteed to be leaky in an unpressedstate. In this way, inadvertently unpressed connections are noticedimmediately when filling the system.Viega guarantees that accidentally unpressed connections becomevisible during a leakage test:n with the wet leakage test in the pressure range from 0.1–0.65 MPa(1.0–6.5 bar)n with dry leakage test in the pressure range from 22 hPa–0.3 MPa(22 mbar–3.0 bar)Fig. 9: SC-Contur2.3.4Sealing elementsThe Megapress press connectors are factory-fitted with EPDM profilesealing elements. The integrally moulded sealing lips also seal pipe sur‐faces with slightly uneven surfaces.Fig. 10: EPDM profile sealing elementArea of use of the EPDM sealing elementArea of useHeatingSolar installationsCompressed airTechnical gasesUsePump hot waterheating systemSolar circuitall pipeline sectionsall pipeline sectionsOperating tempera‐ture [Tmax.]110 C1)60 C—Operating pressure[Pmax]1.6 MPa (16 bar)0.6 MPa (6 bar)1.6 MPa (16 bar)—for flat collectorsdry, oil content 25 mg / m31)Tmax 105 C2)Commentswith radiator con‐nections Tmax: 95 C1)Consultation with the Viega Service Center required2)see Ä „Regulations from section: Sealing elements“ on page 6Megapress15
Product information2.3.5Technical dataObserve the following operating conditions for the installation of thesystem:Operating temperature [Tmax.]Operating pressure [Pmax]2.3.6110 C1.6 MPa (16 bar)Markings on componentsThe press connectors are marked with a coloured dot. The dot identifiesthe SC-Contur where the test medium would escape in the case of aninadvertently unpressed connection.The black dot indicates that the press connection is equipped with theEPDM profile sealing element and the SC-Contur.The black rectangle serves as a warning "Not suitable for potablewater!".The rectangle is to be found in the following places:n on the press end of the press connectorn on the flange of the flange adapterFig. 11: Black dot and inscription "Notsuitable for potable water"Fig. 12: Black dot and inscription "Notsuitable for potable water"Megapress16
Product information2.4Information for use2.4.1CorrosionA zinc-nickel coating protects Megapress press connectors againstexternal corrosion, e. g. in the case of arising condensation water incooling systems.Pipes must be equipped with suitable corrosion protec‐tion.Pipes and press connectors must be insulated accordingto the general rules of engineering.Observe the manufacturer's information.Megapress17
Handling3Handling3.1TransportObserve the following when transporting pipes:n Do not pull the pipes over the sill. The surface could be damaged.n Secure pipes during transportation. Pipes may become bent due toshifting.n Do not damage the protective caps on the pipe ends and do notremove them until immediately before mounting. Damaged pipeends may not be pressed.In addition, observe the instructions provided by the pipemanufacturer.3.2StorageFor storage, comply with the requirements specified in the applicableregulations, see Ä „Regulations from section: Storage“ on page 6:Store components in a clean and dry place.Do not store the components directly on the floor.Provide at least three points of support for the storage of pipes.Where possible, store different sizes separately.Store small sizes on top of larger sizes if separate storage is not pos‐sible.n Store pipes of different materials separately to prevent contact cor‐rosion.nnnnIn addition, observe the instructions provided by the pipemanufacturer.3.3Assembly information3.3.1Mounting instructionsSystem components may, in some cases, become damaged throughtransportation and storage.n Only use original parts in perfect condition.n Damaged parts must be replaced. Do not attempt to repair them.n Store products in a clean and dry place.Megapress18
Handlingn Check the installation pipes for suitable surface properties and themin./max. external diameter.n Do not press on embossed pipe markings.n Pipes and press connectors must be insulated pursuant to the gen‐eral rules of engineering.Fire extinguisher and sprinkler systemsThe following requirements must be observed:n For the applicable directives, see Ä „Regulations from section: Noteson mounting“ on page 6n Observation of the data from the following tableFor sprinkler systems in compliance with VdS, only black,galvanised, or powder-coated steel pipes according tothe specifications for VdS approval may be used.For nominal widths up to and including DN 50, the min‐imum pipe wall thickness of 2.6 mm and the maximumwall thickness of 3.3 mm are applicable. For the distancesand arrangement (fixing intervals) for steel pipesaccording to current regulations, see Ä „Regulations fromsection: Notes on mounting“ on page 6.Permissible pressures, nominal widths and application conditionsPermitted pressure1.6 MPa (16 bar)Nominal widthsD ¾–2Pipe wall thicknessmin. 2.6 mm; max 3.3 mmArea of use (pipeline network)Wet sprinkler units:n Piping network downstream ofthe alarm valve stationDry sprinkler units:n Piping network downstream ofthe alarm valve stationFixing intervals1)Firefighting water additiveGenerally not permitted; excep‐tions only with the manufacturer'spermission and prior agreementof the VdS1)see Ä „Regulations from section: Notes on mounting“ on page 6The following fire hazard classes are covered by Megapress:nnnnFire hazard class LH (light hazard)Fire hazard class OH 1–4 (ordinary hazard)Fire hazard class HHP 1–4 (extra hazard, production risks)Fire hazard class HHS 1–4 (extra hazard, storage risks)See Ä „Regulations from section: Notes on mounting“ on page 6.Megapress19
HandlingPreparation of the pipesAs long as they are free from dirt, smooth, firm, even and undamaged,the following pipe surfaces are suitable for the production of press con‐nections without further treatment:black uncoated pipesgalvanised pipes (maximum external diameter in acc. with Ä Chapter2.3.2 „Pipes“ on page 8)industrially painted or powder-coated pipes (maximum external diam‐eter in acc. with Ä Chapter 2.3.2 „Pipes“ on page 8)Megapress20
HandlingPipe surfaces must be treated around the press connection if theyexhibit the following characteristics:uneven, manually applied layers of paintExceeding the maximum external diameter due to coating that has beenapplied Ä Chapter 2.3.2 „Pipes“ on page 8Bumps, damage, grooves, corrosion or loose adhesionsNOTICE!Leaky press connectionPressings on the embossed pipe marking may causeleaking.n Do not carry out pressings on the embossed pipemarking.Megapress21
HandlingThe following are examples of suitable tools for the work: Wire brush Cleaning fleece or sanding paper (grain 80) Angle grinder with serrated washerMegapress22
HandlingAfter the treatment, the quality of the pipe surface should be as shownin the following graphic:The external diameter of the installation pipe must not fall below theminimum value, see Ä Chapter 2.3.2 „Pipes“ on page 8.In systems where complete corrosion protection is required (e. g.cooling systems), those parts of the previously processed pipe surfacethat are uncovered after pressing must subsequently be equipped withsuitable corrosion protection.3.3.2Potential equalisationDANGER!Danger due to electrical currentAn electric shock can lead to burns and serious injury andeven death.Because all metallic piping systems conduct electricity,unintentional contact with a live part can lead to the wholepiping system and components conn
DIN EN 12828 Scope / Notice Regulations applicable in Ger‐ many Requirements for material storage DIN EN 806-4, Chapter 4.2 Scope / Notice Regulations applicable in Ger‐ many Requirements and notes for fire extinguisher and sprinkler sys‐ tems VdS-Anerkennung G 414021 Permissible pressures, nominal widths and application conditions
ASME B31.1, B31.3, B31.9 ASTM F3226 CRN 23019.5 A/B/C FM Class 1920 IAPMO PS-117 ICC-ES LC1002 NFPA 13, 13D, 13R Compliant With ASME B31: Code for Pressure Piping IAPMO Uniform Mechanical Code (UMC) ICC International Mechanical Code
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