24680019Revision A

December 2013

Save These Instructions

SimplAir®

Product Information

Compressed Air Piping System

EN-3 24680019 Rev A

EN

CoNTENTSCoNTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ABoUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PRoDUCT DESCRIPTIoN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSTALLATIoN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

EXPANSION AND CONTRACTION . . . . . . . . . . . . . . . . . . . . . . . . 7

ASSEMBLY INSTRUCTIoNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DESIGN AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

UV RADIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

SHOCK PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

SOURCES OF HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

AIR LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

EN

24680019 Rev A EN-4

ABoUT THIS MANUAL

PRoDUCT DESCRIPTIoN

INTENDED USEThe SimplAir system has been designed and built for installation on compressed air distribution systems . The product was designed to convey compressed air up to a pressure of 15 barg / 220 Psig .

It may also be used to convey inert gases and may be installed in negative pressure systems . Appropriate for indoor and outdoor applications . Operating temperature must not exceed 80°C / 176°F, in normal or abnormal system operation .

The materials and types of fittings used offer a flexible system that can be integrated with Ingersoll Rand compressed air systems . The product range can be used to build systems featuring a production unit, treatment assembly, loop distribution system and all external connectors .

FEATURESCorrosion resistant - The powder coated marine grade aluminum alloy used for the tubes and the engineered metal fittings protect the system from corrosion .

Durable - The materials of construction offer protection against normal physical contact .

UV radiation resistant - Aluminum is not affected by UV radiation and the system can therefore be installed both indoors and outdoors .

Fire resistant - Aluminum offers excellent fire resistance as it neither feeds nor generates flames .

Excellent flow rate - The SimplAir system offers excellent flow rates given its low coefficient of friction, the large internal section of the piping and the absence of obstacles or bottlenecks .

Easy to install - The SimplAir system is extremely flexible and the speed and simplicity of installation totally eliminate system start-up times .

Meets legislation requirements - All the components of the SimplAir system comply with ASME/ANSI B31 .1/B31 .3 guidelines and are registered with CRN for all provinces .

Compatible with compressor oils - The aluminum and medium-nitrile seals used to produce the SimplAir system are compatible with compressor lubrication oil . Replacement seals are available within the SimplAir portfolio (substitutes may compromise system) .

In addition to rapid installation times, the SimplAir piping system offers leak free, reliable operation .

Table 1 : Physical Characteristics

Characteristics Unit Values

Density Kg/dm3 2 .7

Coefficient of elasticity N/mm2 6890

Expansion coefficient Mm/(m °C) 0 .024

Thermal conductivity W/(m °K) 2 .09

Specific heat at 100° C j/(g °K) .9

Specific resistance µΩ cm 3 .16

Melting point °C / °F 616-654 / 1140-1210

Min/Max temperature °C / °F -20 to 80 / -4 to 176

Table 2 : Alloy

Extruded - Aluminium UNI “6063 T5” - 9006/1 Al Mg 0 .5 Si 0 .4 Fe 0 .2

Ingersoll Rand provides this manual to inform installers, operators, maintenance personnel, supervisors and management of safe practices that must be followed .

It is not intended that the recommendations in this manual take precedence over existing plant safety rules and regulations or OSHA regulations . In the event that some conflict exists between a rule set forth in this manual and a

similar rule already set by an individual company, the more stringent of the two should take precedence .

Original instructions are in English . Other languages are a translation of the original instructions .

Refer all communications to the nearest Ingersoll Rand Office or Distributor .

Table 3 : Mechanical Characteristics

6063 T5

Ultimate Tensile Strength (MPa) 186

Percentage Elongation 12

Brinell Hardness (HB) 60 - 70

Painting Thickness (μm) Max 90 Micron

Table 4 : Chemical Composition

Alloy 6063

AI Mg 0 .5

Si 0 .4

FE 0 .2

EN-5 24680019 Rev A

EN

SAFETYSafety Information -Explanation of Safety Signal Words

Indicates an imminently hazardous situationwhich, if not avoided, will result in death or serious injury .

DANGER

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury .

WARNING

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage .

CAUTION

Indicates information or a company policy that relates directly or indirectly to the safety of person-nel or protection of property .

NOTICE

Safety Symbol Identification

Wear eye protection

Wear hearing protection

Wear hand protection

Wear foot protection

Read manuals

General Safety Information

Product Safety

It is the responsibility of the owner/user to require that all personnel that will install, inspect, test, maintain, and operate the product read the contents of this manual and all manuals furnished by Ingersoll Rand and become familiar with the location and operation of the controls and features .

Do not use this product for purposes other than those recommended .

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Never use a damaged or malfunctioning product .

Use of the product fitted with non Ingersoll Rand approved components is not permitted .

Failure to observe these safety guidelines could expose personnel to hazardous situations which, if not avoided, could result in death or serious injury .

Workplace Safety

The information presented in this manual should be used in conjunction with your workplace safety program .

It is the responsibility of each individual to ensure that they work in a safe manner and in compliance with all applicable standards and regulations (local, state, country, federal, etc .) .

Keep the work area clear of hazards .

Assess hazards, make a list, and discuss with appropriate personnel .

Know how to quickly contact emergency assistance .

Training Programs

It is a responsibility of the product owner/user to make personnel aware of all relevant rules, codes and company safety rules, regulations and instructions and to establish programs to:

Train and designate operators .

Train and designate inspection and maintenance personnel .

Ensure safety procedures are followed .

Ensure all accidents or safety violations are properly reported, and appropriate corrective action is taken prior to further use .

Ensure that all warning tags, labels and the manuals supplied with the product are read .

It is recommended that applicable health and safety standards be reviewed along with other recognized safety sources to provide safe product installation and operation .

Follow all country or regional specific rules, regulations and standards that apply to operator/user training .

Safety Information - Documentation, Decals & Tags

Locate, read, understand and follow all Danger, Warning, Caution, and Operating Instructions on the product and in all Manuals . Failure to comply with safety precautions described in the manuals supplied with the product, this manual or any of the decals and tags attached to the product may result in death, serious injury or property damage .

Check that all decals, tags and nameplates are in place and legible . Do not remove .

If the product is repainted, ensure decals, tags and nameplates are protected and the protection is removed after painting .

Contact Ingersoll Rand for replacement decals, tags, nameplates or manuals if they become missing, damaged or unreadable . Replacement nameplates are available when the product serial number is provided .

It is your responsibility to make this information available to others .

Safety Information - Personal Protective Equipment & Attire

Wear personal protective equipment that is appropriate for the task (e .g . safety glasses with side shields, respirator, hearing protection, cut resistant gloves, safety shoes) at all times .

Keep others a safe distance from your work area and ensure they use appropriate personal protective equipment .

Long hair must be tied back or otherwise secured .

Clothing must be close-fitting .

Do not wear jewelry .

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WARNING

WARNING

WARNING

EN

24680019 Rev A EN-6

Safety Information - When Receiving & Handling the Product

Receipt Inspection

Inspect the shipping package for any signs of shipping damage . Remove shipping material carefully and inspect the product for any damage . Pay close attention to hoses, fittings, brackets, handles, valves, or any other items that attach or protrude from the product . Any item that appears damaged, no matter how slight, shall be inspected and a determination made as to its suitability for use prior to the product being placed into service .

Handling & Transporting

Use suitable lifting equipment (e .g . forklift) to lift and transport the product to the installation site . Ensure the lifting equipment, straps, etc . are capable of supporting the weight of the product . Weight information is printed on a label attached to the shipping container or to the product .

Use suitable equipment for lifting heavy items and ensure loose components are adequately supported to eliminate risk of dropping .

Do not work on or walk under the product while it is suspended .

Safety Information - When Installing the Product

Personnel

Ensure that installation personnel are adequately trained, competent and have read the manuals .

When attempting to identify and remedy any fault or failure, ensure it is only attempted by qualified personnel .

Installation Site

Keep work area clean, uncluttered, ventilated and illuminated .

If the discharged air is to be ultimately released into a confined space, adequate ventilation must be provided .

Be aware of buried, hidden or other hazards in your work environment . Do not contact or damage cords, conduits, pipes or hoses that may contain electrical wires, explosive gases or harmful liquids .

System Design

If more than one compressor is connected to one common downstream plant, effective check valves and isolation valves must be fitted and controlled by work procedures so that one machine cannot accidentally be pressurized /over pressurized by another .

Ensure an accessible emergency shut off valve has been installed in the air supply line, and make others aware of its location .

If a safety valve is installed between the isolation valve and the compressor, it must have sufficient capacity to relieve the full capacity of the compressor(s) .

All system must incorporate a safety valve set at 1 bar (14 .5 psig) above working pressure .

The maximum system working temperature must not exceed 80°C / 176°F .

For existing systems that have been pressurized, residual pressure can exist . Relieve all pressure to avoid injury or property damage prior to beginning any work .

Materials of Construction

It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine .

The piping to and from the product must be in accordance with the operative and safety requirements of the plant .

All components, accessories, and pipework added to the compressed air system should be:

of good quality and type approved by Ingersoll Rand .

clearly rated for a pressure at least equal to the machine maximum allowable working pressure .

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compatible with the compressor lubricant/coolant .

accompanied with instructions for safe installation, operation and maintenance .

All air and water inlet, and air and water discharge pipework to and from the inlet and discharge port connections must take into account vibration, pulsations, temperature, maximum pressure applied, corrosion resistance and chemical resistance . In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; therefore, compatibility between discharge piping, system accessories and lubricants/coolants must be assured .

The use of plastic piping, soldered copper fittings, or rubber hose as part of the discharge piping is not recommended . In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system .

The use of plastic bowls on line filters and other plastic air line components without metal guards can be hazardous . Their safety can be affected by either synthetic lubricants/coolants or the additives used in mineral oils . Use only metal bowls in any pressurized system .

During Installation

Attempt installation only in clean, dry, well lighted and ventilated areas .

Never make any modifications, additions or conversions which might affect safety without the approval of Ingersoll Rand .

Do not remove, adjust, bypass, change, modify or make substitutions for safety valves or other pressure control related devices .

Cover exposed openings with clean cloth or kraft paper to prevent the entry of foreign materials .

After Performing Installation

Ensure tightness of all joints (Refer Page 12) .

Ensure proper installation of overpressure protection equipment .

Ensure the machine is suitably tested . The preparation for and the initial start-up of the product should be done under supervision of an Ingersoll Rand technical representative .

Routine Inspection

All pressure containing parts, especially flexible hoses and their couplings, must be regularly inspected, be free from defects and be replaced according to the product instructions .

All safety valves must be checked periodically for correct operation .

Whenever pressure is released through the pressure relief valve, it is due to excessive pressure in the system . The cause for the excessive pressure should be investigated immediately .

Repair Parts

The use of repair parts other than those included within the Ingersoll Rand approved parts list may:

Create hazardous conditions over which Ingersoll Rand has no control . Therefore, Ingersoll Rand cannot be held responsible .

Decrease compressor performance .

Increase maintenance .

Invalidate all warranties .

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EN-7 24680019 Rev A

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INSTALLATIoNEXPANSIoN AND CoNTRACTIoNAll materials change size as a result of temperature variations;

Compared with a reference temperature (at installation):

- they expand when the temperature rises,

- they contract when the temperature falls .

The main consequences of contraction and expansion are:

Figure 1 : Expansion

deformation of the piping between two fixed points .

compression of fixed fittings, connections or equipment with the risk of deformation, detachment of glue and/or breakage .

Figure 2 : Contraction

pulling of the piping between two fixed points .

compression of the fixed fittings, connections or equipment with the risk of deformation, detachment of glue and/or breakage .

To prevent the effects of expansion/contraction from causing serious damage to the system and making it look unattractive:

support and clamp the system so that the piping can move freely between two fixed points .

If a system is fixed to a solid constructed wall, especially in a closed loop design, expansion / contraction will need to be accommodated .

These variations can be measured using the linear expansion coefficient d

For the SimplAir system, the coefficient of reference d is 0 .024 mm/m/°C i .e ., 0 .024 millimetres per meter per degree centigrade .

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A comparison of the linear expansion coefficients of some frequently used materials is shown below:

Table 5 : Linear expansion coefficients for common materials

Steel 12,8 x 10-6 m/m °C

Copper 16,5 x 10-6 m/m °C

Aluminium 24 x 10-6 m/m °C

PVC—HI 75 x 10-6 m/m °C

ABS 101 x 10-6 m/m °C

PVDF 120 x 10-6 m/m °C

PP 150 x 10-6 m/m °C

PE 200 x 10-6 m/m °C

The design and construction of any system must consider this phenomenon which can be calculated using the following formula:

L=dxLx

Where: d = linear expansion coefficient

L = length of piping

T = temperature difference in degrees centigrade

L = difference in length (expansion or contraction)

e .g .: installation temperature +10°C; length of piping 20 m; operating temperature 35°C

T = 35 - 10 = 25°C

L= 0,024 x20 x 25 = 12 mm

Two of the most effective expansion joint systems are the “LIRA” (or OMEGA) and the “CHANGE OF DIRECTION” .

The LIRA and CHANGE OF DIRECTION comprise elbows and tubes; as they are perfectly compatible with the system and cheap and easy to fit, we consider them to be the best solution to expansion/contraction, unless there is some special reason why they cannot be used .

Figure 3 : LIRA

EN

24680019 Rev A EN-8

Figure 4 : Change of direction

CHANGE OF DIRECTION

L: length of piping at installation

L1: length at minimum temperature

L2: length at maximum temperature

L: difference in length between L1 and L2

B : arm length of “LIRA” or “CHANGE OF DIRECTION”

To determine the arm length B of LIRA or CHANGE OF DIRECTION, use the following TABLE showing the tube diameters and the relative differences in length L .

Table 6 : Tube length

Diameter (mm) Tube length (m) / ft

16 1 .20 / 3 .93

20 1 .40 / 4 .59

25 1 .60 / 5 .25

32 1 .80 / 5 .91

40 2 .00 / 6 .56

63 2 .40 / 7 .87

ANCHoRING

Take great care when choosing the piping supports and clamps . These must have the following features:

The supports must fix the piping to the structure of the building;

They must not scratch or in any way damage the piping;

They must leave enough room between the wall and other obstacles for maintenance work, etc .;

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They must keep the piping perfectly straight, support its weight together with that of all the sliding accessories, and fix it well to the anchors;

Take great care when clamping the accessories and valves . Given that these are subject to stress when they are used, they must be fixed separately from the piping and be able to be used and dismounted;

Take great care when clamping the pipe ends (covers, wall assemblies, and drop lines) .

DISTANCES BETWEEN SUPPoRTS

The DISTANCES between the supports are determined according to the diameter of the piping and the temperature and weight of the conveyed fluid as shown below:

Table 7 : Distance between supports

Do not fix sliding supports near unions or other accessories as otherwise the tube may not slide freely .

For horizontal or vertical tubes installed from 0 to 250 cm from the ground, double the number of supports in order to ensure the piping is perfectly anchored to the structure .

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EN-9 24680019 Rev A

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ASSEMBLY INSTRUCTIoNSAssembling 20 mm to 63 mm Piping

Fitting size 20mm through 40mm:

1 . Debur pipe outer diameter (OD)

Caution: Do not loosen the compression nuts prior to pipe installation . The fitting compression nuts are pre-torqued at the factory .

2 . To install the pipe, push and rotate the pipe into the fitting until fully seated .

3 . Verify the compression nuts are tight .

Minimum torque:

20 mm = 3 .0 Nm / 27 in .lbs

25 mm = 3 .0 Nm / 27 in .lbs

32 mm = 4 .0 Nm / 35 in .lbs

40 mm = 6 .5Nm / 58 in .lbs

Fitting size 50mm and 63mm:

4 . Debur pipe outer diameter (OD)

Loosen the compression nuts prior to pipe installation .

Push and rotate the pipe into the fitting until fully seated .

Tighten the compression nuts to a minimum torque of 65Nm / 48 ft .lbs .

Important: Specific installation instructions for Saddle Clamps

1 . Depressurize the system and ensure that system pressure is at zero psi

2 . Position the drilling jig on the tube . Ensure the correct position of the drilling jig: the guide hole for the boring tool must be perpendicular to the axes of the tube of which you want to add an outlet . It is possible to

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connect a tube to help in the positioning of the drilling jig . Tighten the screw to prevent the drilling jig from moving on the tube .

3 . Bore the tube with the proper boring tool . Take care to not damage the opposite side of the tube .

4 . Disassemble the drilling jig from the tube . Deburr the tube and remove possible residual material .

5 . Assemble and screw the saddle clamp connector on the tube so that the lip seal is aligned correctly on the hole .

6 . Tighten the screw to complete the assembly .

Assembling 70 mm to 220 mm Piping

Tube Grooving

1 . Cut tube ends must be square and smooth .

A 12” miter saw with at least an 80 tooth carbide blade will produce an acceptable cut .

Cut ends must have sharp edges removed to protect seals during installation .

2 . Groove gauge tape must be used to verify pipe diameter . Zero arrow must be within wide black mark to the right of the 2 ½, 3, 4 or 6 . Only approved Victaulic grooving tools must be used to insure correct groove dimensions .

3 . Tube must be grooved according to the instructions as supplied with the tool . Contact Ingersoll Rand for any question about this process .

A setting gauge will be supplied with each grooving tool and can be used as starting point for setting groove depth .

The setting gauge can only be used after the groove tool is installed on the pipe squarely against the stops and the adjustment nut hand tight .

After grooving to the approximate depth with the setting gauge, check the groove with the groove gauge tape and adjust the tool as required .

The zero arrow on the groove gauge tape must be within the narrow black mark to the left of the 2 ½, 3, 4 or 6 .

After the grooving tool is set to provide the correct groove, it should not need to be adjusted .

Important: Every groove must be verified to be in tolerance by using the groove gauge tape .

Fitting Installation:

1 . Inspect fittings to insure sealing surfaces are smooth and clean .

2 . Do not remove the coupling bolts . Apply a coating of the assembly lube on the gasket .

3 . Install the coupling over the tube; mate the fitting to the coupling . Insure the fitting and tube are inserted into the coupling completely . Tighten the bolts evenly until the gap between the coupling halves has been eliminated and the coupling halves are aligned .

4 . Visually inspect the complete system to verify all bolts are tight, coupling halves are together, and couplings are fitted properly into the tube and fitting grooves .

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24680019 Rev A EN-10

Assembling Small and Large Piping Together

1 . Attach saddle clamp to header pipe with female threaded connection 2 . Screw male thread connector into female connector

Do not use slip agents, oil or grease unless you are sure they are compatible .

IF IN DOUBT, ASK US!

3 . Attach smaller piping to fitting

EN-11 24680019 Rev A

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DESIGN AND TESTING

GENERALThe need for continuous developments, expansions and modifications to factory production layouts, together with evolutions in production technology with a strong emphasis on automation, require flexible and generously sized compressed air systems to be installed .

VIBRATIoNSCompressors produce vibrations that can damage the system . Never connect rigid Ingersoll Rand tubes to the compressor; use hoses instead .

If tubes must be connected to sources of vibrations, isolate them with flexible supports .

SHoCK PRoTECTIoNThough the piping conveying compressed air must legally be fixed at least 2 .5 m from the ground, thereby making it unlikely to be hit, if the Ingersoll Rand system is installed at lower heights, even for short distances, it must be suitably protected as, though it is flexible, Ingersoll Rand piping cannot withstand violent impacts, especially from sharp points or cutting edges .

CoLoRPursuant to the ANS1 / ASME A13 .1 2007 standards, piping conveying compressed air must be painted light-blue . The SimplAir system is powder electro-painted light-blue and offers excellent resistance to corrosion . Powder coating is resistant UV Radiation and is therefor suited for outdoor applications .

SoURCES oF HEATGloss: 85+/-5 R .T .F . 2-3MILS Cure: 375F-18 MIN @ PMT Resin: Polyester

The aluminum tube can withstand temperatures up to 80°C / 176°F . The previous points also apply .

SIZING

The main line is a closed loop system .

The lines should slightly incline downwards (2%) towards a condensation collector and drain .

The piping should be large enough to cater for the maximum air flow required for the rated operating pressure, in order to minimize pressure drops that are simply a waste of energy . The maximum quantity of air required for each drop line is based on maximum consumption . Each drop line, multiplied by a factor (between > 0 .1 and 1) representing the frequency of use of the connected equipment, will give average consumption . The sum of the average consumption of all the drop lines will give the maximum air flow required for the main line . A percentage is added to this value for prudential reasons and future growth requirements . After obtaining the maximum air flows required for each drop line and for the main distribution line, the sizing of each pipe can easily be calculated from the tables .

Elements for calculating flow rates

The friction coefficient of the SimplAir systems offers much higher rates of flow than traditional products .

The following table shows the rates of flow in SRA – Standard Reference Atmosphere - at 20°C in litres/minute for a pressure drop of 2 .5% every 100 metres .

Table 8 : Maximum Flow Rate l/m (SRA)*

Diameter of Pipe (mm)

psi Bar 16 20 25 32 40 50 63 70 90 115 168 220

15 1 195 230 420 820 1480 2750 5120 6663 12300 21814 51049 91708

44 3 530 620 1160 2240 4160 7480 12420 14897 28200 48385 109203 192681

73 5 860 1010 1890 3640 6430 11400 21500 29876 51062 90249 210488 377543

102 7 1140 1360 2560 4960 9100 16900 29870 37666 57616 123143 284340 507488

145 10 1630 2050 3840 7350 13600 24100 45300 62238 107741 190385 443836 795844

174 12 2100 2450 4650 8650 15700 29300 55800 75528 135365 241408 568301 1023851

232 16 2800 3250 6200 10900 18600 36500 71400 96589 176363 317556 755204 1367276

Maximum Flow Rate cu .ft/m (SRA)*

Diameter of Pipe (mm)

psi Bar 16 20 25 32 40 50 63 70 90 115 168 220

15 1 7 8 15 29 52 97 181 235 434 770 1803 3239

44 3 19 22 41 79 147 264 439 526 996 1709 3856 6804

73 5 30 36 67 129 227 403 759 1055 1803 3187 7433 13333

102 7 40 48 90 175 321 597 1055 1330 2035 4349 10041 17922

145 10 58 72 136 260 480 851 1600 2198 3805 6723 15674 28105

174 12 74 87 164 305 554 1035 1971 2667 4780 8525 20069 36157

232 16 99 115 219 385 657 1289 2521 3411 6228 11214 26670 48285

* For reference only .

EN

24680019 Rev A EN-12

NORMOGRAM FOR DETERMINING DIAMETER, FLOW RATE, PRESSURE DROP AND PRESSURE

1 . Calculating the (external) diameter of the tube according to pressure, flow rate and permitted pressure drop:

draw a straight line from the pressure value (C axis) to the pressure drop value (A axis) meeting the R axis in X;

draw a straight line from the flow rate value (axis A) to X intersecting the B axis on the diameter to use .

2 . Calculating the flow rate according to diameter, pressure, and permitted pressure drop:

draw a straight line from the pressure drop value (A axis) to the pressure value (C axis) meeting R in X;

draw a straight line from X to the diameter value (B axis) and a straight line intersecting the A axis on the flow rate value .

3 . Calculating the pressure drop according to diameter, pressure, and flow rate:

draw a straight line from the flow rate value (A axis) to the diameter value (B axis) intersecting the R axis in X;

draw a straight line from X to the pressure value (C axis) intersecting the A axis on the pressure drop value .

The flow rate is expressed in SRA = real flow rate of effective pressure (P) x absolute pressure (P+1) in bar .

Temperature correction factor : 273/288 flow rate at 0°C = flow rate at 15°C x

Figure 5 : Normogram at 15°C

The pressure drops in piping are caused by several factors:

Friction in piping

Changes of direction and curves

Obstructions (valves, etc .)

Gradual or sudden changes in cross-sections

It is therefore necessary to use equivalent lengths in tubes of the same diameter for all types of unions; these will be added to the length of the tube when calculating the design length “L” .

TESTINGAll the articles in the SimplAir system is produced according to US, European and Canadian legislation, they are Tested during all the phases of the production process and afterwards .

All products are guaranteed for use within the limits indicated in this

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technical document .

The installations and systems produced with the SimplAir system is also guaranteed as long as the products are used and mounted according to the present specifications and limits .

During installation and afterwards certain checks and final testing should be performed .

INSPECTIoNAfter assembly, check that there are no faults, knocks, cuts, abrasions and make sure that the clamps and the line assembly comply with design specifications . In the event of problems, promptly replace the faulty parts or those parts that do not comply with design specifications .

AIR LEAK TESTINGImmediately after the last joint .

PRESSURE TESTING

WARNING! Before pressurizing the system, the following instructions must be carried out

Instructions:

1 . Check that all nuts on body of fittings are securely tightened .

2 . Insure that all tubing is fully inserted into each fitting .

3 . Insure that all mounting and hanging brackets are securely fastened to a solid structure and to the tubing .

4 . Insure that a pressure relief valve is installed and fully operational in the system to prevent over pressurization . (If not installed on storage tank, one must be fitted into the piping system) . Safety valve must be rated at no more than 1 .5X system max working pressure .

5 . Insure that an isolation valve is installed between the compressors and the piping system and is in a “closed” position . Install a pressure gauge downstream of the isolation valve so that system pressure can be viewed when isolation valve is in either open/closed position .

6 . Close all outlet points in piping system .

7 . Insure that the test area is vacated for the duration of the pressure test .

8 . Run compressor/s and fill storage tank to the required system max working pressure .

Once storage tank is pressurized, open isolation valve “very slowly” . Allow system pressure to build up to 15psig only and close off the isolation valve . (Hold pressure for 10 minutes) .

Inspect system for any leakage or slippage

If system is secure at 15 psig, repeat steps b & c in 15 psi increments until maximum working pressure is achieved .

9 . When full system working pressure is achieved, hold system pressure for 1 hour . (Maximum working pressure not to exceed 220psig) .

10 . Note: All systems will show a small amount of pressure loss over a one hour period . This does not indicate leakage, and is usually due to temperature and humidity conditions .

11 . Re-inspect system for leakage and loose/slipping joints .

12 . If any faults are found in the system, depressurize the system . Correct faults and re- test per item 7 to 11 .

START-UPAfter performing the above procedures, clean and dry the system with compressed air, leaving one or more points in the system open in order to eliminate all the foreign bodies and dry the system .

After the first 48 to 96 hours of operation, check all the joints and make sure all the ring nuts are tight, as these may have loosened due to the settling of the components .

a .

b .

c .

EN-13 24680019 Rev A

EN

PARTS LIST Description IR CCN

20mm - Tubing Blue (16ft lengths) 48779615

25mm - Tubing Blue (16ft lengths) 48779623

32mm - Tubing Blue (16ft lengths) 48779631

40mm - Tubing Blue (16ft lengths) 48779649

50mm - Tubing Blue (16ft lengths) 48779656

63mm - Tubing Blue (16ft lengths) 48779664

70mm - Tubing Blue (16ft Lengths) 48779599

90mm - Tubing Blue (16ft Lengths) 48779573

115mm - Tubing Blue (16ft Lengths) 48779557

168mm - Tubing Blue (16ft Lengths) 48779565

220mm – Tubing Blue (16ft Lengths) 48779581

Straight male Connector 20mm x 1/2” NPT 48779276

Straight male Connector 25mm x 3/4” NPT 48779284

Straight male Connector 32mm x 1” NPT 48779292

Straight male Connector 40mm x 1-1/2” NPT 48779300

Straight male Connector 50mm x 1-1/2” NPT 48779318

Straight male Connector 63mm x 2” NPT 48779326

Straight Union Connector 20mm 48779342

Straight Union Connector 25mm 48779359

Straight Union Connector 32mm 48779367

Straight Union Connector 40mm 48779375

Straight Union Connector 50mm 48779383

Straight Union Connector 63mm 48779391

Straight Union Coupling 70mm,Rigid 48779474

Straight Union Coupling 70mm,Flexible, Aluminum 48779433

Straight Union Coupling 90mm,Rigid 48779524

Straight Union Coupling 90mm,Flexible, Aluminum 48779441

Straight Union Coupling 115mm,Rigid 48779466

Straight Union Coupling 115mm,Flexible, Aluminum 48779417

Straight Union Coupling 168mm,Rigid 48779482

Straight Union Coupling 168mm,Flexible, Aluminum 48779425

Straight Union Coupling 220mm,Rigid, Galv . 48779490

Straight Union Coupling 220mm,Flexible, Galv . 48779516

Straight Union Coupling 220mm, High Temp 48779508

90° Union Elbow 25mm 48779870

90° Union Elbow 32mm 48779888

90° Union Elbow 40mm 48779896

90° Union Elbow 50mm 48779904

90° Union Elbow 20mm 48779912

90° Union Elbow 63mm 48779920

EN

24680019 Rev A EN-14

Description IR CCN90° Union Elbow 70mm (with couplings) 48779748

90° Union Elbow 90mm (with couplings) 48779755

90° Union Elbow 115mm (with couplings) 48779763

90° Union Elbow 168mm (with couplings) 48779771

Union Elbow 90 deg . 220mm Aluminum w/ Couplings (Kit) 48779789

Union Elbow 45 deg . 20mm 48779805

Union Elbow 45 deg . 25mm 48779813

Union Elbow 45 deg . 32mm 48779821

Union Elbow 45 deg . 40mm 48779839

Union Elbow 45 deg . 50mm 48779847

Union Elbow 45 deg . 63mm 48779854

Union Elbow 45 deg . 70mm (with couplings) 48779680

Union Elbow 45 deg . 90mm (with couplings) 48779698

Union Elbow 45 deg . 115mm (with couplings) 48779706

Union Elbow 45 deg . 168mm (with couplings) 48779714

Union Elbow 45 deg . 220mm Aluminum w/ Couplings (Kit) 48779722

Junction Tee 20mm 48777684

Junction Tee 25mm 48777692

Junction Tee 32mm 48777700

Junction Tee 40mm 48777718

Junction Tee 50mm 48777726

Junction Tee 63mm 48777734

Junction Tee 70mm (with couplings) 48777650

Junction Tee 90mm (with couplings) 48777668

Junction Tee 115mm (with couplings) 48777635

Junction Tee 168mm (with couplings) 48777643

Junction Tee 220mm Aluminum w/ Couplings 24680076

Reduction Outlet Tee 20mm x 20mm (With water trap insert) 48777866

Reduction Outlet Tee 25mm x 20mm (With water trap insert) 48778674

Reduction Outlet Tee 32mm x 20mm (With water trap insert) 48778682

Reduction Outlet Tee 32mm x 25mm (With water trap insert) 48778690

Reduction Outlet Tee 40mm x 20mm (With water trap insert) 48778708

Reduction Outlet Tee 40mm x 25mm (With water trap insert) 48778716

Reduction Outlet Tee 50mm x 20mm (With water trap insert) 48778724

Reduction Outlet Tee 50mm x 25mm (With water trap insert) 48778732

Reduction Outlet Tee 50mm x 32mm (With water trap insert) 48778740

Reduction Outlet Tee 63mm x 20mm (With water trap insert) 48778757

Reduction Outlet Tee 63mm x 25mm (With water trap insert) 48778765

Reduction Outlet Tee 63mm x 32mm (With water trap insert) 48778773

EN-15 24680019 Rev A

EN

Description IRCCN

Outlet, Saddle Clamp Reducer 32mm to 20mm 48777890

Outlet, Saddle Clamp Reducer 32mm to 25mm 48777908

Outlet, Saddle Clamp Reducer 40mm to 20mm 48777916

Outlet, Saddle Clamp Reducer 40mm to 25mm 48777924

Outlet, Saddle Clamp Reducer 50mm to 20mm 48777932

Outlet, Saddle Clamp Reducer 50mm to 25mm 48777940

Outlet, Saddle Clamp Reducer 63mm to 20mm 48777957

Outlet, Saddle Clamp Reducer 63mm to 25mm 48777965

Saddle Clamp Outlet, 70mm X 1/2” NPT Female 48779052

Saddle Clamp Outlet, 70mm X 3/4” NPT Female 48779060

Saddle Clamp Outlet, 70mm X 1” NPT Female 48779037

Saddle Clamp Outlet, 70mm X 1 .5” NPT Female 48779045

Saddle Clamp Outlet, 90mm X 3/4” NPT Female 48779102

Saddle Clamp Outlet, 90mm X 1” NPT Female 48779078

Saddle Clamp Outlet, 90mm X 1 .5” NPT Female 48779086

Saddle Clamp Outlet, 90mm X 2” NPT Female 48779094

Saddle Clamp Outlet, 115mm X 3/4” NPT Female 48778948

Saddle Clamp Outlet, 115mm X 1” NPT Female 48778914

Saddle Clamp Outlet, 115mm X 1 .5” NPT Female 48778922

Saddle Clamp Outlet, 115mm X 2” NPT Female 48778930

Saddle Clamp Outlet, 168mm X 1 .5” NPT Female 48778963

Saddle Clamp Outlet, 168mm X 2” NPT Female 48778989

Saddle Clamp Outlet, 168mm X 115mm Grooved (no couplings) 48778971

Saddle Clamp Outlet, 168mm X 90mm Grooved (no couplings 48778955

Saddle Clamp Outlet, 220mm X 2” NPT Female 48779029

Saddle Clamp Outlet, 220mm X 70mm Grooved 48778997

Saddle Clamp Outlet, 220mm X 90mm Grooved 48779003

Saddle Clamp Outlet, 220mm X 115mm Grooved 48779011

Drain Coupling 25mm 48777460

Drain Coupling 32mm 48777478

Drain Coupling 40mm 48777486

Drain Coupling 50mm 48777494

Drain Coupling 63mm 48777502

EN

24680019 Rev A EN-16

Description IRCCN

Outlet Elbow /Bracket Assy 20mm x 1/2”NPT (c/w Mtg Bracket) 48777809

Outlet Elbow /Bracket Assy 25mm x 1/2”NPT (c/w Mtg Bracket) 48777817

Outlet Elbow /Bracket Assy 32mm x 1/2”NPT (c/w Mtg Bracket) 48777825

Double Outlet Elbow /Bracket Assy 20mm x 1/2”NPT (c/w Mtg Bracket) 48777437

Double Outlet Elbow /Bracket Assy 25mm x 1/2”NPT (c/w Mtg Bracket) 48777445

Plug Cap 20mm 48778062

Plug Cap 25mm 48778070

Plug Cap 32mm 48778088

Plug Cap 40mm 48778096

Plug Cap 50mm 48778104

Plug Cap 63mm 48778112

Plug Cap 70mm Ductile Galv . (no couplings) 48778021

Plug Cap 90mm Aluminum (no couplings) 48778039

Plug Cap 90mm Ductile Galv . (no couplings) 48778047

Plug Cap 115mm Aluminum (no couplings) 48777981

Plug Cap 115mm Ductile Galv . (no couplings) 48777999

Plug Cap 168mm Ductile Galv . (no couplings) 48778005

Plug Cap 220mm Ductile Galv 48778013

Reducer, 25mm Body to 20mm Tube 48778559

Reducer, 32mm Body to 20mm Tube 48778567

Reducer, 32mm Body to 25mm Tube 48778575

Reducer, 40mm Body to 20mm Tube 48778583

Reducer, 40mm Body to 25mm Tube 48778591

Reducer, 40mm Body to 32mm Tube 48778609

Reducer, 50mm Body to 25mm Tube 48778617

Reducer, 50mm Body to 32mm Tube 48778625

Reducer, 50mm Body to 40mm Tube 48778633

Reducer, 63mm Body to 40mm Tube 48778641

Reducer, 63mm Body to 50mm Tube 48778658

EN-17 24680019 Rev A

EN

Description IRCCN

Reducer, 90mm TUBE to 70mm TUBE (no couplings) 48778476

Reducer, 115mm TUBE to 70mm TUBE (no couplings) 48778484

Reducer, 115mm TUBE to 90mm TUBE (no couplings) 48778492

Reducer, 168mm TUBE to 90mm TUBE (no couplings)

Reducer, 168mm TUBE to 115mm TUBE (no couplings)

48778518

Reducer, 220mm TUBE to 168mm TUBE, Galv . 48778534

Reducer, 220mm TUBE to 115mm TUBE, Galv 48778526

Adapter, 70mm TUBE to 1 1/2” NPT male (no couplings) 48776967

Adapter, 70mm TUBE to 2” NPT male (no couplings)

48776975Adapter, 70mm TUBE to 2 1/2” NPT male (no couplings)

48776983

Adapter, 90mm TUBE to 1 1/2” NPT male (no couplings) 48776991

Adapter, 90mm TUBE to 2” NPT male (no couplings)

48777007Adapter, 90mm TUBE to 2 1/2” NPT male (no couplings)

48777015

Adapter, 90mm TUBE to 3” NPT male (no couplings) 48777023

Adapter, 115mm TUBE to 2” NPT male (no couplings)

48776926Adapter, 115mm TUBE to 2 1/2” NPT male (no couplings)

48776934

Adapter, 115mm TUBE to 3” NPT male (no couplings) 48776942

Adapter, 115mm TUBE to 4” NPT male (no couplings) 48776959

Adapter, 115mm TUBE to 4”, NPT, female (no couplings) 48777049

Adapter, 70mm TUBE to 2 1/2”, NPT, female (no couplings) 48777056

Adapter, 90mm TUBE to 3”, NPT, female (no couplings) 48777064

Flange, 90mm TUBE to Ansi 3”, 150 Flange 48777601

Flange, 115mm TUBE to Ansi 4”, 150 Flange 48777577

Flange, 168mm TUBE to Ansi 6”, 150 Flange 48777585

Flange, 220mm TUBE to Ansi 8”, 150 Flange, Galv . 48777593

Reducer kit, 90mm TUBE to 6” ANSI 150 Flange 48778443

Reducer kit, 90mm TUBE to 4” ANSI 150 Flange 48778435

Reducer kit, 90mm TUBE to 2 1/2” ANSI 150 Flange 48778419

Reducer kit, 90mm TUBE to 2” ANSI 150 Flange 48778427

Reducer kit, 115mm TUBE to 6” ANSI 150 Flange 48778401

Reducer kit, 115mm TUBE to 3” ANSI 150 Flange 48778393

Reducer kit, 115mm TUBE to 2 1/2” ANSI 150 Flange 48778377

Reducer kit, 115mm TUBE to 2” ANSI 150 Flange 48778385

Reducer Union Coupling 220mm - 168mm 48778450

Tool, Drill Jig Saddle Clamp 32mm 48777528

Tool, Drill Jig Saddle Clamp 40mm 48777536

Tool, Drill Jig Saddle Clamp 50mm 48777544

Tool, Drill Jig Saddle Clamp 63mm 48777551

48778500

EN

24680019 Rev A EN-18

Description IRCCNStem Adapter, 20mm X 1/2” NPT Female 48779128

Stem Adapter, 20mm X 1/2” NPT Male 48779144

Stem Adapter, 20mm X 3/4” NPT Male 48779151

Stem Adapter, 25mm X 1/2” NPT Male

48779169

Stem Adapter, 25mm X 3/4” NPT Male

48779177

Stem Adapter, 25mm X 1” NPT Male

48779185

Stem Adapter, 32mm X 1” NPT Male 48779193

Stem Adapter, 32mm X 1 1/2” NPT Male 48779201

Stem Adapter, 40mm X 1 1/2” NPT Male 48779219

Stem Adapter, 50mm X 1 1/2” NPT Male

48779227Stem Adapter, 50mm X 2” NPT Male

48779235

Stem Adapter, 63mm X 2” NPT Male 48779243

Stem Adapter, 63mm X 2 1/2” NPT Male 48779250

Ball valve, 20mm Tube 48779987

Ball valve, 25mm Tube 48779995

Ball valve, 32mm Tube 48780001

Ball valve, 40mm Tube 48780019

Ball valve, 50mm Tube 48780027

Ball valve, 63mm Tube 48780035

Ball valve, 1/2”F x 1/2”F NPT 48779946

Ball valve, 3/8”M x 3/8” F NPT

48779953Ball valve, 1/2”M x 1/2” F NPT

48779961

Outlet Y Adaptor 1/2”male x 1/2”female NPT 48777874

Quick Coupler, Universal Socket, 3/8” NPT Male 48778351

Quick Coupler, Universal Socket, 1/2” NPT Male 48778336

Quick Coupler, Universal Socket, 1/4” NPT Male 48778344

Quick Coupler, Universal Socket, 1/4” NPT Female 48778302

Quick Coupler, Universal Socket, 3/8” NPT Female 48778310

Quick Coupler, Universal Socket, 1/2” NPT Female 48778294

Quick Coupler, Universal Socket, 1/4” Hose Barb 48778260

Quick Coupler, Universal Socket, 3/8” Hose Barb 48778278

Quick Coupler, Universal Socket, 1/2” Hose Barb 48778252

Manifold, Outlet 1/2” in (4 x 1/2” NPT Female outlets) 48777841

Manifold, Outlet 3/4” (4 x 1/2” NPT Female outlets) 48777858

Plug, Manifold 1/2” NPT w/Seal 48777775

EN-19 24680019 Rev A

EN

Description IRCCN

Plug, 1/4” NPT Male 48778229

Plug, 3/8” NPT Male 48778237

Plug, 1/2” NPT Male 48778211

Plug, 1/4” NPT Female 48778187

Plug, 3/8” NPT Female 48778195

Plug, 1/2” NPT Female 48778179

Plug, 1/4” Hose Barb 48778146

Plug, 3/8” Hose Barb 48778153

Plug, 1/2” Hose Barb 48778138

TEN POSITION - Butterfly valve, 70mm TUBE (with couplings) 48780084

TEN POSITION - Butterfly valve, 90mm TUBE (with couplings) 48780092

TEN POSITION - Butterfly valve, 115mm TUBE (with couplings) 48780050

TEN POSITION - Butterfly valve, 168mm TUBE (with couplings) 48780068

TEN POSITION - Butterfly valve, 220mm w/ Couplings 48780076

Cutting Tool, 32-40mm 48777395

Cutting Tool, 50-63mm 48777403

Bracket, Strut 20mm /Pack 10 48777205

Bracket, Strut 25mm /Pack 10 48777213

Bracket, Strut 32mm /Pack 10 48777221

Bracket, Strut 40mm /Pack 10 48777239

Bracket, Strut 50mm /Pack 10 48777247

Bracket, Strut 63mm /Pack 10 48777254

Spacer Kit, 1”x 3”x1/2”thk, (pack of 10) 24668931

Bracket, Hanging 20mm & 25mm (each) 48777148

Bracket, Hanging 32mm (each) 48777155

Bracket, Hanging 40mm (each) 48777163

Bracket, Hanging 50mm (each) 48777171

Bracket, Hanging 63mm (each) 48777189

Bracket Hanger (3/8” female insert) 70-mm-Steel 48777106

Bracket Hanger (3/8” female insert) 90-mm-Steel 48777114

Bracket Hanger (3/8” female insert) 115mm-Steel 48777098

Bracket Hanger (1/2’ female insert with 3/8” adapter) 168mm-Steel 48777080

Bracket, Hanger, (1/2” threaded insert) 220mm steel 48777122

Wire Hanger 15ft lengths x pk of 10 (3/8” thread) (use with hanging bracket) 48780126

Wire Hanger 15ft lengths x pk of 10 (1/4” thread) (use with strut bracket) 48780118

EN

24680019 Rev A EN-20

Description IRCCNBracket, Wall 20mm (each) 48777270

Bracket, Wall 25mm (each) 48777288

Bracket, Wall 32mm (each) 48777296

Bracket, Wall 40mm (each) 48777304

Bracket, Wall 50mm (each) 48777312

Bracket, Wall 63mm (each) 48777320

Wall Bracket with Pipe Strap & Bolts 70mm 48777353

Wall Bracket with Pipe Strap & Bolts 90mm 48777361

Wall Bracket with Pipe Strap & Bolts 115mm 48777346

Cantelever Wall Bracket 48777379

Tube Cutter 48779532

Deburring tool 48777411

Manual Grooving Tool - common for all three sizes 48777783

Groove Gage 48777619

Assembly Lube, Pack of 12 tubes, 4 .5oz ea 48777742

Assembly Lube, 1 Quart container 48777759

SimplAir Demo Kit, pipe & fittings w/case 48779110

Replacement Seal, 70mm Standard 48778880

Replacement Seal, 70mm High Temperature 48778815

Replacement Seal, 90mm Standard 48778898

Replacement Seal, 90mm High Temperature 48778823

Replacement Seal, 115mm Standard 48778856

Replacement Seal, 115mm High Temperature 48778799

Replacement Seal, 168mm Standard 48778864

Replacement Seal, 168mm High Temperature 48778807

Replacement Seal, 220mm Standard 48778872

Replacement Seat, 220mm High Temp (O Seal) 48778831

Reducer Union Coupling 90 mm x 70 mm 24670143

Reducer Union Coupling 115 mm x 70 mm 24670150

Reducer Union Coupling 115 mm x 90 mm 24670168

Reducer Union Coupling 168 mm x 115 mm 24670176

Reducer Union Coupling 220 mm x 168 mm 48778450

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