HYDRA® GS INSTALLATION MANUAL
Contents
1. After a maximum of 8 seconds the press head will have expanded the connection part The axial pressing tool then switches off automatically and it can simply be pulled out of the corrugated pipe To remove the press head release the slide on the rear of the tool The press head then moves back to Its origi nal position Step 8 Remove the press head Step 9 Seal the connection part 28 mm turning it 90 anticlockwise Remove the press head by pressing the unlocking mechanism on the end and by Wrap with adhesive tape beginning on the hose and working towards the fitting Overlap the layers by approx 0 5 cm Make sure there are no creases Wrap two layers of tape around the hose and the fitting up to the nut 3847uk 1 08 15 10 WITZENMANN 35 5 ASSEMBLY HYDRA GS CLICK Push the end of the hose firmly into the fitting There will be an positive click 5 1 Assembly procedure Step 1 Prepare the hose The initial piece of the rolled up HYDRA GS corrugated pipe must always be cut off with a clean cut prior to use Measure the suitable pipe length Tighten the fitting using a wrench The dis tance between the brass parts of the fitting after tightening should be 0 5 mm max Step 2 Cut the corrugated pipe to length Use the corrugated pipe cutter to cut the sheathed pipe to length The cut must be lo cated in the groove of a corrugation Turn the pipe cutter in one directio2. 1 45 m 7 0 0 9 0 2 8 1 m 128 Pa GDS 6 kW GSD 2 5 m DN 15 2 5 Pa m 3 9 0 5 0 2 0 45 3 25 3847uk 1 08 15 10 260 Pa 20 Pa 35 Pa 66 Pa 9 9 0 6 0 3 0 2 11 0 m Line 2 1 224 Pa 15 Pa 10 Pa 10 Pa Line 3 0 WITZENMANN 25 3 5 Pressure loss calculation with software tool First open the HydraGS xlt file with a double click Important Macros must be activated To fill in the empty dialogue box click one of the two buttons Create new project or Edit project A dialogue box appears which has the same structure If a dialogue box is called up which has already been filled in xls then the Create new project button deletes all previous entries WITZENMANN Calculation Of The Pressure Loss Hydra GS Gent pew BSR Md do Senez Laure ee UE e r CT bege p ery eur Sta Ej a a x mp a b aaa eia prebe ese ITa 1 e e npn diren z hi Selection of the gas type using the drop down menu and the operating conditions in the head of the table The proposed values for gas temperature connection pressure permissible pressure loss and net calorific value can be overwritten e ype Gas temperature C baieta pressure Pa 26 WITZENMANN 3847uk 1 08 15 10 HYDRA Entry of the pipeline routing starting from the house connection in column 2 Select Continue if subdividing into several se
3. WITZENMANN 11 Reducer HYDRA GS Press Reducers have a large 24 cone with a rotatable union nut and a smaller 24 cone with male thread They are used for reducing the diameter of branches to the existing connection This means it is possible to make connections to additional lines using smaller nominal diameters The reduction from DN 20 to DN 16 is made directly with the rotatable connections since these are compatible in diam eter and thread Material brass m O ring HNBR Connection to I piece Nominal diameter x cone x union nut Connection to hose Article number Weight Nominal diameter x thread thread DN DN kg 22 x M30 x 2 25 x 24 x M36 x 2 1198231 0 190 28 X M36 X2 32 x 24 x M48 x 2 1198232 0 397 Conical nipple HYDRA GS Press The cone nipples have a 24 cone with male thread and are connected using a swivel connection in order to con nect two HYDRA GS stainless steel corrugated pipes of the same diameter together Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x cone x thread DN kg barazkiz 1198233 0 083 2A XZA SONS 2 1198234 0 096 280074 x M30 x2 1196235 0 130 32x24 x M43 x72 1198236 0 233 12 WITZENMANN 3847uk 1 08 15 10 HYDRA Press case HYDRA GS Press w HYDRA EE B Tool case Case content 1 Charger 4 Adhesive tape 2 Expansion head 5 4 Press heads DN 15 DN 22 DN 28 DN 32 3 Axial
4. components from other manufacturers can be en tered in columns 12 and 13 a eee ar aa ee bord Pza ern eei kezkei EEE EEE EA in er pee alr Se ES OOO EE a a we A af gt a ae S ee a j a E FEJ tre ew ela fe a E LGA ur Me l e EEE ESA Siasa E Gen TZ a eee C E LO Tb pd SK a ee a a AE EEE EEE EEE Si Pre Tea TT e en ear Se pe pn e Column 14 shows the pressure loss of the individual line and column 15 shows the total for the particular consumer If the result in column 15 is larger than the permissible pressure loss then the result is shown in red In this case it is necessary to Increase the nominal diameter in column 7 from 16 to 20 for line 2 1 Alternatively however changing the type and number of installed parts can produce a successful result 28 WITZENMANN 3847uk 1 08 15 10 HYDRA Once the dialogue box has been closed cross the dialogue box allowing saving and printing with normal Windows functions is activated again The entries can be edited again using the Edit project button Advantages of the software tool compared to using the table m The pressure loss values of the lines are only rounded off at the end of the calculation This makes the result more accurate m The pipeline cross sections can be optimised very quickly The result is displayed immediately after each entry is completed Dialogue boxes that have already been created can be modified for sim
5. corrugated pipe against corrosion If there is damage renew the affected section Avoid using compounds containing chloride e g for detecting leaks Contact with such com pounds can cause the HYDRA GS stainless steel corrugated pipes to corrode 9 RECOMMENDATIONS FOR STORING THE GASKETS At all intermediate stages between manufacture and use store the gaskets in accordance with the recommendations of ISO 22301 Comply with the following points a The storage temperature should be below 25 C preferably below 15 C b The gaskets should be protected against light in particular against strong sunlight and artifi cial light with a high ultraviolet proportion c The gaskets should not be stored in a room containing systems that can generate ozone e g mercury arc lamps or devices with high voltage electricity which can Cause sparking and dark electrical discharges d The gaskets should be stored without stress i e without tension pressure or other deforma tions for example they should not be hung up e The gaskets should be kept clean HYDRA 3847uk 1 08 15 10 WITZENMANN 43 10 REPAIR METHODS 10 1 Damage to the HYDRA GS stainless steel corrugated pipes The flexible corrugated pipes must be renewed without fail if m there is visible damage to the PE sheathing m the corrugated pipe has been bent too tightly leaving a kink m the corrugated pipe has been damaged by a sharp or pointed object m the corruga
6. gas and liquified petrol gas 2nd and 3rd family gas 1 3 Definition 1 3 1 System definition HYDRA GS is a flexible gas installation system for carrying gas in the building technology HY DRA GS is offered in the four nominal diameters DN 15 DN 22 DN 28 and DN 32 HYDRA GS consists of flexible corrugated hoses and HYDRA GS Press fittings or HYDRA GS Click fittings special fastening elements a battery operated axial pressing tool for expanding the HYDRA GS Press fittings and configuration software for determining the size of the pipelines 1 3 2 Flexible corrugated hoses PLT pliable tube Corrugated sheathed pipe which can be bent by hand easily for a limited number of times WITZENMANN 3847uk 1 08 15 10 HYDRA 1 4 Specifications Gas installers shall be in possession of a valid certificate of competence for activities necessary to install and test the gas installation system HYDRA GS see BS 6891 section 4 The valid certificate must have been issued under either the Approved Code of Practise ACoP or the National Accredited Certification Scheme ACS for individual gas installers or an equivalent qualification All businesses and individuals undertaking gas work on Installations supplied with natural gas or LPG must be registered with a body approved by the Health and Safety Executive HSE In Great Britain it is The Gas Safe Register In Northern Ireland the Cannel Islands and the Isle of Man consult the relevant autho
7. press head lock the pull rod with the bayonet socket 32 WITZENMANN Select the appropriate press head from the tool case to match the diameter of the fitting Push the press head from the front into the connection fitting with the threaded part fore most Push the press head as far as possible into the fitting Then insert the press head as far as possible into the axial pressing tool Turn 90 clock wise in the chuck of the axial pressing tool to lock the press head bayonet socket Briefly operate the axial pressing tool to secure the connection part on the centring piece of the axial pressing 3847uk 1 08 15 10 HYDRA Step 5 Carry out visual inspection TAL AAD AAe 3847uk 1 08 15 10 The expanded corrugated pipe is pushed over the connection part The necessary insertion depth has been rea ched when the yellow PE sheathing can be seen in the round viewing holes of the con nection part The corrugated pipe then makes firm metal on metal contact with the connection part Right The viewing window is completely fil led by the corrugated pipe Wrong Inadequate Insertion depth The cut edge of the corrugated pipe must never be visible in the viewing window WITZENMANN 33 _ Step 6 Install the connection part Step 7 Trigger the return stroke 34 WITZENMANN 3847uk 1 08 15 10 The battery operated axial pressing tool is started at the push of a button
8. pressing tool 6 Pipe cutter Pipe cutter HYDRA GS Press a conse e en The corrugated pipe cutter is used for cutting the corruga ted tube to the required length Dimensions Article number Nominal diameter DN 15 16 32 1158149 3847uk 1 08 15 10 WITZENMANN 13 Expansion head HYDRA GS Press 2 2 HYDRA GS Click Expansion head The expansion tool is used for correcting the deformation Threaded BSP fixed taper male HYDRA GS Click of the cut edge created when cutting the corrugated pipe and for expanding the corrugated pipe to the diameter re Threaded BSP fixed taper male acc to DIN EN 10226 1 quired for assembly with the fitting The expander head is compatible with commercially available expansion tongs or electrohydraulic guns with 18 cones are used for connecting the pliable HYDRA GS stainless steel corrugated pipes to the female thread connections of valves fittings or gas sockets Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg 15 3 8 1197725 0 181 15 1 1197726 0 191 EEE 1197727 0 322 28 1 1197728 0 331 ge eae b e 32 14 1197729 0 440 DN Expansion tool 14 WITZENMANN 15 10 32 1060722 15 to 32 1078856 Threaded BSP para fixed female HYDRA GS Click Threaded BSP para fixed female acc to DIN EN 10226 1 are used for connecting the pliable HYDRA GS stainless st
9. A M8 59 44 26 20 1 25 1052556 28 32 35 E M8 65 51 EA r20 x 1 25 1052560 32 114 M8 74 60 34 120x1 25 1052562 Caddy clip HYDRA GS The holding loop is an alternative to the BISMAT Flash pipe clamp and is also used for fastening the corrugated pipes to the building structure or supporting structures Material galvanised steel DN d B A Article number mm Inch mm mm DD 34 60 3 31 8 1052521 28 33 7 E 68 3 36 5 1052527 32 77 8 41 3 1052528 3847uk 1 08 15 10 WITZENMANN 19 Strip earth band HYDRA GS The strip earthing clip is used for potential equalisation for the building installation m Material stainless steel V2A Type for corrugated pipe diameter Article number DN SZ 15 16 32 1051809 Coroplast adhesive tape e HYDRA GS i J Type Length x width Article number PVC302 10mx25 mm 1147254 20 WITZENMANN 3847uk 1 08 15 10 HYDRA 3 DIMENSIONING THE PIPELINE SYSTEM 3 1 Basis for dimensions The design and installation of low pressure gas pipework in domestic premises is specified in BS 6891 2nd family gas and BS 5482 1 3rd family gases whilst pipework with larger bore sizes and higher operating pressure is covered in IGEM UP 2 Latest Edition Strength testing tightness testing and direct purging of installation pipework are covered in the IGE UP 1 standards Natural gas L Natural gas H Propane Operating temperature t GE 15 15 25 Operating pres
10. Press T piece 11 HYDRA GS Press Reducer 12 HYDRA GS Press Conical nipple 12 HYDRA GS Press Press case 13 HYDRA GS Press Pipe cutter 13 HYDRA GS Press Expansion head 14 B HYDRA GS Click 15 HYDRA GS Click Threaded BSP fixed taper male 15 HYDRA GS Click Threaded BSP para fixed female 15 HYDRA GS Click T piece 16 HYDRA GS Click Solder socket 17 HYDRA GS Click Connection BS 746 female 17 HYDRA GS Click Copper compression fitting 18 HYDRA GS Click Straight Coupling 18 de HYDRA GS Press und HYDRA GS Click 19 HYDRA GS BISMAT Flash pipe clamp 19 HYDRA GS Caddy clip 19 HYDRA GS Strip earth band 20 HYDRA GS Coroplast adhesive tape 20 WITZENMANN 3847uk 1 08 15 10 3 Dimensioning the pipeline system 21 dk Basis for dimensions 21 3 2 Preliminary dimensioning using table 21 da Pressure losses in the corrugated pipeline 22 3 3 1 Natural gas L 22 3 3 2 Natural gas H 23 3 3 3 Propane gas 24 dd Example calculation 25 39 Pressure loss calculation with software tool 26 4 Assembly HYDRA GS Press 30 4 1 Assembly procedure 30 5 Assembly HYDRA GS Click 36 Bk Assembly procedure 36 6 Assembly on parts outside the HYDRA GS gas installation system 38 6 1 Valid for HYDRA GS Press and Click Tightening torques 38 6 2 Valid for HYDRA GS Press and Click Minimum bending radii 38 7 General notes on installation 39 7 1 General inst
11. Quality by Witzenmann Witzenmann UK Ltd Head Office 2 Earn Avenue Righead Industrial Estate Bellshill Scotland ML4 3LW Phone 44 1698 74 96 60 Fax 44 1698 74 07 74 infouk witzenmann uk com www witzenmann co uk Office Suite 9 Cwm Cynon Business Centre Cwm Cynon Industrial Park Mountain Ash Mid Glamorgan CF45 4ER Phone 44 1443 471000 Fax 44 1443 479638 infouk witzenmann uk com Unit 4 Whitfield Business Park Manse Lane Knaresborough North Yorkshire HG5 8BS Phone 44 1423 868586 Fax 44 1423 865783 infouk witzenmann uk com 3847uk 1 08 15 10 WITZENMANN HYDRA G INSTALLATION MANUAL United Kingdom and Ireland bsi Stainless Steel Pliable Tubing KITEMARK KM 594313 BS EN 15266 managing flexibility CONTENTS 1 Scope of application and general notes 4 1 1 Validity 4 1 2 The product 4 1 0 Definition 4 1 3 1 System definition 4 1 3 2 Flexible corrugated hoses PLT pliable tube 4 1 4 Specifications 5 15 Standards and codes of practice 6 1 6 System conformity 7 Md Fields of application 7 1 8 Operating conditions 7 2 HYDRA GS installation system and system components 8 HYDRA GS stainless steel corrugated pipes and pipe dimensions g 2 1 HYDRA GS Press 10 HYDRA GS Press Threaded nipple 10 HYDRA GS Press Swivel connection 10 HYDRA GS Press Adaption 11 HYDRA GS
12. ctice m Fittings and components must be arranged and supported so that they cannot transmit any impermissible forces and deformations onto the pipe system Corrugated pipelines do not provide a sufficiently rigid connection m The sealing surfaces of connection parts must remain undamaged during laying m Connection parts must be installed where they are easily accessible m The number of connection parts must be reduced to the minimum necessary m Inner pipes must be laid in accordance with the applicable codes of practice m Charge the battery prior to initial use m Press heads should not be greased HYDRA 3847uk 1 08 15 10 WITZENMANN 39 7 2 HYDRA GS Fire behaviour HYDRA GS stainless steel corrugated pipes have been tested for their fire behaviour in accor dance with EN 13501 1 and have been classified as B S 1 D2 The PE sheathing does not constitute an insulating layer as defined by BS 4102 7 3 Potential equalisation Gas pipe lines may not be used fully or in part as protective or operational earths or as protec tive earth conductors in electrical systems Gas pipelines may not be used as a lightning con ductors or earthings in lightning protection systems The metal inner piping of each building must be connected to the relevant equipotential equalisation system Please observe also BS 6891 8 6 and BS 5482 1 12 3 3 1 Strip earthing clip on hexagon profile 2 HYDRA GS corrugated pipe 3 HYDRA GS union nut nipple w
13. ctions Select Branch if a branch follows If the line ends at the consumer enter End and the nominal load column 5 The lines are numbered automatically columns 1 3 4 Entries are only possible in the white fields o O0 O O 8 10 6 kWh jim Follow on Folow on Follow on Nominal Height connection connection connection load kW difference line 1 line 2 m HYDRA 3847uk 1 08 15 10 WITZENMANN 27 m Enter the nominal diameter in column 7 The subsequent line should only be one nominal diameter smaller than the previous one m After a branch is entered in column 2 two subsequent lines are displayed In column 8 for the first follow on line now select whether the flow through the I piece is straight or as a I branch The second follow on line is always a I branch A diameter reduction of the follow on line is automatically taken into account Column 9 contains the extended pipe length of the line m The number of 90 bends is entered in column 10 However it is also possible to enter frac tions e g 30 0 33 m Connections in column 11 refers to all starting or finishing pieces on the hose irrespective of whether they are threaded or cone connections In the case of reducers the connector must always be entered in the line with the smaller nominal diameter 2 connections must be counted for a hose extension by a cone screw connection m The pressure losses and descriptions of
14. eel corrugated pipes to the male thread connections of valves fittings or gas sockets Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg 15 1 5 1197731 0 20 28 1 2 1197733 0 316 28 3 4 1197735 0 286 EE 0 420 3847uk 1 08 15 10 3847 uk 1 08 15 10 WITZENMANN 15 T piece HYDRA GS Click The I pieces are used as connection elements to other lines and thus make it possible to connect additional Solder socket HYDRA GS Click Connection part with solder lugs for connecting pliable HYDRA GS stainless steel corrugated pipes with copper consumers m Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg 15 1197740 0 517 22 1197739 0 918 28 1197742 0 849 32 1197748 1 54 22 x22x15 1197738 0 863 22x15x15 1197741 0 783 28x28x15 1197744 0 798 28 x22 x22 1197746 0 865 28x22x15 1197747 0 813 32 x28 x 22 1197749 1 446 32x28x15 1197751 1 342 16 WITZENMANN 3847uk 1 08 15 10 lines m Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg DN 22 15 1197772 0 282 DN 28 22 1197767 0 207 DN 28 28 1197768 0 268 DN 32 22 1197769 0 344 DN 32 28 0 349 Connection BS 746 female HYDRA GS Click Connection part for connecting to gas meter with 1 t
15. he building for the fastening points HYDRA 3847uk 1 08 15 10 WITZENMANN 41 Only HYDRA GS BISMAT Flash pipe clamps and HYDRA GS Caddy holding loops certified in accordance with BS EN 15266 may be used to fasten the HYDRA GS stainless steel corrugated hose system The pipe clamps and holding loops are part of the overall approved system HYDRA GS stain less steel corrugated pipes may not be installed using other pipe clamps BISMAT Flash is a screw in pipe clamp made from electrolytically galvanised steel with an acoustic insulation insert made from black EPDM rubber and a quick fastener The maximum permitted load is certified acc to RAL GZ 655 A and is 260 N In order to guarantee an optimum duration of fire resistance use plugs and threaded rods whose fire resistance properties have been tested dimension M8 or M10 strength class 4 6 Insert the pipe Push the clamp closed by Done hand 42 WITZENMANN 3847uk 1 08 15 10 HYDRA 8 PROTECTION AGAINST CORROSION OR DAMAGE Avoid any contact between the gas pipelines and acids alkalis salts or other corrosive sub stances In addition also avoid contact between the gas pipelines and aggressive chemical compounds which can lead to corrosion of stainless steel Should contact occur nevertheless remove the chemical residues thoroughly without delay Check the PE sheathing of the gas pipeline for damage If the PE sheathing is undamaged it will protect the stainless steel
16. hread acc to BS 746 Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg 28 1197764 0 370 32 0 462 3847uk 1 08 15 10 WITZENMANN 17 Copper compression fitting HYDRA GS Click Compression fitting for connecting pliable HYDRA GS stainless steel corrugated pipe with copper lines m Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg DN 15 2 15 1197756 0 203 DN 22 0 15 1197757 0 316 DN 22 22 1197758 0 342 DN 28 22 1197759 0 313 DN 28 28 1197761 0 335 DN 32 22 1197760 0 416 DN 32 0 35 1197 62 0 462 Straight Coupling HYDRA GS Click Connection part to connect two HYDRA GS stainless steel corrugated pipe of same diameter Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg 15 1197752 0 307 dd 1197753 OS 17 28 1197754 0 449 32 1197755 0 581 18 WITZENMANN 3847uk 1 08 15 10 2 3 HYDRA GS Press und HYDRA GS Click BISMAT Flash pipe clamp HYDRA GS The BISMAT Flash pipe clamp is used for fastening the corrugated pipes to building structures or Supporting structures m Material galvanised steel m Seal ring EPDM black DN ow D G B H h bxs Article number Inch mm mm mm mm 18 20 23 Va M8 54 39 23 20 1 25 1052549 22 25 28 G
17. ial brass m Seal ring HNBR m O ring HNBR Dimensions Article number Weight Nominal diameter x cone x union nut thread DN kg 15 x 24 x M30 x 2 0 112 22 x 24 x M30 x 2 1198216 0 131 28 x 24 x M36 x 2 0 178 32 x 24 x M48 x 2 1198221 0 333 10 WITZENMANN 3847uk 1 08 15 10 HYDRA Adapter HYDRA GS Press The adapters have a pipe thread acc to DIN EN 10226 1 and a 24 cone with male thread Together with the ro female threaded connections of valves fittings or gas sockets Material brass Connection to nipple with OE Weight Connection to fitting tating connection they form a conically sealing threaded connection with a swivel connection for connecting the pliable HYDRA GS stainless steel corrugated pipes to the Nominal diameter x thread acc to _ Enon ith EN 10226 1 Nominal diameter x cone x DN thread DN kg Greba 15 x 24 x M30 x 2 1198227 0 077 22RA 22 x 24 x M30 x 2 1198228 0 095 28xR 1 28 x 24 x M36 x 2 1198229 0 166 32x R14 32 x 24 x M48 x 2 1198230 0 254 T piece HYDRA GS Press The T pieces have a 24 cone with male thread at each m Material brass end They are used as connection elements to other lines and thus make it possible to connect additional consumers Dimensions Article number Weight Nominal diameter x thread DN E 15 22 x M30 x 2 0 196 28 x M36 x 2 1198224 0 258 32 x M48 x 2 0 552 HYDRA 3847uk 1 08 15 10
18. icable safety guidelines as well as the corresponding building regula tions and standards 1 7 Areas of application The HYDRA GS made from flexible stainless steel corrugated pipes can be used for New installations of pipeline systems m Renewing existing pipeline systems m Extending existing pipeline systems 1 8 Operating conditions m Max operating pressure 500 mbar m Temperature range 40 C to 60 C Natural gas liquefied gas HYDRA 3847uk 1 08 15 10 WITZENMANN 7 8 2 HYDRA GS INSTALLATION SYSTEM AND THE SYSTEM COMPONENTS The HYDRA GS system offers the installer easy and safe installation of gas pipelines The flexible gas pipe is easy to transport and lay the connecting technology is simple and unprob lematic both in design and in handling The system is available in 2 designs As a Click System for easy assembly with no hydraulic tool For this system the fittings are connected using a simple plug connection The fitting is self locking and only needs to be screwed tight using a spanner or wrench afterwards Information on all components can be found in chapter 2 1 As an alternative there is the Press System with a hydraulic tool for quick and effective assem bly over long distances For this system the fittings are connected using a special hydraulic tool It is light easy to use and is ergonomically shaped This makes it possible to work longer without tiring Information on all components ca
19. ice for domestic butane and propane gas burning installations Part 1 Installations at permanent dwellings residential park homes and commercial premises with installation pipework sizes not exceeding DN 25 for steel and DN 28 for corrugated stainless steel or copper Strength testing tightness testing and direct purging of industrial and commercial gas installations Installation pipework on industrial and commercial premises Test gases Test pressures Appliance categories Cross references to regulations standards and codes of practice refer to the current status at the time when this installation manual was published In the event of updates the user Is responsible for applying the current regulations standards and codes of practice applicable at the given time The generally accepted engineering standards must always be complied with WITZENMANN 3847uk 1 08 15 10 HYDRA 1 6 System conformity Only components from the HYDRA GS system may be used for installation The HYDRA GS installation system made from Witzenmann corrugated pipes is not compatible with the corrugated pipe kits for gas installations from other manufacturers Witzenmann GmbH does not accept any liability for malfunctions that are caused by mixing with system components from other manufacturers For installation of all gas appli ances and other gas fittings It is necessary to comply with the installation instructions of the manufacturer the appl
20. ilar projects t is possible to enter the net calorific value as required thus allowing optimum adaptation to the particular gas supply The same applies to the operating condition of the gas HYDRA 3847uk 1 08 15 10 WITZENMANN 29 4 ASSEMBLY HYDRA GS PRESS 4 1 Assembly procedure Step 1 Prepare the hose Step 2 Cut the corrugated pipe to length 30 WITZENMANN The initial piece of the rolled up HYDRA GS corrugated pipe must always be cut off with a clean cut prior to use Measure the suitable pipe length Use the corrugated pipe cutter to cut the sheathed pipe to length The cut must be lo cated in the groove of a corrugation Turn the pipe cutter in one direction and slowly tighten the pressure roller after each turn Important Tightening too much leads to irregular cuts and deformations Avoid kinking and tearing the corrugated pipe after an incomplete cut 3847uk 1 08 15 10 HYDRA Step 3 Expand the corrugated pipe 3847uk 1 08 15 10 Now the end of the cut to length pipe must be expanded in order to allow the connection parts to be fitted To do this the expansion head from the tool case is screwed onto standard expander tongs The closed tool is pushed into the end of the corrugated pipe up to the collar The expander tong is open at this stage Operate close the tong once up to the stop point Remove the expansion head WITZENMANN 31 Step 4 Fit the connection part onto the
21. ith adapter 1 Strip earthing clip on hexagon profile 2 HYDRA GS corrugated pipe 3 HYDRA GS threaded nipple 40 WITZENMANN 3847uk 1 08 15 10 HYDRA 7 4 Fastening and fastening distances Gas pipelines may not be attached to other pipelines nor may they be used as supports for other pipelines and loads They must be arranged so that drips and condensation from other pipelines cannot have any effect on them Depending on the mechanical strength tensile strength of their pipe connections they must be attached to components with an adequate structural strength by means of pipe brackets The supporting parts of the pipe brackets e g pipe clamps clips bolts must be made from non flammable materials The following table provides guidance values for fastening distances of laid pipelines It is essential to comply with the recommended fastening distances Nominal diameter Recommended fastening distance oN vertical Bend m m 22 IE 25 2 00 0 30 28 2 50 0 40 32 2 50 0 45 Plastic plugs can be used if the mechanical strength of the pipeline will not be impaired in case of fire at temperatures up to 650 C In pipelines with pipe connections which no longer guarantee the required mechanical strength tensile strength when exposed to temperatures up to 650 C it is necessary for the plugs used to be able to withstand these temperatures e g metal plugs Furthermore solid or comparable structural components are required in t
22. minal load 3 3 1 Natural gas L Pressure loss in corrugated pipelines for natural gas L 15 C 20 mbar 8 6 kW m Pressure losses of the connection parts Ol values in kW 200 DN mm 15 22 28 ZG e 5 10 25 E 6 11 29 7 13 oo 4 14 36 8 16 39 9 17 42 5 18 45 10 19 48 6 12 21 54 7 13 24 60 14 26 65 8 15 28 70 9 17 Ea 79 10 19 34 87 11 20 oF 95 12 22 40 102 13 23 43 108 14 24 45 115 15 21 50 127 16 29 54 138 17 31 58 148 20 35 66 167 system components DN 15 DN 22 Pa m DN 28 DN 32 additional lengths I to the overall pipe length for DN Pressure losses in metres 90 bends T straight T branch 16 0 15 ORO 0 4 05 25 0 25 0 2 0 4 0 8 32 0 4 1 3 22 WITZENMANN 3847uk 1 08 15 10 3 3 2 Natural gas H Pressure loss in corrugated pipelines for natural gas H 15 C 20 mbar 10 6 kW m DN mm P 10 24 6 12 30 14 36 16 40 a 18 44 10 19 48 EE 52 12 29 55 23 59 5 14 26 66 16 29 73 17 32 80 E 18 34 86 38 97 93 42 107 46 116 97 49 125 53 133 30 56 141 61 156 36 67 169 72 182 43 81 205 200 Pa m DN 15 DN 22 DN 28 DN 32 Pressure losses of the connection parts additional lengths l to the overall pipe length for system component
23. n and slowly tighten the pressure roller after each turn Step 4 Seal the connection part Important Tightening too much leads to irregular cuts and deformations Avoid kinking and tearing the corrugated pipe after an incomplete cut Wrap with adhesive tape beginning on the hose and working towards the fitting Step 3 Assemble the connection part Ed E Remove sheath from the first 6 corrugations see sketch Overlap the layers by approx 0 5 cm Make sure there are no creases 6 corrugations gt Loosen screw fitting lightly by hand Wrap two layers of tape around the hose and the fitting up to the nut 36 WITZENMANN 3847uk 1 08 15 10 HYDRA HYDRA 3847uk 1 08 15 10 WITZENMANN 37 6 ASSEMBLY ON PARTS OUTSIDE THE HYDRA GS GAS INSTALLATION SYSTEM 6 1 Valid for HYDRA GS Press and HYDRA GS Click External systems and fittings may only be connected together using screw fittings with standardised thread or a 24 cone Tightening torque for HYDRA GS Press Screw connections for HYDRA GS Press should be tightened with the tolerated torques as specified in the following table Nominal diameter of corrugated pipe Tightening torque for DN union screw connection Nm 15 30 10 ZG 30 10 28 35 10 3 50 10 6 2 Valid for HYDRA GS Press and HYDRA GS Click Minimum bending radii When bending corrugated pipes make sure the bending radii are not less than the minimum bending radii
24. n be found in chapter 2 2 Country specific approvals ensure that HYDRA GS systems fulfil all requirements for a long and safe service HYDRA GS HYDRA Corrugated Hose HYDRA GS CLICK The manual Quick System HYDRA GS PRESS The system using a hydraulic tool WITZENMANN 3847uk 1 08 15 10 HYDRA HYDRA GS corrugated pipes and pipe dimensions Stainless steel corrugated pipe for gas installation Pipe material 1 4404 stainless steel m Sheathing material PE polyethylene Pipe dimensions Corrugated DN pipe length d1 PE d2 d3 on drum mm mm mm M 15 SEO 21 2 15 30 75 22 27 3 26 4 20 5 15 30 75 28 32 6 31 7 15 30 75 SP 41 5 40 6 35 5 15 30 75 3847uk 1 08 15 10 WITZENMANN 9 2 1 HYDRA GS Press Threaded nipple HYDRA GS Press Threaded nipples with male thread acc to DIN EN 10226 1 are used for connecting the pliable HYDRA GS stainless steel corrugated pipes to the female thread connections of valves fittings or gas sockets Material brass m Seal ring HNBR Dimensions Article number Weight Nominal diameter x thread acc to EN 10226 1 DN kg ISR 1198211 0 064 AR A 1198212 0 120 220X 1198213 0 175 RI 1198214 0 248 Swivel connection HYDRA GS Press The rotating connection has a 24 cone and is used for connecting the pliable HYDRA GS stainless steel corrugated pipes to valves or fittings with an male thread and a 24 cone m Mater
25. rities for up to date guidance All gas appliances and other gas fittings must be installed in accordance with The Gas Safety Installation and Use Regulations 1998 building regulations and manufacturers installation instructions Installations should also comply with British Standards Our Design and Installation Guide revisions will follow any amendments to the Regulations or British Standards at a later date and thus in the event of any conflict the Regulations and or British Standards will take precedence over this Design and Installation Guide For detailed information about connection disconnection of pipes installation in different materials e g wooden joist floors walls cavities walls etc see BS 5482 1 sections 12 3 ff and BS 6891 section 8 6 ff Note these standards are currently under revision with the aim to condense the design and installation specifications for all domestic fuel gas pipework systems into one standard Installation for industrial and commercial premises shall follow IGEM UP 2 Latest Edition for sizes above DN 32 and working pressure above 21 mbar and IGE UP 1 Lat est Edition strength and tightness testing and purging Additional local regulations shall also be followed Please contact local authorities for necessary information This installation guide cannot cover all possible variations in construction style building config uration appliance requirements or local restrictions If the installer is
26. ructions o9 1 2 HYDRA GS fire behaviour 40 d Potential equalisation 40 7A Fastening and fastening distances 41 8 Protection against corrosion or damage 43 9 Recommendations for storing gaskets 43 10 Repair methods 44 10 1 Damage to HYDRA GS stainless steel corrugated pipes 44 HYDRA 3847uk 1 08 15 10 WITZENMANN 4 1 SCOPE OF APPLICATION AND GENERAL NOTES 1 1 Validity This installation instruction is valid for the gas installation system HYDRA GS made by Witzen mann GmbH Germany It is intended to guide the gas pipe installer in the design installation and final testing stages All specifications in this manual must be complied with during work and installation No deviations from the installation specifications in this manual are permitted without prior consultation with Witzenmann GmbH 1 2 The product The Witzenmann gas installation system HYDRA GS complies to and is tested according to the requirements of BS EN 15266 2007 Stainless steel pliable corrugated tubing kits in buildings for gas with an operating pressure up to 0 5 bar The gas installation system HYDRA GS has been granted Kitemark Licence Number KM 594313 by British Standards Institution covering sizes DN 15 DN 22 DN 28 and DN 32 and associated fittings The certification also includes resistance to high temperatures HTB according to BS EN 1775 HYDRA GS can be installed in domestic industrial and commercial buildings HYDRA GS is suitable for natural
27. s DN Pressure losses in metres 90 bends Hose connection T branch 16 0 15 0 2 0 4 0 5 20 0 2 0 3 0 6 0 9 32 0 3 0 2 1 3 3847uk 1 08 15 10 WITZENMANN 23 3 3 3 Propane gas Pressure loss in corrugated pipelines for propane 25 C 50 mbar 26 8 kW m oO O1 Ce values in kW 24 WITZENMANN DN mm ae ee ee ee D 9 17 43 6 12 21 54 7 13 25 63 8 ID 28 71 9 17 31 719 10 18 34 85 11 20 36 92 21 39 98 12 22 41 104 14 25 46 117 129 141 151 171 188 24 43 80 205 25 46 36 220 ZA 49 G2 239 29 52 97 249 31 b7 107 274 34 62 116 298 36 EA 125 321 41 d 141 362 3847uk 1 08 15 10 200 0 5 10 15 20 Pa m DN 1S DN 28 Ez DN 22 eae DN 32 3 4 Example calculation Combination water heater result pressure loss lt 300 Pa wn m Nominal load 18 kW Med m Appliance connection fitting straight pattern 20 Pa gel m Height difference 8 9 m 3b Pa 6 Pa m m Selected cross section DN 22 66 Pa m Pipe resistance 6 Pa m Table 1 natural gas L m Pipe length 9 9 m m Straight I piece Tab 14 I 0 6 m m Threaded connection reduced 0 3 m m 90 bend 0 2 m 33 kW DN 28 6 Pa m 2 1 0 5 0 4 3 0 m Line 1 0 3 0 H 155 Pa 9 kW 15 E 10 Pa 5 4m 21 Pa DN 15 38 Pa 5Pa m 6 4 0 5 0 2 0 45 7 55 m SO bine 2 y 33 kW 24 kW 209 Pa DN 28 9 Pa DN 22 81 Pa 6 Pa m 10 Pa m 1 0 0 25 0 2
28. specified in the following table Nominal diameter of corrugated pipe Minimum bending radius DN mm 15 25 GE 30 28 45 oy 60 38 WITZENMANN 3847uk 1 08 15 10 HYDRA 7 GENERAL NOTES ON INSTALLATION 7 1 General instructions m Store all HYDRA GS Press components in their original packing in a dry place m Make sure that the components are stored at room temperature directly before being laid m f the HYDRA GS stainless steel corrugated pipes were subjected to low temperatures store them at room temperature until they themselves have room temperature Before fitting make sure that sufficient HYDRA GS system components are available for the required length and diameters m Install HYDRA GS stainless steel corrugated pipes in such a way that they are protected from mechanical damage m During fitting avoid kinking crimping over bending over stretching or twisting the HYDRA GS Stainless steel corrugated pipe Also avoid contact with sharp objects Renew damaged parts m Avoid impairing the free flow cross section of HYDRA GS stainless steel corrugated pipes m Make sure that no foreign bodies enter the corrugated pipe HYDRA GS stainless steel corrugated pipes may not under any circumstances be used as flexible connections for apparatus for example instead of gas hoses m Prior to taking a completed installation into operation the entire installation must be checked In accordance with the technical codes of pra
29. sure absolute D Pa 103300 103300 106300 Net calorific value His kWh m 8 6 10 6 26 8 Dimensioning with the software tool allows a free choice of entries 3 2 Preliminary dimensioning using table When using the table the pressure losses of the components are read In relation to the load The pressure loss of the entire pipeline system is calculated by adding up the pressure losses along the course of the pipeline As a rule the tables apply to individual lines When there are several consumers calculate backwards from them From the branch onwards calculate by taking the total of the individual loadings whereby it is also possible to take into account a simultaneity factor for reducing the overall load The pressure losses of the straight corrugated pipes are specified below per metre Bends and connection parts inherent in the system are taken into account as additional pipe length p R i 1 in m For all other components flow monitor gas meter appliance connection fitting etc use the information from the manufacturers Ap Aus APoa The height difference between the start of the pipeline at the gas pressure control installation and the installation connection is taken into account acc to the following formula Ap ldi H H in m The pressure loss in the pipeline is Ap Ap Aps A Eee erat HYDRA 3847uk 1 08 15 10 WITZENMANN 21 3 3 Pressure losses in the corrugated pipeline depending on the no
30. ted pipe has been significantly compressed m there is a pressure loss in the hose assembly Renewal of the entire corrugated pipe length is recommended for safety reasons in order to avoid having screw connections in cavities In addition in most cases this procedure is more economical than repairing only part of a section If a section is to be repaired it is possible depending on the length of the pipeline remaining to remove the damaged part and connect the parts left using HYDRA GS screw connections If the remaining lengths are short it is possible to use a pipeline section with two HYDRA GS screw connections between the two remaining sections Note A leak test must always be carried out after each repair 44 WITZENMANN 3847uk 1 08 15 10 HYDRA HYDRA 3847uk 1 08 15 10 WITZENMANN 45
31. unsure about the proper application of HYDRA GS we recommend you contact us or a local representative 3847uk 1 08 15 10 WITZENMANN 5 6 1 5 Standards and codes of practice As well as the planning and installation instructions given in this installation manual it is also necessary to comply with the current editions of the following codes of practice when planning and installing the entire gas supply system in the building BS EN 15266 2007 BS EN 549 BS EN 10226 1 2004 09 BS EN 14291 2005 4 BS EN 837 1 1997 02 BS EN 681 1 2003 8 BS 6891 BS 5482 1 IGE UP 1 Edition 2 IGEM UP 2 Edition 3 BS EN 437 Important Note Stainless steel pliable corrugated tubing kits in buildings for gas with an operating pressure up to 0 5 bar Rubber materials for seals and diaphragms for gas appliances and gas equipment Pipe threads where pressure tight Joints are made on the threads Part 1 Taper external threads and parallel internal threads Dimensions tolerances and designation Foam producing solutions for leak detection on gas installations Pressure gauges Part 1 Bourdon tube pressure gauges Dimensions metrology requirements and testing Elastomeric seals Material requirements for pipe joint seals used in water and drainage applications Part 1 Vulcanized rubber Installation of low pressure gas pipework of up to 35 mm R1 1 4 in domestic premises 2nd family gas Specification Code of pract
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