BULLETIN E-RE-01BE-RE-01B - ROSS EUROPA€¦ · temperature (20°C/ 68°F), acc. to EN 13480-3, and for predominantly static loads. Temperature stability All ZeroCon®-Crown components

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E-RE-01BBULLETIN E-RE-01B

Absolutely Leak-tight • Extremely Temperature-stable Best Surface Finish • Easy Installation

Absolutely Leak-tight • Extremely Temperature-stable Best Surface Finish • Easy Installation

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Contents

Technical Description ................................................................................................... 3

Features .......................................................................................................................... 3

Materials .......................................................................................................................... 4

Pressure rating ................................................................................................................ 4

Temperature stability ....................................................................................................... 4

Portings ........................................................................................................................... 4

Cleaning .......................................................................................................................... 4

Ultra-purity application ..................................................................................................... 4

Testing ............................................................................................................................. 4

ZeroCon®-Crown Components ..................................................................................... 5

Ordering information ........................................................................................................ 5

Complete connection, incl. sealing ring, screw joint & nut ............................................... 5

Threaded joint with welding hub ...................................................................................... 6

Pressure joint with welding hub ....................................................................................... 7

Blind cap for threaded joint .............................................................................................. 8

Blind cap for pressure joint .............................................................................................. 8

Sealing ring ..................................................................................................................... 8

Nut ................................................................................................................................... 8

Tools ............................................................................................................................... 8

Universal dismantling fork .............................................................................................. 8

Application Examples / Benefits .................................................................................. 9

Assembly Instructions ................................................................................................ 10

Disassembly Instructions ........................................................................................... 11

ROSS® DALE-Poppet Valves & ZeroCon®-Crown ...................................................... 12

PLEASE NOTE:

When making your selection from the offering described in this Bulletin, be sure to consider the appli-cation criteria of all parts in your system and its environment in order to secure trouble-free functioning and safe use of the respective products/components. Careful consideration of all relevant parameters concerning function, field of use, material compatibility, performance data, operation limits as well as proper system-start-up, handling and maintenance are subject to the responsibility of the user or the system planner, respectively.

We reserve the right to introduce technical changes without prior notice.


Technical Description

FEATURESZeroCon®-Crown is made of solid high-purity stainless steel and serves as a safe and quick threaded connection of pipe networks, pipe joints and welded systems.

(1) Absolutely leak-tight Consistent material quality — Helium-leak-rate is ≤ 10-14mbar | s-1

(2) Zero dead spaces Space between seal ring and joint: ≤10µm

(3) Perfect pharmaceutical barrier No risk of bio-burdening; aseptic design

Robust connection Suitable for application under high-pressure, critical vacuum and extreme temperature conditions

Dynamic stress resistance Interlocking geometry designed to prevent influence of external forces and moments.

Temperature-stable, from -273°C to +450°C

Zero flow disturbances Highest-grade surface finish Ra ≤ 0,4 µm

Zero material outgassing Stainless steel 1.4435 acc. to EN 10088-3

Easy installation Self-centering, end stop and integrated leak-test port

Nut threads are partly silver-plated to prevent thread galling and guarantee easy and consistent installation

Best surface finish for all ZeroCon componentsRa ≤ 0,4 µm

Integrated leak-test port

Solid connectionRotation is prevented due to interlocking of the crenelations

Threaded joint Seal ring Nut Pressure joint

Zero maintenance No preventive elastomer maintenance required

Full component traceability Marking of all components

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Technical Description

Materials

PlatingZeroCon®-Crown nuts, system sizes 3 (3/4") and larger, are silver-plated on the inside. This surface treatment reduces friction during assembly/disassem-bly, and ensures proper mounting position.

Material traceability

Acceptance test certificate 3.1 acc. to DIN EN 10204 for primary materials and marking transfer documents for materials and products are available on request.

Pressure ratingsAll pressure ratings (maximum operating pressure) are based on calculations for straight pipes/tubes, at room temperature (20°C/ 68°F), acc. to EN 13480-3, and for predominantly static loads.

Temperature stability

All ZeroCon®-Crown components are made of the same material — high-grade stainless steel. There are no elastomers involved which would limit temperature stability.

Part Lowest Temperature Maximum Temperature °C / °F °C / °F

Seal ring -273 / -459,4 450 / 842

Threaded joint

Pressure joint -273 / -459,4 450 / 842

Part Material* Seal ring 1.4435

Threaded joint

Pressure joint 1.4435

Blindcap-pressure joint

NITRONIC 60 Nut 1.4435-inside silver-plated

PortingsWelding hubs are prepared ready for orbital welding.

CleaningPrior to packaging, all ZeroCon®-Crown components are cleaned and rinsed in ultra-pure water to meet the requi-rements. The parts are free from production residues such as oil, lubricant and loose particles. All components are packed as separate units in individually sealed bags.

Ultra-purity applications On request, all joints, seals and nuts are available with electro-polished finish and rinsed in ultra-pure water to meet clean room and ultra-pure fluid application requirements.

Leak-testingZeroCon®-Crown shows absolute leak-tightness by helium leak test. Based on state-of-the-art measurement technology a leak rate of ≤ 10-14mbar | s-1 is measured.

Bacteria swab testingSpace between sealing and joint is at its maximum 10 µm which is smaller than the size of the smallest being (fungus, 20 µm). Therefore, ZeroCon®-Crown prevents any accumulation of bacteria or other micro-small beings. Bacteria swab test results are available upon request.

* Other stainless steel grades on request.


ZeroCon®-Crown Components

Ordering information All dimensions are given for reference only, and are subject to change.

Tube outer diameter and tube wall thickness vary within the system, up to the maximum size of the next smaller system.

Standard sizes are high-lighted in bold print. Complete systems are available within one standard system size only, with the same tube diameters on threaded and pressure joint side. Further system variations can be configured individually.

L

s

d

L

s

d

A

SWH1

SWH2

Complete connection, including seal, pressure and threaded joint, nut

IMPERIAL

System Inch Model Number d [mm] s [mm] A [mm] L [mm] H1 [Inch] [mm] H2 [Inch] [mm] [bar] [psi]

1 1/4 RE 1231 0000 6,35 0,89 62,80 19 7/16 11 3/4 19 424 6149

2 3/8 RE 1232 0001 9,35 0,89 62,80 19 5/8 16 1-1/16 27 271 3930

2 1/2 RE 1232 0000 12,70 1,24 62,80 19 5/8 16 1-1/6 27 287 4162

2 1/2 RE 1232 0002 12,70 1,65 62,80 19 5/8 16 1-1/16 27 368 5337

3 3/4 RE 1233 0000 19,05 1,24 62,80 19 7/8 22 1-1/4 32 186 2698

3 3/4 RE 1233 0001 19,05 1,65 62,80 19 7/8 22 1-1/4 32 251 3640

4 1 RE 1234 0000 25,40 1,65 62,80 19 1-1/16 27 1-1/2 38 185 2683

ISO

System NW Model Number d [mm] s [mm] A [mm] L [mm] H1 [Inch] [mm] H2 [Inch] mm] [bar] [psi]

2 8 RE 1232 0104 13,50 1,60 62,80 19 5/8 16 1-1/16 27 344 4989

3 10 RE 1233 0101 17,20 1,60 62,80 19 7/8 22 1-1/4 32 264 3829

4 15 RE 1234 0101 21,30 1,60 62,80 19 1-1/16 27 1-1/2 38 209 3031

METRIC

System NW Model Number d [mm] s [mm] A [mm] L [mm] H1 [Inch] [mm] H2 [Inch] mm] [bar] [psi]

1 4 RE 1231 0100 6,00 1,00 62,80 19 7/16 11 3/4 19 452 6555

2 6 RE 1232 0101 8,00 1,00 62,80 19 5/8 16 1-1/16 27 328 4757

2 8 RE 1232 0102 10,00 1,00 62,80 19 5/8 16 1-1/16 27 258 3742

2 10 RE 1232 0103 12,00 1,00 62,80 19 5/8 16 1-1/16 27 212 3075

2 10 RE 1232 0100 13,00 1,50 62,80 19 5/8 16 1-1/16 27 330 4786

3 15 RE 1233 0102 18,00 1,50 62,80 19 7/8 22 1-1/4 32 232 3365

3 15 RE 1233 0100 19,00 1,50 62,80 19 7/8 22 1-1/4 32 219 3176

4 20 RE 1234 0100 23,00 1,50 62,80 19 1-1/16 27 1-1/2 38 178 2582

Dimensions

Dimensions

Dimensions

Operating pressure

Operating pressure

Operating pressure

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Threaded joint with welding hub

IMPERIAL

System Inch Type Model Number d [mm] s [mm] L [mm] A [mm] H [Inch] [mm] [bar] [psi]

1 1/4 Standard RE 1211 1000 6,35 0,89 19 33,90 7/16 11 424 6149

2 1/4 Reduction RE 1212 1003 6,35 0,89 19 33,90 5/8 16 424 6149

2 3/8 Standard RE 1212 1001 9,53 0,89 19 33,90 5/8 16 271 3930

2 1/2 Standard RE 1212 1000 12,70 1,24 19 33,90 5/8 16 287 4162

2 1/2 Standard RE 1212 1002 12,70 1,65 19 33,90 5/8 16 368 5337

3 3/8 Reduction RE 1213 1002 9,53 0,89 19 33,90 7/8 22 271 3930

3 1/2 Reduction RE 1213 1003 12,70 1,24 19 33,90 7/8 22 287 4162

3 1/2 Reduction RE 1213 1004 12,70 1,65 19 33,90 7/8 22 368 5337

3 3/4 Standard RE 1213 1000 19,05 1,24 19 33,90 7/8 22 186 2698

3 3/4 Standard RE 1213 1001 19,05 1,65 19 33,90 7/8 22 251 3640

4 3/4 Reduction RE 1214 1001 19,05 1,24 19 33,90 1-1/16 27 186 2698

4 3/4 Reduction RE 1214 1002 19,05 1,65 19 33,90 1-1/16 27 251 3640

4 1 Standard RE 1214 1000 25,40 1,65 19 33,90 1-1/16 27 185 2683

ISO

System NW Type Model Number d [mm] s [mm] L [mm] A [mm] H [Inch] [mm] [bar] [psi]

2 8 Standard RE 1212 1104 13,50 1,60 19 33,90 5/8 16 344 4989

3 8 Reduction RE 1213 1107 13,50 1,60 19 33,90 7/8 22 344 4989

3 10 Standard RE 1213 1101 17,20 1,60 19 33,90 7/8 22 264 3829

4 10 Reduction RE 1214 1104 17,20 1,60 19 33,90 1-1/16 27 264 3829

4 15 Standard RE 1214 1101 21,30 1,60 19 33,90 1-1/16 27 209 3031

METRIC

System NW Type Model Number d [mm] s [mm] L [mm] A [mm] H [Inch] [mm] [bar] [psi]

1 4 Standard RE 1211 1100 6,00 1,00 19 33,90 7/16 11 452 6555

2 4 Reduction RE 1212 1105 6,00 1,00 19 33,90 5/8 16 452 6555

2 6 Standard RE 1212 1101 8,00 1,00 19 33,90 5/8 16 328 4757

2 8 Standard RE 1212 1102 10,00 1,00 19 33,90 5/8 16 258 3742

2 10 Standard RE 1212 1103 12,00 1,00 19 33,90 5/8 16 212 3075

2 10 Standard RE 1212 1100 13,00 1,50 19 33,90 5/8 16 330 4786

3 6 Reduction RE 1213 1103 8,00 1,00 19 33,90 7/8 22 328 4757

3 8 Reduction RE 1213 1104 10,00 1,00 19 33,90 7/8 22 258 3742

3 10 Reduction RE 1213 1105 12,00 1,00 19 33,90 7/8 22 212 3075

3 10 Reduction RE 1213 1106 13,00 1,50 19 33,90 7/8 22 330 4786

3 15 Standard RE 1213 1102 18,00 1,50 19 33,90 7/8 22 232 3365

3 15 Standard RE 1213 1100 19,00 1,50 19 33,90 7/8 22 219 3176

4 15 Reduction RE 1214 1102 18,00 1,50 19 33,90 1-1/16 27 232 3365

4 15 Reduction RE 1214 1103 19,00 1,50 19 33,90 1-1/16 27 219 3176

4 20 Standard RE 1214 1100 23,00 1,50 19 33,90 1-1/16 27 178 2582

L

s

d

A

SWH d

L

s

A

SWH

Standard Reduction

Dimensions

Dimensions

Dimensions

Operating pressure

Operating pressure

Operating pressure


Pressure joint with welding hub

IMPERIAL

System Inch Type Model Number d [mm] s [mm] L [mm] A [mm] [bar] [psi]

1 1/4 Standard RE 1211 2000 6,35 0,89 19 28,90 424 6149

2 1/4 Reduction RE 1212 2003 6,35 0,89 19 28,90 424 6149

2 3/8 Standard RE 1212 2001 9,53 0,89 19 28,90 271 3930

2 1/2 Standard RE 1212 2000 12,70 1,24 19 28,90 287 4162

2 1/2 Standard RE 1212 2002 12,70 1,65 19 28,90 368 5337

3 3/8 Reduction RE 1213 2002 9,53 0,89 19 28,90 271 3930

3 1/2 Reduction RE 1213 2003 12,70 1,24 19 28,90 287 4162

3 1/2 Reduction RE 1213 2004 12,70 1,65 19 28,90 368 5337

3 3/4 Standard RE 1213 2000 19,05 1,24 19 28,90 186 2698

3 3/4 Standard RE 1213 2001 19,05 1,65 19 28,90 251 3640

4 3/4 Reduction RE 1214 2001 19,05 1,24 19 28,90 186 2698

4 3/4 Reduction RE 1214 2002 19,05 1,65 19 28,90 251 3640

4 1 Standard RE 1214 2000 25,40 1,65 19 28,90 185 2683

ISO

System NW Type Model Number d [mm] s [mm] L [mm] A [mm] [bar] [psi]

2 8 Standard RE 1212 2104 13,50 1,60 19 28,90 344 4989

3 8 Reduction RE 1213 2107 13,50 1,60 19 28,90 344 4989

3 10 Standard RE 1213 2101 17,20 1,60 19 28,90 264 3829

4 10 Reduction RE 1214 2104 17,20 1,60 19 28,90 264 3829

4 15 Standard RE 1214 2101 21,30 1,60 19 28,90 209 3031

METRIC

System NW Type Model Number d [mm] s [mm] L [mm] A [mm] [bar] [psi]

1 4 Standard RE 1211 2100 6,00 1,00 19 28,90 452 6555

2 4 Reduction RE 1212 2105 6,00 1,00 19 28,90 452 6555

2 6 Standard RE 1212 2101 8,00 1,00 19 28,90 328 4757

2 8 Standard RE 1212 2102 10,00 1,00 19 28,90 258 3742

2 10 Standard RE 1212 2103 12,00 1,00 19 28,90 212 3075

2 10 Standard RE 1212 2100 13,00 1,50 19 28,90 330 4786

3 6 Reduction RE 1213 2103 8,00 1,00 19 28,90 328 4757

3 8 Reduction RE 1213 2104 10,00 1,00 19 28,90 258 3742

3 10 Reduction RE 1213 2105 12,00 1,00 19 28,90 212 3075

3 10 Reduction RE 1213 2106 13,00 1,50 19 28,90 330 4786

3 15 Standard RE 1213 2102 18,00 1,50 19 28,90 232 3365

3 15 Standard RE 1213 2100 19,00 1,50 19 28,90 219 3176

4 15 Reduction RE 1214 2102 18,00 1,50 19 28,90 232 3365

4 15 Reduction RE 1214 2103 19,00 1,50 19 28,90 219 3176

4 20 Standard RE 1214 2100 23,00 1,50 19 28,90 178 2582

d

L

s

A

d

L

s

A

Standard Reduction


Dimensions

Dimensions

Dimensions Operating pressure

Operating pressure

Operating pressure

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Blind cap for threaded joint

Dimensions System Model Number d [mm] L [mm] A [mm] H [Inch] [mm]

1 RE 1211 1200 6,35 6,0 20,65 7/16 11

2 RE 1212 1200 12,70 6,0 20,65 5/8 16

3 RE 1213 1200 19,05 6,0 20,65 7/8 22

4 RE 1214 1200 25,40 6,0 20,65 1-1/16 27

Blind cap for pressure joint

Dimensions

System Model Number d [mm] L [mm] A [mm]

1 RE 1211 2200 6,35 6,0 15,65

2 RE 1212 2200 12,70 6,0 15,65

3 RE 1213 2200 19,05 6,0 15,65

4 RE 1214 2200 25,40 6,0 15,65

Dimensions

System Model Number d [mm] s [mm]

1 RE 1201 0000 9,35 2,15

2 RE 1202 0000 15,30 2,50

3 RE 1203 0000 21,65 2,50

4 RE 1204 0000 27,25 2,50

Dimensions

System Model Number H [Inch] H [mm]

1 RE1221 0000 3/4 19

2 RE1222 0000 1-1/16 27

3 RE 1223 0000* 1-1/4 32

4 RE 1224 0000* 1-1/2 38

*Thread silver-plated (see Page 4)

d

LA

SWH

d

LA

Sealing ring

d s

Nut

TOOLUniversal dismantling forkTo disassemble the tightly pressed connector, the dismantling fork should be placed at the pressure joint (see disassembly instructions, page 11). By unscrewing the nut, the joint components will be separated from each other and can be removed.

System Model Number

1, 2, 3, 4 RE 1240 0000


ZeroCon®-Crown — Premium Quality. No Compromise!

Industries using ZeroCon®-Crown. Your Benefits:

As leak-tight as a welding seam, up to high-pressure level No medium losses / no spilling of toxic media into the environment, no contamination of the medium.

No particle deposits / no formation of cultures / no bacteria films

100% sterilization, and shorter wash-down times.

No negative, outside impact of forces and/ or moments on the connection No loosening of the connection through torsion forces. Self-centering, due to interlock design.

No turbulences, no flow restrictions

Suitable for ultra-high vacuum

100% stainless steel; no elastomer No contamination of the process medium caused by material outgassing. Temperature- stable (from -273°C to + 450°C). Easy hot-steam sterilization. Much higher resistance to aggres-sive media as compared to resilient-type seals.

Easy and clear switch to other dimensions Clearly arranged and simplified product range (sealing)

Meets highest purity standards

Quick and easy installation / disassembly No danger of damages due to excessive torque rating

Easy and fast leak test in installed condition

Frequent re-usability of flanges and nut

Easy and simple joining of the system with downstream pipe / line networks

For use in explosive environments

High resistance to environmental in-fluences (sodium liquids, brine, etc.)

No maintenance required

Markings provide full traceability of all components

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Assembly Instructions

Step 1 (Picture 1)

Place the seal ring inside the pressure joint. The seal ring will stay in place.

Step 2 (Picture 2)

Install the threaded joint oppositely to the pressure joint. Align the joints to each other by interlocking the crenela-tions. The system will be centered by the crenelations and the seal itself. All components are already in place.

Step 3 (Picture 3)

1. Place the nut from the pressure joint side on the threaded joint (F1).2. Screw the nut (F2) on the pressure joint to pre-tighten the connection.

Assembly: Picture 1

Assembly: Picture 2

Assembly: Picture 3

Step 4 (Picture 4)

1. Hold the connection with wrench A on the threaded joint side.2. Place wrench B on the nut.

Step 5 (Picture 5)

1. Tighten the nut and crimp the connection by turning wrench B with Torque 1.2. The installation is complete when the required Torque 2 (as per table below) is reached.

System Torque 1 [Nm] Torque 2 [Nm]

1 30 45

2 & 3 45 70

4 60 90

Assembly: Picture 4

Assembly: Picture 5

System Wrench - A Wrench - B [Inch] [mm] [Inch] [mm] 1 7/16 11 3/4 19 2 5/8 16 1-1/16 27 3 7/8 22 1-1/4 32 4 1-1/16 27 1-1/2 38

Wrench-A Wrench-B


Step 1 (Picture 1)

1. Place the dismantling fork on the threaded joint. Leave it freely suspended.2. Place wrench A on the threaded joint side.3. Place wrench B on the nut.

Disassembly Instructions

Step 2 (Picture 2)

1. Hold the connection with wrench A (FA).2. Turn wrench B counter-clockwise (FB) to loosen the nut.3. Unscrew the nut completely. Both joint parts will be pushed apart. The sealing ring will remain in one of the two joints.

Step 3 (Picture 3)

Should the sealing ring remain in the pressure joint, remove the nut. Otherwise continue with step 4.1. Detach the dismantling fork.2. Remove the nut in the shown direction (F1), see Picture 3.

Step 4 (Picture 4) Remove the seal ring using a screw driver as a lever, alter-nately on both sides. Place the screwdriver on the top of the crenelations and in the groove of the sealing ring.Exert a force (F2) to lever out the seal, as shown.

Disassembly: Picture 1




System Wrench - A Wrench - B [Inch] [mm] [Inch] [mm] 1 7/16 11 3/4 19 2 5/8 16 1-1/16 27 3 7/8 22 1-1/4 32 4 1-1/16 27 1-1/2 38

F1

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Application Example: Leak Testing The ROSS-DALE Series is an excellent fit for processes requiring leak tight valves. DALE valves feature poppet construction for zero leakage and high dirt tolerance. Practically every pressure-containing vessel is leak-tested during production or assembly. DALE valves are specifically designed for leak-free operation at high pressure levels. Series CX and LX valves are not only absolutely leak-proof, they also stand out for the fact that they allow flow in both directions. Thus, they are the perfect choice for vacuum applications or helium-leak-test challenges.

Why is it important that the valves used in testing procedures are absolutely leak-tight? If the valves being used to control the test are themselves leaking, it is impossible to tell if the product under test is leaking. Benefits of the DALE Valve Line at a Glance: Bubble-Tight. The patented DALE poppet design makes sure that no internal leakages occur.

High Flow. Leak tight plus high flow equals minimized test time.

Independent Pressure Ports. Provides the ability to have pressure or vacuum on any port at any time.

Integrated Sensor Ports. The manifolds customized for leak-testing come with integrated sensor ports.

Compact Installation. The compact manifolds eliminate spacing between valves. For detailed information, consult ROSS Bulletin 200. ROSS' application experts will be happy to assist you in finding optimum opportunities for integrating ZeroCon®-Crown and DALE into your pneumatic system.

ROSS® DALE-Poppet Valves & ZeroCon®-Crown

The perfect match. No leaks involved.

LT-Valve Manifolds 3/4-Way Valves, G 1/4

CP & CX 3/2-Way Valves,

G 3/4 and G 1

Solenoid actuated

Port plate flexibility

Full port flow

Dynamic sealing

Speed control

Internally or

externally piloted


ROSS EUROPA GmbHRobert-Bosch-Strasse 2D-63225 LangenTel.: 0049-6103-7597-0Fax: 0049-6103-74694e-mail: [email protected]

DIMAFLUID S.A.S.69/73 Boulevard Victor HugoBâtiment 6-893400 Saint-Ouen, FrankreichTel.: 0033-1-49456565Fax: 0033-1-49456530e-mail: [email protected]

ROSS CONTROLS® 1250 Stephenson Hwy.Troy, Michigan 48083 U.S.A.Tel.: 001-248-764-1800Fax: 001-248-764-1850www.rosscontrols.com

ROSS SOUTH AMERICA Ltda.e-mail: [email protected]

ROSS UK Ltd.e-mail: [email protected]

ROSS ASIA K.K.www.rossasia.co.jp

ROSS CONTROLS (CHINA) Ltd.www.rosscontrolschina.com

ROSS CONTROLS INDIA Pvt. Ltd.www.rossindia.com

Printed in Germany - Rev. 09-2014 © 2014, ROSS EUROPA GmbH. All Rights reserved. RE-E-A10216

GLOBAL Reach with a LOCAL Touch.

ROSS® is a reputed manufacturer of premium pneumatics, well-established on all continents. Our potential to deve-lop unique, customized products and ready-for-use control units is widely appreciated. ROSS® experts are familiar with the processes and technical challenges in all major industries so that our customers can look forward to fluid power solutions on highest productivity levels. ROSS‘ extensive design-, distribution- and service network provides GLOBALLY exemplary performance power which is LOCALLY available for further enhancement of your proces-ses. Be sure that ROSS® will always be ready to help YOU!

Warranty and Important Notes.

Standard ROSS Warranties and Application Notes apply. We will be glad to inform you in full detail. For more infor-mation, please visit ROSS EUROPA's website ( www.rosseuropa.com ).

Documents

BULLETIN E-RE-01BE-RE-01B - ROSS EUROPA€¦ · temperature (20°C/ 68°F), acc. to EN 13480-3, and for predominantly static loads. Temperature stability All ZeroCon®-Crown components