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Imagine Life Without Brazing
ZoomLock Product guide
Braze-free copper fittings for the Air Conditioning and Refrigeration Industry
V.2
ContentsSection 1
Introduction to ZoomLock 03 Section 2
Features & Benefits of ZoomLock 04Section 3
ZoomLock Product Range ZoomLock Kit 06 ZoomLock Fittings 07 ZoomLock Accessories & Spares 10
Section 4Installation Instructions 11
Section 5CPD’s and Product Demonstrations 13
Section 6Testimonials 14
Section 7Technical
Frequently Asked Questions 15 Specifications 17
Performance Data/Reports 18 Manufacturer Commentaries 19
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Fast, Safe, Clean, Simple
ZoomLock offers a braze-free alternative to using Refrigeration Copper Fittings.With feedback from the many contractors who have already invested in ZoomLock, we confidently guarantee ZoomLock will increase the Speed, Quality, Productivity and Profitability of your installations!
Significant labour savings gives you a quick return on your investment, along with saying goodbye to hassle factors associated with traditional brazing. No more hot works permits, or nitrogen purging, fire wardens, or cooling down time.
A Brilliant Idea. A Simple Solution. The ZoomLock braze-free connecting process is based on exclusive, patented crimping technology. You only need two hands and a few simple tools. No brazing, no experience and practically no time at all.
ZoomLock BRAZE-FREE TUBE FITTINGS CHANGES EVERYTHING ZoomLock fittings are specially designed to work without brazing, which automatically makes your job simpler and faster when joining copper tube. In addition, the one-piece fittings are reliably secure, leak-proof and more repeatable than brazed connections - so there’s no compromise on quality or performance.
MEET ZOOMLOCK THE 10-SECOND FLAME-FREE
REFRIGERANT FITTING.
• Ten-second leak-proof refrigerant fitting.• Reduce labour cost up to 60%• No brazing. No flame. No fire warden.
Gives your company significant time savings
Welcome to ZoomLock!
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ZoomLock Product G
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ZoomLockTM fittings are specially designed to work without brazing, which automatically makes your job simpler and faster when joining refrigeration copper tubes.
Features & Benefits of ZoomLock
The ZoomLock Advantage Increases speed and quality of installations
No hot work permits required
No need to nitrogen-purge
Gives you a clean system
More flexible access to job sites
Less equipment and no gas needed
Safer conditions, no fire hazards
More environment friendly
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Quick. Easy. Clean. Repeatable.
ZoomLock Crimping Tool
Tube cutter
De-burring tool
Depth Gauge
Scotch-Brite
Marker Pen
Time-Consuming. Risky. Dirty. Imperfect.
Torch kit with gas regulators
Gas tanks (3 - Nitrogen, Acetylene, Oxygen)
Tube cutter
De-burring tool
Brazing Rods
Scotch-Brite
Cooling rag
Access to water
Solder and flux
Fire extinguisher
Fire safety equipment
Hot Works Permit
Fire Warden
Goggles
Gloves
Pliers
Expanders
VS ZoomLock Fittings
Brazing
All together in one simple carry case.
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Training provided by Greenmill.Need training on site?Give us a call today on 01206 864467
ZoomLock Product RangeComplete ZoomLock Kit
7 Piece Jaw kit, 1/4” - 1-1/8”
15kN ZoomLock Crimping Tool
Tubing Cutter
Deburring Tool
Crimp Gauge
Stainless Steel Brush
Abrasive Pad
Permanent Marker
Battery Charger
2 Lithium-lon Rechargeable Batteries
Part Number: GMZL7 - TAJ
Kit Includes:
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ZoomLock FittingsZoomLock Braze-Free FittingsConnectors
Dimensions
Part Number
Description Dimensions
A B C D
Inch mm Inch mm Inch mm Inch mm
GMZL501 Connector 1/4” C - C 0.26 6.6 0.34 8.6 0.45 11.5 0.95 24.1
GMZL502 Connector 3/8” C - C 0.39 9.8 0.47 11.8 0.59 14.9 0.98 24.9
GMZL503 Connector 1/2” C - C 0.51 13.0 0.59 15.0 0.73 18.6 1.25 31.8
GMZL504 Connector 5/8” C - C 0.64 16.1 0.74 18.7 0.89 22.5 1.24 31.5
GMZL505 Connector 3/4” C - C 0.76 19.3 0.88 22.4 1.07 27.2 1.29 32.8
GMZL506 Connector 7/8” C - C 0.89 22.5 1.02 25.8 1.19 30.2 1.31 33.3
GMZL507 Connector 1 1/8” C - C 1.14 28.8 1.29 32.6 1.44 36.7 1.29 32.8
A
D
B C
DimensionsA
B C
D
E
Part Number
Description Dimensions
A B C D E
Inch mm Inch mm Inch mm Inch mm Inch mm
GMZL601 90° Long Radius Elbow 1/4” 0.26 6.6 0.34 8.6 0.45 11.5 2.01 51.1 0.50 12.7
GMZL602 90° Long Radius Elbow 3/8” 0.39 9.8 0.47 11.8 0.59 14.9 2.27 57.7 0.65 16.5
GMZL603 90° Long Radius Elbow 1/2” 0.51 13.0 0.59 15.0 0.73 18.6 2.88 73.2 0.90 22.9
GMZL604 90° Long Radius Elbow 5/8” 0.64 16.1 0.74 18.7 0.89 22.5 3.21 81.4 1.13 28.7
GMZL605 90° Long Radius Elbow 3/4” 0.76 19.3 0.88 22.4 1.07 27.2 3.47 88.0 1.50 38.1
GMZL606 90° Long Radius Elbow 7/8” 0.89 22.5 1.02 25.8 1.19 30.2 3.75 95.3 2.25 57.2
GMZL607 90° Long Radius Elbow 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 4.29 108.8 2.85 72.4
90o Long Radius Elbows
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Dimensions
D
D
A B C
Part Number
Description Dimensions
A B C D
Inch mm Inch mm Inch mm Inch mm
GMZL702 Equal Tee 3/8” 0.39 9.8 0.47 11.8 0.59 14.9 1.63 41.4
GMZL703 Equal Tee 1/2” 0.51 13.0 0.59 15.0 0.72 18.2 2.23 56.6
GMZL704 Equal Tee 5/8” 0.64 16.1 0.74 18.7 0.87 22.0 2.29 58.2
GMZL705 Equal Tee 3/4” 0.76 19.3 0.88 22.4 1.05 26.6 2.37 60.2
GMZL706 Equal Tee 7/8” 0.89 22.5 1.02 25.8 1.19 30.2 2.44 62.0
GMZL707 Equal Tee 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 2.56 65.0
Equal Tees
Part Number
Description Dimensions
A B C D E F G
Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm Inch mm
GMZL800 Reducing Coupling 3/8” - 1/4” C x C 0.39 9.8 0.47 11.8 0.59 14.9 0.26 6.6 0.34 8.6 0.45 11.5 2.20 55.9
GMZL808 Reducing Coupling 1/2” - 1/4” C x C 0.51 13.0 0.59 15.0 0.73 18.6 0.26 6.6 0.34 8.6 0.45 11.5 2.63 66.8
GMZL801 Reducing Coupling 1/2” - 3/8” C x C 0.51 13.0 0.59 15.0 0.73 18.6 0.39 9.8 0.47 11.8 0.59 14.9 2.63 66.8
GMZL809 Reducing Coupling 5/8” - 1/4” C x C 0.64 16.1 0.74 18.7 0.89 22.5 0.26 6.6 0.34 8.6 0.45 11.5 2.70 68.6
GMZL810 Reducing Coupling 5/8” - 3/8” C x C 0.64 16.1 0.74 18.7 0.89 22.5 0.39 9.8 0.47 11.8 0.59 14.9 2.70 68.6
GMZL802 Reducing Coupling 5/8” - 1/2” C x C 0.64 16.1 0.74 18.7 0.87 22.0 0.51 13.0 0.59 15.0 0.72 18.2 3.00 76.2
GMZL811 Reducing Coupling 3/4” - 1/2” C x C 0.76 19.3 0.88 22.4 1.05 26.6 0.51 13.0 0.59 15.0 0.72 18.2 3.10 78.7
GMZL803 Reducing Coupling 3/4” - 5/8” C x C 0.76 19.3 0.88 22.4 1.05 26.6 0.64 16.1 0.74 18.7 0.87 22.0 3.00 76.2
GMZL812 Reducing Coupling 7/8” - 1/2” C x C 0.89 22.5 1.02 25.8 1.19 30.2 0.51 13.0 0.59 15.0 0.72 18.2 3.05 77.5
GMZL804 Reducing Coupling 7/8” - 5/8” C x C 0.89 22.5 1.02 25.8 1.19 30.2 0.64 16.1 0.74 18.7 0.87 22.0 3.05 77.5
GMZL805 Reducing Coupling 7/8” - 3/4” C x C 0.89 22.5 1.02 25.8 1.19 30.2 0.76 19.3 0.88 22.4 1.05 26.6 3.11 79.0
GMZL813 Reducing Coupling 1 1/8” - 1/2” C x C 1.14 28.8 1.29 32.6 1.44 36.7 0.51 13.0 0.60 15.0 0.72 18.2 3.25 82.6
GMZL814 Reducing Coupling 1 1/8” - 5/8” C x C 1.14 28.8 1.29 32.6 1.44 36.7 0.64 16.1 0.74 18.7 0.87 22.0 3.25 82.6
GMZL806 Reducing Coupling 1 1/8” - 3/4” C x C 1.14 28.8 1.29 32.6 1.44 36.7 0.76 19.3 0.88 22.4 1.05 26.6 3.25 82.6
GMZL807 Reducing Coupling 1 1/8” - 7/8” C x C 1.14 28.8 1.29 32.6 1.44 36.7 0.89 22.5 1.02 25.8 1.12 28.4 3.11 79.0
Reducing CouplingsDimensions
G
A D E FBC
ZoomLock Braze-Free Fittings
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End Caps
Part Number
Description Dimensions
A B C D
Inch mm Inch mm Inch mm Inch mm
GMZL901 End Cap 1/4” 0.26 6.6 0.34 8.6 0.45 11.5 1.11 28.2
GMZL902 End Cap 3/8” 0.39 9.8 0.47 11.8 0.57 14.5 1.13 28.7
GMZL903 End Cap 1/2” 0.51 13.0 0.59 15.0 0.72 18.2 1.47 37.3
GMZL904 End Cap 5/8” 0.64 16.1 0.74 18.7 0.87 22.0 1.56 39.6
GMZL905 End Cap 3/4” 0.76 19.3 0.88 22.4 1.05 26.6 1.57 39.9
GMZL906 End Cap 7/8” 0.89 22.5 1.02 25.8 1.19 30.2 1.60 40.6
GMZL907 End Cap 1 1/8” 1.14 28.8 1.29 32.6 1.44 36.7 2.05 52.1
Dimensions
D
AB C
Euro Flare FittingsDimensions
A B
D
C
Part Number
Description Dimensions
A B C D
Inch mm Inch mm Inch mm Inch mm
GMZL1001 Euro Flare Fitting 1/4” 0.26 6.6 0.45 11.5 1.38 35.1 0.56 14.2
GMZL1002 Euro Flare Fitting 3/8” 0.39 9.8 0.59 14.9 1.38 35.1 0.58 14.7
GMZL1003 Euro Flare Fitting 1/2” 0.51 13.0 0.72 18.2 1.13 28.7 0.75 19.1
GMZL1004 Euro Flare Fitting 5/8” 0.64 16.1 0.87 22.1 1.48 37.6 0.75 19.1
ZoomLock Braze-Free Fittings
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ZoomLock Accessories and SparesReplacement Parts and Accessories
ZoomLock JawSize Part Number1/4” GMZL201
3/8” GMZL202
1/2” GMZL203
5/8” GMZL204
3/4” GMZL205
7/8” GMZL206
11/8” GMZL207
ZoomLock Makita 18V Battery Charger240V battery charger for 18V Li-Ion batteries. Extremely short charging time.
Part Number: GMZLCHAR
ZoomLock Makita 18V 1.5Ah Rechargeable BatteryHigh performance, 1.5 Ah, 18V Li-Ion battery.
Part Number: GMZLBAT15
ZoomLock Insertion Depth ToolMetal depth gauge confirms the proper insertion depth of the tubing.
Part Number: GMZL014
ZoomLock Crimp GaugeConfirms the measurement of the finished crimp band diameter
Part Number: GMZL005
Tubing CutterZoomLock approved tubing cutter
Part Number: GMTC135
ZoomLock Tube Deburring Tool
Part Number: GMZL007
ZoomLock Marker Pen Part Number: GMPMP
ZoomLock Scotch Brite Scourer Pad
Part Number: GMZL020
For illustration purposes only
For illustration purposes only
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Installation Instructions
Step 1Slide battery into charger. Plug charger into a power source. Check to see that the charging light is on. When red lights turns off and green light turns on, battery is fully charged - 20 minutes.
Step 2Press the locking pin, then rotate 45° to release.
Step 3Slide jaws over Crimping Tool head, then depress locking pin until it clicks.
Step 7Use the supplied deburring tool to remove any residual burrs from the outside and inside of the copper tube.
Step 8Use a heavy duty scouring pad to clean the ends of the copper tubes to be joined. Tube ends should be free and clear of oxidation, or debris.
Step 9Inspect the copper tube for imperfections such as deep surface scratches and incise marks within the o-ring sealing area that may provide a leak path for refrigerant. If scratches are present, cut off the affected area or sand thoroughly to remove.
WARNING: COPPER TUBE ENDS SHOULD BE INSPECTED AND ANY SHARP EDGES SHOULD BE ADDRESSED, SHARP EDGES MAY CAUSE DAMAGE TO THE O-RING.
Step 4Slide charged battery into base of Crimping Tool.
Step 5Press and hold trigger and Crimping Tool to calibrate. Calibration is recommended daily, prior to use.
Step 6Cut the copper tube using the supplied tube cutter. Do NOT use a hacksaw or reciprocating saw as this creates a rough surface that may damage the o-ring.
Deep Scratches
Incise Marks
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Step 10Using the depth gauge provided determine the minimum insertion depth. Mark the tubing with a permanent marker to indicate proper insertion depth on every tube.
Step 11Ensure both ‘O’ rings are correctly located in the fittings. Push the fitting onto the tube. Use the mark to assure insertion depth and secure fit.
Step 12Open the jaws of the ZoomLock Crimping Tool.
Step 15Open the jaws of the ZoomLock Crimping Tool and remove from the fitting. If the jaws do not open, the crimping cycle was not completed. For manual override, slide the manual release button down to open the jaw in case of emergency.
Step 16A special “RLS” mark will be displayed on the tube to let you know the connection is crimped properly.
Step 17The supplied RLS CrimpGauge will confirm the measurement of the finished crimp band diameter. See crimp band locations noted in Step 16. It may be necessary to rotate the gauge in order to not interfere with the copper tube flashing left from the crimping process.
Step 14Press and hold the trigger on the ZoomLock Crimping Tool to begin the crimping process. Continue to hold the trigger until the ZoomLock Crimping Tool completes its cycle.
Manual Release Slide
Step 13Properly place the crimping jaws onto the fitting. Grooves in the jaws make it easy to align. See illustration above right for proper crimping alignment.
WARNING: ZOOMLOCK IS DIFFERENT THAN OTHER INDUSTRY CRIMP TECHNOLOGY. DO NOT CRIMP WITH JAW CENTERED ON O-RING.
JAW MUST ALIGN BETWEEN O-RING AND OUTER FLANGE.
Installation Instructions Cont
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Hands On/On-site TrainingBoardroom Training
Training, CPD’s and Demonstrations
If your company is interested in arranging a CPD Session or a product demonstration for your team please contact our sales office on 01206 864467 or by email [email protected]
CPD (Continual Professional Development) Training SessionsGreenmill offer to hold CPD training sessions in your own premises to ensure all your team get the opportunity to get up to date with this innovative, game changing system. Our Zoomlock Product Advisors come equipped with everything to create a stimulating and hands on Zoomlock presentation, from the Zoomlock Tool and Fittings to a great PowerPoint Presentation with a great selection of videos.
On Site Demonstrations & Training SessionsGreenmill also offer to hold Zoomlock Product Demonstration sessions on site or at your office to help you evaluate the product and see for yourself the features and benefits of this incredible system. We appreciate you may want to try the Zoomlock to fully appreciate how quickly this product could be saving you time and money. To organise a Zoomlock Demonstration for you or your team please get in touch today.
Greenmill recognises how important it is for the engineers to install Zoomlock correctly so we provide an online training video, which once completed qualifies the engineers for a Zoomlock Training Certificate
Continuous Professional Development CertificationAwarded to
For attending and completing the programme onZoomLock Braze-free pipework connection
Date: 3rd April 2017
John SmithABC Air Conditioning Company Ltd
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TestimonialsAngus Pearce - Director at EAC Services LtdVery Pleased with our ZoomLock purchases as well, have used on a number of sites now, all where hot works permits may have caused potential difficulties and installs all went in problem free. We haven’t calculated out cost savings as yet but it would suggest in time alone decent savings are made over brazing. Would recommend ZoomLock to all to include as an option for any installation projects.
Mark Williams - Maintenance EngineerWhen I was working at a college, the learners loved using this bit of kit. Obviously they were taught all types of jointing. We always found that the best thing to do if you want to test a new bit of kit, is to give it to an apprentice. They will either break it, steal it or eat it. And they managed neither. They loved the time races we had with ZoomLock, brazing, flares etc. And to be fair ZoomLock was the easiest and fastest to set up and use. Very very good piece of kit.
Lee Tindall - Client Service Manager at Johnson ControlsWe have being using ZoomLock on petrochemical and nuclear sites with great results, just need to expand the fitting range which I believe is in hand.
Raymond Knox - Capital Cooling, EdinburghRaymond Knox – “Great piece of kit, used it in a recent VRV installation with a pipe run of 60m with no leaks what so ever”
Tod Harvey – “Thanks for the feedback Raymond Knox, quite a prestigious project wasn’t it? (Hilton Hotel)
Raymond Knox – “Yeah Tod it allowed us to work for a major customer during working hours with no fuss or need for fire alarm isolation”
Stuart Inglis - Director, Inglis Cooling Services LtdGreat machine, saves us time not only on installation but on getting very Hot Work Permits, no fire watch required, no waiting on pipes cooling down and no nitrogen purging required.
Ben Rabbitt - Refrigeration Engineer at Three Nations LtdThis is the hassle free alternative to brazing. It’s clean, quick and reliable. Good job Greenmill, another great product from a great team.
Josh Graves - Specialist HVACR EngineerThe Future of A/C pipework! Tested a crimp fitting suitable for A/C pipework on soft drawn copper 1/2” at 30 bar. Amazed at how quick it is compared to flare and brazed! Very impressed at just how easy and secure the crimp is.
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Technical - Frequently Asked Questions1. How many crimps can you complete on a complete
battery charge?
On average you can achieve 100-150 crimps per charge depending on the size fittings being crimped. Each kit comes with 2 Makita Lithium-ion batteries and a rapid charge charging system. To prevent any downtime, it is recommended that you have both batteries charged before going to the jobsite and to have one charging while the other is in use.
2. Can you use ZoomLock to crimp to aluminum, steel, or stainless steel?
No, ZoomLock is specifically designed for copper to copper connections. Connecting to dissimilar metals can cause formicary corrosion issues that could cause a failure.
3. What material is the o-ring made of?
The o-ring is a highly engineered HNBR Parker o-ring that has been used in HVAC applications by OEMs and suppliers for many years with no issues.
4. What is the expected life of the o-ring in the system?
The expected life of the o-ring that stays within the product specifications for temperature and pressure should be 30 years.
5. Are there any shelf life concerns?
No, the shelf life of the product is estimated at or above 30 years.
6. Is there a concern about ice building up and then thawing under fitting in a horizontal or vertical configuration?
No, ZoomLock has been thoroughly tested in freeze/ thaw applications with over 10,000 cycles completed in both vertical and horizontal configurations with no leakage concerns.
7. Can you braze the fitting after crimping it?
No. Trying to braze the fitting will very likely melt the o-ring material and thus introduce contaminants into the system that could cause other system issues.
8. Are there any concerns with corrosion due to coastal applications, cleaning agents, or offgassing of produce/vegetables?
No, ZoomLock has gone through a battery of corrosion testing, completing over 2,000 hours of salt spray testing without failure, which proves the resilience of the product.
9. How do you slide insulation over these fittings (the flare will grab insulation?
If the flare of the fitting tends to be a problem, you can smooth the transition over the fitting by adding duct tape around the flared edge of the fitting to the tube.
10. How do you know when the tool needs to be serviced?
The tool has a red LED on the back of the tool that will blink for 20 seconds after a crimp. When this occurs, take the tool back to an authorized dealer to have the tool analyzed. They will be able to verify if the tool needs to be sent in for service.
11. What is the expected life of the jaws?
Each jaw has an expected life of 10,000 to 12,000 crimps.
12. How do you know when the jaw needs to be replaced?
You will know when the jaw needs to be replaced when the contact point between the upper and lower jaw starts to open up/widen. A good indication of failure is when the crimp gauge no longer engages.
13. Do you have a solution for crimping onto flared tubing like that coming out of the condenser and evaporator on residential units?
No, we do not have a specific product designed to crimp over the flared tubing. However, if there is at least 2 inches of straight copper tubing after the flared end and is accessible with the jaws, we suggest that you cut the flared end off and crimp directly to the tube.
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16. Does the o-ring compensate for imperfections in the piping to make a tight seal?Yes, the o-ring does compensate for small/minor scratches on the surface of the tube; however, the tubing needs to be inspected prior to use per ASTM B280 and the Copper Tube Handbook published by the Copper Development Association (CDA) specifications. Imperfections in and adjacent to the crimp area could inhibit the joint integrity. These imperfections may include surface scratches,
incise marks, and tubing out of round.
17. The product specifications state that the application temperature limits are -40°F to +300°F / -40°C to +150°C. What happens if we go beyond that limit?If the application that the fitting is being used in goes beyond the specified limits of the o-ring (-40°F to +300°F / -40°C to +1 50°C) then ZoomLock should not be used in this instance.
18. Can I use ZoomLock in a transportation application where fitting vibration is high?Yes, ZoomLock has gone through extensive vibration testing and results are actually better than that of a braze joint. Please review the vibration testing procedure and conclusion for
more information.
14. How do I know the correct insertion depth whenpushing the ZoomLock fitting onto the copper tube?
Use the depth gauge provided or the chartbelow to determine the minimum insertiondepth. Mark the tubing with a permanentmarker to indicate proper insertion depth onevery tube.
Minimum Insertion Depth
Fitting Size Inches mm
1/4 15/16 23.8
3/8 15/16 23.8
1/2 1-1/4 31.8
5/8 1-1/4 31.8
3/4 1-1/4 31.8
7/8 1-1/4 31.8
1-1/8 1-1/4 31.8
15. How much tolerance can the ZoomLock handle onthe pipe being crimped?
We know that not all copper tubing is thesame, but we have tested ZoomLock withmost EN12735-1 conforming copper tubemanufacturers with no issues. The tolerancefor each tube to ensure a good leak-free jointis +.002/-.007. (Greenmill’s stock of refrigerationcopper tube always conforms to EN 12735-1)
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Technical - SpecificationsZoomLock Braze-Free Fittings
ApplicationsHigh Pressure HVAC/R
Product ParametersContinuous Operating Temperature (COT):250°F / 121°C
O-Ring Temperature Rating:-40°F to +300°F-40°C to +148.9°C
Maximum Rated Pressure (MRP):700 psi / 48 bar
Maximum Burst Pressure:3000 psi / 207 bar+
Vacuum Pressure Capability:20 Microns
External Leak Rate:<0.1 Ounces of Helium per Year at Operating Pressure Range
Vibration Resistance: Conforms to UL109
Size Availability (Inches):1/4, 3/8, 1/2, 5/8, 3/4, 7/8, 1-1/8
Fitting MaterialsFitting Body:Refrigerant Grade Copper, per ASTM-B280
O-Ring: HNBR
Fitting Warranty5 years.
CompatibilityApproved Oils: Mineral Oil, POE, PVE, PAG
Approved Tubing Materials: Copper to Copper Connections
Approved Copper Tubing Types for Use with the ZoomLock Jaws:Half Hard Copper Straights - 3/8” - 1-1/8”
Soft Annealed Copper Coils - 1/4” – 7/8”
R410A
R407C
R32
R404A
R134A
R1234YF
R1234ZE
R125
R143A
R407A
R417A
R422D
R407F
R438A
R447A
R448A
R449A
R450A
R452A
R507A
R513A
R718
R290 (Propane)
R600a (Isobutane)
R600 (Butane)
Not approved for R22
Approved Refrigerants
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Technical - Performance DataPressure Testing of a 'Greenmill-ZoomLock' Sample
Methodology
A time study was conducted in a controlled environment, with two
stations set up for joining refrigeration tube: one by brazing and one
by using ZoomLock braze-free fittings. Two different installers were
used, one very experienced in making brazed connections and one
very experienced in using the ZoomLock press tool.
The two installers were timed independently making connections
using various sized copper tube and fittings. Before timing began,
tube was cut to length and the ends were prepared for connection
(as these procedures are the same for both connection methods).
Three connections were timed for each size of tube/fitting for each
installer, and the three times were averaged. The results are shown
in the table below.
Key Findings and Conclusions
The time savings achieved while joining tube using ZoomLock
brave-free fittings, compared to brazed connections, ranged from 31%
on the smallest fittings timed to 77% on the largest. The average time
savings over the fittings sizes timed was approximately 50%. So, on
average, ZoomLock braze-free fittings were made in roughly half the
time of brazing - and in less than one- quarter the time on the largest
fitting size.
Based on the study, brazed connections take longer to complete
than ZoomLock braze-free fittings. When analysing the installation
techniques for both connections, a brazed connection requires a
period of time to raise the temperature of the fitting and tube to
about 1000°F (538°C). As the tubing and fitting increases in diameter, the
amount of time it takes to heat them also increases. The ZoomLock
braze-free fittings only require the connection of a press control tool,
which takes less than ten seconds to complete the actual pressing
operation (two crimps) - and the time to connect does not increase
significantly as the diameter of tubing and fittings increases in size.
In a controlled environment, such as the work station where the
time study was conducted, the brazing operation takes less than
a similar joint made on a construction or repair project in the field.
The controlled environment is already set up for brazing, with all
necessary equipment and materials close at hand. However, using
the ZoomLock press tool and fitting require approximately the same
amount of time in any environment. Therefore, it can be assumed
that the ZoomLock time savings would be even greater outside of a
controlled environment.
Time and Motion StudyReplacement Parts and AccessoriesConducted by:
Jay Peters, Principal Advisor, Codes and Standards International
Labour Time for Installing a Copper Coupling
Fitting Size 1/4” 5/8” 1-1/8”
Brazed Connection 35 Seconds 42 Seconds 1:15 Minutes
ZoomLock Braze-Free Fitting 24 Seconds 24 Seconds 25 Seconds
% Time Savings 31% 43% 77%
ACR Loss CoefficientACR Pressure Drop (10ft. long)
3/8” ACR Tube Pressure Drop vs. Velocity 3/8” ACR Tube Loss Coefficient vs. Reynolds Number
3/4” ACR Tube Loss Coefficient vs. Reynolds Number
7/8” ACR Tube Loss Coefficient vs. Reynolds Number
3/4” ACR Tube Pressure Drop vs. Velocity
7/8” ACR Tube Pressure Drop vs. Velocity
TECHNICAL BULLETIN
JOINTING METHODS FOR RACHP PIPEWORK
2.1 COPPER
This is still the most common material used in light commercial and residential refrigeration, air
conditioning and split or multi-split/VRF style heat pump units. It is essential that copper tubing
used for this purpose is of refrigeration quality, kept free of moisture or contaminant ingress, and of
sufficient wall thickness for the purpose and gas in use. Copper has a high scrap metal value and has
been known to be stolen from sites and even from working systems resulting in total loss of refrigerant.
Copper is suitable for all jointing methods outlined in the next section.
2.2 ALUMINIUM
As concerns about theft and of availability of copper in the long term have increased, there has
been an increase in the use of aluminium tubing. Aluminium has an insignificant scrap metal value
rendering it virtually worthless to thieves. It is also very lightweight compared to copper and relatively
pliable at room temperature and is, therefore, very easy to work with.
Aluminium is not suitable for all jointing methods outlined in the next section. Particular attention
needs to be given where brazing/welding takes place as the melting point of aluminium is significantly
lower than copper and normal brazing equipment will simply melt the tube. A soft solder propane
flame should be used for brazing aluminium tubing.
2.3 DUAL COPPER/ALUMINIUM
Concerns about long term structural integrity of aluminium tubing led to the availability of dual
tubing which comprises of 1/3 copper and 2/3 aluminium. The inner core is copper for the strength and
integrity, while the outer sheath is aluminium to create the impression the whole pipe is aluminium
and, therefore, of no value to thieves as well as having a significant effect on the weight of a coil of
tubing.
As with the aluminium tubing, particular care should be taken when brazing this tube. A propane soft
solder flame should be used to braze dual material tubing.
2.4 CAUTION
Particular care should be given when jointing dual tubing or if there are instances of different pipe
materials used in a pipe run as there is the potential for galvanic corrosion where two materials of
different galvanic potential come into contact with a common fluid flowing between them. Galvanic
corrosion will compromise the integrity of the tubing over time and cause significant leak potential.
Earth bonding between the different materials can overcome this potential but, where possible, you
should always ensure the same pipe material is used throughout the length of its run.
1 | 2
1 OBJECTIVE
2 MATERIALS IN USE
The objective of this technical bulletin is to inform members of the various methods currently
available in the light commercial and domestic RACHP sector for joining the various different
pipe materials currently available on the market and approved for use by manufacturers. Large
commercial systems using steel pipework are covered in other publications.
TB/012
PLEASE NOTE This technical bulletin is not designed to endorse or approve one or more products or
methods above any other but seeks to impartially provide information for BESA Members to aid them
in deciding which pipe material or joining method to use for different applications. Compatibility
with materials and specific refrigerants should be checked before use as many new refrigerants are
entering the marketplace and there may be issues with oils and/or refrigerant gases. At the time of
publishing there are no known issues with refrigerant compatibility and any of the jointing/material
methods outlined below. This technical bulletin should be seen as a fluid document that may be
amended frequently through time as new technologies, materials and methods become available.
GuidetoGoodCommercial
RefrigerationPractice
Part4SystemInstallation
BritishRefrigerationAssociation
InstituteofRefrigeration
Issue1October2008UpdatedMay2016
PMG-1296CSI: DIVISION: 23 00 00—HEATING,
VENTILATING AND AIR CONDITIONING
(HVAC)
Section: 23 20 00–HVAC Pipe and
Fittings
Product certification system:
The ICC-ES product certification
system includes testing samples
taken from the market or supplier’s
stock, or a combination of both, to
verify compliance with applicable
codes and standards. The system
also involves factory inspections, and
assessment and surveillance of the
supplier’s quality system.
Products: Refrigeration Tubing Connectors
Listee: RLS, LLC
101 S. Douglas Street
Shelbina, MO 63468
www.rlspressfittings.com
Additional Listee: Parker Sporlan
206 Lange Drive
Washington, MO 63090
www.parker.com
Compliance with the following codes: 2015, 2012, 2009 and 2006 International
Mechanical Code® (IMC)
2015, 2012, 2009 and 2006 International
Residential Code® (IRC)
2015, 2012, 2009 and 2006 Uniform
Mechanical Code® (UMC)*
*Copyrighted publication of the
International Association of Plumbing
and Mechanical Officials.
Compliance with the following standards: UL 207 (Edition 8), Standard for
Refrigerant-Containing Components
and Accessories,
Nonelectrical
Identification: The refrigerant tubing connectors
shall be legibly and permanently
marked with the manufacturer’s
name, trade name, trademark,
or identifying symbol or other
descriptive maring by which
the organization responsible for
the product may be identified.
The shipping carton, a separate
instruction sheet included with the
shipping carton or a tag attached
to the component shall include a
distinctive model, part number, or
type designation for the connector
and include information for each
refrigerant type for which the
connector is intended and the ICC-ES
PMG listing mark.
Installation: The refrigerant tubing connectors
must be installed in accordance with
the manufacturer’s
published installation instructions, the
applicable codes and this listing.
Mechanical joints shall not be used
on annealed temper copper tube in
sizes larger than 7/8-inch (22.2 mm)
OD size per IMC and 3/4” of an inch
nominal size per UMC.
Models: The refrigerant tubing connectors
are intended for connection of
copper, aluminum, titanum and
other types of tubing approved by
the manufacturer. The connection
is accomplished by compressing
(solder-free) the fitting to a pipe. The
refrigerant tubing connectors are
only suitable for type A1 refrigerants
(R1234yf, R1234ze, R125, R134a, R143a,
R32, R404a, R407a, R407c, R407f,
R410a, R417a, R422d, R438a, R447a,
R448a, R449a, R450a, R452a, R507a,
R513a, R718).
ICC-ES Evaluation ReportEffective Date: January 2015
Revision Date: January 20, 2016
B.R.ABESA
BSRIA Report ACR Pressure ReportICC-ES Report Helium Leak Test Report
Time and Motion Study
EU Declaration of Conformity
CE Declaration of Conformity
Helium Leak Test Report
page 1 of 2
Customer: Marmon Refrigeration Technologies Project No.: 12866CSL-01
Equipment: Veeco MS-40 Date Reported: January 10, 2013
Project Engineer: Jim Busch Principal Tech: Barb Christel
1250 Arthur E. Adams Drive Columbus OH 43221 (614) 688-5000 FAX: (614) 688-5001 http://www.ewi.org/
1250 Arthur E Adams Dr., Columbus, OH 43221 LAB SERVICES
Scope: To test and report the leak rate of RLS press connections.
Background: Marmon Refrigeration Technologies (MRT) submitted RLSTM press connection samples for
helium leak testing. Six (6) different RLS TM sizes were chosen to connect commercially available ACR
tubing (see Table 1). Thirty (30) union connections were chosen as a sample lot with two (2) connections
per fitting. Each sample connected two pieces of tubing approximately nine (9) inches long. One of the
tubes was brazed shut at one end and the other tube was reduced to a ¼” tube stub.
Table 1. Tube Diameters Tested EWI Leak Testing Approach: Prior to testing each lot of samples, the Veeco MS-40 helium leak tester
was calibrated. After calibration, a solid ¼” dowel was tested to verify the integrity of the seals on the
helium leak test fixture. The ¼” tube stub was wiped down with methanol and connected to the leak detector a via a Swagelok ¼”
Ultra-Torr vacuum fitting (see Figure 1). Each sample was pumped down to a level of approximately 500
millitorr prior to applying helium gas near the RLS TM crimp joint (at atmospheric pressure). The helium leak
rate was measured and recorded for each of the sixty (60) connections in a thirty (30) piece sample lot.
Tube O.D. (in)
# of Samples
Total # of Tested Connections
Notes
0.250 30 60 Samples were made from commercially available ACR tubing (soft) 0.313 30 60
0.375 30 60
0.750 30 60
0.875 30 60
1.125 30 60
For a copy of these reports please contact one
of our Zoomlock Product Advisors on 01206 864467 or email your request to
18 Call us on 01206 864467
Zoom
Lock
Pro
duct
Gui
de |
Sec
tion
7
Technical - Manufacturer Commentaries
Also availableThese manufacturer warranties, will not be invalidated when
using ZoomLock as the preferred jointing method.
If you require a copy of these documents, please contact
one of our ZoomLock Product Advisors on 01206 864467 or
email your request to [email protected].
Page 1 of 1
Fujitsu-General Air Conditioning (UK) Ltd, Unit 150, Centennial Park, Centennial Avenue, Elstree, Borehamwood, Hertfordshire, WD6 3SG
’
September 2015
Page 1
Statement regarding alternative pipework materials and jointing methods for use on Daikin UK DX Airconditioning and/or heating systems.
The use of alternative materials for jointing and piping direct expansion systems is growing within the industry. As an equipment manufacturer, we understand that the use of these products can enable the reduction or elimination of hot works on site, which can be a requirement of the customers’ specification.
Our equipment warranty relies on high quality pipework installations being performed to the standards as specified in our installation manuals. Using methods or materials for this purpose that are not described in our installation manuals are the sole responsibility of the installing contractor. We will however continue to maintain our manufacturer warranty on systems using these alternative methods, providing that the following criteria are met:
• Any system piping or jointing materials & methods must meet all local and European legislation, including F-Gas obligations, to minimise or eliminate the possibility of refrigerant leaks, and uphold the safety and environmental requirements of BS-EN378.
• Any damage caused directly or indirectly to the installed Daikin system through installation or use of these methods or materials will not be covered by the Daikin warranty. This includes increased wear and tear on the system caused by a lack of refrigerant.
• All refnet joints used on Daikin systems must be original Daikin supplied parts. This is to ensure correct system pressure, oil and gas distribution. The use of third party refnets, Y or T pieces is not supported and could invalidate the warranty.
• Any materials used should not increase the pressure drop or introduce any foreign substances into the refrigerant circuit when compared to the recommended refrigerant grade copper mentioned in the relevant Daikin installation manuals.
• Any installation using different pipework materials (i.e. Cu to Al) must use a system that prevents any dielectric / bi-metal / galvanic corrosion from occurring through the operational life of the system, including maintenance and service activities.
For further information contact Product Management Richard Green
19Email us at [email protected]
ZoomLock Product G
uide | Section 7
Greenmill Emerald House, Whitehall Road, Colchester CO2 8HAT 01206 864467 E [email protected] www.greenmillac.com
Imagine Life Without Brazing