The Press-fit Jointing System - THE PRESS-FIT JOINTING SYSTEM XPress system advantages ... † Prefabrication † Tube bending † Tool maintenance The principle of the XPress joint

The Press-fit Jointing System

02

CONTENTS

XPRESS - THE PRESS-FIT JOINTING SYSTEM

XPress system advantagesAt Yorkshire Fittings we are constantly striving todevelop jointing solutions that meet the changingneeds of specifiers and installers alike. With thelatest developments to the XPress range of press-fit fittings, we’ve provided a wider choice of materials to suit a broader spectrum ofapplications in the domestic, commercial andindustrial sectors.

Total system solutionsThe XPress System features: XPress Copper fittings(copper and copper alloy fittings for use withcopper tube), XPress Stainless (stainless steelfittings and tube) and XPress Carbon (carbon steelfittings and tube). The range is furthercomplemented by XPress Gas (copper and copperalloy fittings for use with copper tube) specificallydesigned for gas installation pipework, and all thenecessary tools and accessories.

These ranges have been developed by YorkshireFittings to deliver major cost saving benefits byimproving the jointing process and significantlyreducing installation times, particularly on largesize applications.

The principal of the XPress jointXPress fittings achieve a sound joint through theexertion of pressure from a press-fit tool; a purposedesigned ‘O’ ring provides the mechanism by whicha perfect seal is created.

Ensuring that the tube is fully inserted into thefitting, the jaws of the press-fit tool are placedaround the collar of the fitting, which contains a butyl or EPDM 'O' ring (the XPress Gas rangecontains NBR ‘O’ rings). With the jaws at a 90ºangle to the fitting, the press-fit tool is activatedand the jaws compress the 'O' ring tightly onto thetube creating a strong and reliable joint.

The Xpress Copper and Xpress Carbon ranges nowhave a Leak Before Press (LBP) feature, meaningthat any assembled joints inadvertently left un-pressed will exhibit a leak during systemtesting. This enables contractors to easily identifyun-pressed fittings before commissioning.

Advantages of XPressThe heat-free principle of the jointing process isone of the major benefits of the XPress System,removing the need to apply for hot work permitswhich can have costly insurance implications, andeliminating the possibility of flame damage.

XPress Systems combine all the known advantages ofcopper, stainless steel and carbon steel with clean,rapid, heat-free jointing technology. Removing someof the disadvantages associated with other heat-freejointing methods, XPress Systems avoid complicatedclamping techniques, long preparation proceduresand adhesive curing times which can all lead toincreased installation times.

Together with the Tectite range of push-fit fittings,XPress offers the system designer a choice of heat-free jointing methods, which result in anuncontaminated installation, fitted in a fraction ofthe time taken using other jointing methods.

Another primary concern for the contractor is theamount of time spent on-site fitting andcommissioning plumbing and heating services. Withthe XPress range, the time taken to joint tubes in avariety of materials and sizes up to 108mm issignificantly reduced. The jointing process is simpleand tube preparation requires no more than theapplication of good plumbing practice, both ofwhich contribute further to installed cost savings.

The cost benefits of the system do not stop there.The creation of a sound joint requires only the useof a press-fit tool. The need to purchase and storegases, adhesives, fluxes, solders, threading machinesor any other materials or equipment is avoided.

XPress fittings go on saving time and costimmediately after installation. The XPress System isintrinsically clean, therefore no allowance foradhesive curing or long flushing times to removeflux residue is required.

The whole XPress range guarantees electricalcontinuity once the joints are pressed.

XPRESS GAS

XPress Gas fittings can bedistinguished from theXPress Copper equivalent bythe yellow/tan NBR ‘O’ ringand yellow product marking.

PAGE 02 – 03Introduction: The advantagesand benefits of XPress

PAGE 04 – 05Current and future standards

PAGE 06 – 07Further benefits of XPress• Tube compatibility• Material specifications• Quality systems

PAGE 08 – 09XPress specifications• Working temperatures

and pressures• Pressure Equipment Directive• Localised annealing• Equipotential bonding• Specification clauses

PAGE 10 – 11XPress Copper, XPress Gas,XPress Stainless and XPress Carbon installationinstructions, sizes from 15mm to 35mm

PAGE 12 – 14XPress Copper, XPress Gas,XPress Stainless and XPress Carbon installationinstructions, sizes from 42mm to 108mm

PAGE 14 - 15Tools and jaws

PAGE 16 -17Design considerations• Pipe restraint• Insulation• Thermal movement

PAGE 18 – 19 Service considerations• System design• Prefabrication• Tube bending• Tool maintenance

The principle of the XPress joint

XPRESS - THE PRESS-FIT JOINTING SYSTEM 03

Presenting the XPress rangeThe XPress concept has been developed andextended to become a truly versatile package. To complement the established products and usingcommon tooling, fittings and tube for variousspecific applications, across a broad spectrum ofinstallations have now been introduced.

XPress Copper fittings are manufactured fromcopper or copper alloy and are ideal for the fast,efficient jointing of copper tube to BS EN 1057R250 and R290 in sizes from 15mm to 108mm.They are designed for use on hot and cold waterservices, vented and unvented closed circuitheating, chilled water and oil free compressed airapplications within permissible pressure andtemperature limits.

XPress Gas fittings are also manufactured fromcopper or copper alloy and are designed specificallyfor use on internal and external, above ground 2ndand 3rd family gas installation pipework. Availablein sizes from 15mm to 54mm, the fittings arecompatible with copper tube to BS EN 1057 R250and R290.

XPress Stainless is our stainless steel systemoption. Optimised for use as a system, the rangeincorporates both stainless steel press-fit fittings

and stainless steel 316 System tube. Designed forpotable water applications where water quality andhygiene are crucial, particularly in the food,pharmaceutical and health care industries, XPressStainless is available in sizes from 15mm to 108mm.

XPress Carbon is our carbon steel system option.Again optimised for use as a system the rangeincorporates carbon steel press-fit fittings in sizesfrom 15mm to 108mm and two carbon steelSystem tube options – galvanised carbon steelSystem tube in sizes from 15mm to 108mm andplastic coated carbon steel System tube in sizesfrom 15mm to 54mm. XPress Carbon is designedfor vented and unvented closed circuit heating andchilled water applications.

Guaranteed for decadesWhere XPress fittings are installed with products fromother manufacturers (to meet minimum requirementsas laid down under tube compatibility on page 6) aspart of a standard pipeline system, you’ll receive ano-quibble 25-year guarantee (5 years for XPressCarbon) against all manufacturing defects.

All guarantees are subject to the use of YorkshireFittings approved tools, jaws and slings and theapplication of good installation practice.

Copper - Where pipeline systems are constructedexclusively from XPress Copper fittings or XPressGas fittings and Yorkex copper tube to BS EN 1057from Yorkshire Copper Tube limited, the resultinginstallation will be deemed an XPress CopperSystem and as such qualify for a 30 year guaranteeagainst all manufacturing defects.

Stainless steel - Where stainless steel pipelinesystems are constructed exclusively from XPressStainless fittings and stainless steel 316 Systemtube, the resulting installation will be deemed anXPress Stainless System and as such qualify for a 30year guarantee against all manufacturing defects.

Carbon steel - Where carbon steel pipeline systemsare constructed exclusively from XPress Carbonfittings and carbon steel System tube of either orboth variants (galvanised or plastic coated), theresulting installation will be deemed an XPressCarbon System and as such qualify for a 10 yearguarantee against all manufacturing defects.

We could not offer such a comprehensive packageof guarantees but for the integrity and quality ofevery XPress product.

GUARANTEES

25 YEAR GUARANTEEThe XPress Copper, Gas andStainless ranges areguaranteed against allmanufacturing defects for 25 years when installed alongwith other manufacturerspipeline componentsconforming to the specifiedstandard.

30 YEAR GUARANTEEWhere pipelines areconstructed exclusively fromcompatible XPress Copper, Gas and Stainless fittings and tubes, the resultinginstallations will be deemedXPress Systems and as suchqualify for a 30 yearguarantee against allmanufacturing defects.

QUALIFYING SYSTEMS• XPress Copper fittings and

Yorkex copper tube • XPress Gas fittings and

Yorkex copper tube • XPress Stainless fittings

and stainless steel 316System tube

XPRESS CARBON• XPress Carbon fittings are

guaranteed for 5 yearsagainst all manufacturingdefects when installed alongwith other manufacturerstubes conforming to thespecified standard.

• Where pipelines areconstructed exclusively fromXPress Carbon fittings andtubes, the resultinginstallations will be deemedXPress Carbon Systems andas such qualify for a 10 yearguarantee against allmanufacturing defects.

To qualify for guarantees, allproducts must be installed inaccordance with ourinstructions on specifiedapplications.

Introducing the XPress range

04

Current and future standardsWe at Yorkshire Fittings are dedicated to designing,developing and manufacturing products of thehighest quality. It is on this basis that you cantrust the XPress range to achieve all relevantBritish, European and International standards.

Over recent years, tube and fittings for plumbingand heating systems have been subject to a gradualharmonisation of standards. Today, a furtherharmonisation is taking place that is set toincorporate copper and copper alloy press-fitfittings within PR EN 1254 under Part 7.

It is a sign of our standing in the industry that weat Yorkshire Fittings are helping to draft this andother new European standards, assisted by ourfellow members on the various European standardscommittees.

So, you can rest assured that whateverdevelopments arise, our products will always meetthe very latest standards.

XPress fittingsXPress fittings have been designed withcompatibility in mind to work with a wide varietyof tube systems.

More specifically, the XPress range meets thefollowing key standards:

WRAS All XPress Copper fittings and XPressStainless fittings are listed and comply with therequirements of the United Kingdom WaterRegulations/Byelaws (Scotland).

DVGW XPress Copper fittings and XPress Stainlessfittings have been approved by the Germanapproval authority. They comply with DVGWArbeitsblatt W534, which covers fittings and jointsfor tubes in potable water installations.

KIWA XPress Copper and XPress Stainless fittingshave the approval of the Dutch certification andapproval body KIWA.

ÖVGW XPress Copper fittings have the approval ofthe Austrian certification and approval body ÖVGW.

CSTB XPress Copper fittings have the approval ofthe French certification and approval body CSTB toAVIS Technique 14/01-639.

SITAC XPress Copper and XPress Stainless fittingshave the approval of the Swedish certification andapproval body SITAC.

Advantica (formerly British Gas) XPress Gasfittings have been approved to DVGW VP614 by theGWI and verified by Advantica, which coversfittings and joints for tubes in 2nd and 3rd familygas installation pipework.

GASTEC XPress Gas fittings have the approval of theDutch certification and approval body GASTEC.

XPress fittings also meet these other importantspecifications where applicable:

BS 21/ISO 7 Specification for tube and fittingpipe-threads, where pressure-tight joints are madeon the threads (metric dimensions).

BS EN ISO 228:2003 (formerly BS 2779/ISOR228/1) Specification for tube and fitting pipe-threads, where pressure-tight joints are not madeon the threads (metric dimensions).


QUALITY SYSTEMSYorkshire Fittings Limited is aBritish Standards Institutionregistered company.

EVALUATED BY THE WRASThe XPress Copper and XPressStainless ranges have beentested by the WRAS and areaudited periodically.

KEY EUROPEAN APPROVALSApplicable XPress componentsare DVGW approved.

INTERNATIONAL STANDARDSORGANISATIONInternational standards areconformed to where appropriate.

FM 27630

KEYWORD IS QUALITY

MALE CONNECTORSXPress male threaded connectorshave taper male BSP threads toBS 21/ISO 7. Inert jointingcompound or PTFE tape shouldbe applied to the threads. Do not use PTFE tape onstainless steel fittings.

FEMALE CONNECTORSXPress female threadedconnectors have internalthreads to BS EN ISO 228:2003(formerly BS 2779/ISOR228/1).

CONNECTORS

Current and futurestandards


For convenience and peace of mind the XPressStainless and XPress Carbon ranges incorporatesystem tube in all sizes. Where System tube is notavailable or alternative tube is to be used, therequired specifications must be adhered to.

Stainless steel 316 system tubeStainless steel 316 System tube is available in 6mstraight lengths in a range of sizes from 15mm to108mm. In sizes from 15mm to 54mm the tube ismanufactured from BS 316 S31/DIN 1.4401stainless steel strip conforming to BS10088 Part 2and thanks to its thin-walled geometry, is stiff,lightweight and truly easy to handle. In sizes above54mm the tube conforms to DVGW W541.

With practicality in mind, all sizes of stainless steel316 System tube are permanently marked inaccordance with DVGW W541 requirements for easeof identification once installed. The sleek goodlooks of its finish are clear for all to see.

In sizes up to 28mm stainless steel 316 Systemtube is suitable for bending using bespoke bendformers and specified bending machines (refer tothe tube bending section on page 18).

When used as part of a complete XPress StainlessSystem, this tube comes with an extended 30-yearguarantee against all manufacturing defects.

Carbon steel system tubeCarbon steel System tube is available in twodifferent specifications – galvanised carbon steelSystem tube in sizes from 15mm to 108mm andplastic (polypropylene) coated carbon steelSystem tube in sizes from 15mm to 54mm.

Galvanised carbon steel System tube ismanufactured in accordance with DIN 2394/NEN1982 from material with a very low carboncontent and has a thin walled profile resulting in alightweight easier to handle product.

The galvanised coating has a minimum thicknessof 7 microns and is thermally applied whichprovides a superior bond to the tube. Anadditional layer within the tube provides furtherresistance to corrosion.

Plastic coated carbon System tube ismanufactured to exactly the same specification asthe galvanised tube including galvanised coating,before the addition of a polypropylene coating toprovide extra protection.

In sizes up to 28mm, Carbon steel System tube,(both variants) is suitable for bending usingbespoke bend formers and specified machines(refer to page 18).

XPress Carbon fittings and tube come with a 5 yearguarantee against all manufacturing defects.

COPPER TUBEXPress Copper and XPress Gasfittings offer optimumperformance when used withcopper tube to BS EN 1057.

STAINLESS STEELXPress Stainless fittings areoptimised for use with stainlesssteel 316 System tube.

TUBE

CARBON STEELXPress Carbon steel fittings aredesigned for use withgalvanised and plastic coatedcarbon steel System tube.

316 System tube bends

Size Minimum Radii

15mm 52.5mm18mm 72mm22mm 88mm28mm 112mm

Stainless steel tube specification

Wall thickness

Outside 316 System DVGW BS 4127:diameter tube W541 1994

15mm 0.6mm 1.0mm 0.6mm

18mm 0.6mm 1.0mm 0.7mm

22mm 0.6mm 1.2mm 0.7mm

28mm 0.8mm 1.2mm 0.8mm

35mm 1.0mm 1.5mm 1.0mm

42mm 1.0mm 1.5mm 1.1mm

54mm 1.0mm 1.5mm 1.2mm

76mm 2.0mm 2.0mm -

89mm 2.0mm 2.0mm -

108mm 2.0mm 2.0mm -

Wall thickness

Outside Galvanised Including diameter tube plastic coating

15mm 1.2mm 2.2mm

18mm 1.2mm 2.2mm

22mm 1.5mm 2.5mm

28mm 1.5mm 2.5mm

35mm 1.5mm 2.5mm

42mm 1.5mm 2.5mm

54mm 1.5mm 2.5mm

76mm 2.0mm -

89mm 2.0mm -

108mm 2.0mm -

Carbon steel System tube bends

Size Minimum Radii

15mm 30mm18mm 36mm22mm 44mm28mm 56mm

Carbon steel System tube specification

XPress System tubes

06

Tube CompatibilityNow let’s take a look at the specific standards thatother manufacturers tube must achieve to beacceptable for use with XPress fittings.

Copper tubeCopper tubes used with XPress Copper and XPressGas fittings must meet the requirements of BS EN 1057 R250/R290.

BS EN 1057 specifications for copper and copperalloy – seamless round copper tubes for water (andgas) in sanitary and heating applications.

BS EN 1057 includes specified temper conditions(material strength) expressed as an ‘R’ number.Quite simply, the higher the number, the harder thematerial. As a result, tube diameter, wall thickness,length and the material temper must all bespecified for full product designation.

R250 Half hard condition with a tensile strength of250N/mm2 supplied in straight lengths suitable forconnection by push-fit, press-fit, capillary andcompression fittings. Can be bent with suitablebending tools.

R290 Hard condition with a tensile strength of290N/mm2 supplied in straight lengths suitable forconnection by push-fit, press-fit, capillary and non-manipulative compression fittings. Not suitablefor bending.

Stainless steel tubeXPress Stainless fittings are specifically intended tobe used with our stainless steel 316 System tubebut are also compatible with other stainless steeltubes to BS 4127:1994 and DVGW W541.

Carbon steel tubeXPress Carbon fittings are specifically intended foruse with our carbon steel System tube but are alsocompatible with other carbon steel tubes to DIN 2394/NEN1982.

Yorkshire fittings brand recommendationsAlthough XPress fittings can be used successfully inconjunction with the above types of tubes, they arespecifically intended to achieve their optimumperformance when used with our own-brand orrecommended third party products whereapplicable. XPress Copper and XPress Gas fittingswith Yorkex copper tube, XPress Stainless fittingswith stainless steel 316 System tube and XPressCarbon with carbon steel System tube. Wheninstalled in the configurations described, eachXPress System will provide optimum performanceand qualify for an enhanced guarantee against allmanufacturing defects (refer to page 3).

Material specificationsAll XPress products are designed and manufacturedto strict specifications and quality systems.


TRADE BODIES

CONTACT WITH THE TRADEYorkshire Fittings areindustrial associates of theInstitute of Plumbing.www.plumbers.org.uk

LINKS WITH MERCHANT GROUPSIndustry trends can bemonitored through the BMF.www.bmf.org.uk

LINKS WITH END USER GROUPSThe company is a member ofthe Association of Plumbingand Heating Contractors.www.plumbingpark.co.uk

REGIONAL PATTERNSAssociation with regionalbodies like SNIPEF also helpsto create a broader picture ofthe industry. www.snipef.co.uk

BS EN 1057 copper tube compatible with XPress Copper fittings

Outside Wall thickness

diameter 0.7mm 0.8mm 0.9mm 1.0mm 1.2mm 1.5mm 2.0mm 2.5mm

R250/R290

R290

R290

R290

R290R250/R290

R250

R250

R250/R290

R250/R290

R290 R250

R250/R290

R250/R290

R250/R290

R250/R290

R250

15mm

22mm

28mm

35mm

42mm

54mm

67mm

76mm

108mm R290

Xpress tube compatibility


XPress Copper fittings are manufactured fromcopper or copper alloy (typically gunmetal) andcontain black Ethylene Propylene Diene Monomer(EPDM) ‘O’ rings.

XPress Gas fittings are manufactured from copperor copper alloy (typically gunmetal) and containyellow/tan Acrylonitrile Butadiene Rubber (NBR) ‘O’ rings.

XPress Stainless fittings are manufactured from316 (BS 316S31/DIN 1.4401) or 316Ti(BS 320S31/DIN 1.4571) stainless steel and haveblack EPDM ‘O’ rings.

XPress Carbon fittings are manufactured from EN 10027-1S205G2T (formerly known as Rst34-2)carbon steel and have black EPDM ‘O’ rings.

Quality SystemsContinuous product development is the cornerstoneof Yorkshire Fittings’ company policy.

This is true both in terms of the design of excitingnew lines and the development of existing ones.

To ensure our products continue to remain of thehighest quality, we constantly scrutinise, monitorand evaluate our manufacturing processes.

Yorkshire Fittings operate a Quality ManagementSystem for the development, manufacture and supplyof fittings, tube, valves and accessories whichcomplies with the requirements of BS EN ISO 9001:2000.

Product identificationXPress Copper and XPress Gas fitting bodies aremanufactured to the same specification, theirdifferent usage being determined by the ‘O’ ring.Xpress Copper fittings have butyl or EPDM ‘O’ ringswhich are black. XPress Gas fittings have NBR ‘O’rings, which are yellow/tan and also carry a “Gas”mark in a yellow block on the fitting body.

XPress Stainless fittings and XPress Carbon fittingscan be differentiated by the markings on the body– stainless steel fittings are marked 316 and carbonsteel fittings carry a red sticker.

Mixed material systemsFittings and tubes from each of the XPress rangescan be combined in the same system in accordancewith the table below.

IMPORTANT

Strict specification ofparticular contracts mayrequire proprietary chemicalsto be used in the cleaning orflushing of pipework prior tocommissioning. For advice onthe compatibility of specificproducts with XPress pleasecontact us.

XPress fittings must not comeinto contact with householdcleaning products, paints,greases, fluxes, mineral oils,adhesives or other solventbased materials that may beused during installation,lagging or after installation.These materials may affect the‘O’ rings in XPress fittings. XPress fittings should notbe painted.

Copper tube

Carbon steel tube

Stainless steel tube

It is advisable to make copper to steel connections via gunmetal/copper alloy fittings.

Yes

YesYes

No

No

No

No

Yes, closed circuit systems

Yes, closed circuit systems

Yes YesNo

Gunmetal/Tube type Copper copper alloy Carbon steel Stainless steel

Fitting and tube compatibilityFittings

Material specificationsand quality

08 XPRESS - THE PRESS-FIT JOINTING SYSTEM

Working temperatures and pressuresXPress Copper fittings have all been tested and aresuitable for use with approved tubes attemperatures from -24ºC to 110ºC at a maximumworking pressure of 16 bar throughout thetemperature range.

XPress Stainless and XPress Carbon fittings havebeen tested and are suitable for use with approvedtubes at temperatures from -20ºC to 110ºC at amaximum working pressure of 16 bar throughoutthe temperature range.

In hydraulic based installations we recommend allsystems be thoroughly tested upon completion, inthis type of system the installation may be testedto 1.5 times the working pressure of the system,up to a maximum of 16 bar. If higher testpressures are required advice should be soughtfrom Yorkshire Fittings.

We recommend the use of XPress Copper, XPressStainless and XPress Carbon for the distribution ofcompressed air up to a maximum working pressureof 10 bar. In all such XPress Systems thecompressed air should comply with ISO 8573 Part 1.

On completion, compressed air pipeline systemsmust be properly tested. The system designer andinstallation contractor must ensure safe methodsare selected for system testing which will complywith all current Health and Safety regulations.

This may include testing compressed air lines withfluids or compressed air at a limited pressure, or acombination. In any event we do not recommendthe maximum working pressure of the product beexceeded during this procedure.

XPress Gas fittings are approved for use withcopper tubes to BS EN 1057 at temperatures from-20ºC to 70ºC and a maximum working pressure of5 bar for outside above ground pipework and 1 bar within buildings.

As part of the DVGW approvals process, XPress Gasfittings have passed the HTC test (Higher ThermalCapacity) at 650°C for 30 minutes at PN1.

N.B. The maximum temperature and pressure rangein any system is dictated by the component withthe lowest performance rating.

Pressure Equipment DirectiveXPress fittings are not considered to be a productunder the terms of the PED (Pressure EquipmentDirective) guideline 1/9. As such, they are exempt

from the PED, but are manufactured in accordancewith the SEP (Sound Engineering Practice) asdefined in the PED. For more information, visit ourwebsite www.yorkshirefittings.co.uk

Localised annealing of copper tubeXPress Copper installation should not be carried outwithin 300mm of a brazed or soldered joint, as thehigh temperature required for capillary jointinganneals the copper tube rendering it too soft forpress-fit jointing. In an existing XPress Copperinstallation, brazing or soldering should not becarried out within 300mm of an existing press-fitjoint as this may damage the ‘O’ ring.

Do not braze or weld carbon or stainless steel tubes.

Equipotential bondingPlease ensure all metallic pipework systems complywith the equipotential bonding requirements of thecurrent edition of the IEE electrical wiringregulations (BS 7671: 1992).

All XPress products provide guaranteed electricalcontinuity once the joints are pressed.

After all plumbing work has been completed, alwaysensure continuity checks are conducted by aqualified electrician in accordance with regulations.

SPECIFICATIONS

For your convenience thespecification clauses on theopposite page are available onour website atwww.yorkshirefittings.co.uk/technical.cfm

Also available on our website is a PDF version of this and allour other data books and acomprehensive productcatalogue.

IDENTIFICATION OF UN-PRESSED FITTINGS

The Xpress Copper and XpressCarbon ranges now have a LeakBefore Press (LBP) feature,meaning that any assembledjoints inadvertently left un-pressed will exhibit a leakduring system testing. Thisenables contractors to easilyidentify un-pressed fittingsbefore commissioning.

Working temperatures and pressures


Once the appropriate XPress product has been selected the use of oneof the following specification clauses will provide the exact wordingrequired to ensure that the correct product for the job is used.

XPress Copper fittings specification"Press-fit fittings shall be of copper or copper alloy to the draft proposalPr EN 1254 Part 7 and certified by WRAS and DVGW, capable ofoperating between –24°C and 110°C and rated 16 bar throughout thetemperature range. Available in sizes from 15mm to 108mm they will besuitable for use with copper tube to BS EN 1057 R250/R290 on hot andcold water services, vented and unvented closed circuit heating, chilledwater and low temperature hot water. They will provide electricalcontinuity, have a guarantee of 25 years against all manufacturingdefects, and be drawn from the XPress Copper range manufactured byYorkshire Fittings Limited".

XPress Copper System specification"Press-fit fittings shall be of copper or copper alloy to the draft proposalPr EN 1254 Part 7 and certified by WRAS and DVGW. Available in sizesfrom 15mm to 108mm they will be capable of operating between –24°Cand 110°C and rated 16 bar throughout the temperature range. Theywill provide electrical continuity and be drawn from the XPress rangefrom Yorkshire Fittings Limited. Copper tube shall be to BS EN 1057R250/R290, be WRAS listed and drawn from the Yorkex rangemanufactured by Yorkshire Copper Tube Limited. The System whenconstructed exclusively from XPress Copper and Yorkex components willbe suitable for use on hot and cold water services, vented and unventedclosed circuit heating, chilled water and low temperature hot water andhave a guarantee of 30 years against all manufacturing defects".

XPress Gas fittings specification"Press-fit fittings shall be of copper or copper alloy to the draft proposalPr EN 1254 Part 7 and approved to DVGW VP614 by the GWI and verifiedby Advantica for use with copper tube on 2nd and 3rd family gasinstallation pipework. Available in sizes from 15mm to 54mm they willbe rated 5 bar for outside above ground use and 1 bar within buildings,capable of operating between –20°C and 70°C and tested to therequirements of HTC. The fittings will have a guarantee of 25 yearsagainst all manufacturing defects, and be drawn from the XPress Gasrange manufactured by Yorkshire Fittings Limited".

XPress Gas System specification"Press-fit fittings shall be of copper or copper alloy to the draft proposalPr EN 1254 Part 7 and approved to DVGW VP614 by the GWI and verifiedby Advantica for use with copper tube on 2nd and 3rd family gasinstallation pipework. Available in sizes from 15mm to 54mm they willbe rated 5 bar for outside above ground use and 1 bar within buildings,capable of operating between –20°C and 70°C and tested to therequirements of HTC. Copper tube shall be to BS EN 1057 R250/R290,and drawn from the Yorkex range manufactured by Yorkshire CopperTube Limited. The System when constructed exclusively from XPress Gasand Yorkex components will have a guarantee of 30 years against allmanufacturing defects".

XPress Stainless fittings specification"Press-fit fittings shall be of stainless steel material to BS 316 S31/Din 1.4401 and certified by WRAS and DVGW, capable ofoperating between –20°C and 110°C and rated 16 bar throughoutthe temperature range. Available in sizes 15mm to 108mm they willbe suitable for use with stainless steel 316 System tube fromYorkshire Fittings Limited or other stainless steel tube to BS 4127 orDVGW W541 on potable water services, general hot and cold waterapplications, heating, chilled water and low temperature hot water.They will provide electrical continuity, have a guarantee of 25 yearsagainst all manufacturing defects, and be drawn from the XPressStainless range from Yorkshire Fittings Limited".

XPress Stainless System specification"Press-fit fittings shall be of stainless steel material to BS 316 S31/Din 1.4401 and certified by WRAS and DVGW.Available in sizes 15mm to 108mm they will be capable ofoperating between –20°C and 110°C and rated 16 bar throughoutthe temperature range. They will provide electrical continuity andbe drawn from the XPress Stainless range manufactured byYorkshire Fittings Limited. Stainless steel tube will be from BS 316 S31/ Din 1.4401 stainless steel strip to BS 10088 Part 2and be drawn from the stainless steel 316 System tube range fromYorkshire Fittings Limited. The System, when constructedexclusively from XPress Stainless fittings and stainless steel 316System tube will be suitable for use on potable water services,general hot and cold water applications, heating, chilled waterand low temperature hot water, and have a guarantee of 30 yearsagainst all manufacturing defects".

XPress Carbon fittings specification"Press-fit fittings shall be of carbon steel in sizes from 15mm to108mm, they will be capable of operating between –20°C and 110°Cand rated 16 bar throughout the temperature range. Suitable for useon vented and unvented closed circuit heating and chilled waterapplications, with galvanised or plastic coated carbon steel Systemtube to DIN 2394/NEN 1982 or other carbon steel tube to DIN 2394/NEN 1982. They will provide electrical continuity, have aguarantee of 5 years against all manufacturing defects and be drawnfrom the XPress Carbon range from Yorkshire Fittings Limited".

XPress Carbon System specification"Press-fit fittings shall be of carbon steel in sizes from 15mm to108mm, they will be capable of operating between –20°C and 110°Cand rated 16 bar throughout the temperature range. They will provide electrical continuity and be drawn from the XPressCarbon range from Yorkshire Fittings Limited. Tubes shall begalvanised/plastic coated carbon steel System tube to DIN 2394/NEN 1982 drawn from the XPress Carbon range fromYorkshire Fittings Limited. The system will be constructed exclusivelyfrom XPress Carbon components, will be suitable for use on ventedand unvented closed circuit heating and chilled water applicationsand have a guarantee of 10 years against all manufacturing defects".

Specification clauses


The following instructions illustrate the ease andefficiency of installing XPress fittings. The jointingprocedure is exactly the same for Xpress Copper,XPress Gas, XPress Stainless and XPress Carbonfittings. It is always advisable to leave the fittingin its packaging until immediately prior toinstallation. This ensures the fitting remains clean,the ‘O’ ring is protected from damage and on-sitedebris, and the ‘O’ ring lubricant does not dry out.

PreliminariesSelect the correct size of tube and fitting for thejob. Ensure that both are clean, in good conditionand free from damage and imperfections.

Preparation1. Cut the tube square using a rotary tube cutterwhenever possible. If a hacksaw is used to cut thetube, a fine toothed blade should be used, caremust be taken to ensure that the tube is cut squareand properly de-burred.

2. When using plastic coated carbon steel tube, thecoating must be removed to the exact socket depthof the fitting using the S115 stripping tool.

Having selected the appropriately sized S115stripping tool, fully insert the tube and twist thetool until the excess of plastic is completelydetached. For sizes 15mm to 28mm this processwill also deburr the inside of the tube. To deburrthe outside, insert the tube into the opposite endof the tool and twist.

3. It is important that all tube ends are deburredbefore they are inserted into a fitting. Internal andexternal tube ends should be deburred using a finetoothed file. The tube-end should then be wipedclean of all swarf and debris, to avoid damage tothe 'O' ring upon tube insertion.

4. On copper installations the S120 deburring toolmay be used to prepare the tube ends.

5. An alternative method of preparing the tubeend before inserting into the fitting is to use theappropriately-sized S122 XPress percussiondeburrer. The cup of the deburrer is placed on theend of the tube and struck with a sharp blow froma copper faced hammer. In addition to removingburrs and sharp edges this tool also creates aslight taper, aiding insertion into fitting.

Size XPress Copper/Gas XPress Stainless/Carbon

15mm 20mm 20mm18mm - 20mm22mm 21mm 21mm28mm 23mm 23mm35mm 26mm 26mm42mm 30mm 30mm54mm 35mm 35mm67mm 50mm -76mm 50mm 55mm89mm - 64mm108mm 64mm 78mm

1.

4.

3.

TUBE END PREPARATION

New tube ends should have anytape, labels and adhesiveremoved, care must be takennot to damage the tube in theprocess. Then check that thetube is round, clean and freefrom burrs and scores, ifnecessary trim and prepare asbelow.

TUBE CUTTERSWe recommend the use of agood quality rotary tubecutter with a sharp wheelwhich will produce the idealtube end for use with XPressfittings. For carbon andstainless steel tubes, a hardwheel should be used.Clean square cut tube endsshould also have a chamferapplied.

REMOVE BURRSIf a hacksaw is used, careshould be taken to ensure thetube is cut square and allburrs and sharp edges areremoved.

For marking fitting socketdepths on tube larger than54mm or where a depth gaugeis not available a tape measureand marker pen should beused. Refer to socket depthtable for dimensions.

Fitting socket depths

2.

Installation instructions 15mm to 35mm

6. To make a perfect joint, the tube must be fullyinserted into the fitting until it meets the tubestop. Using a S110 XPress depth gauge or a ruler,mark the insertion depth of the fitting onto thetube so that inadvertent tube movement can bedetected, particularly if joints are not to be pressedimmediately after insertion.

7. Ensure that the 'O' ring is seated correctly withinthe fitting socket.

Jointing1. Assemble the joint, ensuring that the tube isinserted into the fitting until it meets the tubestop. The mark on the tube made earlier should beused as a guide to ensure this is the case. Forplastic coated carbon steel tube, the mouth of thefitting should be in contact with the plasticcoating. Only when the tube reaches the tube stopshould the pressing operation be undertaken.

2. With the correctly sized jaws inserted into thepress tool, place them over the bead at the mouthof the fitting. A 90º angle between tube and jawsmust be maintained to ensure a sound joint is made.

3. Depressing the trigger or button will commencethe compression cycle of the tool, which is completewhen the jaws fully enclose the mouth of the fitting.The jaws should then be released from around thefitting. Please refer to the tool manufacturersinstructions for further detailed information.

SpacingIn order to make a joint correctly sufficient clearancearound each fitting must be left to allow press-fitjaws to be attached without hindrance. Tablescontaining critical dimensions can be found in thedesign considerations section on page 18. An assembly sequence for fittings positioned in closeproximity to each other can be found on page 12.


6.

7.

5.

1.

2.

3.

REPLACEMENT ‘O’ RINGS

A range of replacement ‘O’ rings is available in theevent that any are lost ordamaged on-site. Werecommend the use of S130XPress Silicone lubricant toaid insertion of thereplacement ‘O’ ring into thebead of the fitting as these ‘O’ rings are supplied un-lubricated.

WARNING:Silicone lubricant should beused sparingly as overapplication may compromisejoint integrity.

IMPORTANT

We recommend that eyeprotection is worn whenoperating all press-fit tools.

Do not activate a press-fit toolwithout a fitting in the jaw.


IDENTIFICATION OF UN-PRESSED FITTINGS

Xpress Copper and XpressCarbon fittings now have aLeak Before Press (LBP)feature. During systemtesting, fittings which havebeen assembled but remain un-pressed will leak and aretherefore easily identified. If all the installationinstructions given on thesepages are correctly followedthe fitting will not leak.

ASSEMBLY SEQUENCE

DRI-SLIDE LUBRICANT

108MM SECOND PRESS

Again, the jointing procedure for large sizedfittings is exactly the same for Xpress Copper,XPress Gas, XPress Stainless and XPress Carbon.

The jointing process for larger size fittings is slightlydifferent to 15mm to 35mm sizes as sling jaws mustbe used on XPress fittings in sizes above 35mm.Slings give an improved performance over two-piecejaw sets and provide an equally distributed pullaround the circumference of the fitting, especially onlarger sizes.

When jointing 108mm copper fittings, care must betaken to ensure that the sling is clearly markedcopper only. Unmarked 108mm slings must only beused on stainless and carbon steel fittings. Thesecondary press referred to in No.8 must always beundertaken.

Important: A sound 108mm joint is not madeuntil the second press is completed.

LubricationThe use of S135 Dri-Slide lubricant is essentialwhen jointing these larger size copper fittings. The pressing profile groove should be cleaned andlubricated after every 50 joints for 42mm to 76mmsizes and every 5 joints for 108mm.

Preliminaries and preparationThe same care and attention should be taken withtube preparation and socket depth marking whenjointing 42mm to 108mm fittings as outlined inthe preliminaries and preparation sections for15mm to 35mm fittings.

Jointing1. Assemble the joint, ensuring that the tube isinserted into the fitting until it meets the tubestop. The mark on the tube made earlier should beused as a guide to ensure this is the case. Onlywhen the tube reaches the tube stop should thepressing operation be undertaken.

2. When the appropriate sling jaw has beenselected it should be opened by depressing thespring loaded pin, the sling should then be pulledapart and positioned over the fitting.

3. Care should be taken to ensure that the groovein the sling corresponds to the bead on the fittingand that the support plate on the sling fits overthe tube side of the joint.


2.

3.

1.

It is very important whenjointing XPress Copper/Gas thatpress-fit sling grooves in sizesabove 35mm are lubricatedwith Dri-Slide lubricant. Caremust be taken not to allowlubricant to make contact with‘O’ rings in the fittings.

On installations larger than28mm where fittings arecloser than 100mm, all jointsshould be assembled beforepressing commences. Theforces required to make theselarger sized joints can distortshort tube lengthssufficiently to preventinsertion into the fitting.

108mm fittings must bepressed twice. After the firstpress is made, the sling is leftin place on the fitting but theadaptor which is attached tothe tool is replaced by thesecond press adaptor and thejointing procedure repeated.



4. Turn the catch mechanism toward the lockingpin, depress the pin and push the catch into thepin until the mechanism engages. Revolve the slingaround the fitting to the desired pressing position.

5. Attach the appropriate adaptor to the press tooland close the breach bolt. Attach the adaptor tothe sling by depressing the jaw levers and insertingthe claws as far as possible into the grooves of thesling. Pressing must not commence until theadaptor is correctly connected to the press sling.

6. The pressing operation should then becommenced, by depressing the button on the press-fit tool for at least two seconds.

7. When the pressing operation has beencompleted, the adaptor should be disengaged bydepressing the jaw levers, and the slings removedfrom the fitting.

8. For 108mm fittings the press sling should be leftin place and the secondary adaptor S324 attachedas previously described in No. 5. Re-check toensure the tube is inserted into the fitting up tothe tube stop and repeat the pressing operation tocomplete the procedure.

The 108mm joint is not fully made until thefitting has been through two pressing operations.

4.

6.

7.

8.

5.

It is important that theoperator supports the weightof the tool during the jointingcycle and that no side to sideor up and down load isapplied.

SLING JAWS FOR COPPER

108mm XPress Copper fittingsmust only be pressed usingsling jaws marked ‘copper only’.

TOOL PRESENTATION



POWER SUPPLY

Mains powered press-fit toolscontain electronic circuitrywhich requires a stableuninterrupted power supply.Transformers should have aminimum rating of 3kVA.

PRESS SLINGS

Sling jaws must be used onXPress fittings in sizes above35mm, as these provide amore equally distributed forcethan two piece jaws. Theautomatic action of the press-fit tool ensures the rightforce is always applied and thejaws and slings close reliably.

The making of an XPress joint relies upon the useof a press-fit tool together with a set of jaws orslings in the appropriate size. Sets of jaws or slingsare available for each size of fitting and only thecorrect size jaws or slings will ensure a sound jointis made.

Tools are available with three power options to suitmost on site installation situations, 110V and 240Vmains and cordless. Yorkshire Fittings supply tooloptions to suit budget and application, comprisingtools from the Novopress and REMS press-fit toolranges. Tools supplied by Mapress are also suitablefor use with XPress fittings. However, early versionsof some Mapress tools and jaws are unsuitable foruse with XPress fittings, please contact us forconfirmation of suitability.

Novopress toolsPropressThe Propress S200/EFP2 machine is a robust press-fit tool with the ability to press fittingswith a diameter of 15mm to 54mm. The rotatablehead can be turned to any angle to gain accessin tight or awkward installations. The minimumdimensional requirements for this tool appear inthe design consideration section.

PressboyThe Pressboy S202/ECO1 & S204/ACO1 tools are lowcost options from Novopress. Designed for jointingsizes 15mm to 54mm the Pressboy tool provides anergonomically designed and light weight alternativeto the more robust Propress S200/EFP2, whilstutilising the same jaw/sling type.

Available in 3 power options, 110V or 240Vmains powered and cordless. The mains tool hasa safety clutch and automatic pressing forcefeature which ensures a perfect joint is madeevery time.

Propress technical specification Mains

Power consumption 380WPower supply frequency 50HzPiston force 32kNCompression force 100kNLength without jaws 450mmWidth 80mmHeight 185mmWeight without jaws 5.9kg15mm jaws weight 1.8kg22mm jaws weight 1.8kg28mm jaws weight 2.2kg35mm jaws weight 2.2kgSling jaws adaptor weight 2.3kg42mm sling weight 1.8kg54mm sling weight 1.8kg

Pressmax technical specification Mains

Power consumption 400 WPower supply frequency 50 HzPiston force 36kNCompression force Adapts to force curve requiredLength without jaws 420mmWidth 85mmHeight 110mmWeight without jaws 4.5 kg15mm jaws weight 1.8 kg22mm jaws weight 1.8 kg28mm jaws weight 2.2 kg35mm jaws weight 2.2 kgSling jaws adaptor weight 42, 54 & 67mm 2.3 kgSling jaws adaptor weight 76 & 108mm 4.1 kgSling jaws adaptor weight 4.1 kgsecondary operation 108mm

Pressboy technical specification Mains Battery

Power consumption 400W –Power supply frequency 50Hz –Piston force 32kN 32kNCompression force 100kN 100kNLength without jaws 465mm 450mmWidth 85mm 85mmHeight 115mm 135mmWeight without jaws 4.7kg 4.4kgFor weight of jaws refer to Propress table above

Pressboy S202/ECO1 (mains)

Propress S200/EFP2

Pressboy S204/ACO1 (cordless)

Novopress press-fit tools


For detailed information onthe use of press-fit tools referto the manufacturersinstructions which are suppliedwith the product.

The tool manufacturersoperating and safetyinstructions must be adhered to.

PressmaxThe Pressmax S301/ECO3 is an electromechanicaltool with electronic monitoring functions to ensurea perfect joint is achieved. This function providesprecision and reliability in the jaw/slingperformance. The tool incorporates a fullyautomatic overload, short circuit, jaw/sling wearand defective pressing monitoring system to ensurethe tool operates effectively at all times.

The Pressmax tool will press fittings from 15mm to108mm. Previously only an electro-hydraulic (HCP)tool could complete the pressing operation onlarger sizes. This advancement has been achievedby the development of lightweight slings in 67, 76,89 and 108mm sizes by Novopress and YorkshireFittings. Increasing the output of Pressmax has alsocontributed to its ability to press joints over such awide range of sizes.

REMS toolsPower-Press 2000The S401 is a robust tool available in both 110Vand 240V power options for fast efficient pressingwith jaws from 15mm to 35mm. The tool completesa sound joint when the jaws are completely closedand the machine automatically stops, the jawsremain closed at this point until the tool isswitched into reverse. The trigger can then bedepressed and the jaws disengaged from the fitting.

Akku-PressThe S403 cordless machine is ideal for use on sizes15mm to 35mm on sites where there is no mainspower, or where the power source is infrequent.Compact and versatile, the tool has a rotatablehead to allow pressing in a variety of positions andfor hard to get at situations. An audible signal andfully closed jaws indicate a sound joint has beenmade. The tool can then be disengaged from thefitting by depressing the locking button. Jaws arereadily interchangeable between both Akku-Pressand Power-Press 2000.

Power-Press 2000 technical specification Mains

Power consumption 500 WPower supply frequency 50 – 60HzLength without jaws 440mmWidth 80mmHeight 240mmWeight without jaws 4.8 kg15mm jaws weight 1.822mm jaws weight 1.828mm jaws weight 1.835mm jaws weight 1.9

Akku-Press technical specification Battery

Power consumption –Power supply frequency –Length without jaws 340mmWidth 80mmHeight 300mmWeight without jaws 4.5 kg15mm jaws weight 1.822mm jaws weight 1.828mm jaws weight 1.835mm jaws weight 1.9

Pressmax S301/ECO3

Power-Press 2000 – S401

Akku-Press S403

OPERATORS INSTRUCTIONS

Pressmax and Pressboy toolshave indicator lights which canhelp the operator determinethat the tool is operatingcorrectly. For further detailsconsult the manufacturersinstructions.

Akku Press tools have anaudible tone to indicate thatthe joint has been made, onlythen should the pressingoperation be reversed.PowerPress 2000 tools rely ona visual check to ensure thepressing operation has beensuccessfully completed.

PERFORMANCE INDICATORS

REMS press-fit tools

16

Let’s now take a closer look at some of the specificdesign considerations it is important to takeaccount of when designing and installing pipeworksystems containing XPress fittings.

Design considerationsSome contracts may still require the use ofproprietary chemicals to cleanse and flush pipeworkbefore full commissioning. XPress is compatible witha wide selection of specific products, to find outmore please contact us.

Pipe restraintIn any installation, the system should be supportedto ensure the minimum stress is imposed on the

tube and joints. For the maximum spacing ofsupporting brackets for internal installations, pleasesee the tables below.

InsulationFor all XPress Systems, we recommend you adhereto the insulation requirements as specified by theWater and Building regulations for copper tube.These requirements are equally applicable tostainless and carbon steel tube.

Phenolic foamWhen using rigid phenolic foam (or other thermalinsulation) to lag pipework, always remember torefer to the lagging manufacturer’s fixinginstructions.

To avoid the risk of external corrosion of pipeworklagged with this foam, the European Phenolic FoamAssociation recommend that such insulationproducts be installed with a moisture barrier.Materials like Densopaste or plastic coveringsapplied by the tube manufacturer provide anappropriate barrier between the outer surface of thetube or fitting and the foam.

Some manufacturers of this type of lagging supplytheir products with an internal, factory-appliedsodium silicate barrier to prevent external corrosionproblems. However, if you do need to add a barrierproduct, we recommend that all XPress fittings befully installed before these are applied and that theyare completely coated.

Thermal movementThermal movement is a major consideration whendesigning plumbing and heating systems.

Pipework systems expand and contract with changesin temperature. If they are fixed too rigidly andtheir movement restricted, the systems will besubject to stress, which must be avoided. So it’simportant to take the effect of thermal movementinto account when designing or installing a system.

It’s especially important to avoid stressconcentrations between fixed points typically foundat radiators, valves and other fittings.

Expansion of copper tubeCopper has a coefficient of linear expansion of 17 x 10-6/°C. For example, a 10 metre length ofcopper tube carrying hot water at 60°C will increasein length by almost 7mm when heated from anambient temperature of 20°C.


Wall Horizontal Vertical Size thickness Temper pitch pitch

15mm 0.7mm R250/R290 1.20m 1.80m22mm 0.9mm R250/R290 1.80m 2.40m28mm 0.9mm R250/R290 1.80m 2.40m35mm 1.2mm R250/R290 2.40m 3.00m42mm 1.2mm R250/R290 2.40m 3.00m54mm 1.2mm R250/R290 2.70m 3.00m67mm 1.2mm R250/R290 3.00m 3.60m76mm 1.5mm R250/R290 3.00m 3.60m108mm 1.5mm R250/R290 3.00m 3.60m

Maximum spacing of support brackets for 316 System tube, BS4127 and W541 stainless steel tube and plastic coated andgalvanised carbon steel tube

Horizontal Vertical Size pitch pitch

15mm 1.80m 2.00m18mm 2.10m 2.30m22mm 2.40m 3.00m28mm 2.40m 3.00m35mm 2.70m 3.00m42mm 3.00m 3.60m54mm 3.00m 3.60m76mm 3.00m 3.60m89mm 3.60m 4.50m108mm 3.60m 4.50m

Maximum Spacing of Support Brackets for Copper tube to BS EN 1057

IMPORTANT

XPress Copper systems mustnot be exposed to ammonia or nitrates.

XPress Stainless systems mustnot be exposed to chlorides.

System designconsiderations


What’s more, assuming that temperature cycling ofthe system is 20°C, then there will be a continuouscycle of expansion and contraction of 3.4mm.

Expansion of stainless steel 316 System tubeStainless steel 316 System tube has a coefficientof linear expansion of 16 x 10-6/°C. For example, a

10 metre length of 316 System tube carrying hotwater at 60°C will increase in length by almost6.5mm when heated from an ambient temperatureof 20°C.


Expansion of carbon steel System tubeCarbon steel System tube has a coefficient oflinear expansion of 12 x 10-6/°C. For example, a10 metre length of carbon steel System tubecarrying hot water at 60°C will increase in lengthby almost 5mm when heated from an ambienttemperature of 20°C.


TOOL ACCESS

FITTING SPACINGSufficient space must be leftbetween fittings to allow jawsor slings to be attached. Referto adjacent table for details.

MINIMUM PROJECTIONSimilar consideration shouldbe given to the distance pipestubs project through a wall orbulkhead. Refer to table.

GOOD PRACTICEProjection distances shown inthe table will also ensure thatthe subsequent installationwill be a convenient distancefrom the wall.

Carbon Steel tube expansionTemperature Tube lengthchange 3m 4m 5m 6m 7m 8m 9m 10m 12m 25m

10ºC 0.4mm 0.5mm 0.6mm 0.7mm 0.8mm 1.0mm 1.1mm 1.2mm 1.4mm 3.0mm20ºC 0.7mm 1.0mm 1.2mm 1.4mm 1.7mm 1.9mm 2.2mm 2.4mm 2.9mm 6.0mm30ºC 1.1mm 1.4mm 1.8mm 2.2mm 2.5mm 2.9mm 3.2mm 3.6mm 4.3mm 9.0mm40ºC 1.4mm 1.9mm 2.4mm 2.9mm 3.4mm 3.8mm 4.3mm 4.8mm 5.8mm 12.0mm50ºC 1.8mm 2.4mm 3.0mm 3.6mm 4.2mm 4.8mm 5.4mm 6.0mm 7.2mm 15.0mm60ºC 2.2mm 2.9mm 3.6mm 4.3mm 5.0mm 5.8mm 6.5mm 7.2mm 8.6mm 18.0mm70ºC 2.5mm 3.4mm 4.2mm 5.0mm 5.9mm 6.7mm 7.6mm 8.4mm 10.1mm 21.0mm80ºC 2.9mm 3.8mm 4.8mm 5.8mm 6.7mm 7.7mm 8.6mm 9.6mm 11.5mm 24.0mm90ºC 3.2mm 4.3mm 5.4mm 6.5mm 7.6mm 8.6mm 9.7mm 10.8mm 13.0mm 27.0mm100ºC 3.6mm 4.8mm 6.0mm 7.2mm 8.4mm 9.6mm 10.8mm 12.0mm 14.4mm 30.0mm

Copper tube expansionTemperature Tube lengthchange 3m 4m 5m 6m 7m 8m 9m 10m 12m 25m

10ºC 0.5mm 0.7mm 0.9mm 1.0mm 1.2mm 1.4mm 1.5mm 1.7mm 2.0mm 4.3mm20ºC 1.0mm 1.4mm 1.7mm 2.0mm 2.4mm 2.7mm 3.0mm 3.4mm 4.0mm 8.5mm30ºC 1.5mm 2.0mm 2.6mm 3.1mm 3.6mm 4.1mm 4.6mm 5.1mm 6.1mm 13mm40ºC 2.0mm 2.7mm 3.4mm 4.1mm 4.8mm 5.4mm 6.1mm 6.8mm 8.2mm 17mm50ºC 2.6mm 3.4mm 4.3mm 5.1mm 6.0mm 6.8mm 7.7mm 8.5mm 10.2mm 21mm60ºC 3.1mm 4.1mm 5.1mm 6.1mm 7.1mm 8.2mm 9.2mm 10.2mm 12.2mm 26mm70ºC 3.6mm 4.8mm 6.0mm 7.1mm 8.3mm 9.5mm 10.7mm 11.9mm 14.3mm 30mm80ºC 4.1mm 5.4mm 6.8mm 8.2mm 9.5mm 10.9mm 12.2mm 13.6mm 16.3mm 34mm90ºC 4.6mm 6.1mm 7.7mm 9.2mm 10.7mm 12.2mm 13.8mm 15.3mm 18.4mm 38mm100ºC 5.1mm 6.8mm 8.5mm 10.2mm 11.9mm 13.6mm 15.3mm 17.0mm 20.4mm 43mm

Stainless Steel 316 System Tube expansionTemperature Tube lengthchange 3m 4m 5m 6m 7m 8m 9m 10m 12m 25m

10ºC 0.5mm 0.6mm 0.8mm 1.0mm 1.1mm 1.3mm 1.4mm 1.6mm 1.9mm 4.0mm20ºC 1.0mm 1.3mm 1.6mm 1.9mm 2.2mm 2.6mm 2.9mm 3.2mm 3.8mm 8.0mm30ºC 1.4mm 1.9mm 2.4mm 2.9mm 3.4mm 3.8mm 4.3mm 4.8mm 5.8mm 12.0mm40ºC 1.9mm 2.6mm 3.2mm 3.8mm 4.5mm 5.1mm 5.8mm 6.4mm 7.7mm 16.0mm50ºC 2.4mm 3.2mm 4.0mm 4.8mm 5.6mm 6.4mm 7.2mm 8.0mm 9.6mm 20.0mm60ºC 2.9mm 3.8mm 4.8mm 5.8mm 6.7mm 7.7mm 8.6mm 9.6mm 11.5mm 24.0mm70ºC 3.4mm 4.5mm 5.6mm 6.7mm 7.8mm 9.0mm 10.1mm 11.2mm 13.4mm 28.0mm80ºC 3.8mm 5.1mm 6.4mm 7.7mm 9.0mm 10.2mm 11.5mm 12.8mm 15.4mm 32.0mm90ºC 4.3mm 5.8mm 7.2mm 8.6mm 10.1mm 11.5mm 13.0mm 14.4mm 17.3mm 36.0mm100ºC 4.8mm 6.4mm 8.0mm 9.6mm 11.2mm 12.8mm 14.4mm 16.0mm 19.2mm 40.0mm

TEE SPECIFICATION

UK SPECIFICATIONFirst quote the ends on the run(larger end first) and then the branch.

EUROPEAN SPECIFICATIONQuote the larger end first, thenthe branch, followed by theremaining end.

15mm 10mm 40mm18mm 10mm 40mm22mm 10mm 40mm28mm 10mm 60mm35mm 10mm 70mm42mm 20mm 70mm54mm 20mm 70mm67mm 30mm 70mm76mm 40mm 80mm89mm 50mm 90mm108mm 50mm 100mm


Minimum tubeprojection

Minimum gapbetween fittingsSize

Fitting spacing

15mm 25mm 28mm 75mm 131mm18mm 25mm 28mm 75mm 131mm22mm 31mm 35mm 80mm 150mm28mm 31mm 35mm 80mm 150mm35mm 31mm 44mm 80mm 170mm42mm 75mm 75mm 115mm 265mm54mm 85mm 85mm 120mm 290mm67mm 100mm 100mm 145mm 345mm76mm 115mm 115mm 165mm 395mm89mm 125mm 125mm 185mm 435mm108mm 135mm 135mm 200mm 470mm

18

A word of warning about ‘cold pull techniques’Never use so-called ‘cold pull techniques’ whendesigning expansion joints into a system containingany press-fit fittings. These techniques maycompromise the integrity of the surrounding joints.

Correct anchoring Always ensure the spur used to anchor the branch ofa tee or connect to a radiator is long enough toallow normal thermal movement. Failure to observethis simple rule can lead to a failure.

Incorporating expansion loops or bellows devicesinto the system can help guard against suchproblems, whilst a horseshoe link is an ideal way tocounteract continual thermal cycling.

Covered pipeworkMaking provision for thermal movement is vital wherepipework of any material is installed under screed orplaster or passes through brick or blockwork.

The preferred practice is to pass tubes and pipesthrough sleeves or conduits or to lay them in ductssurrounded by loose, non-rigid material such asvermiculite or glass wool. For further information,consult the publication BS 6700: Water Services in Buildings.

Local Water AuthorityIt’s wise to take the view of the local water authorityinto account when it comes to pipework accessibility.

PrefabricationIn certain situations, the prefabrication of selectedsections of pipework can be advantageous. If theinstallation takes place in a confined or restrictedspace, bending, jointing and assembly ofcomplicated sections can be undertaken moreeffectively in the ideal conditions of a workshop.XPress Systems are ideally suited to this method of

working. Joints can be made quickly and easily inthe prefabrication area and the resulting pipeworkincorporated into the existing system.

Tube bendingPortable bending machines are ideal for copper andcarbon steel tubes up to 28mm. Most machinesbend the tube between matched formers and backguides that support the OD of the tube; thiseliminates the risk of the tube wall collapsing.

The point at which the bending pressure is exertedmust be maintained at the correct distance in frontof the former’s point of support. It’s also importantto keep formers and guides well lubricated.

Yorkshire Fittings has worked with Rothenbergerto develop multi-material tooling for the RO Bend3000 electronic bending machine, making itsuitable for use with stainless steel 316 Systemtube. Due to the superior strength of 316 Systemtube, it is not practical to bend it withconventional hand bending tools.

Perfect results every timeBending tubes correctly will avoid any wrinkling andflattening that can affect flow conditions. Usingadjustable bending machines (which allow the


PIPEWORK CLEARANCE

Pipework clearance

Size A B C D

When designing an XPressSystem, please take care toensure all joints can be madeeffectively with sufficientroom for the tool to operate(see table below).Therefore, minimum gaps andinsertion distances must beobserved to ensure the jawscan complete a sound joint.

PIPEWORK CLEARANCE 15mm to 35mm

PIPEWORK CLEARANCE 42mm to 108mm



pressure on the back guide to be adjusted) willensure perfect bends every time so long as the root(inside) bending radius is at least 3 times theoutside diameter of the tube.

Service considerationsLike any other power tool, press-fit tools, jaws,slings and adaptors require regular servicing toensure they meet with guarantee requirements andpress joints with continued efficiency. It is the tooluser’s responsibility to ensure that all tools arecorrectly maintained and calibrated, details ofservice conditions and service centres are includedwith each tool. Alternatively details are availablefrom Yorkshire Fittings.

Multi material toolingAll approved jaws and slings can be used onappropriate XPress fittings. However, if these havebeen used on stainless or carbon steel fittings, theyshould be re-calibrated and serviced before using onXPress Copper fittings.

Ongoing serviceAs a guide, Novopress recommend that tools andjaws should be serviced by a recognised Novopressservice agent after 2500 pressings or 6 months.

REMS advise their tools should be serviced followinga year of use.

Between these services all tools should be routinelycleaned and maintained, as this is essential forgood jointing performance to be achieved.

Routine maintenanceJaws and Slings should be cleaned using a solventsuch as methylated spirit and protected using ananti rust and corrosion spray.

It is particularly important to ensure the pressingprofile is kept clean and free of debris. All residualmaterial or material build up should be removedregularly from the inner surface of the pressingprofile using a solvent based cleaning agent.

Novopress recommend that slings should be cleanedfollowing 20 pressing operations. They should thenbe sprayed with anti-rust and corrosion agent.

Following 200 pressing operations graphite oilshould be sprayed into the joints of the slidingsegments of the sling to ensure smooth andequally distributed pressure is applied to the beadof the fitting.

The tools themselves should also be regularlymaintained by cleaning the roller driver, guide andjaw retaining pin and lubricating with grease ormachine oil.

Power supplyIt is essential when preparing to undertake aninstallation using XPress fittings and tools that asuitable constant power source is available. If thesupply of power is not constant it may affect theperformance of the tool and subsequently theperformance of the joint.

Checking the power source is particularlyimportant prior to jointing with the S301/ECO3Pressmax tool as it includes safety software,which detects the amount of power available tothe machine. If there is not enough for the toolto initiate the pressing cycle and complete asound joint the tool will not commence thepressing operation. This feature is particularlyuseful when installing large size press fittings, asthe pressure required to press these fittings issignificantly greater than for smaller fittings,hence the power supply to the tool must beguaranteed.

It is therefore recommended that when using aportable transformer to provide power to thepress tool, the transformer should be a minimumof 3kVA rated in order that a continuousuninterrupted power supply is always available.

When a semi-permanent source of power such asa generator is being used, it is essential theplant is well maintained. The maximum cable sizefrom generator to outlet and the minimum lengthof cable between power outlet and tool shouldbe used.

Press-fit toolmaintenance

The Press-fit Jointing System

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THE PRESS-FIT JOINTING SYSTEM

THE PUSH-FIT JOINTING SYSTEM

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plumbing and heating fittings.It has an established

reputation for manufacturingquality products.

For further information, please contactyour appropriate Sales Office

UKTelephone: 0113 270 6945 / 0113 272 5380

Fax: 0113 270 5644 / 0113 272 5385Email: [email protected]

Northern IrelandTelephone: 028 9070 6990

Fax: 028 9070 6999Email: [email protected]

EXPORTTelephone: +44 (0) 1302 560 330

Fax: +44 (0) 1302 730 513Email: [email protected]

Technical SupportTelephone: 0113 270 6945

Fax: 0113 270 5644Email: [email protected]

Yorkshire Fittings Limited, Haigh Park Road, Stourton,Leeds, West Yorkshire, LS10 1RT, England.

www.pegleryorkshire.co.ukRegistered Company No. 00401507. Place of Registration: England

All brand names and logo styles are registered trademarks.

Maintaining a policy of continual product development, Pegler Yorkshire reserve the right to change specifications, design and materials of productslisted in this price list without prior notice. LIT.REF: 880296/20013.01.08

Documents

The Press-fit Jointing System - THE PRESS-FIT JOINTING SYSTEM XPress system advantages ... † Prefabrication † Tube bending † Tool maintenance The principle of the XPress joint