ALUMINIUM FITTINGS INSTALLATION

168mm

PREPARATORY STEPS FOR COUPLING INSTALLATION

1

Check Pipe Ends
The outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections (including weld seams), and roll marks to ensure a leak-tight seal.

2

Check Gasket and Lubricate
Check the gasket to make sure it is suitable for the intended service. Apply a thin coat of WolfGrip lubricant to the gasket sealing lips and exterior.

3

Position Gasket
Position the gasket over the pipe end. Make sure the gasket does not overhang the pipe end.

4

Join Pipe Ends
Align and bring the two pipe ends together. Slide the gasket into position and center it between the groove in each pipe end. Make sure no portion of the gasket extends into the groove in either pipe end.

STEPS FOR ALCR168 COUPLING INSTALLATION

1

Follow steps 1-4 of the “Preparatory Steps for Coupling Installation” section.

2

Assemble Housings
Insert one bolt into the housings, and thread the nut loosely onto the bolt to allow for the “swing-over” feature, as shown above.

NOTE: The nut should be backed off no further than flush with the end of the bolt.

3

Install Housings
Using the “swing-over” feature, install the housings over the gasket. Make sure the housings’ keys engage the grooves completely on both pipe ends.

4

Install Remaining Bolt / Nuts
Install the remaining bolt, and thread the nut finger-tight onto the bolt. Make sure the oval neck of each bolt seats properly in the bolt hole.

5

Tighten Nuts
Tighten all nuts evenly by alternating sides until metal-to-metal contact occurs at the angle bolt pads. Make sure the housings’ keys engage the grooves completely on both pipe ends and that the offsets are equal at the bolt pads. Equal, positive offsets are necessary to ensure a rigid joint (refer to the example above).

NOTE: It is important to tighten all nuts evenly to prevent gasket pinching.

6

Visually inspect the bolt pads at each joint to ensure metal-to-metal contact is achieved.

CAUTION
MAKE SURE THE GASKET DOES NOT BECOME ROLLED OR PINCHED WHILE INSTALLING THE HOUSINGS.
FAILURE TO FOLLOW THIS INSTRUCTION COULD CAUSE DAMAGE TO THE GASKET, RESULTING IN JOINT LEAKAGE.

STEPS FOR ALCF168 COUPLING INSTALLATION

1

Follow steps 1-4 of the “Preparatory Steps for Coupling Installation” section.

2

Install Housings
Install the housings over the gasket. Make sure the housings’ keys engage the grooves completely on both pipe ends.

3

Install Remaining Bolts/Nuts
Install the bolts, and thread a nut finger-tight onto each bolt. For couplings supplied with stainless steel hardware, apply an antisieze compound to the bolt threads. Make sure the oval neck of each bolt seats properly in the bolt hole.

WARNING

• For Coupling rigid, angle-bolt-pad couplings, the nuts must be tightened evenly by alternating sides until metal-to-metal contact occurs at the bolt pads.

• For Coupling rigid, angle-bolt-pad couplings, equal offsets must be present at the bolt pads.

• Keep hands away from coupling openings during tightening.

Failure to follow these instructions could cause joint failure, serious personal injury, and property damage.

CAUTION

• Make sure the gasket does not become rolled or pinched while installing the housings.

Failure to follow this instruction could cause damage to the gasket, resulting in joint leakage.

FLANGE ADAPTOR INSTALLATION

Flange Adaptors require a smooth, hard surface at the mating flange face for proper sealing. Some applications, for which the Flange Adaptor is otherwise well suited, do not provide an adequate mating surface. In such cases, a metal Flange Washer is recommended for insertion between the Flange Adaptor and the mating flange to provide the necessary sealing surface.

A. WHEN MATING A FLANGE ADAPTOR TO A SERRATED FLANGE

A flange gasket shall be used against the serrated flange. The Flange Washer should then be inserted between the Flange Adaptor and the flange gasket.

B. WHEN MATING A FLANGE ADAPTOR TO A WAFER-TYPE VALVE THAT IS RUBBER-LINED AND PARTIALLY RUBBER-FACED (SMOOTH OR NOT)

The Flange Washer shall be placed between the valve and the Flange Adaptor.

C. WHEN MATING A FLANGE ADAPTOR TO A RUBBER- FACED, VALVE, ETC.

The Flange Washer must be placed between the Flange Adaptor and the rubber-faced flange.

D. WHEN MATING A FLANGE ADAPTOR TO COMPONENTS (VALVES, STRAINERS, ETC.) WHERE THE COMPONENT FLANGE FACE HAS AN INSENT

Follow the same arrangement as if the Flange Adaptor was being mated to a serrated flange. Refer to application “A” above.

E. ADAPTORS

The Flange Washer must be placed between the two Flange Adaptors with the hinge points oriented 90° to each other. If one flange is not a WolfGrip Flange Adaptor (i.e. flanged valve), a flange gasket must be placed against the non-WolfGrip Flange. The Flange Washer must then be inserted between the flange gasket and the Flange gasket.

EXAMPLE

STEPS FOR FLANGE ADAPTOR INSTALLATION

1

Check Pipe Ends
The Outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections (including weld seams), and roll marks to ensure a leak- tight seal. All oil, grease, loose paint, dirt, and cutting particles must be removed.

2

Check Gasket and Lubricate
Check the gasket supplied to make sure it is suitable for the intended service. The colour code identifies the gasket grade. Apply a thin coat of WolfGrip lubricant to the gasket lips and exterior.

3

Install the Gasket
Install the gasket over the pipe end. Make sure the gasket is positioned properly, as shown above.

NOTE: The lettering on the outside of the gasket must face the flange-adapter gasket pocket. When installed correctly, the lettering on the gasket will not be visible.

4

Install Flange Adaptor
Open the hinged flange adaptor fully, and install the flange over the gasket. Make sure the flange key section engages the pipe groove properly.

5

Insert Mating Bolts
Insert a standard, full-shank diameter assembly bolt through each of the two mating holes in the flange adaptor. This will maintain the position of the flange in the pipe groove.

5a

Make sure the gasket is seated properly in the flange adaptor.

Closure lugs are provided for ease of installation. If necessary, use an adjustable wrench to bring the flange holes into alignment. This will ease insertion of the

6

Join Flange Adaptor and Mating Flange
Join the flange adaptor with the mating flange by aligning the bolt holes.

6a

Thread standard flange nuts finger-tight onto the two mating bolts.

7

Install Remaining Bolts / Nuts
Insert a standard, full-shank diameter assembly bolt through each remaining hole in the flange adaptor / mating flange. Thread standard flange nuts finger-tight onto all bolts.

8

Tighten Nuts
Tighten the nuts evenly, as with a regular flange assembly. Continue tightening until the flange faces come into firm, metal-to-metal contact or the standard, flange-bolt torque requirement is achieved.

QUICK BRANCH PLUG INSTALLATION

Proper preparation of the hole is essential for sealing and performance. Make sure the correct hole saw size is being used. Refer to the Pipe Preparation Requirements table.

Holes MUST be drilled on the centerline of the pipe.

Ensure that a 5/8 inch / 16mm area around the hole is clean, smooth, and free from indentations and/or projections that could affect gasket sealing (refer to the sketch below). Remove any burrs and sharp or rough edges from the hole. Burrs and sharp edges might affect assembly, proper seating of the locating collar, flow from the outlet, or gasket sealing.

The pipe around the entire circumference, within the “A” dimension shown in the sketch below, must be free from any dirt, scale, or projections that might prevent the housing from seating fully on the pipe. Refer to the Pipe Preparation Requirements table.

DO NOT USE WOLFGRIP QUICK BRANCH OUTLETS ON OTHER PIPES.

PIPE PREPARATION REQUIREMENTS

† 2 x 1 1⁄2-inch / 60.3 x 48.3-mm products require a 1 3⁄4-inch / 44-mm hole.
‡ 8 x 2-inch / 219.1 x 60.3-mm products require a 2 3⁄4-inch / 70-mm size hole.

STEPS FOR QUICK BRANCH PLUG INSTALLATION

1

Assemble Housings
Insert a bolt into the two housings. Thread a nut loosely onto the end of the bolt.

2

Check Gasket and Lubricate
Inspect the sealing surface of the gasket to make sure no debris is present.

3

Install Housings
Rotate the lower housing so that it is positioned approximately 90° to the upper (outlet) housing, as shown above. Place the upper (outlet) housing onto the face of the pipe in line with the outlet hole cut into the pipe. Rotate the lower housing around the pipe.

Gasket
The Correct Gasket is Shipped With the Appropriate Product.

3a

Make sure the locating collar engages the outlet hole properly. Check this engagement by rocking the upper (outlet) housing in the hole.

4

Install Remaining Bolt / Nut
Insert the remaining bolt. Thread a nut onto the bolt finger-tight.

NOTE: Make sure the oval neck of each bolt seats properly in the bolt hole.

5

Tighten Nuts
Make sure the locating collar is still positioned properly in the outlet hole. Tighten the nuts evenly by alternating sides until the upper (outlet) housing contacts the pipe completely.