Compressed Air Systems Pneumatic Fittings LLDPE Tube

John Guest LimitedHorton Road, West Drayton, Middlesex UB7 8JL, EnglandTel: 01895 449233 Fax: 01895 420321. www.johnguest.comandare registered trademarks ofJohn Guest International Limited © Copyright 2004.Compressed Air SystemsPneumatic FittingsLLDPE TubeZ2105/163/05/04May 2004

The John Guest Group has a long establishedreputation as a world leading manufacturer of push-infittings, tube and other fluid control products.A reputation built on producing consistently highquality products with an ongoing commitment tovalue engineering and product development.Quality ManufactureA commitment to quality is at the heart of theJohn Guest philosophy.The strictest control is maintained by virtue of thefact that design and manufacture is carried outin modern purpose built manufacturing centres inwest London and at Maidenhead in Berkshire.Maintaining control over the whole process frominitial tool design and tool making through to finalassembly and testing ensuring that only productsof the highest quality are produced.The company believe it is this commitment toquality that has led to it receiving prestigiousawards from many of the world’s leading testingand approvals organisations.John Guest is a preferred supplier to manyinternational companies.Since 1989 BS 1400101 02

The easy to use push fitsystem for Compressed AirThe John Guest range of push-in fittings andpipe provide the ideal connection from compressorreceiver to air line service components throughto complete ring main and take off points.A compressed air system can be installedquickly and easily, compared with other installationmethods, time savings of at least 50% areeasily achievable.No need to prepare threaded pipe or solvent, allthe connections can be made with a simplepush-in action. The system is then immediatelyready for use. Complex systems can be assembledmuch more rapidly than with traditional methodsand because fittings are easy to disconnect,systems can be altered or extended with muchreduced production down time.The fittings are produced in either a toughengineering plastics material or in brass insizes 12mm to 28mm. They are intendedfor use with John Guest nylon pipe butcan also be used with copper oraluminium pipe.• Installation time reduced by at least 50%• Safe, secure, leakproof• Easy to alter or extend a system• Lightweight and easy to handle• No corrosion, reduced maintenance05 06

EASY TO MAKE A CONNECTION‘O’ RingStainless Steel TeethPipe Stop28MM FITTINGSPipe•The John Guest Push inFitting has a collet (gripper) withstainless steel teeth which hold thepipe firmly in position and an ‘O’ ring toprovide a permanent leak proof seal.ColletCollet• •Screw Cap•Body28mm fittings also have a collet with stainless steel teethand an ‘O’ ring.THREE EASY STEPSFittings and pipe should be kept clean and undamaged before use.Cut the pipe square.We recommend the useof the JG Pipe Cutter.After inserting the pipe,a screw cap is turnedapprox 1/4 turn. Thislocks the collet in placeand reduces lateral andsideways movement ofthe pipe.DO NOT use a hacksaw.To avoid damage to the‘O’ ring remove burrs andsharp edges.✗✗To disconnect, turn thescrew cap 1/4 turn, pushin the collet and removethe pipe. The fitting andpipe can be reused.Push up to pipe stop.Pull to check secure.Test the systembefore use.To disconnect, ensure thesystem is depressurised.Push the collet towardsthe fitting and removethe pipe. The fitting canbe reused.Nylon, Copper & Aluminium PipeWhilst we recommendthe use of John GuestRigid Nylon Pipe, JohnGuest Fittings can alsobe used with copper oraluminium pipe.09 10

UNIQUE FEATURESSTEM ELBOWDesigned to simplify pipe connections in restricted spaces,the Swivel Elbow gives an instant swivel fitting so a pipe canbe orientated in any direction.Can be used with anelbow to make‘U’ turn connection.Please note a collet cover cannotbe used on a Speedfit end assembledwith the stem of a 22mm Stem Elbow.Can be usedwith a Tee.WATER TRAP TEE CONVERTORThe Water Trap Tee Convertor is a simple convenient way ofconverting a standard John Guest 28mm Tee to a Water Trap Tee.This will stop condensing water entering the vertical takeoff spur.The air supply needs to be installed with the correct fall andwater drain points regularly vented.To AssembleUse either John Guest 28mm Nylon Pipe or 28mm copper pipe.The pipe to be cut square and be free of burrs.Press the shorter spigot into the pipe. The fit on copper pipe willbe loose, this will not affect the function.Push the pipe and convertor up to the pipe stop of the centre legof the tee.Turn the screw cap approx 1/4 turn to lock the pipe in position.1.2.WATER TRAP TEE “WET”AIRThe new Water TrapTee from John Guestsolves the on-goingproblem of moisture in acompressed air systemand provides the easyalternative to the need toinstall “Swan Necks”.WATER“TRAPPED”“DRY” AIRThe ingenious inside arrangement of the fitting allows air to flow,with minimum head loss, from the main to take-off point withoutallowing water to follow. The moisture is retained in the line tobe drawn off at some suitable location.END STOPThe End Stop can be used to provide a permanentconnection but because it is easy to disconnect from the pipe itserves a useful purpose as a means of providing a temporaryshut off which can be removed at a later date to allow a systemto be extended or modified.InstallationIt is of vital importance for the correct function of the Water TrapTee that the air distribution system be nearly horizontal and thatthe outlet port be facing downwards.11 12

COMPRESSED AIR FITTINGSEQUAL TEEA push fit system of fittings and pipe which means a compressedair system can be installed quickly and easily with much reducedproduction down time. It is also easy to rearrange and extenda system.STRAIGHT ADAPTORPART NO. PIPE THREADOD BSPPM011213E 12 3/8PM011214E 12 1/2PM011514E 15 1/2PM011516E 15 3/4PM011814E 18 1/2PM012216E 22 3/4REDUCING TEESTEM ADAPTORPART NO.PIPE ODPM0212E 12PM0215E 15PM0218E 18PM0222E 22PM0228E 28PART NO. PIPE OD TUBE ODENDS BRANCHPM3018AE 18 15PM3022AE 22 15EQUAL ELBOWPART NO. STEM THREADOD BSPPART NO.PIPE ODPM0312E 12PM0315E 15PM0318E 18PM0322E 22PM0328E 28Converts push fit endto male threadPM051213E 12 3/8PM051214E 12 1/2PM051513E 15 3/8PM051514E 15 1/2PM051814E 18 1/2PM052214E 22 1/2PM052216E 22 3/4STRAIGHT CONNECTORJohn Guest AdaptabilityStandard Super Speedfit ® products can becoupled together to form integral new fittings.PART NO.PIPE ODPM0412E 12PM0415E 15PM0418E 18PM0422E 22PM0428E 28+ =+ =13 14

STEM ELBOWALUMINIUM WALL BOXPART NO. PIPE STEMOD ODPART NO.SIZEStem can swivel in any direction,see page 11.PM221212E 12 12PM221515E 15 15PM221818E 18 18PM222222E 22 221/2 or 3/4 female thread on the top.Both products have 3 x 1/2” femalethreads on the side.JGWALLBOX 1/2 1/2JGWALLBOX 3/4 3/4REDUCERU-BENDPART NO. STEM PIPEOD ODPART NO.SIZEPM061512E 15 12PM061815E 18 15PM062215E 22 15PM062218E 22 18PM062815E 28 15PM062822E 28 22PMUB15E 15WATER TRAP TEEPART NO.PIPE ODENDSPMTT22E 22END STOPNEWProvides permanent or temporaryshut off, see page 12.PART NO.PIPE ODPM4615E 15PM4622E 22Solves the problem of moisture in acompressed air system, see page 11.PORTING BLOCKPLUGPART NO. STEM OD COLOURPART NO.JG-L-WSK 5 1/2”ConnectionsPM0812R 12 REDPM0815E 15 BLACKPM0818E 18 BLACKPM0822E 22 BLACKPM0828E 28 BLACK15 16

COMPRESSED AIR FITTINGSBRASS FITTINGSFEMALE BRASS STEM ADAPTORPART NO. STEM OD THREADWATER TRAP TEE CONVERTORPART NO.SIZEWTC28 28Converts a standard tee to awater trap tee, see page 12.Converts push fit endto female thread.MM501514N 15 1/2 BSPMM502216N 22 3/4 BSPEasy to extend a galvanised system.BRASS WINGBACK ELBOWPART NO. PIPE OD THREADPM15WB 15 1/2 BSPPM22WB 22 3/4 BSPJohn Guest fittings and pipe can form astand alone system or be used toUsing a Straight Adaptor. modify or extend an existinggalvanised system.Using a Female Stem Adaptor.Using a Male Stem Adaptor.BRASS STRAIGHT ADAPTORPART NO. PIPE OD THREADMM011504N 15 1/2 BSPTMM012206N 22 3/4 BSPTMM012808N 28 1 BSPTCOMPRESSED AIR PIPEAND ACCESSORIESRIGID NYLON PIPEMALE BRASS STEM ADAPTORPART NO.SIZEMM X MConverts push fit endto male thread.PART NO. STEM OD THREADMM051504N 15 1/2 BSPTMM052206N 22 3/4 BSPTMM052818N 28 1 BSPMM052226N 22 3/4 NPTMM052228N 22 1 NPTMM052828N 28 1 NPT3 metre straight lengths.12 to 22mm in packs of 203m lengths.28mm in packs of 103m lengths.PA-RM1209-3M-20B 12 x 3PA-RM1512-3M-20B 15 x 3PA-RM1814-3M-20B 18 x 3PA-RM2218-3M-20B 22 x 3PA-RM2823-3M-10B 28 x 317 18

RELEASE AIDINSTALLING A SYSTEMCOLLET COVERSPART NO.PIPE OD15RA 1522RA 22The action of pressure in a systemcould increase the grip of the collet.The Release Aid allows a firmer gripon the collet while removing the pipe.PART NO. PIPE OD COLOURSPM1912E 12 BLACKPM1915E 15 BLACKPM1918E 18 BLACKPM1922E 22 BLACKCollet Covers prevent accidental removal or tampering withpiping. The pipe can be inserted with the Collet Coveralready attached to the fitting or the cover can slide into positionafterwards.We recommend covers be fittedwhen pipework is hidden insidewalls, ceilings etc.Collet Covers can be removed to allow the pipe to be disconnected asand when required.PIPE CLIPS AND SPACERSThermoplastics have different properties to steel pipes andso different techniques need to be employed for the installationof the system. For example plastic pipe expands considerablymore than metallic pipe, so the method of constraining thepipe needs to be suitable for this expansion to take place. If thepipe is constrained at both ends it will buckle and generate sideloads and stress in the pipe. This can be alleviated by an expansionbend in the pipe work. Pipe should be able to slide through mountingbrackets. Plastic pipe work is much lighter than that of steel pipework and so the mountings do not need to be as robust and usingJohn Guest connectors means that the system can be easily modifiedto any new requirements quickly and without significant specialisttools such as threading equipment and pipe benders. Using JohnGuest connectors means that no solvents or adhesives need to beemployed in the installation. The coefficient of linear expansion ofRigid Nylon pipe is approximately 0.00012 metre per metre length per ºC.John Guest compressed air equipment is suitable to use aboveground and below ground but we would strongly suggest that if it isinstalled below ground that it is installed in conduit so that the pipecan expand with temperature fluctuations and can easily be removedfor service or maintenance. John Guest Ltd. would remind all personsinvolved with installation and service of compressed air systems thatreference should be made to “Approved Code of Practice - Safety ofPressure Systems” available from HMSO in the United Kingdom. Forinstallation in other countries, the appropriate Codes of Practiceshould apply.CLIPPART NO. PIPE OD COLOURSPC15E 15 BLACKPC22E 22 BLACKPC28E 28 BLACKSPACERPART NO.PCSEFor Pipe cutters seepages 59-60.COLOURSBLACKOn long pipe runs, it is advisable to install an expansion bend,as shown in the diagram.Condensate and dirt in the systemIt is always desirable to have clean dry air at the outlets of acompressed air system, as condensate and dirt will affect theperformance and life of ancillary equipment. We would stronglyrecommend that a filter be fitted to the system to clean the air andthat John Guest Water Trap Tees be used to trap any residuecondensate and this should be taken to a “drain off” facility to extractit from the system.19 20

When installing a compressed air system, it is advisable to firstattach the horizontal pipe clips and only attach the clips tothe vertical pipes after a small amount of pressure has beenapplied to the system. This will ensure that the vertical pipes havepositioned themselves correctly before they are clipped.When installing around a column or pillar, maintain a distanceof approximately 10cm between the wall and the pipe. Alwaysmaintain a distance of 400mm between the fittings and the pipe clip.Column/Pillarsmaller than 1 metrePhase 1: System without pressureColumn/Pillar largerthan 1 metrePhase 2: System with pressureNote: All compressed air systems should be equipped with anair line water trap, we recommend our PMTT22E Water TrapTee for this purpose (as shown on page 11 of this brochure).21 22

TECHNICAL SPECIFICATION -Working Temperature RangeMinimum Working Temperature -20°CMaximum Working Temperature +70°CThe above is for use with air. For below 0°Cplease consult our Customer Service Department.Working PressureThe John Guest Compressed Air System is suitable for the followingtemperatures and pressuresTemperaturePressure+ 23°C 10 BAR+ 70°C 7 BARThe above ratings are for air. For use with other fluids or at other temperaturesand pressures please contact our Customer Service Department.Pipe TypesJohn Guest fittings are intended for use with John Guest nylon pipe but arealso suitable for use with a wide range of plastic and soft metal pipesincluding UPVC, ABS, Polyethylene, Nylon, mild steel and copper to thetolerances set out below. Soft plastic pipe, such as Nylon to have aminimum wall thickness of 1.5mm. The pipe must have a good qualitysurface and be damage free.Pipe TolerancesThe John Guest fittings featured in this brochure are intended for pipeswith outside diameters to the following tolerancesCOMPRESSED AIR SYSTEMMaterial SpecificationThe fittings are made up of three components:Bodies are produced in strong engineering plastic or in brass.‘O’ Rings are Nitrile rubber.Collets are produce in acetal copolymer with stainless steel teeth.ApplicationsPipe and fittings should be kept clean and undamaged before use. Theseproducts are designed for use with air. For other applications pleasecontact our Customer Services Department.The system is not recommended for use with explosive gases, petroleumspirits and other fuels or for central heating systems.Installations - Our RecommendationsThe pressure rating and installation guidelines of the tubing employedmust also be considered during the design of compressed air system.Pipe should be supported at minimum 800mm to prevent excessive loadbeing applied to the fitting. These supports should not be closer than25mm from the end of the fitting.John Guest fittings and pipe should only be connected after the airreceiver and not direct to a compressor.We recommend collect covers be fitted when pipework is hidden insidewalls and ceilings.It is recommended that all pipe and fittings installations are pressure testedafter installation and before handing over to the final user.SizeTolerance12mm to 28mm OD+0.05 to -0.10mm ODMaximum Torque ValuesThe following maximum torque values should be applied.Size 3/8'' 1/2'' 3/4'' 1''Plastic threads 3.0Nm 3.0Nm 4.0Nm N/AMetal threads N/A 4.0Nm 5.0Nm N/AIt is recommended that all installations are checked prior to use todetermine that a seal has been made. The maximum torque figuresquoted for use with John Guest fittings are dependant on the matingthread conforming to the relevant British or International thread standard.Do not over tighten plastic fittings as this could cause undue stressand eventual failure. Recommended torque figures are shown above andmust be adhered to. John Guest recommend OEM Customers considerreplacing threaded ‘ports’ with the modern method of using John GuestCartridge Systems.23 24

TECHNICAL SPECIFICATION -Working Temperature RangeMinimum Working Temperature -20°CMaximum Working Temperature +70°CThe above is for use with air. For below 0°Cplease consult our Customer Service Department.Working PressureThe John Guest Compressed Air System is suitable for the followingtemperatures and pressuresTemperaturePressure+ 23°C 10 BAR+ 70°C 7 BARThe above ratings are for air. For use with other fluids or at other temperaturesand pressures please contact our Customer Service Department.Pipe TypesJohn Guest fittings are intended for use with John Guest nylon pipe but arealso suitable for use with a wide range of plastic and soft metal pipesincluding UPVC, ABS, Polyethylene, Nylon, mild steel and copper to thetolerances set out below. Soft plastic pipe, such as Nylon to have aminimum wall thickness of 1.5mm. The pipe must have a good qualitysurface and be damage free.Pipe TolerancesThe John Guest fittings featured in this brochure are intended for pipeswith outside diameters to the following tolerancesSizeTolerance12mm to 28mm OD+0.05 to -0.10mm ODMaximum Torque ValuesThe following maximum torque values should be applied.Size 3/8'' 1/2'' 3/4'' 1''Plastic threads 3.0Nm 3.0Nm 4.0Nm N/AMetal threads N/A 4.0Nm 5.0Nm N/AIt is recommended that all installations are checked prior to use todetermine that a seal has been made. The maximum torque figuresquoted for use with John Guest fittings are dependant on the matingthread conforming to the relevant British or International thread standard.Do not over tighten plastic fittings as this could cause undue stressand eventual failure. Recommended torque figures are shown above andmust be adhered to. John Guest recommend OEM Customers considerreplacing threaded ʻportsʼ with the modern method of using John GuestCartridge Systems.23

COMPRESSED AIR SYSTEMMaterial SpecificationThe fittings are made up of three components:Bodies are produced in strong engineering plastic or in brass.‘O’ Rings are Nitrile rubber.Collets are produce in acetal copolymer with stainless steel teeth.ApplicationsPipe and fittings should be kept clean and undamaged before use. Theseproducts are designed for use with air. For other applications pleasecontact our Customer Services Department.The system is not recommended for use with explosive gases, petroleumspirits and other fuels or for central heating systems.Installations - Our RecommendationsThe pressure rating and installation guidelines of the tubing employedmust also be considered during the design of compressed air system.Pipe should be supported at minimum 800mm to prevent excessive loadbeing applied to the fitting. These supports should not be closer than25mm from the end of the fitting.John Guest fittings and pipe should only be connected after the airreceiver and not direct to a compressor.We recommend collect covers be fitted when pipework is hidden insidewalls and ceilings.It is recommended that all pipe and fittings installations are pressure testedafter installation and before handing over to the final user.Side LoadsFittings should not be subject to excessive side loads and should not beused as support brackets. Tubing and fitting should be adequatelysupported to prevent excessive side loads.Note: Aluminum pipe should NOT be connected direct to a compressor.24