Invented, developed and produced in Europe

Agenda

• IBP Group Introduction

• >B< MaxiPro

• Rothenberger Press tools

• Installation instructions

• System testing

ABOUT US

Conex Banninger

International Locations UK: West Midlands: • HQ • UK &

International Sales Office & Distribution

Germany: Linden • Central European

sales office, Wetzlar tool centre,

Poland: Poznan • Production

Red Brass, Copper, Solder Ring, OEM, Press & K65

Sady • International

DC

Spain: Cordoba • Production Press, >B< MaxiPro, Copper, K65, OEM • Distribution

Madrid • Spanish Sales Office

Italy: Parma • Italian Sales Office

France: Paris • French Sales Office

Gulf: Dubai • Sales Office & Distribution

North America: • Sales Office,

China: Shanghai • IBP China

Over 70,000 m2 of manufacturing, packaging and warehousing facilities.

Capacity to produce over 500 million fittings & valves annually.

Ship directly to 76 countries worldwide.

Product Development Timeline

Over 100 years of innovative & versatile jointing solutions

1909

• Bänninger founded

1920

• Bänninger >B< Mark Introduced

1980

• First copper alloy press fittings developed

2002

• >B<Oyster launched

• >B< Press leak before press indicator introduced

1932

•Red brass added to production - only red brass producer in Europe

•Conex Sanbra launch Compression fittings

1992

• >B< production moves to Poland

• Conex & Bänninger brands merge

1919

•Conex Sanbra founded

2011

•K65 launched - tube system for high pressure applications

1940

•Production of copper fittings and valves

2015

•Development of multilayer fittings for multiple pipes

2016

• Development of

>B< MaxiPro

Conex Bänninger Brands

Approvals

>B< MAXIPRO

Join the Press Revolution

Be part of the global team leading the transition from brazing to >B< MaxiPro press technology in air conditioning and refrigeration (ACR) applications.

• The conversion from brazing/soldering to >B< Press is still growing after 30 years with no sign of slowing down within the plumbing industry.

• ACR is about to embark on this transition, which will provide significant opportunities for decades to come.

• >B< MaxiPro was invented as an extension of press technology and is capable of handling the higher pressures involved in air conditioning and refrigeration applications.

• Global partnership with Rothenberger – not just a fitting but a system.

The Opportunity – Move from Brazing to Pressing

The Opportunity

Supermarkets Cold stores

Air conditioning Plant rooms

Key Product USP's Design: The most efficient in the global market with unique design features.

Flame free: Flame free installation avoids the need for a hot work permit and the risk of fire and damage on sites.

Lower installation costs: Quick, repeatable, predictable and simple to install ensuring a sound joint every time. Significantly faster than brazing.

Higher productivity / flexibility: Easier site access and fast installation. Professional installation kit, no large gas bottles, cylinder, fire or flames.

Nitrogen purge: Not required, saves time and cost.

Testing / guarantee: UL certified recognised component, extensively tested with a design life of 25 years supported by a 5 year guarantee on completion of certified training.

Patent Protection: Design protected, patent pending.

X

X

X

Press Fittings

• Key performance differences between systems - Plumbing v Refrigeration

Function >B< Press Water prEN1254-7, DVGW W534

>B< MaxiPro AC-R EN378-2, EN16084

Maximum Operating Pressure 16 bar 1600 kPa 48 bar 4800 kPa

Fitting test pressure EN standard 24 bar 2400 kPa 144 bar 14400 kPa

System test Medium / pressure Water 24 bar 2400 kPa Air 10 bar 1000 kPa

Nitrogen 36 bar 3600 kPa Helium 10 bar 1000 kPa

Medium particle size (Angstroms) Water 2.75 Nitrogen 1.5 Helium 0.98

Vibration test +/-1mm, 20Hz, 1m cycles 0.25mm, 200Hz, 2m cycles After temperature & pressure cycling

System Operating Temperature -35oC to 110oC -40oC to 121oC

O-ring operating temperature -35oC to 110oC -40oC to 140oC

>B< MaxiPro Technology

• A tube stop controls tube insertion depth.

• The compressed O-ring forms a permanent and secure seal.

• On fittings 1/2” and upwards, a hook grips the pipe providing an even higher pressure tolerance.

• Five second press cycle.

1. O-ring 2. Bead 3. Socket 4. Tube stop 5. Three press points; one each side of

the bead, and one press point compressing the O-ring

Hook

>B< MaxiPro Technical Data

Parameters Capability

Applications Air conditioning and refrigeration

Connections Copper to copper

Approved tube: Copper tube conforming to EN 12735-1* or ASTM-B280

Fitting / pipe range (inches) 1/4, 3/8, 1/2, 5/8, 3/4, 7/8, 1, 1 1/8

Fitting material Refrigerant grade copper (C12200 min 99.9% pure)

O-ring HNBR

Approved oils POE, PAO, PVE, AB and mineral oil.

Not compatible with PAG.

Maximum operating pressure 48 bar / 4800 kPa / 700 PSI

Burst pressure >3 x maximum operating

and abnormal pressure (EN 378-2) >144 bar / >14400 kPa / >2100 psi**

O-ring temperature range -40oC to 140oC

UL listing continuous operating temperature -40oC to 121oC

* Please refer to >B< MaxiPro Technical Manual - Tube Compatibility Table. ** Tube dependent

Compatible Refrigerants

Note: Not for use with Ammonia (R-717).

Certification, Standards and Testing

Some examples of >B< MaxiPro testing:

• UL Certified Recognised Component, file no SA44668.

• UL 207 fatigue test.

• UL 109 pull test and vibration test.

• UL 1963 gasket compatibility test on various refrigerants.

• ISO 5149-2, EN378-2 compliant.

• ISO 14903, EN16084 tightness test – helium.

• ISO 14903, EN16084 temperature, pressure cycling and vibration test, (0.25mm, 200Hz, 2m cycles).

• ISO 14903, EN16084 freeze / thaw test.

• ASTM G85 salt spray (fog) test.

• EN378 pressure test 3 x max. allowable pressure

• Hydrostatic pressure to burst test.

• Vacuum tested to 200 microns.

• Fatigue shock test for 250k cycles.

• Oven ageing test of the seal. Lifecycle > 25 years.

• Cleanliness as Copper Tube Standards EN12735-1 & ASTM B280.

• Products manufactured in an ISO 9001 registered facility.

Typical salt spray test

UL 207 Certificate

The Range

>B< MaxiPro packaging details the:

• Maximum operating and abnormal pressure

• Operating temperature range

• Compatible refrigerants

• Compatible oils

• Installation instructions

• Use QR code app on your smart phone or tablet to access >B< MaxiPro home page

Remember to:

• Keep the ziplock bag sealed to protect fittings from contamination.

• To protect HNBR O-rings, store away from direct sunlight, sources of strong UV light, and equipment producing high levels of ozone.

Packaging

PRESS TOOLS

Rothenberger

Rothenberger Compact TT Press Tool & Jaws for >B< MaxiPro

Warranty Coverage – 12 Month

Tool minimum 12 month* guarantee against material and manufacturing defects.

Jaws minimum 12 month* guarantee against material and manufacturing defects.

Battery and charger minimum 12 month* guarantee against material and manufacturing defects.

A press cycle count will be made as part of your tool and jaw servicing and report.

If a serial number sticker is damaged the warranty will be null and void.

The warranty does not cover damage caused by incorrect use of the equipment.

* Special arrangements by the different Rothenberger market organizations can extend the 12 month warranty.

For tool warranty period and more detailed information please contact your local Rothenberger Market

Organization.

Installation Instructions

Health & Safety / Safe Working Practices

• >B<MaxiPro fittings must be installed by an installer who is appropriately trained and qualified to work on air conditioning and refrigeration installations.

• Installers must undergo the >B< MaxiPro training and be certified.

• All installations must be completed in line with local regulations and by-laws governing the installation, and all applicable health and safety practices must be adhered to.

• When using the press tools, care must be taken to ensure hands are away from the jaw during the pressing process. Always wear ear and eye protection.

• Use a rotary tube cutter. • Ensure that tube is cut square.

• Check tube has retained its shape

and is damage free.

1. Cut tube to length

• Deburr tube ends both internally and externally.

• Angle tube downwards to prevent filings entering tube.

• Use a pencil type deburrer on internal tube edges.

• Make sure internal and external surfaces of tube ends are smooth and free from burrs or sharp edges.

2. Deburr tube ends

• Thoroughly clean tube ends using Rothenberger Rovlies or similar cleaning pad in a rotating action.

• Tube ends must be free from scratches, oxidation, dirt and debris.

• If deep scratches are still visible, cut tube back to a clean section.

3. Clean tube ends and check for scratches

• Check the fitting is the correct size for the tube.

• Check the O-rings are present and

correctly seated.

• Additional >B< MaxiPro lubrication may be used to aid tube insertion.

4. Check O-ring

• Insert tube into correct socket in depth gauge.

• Check window to see the tube is fully inserted.

• Mark insertion depth on tube.

5A. Mark insertion depth using depth gauge

• The tube must be fully inserted into fitting until it reaches tube stop.

• To reduce risk of dislodging O-ring rotate tube (if possible) while slipping it into fitting.

• Mark insertion depth on the tube.

• Remove tube and align with fitting socket, check that depth mark is correctly positioned.

• The insertion depth mark is used

as a reference prior to pressing joint.

5B. Alternatively mark insertion depth using fitting

x

• Insert tube fully into the fitting up to tube stop.

• To reduce risk of dislodging the O-ring rotate tube (if possible) while slipping it into the fitting.

• Prior to pressing ensure tube has not moved out

from the fitting socket.

• Use insertion depth mark as a guide.

6. Ensure tube is fully inserted prior to pressing

• Ensure pipework aligned prior to pressing.

• Ensure correct size jaw is inserted into tool.

• Jaws must be placed squarely on fitting locating groove on bead.

• Bead should fit centrally in groove of jaw.

7. Ensure correct alignment prior to pressing

• Depress and hold button to complete pressing cycle.

• Pressing completed when jaws are fully closed and piston retracts.

• Complete press cycle once only – do not repress.

• Release jaws from pressing.

8. Press the joint

• Mark the completed joint after pressing.

• This enable joints to be inspected easily before testing and insulating the pipe-work.

9. Mark completed joint

Key Installation Points

• Tube preparation

Time and care must be taken to prepare the tube ends in accordance with the full instructions

Tube ends must be clean and free from scratches, oxidation, dirt and debris

Tube ends must be deburred internally and externally

• Tube marking and insertion

Before inserting the tube, check to see that the o-ring is seated correctly in the fitting

The tube end must be marked with the socket depth by using either the fitting or the >B<MaxiPro depth gauge

• Installation examination prior to pressing

Ensure the pipe-work is correctly aligned and there are no undue stresses pulling on the joint

• Pressing the fitting

Align the jaw correctly, groove on the bead and squarely to the fitting

Check the tube is fully inserted and the depth mark is in the correct position before pressing

Complete one full cycle of the tool – do not repress

• Installation examination after pressing

Check that all joint have been pressed and marked to indicate completion

Technical Brochure

• Important information is contained in the >B< MaxiPro technical brochure, including:

Tube compatibility table

Socket depths

Space required for pressing tool access

Installation dimensions

Installing close to an existing brazed joint

Brazing near to an installed >B< MaxiPro joint

• Refer to the Technical Brochure

Tube Compatibility Table

Space Required for Tool Access Compact Tool

Space required for completing a

pressing between pipes

Space required for completing a

pressing between pipes

External pipe

X

mm

Y

mm External pipe

X

mm

Y1

mm

Y2

mm

1/4" 30 55 1/4" 40 40 100

3/8" 30 55 3/8" 40 40 105

1/2" 25 55 1/2" 40 40 105

5/8" 25 55 5/8" 40 40 105

3/4" 25 55 3/4" 40 40 105

7/8" 30 55 7/8" 55 55 110

1" 30 55 1" 60 60 115

1 1/8" 35 55 1 1/8" 60 60 115

Insertion Depth and Minimum Distances Between Pressings

Nominal Size

inches

Minimum distance

A mm

Insertion depth E mm

1/4" 10 18.0

3/8" 10 18.0

1/2" 15 19.0

5/8" 15 22.0

3/4" 20 23.0

7/8" 20 25.0

1" 25 24.0

1 1/8" 25 26.5

Due to the reforming of the tube profile when pressed, it is advised that a minimum distance is allowed between each fitting.

Pressing Close to an Existing Brazed Joint

Localised annealing To ensure proper sealing of both the brazed and >B< MaxiPro joint the minimum distances listed in the above table must be maintained between the two fittings. The distances provided are there to ensure the original characteristics of the tube are maintained.

Tube Size Inches

Minimum Clearance mm

1/4" 10

3/8" 10

1/2" 15

5/8" 15

3/4" 20

7/8" 20

1" 25

1 1/8" 25

Note: It is important that there is no residual brazing or other foreign debris on the tubing to be inserted into the >B< MaxiPro fitting. The surface condition on the area of press joint should be clean and free from debris and comply with EN 12735-1 and ASTM-B280.

Brazing Close to an Existing >B< MaxiPro Joint

Tube Size Inches

Minimum Clearance mm

1/4" 250

3/8" 300

1/2" 350

5/8" 450

3/4" 500

7/8" 600

1" 650

1 1/8" 700

Brazing Caution – Brazing near to >B< MaxiPro joints should be avoided as this may cause the seal to degrade due to heat transfer. The minimum distances must be maintained to ensure the integrity of the joint. Where minimum distances cannot be maintained adequate precautions must be taken:

• Fabricating the brazed section prior to assembly with the press fittings.

• You must then comply with the minimum distances stated in the table relating to localised annealing.

SYSTEM TESTING

>B< MaxiPro

System Testing

• System testing should be carried out in accordance with local regulations, codes of practice and relevant standards.

• Dry oxygen free nitrogen (OFN) should be used for tightness and strength testing as it is inert. Do not use oxygen for pressure testing, under pressure it reacts violently with hydrocarbons (oil and grease) resulting in explosions and fire.

• The maximum test pressure to be identified by the installer. This will be calculated from the system pressure and the test parameters.

• To ensure >B< MaxiPro fittings are tested safely, during the strength pressure and/or tightness test, the pressure should be raised gradually up to the desired test pressure of the system as established by the installer.

• Measure the system pressure and the ambient temperature at the start and finish of the tightness test – a rise in ambient temperature can mask a leak if this is not taken into account. There will be a pressure change of approximately 0.7 bar with a temperature change of 5oC.

• Care must be taken to ensure a >B< MaxiPro joint will not be close enough to the liquid charging point that the temperature of the joint drops below -40°C when breaking a vacuum by liquid charging the system.

Problem Solving Vacuum Evacuation

Vacuum evacuation removes air, moisture, and non-condensable gases prior to system charging.

Failure to achieve a vacuum:

• A leak or moisture in the system (see below).

• Vacuum pump not working correctly.

• Vacuum pump does not have sufficient capacity.

Failure to hold a vacuum:

• A leak in the system or the connections to the system – find all leaks and repair them.

An ultrasonic leak detector can help pinpoint leaks on a system under vacuum.

• Moisture or refrigerant still in the system – continue evacuation.

• No remedial action e.g. cutting out fittings from the system should be taken until a proper fault finding exercise has been completed.