RLS TZ1001A Flame-Free Refrigerant Press Fittings Instruction Manual

: October 30, 2023
: RLS

Table of Contents

Prepare Tool and Installation Aids
SAFETY INSTRUCTIONS
RLS Product Specifications
Warnings
Troubleshooting
Patents
Documents / Resources

RLS TZ1001A Flame-Free Refrigerant Press Fittings Instruction Manual

Prepare Tool and Installation Aids

Assure that all the tools and installation aids are available prior to beginning installation. The following list is to be used as a reference:
- RLS fitting (Figure 1)
- RLS approved press tool and jaws – sized appropriately (Figure 2)
- RLS installation aids (Figure 3)
- Deburring tool
- Tube cutter
- RLS depth gauge
- Brush
- Permanent marker
- RLS press gauge
- Abrasive pad
  Inspect Fitting and Tube
To ensure the integrity of the joint, visually determine if the O-rings are present and visually inspect the O-rings for obvious damage such as nicks or tears. Caution: If an O-ring appears to be damaged, is out of position, or is missing, DISCARD OLD FITTING AND USE A NEW ONE.
Perform a visual and tactile inspection of the tubing for surface imperfections referenced in ASTM B280, B88, or B1003 and the Copper Tube Handbook published by the Copper Development Association (CDA). Imperfections in and adjacent to the press or seal area could inhibit the joint integrity. These imperfections may include, but are not limited to:
- Surface scratches
- Incise marks (a required permanent mark of the tube manufacturer’s name or logo)
- Out of round (oval) on the cut ends
- Dirt or debris
- Items that may interfere with the O-ring Should any of the above situations be identified, select a different area of the tubing. If necessary, cut off th portion with the imperfections.
  Cut Tube
Cut the copper tube using the supplied or similar tube cutter (Figure 4). Ensure tube section to be pressed is straight. Caution: Do not proceed if the tube is cut at any visible angle other than 90 degrees or if the tube |is not straight. Do not use a worn or damaged tube cutter, which can damage the tube and compromise the installation. This may lead to injury, equipment damage or failure of the system.

Prepare Tube
Use the deburring tool to remove any residual burrs from the outside and inside of the tube (Figure 5). Visual and tactile inspection should indicate no sharp edges or burrs remain. This is critical to avoid damaging the O-ring.
Use the included abrasive pad or adequate substitute (e.g. sand paper or sand cloth) to clean the end of the tubes to be joined (Figure 6). Tube ends should be free and clear of oxidation, dirt and debris. The surface should appear bright and shiny. Do not drop the tube, as this may cause damage and lead to improper installation. If the tube has been dropped, inspect it carefully and discard the tube if any damage is found.

Connect Tube
Use the supplied depth gauge (Figure 7) or table below to mark inserted tube for insertion depth. Each tube must be marked to the correct insertion depth every time.
Push fitting onto tube and continue until a hard stop is felt or the insertion marks are aligned with the end of the fitting. Make sure the tube is completely inserted into the fitting using the marks made in Step 7 (Figures 8 & 9)

Minimum Insertion Depth

Fitting Size

| 1/4″ – 3/8″| 1/2″ – 1-1/8″| 1-1/4″ – 1-3/8″
---|---|---|---

Depth (in)

| 1| 1-1/4| 1-1/2

Depth (mm)

| 25.4| 31.8| 38.1

Note: It is possible that the tube may be fully inserted and the marks may still be slightly visible as a result of the dimple or accuracy of marks.
Note: Fitting installation should be relatively easy with little resistance felt. If it seems overly difficult to install the fitting, remove from tube and check to make sure the O-ring hasn’t been unseated. If this is the case, discard the fitting and use a new, replacement fitting
WARNING

  * Only RLS approved tools and jaws should be used to install RLS fittings.
  * Failing to use the RLS app

Press the tool locking pin (Figure 10), then rotate 45° to release (Figure 11).
Slide the appropriate size jaw into the press tool head (Figure 12) , then depress the locking pin until it clicks (Figure 13).
Slide the charged battery onto the base of the tool (Figure 14). Press and hold the trigger on the tool until the cycle is completed to calibrate (Figure 15). Calibration is recommended every time a jaw is changed, prior to use.
Press at the base of the jaws to open (Figure 16) and place the jaws onto the fitting as shown (Figure
Grooves in the jaw should line up and seat onto a groove located on the fitting. Ensure the tool is positioned between the flare and groove (Figure 18), NOT over the groove (Figure 19). Align the bottom portion of the jaw and the top portion will follow. SPECIAL ATTENTION SHOULD BE GIVEN TO THE CORRECT SEATING OF THE JAW.
Visually verify the inserted tube has remained in place and is still at the correct insertion depth as indicated by the mark (Figure 18).

Note: For 1-3/8″ fittings only (when using 19 kN or 24 kN jaws), after the 1st press, a 2nd press must be made with the 2nd press rotated at least 60° (approximate) from the 1st (Figure 21). When using 32 kN jaws, only one press is required.

Verify Connection
To verify the press cycle was completed properly, a witness mark (RLS) will appear within the press bands (Figure 22). The mark will be more pronounced when pressed on hard tube vs. ACR tube, but will be visible. Failure to create the witness mark either means an unauthorized jaw or the wrong sized jaw was used. If a fitting is incorrectly pressed, then it must be removed and the procedure restarted with a new fitting.
The RLS press gauge will confirm the finished press band diameter. The gauge is marked to align with the proper size fitting and press required. When the fitting is properly pressed, the RLS press gauge allows the marked slot to fit snug on the press band (Figure 23). If the press band is unable to fit within the marked slot on the gauge, it is under-pressed and will need to be re-pressed starting with Step 12.

Note: Flashing may be left over from the pressing process on hard tube. If so, rotate the gauge so that the flashing is in line with the size marking when placed over the press bands. This will allow the diameter to be checked without interference from the flashing
Use caution – flashing may be sharp

Minimum Distance From Braze to Nearest Fitting End

Tube Diameter| 1/4″ – 1/2″| 5/8″| 3/4″| 7/8″ – 1″| 1-1/8″| 1-1/4″ – 1-3/8″
---|---|---|---|---|---|---
Distance (in)| 5| 7| 8| 9| 12| 14
Distance (mm)| 127| 177.8| 203.2| 228.6| 304.8| 355.6

SAFETY INSTRUCTIONS

Do not rest the weight of the tool on the tube or fitting.
Periodically check to ensure the jaws are meeting and aligned.
Do not leave battery on charger unattended or overnight.
Use brush to ensure jaws are debris free.
Do not braze or solder within distance indicated in the chart to the left.

Note: For specific tool and jaw care and maintenance, refer to the manufacturer’s instructions.

SAE/Euro Flare Torque Requirements(Per ARI Guideline M-97 45° Refrigeration Flare Fittings and Copper Tubing)

Size	*Torque, ft-lbs [Nm]**
Minimum	Maximum
1/4″	8 [11]
3/8″	15 [20]
1/2″	25 [34]
5/8″	40 [54]
3/4″	50 [68]

Note: Per Section 9.5 of the M-97 Guideline, when applying torque to the flare connection the use of lubricants/lubrication is not recommended.

Note: Applying a torque above the maximum limit may distort or damage the sealing surface of the flare.

RLS Product Specifications

Applications
High-pressure HVAC/R, glycol, non-potable water

Approved Copper Tubing Types

Approved Copper Tubing Types for 32 kN Tool/Jaws
- Hard/Drawn: 1/4″ – 2-1/8″ Type ACR, L, K
- Soft/Annealed: 1/4″ – 1-3/8″ Type ACR, L, K
Approved Copper Tubing Types for 19 kN and 24 kN Tool/Jaws
- Hard/Drawn: 1/4″ – 1-3/8″ Type ACR, L, K
- Soft/Annealed: 1/4″ – 1-3/8″ Type ACR, L, K
Approved Copper Tubing Types for 15 kN Tool/Jaws
- Hard/Drawn: 1/4″ – 1-1/8″ Type ACR, L; 1/4″ – 7/8″ Type K
- Soft/Annealed: 1/4″ – 1-1/8″ Type ACR, L; 1/4″ – 7/8″ Type K

Application Parameters

Temperature Range: -40°F to +300°F (-40°C to +149°C)
Continuous Operating Temperature : 250°F (121°C)
Maximum Rated Pressure: 700 psi (48 bar)

Agency Certifications and Approvals

UL Listed: 207, SA#33958, SDTW (7) (Except where noted)
UL Listed: Approved Use For Field & Factory Installations
ISO 5149-2: Part 2 Compliant
ASHRAE-15, ANSI 15, ASME B31.5 (504.7)
ICC-ES, PMG-1296
2021, 2018, 2015, 2012, 2009, 2006 International Mechanical Code (IMC)
2021, 2018, 2015, 2012, 2009, 2006 International Residential Code (IRC)
2021, 2018, 2015, 2012, 2009, 2006 Uniform Mechanical Code (UMC)
CRN Approved (0A22551 and 0A18303)

Approved Refrigerants
For a list of approved refrigerants, visi rapidlockingsystem.com

Warnings

Use only with approved refrigerants. Review product specifications for more details.
Periodically check to ensure the jaws are meeting and aligned.
Wear proper eye protection during installation.
Keep hands and fingers away from the jaws during use.
Use supplied brush to ensure jaws are debris free.
If brazing or soldering nearby, ensure proper sealing of the fitting by maintaining a minimum braze distance from connections. Refer to the table on page 9 for minimum distance from a fitting to a braze joint per tube size. The installer should take the conventional precautions to keep the fitting cool by providing a heat sink (wet ragging, heat block, etc). This will ensure that the O-ring is not damaged during the brazing process.

Troubleshooting

Recommended steps if a coupling leaks after it is pressed.

Inspect tubing for scratches, incise marks and dents prior to tube cutting. Be careful when using a knife to cut off plastic shipping caps on tubes.
Take time to cut the tubing properly using a tubing cutter. Rushing through the cutting process may cause dents or oval tubing, which can create leaks.
Verify proper deburring and sanding/cleaning of tube surface per steps 5 and 6.
Verify proper tube insertion depth using the insertion gauge. One gauge is provided with the tool kit, and can also be ordered separately. Refer to the “Minimum Insertion Depth” table on page 5 if you do not have a gauge.
Verify the proper press diameter using the provided press gauge.
Verify correct jaw is installed for the fitting you are trying to press.
If jaw is sticking during press, try applying a light coating of spray lubricant such as WD-40 directly to the jaws.
Let jaw and tool do the work. If the fitting is in a hard to reach place, it is important to let the tool body move freely.
Avoid applying any sort of pulling or twisting of the tool during the press process.
If the fitting was recently pressed (15-20 minutes) prior to pressurization, it is possible the bubbles are a result of trapped air in the double press area that can leak out over time, and IS NOT a fitting leak. This is more likely to occur on smaller fittings.

If a fitting does leak, do not braze it.

Trying to braze the fitting will very likely melt the O-ring material and thus introduce contaminants into the system that could cause other system issues. THE FITTINGS SHOULD NEVER BE BRAZED.

Patents

RLS designs, develops and manufactures the original, patented press-to-connect fittings engineered for high-pressure refrigeration lines used in the air conditioning and refrigeration industries. This page is intended to serve as notice, including notice under 35 U.S.C. § 287(a).

RLS Fitting Patents:

U.S. Patent No. 9,145,992
U.S. Patent No. 9,638,361
U.S. Patent No. D730,494
Australian Patent No. 2012362443
Brazilian Patent No. BR112014016012-0
Canadian Patent No. 2,800,360
Canadian Design Registration No. 149228
EUIPO Registered Community Design No. 002218636-0001
Japanese Patent No. 6051468
Other pending patent applications

For technical questions or replacement information for any of the RLS installation aids, send an email to info@rapidlockingsystem.com.
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Documents / Resources

| RLS TZ1001A Flame-Free Refrigerant Press Fittings [pdf] Instruction Manual
PZK-KK5, TZ1001A, TZ1001A Flame-Free Refrigerant Press Fittings, TZ1001A, Flame-Free Refrigerant Press Fittings, Refrigerant Press Fittings, Press Fittings
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