ROMAC INDUSTRIES FCA501 Flanged Yellow Shop Coated Ductile Iron Coupling Adapter Installation Guide

ROMAC INDUSTRIES FCA501 Flanged Yellow Shop Coated Ductile Iron Coupling

Adapter

Product Information

The Style FCA501 Flanged Coupling Adapter is a product manufactured by ROMAC INDUSTRIES, INC. It is designed to provide a secure and leak-proof connection between pipes with flanged ends. The coupling adapter is made of durable materials and is suitable for use in various applications.

Product Features

• Flanged coupling adapter for connecting pipes
• Available in different sizes
• Comes with anchor pins for added axial force protection (Note: Couplings without anchor pins do not provide axial force protection)
• Includes a gasket with a beveled edge for a secure seal
• Easy to install and maintain

Product Usage Instructions

1. Before installing the coupling adapter, read the installation instructions provided in the user manual.
2. Inspect the parts to ensure that no damage has occurred during transit and that no parts are missing.
3. Check the diameter of the pipe and verify that it matches the range marked on the coupling adapter to ensure proper sizing.
4. Clean the pipe to remove dirt and corrosion from the pipe surface. Use soapy water or an approved pipe lubricant to lubricate and clean both the gasket and plain pipe end.
5. Ensure that there are no dents, projections, gouges, or other obstructions that may interfere with the gasket seal. If necessary, grind any welds flush.
6. Remove the anchor pins from the body of the coupling adapter.
7. Slide the flanged coupling body onto the pipe end, making sure it is centered with an even space between the outside diameter of the pipe and the inside diameter of the coupling body.
8. Position the flanged coupling against the mating flange and assemble the flanged joint using flange bolts.
9. Place the gasket next to the end ring with the beveled edge facing toward the pipe end.
10. Slide the flanged coupling gasket into position, ensuring that the beveled edge engages with the beveled end of the flanged coupling body.
11. Tighten the flange bolts evenly, alternating to diametrically opposite positions, in approximately 20 ft-lb increments until the recommended tightness is achieved. Refer to the recommended torque values provided in the user manual for specific coupling sizes.
12. Wait for 10 minutes and then retighten the bolts to account for any settling of the gasket.
13. Inspect the installation for leaks by visually checking the connection and conducting a pressure test if necessary.

Precautions

1. Ensure that the diameter of the pipe matches the correct size coupling adapter. Also, verify that the gasket is of the correctsize.
2. Properly clean the pipe surface before installation to ensure a secure connection.

INSTALLATION INSTRUCTIONS

Read installation instructions first before installing. Check parts to ensure that no damage has occurred during transit and that no parts are missing. Also check the diameter of the pipe and the range marked on the coupling to ensure you have the proper size.

Style FCA501 Flanged Coupling Adapter

• Step 1 • Check the flanged coupling parts and confirm that no damage has occurred during transit and that no parts are missing.

• Step 2 • Clean pipe end for a distance of 2″ greater than length of the coupling.

• Step 3 • Check area where gaskets will seat to make sure there are no dents, projections, gouges, etc., that will interfere with the gasket seal. Welds must be ground flush.

• Step 4 • Place end ring on pipe end.

• Step 5 • Lubricate gaskets with a suitable gasket lubricant. Place gasket next to end ring with beveled edge toward thepipe end.

  • Note: Flanged Couplings without anchor pins do not provide protection against axial force. Suitable anchorage should be provided.

• Step 6A • Flanged Couplings with Anchor Pins:

  • i. Remove anchor pins from the body of the coupling.

  • ii. Slide the flanged coupling body onto the pipe end.

  • iii. Position the flanged coupling against the mating flange. Assemble the flanged joint using flange and through bolts. Insert the pipe the minimum amount as shown in Table 1(below).
    Table 1

  • iv. Thread a short pipe nipple into the threaded anchor pin hole. Using the largest drill bit that will fit into the pipe nipple, drill a center mark on the pipe. Do not drill through.

  • v. Drill a 5/16″ hole through the center mark made in step iv.

  • vi. Remove the pipe nipple, and complete the hole through the pipe (see Table 2 for the hole size). Use care so as not to damage the threads.
    Table 2

  • vii. Install the anchor pins. Apply a suitable thread sealant and tighten to prevent leakage.

• Step 6B • Flanged Couplings without Anchor Pins: Slide the flanged coupling assembly onto the pipe. Position the the pipe and flanged coupling against the mating flange. Assemble the flange joint using flange bolts.

• Step 7 • The pipe should be centered such that the space between the OD of the pipe and the ID of the FCA body is even all around the pipe. Slide flanged coupling gasket intoposition with the beveled edge engaging the beveled end of the flanged coupling body.

• Step 8 • Slide end ring into position (engaging the through bolts) against the gasket.

• Step 9 • Bolt tightening should be done evenly, alternating to diametrically opposite positions at  approximately 20 ft-lbs.increments to bring bolts to recommended tightness.

RECOMMENDED TORQUE

FCA501 SIZE| END RING BOLTS| FLANGE BOLTS
3″| 60 – 70 FT-LBS| 75 – 85 FT-LBS
4″| 60 – 70 FT-LBS| 75 – 85 FT-LBS
6″| 75 – 85 FT-LBS| 90 – 100 FT-LBS
8″| 75 – 85 FT-LBS| 90 – 100 FT-LBS
10″| 60 – 70 FT-LBS| 150 – 160 FT-LBS
12″| 85 – 95 FT-LBS| 150 – 160 FT-LBS
16″| 60 – 70 FT-LBS| 235 – 245 FT-LBS

• * Wait 10 minutes and retighten to account for settling of the gasket.

• Step 10 • Confirm proper installation by pressurizing the line and checking for leaks.

PRECAUTIONS

1. Check diameter of pipe to make sure you are using the correct size coupling; also check gasket to make sure it is the size you think it is.
2. Clean pipe to remove dirt and corrosion from pipe surface. Lubrication and additional cleaning should be provided by brushing both the gasket and plain pipe end with soapy water or approved pipe lubricant per ANSI/AWWA C111/A21.11.
3. Make sure no foreign materials lodge between gasket and pipe.
4. Avoid loose fitting wrenches, or wrenches too short to achieve proper torque.
5. Keep threads free of foreign material to allow proper tightening.
6. Take extra care to follow proper bolt tightening procedures and torque recommendations. Bolts are often not tightened enough when a torque wrench is not used.
7. Pressure test for leaks before backfilling.
8. Backfill and compact carefully around pipe and fittings.
9. When reinstalling parts with stainless steel hardware, there may be a loss in pressure holding ability due to worn or damaged threads during the original installation.

COMMON INSTALLATION

COMMON INSTALLATION PROBLEMS

1. Bolts are not tightened to the proper torque.
2. Rocks or debris between pipe and gasket.
3. Dirt on threads of bolts or nuts.
4. Not enough pipe insertion when installing anchor pins.

CONTACT

• 21919 20th Avenue SE
• Suite 100
• Bothell, WA 98021
• Phone 425-951-6200
• 1-800-426-9341
• Fax 425-951-6201

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