Gas connector installation is a critical task that requires precision, adherence to safety standards, and a clear understanding of product limitations. BrassCraft, a leading manufacturer of gas appliance connectors, provides detailed documentation outlining installation procedures, compatibility, and safety requirements. This guide compiles key information from BrassCraft’s official resources and technical specifications to assist professionals and DIY users in understanding how to properly install and maintain gas connectors in compliance with U.S. codes and industry standards.
This article is based on verified technical data from BrassCraft’s resources and other supporting documentation, ensuring that all recommendations align with the manufacturer’s specifications and model plumbing codes.
Introduction
Gas connectors are essential components in gas appliance systems, linking the gas supply line to the appliance itself. BrassCraft offers a range of flexible gas connectors designed for use with natural gas, LP (propane), and mixed gas types under 1/2 PSI pressure. These connectors are widely used in residential and manufactured home applications and are subject to strict regulations regarding installation, maintenance, and re-use.
Proper installation involves not only mechanical precision but also a clear understanding of the potential risks associated with gas leaks, valve tripping, and incorrect fittings. BrassCraft explicitly prohibits certain installation practices, such as connecting two connectors to extend length or re-installing a previously used connector. This article explores the technical specifications, installation best practices, and safety considerations for BrassCraft gas connectors.
Technical Specifications and Operating Conditions
BrassCraft gas connectors are manufactured to meet industry standards for performance, durability, and safety. Below is a summary of key technical specifications:
- Approved Fuels: Natural gas, manufactured gas, mixed gas, LP (propane), and LP gas mixtures.
- Maximum Operating Pressure: 1/2 PSI.
- Temperature Range:
- BrassCraft connectors are approved for continual exposure to 150°F (per ANSI Z21.75).
- Vinyl and braided connectors operate in a range of 40°F to 160°F, with intermittent use up to 180°F.
- Certifications:
- ANSI Z21.24/CSA 6.10 for indoor gas appliance connectors.
- ANSI Z21.75/CSA 6.27 for outdoor gas appliances and manufactured homes.
- Material Compatibility:
- Copper and CPVC tubing are compatible with push-connect stops.
- No plumbers’ putty, pipe thread tape, or other sealant should be used during installation.
Installation Best Practices
Installation of BrassCraft gas connectors must be performed with care to avoid leaks, valve activation, and mechanical failure. Below are the key steps and recommendations for proper installation:
1. Preparing the Pipe
Before attaching a gas connector, it is essential to prepare the pipe correctly. BrassCraft recommends the following steps:
- Cutting the Pipe: The pipe must be cut square to ensure a proper fit and to prevent leaks.
- Removing Burrs: All burrs should be removed from the end of the pipe. A deburring tool or fine sandpaper is recommended for this task.
- Inserting the Tube Stiffener: While not required for copper or CPVC installations, the use of a pre-inserted tube stiffener will not interfere with the installation.
2. Connecting the Gas Connector
BrassCraft gas connectors are designed to be push-fit, eliminating the need for additional sealants. However, there are several key points to consider:
- Do Not Use Sealants: The use of plumbers’ putty, gasket material, or pipe thread tape is explicitly prohibited. These substances can introduce dirt or debris into the connection, potentially causing blockages or leaks.
- Ensure Full Insertion: The water stop (or gas stop in the case of gas connectors) must be pushed to the 1" mark on the pipe. The stop will bottom out once fully seated, ensuring a secure connection.
3. Opening the Gas Valve
After the connector is installed, the gas ball valve (gas shut-off valve) must be opened very slowly. Sudden gas flow can cause the excess flow valve (EFV) or thermal excess flow valve (TEFV) to trip prematurely. If this occurs:
- Close the Gas Ball Valve: Immediately turn off the gas supply.
- Wait for Reset: Allow a few minutes for the (T)EFV to reset.
- Reopen the Valve: Turn the gas on again at a slow rate.
4. Checking for Leaks
After installation, it is crucial to check for gas leaks upstream of the (T)EFV. If a gas odor is detected:
- Ensure Ventilation: Open windows and doors to allow for proper air circulation.
- Avoid Using Powered Equipment: Do not use motorized equipment or fans to disperse gas vapors.
- Seek Professional Help: If the leak cannot be resolved, contact a licensed plumber or gas technician.
5. Prohibited Installation Practices
BrassCraft explicitly prohibits the following installation practices:
- Connecting Two Connectors: Connecting two gas connectors to achieve a longer length is not allowed. This can affect gas flow rate, introduce new leak paths, and is prohibited by model codes.
- Reusing Connectors: Once a gas connector or fitting is removed, it must not be re-installed. Reuse is not permitted due to potential damage during removal or reinstallation, which can compromise safety.
- Using with Fuel Oil: BrassCraft gas connectors are not approved for use with fuel oil. They are only suitable for natural gas, LP, and mixed gas types.
6. Grounding and Bonding
Flexible gas connectors are not considered corrugated stainless steel tubing (CSST) and therefore do not require individual grounding or bonding. However, the home’s main gas supply system must be bonded if local codes require it. Users should consult local plumbing and electrical codes for bonding requirements.
Troubleshooting Common Installation Issues
Even with careful installation, issues may arise. Below are some common problems and their solutions based on BrassCraft documentation.
1. Gas Not Flowing to the Appliance
If the gas is not reaching the appliance despite a properly installed connector, the following factors may be at play:
- EFV/TEFV Tripped: As mentioned earlier, the EFV or TEFV may have tripped due to sudden gas flow. The gas ball valve must be closed and reopened slowly to allow the valve to reset.
- Leak in the System: A leak upstream of the (T)EFV may prevent gas from flowing properly. A thorough leak check is necessary before proceeding.
2. Small Leak After Installation
If a small leak is detected after installation:
- Check Pipe Preparation: Ensure the pipe was cut square and all burrs were removed.
- Verify Stop Position: Confirm that the water stop is pushed to the 1" mark on the pipe.
- Reinstall if Necessary: If the leak persists, the connector must be removed and a new one installed. Reuse is not permitted.
3. Connector Not Working with Safety+PLUS® or Safety+Plus®2
If the Safety+PLUS® or Safety+Plus®2 model is not functioning properly:
- Follow EFV Reset Procedure: Close the gas ball valve, wait for the EFV to reset, and then reopen the valve slowly.
- Check for Leaks: If a leak is present upstream of the (T)EFV, it must be addressed before the system can operate correctly.
Safety Protocols and Code Compliance
Gas connector installation must be performed in accordance with local, state, and national codes. BrassCraft gas connectors are listed to ANSI Z21.24/CSA 6.10 and ANSI Z21.75/CSA 6.27, ensuring compliance with industry standards. However, local jurisdictions may impose additional requirements.
Key Safety Guidelines
- Do Not Attempt DIY Repairs: Any suspected leaks or malfunctions should be addressed by a licensed professional.
- Avoid Using Prohibited Materials: Sealants, putty, or gasket material must not be used during installation.
- Use Only Approved Connectors: BrassCraft gas connectors are not approved for use with fuel oil and must not be connected to non-approved fuel types.
- Never Reuse Connectors: Once a connector is removed, it must be discarded and replaced with a new one.
Code Compliance Considerations
- Length Restrictions: Some jurisdictions, such as Massachusetts, prohibit the use of connectors longer than 48 inches in certain applications.
- Pressure Drop Adjustments: The BTUH capacity of a gas line must be adjusted for pressure drop. Multiply the BTUH by 0.632 to convert to standard capacity at 50 Pa (0.02 in water column) pressure drop.
- Minimize Bends: The number of bends in the tubing affects gas flow. Keep bends gentle and minimize their number to ensure optimal performance.
Gas Flow and BTU Capacity Considerations
Gas flow rates are directly affected by the length, diameter, and number of bends in the tubing. BrassCraft provides a reference table for BTUH capacity based on tubing diameter and length. This table is adapted from manufacturer specifications and should be used as a guide for selecting the appropriate connector for a given application.
| Tubing Inside Diameter | Tubing Color Code | BTUH Capacity (1000 Input BTUs per Hour) |
|---|---|---|
| 1/4" (Purple) | Purple | 48.0, 43.8, 40.0, 36.4, 33.4, 28.3, 24.9, 23.1 |
| 3/8" (Green) | Green | 102, 93.1, 85.5, 77.1, 71.1, 60.5, 53.2, 48.1 |
| 1/2" (Gold/Yellow) | Gold | 180, 164.2, 150, 136, 125, 106, 93.2, 86 |
Note: These values are based on natural gas at 0.64 specific gravity with a heating value of 1,600 BTUs per cubic foot. For propane, the heating value is approximately 2,516 BTUs per cubic foot. Some jurisdictions may limit the maximum allowable length of the tubing, and local codes must be followed.
Conclusion
BrassCraft gas connectors are engineered to provide reliable and safe gas flow to residential and manufactured home appliances. However, their effectiveness and safety depend on proper installation, maintenance, and adherence to manufacturer guidelines. Key considerations include the use of approved materials, the avoidance of prohibited installation practices, and the implementation of safety protocols to prevent leaks and valve activation.
For DIY users and professionals alike, understanding the technical specifications, installation best practices, and code requirements is essential to ensuring the safe and efficient operation of gas appliances. BrassCraft provides comprehensive documentation and support resources to assist in these tasks, reinforcing the importance of precision and safety in gas system installation.