LEADERS IN MARINE COMPOSITE FITTINGS

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1 LEADERS IN MARINE COMPOSITE FITTINGS 1

2 TABLE OF CONTENTS 04 Introduction 08 Electronic Aquavalve 10 Manual Aquavalve 13 Vented Loops 14 Ball Valves 16 Skin Fittings 18 Hose Fittings 21 Miscellaneous 22 ISO Standards & Certification 26 Nozzle Range 29 Nozzle Accessories Installation of parts featured in this catalogue must be installed as per installation instructions provided with each unit. Tru Design Plastics Limited will not be held accountable for damages incurred as a result of improper installation. 2

3 The boat photos throughout this catalogue are courtesy of Mustang Cruisers Australia. Photos on page 11, 16, 24 (top left) courtesy of John Spray. 3

4 Based in New Zealand, Tru-Design specialises in the design, manufacture and marketing of high quality marine valves, skin fittings, hose nozzles and associated products. All our products are made in New Zealand and are made out of the latest high impact resistant composite plastic materials designed to meet the demands of the modern boating industry and conform to rigid ISO Marine Standards. Established in 1974, we are an ISO 9001 company with over 35 years experience in design tooling and manufacture of injection moulded engineering plastics. We have over 50 staff including designers, engineers, toolmakers and quality assurance specialists. Tru-Design is well positioned to take products from design concept through tooling and into moulded production, assembly, testing then product approval and despatch. The marine range was developed as a result of the growing concern and regulation of untreated sewage being discharged from marine vessels. The multi-port diverting valve (Aquavalve ) was developed along with associated Skin Fittings and Vented Loops to allow commercial and recreational craft to comply with the new regulations. The marine range has grown significantly to include the electronic diverting valve (Electronic Aquavalve ) and a comprehensive Ball Valve range that includes electronic monitoring of the Ball Valve position. We have a continuous product development programme with new designs being introduced each year. The Nozzle range was produced in 1978 and is used extensively throughout the world in specialist applications such as fire fighting, marine and agriculture where strength, quality and reliability are paramount. We thank our customers for their continued support and feedback and we look forward to providing future innovative marine fittings solutions. 4

5 5

6 WHY COMPOSITES? WHAT ARE COMPOSITES? Composites are created from 2 or more materials with different physical and properties combined at a macroscopic level, resulting in a better material than the constituents on their own. WEIGHT Tru-Design marine fittings are significantly lighter weight than similar metallic fittings. With the use of composites throughout vessels to improve performance, why not do the same to your plumbing? Tru-Design use a number of different grades - predominately a Polyamide 6 (nylon) matrix, with Glass Fibre reinforcement, giving excellent chemical resistance, stiffness, impact strength, heat resistance, and ultimate strength - ideal for marine environments. All white grades have additives to provide increased UV resistance to ensure long life of exposed fittings. 1 ½ BSP Bronze 770g Tru Design 1 ½ BSP Composite 128g CORROSION The material used in Tru-Design marine fittings do not corrode, or conduct electrical currents so do not contribute to galvanic corrosion. They are immune to stray electrical currents. The use of composite marine fittings gives `peace of mind knowing that important thru hull fittings and sea-cocks are not slowly corroding away, opening up the vessel to the sea. CEproof International Ltd All metal parts suffer from corrosion to some extent, due to the electrolytic properties of sea water. Many different methods are employed to reduce the effect of corrosion in metal fittings; Barrier coatings e.g. paint Anodes Electrical bonding These methods will still be needed on a vessel to protect stern gear etc, but there is no longer any need to worry about thru hull fittings and sea cocks. QUALITY Tru-Design marine fittings are produced from the same grade of material, from the same manufacturer every time. Can you guarantee the same when you buy metallic fittings? With the influx of different manufacturers of fittings and the need to cut costs, it is becoming more and more difficult to ensure you are purchasing quality materials. STRENGTH Our range of Skin Fittings and Skin Fittings with Tail are the only polymer Skin Fittings to be certified by the International Marine Certification Institute (IMCI) in Belgium to ISO Standard Tru-Designs range of Ball Valves are certified by the International Marine Certification Institute (IMCI) in Belgium to ISO Standard

7 PRODUCT RANGE Aqualarm Panel (pg 20) Ball Valve Panel (pg 15) Aquavalve Control Panel (pg 08) Carbon Filter (pg 19) Vented Loop with Solenoid (pg 13) Vented Loop (pg 13) Aquavalve Bend (pg 12) Connector 90 (pg 19) Y - Piece (pg 19) Aquavalve electronic (pg 08) Connector (pg 18) Threaded Connector (pg 12) Reducer (pg 18) Tank Sensor Switch (pg 20) TANK PUMP Tail Long Thread Bend (pg 17) Tail - Long Thread (pg 17) Skin Fitting (pg 16) Position Monitored Ball Valve (pg14) INLET OUTLET Aquavalve Manual (pg 10) Plumbing layouts are indicative only. If in doubt, seek professional advice. Not drawn to scale. 7

8 ELECTRONIC AQUAVALVE Model EA015 - (Patent Application No ) The Tru-Design Electronic Aquavalve is designed and made in New Zealand for use in applications where remote Push Button diversion and control of the flow of water or effluent is desired. The Tru-Design Aquavalve is the most versatile valve on the market today. The Electronic Aquavalve has been designed to allow the Diverting Valve to be operated from the Control Panel with the push of a button. LED s on the Control Panel clearly denote whether the Valve is in the Holding Tank or Overboard position. The Tru-Design Aquavalve is predominantly used in marine toilet applications where protection for the environment necessitates the need to control effluent discharge in many countries this is governed by regulation. The effluent can be held in a holding tank for later discharge overboard or to a shore side facility. The Tru-Design Aquavalve is moulded from a glass reinforced nylon composite. High strength, highmodulus glass fibres impregnated into the nylon provides dramatic strength, stiffness, toughness and dimensional stability. The Tru-Design Aquavalve is a excellent choice for modern boats as it can be integrated into a boats electronic systems, giving full control from one location. CONTROL PANEL The control panel is used to remotely actuate the Aquavalve. The control panel can be mounted in a convenient location for easy control of the valve allowing the valve and toilet plumbing to be hidden from view. Other control panel options available. Please contact us for details. 8

9 ELECTRONIC AQUAVALVE SPECIFICATIONS The Electronic AquaValve is available in 2 voltage variants (12 & 24V DC) Electrical Specifications Supply voltage 12v DC 24v DC Stand by current 0.04A 0.028A Operating current 3.3A 1.2A Stall current 20A 8.4A The Electronic Aquavalve and Control Panel both carry an IP55 Rating. Dust and Water spray proof. CE approved. The Electronic Aquavalve is supplied complete with the following: Electronic Aquavalve body EA015 Control Panel CP05 Aquavalve Spanner Manual Socket 5 metre length of 8 core cable complete with waterproof connection for Aquavalve and push in connector for control panel All mounting screws s/steel Maintenance grease Comprehensive Installation and Operator Instructions As per the manual Aquavalve, the Electronic Aquavalve requires the choice of fitting methods and utilises a range of tail sizes and angles to meet the demands of plumbing in confined spaces see page 12 for full details Please Note: This is a Diverting Valve and not a Gate Valve or Shut Off Valve. The Silicone Rotor Seal is designed to seal with low pressure therefore may not be suitable for vacuum toilets depending on the position of the valve relative to the toilet. It is important to wire the Electronic Aquavalve so that the valve is activated each time the boat power is turned on. On activation the electronics will quickly cycle the valve to move the seal from Port to Port. This is an important function as it keeps the seal lubricated. 9

10 MANUAL AQUAVALVE Multiport Diverting Valve - (Registered Design No: ) MANUAL AQUAVALVE The Tru-Design Aquavalve is the most versatile valve on the market today. Designed and made in New Zealand for use in applications where diversion and control of the flow of water or effluent is desired. Typically used in marine toilet applications where protection of the environment necessitates the need to control effluent discharge in many countries this is governed by regulation. The effluent can be held in a holding tank for later discharge overboard or to a shore side facility. The Tru-Design Aquavalve is moulded from a glass reinforced nylon composite. High strength, highmodulus glass fibres impregnated into the nylon provides dramatic strength, stiffness, toughness, and dimensional stability. FEATURES Clear indication of which port is in the closed position Versatilie - many plumbing options Easy mounting - screws directly to bulkhead or floor Stainless steel fastenings. Design has been pressure tested to 300 psi (2000kpa). Each valve leak tested during production. User serviceable - Full service and parts backup. Lockable feature - no ability for accidental discharge Each valve supplied with spanner MODELS Aquavalve - Through Bulkhead AquaValve - Black AquaValve - White Please Note: This is a Diverting Valve and not a Gate Valve or Shut Off Valve. The Silicone Rotor Seal is designed to seal with low pressure therefore may not be suitable for vacuum toilets depending on the position of the valve relative to the toilet. 10

11 AQUAVALVE VERSATILITY REVERSIBLE FACEPLATE The reversible faceplate allows the user to install both the AquaValve and the AquaValve through Bulkhead in the most suitable way, then adjust the faceplate to suit the plumbing. This greatly improves ease of installation and gives tidier more efficient plumbing. THROUGH BULKHEAD FITTING The Through Bulkhead version allows the plumbing and valve body to be hidden behind a wall or panel. The Aquavalve Through Bulkhead suits wall thicknesses up to 15mm. If your bulkhead is thicker than 15mm, the Extension Pack Through Bulkhead is available for walls up to 37mm. 3 WAY CONNECTOR The 3 Way Connector is an excellent choice for connecting hoses back together in marine plumbing systems. It offers the same versatility as the Aquavalve through its large range of options for connecting the plumbing. With its flanged base, mounting is easy, eliminating hoses rattling and flapping around in heavy seas. 15mm max 37mm max 11

12 AQUAVALVE INSTALLATION - MANUAL AND ELECTRONIC To install the Tru-Design AquaValve, a full range of fittings of different sizes and angles are available. The Aquavalve is supplied with seals already in place, allowing tails to be installed directly. Tail sizes are available in common hose sizes from 19 38mm. To further improve versatility and allow tidy routing of hoses, a range of bends are available. The bends are supplied with a thicker seal option (Blue), which can be used to replace the red seal supplied, and give a further 180 of positioning options. AQUATAIL Available in 4 sizes 19mm ¾ 25mm 1 32mm 1 ¼ 38mm 1 ½ Thread size 11/2 BSP AQUAVALVE BEND Including Blue Seal - Black & White 25mm Hose Adaptor 38mm Hose Adaptor AQUAVALVE ELBOW including Blue Seal - Black & White 25mm Hose Adaptor 38mm Hose Adaptor THREADED CONNECTOR FOR RIGID PLUMBING With a recent trend towards rigid plumbing to reduce permeation issues, the Threaded Connector allows connection to these systems. Use the threaded connector to connect the AquaValve or 3 Way connector to a Female Adapter which is solvented to the plumbing system. The Threaded connector uses a 1 ½ BSP thread as is commonly used for connecting to standard PVC plumbing. AQUAVALVE SPANNER Supplied with Aquavalve PLUG 1 ½ BSP SEAL KIT Contains: 1 x o-ring, 1 x silicon seal, 1x seal holder & grease sachet 12

13 VENTED LOOPS Tru-Design Vented Loops have been designed and manufactured in New Zealand for use in marine applications. Vented Loops are commonly used in marine toilet installations and engine cooling systems and guard against the danger of water siphoning through pipe work in below water installations. AVAILABLE IN 3 SIZES - Black & White 19mm ¾ 25mm 1 38mm 1 ½ SPARE PART KITS Contains Valve Cap & Peg for clearing of vent hole Our test results show a 25% drop in inlet water supply due to the Vented Loop. Not recommended for manual toilets due to the lower volume of intake water. VENTED LOOP WITH SOLENOID When connected to an electric toilet intake, the Vented Loop with Solenoid seals upon energizing, allowing full fluid flow. When not energized, the siphon is broken as per the manual system (although quicker). Power Consumption (Upon energizing) AVAILABLE IN 3 SIZES 19mm ¾ 25mm 1 38mm 1 ½ IMPORTANT: The Vented Loop must be mounted a minimum of 250mm above the water line and we suggest mounting as high as the installation allows. 13

14 POSITION MONITORED BALL VALVES Developed from the standard Ball Valves, we can now offer a Ball Valve that can be simply wired to a monitor so that it is very clear as to which valves are open and which are closed. Other advantages are where the engine intake wired Ball Valve is wired to the ignition switch so that the intake water valve has to be open before the engine starting sequence is activated. Made in New Zealand for use in Marine Applications above and below the water line. They are IMCI approved to ISO standard The Seacock Monitor Panel gives the operator a clear visual indication of the position of the Ball Valve - open or closed. Available in 12volt only. It can also be used in a holding tank pump out system, so that the system knows when the outlet is open to allow discharge. MONITOR PANEL Available in the following sizes. ½ BSP ¾ BSP 1 BSP 1 ¼ BSP 1 ½ BSP 2 BSP Includes spanner and comprehensive wiring instructions. Winner 2009 HISWA Innovation Award 14

15 MANUAL BALL VALVES Tru-Design Ball Valves are designed and made in New Zealand for use in marine applications above and below the water line. They are IMCI approved to ISO Standard and ideal for controlling inlet and outlet water requirements. The body of the Ball Valve is moulded in Glass Reinforced Polymer for high impact and tensile strength resulting in light weight and freedom from corrosion and electrolysis. The ball and seal ring are moulded in a PTFE filled polymer for lubrication and continuous ease of operation over many years. Each Ball Valve is leak tested and the design has been pressure tested to 750psi (5000kpa). The Ball Valve spanner is available to tighten valve to skin fitting. Full range of spanners available. Available in the following sizes. ½ BSP ¾ BSP 1 BSP 1 ¼ BSP 1 ½ BSP 2 BSP 15

16 SKIN FITTINGS Tru-Designs range of Skin Fittings are the only polymer through hull to be certified by the International Marine Certification Institute (IMCI) in Belgium. The white skin fittings are moulded in a high UV stabilised Glass Reinforced Nylon 6 to prevent yellowing. All Skin Fittings are supplied complete with a nylon washer to increase locknut support on through hull assembly. These Glass Reinforced Nylon Skin Fittings eliminate corrosion and avoid electrolysis problems. The ISO Certification was gained after exhaustive testing was carried out in accordance with the IMCI. Designed and manufactured in New Zealand, the Skin Fittings have been moulded in a special grade of Glass Reinforced Nylon 6 Polymer, resulting in a quality product with high impact and tensile strength. ½ BSP 13mm ID ¾ BSP 19mm ID 1 BSP 24mm ID 1 ¼ BSP 32mm ID 1 ½ BSP 37mm ID 2 BSP 48mm ID SCOOP STRAINERS Keeps debris from entering the water intake while promoting a healthy flow of water. Designed and moulded in Glass Reinforced Nylon 6 Polymer for strength and elimination of electrolysis. For use with 1 ¼ and 2 Skin Fittings. ROUND STRAINER Ideal strainer for small gensets and water makers. Fits 1 ¼ skin fitting. 1 ¼ 2 16

17 THREADED FITTINGS TAILS STRAIGHT Tail size Thread size 13mm 19mm 25mm 32mm 32mm 38mm 50mm ½ BSP ¾ BSP 1 BSP 1 ¼ BSP 1 ½ BSP 1 ½ BSP 2 BSP TAILS 90 BEND Tail size Thread size 19mm 25mm 32mm 38mm 50mm ¾ BSP 1 BSP 1 ¼ BSP 1 ½ BSP 2 BSP TANK FITTING For emptying or filling tanks. 1 ½ BSP Thread Tail Long (500mm) Short(200mm) 19mm ¾ 25mm 1 32mm 1 ¼ 38mm 1 ½ Custom lengths available on request. Please contact Tru-Design to discuss requirements Outlet Inlet - reduces splashing Inlet - eliminated backflow 17

18 HOSE FITTINGS SKIN FITTINGS WITH TAIL For use above heeled waterline. Tru-Design Skin Fittings with Tail are the only plastic Skin Fittings to be certified by the International Marine Certification Institute (IMCI) in Belgium. They are made of the same materials and with the same attention to detail as the range of below water skin fittings. Sizes ½ BSP ¾ BSP 13mm Tail 19mm Tail 1 BSP 25mm Tail 1 BSP 28mm Tail 1 ¼ BSP 32mm Tail 1 ½ BSP 38mm Tail 2 BSP 50mm Tail All Skin Fittings are supplied complete with a nylon washer to increase locknut support on through hull assembly. These Glass Reinforced Nylon Skin Fittings eliminate corrosion and avoid electrolysis CONNECTORS Hose connectors to join sizes below. 13mm - 13mm 19mm - 19mm 25mm - 25mm 32mm - 32mm 38mm - 38mm 50mm 50mm REDUCERS A range of reducers to connect different size hoses 19mm - 13mm 19mm - 16mm 25mm - 19mm 32mm - 25mm 38mm - 25mm 38mm - 32mm 18

19 HOSE FITTINGS 90 BEND CONNECTORS Hose connectors to facilitate tidy routing of hoses round 90 corners, reducing crimped hoses and stress on hoses. 25mm - 25mm 38mm - 38mm 50mm - 50mm Y-PIECES These Y Pieces are available in a variety of sizes to allow 25mm and 38mm drain hoses to branch into one line. Manufactured in Glass Reinforced Nylon 6 Polymer, they are extremely tough and will handle both hot and cold water. 25, 25, 38mm 25, 25, 25mm 38, 38, 38mm CARBON FILTER The Carbon Filter is designed for holding tank venting. It must be mounted vertically and away from the tank to eliminate liquid contacting the carbon. Supplied complete with mounting bracket and hose tails 20mm, 25mm. Note: 200mm length. 19

20 LEVEL SENSORS AQUALARM The Aqualarm has been designed as a simple alarm system to indicate when a marine sewage or fresh water holding tank is nearly full. This basic design allows for easy installation and the surface or recessed control panels suit through or on wall positioning. TANK SENSOR SWITCH AQUALARM SURFACE PANEL AQUALARM RECESSED PANEL The system is designed to operate on 12 Volt DC. Surface or Recessed Control Panels to suit all applications. Comprehensive installation instructions supplied. Stainless Steel fastenings. Internal Wire tinned against corrosion. Each unit circuit tested. Full service and parts backup. CAUTION! DO NOT USE IN FUEL TANK Custom solutions are available for different length applications. Contact Tru-Design to discuss options. TANK SENSOR SWITCH - LONG 1 BSP Thread 20

21 MISCELLANEOUS POWER SPRAY NOZZLE Made from Super Tough Nylon 6 Adjustable spray pattern Quick trigger action COUNTERSUNK WASHERS 20 Pack - Black or white 6mm 3/16 BATTERY OPERATED PUMP A very popular product used to pump out water from those hard to get at places in the bilge. FUEL / WATER SPANNER Ideal special purpose Spanner for those fuel & water deck fittings. MULTISTRAP The Multistrap has been designed to secure electrical and plumbing hose and attachment looms utilising the strong screw hole. Moulded in Nylon 6, it has tested to carry 5 kg. Available in both black & white. MARINE HINGE Available in Black & White with Stainless Steel Hinge Pin. 2 per pack. Short / Long 21

22 EXPLAINING ISO Certification for seacock and thru hull fittings Tru-Design below water Skin Fittings are the only polymer Skin Fittings to be certified by The International Marine Certification Institute (IMCI) to meet ISO which specifies requirements for the manufacture and installation of non-metallic throughhull below water fittings, seacock and hose fittings. Designed and made in New Zealand, our Ball Valves and Skin Fittings are moulded from Nylon glass reinforced plastic with demonstrably high-strength, high-modulus fibers providing dramatic increases in strength and stiffness, toughness, and dimensional stability. THE ISO TEST Ball Valve assemblies and underwater Skin Fittings: To meet ISO the finished product must meet the following strength test, and still function: COMPLIANCE TruDesign products that comply with the ISO standard are: Skin Fittings Skin Fittings with Tail Ball Valve Range HOW TRU-DESIGN STACKS UP Tru-Design certified fittings meet and exceed the below tabled (and graphed below) ISO and ABYC standards: Tensile Strength (Units : MPa) A force of at least 1500 N applied a minimum of 10 cycles from a position 20mm off the end of the fitting. The fitting shall show no leakage to the outside of the assembly when subjected to an internal water pressure of 0.1 MPa (1 Bar) after this strength test and will perform as intended. Flexural Modulus (Units : MPa) Impact Strength (Units : kj/m2) 22

23 23

24 FROM IDEA TO FINISHED PRODUCT WHERE THE PRODUCTS COME FROM From mucking about in boats Talking to customers We come across new ideas and concepts, which through: Testing Development Evolve into a useful design 24

25 USING OUR LEADING EDGE TOOLS CAD Tool Design CAM Manufacturing We are able to produce parts using our High Quality Tooling Modern Moulding Machines These parts are then Assembled Tested To be proudly shipped to customers as a Tru-Design product 25

26 NOZZLES The Tru-Design Powerjet range of nozzles is durable yet lightweight. Made from high impact strength polycarbonate polymer, these nozzles can be adjusted easily and smoothly with a twist of the wrist for a strong jet throw, cone spray or fog pattern. Applications include industrial and agricultural wash down, wildland firefighting, industrial fire protection, fire department use and marine fire protection on boats and dockside. Powerjet nozzles are approved for use as fire hoses on surveyed vessels. Stainless fasteners for long life Large protector to extend life Brass or Composite Valve Hose tail seal no messy thread tape required Large grips for using with wet hands/gloves Double o-rings for easy spray application A range of Hose Tail sizes for all common hose sizes. Note purchased separately Hose Clamps available for secure hose fixing and added protection 26

27 POWER JET LARGE POWERJET Composite Valve Brass Valve Thread Size 1 ½ BSP Performance Test Results - Powerjet kpa PSI FLOW: Litres/min SMALL POWERJET Composite Valve Brass Valve Thread Size 1 BSP Performance Test Results - Small Powerjet kpa PSI FLOW: Litres/min TAILS Nozzles are sold without the Tail. Choose from the range of tails to fit your hose. LARGE POWERJET TAIL 19mm 25mm 32mm 38mm SMALL POWERJET TAIL 19mm 25mm 32mm 27

28 NOZZLES HOSE REEL NOZZLE Made from tough Polycarbonate polymer Ideal for all agricultural, industrial and marine applications Designed to meet both New Zealand and Australian Fire Hose Reel Standards Ideal marine fire hose or wash down nozzle Thread Size ¾ BSP Performance Test Results - Hose Reel kpa PSI FLOW: Litres/min POWER SPRAY Made from super tough Nylon 6. Ideal for all agricultural, horticultural, marine and industrial spraying applications. Adjustable spray pattern from strong jet throw to fine spray. Quick trigger action from open to shut off position. Flow rate at 400kpa - 42 litres/min. Thread Size ¾ BSP TAILS Nozzles are sold without the Tail. Choose from the range of tails to fit your hose. 13mm 19mm 25mm SNAP CONNECTOR For quick connection to universal hose connectors. MINI SPRAY Ideal teat wash down spray. Fine spray pattern on low pressure. Auto shut off when released. Designed for 13mm hose. 28

29 NOZZLE ACCESSORIES HOSE CLAMPS Field tests have proven the Hose Clamp to be ideal when used on our hose and nozzle range. The strong Nylon 6 moulding acts as a protector and support to the Nozzle and eliminates the sharp hose clip problems experienced with standard hose clip systems. The fastenings are in stainless steel to guarantee long life and reports on these Hose Clamps have been very positive. Available in sizes: 13mm 19mm 25mm 32mm 38mm STRAINERS The Strainers have been designed to attach to the suction end of the hose when sucking water from a stream, lake, water race etc. The grill on the Strainer is designed to stop small particles from entering and blocking the pump system. The volume of the grill area is designed to ensure there is no restriction to the water flow. Available in sizes: 32mm 38mm 50mm 75mm 29

30 NOZZLE SALES/SERVICE DISPLAY CARTONS POWERJET SMALL POWERJET POWER SPRAY SPARE PARTS POWERJET Valve, nut & washer Composite Brass SMALL POWERJET Valve, nut & washer Composite Brass POWER SPRAY Stem spring, o ring & nut 30

31 PLANS 31

32 2010 / 2011 LEADERS IN MARINE COMPOSITE FITTINGS P: F: E: Tru-Design Plastics Limited 243 Ti Rakau Drive, East Tamaki, Manukau 2013, New Zealand PO Box , Panmure, Auckland 1741, New Zealand

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