aquatherm INSTALLER MANUAL

aquatherm
500 S 500 W | Lindon, UT | 84042 | 801.805.6657 support@aquatherm.com www.aquatherm.com This manual is designed to accompany the Aquatherm Installer Training Course and act as a reference for trained installers. It is not a substitute for taking the Installer Training Course.
2012 aquatherm NA L.C. All rights reserved

aquatherm
INSTALLER MANUAL

2nd ed.

11.12 2nd Edition Printed in USA

Aquatherm Installer Manual

For the proper installation of PP-R pipe and fittings manufactured exclusively by Aquatherm Required for the Aquatherm Installer and Aquatherm Butt Welding Courses
2012 aquatherm NA L.C. All rights reserved

This manual was produced by Aquatherm NA L.C. and is intended strictly for the North American market. It combines information published by Aquatherm GmbH with accepted fusion practices in the USA and Canada. Aquatherm GmbH assumes no responsibility for the content of this manual beyond what they have specifically published. Aquatherm NA L.C. does not warranty the completeness or accuracy of the information contained herein. In the event of a discrepancy between this manual and information published by Aquatherm GmbH, the information published by Aquatherm GmbH will be considered correct. The information in this manual is superseded by any subsequent editions of this manual. Aquatherm NA L.C. retains the right to modify the proper installation procedures at any time via technical bulletins.

Contents Chapter 1
Welcome to Aquatherm Getting started Working with PP-R Aquatherm improvements The world leader in PP-R pipe Material handling Sizing Wall thickness Identification Hot water aquatherm greenpipe Cold water aquatherm greenpipe Thick-wall climatherm Thin-wall climatherm aquatherm lilac Molded fittings Segmented fittings Sizing 1.1 1.2 1.3 1.4 1.5 1.6 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 Operating pressures Weights and capacities Listings and approvals Heat fusion Safety Tooling Cutting the pipe Inspecting the cut How fusion works Avoiding improper fusions Socket fusion Welding heads Welding irons Welding iron safety Tool assembly Marking the pipe Heating times 1.19 1.22 1.24

Chapter 2
2.1 2.2 2.3 2.4 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.14 2.15 2.16

Socket fusion instructions Inspection Troubleshooting bad connections Assisted fusions Mechanically assisted fusions ASDAC welding jig instructions Fusion outlets Fusion outlet instructions Electrofusion Electrofusion instructions Butt welding machine Explanation of butt welding Butt welding overview Butt welding heating and cooling times Adjustment bead height McElroy adjustment and welding pressures Ritmo adjustment and welding pressure Widos adjustment and welding pressures

2.18 2.20 2.21 2.22 2.23 2.24 2.26 2.27 2.30 2.31 2.34 2.35 2.36 2.37 2.39 2.40 2.42 2.44

Butt welding instructions Reducing cooling times Tolerances on segmented elbows Internal alignment ASDAC tools McElroy tools Ritmo tools Widos tools Repairs Installation Getting started Tips for in-place installation Tips for on-site assembly Tips for off-site prefabrication Technical bulletins Clamps and hangers Fixed and sliding points

2.46 2.52 2.53 2.54 2.55 2.56 2.58 2.60 2.62

Chapter 3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Support intervals Increased hanger spacing Fire rating Aquatherm Advanced installation Linear expansion Expansion controls Length of bending side Chemical compatibility Integration with copper tubing Connecting to a boiler PP-R to Copper Transition Fittings Bushings, reducers, and reducing couplings Threaded Connections Flanges Butterfly valves Branch lines Buried applications Maximum pull force

3.9 3.12 3.13 3.14 3.16 3.20 3.22 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.34 3.35 3.36 3.37

Insulation sizing, thrust blocking, noise generation, and vibration isolation 3.38 Flushing, grounding, and freeze protection 3.39 UV protection and painting 3.40 Fusing UV pipe 3.41 Pressure testing 3.42 Warranty claims 3.46

Chapter 4
Pipe and fittings aquatherm greenpipe SDR 7.4 aquatherm greenpipe SDR 11 climatherm SDR 7.4/11 climatherm SDR 17.6 aquatherm greenpipe UV SDR 7.4 climatherm UV SDR 7.4/11 aquatherm lilac SDR 7.4/11 aquatherm Advanced wrap Foil tape 4.1 4.2 4.2 4.3 4.3 4.4 4.4 4.5 4.6 4.6

Coupling Bushing Butt weld reducer Reducing couplings Elbow 90 Elbow 45 Street 90 Street 45 Cross End cap Tee Reducing tee Fusion outlet Cross-over Flange adapter Flange ring Union Electrofusion coupling

4.7 4.7 4.8 4.9 4.10 4.11 4.13 4.13 4.13 4.14 4.15 4.17 4.23 4.25 4.25 4.26 4.27 4.28

Wing back 90 elbow Back plate elbow ISO plug for pressure tests ISO transition piece Transition fitting NPT transition fitting NPT transition elbow NPT transition street elbow NPT transition tee Transition to compression fitting Stub out PEX adaptor Draining branch Transition elbow Transition tee NPT fusion outlet Distribution block plumbing Distribution pipe

4.28 4.29 4.29 4.30 4.31 4.31 4.33 4.33 4.34 4.34 4.35 4.35 4.35 4.36 4.36 4.37 4.40 4.40

Distributor end piece Ball valve Screw-down stop globe valve Concealed valve Stop valve body ISO Inclined valve Inclined check valve Ball valve Welding jig Temperature protective gloves Welding heads Repair set Repair plug Drill bit Fusion outlet welding heads

4.41 4.41 4.41 4.42 4.43 4.44 4.44 4.44 4.46 4.46 4.46 4.46 4.46 4.47 4.47

Owner

Installer Number

Trainer Name

Trainer Contact Info.

Chapter 1: Welcome to Aquatherm

This manual has been compiled to help ensure safe and consistent installation of Aquatherms piping materials. Please read all instructions before beginning installation. Installers must take the appropriate training course from an authorized Aquatherm trainer before beginning installation. This training will save you time and money on the jobsite, and help you take full advantage of Aquatherms many benefits.

1.1

Getting started
Before you get started, you should know a little about the pipe you are installing. Aquatherms pipes and fittings are made from an engineered variation of polypropylene-random copolymer, or PP-R. This material offers many benefits over metals and other plastics, such as durability, longevity, and chemical purity. Aquatherms polypropylene pipes and fittings are produced in Germany and have been used around the world for nearly four decades. The pipe and fittings are made to the highest international standards of quality, so you can trust the material every time you install it. If the pipe and fittings dont have Aquatherm labels, return them and dont install them. Only genuine Aquatherm products are protected by Aquatherms warranty and decades of expertise with PP-R. If you have not worked with Aquatherms fusible pipe before, it is best not to rush and get ahead of yourself. Just as you were not able to make beautiful welds your first day as an apprentice, it will also take you some time to become proficient at heat fusion. Fortunately, youll find that learning fusion is quick and easy. This manual will act as your guide while you learn, and as you continue to fuse pipe for years to come.

1.2

Working with PP-R

Polypropylene is a thermoplastic, similar to polyethylene pipe. It is made from an oil by-product, so it naturally repels water. This makes it ideal for a piping material, as it does not affect, and is not affected by, the water it carries. PP is made from chains of hydrogen and carbon, so there are no toxic chemicals that can affect drinking water. PP-R is polypropylene copolymerized (combined) with a small amount of ethylene. This combination, enhanced by Aquatherms proprietary formula, gives the material a balance of durability, rigidity and flexibility. PP-R is connected using heat fusion, which involves heating and cooling the pipe to join it to an identical material. This is covered in detail in chapter 2. All of Aquatherms pipes and fittings are made from PP-R, so they will have the same properties. They can be heatfused together without any strength loss, and have the same densities, durability, and resistances. Aquatherms PP-R has been engineered for improved performance and should not be mixed with other brands of PP-R. PP-R should never be fused to PP, PVDF, PE, CPVC, or any other type of plastic. Never use solvent cements on Aquatherms PP-R, as they may damage the pipe and wont bind properly.

1.3

Aquatherm improvements
Every piping material has advantages and disadvantages. PP-R is proven to have very few disadvantages, and several innovations unique to Aquatherm help address these minor shortfalls. Aquatherms special blend of PP-R is called Fusiolen, which is used in each Aquatherm pipe and fitting.

1.4

Normal plastic
Burns during fusion, resulting in strength loss Damaged when exposed to high temperatures Significant linear expansion when heated Chemically reactive, resulting in failures Faser-composite is a mix of PP-R and glass fibers that reduces expansion but does not affect fusion properties.

Aquatherms Fusiolen PP-R

VS
Pipe integrity (at 400 oF)

Does not burn during fusion, for 100% strength Heat-stabilized to withstand high temperatures Faser-composite layer cuts expansion by 75% Completely inert to water and most chemicals
Aquatherm PP-R Regular PP-R

Heat stabilization protects the pipe during brief exposure to extreme temperatures.

Time (min.)

42

The world leader in PP-R pipe

Aquatherm is the world leader in PP-R pressure piping systems. When you work with our products, you get decades of research and experience to back you up. All Aquatherm products are thoroughly tested before, during, and after production by the best equipment and experts in the industry. This quality control helps ensure consistency in every Aquatherm pipe and fitting. Aquatherm backs its products with a 10-year warranty that doesnt just cover replacement parts it also covers the replacement labor, incidental damages, medical costs, and financial loss, giving you and your customers real peace of mind. Coverage begins at the time of installation for the current coverage amount. The installation date is confirmed through the pressure test. Exact coverage amounts are subject to the exchange rate with the Euro at the time coverage is Note: The Aquatherm warranty only applies to systems that are properly installed by awarded. PP-R is durable, both physically and chemically, and is more resilient against oils, freezing, impact, etc. than other plastics and even metals. However, it is not indestructible. Proper care should be taken when working with Aquatherm pipes and fittings. The Aquatherm warranty does not cover damage caused by post-factory mishandling, jobsite abuse, UV damage, or improper installation.
an Aquatherm-trained installer. Improper installation or fusing to non-Fusiolen parts will void the warranty for those connections. Following all the procedures in this manual will minimize the risk of material failure and help ensure coverage in the event of a problem. Pressure testing is required to verify proper installation.

1.5

Material handling : Do

1.6

Inspect pipe upon receiving it. Aquatherm does not accept responsibility for damage that occurs after the pipe is shipped.

Dont fuse damaged pipe. Remove damaged sections and install the remaining pipe. Follow your distributors policy for returns.

Keep the pipe on a flat surface or close supports to avoid bowing. Use at least 3 supports for 13 pipes and 4 for 19 pipes.

Keep the pipe in its protective bag until you are ready to install it. The bag protects the pipe from dirt, scratches, and UV rays.

Handle the pipe carefully, especially in freezing weather. Plastic becomes brittle at cold temperatures, so treat it accordingly.

Cover unbagged pipe with a light-colored tarp if storing it outside. A dark tarp generates heat and may cause warping.

Material handling: Dont

1.7

Dont run over the pipe with any type of vehicle or crush the ends. This is the most common cause of pipe damage.

Dont drop the pipe or handle it roughly. PP-R can handle most impacts without issue, but there is no reason to risk damaging it.

Dont insert sharp or unpadded objects into the ends of the pipe. These can gouge the inside of the pipe.

Dont store pipe outside for more than 6 months uncovered. The pipe should be stored under a tarp or shade, or in bags.

Keep the fittings in their bags until you use them. Dont mix unbagged fittings as most fittings only have basic labeling on them.

Dont use pipe that is gouged deeper than 10% of the wall thickness on the outside, or if it has scratches that can be felt inside.

Sizing
Aquatherm pipe is made to metric sizes (millimeters). This is part of its design and listings, but it is easy to learn the matching imperial sizes (inches). This chart gives the matching sizes. These sizes are based on flow rate and physical size. Use the nominal size when switching from imperial pipe. Use the actual size for clamps and insulation. Metric pipes use standard dimension ratios (SDR) instead of schedules. This means that the wall thickness is proportional to the diameter of the pipe. From a performance standpoint, this makes the flow speed and pressure rating of the pipe consistent through each size. 4 pipes come in 13.12 ft (4 meter) lengths. 6 24 pipes come in 19.69 ft (6 meter) lengths.

1.8

Socket fusion
Factory metric OD 20 mm 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm 110 mm 125 mm Nominal diameter 1 1 1 2 2 3 3 4

Butt welding
Factory metric OD 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm 500 mm 560 mm 630 mm Nominal diameter 6 8 10 12 14 16 18 20 22 24

Wall thickness

1.9

1 / 7.4 total diameter

1 / 11 total diameter

1 / 17.6 total diameter

SDR 7.4 A heavy wall provides increased pressure and temperature ratings for high-stress applications such as hot water recirculation.
aquatherm greenpipe faser-composite

SDR 17.6 A balanced wall thickness provides A thinner wall provides maximum higher flow rates while maintaining flow rate while minimizing material high pressures. Suitable for most weight, cost, and fusion times. For applications. chilled, cooling, and condenser applications. aquatherm greenpipe
climatherm faser-composite aquatherm lilac climatherm faser-composite

SDR 11

Identification
Aquatherm has several lines of pipe that are specifically engineered for certain applications. Stripes and color indicate the type of pipe.

1.10

aquatherm greenpipe faser-composite

climatherm

aquatherm greenpipe non-faser

aquatherm lilac

Aquatherm Greenpipe faser-composite pipe 63x8.6mm (2 N.D.) PP-R80 SDR 11 cNSF CSA b137.11 ASTM F2389 ICC ESR-1613 Made in Germany

Expansion control label

(not present on non-faser pipes)

Material

Relevant code listings

(varies by pipe type)

Pipe name
(only genuine Aquatherm pipe and fittings are backed by our 10-year warranty)

Production size and nominal diameter

Wall thickness
(based on pipe diameter)

Additional information
(incl. timestamp)

Hot water aquatherm greenpipe

Color: Green 1.11 Stripes: Dark green Wall thickness: SDR 7.4 Size range: - 14 Faser-composite (expansion-controlled): Yes Maximum operating pressure at 50 F: 415 psi Maximum operating pressure at 180 F: 100 psi Recommended applications: Domestic (potable) hot water, food processing, light-hazard fire sprinkler Acceptable applications: Domestic (potable) cold water, heating, cooling, compressed air, chemical transport, and any other application suitable for PP-R

Cold water aquatherm greenpipe

Color: Green 1.12 Stripes: Light blue Wall thickness: SDR 11 Size range: - 18 Faser-composite (expansion-controlled): No Maximum operating pressure at 50 F: 220 psi Maximum operating pressure at 140 F: 93 psi Recommended applications: Domestic (potable) cold water, food processing Acceptable applications: Cooling, compressed air, chemical transport, and any other lower temperature application suitable for PP-R

Thick-wall climatherm
Color: Blue 1.13 Stripes: Green Wall thickness: SDR 11, 7.4 (1 or smaller only) Size range: - 18 Faser-composite (expansion-controlled): Yes Maximum operating pressure at 50 F: 350 psi Maximum operating pressure at 180 F: 62 psi Recommended applications: Compressed air, heating and cooling distribution, chemical transport, swimming pools (verify treatment levels), in-floor heating Acceptable applications: Irrigation and any other nonpotable piping application

Thin-wall climatherm
Color: Blue 1.14 Stripes: Green Wall thickness: SDR 17.6 Size range: 6 - 24 Faser-composite (expansion-controlled): Yes Maximum operating pressure at 50 F: 160 psi Maximum operating pressure at 140 F: 70 psi Recommended applications: Geothermal, district cooling, low-pressure cooling distribution, condenser water piping to cooling towers Acceptable applications: Any non-potable, low pressure, low temperature applications suitable for PP-R

aquatherm lilac
Color: Purple 1.15 Stripes: None Wall thickness: SDR 11 Size range: - 10 Faser-composite (expansion-controlled): No Maximum operating pressure at 50 F: 220 psi Maximum operating pressure at 100 F: 135 psi Recommended applications: Rainwater, greywater, reclaimed water, irrigation

Molded fittings
Single piece 1.16 - 4 fittings socket fuse over the pipe wall 6+ fittings butt weld in-line with the pipe All pipes use the same PP-R fittings Markings on the fittings Markings on the bag Keep fittings in their bags until ready for use Pressure rating meets or exceeds the pressure rating of the pipe

Segmented fittings
Usually 2 - 4 fused pieces 1.17 Butt weld in-line with the pipe 6 - 24 (elbows & tees) Made from Greenpipe or Climatherm to match piping system Size marked on label Stamped on the side to indicate origin Greenpipe fittings may be used with Climatherm installations -- do not use Climatherm fittings with Greenpipe installations Pressure rating meets the pressure rating of the pipe

Sizing
For most applications, use the same size Aquatherm pipe as you use for other piping materials. The lower friction and higher flow speed of PP-R compensates for the smaller ID which occurs in some sizes. The following table gives the flow rate based on an 8 ft/s flow speed. In some applications, Aquatherm pipes can run up to 12 ft/s. Higher head loss in some systems may require a larger pump. See the Aquatherm catalog or website for HL calculations.
Nominal diameter 1 1 1 2 2 3 3 4 GPM SDR 7.4 6.3 9.8 16.3 25.5 39.8 63.7 89.8 129 193 250 GPM SDR 11 8.0 12.6 20.8 32.3 50.5 80.2 114 164 245.9 317.0 GPM SDR 17.6 Nominal diameter 6 8 10 12 14 16 18 20 22 24 GPM SDR 7.4 409 639 1001 1604 2038 GPM SDR 11 519.3 812.4 1270 2020 2600 3252 4116 GPM SDR 17.6 611 954 1491 2367 3006 3817 4831 5964 7481 9468

1.18

Operating pressures
Systems with constant operating parameters (60-year expected minimum) 1.19 aquatherm greenpipe SDR 11 (non-faser) 220 180 135 112 93 aquatherm climatherm greenpipe SDR 11 (faser) SDR 7.4 (faser) Permissible working pressure (psi) 415 350 340 275 255 212 213 180 180 150 120 100 100 62 45 30

Temperature 50 F 80 F 100 F 120 F 140 F 160 F 180 F 200 F

climatherm SDR 17.6 (faser) 160 125 95 80 70 45 30 15

Operating pressures
Systems with constant operating parameters (25-year expected minimum) 1.20 aquatherm greenpipe SDR 11 (non-faser) 225 185 140 116 97 aquatherm climatherm greenpipe SDR 11 (faser) SDR 7.4 (faser) Permissible working pressure (psi) 420 360 360 280 260 220 220 185 185 155 140 115 110 75 55 45

Temperature 50 F 80 F 100 F 120 F 140 F 160 F 180 F 200 F

climatherm SDR 17.6 (faser) 165 130 100 85 72 55 35 20

Operating pressures
Systems with seasonal peaks (60-year expected minimum)

1.21

Temperature Regular load 160 F 160 F 160 F aquatherm greenpipe SDR 11 (non-faser) 125 Seasonal load 175 F 185 F 195 F

60 days at max. load

90 days at max. load

climatherm SDR 11 (faser) 90 80 70

climatherm SDR 17.6 (faser)

climatherm SDR 11 (faser)

climatherm SDR 17.6 (faser) 50 45 35

Permissible working pressure (psi) 55 85 50 75 40 65

Compressed air (assumes air temp < 100 F) aquatherm climatherm greenpipe SDR 11 (faser) SDR 7.4 (faser) Permissible working pressure (psi) 200 125 climatherm SDR 17.6 (faser) -

Aquatherm Greenpipe and Lilac Weights and capacities

aquatherm greenpipe faser-composite SDR 7.4
Pipe ND 1 1 1 2 2 3 3 4 6 8 10 Capacity gal/ft 0.013 0.024 0.034 0.053 0.083 0.133 0.187 0.270 0.402 0.521 0.854 1.333 2.084 Weight lb/ft 0.106 0.165 0.265 0.412 0.642 1.008 1.435 2.055 3.075 3.959 6.409 10.114 15.777 Pipe ND 12 14 Capacity gal/ft 3.340 4.242 Weight lb/ft 25.05 31.82

1.22

aquatherm greenpipe pipe SDR 11 Lilac SDR 7.4/11

Pipe ND 1 1 1 2 2 3 3 4 6 8 Capacity gal/ft 0.017 0.026 0.043 0.067 0.105 0.167 0.237 0.343 0.512 0.661 1.082 1.692 Weight lb/ft 0.073 0.111 0.178 0.279 0.433 0.682 0.951 1.374 2.107 2.639 4.311 6.713 Pipe ND 10 12 14 16 18 1 Capacity gal/ft 2.646 4.201 5.340 6.787 8.573 0.017 0.026 0.043 0.013 0.020 Weight lb/ft 10.442 16.564 21.033 26.74 33.84 0.726 0.106 0.173 0.099 0.155

The following items are supplied in coils

The following items are Lilac 7.4

Climatherm weights and capacities

climatherm faser-composite SDR 7.4/11
Pipe ND 1 1 1 2 2 3 3 4 6 8 10 Capacity gal/ft 0.013 0.024 0.043 0.067 0.105 0.167 0.237 0.343 0.512 0.661 1.082 1.692 2.646 Weight lb/ft 0.107 0.167 0.189 0.292 0.454 0.716 0.996 1.441 2.134 2.767 4.521 7.042 10.953 Pipe ND 12 14 16 18 1 Capacity gal/ft 4.201 5.387 6.787 8.573 0.017 0.026 0.043 Weight lb/ft 17.256 21.906 27.82 35.21 0.107 0.164 0.261

climatherm faser-composite SDR 17.6

Pipe ND 6 8 10 12 14 16 18 20 22 24 Capacity gal/ft 1.272 1.986 3.105 4.930 6.267 7.952 10.068 12.422 15.596 19.733 Weight lb/ft 2.93 4.57 7.11 11.25 14.25 18.10 22.86 28.27 35.31 44.71

1.23

The following items are supplied in coils

Aquatherm listings and approvals

NSF 14, 51 (Greenpipe only), 61 (Greenpipe only) 1.24 CFIA A508 (Greenpipe only) ICC ESR-1613/PMG Listing 1014 DIN EN ISO 9001 IPC 2009 Section 605 (Greenpipe, Lilac) IMC 2009 Chapter 12 IRC 2009 Chapter 21 & 56 UMC 2009 Chapter 12 UPC 2012 Chapter 6 (Greenpipe, Lilac) IAPMO File M-6022 IAPMO File 5053 (Greenpipe, Lilac) ASTM F 2389 CSA B137.11 CSA B214 BNQ 3660-950 (Greenpipe only) ISO 15874 ASTM F 2023 ASTM D 635 FM 1635 (Greenpipe 7.4 only) NFPA 13 D (Greenpipe 7.4 only) DIN EN ISO 14001

: Chapter 2 Heat fusion

Aquatherm is a rigid system, similar to copper and steel. Proper training helps ensure proper connections. Your own care and attention to detail will yield impressive results, whereas sloppy workmanship will yield poor results. This chapter will cover the basic techniques for heat fusing pipe. From there, it is up to you to provide the quality labor that will make each installation a work of art. 2.1

Socket fusion

Outlet fusion

Butt fusion

Electrofusion

Safety
There are procedures that should be followed to work safely with Aquatherm pipe. These include: Take proper precautions around electrical equipment and follow all instructions. 2.2 Follow Aquatherm-specific guidelines for proper material installation. Wear steel-toe shoes. Wear safety glasses.

Wear heat-resistant gloves while handling welding irons. Be careful when handling hot irons or irons that may be hot.

Wear a rated hard hat at all times.

Tooling
Working with Aquatherm pipe requires tools that meet certain criteria. For cutting the pipe, you may use saws and blades from any manufacturer, as long as the cutting tools meet the requirements laid out in this manual and produce acceptable results. For fusing the pipe, Aquatherm provides a few basic tools to installers. However, for better selection, pricing, and support, installers are encouraged to use tools from an approved tool manufacturer instead. As of the printing of this edition, Aquatherm has approved tool lines from McElroy, Ritmo, Widos and ASDAC. Each of these manufacturers provides tools with the correct sizings, temperatures, and pressure settings to work with Aquatherm pipe. Contact information for these manufacturers can be found near the end of this chapter. For handling and supporting the pipe, you will need to use hangers and clamps that are compatible with the metric sizes of Aquatherm pipe. You will also need to ensure the clamps will not damage the pipe or fittings. More information regarding hangers and clamps can be found in chapter 3 of this manual. 2.3

Cutting the pipe

Ratchet cutters and tube (rolling) cutters give clean edges that are easy to fuse. Cuts should be as square as possible (never more than 5). Always use sharp cutters, as dull cutters can crack the pipe. Check for longitudinal cracks on the pipe wall after each cut.

2.4

Use ratchet cutters with a sharp, pointed blade. The pointed blade prevents the pipe from ovaling during the cut.

Dont use ratchet cutters with a dull or flat blade. Dull or flat blades can oval the pipe and cause it to crack.

Support the pipe while cutting to prevent bouncing or snapping.

Use tube cutters with a wheel wider than the pipe wall. Smaller wheels might not reach through the entire pipe wall.

Hacksaws are a safe alternative, even in cold weather.

Cutting the pipe

When using hand saws, use plastic or metal-safe teeth. With powered saws, blades that are intended for hardwood will yield the best results. Avoid jagged or angled cuts, as these require additional prep to fuse.

2.5

Use a circular hardwood blade (60-100T) with carbide teeth. This will produce a cut that needs little to no clean-up.

Band and reciprocating saws are safe to use. The thinner blades leave a smooth cut, but you will also have some shavings.

A wide-toothed blade (24-40T) will produce a jagged cut that is rough and not desirable for socket fusion.

A fine-toothed blade (180T) will overheat the pipe, as will cutting too slowly. Make your cut as quickly and squarely as possible.

Dont use power cutters if the pipe is 40 F or colder. Cold pipe has a chance to crack and split.

Inspecting the cut

Upon receiving the pipe and after cutting it, inspect the ends for cracks or damage. Mark and remove damaged sections, cutting a few inches past the damage. Fusing pipe that is cracked will result in joints that leak.

2.6

Remove any debris left from cutting the pipe. This is common with powered saws. Often, you can simply pull them out by hand. You may need to carefully cut them away with a blade or reaming tool.

A good cut is smooth, square, and has no cracks or stress marks inside or outside the pipe.

Remove standing dirt and oil using an alcohol-based cleaner. Dirty pipe will not form proper beads during fusion. Be careful not to wipe off the printed label.

White stress marks and cracks indicate damage. Reassess any cutting tools that leave cracks. You may need to squeeze the end of the pipe to see small cracks.

How fusion works

2.7

PP-R plastic is made up of small chains of hydrogen and carbon. When cold, the chains are closed and wont react or bind with most common chemicals.

As the pipe is heated, the chains open and can be pressed together to form a connection. Pressure causes the chains to cross the gap, eliminating any leak path.

When they cool, the chains close again, forming a connection that is identical to the original material. This makes for a perfect connection with no foreign materials or leak path.

Avoiding improper fusions

Dont twist the fitting Never twist a fusion connection. Twisting breaks the chains while they cool and will lead to a weakened connection. You may make some minor adjustments early in the cooling process, but avoid turning the fitting more than 2 degrees.

2.8

Prevent water contact Like oil, PP-R is hydrophobic and repels water. Any water contact on the fusion area will cause the chains to close and prevent a proper fusion. Make sure the pipe is dry before beginning the fusion and that rain/snow cannot reach the fusion surfaces.

Use enough heat/Dont wait to fuse Insufficient heat will cause the chains to close early, preventing a full connection. This can be caused by the iron being too cold, an extended delay after removing from the iron, or insufficient heat time. Make sure that you follow all the instructions while fusing and that your iron has sufficient power.

Socket fusion
In socket fusion, a fitting is fused over the outside of the During fusion, the inside layer of the fitting is removed, pipe, leaving the inside open and unrestricted. as is the outside layer of the pipe.

2.9

The fittings are sized to be too small to fit over the pipe unheated. This makes dry-fitting impossible, so connections cannot be accidentally left unfused. Also, the difference in thickness between the fitting and pipe creates the required pressure for fusion.

The heating process removes surface impurities and allows the pipe to be inserted into the fitting. The inner wall of the fitting fuses to the outer wall of the pipe, forming a bond that is stronger than the pipe wall itself. The connection forms on the entire fused surface.

Welding heads
Socket fusions are made using welding heads. Welding heads are specifically sized to match the pipe and fittings for a perfect fit. Different welding head sets are required for each size of pipe.

Size markings

Threaded bolt Taper for easier fusion

2.10

Heads store inside each other to avoid scratches. Before setting up the iron, clean the welding heads with rubbing alcohol or a similar non-corrosive agent if they are dirty. Pipe (female) side

Teflon-coated Fitting (male) side

Stopline

Welding irons
The welding heads can be interchangeably attached to a welding iron, which provides the heat for the fusions.
Power cord (electric irons give more consistent temperatures over time) Heat shield Neck brace Heating plate

2.11

Heat cycle indicator (turns on while iron is heating, turns off when iron reaches preset temperature) Power indicator Heat sink Welding heads

1-inch iron

4-inch iron

2-inch iron

Welding iron safety : Do

Compared to open flames or noxious glues, a welding iron is fairly safe to use. However, the iron is hot enough to burn on contact and can remain hot for 30 minutes after it is unplugged. Take care in its use and handling. Never use water to cool an iron or head.

2.12

Wear heat-resistant gloves while handling the iron. Few gloves are heat-proof, so know the limitations of your gloves.

After use, return the iron to its case for storage. The case will protect the iron from impact and damage.

Post a sign near irons to warn that they are hot. Irons can remain hot for up to 30 minutes after being turned off.

Be aware of where other people are at all times while fusing. Make sure they are clear before you move the hot iron around.

Keep the cord away from the heat surfaces. Some cords are heat-resistant, but it is best to avoid finding which are which.

Welding iron safety: Dont

2.13

Dont leave the iron unattended. Passers-by may not know if the iron is hot and could accidentally burn themselves.

Dont drop the iron or hold it by its cord. The cord is not intended to hold weight and dropping the irons will break them.

Dont touch the iron with bare hands unless you are certain the iron has cooled. Assume irons and heads are hot until tested.

Dont store multiple irons in a single box. Irons can easily damage each other and should be stored separately.

Dont let the iron touch flammable or meltable surfaces. This is a fire hazard and can damage the plate or heads.

Dont use the welding iron if the plate or heads are dirty. Clean the plate with a soft wire wheel and the heads with a cloth.

Tool assembly
Plug in the iron early, as it will take 5-10 minutes to heat up. Make sure that you have sufficient power for the iron. Low-gauge extension cords can be used to deliver power over long distances if needed. Be aware of other devices drawing power if you are using a limited power source, as this can cause fluctuations in temperature. Use a compatible power source for your iron. A surge protector will protect the iron from on-site power surges.

2.14

Set welding heads loosely in place while the iron heats up. The plate will expand as it heats and leave indentations if the heads are too tight.

When the iron is hot, tighten the welding heads for full contact. Full contact will ensure uniform heating of the welding head.

Check the temperature using a digital thermometer. Test on the inside of the welding heads (at close range if using an infrared thermometer). The temperature for socket fusion should always be around 500 F (+/- 18 F). If the iron constantly cycles on and off, or if the heating phase takes a long time, there may be a power supply issue. If the iron does not reach 500 F or goes past it, the thermometer may be faulty. Use a contact thermometer if you are unsure.

Marking the pipe

The marking guide helps ensure proper insertion depth. The green marking guide ( - 4) is ideal for smaller pipes and the blue marking guide is designed for larger pipes (2 - 4). Marking on several sides can help you line up the connection.

2.15

Under-inserting will weaken the connection by reducing the amount of fusing surface.

Over-inserting will form a bead inside the fitting, causing a restriction in the pipe. If the cut is slightly angled (but not enough to prohibit fusion), make only one mark on the long side. Use this mark to prevent over-insertion. Inserting to a mark on the shorter side will leave a partial bead in the pipe. Inserting to the long side will leave a slight internal gap, but this will not affect the connection strength.

When using the blue marking guide, insert the fitting to the beginning of the mark, not the middle. The bead may roll over during fusion and cover the initial mark, so the tail shows that the pipe was properly marked upon inspection. Add a tail if using a green guide on large pipe.

Heating times
Column A: Nominal diameter in inches
This is the size of standard pipe that the Aquatherm pipe normally replaces. In some cases, it may be possible to use a smaller Aquatherm pipe based on flow rate.

Column F: Heating time for cold weather

For 40 F or colder, use these times. You may also use these times if you are having a hard time inserting the pipe all the way into the fitting within the welding time (G) but be careful not to overheat the pipe.

Column B: Metric OD in mm 2.16

This is the manufactured size of the pipe.

Column G: Welding time

This is the window of time from when you begin inserting the pipe completely into the fitting before it cools. If you exceed this time, you risk having the connection cool off and cause an incomplete insertion. If you cannot fully insert the pipe into the fitting in this time, get another installer or a fusion machine to help you.

Column C: Actual OD in inches

This is the actual size of the pipe in inches. Use this for sizing clamps and spaces.

Column D: Welding depth in inches

This is the depth the pipe should be inserted into the socket fitting. Use this for planning the length of a cut and if no marker is available.

Column H: Cooling time

Pipe should not be pressurized or stressed during this time. You will need to fully support the pipe for up to of this time while the connection sets. *When using SDR 11 non-faser pipe in small sizes ( & ), reduce the observed time by 1 second to avoid overheating and collapsing the pipe wall. Insert the pipe into the fitting as quickly as possible.

Column E: Heating time for normal weather*

Usually 40 - 100 F. Reduce this time slightly if working in extreme heat (100 F+). Never use less than 80% of the heat time in these circumstances.

Heating times table

Pipe diameter ND (inch) A 1 1 1 2 2 3 3 4 OD (mm) B 20 25 32 40 50 63 75 90 110 125 Actual OD (inch) C 0.79 0.98 1.26 1.57 1.97 2.48 2.95 3.54 4.33 4.92 Welding depth inch D
9 16 58

Heating time in sec. above 40 F E 5 7 8 12 18 24 30 40 50 60 below 40 F F 8 11 12 18 27 36 45 60 75 90

Welding time sec. G 4 4 6 6 6 8 8 8 10 10

Cooling time min. H 2 2 4 4 4 6 8 8 8 8

2.17

11 16

13 16 15 16

1 1
18

1
5 16

1 9 16

Socket fusion instructions (page 1 of 2)

In socket fusion, you are heating the outside of the pipe and fusing it to the inside of the fitting. This creates a large joining surface with no leak path, so proper connections will never leak or blow off. You must use the properly sized welding heads for a proper fusion. These heads are available through Aquatherm and approved tool manufacturers (page 2.3). The heating times (columns E or F) begin then the pipe and fitting are fully inserted onto the welding head,

2.18

Insert the pipe and fitting into the iron. Pushing both sides at the same time helps hold the iron steady.

Stop the pipe when you hit the mark (column D). Over-insertion will cause a restriction in the pipe and lower performance.

Stop the fitting when you reach the stopline (page 2.10). Tapered heads will offer little resistance until just before the stop.

Observe the heating time (column E or F). A bead will form and become shiny as the fusion nears readiness.

Socket fusion instructions (page 2 of 2)

Remove fitting and pipe from welding heads. Use a clamped stand or an extra hand to hold the iron in place.

Immediately* insert the pipe into the fitting. Push the pipe until the rings meet within the welding time (column G).

2.19

Do not touch the face of the pipe to the edge of the fitting. This flattens the beads and can cause an improper connection.

Once the rings meet, you will have 5 to 15 seconds to make adjustments to the alignment, depending on the pipe size.

Align the pipe and observe cooling time (column H). You may need to provide full support for at least 1/4 of the cooling time.

*You will normally have 5-10 seconds to begin joining the connection after you remove it from the iron. This time will vary with pipe size and conditions. Waiting too long will let the pipe surface cool and make fusion impossible.

Inspection
The following indicators will allow you to know that your connections have been performed properly. However, you will still need to do a pressure test to confirm the integrity of the joint. 2.20 Information on the pressure test can be found on page 3.40. Certain fusion assistance machines have integrated depth controls. These controls should be used for their accuracy, but it is best to mark the pipe for inspection. Some machines will not bring rings completely together, but this is acceptable as long as the gap is consistent and the pipe reaches the inside of the fitting.
Both rings of PP-R should be visible and joined all the way around. The edge of the mark should be visible to indicate that the proper insertion depth was reached.

The pipe should be square with the fitting. If intentionally angled, the angle per connection should not exceed 1 degree.

Troubleshooting bad connections

Pipe wont fully insert into fitting Welding heads are too cold Make sure temp > 475 F Extended delay after removing from iron Fuse immediately after heat time Insufficient heating time Increase heating time by up to 50% Fusion machine depth control is set to the wrong size Double-check machine settings Marks no longer visible/internal bead Over-insertion Verify marking depth and stop just before the marks Fitting does not look square Insufficient support during cooling Hold pipe squarely for at least 25% of the cooling time Fitting was overheated Reduce heating time slightly The pipe sheets back instead of forming a bead Pipe too dirty for fusion Clean pipe before fusing 2.21

No ring visible Only one side heated Make sure both sides are heated

Problem Possible cause Solution

Assisted fusions
When fusing sizes larger than 2, it may be difficult to make the connections by yourself. There are several tips for assisted (two man) fusions: Increase the heating time by up to 50% if needed. It can take longer to fuse the pipe and fitting by hand, so overheating them makes the connection easier and prevents it from sticking midfusion. The ideal amount of overheating depends on the ambient temperature, the size of the pipe, and the strength of the installers. Use your best judgment to prevent the pipe from becoming too soft. Dont waste time. Once the pipe and fitting are removed from the iron, push them together immediately. PP-R doesnt burn while heating, so you can put the pipe and fitting back on the welding heads and start again if the connection is underheated. Pipes and fittings may be safely reheated once after the initial heating. Mark the pipe on several sides. This will help you line up the fitting squarely. If you cant push the pipe or fitting all the way onto the iron, allow the heat to melt the PP-R and then continue. Remember that the fitting welding heads are tapered, so they will not offer much resistance until the fitting is almost entirely on.

2.22

Mechanically assisted fusions

For larger fittings, it is generally faster and more accurate to use a fusion machine. Fusion machines act as an additional set of hands during the fusion, aligning the pipe and fitting while providing a mechanical advantage. There are many different types of fusion machines. Some lighter machines are easier to operate overhead, but may not offer additional support or have a way to hold the iron for you. Heavier bench-style machines offer increased stability and accuracy, but are less mobile. Other fusion processes, such as butt welding and electrofusion, require special tools to complete them. These, as well as the tools for socket fusion, are available from Aquatherms approved tool manufacturers. These manufacturers supply properly sized tools for Aquatherms piping systems and have an established history of providing excellent support to Aquatherm installers. A complete list of these manufacturers can be found at the end of the chapter. Do not use fusion tools from an unapproved manufacturer.

2.23

ASDAC welding jig instructions (page 1 of 2)

The Aquatherm welding jig is well suited for assisting overhead connections where the iron cannot be left in a clamp or stand. However, the jig does not provide any additional support, so the pipe should be on hangers or in clamps.

1
Insert the jaws into the slides on the jig. Alternatively, you can secure the jaws to the pipe and then attach the jig. If you are using an older model, set the jaws in the slot matching the pipe size. Models with offset jaws will not work on odd-sized fittings, such as flanges and bushings, so those connections must be done by hand or with another machine. Newer jig models simply open and close on center and work with all socket fittings (as shown here).

Lock the jaws in place. The locking mechanism may vary by model. Keep all moving parts clean and oiled.

Use the bit and an impact driver or drill to provide power. Dont leave your driver hanging from the jig.

2.24

Tighten jaws against the pipe and fitting. One jaw has a lip that the fitting sits against. The fitting should touch all four faces on the clamp. This lip will help you square up the fitting during the fusion. Make sure both jaws are tight enough to prevent slipping. Use gloves when handling the clamps, as the jaws can be very sharp. Make sure the pipe is fully supported independently of the jig in order to avoid connections that are not square.

ASDAC welding jig instructions (page 2 of 2) Pro tip:

Push the pipe and fitting onto the iron. Stop when you reach the mark and reverse slightly to correct any deflection.

Heat the pipe and fitting following normal procedures and times, as found on page 2.17. Hold the iron in a neutral position.

Avoid motor damage by using short bursts to drive the jig during the heating phase. If the jig is struggling, give the iron time to heat the pipe and fitting before continuing. Let the iron do the work. This will give you better results and extend the life of your welding jig.

2.25

Reverse the jig and remove the iron. Take care not to smash the bead or pipe end while doing this.

Bring the heated pipe and fitting together as quickly as possible. Stop when the beads meet and do not over-insert the pipe.

Square up the jaws as soon as you bring them together to help avoid deflection. Remove jig once the connection has set.

Fusion outlets
Using a technique similar to socket fusion, branches and outlets can be easily added to the walls of the pipe. This technique helps save time and money while providing flexibility for expansion following installation.
Fusion outlet Main size Branch size Guide bit

2.26

Drilling bore

Curvature matches pipe wall

Pipe-wall insert Pipe-side welding head

Fitting-side welding head

Fusion outlet instructions (page 1 of 3)

When drilling out a fusion outlet hole, there are two important things to remember: 1. Make sure to remove the material from the hole so it will not clog the main line. 2. The hole needs to be 1-3 mm (124 - 18) smaller than the OD of the branch line. Aquatherms boring tools are designed to do both. The smaller bores can use a hand-held drill. Bores over 2 inches require a drill press with a Morse Taper shank. You may use hole saws or bores provided by other manufacturers, so long as they can cut a smooth, even, and properly sized hole. An oversized hole will result in an incomplete fusion. An undersized hole will make it difficult to insert the welding head. 2.27

Mark the pipe where you want the outlet. Once you begin drilling, you cannot move the hole, so be sure of your placement.

Use the guide bit to start the hole to ensure accurate positioning. Drill at a right angle to the pipe.

Quickly drill out the hole. The bore should pull the shavings out so that they dont fall into the pipe.

Fusion outlet instructions (page 2 of 3)

2.28

Clear away any excess debris. Flush any leftover shavings when you flush the rest of the system.

Set up the welding iron following normal socket procedures, found on page 2.14.

Dont forget to tighten the welding heads after the plate is hot and check the temperature before starting.

Pro tip:

The welding head should not stick out past the iron. This will lead to uneven heat transfer and can prevent proper fusion.

Insert the welding head into the hole and fitting into the head. Push down gently to keep the iron in contact with the PP-R.

For branches smaller than 2, dont use the fitting to push the iron into the pipe. This overheats the fitting. Instead, push the welding head into the pipe, and then set the fitting on the iron. For larger sizes, you may use the fitting to push the welding head into the pipe.

Fusion outlet instructions (page 3 of 3) Pro tip:

Rather than putting excessive force on the neck of the iron, you may use a dowel or a board to help push the iron into the pipe.

Make sure the welding head you are using matches the pipe and fitting. In an emergency, it is possible to use a head with the wrong curvature, but you must have the right branch size. Turning the welding head slightly from side to side can help ensure contact at all points.

Look for a ring to form around fitting, This does not take much pressure. Too much pressure will cause internal restriction.

2.29

Ensure the welding head makes a full impression on the pipe. Check and adjust the head until the ring is complete.

10

Set the fitting in the hole and hold in place. Use only enough pressure to maintain contact between the heated surfaces.

11

Level and square the fitting as it cools. Like the socket fittings, you only have a few seconds before the fitting sets.

12

Electrofusion
Electrofusion is another technique for fusing a socket onto a pipe. Rather than using contact heat, electrofusion uses electrical resistance heat from a copper coil inside the fitting. The fitting is attached to an electrofusion machine using a pair of leads, and a set voltage is applied to the coil for a set time. The time and voltage can be found on the label of the fitting. 2.30 Electrofusion is particularly useful for situations where there is not enough space or mobility to perform a traditional socket fusion. However, electrofusion has more steps and is more difficult to visually inspect. Therefore, the choice to use electrofusion over traditional socket fusion depends on the physical restrictions of the installation and the installers preferences. Electrofusions may be integrated with traditional socket fusion and butt welding if necessary. Electrofusion machines are available from approved tool manufacturers. It is best to plug in the machine and familiarize yourself with the controls and interface before beginning the electrofusion process.

Electrofusion instructions (page 1 of 3) Pro tip:

Make sure the pipe is cut exactly square. Chamfer or ream the pipe to remove any rough edges.

Use a peeling tool to remove the outside of the pipe. Peel back at least half the length of the coupling being fused.

Multiple passes may be necessary. Peeling tools are available from approved manufacturers. Make sure that you use metric or metric compatible peelers. Avoid over-peeling the pipe. You can always make one more pass, but you cannot unpeel the pipe.

2.31

Repeat with the other pipe. If you are using the fitting as a slip coupling, peel one side back the entire length of the coupling.

Clean the outside of the pipes with an alcohol wipe. Avoid touching those surfaces after cleaning them.

Dont open the fitting bag until you are ready to fuse the connection. This helps keep dirt and damage off of the fusion surface.

Electrofusion instructions (page 2 of 3)

2.32

Mark the pipe at half the depth of the fitting. The two pipe sections will meet in the middle of the fitting.

Do not touch the peeled pipe or inside the fitting. Any oils, dirt, dust, or other contaminants may ruin the connection.

Insert pipe into the fitting. The pipes should fit snugly, but without any force. You should be able pull them apart.

Pro tip:
If the fitting cannot be pushed into the coupling without a significant amount of force, make another pass with the peeling tool. Remember to wipe the welding surface with rubbing alcohol, as the peeler may be dirty.

Attach the leads to the fitting. Most leads slide in with little resistance, so dont force them. Be careful not to bend them.

Make sure there is no gap in the middle. You wont be able to see the gap, so use your depth marks.

Electrofusion instructions (page 3 of 3)

Scan the tag on the fitting. Rescan if needed. On smaller couplings, the tag can be removed and laid flat for better reading.

Verify that the display matches the sticker. If the label and the machine dont match, rescan the fitting label or input manually.

10

Follow the directions on the machine. Verify your prep work and then begin heating upon confirmation.

11

2.33

Make sure both sides of the pipe and fitting are fully supported for the entire fusion process. The fitting will become extremely soft after it is heated and will lose its shape if subject to any stresses.

Remove leads when heating is finished. The pipe and fitting will get hotter before cooling down again.

12

The black indicator on the top of the fitting will drop in after the connection is done heating, as long as the electrical leads are pointing up. You will only be able to verify the fusion during the pressure test. All electrofusion sockets are rated to 300 psi.

Butt welding machine

Butt welding is a process by which two pipes are joined at the ends using heat fusion. This eliminates the need for a socket-type fitting while maintaining the full strength of the connection. As with any fusion, the primary elements are heat and pressure. Therefore, a butt welding machine is designed to provide both, as well as support the pipe and prepare the pipe face for fusion. 2.34
Unit controls (vary by manufacturer) Carriage Hydraulic cylinders Compressor

Aquatherm only supports butt welding on sizes larger than 4. Installers may decide to butt weld smaller sizes, at their own risk.

Hydraulic hoses Clamps Inserts for clamps (not shown)

Explanation of butt welding

Before beginning, review the heating pressures and times for the pipe and machine you are using. Aquatherms pipes are optimized for the DVS standard on heat fusion, which is different from the PPI standard commonly used for PE piping. Aquatherms PP-R fuses best using an interfacial pressure of 1 bar (14.5 psi). The interfacial pressure is the actual pressure per square inch between the pipe faces and is generally much lower than the cylinder or gauge pressure. The difference between the interfacial pressure and gauge pressure is dependent on the size of the hydraulic cylinders and the thickness of the pipe walls being fused. As a result, there are different welding pressures for each size and SDR of pipe for each machine. Tables for each of the approved machines can be found starting on page 2.40. If there is any discrepancy between the tables here and the manufacturers recommendations, consult your trainer or your Aquatherm sales representative. Make sure you have been trained on the specific brand of machine you are using before beginning the installation. The heating and cooling times for each size and SDR is the same, regardless of the machine being used. Tables giving the times and pressure for each size can be found starting on page 2.37.

2.35

Butt welding overview

The following instructions are the basic steps for a proper butt welding. More detailed instructions can be found after the charts. Calculate: Assess the heating time, cooling time, adjustment bead height, controls, welding pressure, drag pressure, etc. Heating and cooling times vary with pipe size and wall thickness. Gauge pressure varies by machine and cylinder size. Write these numbers down if you wont be able to remember them. Prepare: Set up the machine, turn on the iron, set and align your pipes and/or fitting, etc. This step depends greatly on the machine you are using and the configuration of the connections. Face: Plane and clean the faces for fusion. Adjust: Push out the top layer of the pipe, exposing new PP-R for the fusion. This is done at full pressure and determines the size of the bead when you are finished. Heat: Allow heat to permeate the pipe at little to no pressure. In this step, heat is soaking as deeply into the pipe as possible without pushing up a larger bead. Weld: Push the heated ends of the pipe together and allow them to cool under pressure. The pressure helps form solid connections that are as strong or stronger than the original pipe.

2.36

Butt welding heating and cooling times (6 - 12)

Dimension ND (OD mm) 6 (160 x 9.1) 6 (160 x 14.6) 6 (160 x 21.9) 8 (200 x 11.4) 8 (200 x 18.2) 8 (200 x 27.4) 10 (250 x 14.2) 10 (250 x 22.7) 10 (250 x 34.2) 12 (315 x 17.9) 12 (315 x 28.6) 12 (315 x 43.1) SDR 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4 Heating Heating time 3 min. 24 sec. 4 min. 37 sec. 6 min. 1 sec. 3 min. 57 sec. 5 min. 20 sec. 6 min. 52 sec. 4 min. 32 sec. 6 min. 8 sec. 7 min. 46 sec. 5 min. 17 sec. 7 min. 8 min. 40 sec. 6 sec. 8 sec. 10 sec. 7 sec. 9 sec. 11 sec. 8 sec. 10 sec. 13 sec. 9 sec. 12 sec. 15 sec. Welding (Fusion) Max. transition time Time of pressure build-up 9 sec. 13 sec. 19 sec. 11 sec. 16 sec. 23 sec. 13 sec. 20 sec. 30 sec. 16 sec. 24 sec. 37 sec. Cooling Cooling time 15 min. 24 min. 34 min. 19 min. 29 min. 42 min. 23 min. 35 min. 52 min. 28 min. 44 min. 62 min.

2.37

Butt welding heating and cooling times (14 - 24)

Dimension ND in (OD mm) 14 (355 x 20.1) 14 (355 x 32.2) 14 (355 x 48.0) 16 (400 x 22.7) 16 (400 x 36.3) 18 (450 x 25.5) 18 (450 x 40.9) 20 (500 x 28.4) 22 (560 x 31.7) 24 (630 x 35.7) SDR 17.6 11 7.4 17.6 11 17.6 11 17.6 17.6 17.6 Heating Heating time 5 min. 41 sec. 7 min. 28 sec. 9 min. 25 sec. 6 min. 7 sec. 8 min. 6 min. 35 sec. 8 min. 28 sec. 6 min. 59 sec. 7 min. 24 sec. 7 min. 55 sec. 9 sec. 13 sec. 17 sec. 10 sec. 14 sec. 11 sec. 15 sec. 12 sec 12 sec. 14 sec. Welding (Fusion) Max. transition time Time of pressure build-up 18 sec. 28 sec. 42 sec. 20 sec. 31 sec. 22 sec. 36 sec. 24 sec 27 sec. 31 sec. Cooling Cooling time 32 min. 48 min. 70 min. 35 min. 54 min. 39 min. 59 min. 43 min. 48 min. 53 min.

2.38

Adjustment bead height (6 - 24)

Size 6 (160 mm) 8 (200 mm) 10 (250 mm) 12 (315 mm) 14 (355 mm) 16 (400 mm) 18 (450 mm) 20 (500 mm) 22 (560 mm) 24 (630 mm) SDR 7.4 0.06 (1.5 mm) 0.08 (2.0 mm) 0.08 (2.0 mm) 0.1 (2.5 mm) 0.1 (2.5 mm) SDR 11 0.04 (1.0 mm) 0.04 (1.0 mm) 0.06 (1.5 mm) 0.08 (2.0 mm) 0.08 (2.0 mm) 0.08 (2.0 mm) 0.1 (2.5 mm) SDR 17.6 0.04 (1.0 mm) 0.04 (1.0 mm) 0.04 (1.0 mm) 0.04 (1.0 mm) 0.06 (1.5 mm) 0.06 (1.5 mm) 0.06 (1.5 mm) 0.08 (2.0 mm) 0.08 (2.0 mm) 0.08 (2.0 mm)

The height of the bead is important during the fusion, as too small of a bead may lead to an improper connection, whereas too large of a bead can create a flow restriction. You will need to carefully watch the bead during the adjustment phase and reduce the pressure once the bead reaches its required height. Remember that 1 mm is only 1/25th of an inch and is difficult to measure. Generally, when you can first see the bead, that is when it is at the 1 mm height. If your final bead (when the connection is all finished) looks too large, try reducing the size of your adjustment bead slightly.

2.39

Bead height reference

1 mm 1.5 mm 2 mm 2.5 mm

McElroy adjustment and welding pressures

Pitbull 26 15 Lever 28 Low Force DM 250 EP 412 & 618 Low Force 412, 618, & T500 Med Force 824 & 1236 Low Force 824 & 1236 Med Force

Installers should always use the operators manual included with the butt welding machine, or the manufacturers online information, to calculate the adjustment pressure. This table is based on the information available to Aquatherm at the time of this manuals printing and may not be complete, accurate, or current. If there is a discrepancy between this table and any information provided by the tool manufacturer, the tool manufacturers information shall be considered correct.

Dimension ND (OD mm) 6 (160 x 9.1) 6 (160 x 14.6) 6 (160 x 21.9) 8 (200 x 11.4) 8 (200 x 18.2) 8 (200 x 27.4) 10 (250 x 14.2) 10 (250 x 22.7) 10 (250 x 34.2) 12 (315 x 17.9) 12 (315 x 28.6) 12 (315 x 43.1)

SDR 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4

Adjustment pressure (psi) 9 ft-lbs 14 ft-lbs 20 ft-lbs 60 93 132 94 145 207 60 93 132 94 145 207 142 218 309 32 49 70 50 77 109 78 120 170 124 191 270 17 26 37 26 40 58 41 63 90 65 100 141 17 26 36 26 40 56 41 63 90 10 16 23 16 25 35 25 39 55

2.40

McElroy adjustment and welding pressures

412 & 618 Low Force 412, 618, T500 Med Force 82 126 179 104 161 132 203 163 824 & 1236 Low Force 52 81 114 66 102 84 129 104 130 164 824 & 1236 Med Force 32

Dimension ND (OD mm) 14 (355 x 20.1) 14 (355 x 32.2) 14 (355 x 48.0) 16 (400 x 22.7) 16 (400 x 36.3) 18 (450 x 25.5) 18 (450 x 40.9) 20 (500 x 28.4) 22 (560 x 31.7) 24 (630 x 35.7)

SDR

Adjustment pressure (psi) 17.6 11 7.4 17.6 11 17.6 11 17.6 17.6 17.6 157 242 343 199 308 252 389 -

2.41

50 70 41 63 52 80 64 80 101

Ritmo adjustment and welding pressure

Dimension ND (OD mm) 6 (160 x 9.1) 6 (160 x 14.6) Delta Dragon 160 247 392 551 Delta Dragon 250B 116 189 276 189 290 421 305 464 653 Delta Dragon 315B 102 160 232 160 261 363 261 406 566 406 638 914 Delta Dragon 355B 44 73 102 73 102 160 102 160 232 174 261 377

SDR 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4

Adjustment pressure (psi)

2.42

6 (160 x 21.9) Installers should always use the operators manual included with the butt welding machine, or the manufacturers online information, to calculate the adjustment pressure. This table is based on the information available to Aquatherm at the time of this manuals printing and may not be complete, accurate, or current. If there is a discrepancy between this table and any information provided by the tool manufacturer, the tool manufacturers information shall be considered correct. 8 (200 x 11.4) 8 (200 x 18.2) 8 (200 x 27.4) 10 (250 x 14.2) 10 (250 x 22.7) 10 (250 x 34.2) 12 (315 x 17.9) 12 (315 x 28.6) 12 (315 x 43.1)

Ritmo adjustment and welding pressure

Dimension ND (OD mm) 14 (355 x 20.1) 14 (355 x 32.2) 14 (355 x 48.0) 16 (400 x 22.7) 16 (400 x 36.3) 18 (450 x 25.5) 18 (450 x 40.9) 20 (500 x 28.4) 22 (560 x 31.7) 24 (630 x 35.7) Delta Dragon 355B 218 334 479 Delta Dragon 500 174 276 218 334 276 Delta Dragon 630 73 102

SDR 17.6 11 7.4 17.6 11 17.6 11 17.6 17.6 17.6

Adjustment pressure (psi)

2.43

160 87 131 116 174 145 174 218

Widos adjustment and welding pressures

Dimension ND (OD mm) 6 (160 x 9.1) 6 (160 x 14.6) Maxiplast WI 4400 261 392 566 WI 4900 116 174 247 174 261 377 261 406 580 421 638 WI 5100 & 5500 73 116 160 116 174 247 174 276 WI 6100 145 218 -

SDR 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4 17.6 11 7.4

Adjustment pressure (psi) 94 145 207 -

2.44

6 (160 x 21.9) 8 (200 x 11.4) Installers should always use the operators manual included with the butt welding machine, or the manufacturers online information, to calculate the adjustment pressure. This table is based on the information available to Aquatherm at the time of this manuals printing and may not be complete, accurate, or current. If there is a discrepancy between this table and any information provided by the tool manufacturer, the tool manufacturers information shall be considered correct. 8 (200 x 18.2) 8 (200 x 27.4) 10 (250 x 14.2) 10 (250 x 22.7) 10 (250 x 34.2) 12 (315 x 17.9) 12 (315 x 28.6) 12 (315 x 43.1)

Widos adjustment and welding pressures

Dimension ND (OD mm) 14 (355 x 20.1) 14 (355 x 32.2) 14 (355 x 48.0) 16 (400 x 22.7) 16 (400 x 36.3) 18 (450 x 25.5) 18 (450 x 40.9) 20 (500 x 28.4) 22 (560 x 31.7) 24 (630 x 35.7) WI 5100 & 5500 218 348 290 435 363 551 435 WI 6100

SDR 17.6 11 7.4 17.6 11 17.6 11 17.6 17.6 17.6

Adjustment pressure (psi) 189 276

2.45

232 348 290 450 363 450 566

Butt welding instructions (page 1 of 6)

Only perform maintenance on a machine if you are trained to do so. Otherwise, maintenance should be performed by the manufacturer or authorized dealer. Only refill the hydraulic oil according to the manufacturers specifications. Make sure that your power supply is fully compatible with the machine you are using.

2.46

Set up and inspect the machine. Follow all of the manufacturers directions. Perform any maintenance if needed.

Check and tighten seals if needed. Release any air bubbles by bringing the machine to full pressure and slowly releasing it.

Inspect welding iron and turn it on. Make sure that the iron is clean and set to 410 F (210 C) +/- 18 F.

Set in the correct metric inserts, if needed. The manufacturer will know which clamps and inserts are compatible.

Cut the pipe as squarely as possible. Jagged cuts will require more planing, which takes additional time and dulls the facer blades.

Butt welding instructions (page 2 of 6)

Set pipe and/or fitting into the clamps. If possible, use at least 2 clamps for each pipe length. Adjust configuration as needed.

Leave a lip of 1/2 - 1 (more if cut is uneven). A thumbs width is normally a good measurement. Leave room for the facer.

Reposition clamps to accommodate fittings if needed. Some clamps slide and others can be removed entirely.

2.47

Tighten clamps and bring the pipe ends together. Make sure all hands are clear of the carriage while it is in motion.

Increase the pressure control until the carriage begins to move, taking note of what pressure it begins to move at. This pressure is called drag pressure. Add the drag pressure to your adjustment and welding pressures. Full pressure is the adjustment (welding) pressure plus the drag pressure. Drag varies by machine and with pipe size.

10
Check alignment of pipe by running your finger or the end of a pen across the gap. Tighten down the side that is higher.

11

Butt welding instructions (page 3 of 6)

2.48

Open the carriage and set in planing tool. Make sure your planing tool locks in securely.

12

Turn on facer and let it reach full speed. Never turn on the facer if it is pinched between pipes.

13

Close pipes on facer. Increase the pressure until the facer begins shaving off ribbons of PP-R. Dont use excessive pressure.

14

Pro tip:

If one side begins planing before the other one, try opening and closing the jaws again to give the facer a bump. You can also try inserting wood blocks between the clamps and the planing tool in order to force the facer to shave the other side.

Drive the carriage forward whenever the pressure drops or the facer stops facing. Replace the blades if they are too dull.

15

Inspect shaved ribbons to see face condition. Proper facing will leave a fullwidth ribbon that goes all the way around.

16

Butt welding instructions (page 4 of 6)

Open pipes when you get full ribbons on both sides. Adjust the planer if one side is ready before the other.

17

Switch off and remove planer. Dont turn off the facer while the carriage is still closed, as this can leave nicks on the pipe face.

18

Close carriage and check for gaps. Replane or realign if needed. Wipe down the pipe face with rubbing alcohol.

19

2.49

Set your max pressure level (adjustment + drag). Controls vary by manufacturer. Dont change this pressure after setting it.

20

Open carriage and insert the heating iron. Make sure your heating iron is at or near 410 F (210 C).

21

Bring machine up to full pressure. This pushes out the exposed pipe surface, just like on a socket fusion.

22

Butt welding instructions (page 5 of 6)

The heating phase requires as little pressure as possible. Some machines lock in place, so the heating pressure is 0. Others require a slight positive pressure to keep them in place, but this is never more than drag + 10% adjustment pressure. Excessive pressure during the heating phase can create a restriction in the pipe.

2.50

Watch for the bead to reach the specified height. The guide is on page 2.39. Do not let your bead get larger than required.

23

Drop the pressure to 0 (if your machine has a locking carriage) or to drag pressure (if it does not).

24

Wait for the entire heating time (use a timer). Too little time will create an improper connection. Do not exceed the heating time.

25

Open carriage and remove iron. Make sure you have a safe place to set it down immediately if you cant hold it in one hand.

26

Bring pipes together within the transition time. Presetting your max pressure will make this easier and faster.

27

Butt welding instructions (page 6 of 6)

Hold manual controls for the full build-up time to counter any fluctuations in pressure. Bring pressure back up if it drops again.

28

Wait for the cooling time to pass. Do not try and shorten the cooling time by pouring water on the connection.

29

2.51

The final bead should look like one solid piece. A bad PP-R fusion will have a split bead with two distinct sides.

The cooling time can vary with the size and support of the pipe being fused. Short sections of pipe and long sections that are properly supported can use a reduced (50%) cooling time. Long sections that will not be supported must use the full time. A visual guide for the support requirements can be found on the next page.

Release pressure and undo clamps. Dont loosen the clamps until pressure has been fully released.

30

Remove the connection from the machine. Remember to keep the pipe supported if you have reduced the cooling time.

31

Reducing cooling times

Cooling times for butt-welded connections can be reduced by 50% if the joint is properly supported for the remainder of the cooling time. For example, the cooling time for 6 SDR 11 pipe can be reduced from 24 minutes to 12 minutes if the joint is not subjected to any undue stress for the remaining 12 minutes. The following images show proper and improper support for the pipe.

Correct

Incorrect

2.52

Whether on hangers or blocks, the pipe should be supported on either side of the connection, as well as further down the line.

Failure to support the pipe near the connection can result in undue stress on the bottom of the joint.

Incorrect
Correct

The pipe can also lay flat on the ground or a similar level surface.

Failure to support the pipe further away from the connection can result in undue stress at the top of the joint.

Incorrect

Failure to support the pipe on both sides of the connection can cause undue stress across the joint.

Tolerances on segmented elbows

Due to the physical limitations of mitered clamps and the butt welding process, many segmented elbows are not perfect 90 (or 45) fittings. Aquatherm attempts to manufacture all segmented elbows to within 0.5 of square, and does not ship fittings that are beyond 2. Before installing any segmented elbow, use a level and/or square to verify the angle of the fitting and decide if it will be suitable. If no variation can be tolerated, the installer may correct the angle during the fusion process. To correct an angle less than 90, place a shim at the bottom of the middle jaw on the fitting side before tightening the clamps down. Adjust the thickness of the shim as needed. (Thick fabric works well as a shim.) The shim will lean the fitting back, making the free side 90 to the pipe being fused. The side being fused will have a slight deflection in it, but the free side of the elbow can then be fused normally. Plane the fitting until it aligns with the pipe face. For an angle greater than 90, place a shim on the outer jaw of the fitting side before tightening the clamps down. This will lean the fitting forward and make the free side 90 with the pipe being fused. Plane the fitting until it aligns with the pipe face. This process can also be used to correct 45 elbows.

2.53

Shimming front clamp

Shimming rear clamp

Internal alignment
Due to gravity and the physics of extrusion, larger pipes tend to be slightly thicker on the bottom than they are on the top. However, the top will always be at least as thick as the production SDR, so there is no concern over pressure and temperature ratings. This difference is not enough to cause problems with the flow calculations or to require a change in fusion pressures. The only concern is simply an aesthetic one, where the internal bead will be misshapen if a thinner top is fused to a thicker bottom. To avoid this, line up the tops and bottoms of the pipe before fusing them. The easiest way to align the pipes is using the printed label on the side, as the label is always in the same relative position to the top of the pipe. Aligning the labels will help eliminate internal misalignment. If aligning the labels does not fix this issue, use your best judgment when aligning the pipe. The issue does not affect the outer wall of the pipe, which will always be consistent.

2.54

1.5 0.25 1.75

ASDAC tools
ASDAC tools are compatible and approved for use with Aquatherm products.

C.N.C. MACHINGING LTD.

250-769-0284 www.asdac.net

ASDAC

2.55

McElroy tools
McElroy tools are compatible and approved for use with Aquatherm products.
DynaMcTM 250 EP DynaMcTM 412 EP
(in 2-jaw and 4-jaw models)

2.56

918-836-8611 fusion@mcelroy.com www.mcelroy.com

28 - 618 - 412 - 824 - 1236 Rolling version
(Removable Carriage)

EP = Electric Pump

Low-profile rollers

McElroy tools
PolyPorter
TM

Pit Bull 26

2.57

Machine stand also available

DynaMcTM 250 HP DynaMcTM 412 HP

(in 2-jaw and 4-jaw models)

Ritmo tools
Ritmo tools are compatible and approved for use with Aquatherm products.
2 Socket fusion iron Prisma 125 Lite

2.58

863-679-8655 info@ritmoamerica.com www.ritmoamerica.com

Peeling tools

4 Socket fusion iron

Welding heads

Ritmo tools
Prisma 125 Chamfer tools Butt fusion machines: Delta Dragon 160, Delta Dragon 250B, Delta Dragon 315B, Delta Dragon 355B, Delta Dragon 500, Delta Dragon 630

2.59

Elektra Light Elektra 400

Widos tools
Socket fusion 2 Welding heads

Widos tools are compatible and approved for use with Aquatherm products.

2.60

Widos 3500

678-376-4379 info@widoswelding.com www.widoswelding.com

Widos tools
Widos Maxiplast Butt fusion machines: WI 4900, WI 5100 WI 5500, WI 6100

2.61

Widos 75

Repairs
For small holes in the pipe, such as holes from nails or screws, you can use the repair pin shown here. For larger holes, install and cap an outlet or remove the pipe and fit in a new section.

2.62

Attach the repair head to a welding iron. Heads are available in 5/16 and 7/16 sizes. Use a size that is larger than the hole.

If the hole is too small, drill it out. Use a 1/4 bit for the 5/16 head, and a 3/8 bit for the 7/16 head.

Insert the repair head into the iron and insert the repair pin into the repair head. Heat for 5 seconds.

Remove the pin from the head and the welding head from the pipe. Insert the pin into the pipe wall. Do not overinsert the pin.

Once the pin has set, you may use cutters to remove the rest of the pin. Pressure test the system to ensure a proper repair.

Chapter 3: Installation 3
Heat fusion is a simple, reliable, and fast process. Your skill in planning and fabrication can make it even faster. This chapter will discuss ways to speed up the installation process, minimize material costs, and avoid problems or callbacks. It also includes information on pipe sizing, hanger spacing, expansion controls, insulation, and pressure testing. Remember that, when using an engineered system like PP-R, planning and finesse will yield better results than brute force.

3.1

Getting started
There are several unique features of Aquatherm pipe that can help you accelerate your install times. 3.2 Fusion outlets allow you to add branches after installing mains Lightweight material is easier to carry in large amounts Reduced contraction and expansion makes layout easier Fused joints wont crack during transport Flexible pipe can be fed into tight spaces

For each part of the installation, you should decide what parts to build in a shop or on a workbench (prefab) and which parts need to be built in place. Prefabrication gives you access to a wider range of fusion tools and makes it easier to make the fusions square and accurate. In general, prefabricated joints are also faster. As you continue installing Aquatherm pipe, you will find a balance of prefab and in-place installation that works for you. Looking for ways to help streamline the installation process can lead to significant savings in the overall installation time.

Tips for in-place installation

When installing the pipe in place, plan your work around the connections. Prefab any connections that you will not be able to reach. Work from areas with little space toward areas with more space. Use the pipes flexibility to your advantage. Leave enough space for the welding iron. Hand connections and welding jig connections tend to require less space than other machines. Leave enough lateral movement in the pipe for socket fusion. Use flanges, unions, or electrofusion sockets in areas where you cant move the pipe laterally. Use hangers and clamps to support the pipe during fusion. Leave space to drill holes for fusion outlets, if you plan on adding them later. Provide support (such as a lift or a hoist) for larger machines, such as a butt welding machine. These machines can be clamped onto the pipe if the pipe has enough support. 3.3

Tips for on-site assembly

Many fusion machines can be used to set up an on-site pre-fab station, giving you the advantages of shop connections with the convenience and flexibility of being at the jobsite. Heavier fusion machines tend to offer more support and mechanical advantage, but are difficult to use in place. Where possible, attach one end of the fitting before moving it into place. This cuts the number of in-place connections in half. Pre-fab complicated sections and then move them into place. This may take an extra connection or two, but it will save time on the complicated section. Butt welding machines are heavy, so perform as many connections on the ground or on a table as possible. To avoid unsquare connections, leave the pipe in the machines long enough for the joints to become completely solid. Make sure you have sufficient electrical power for your machines.

3.4

Tips for off-site prefabrication

Off-site prefabrication is a great way to save time, maximize equipment output, and ensure quality control over critical elements of the piping system. Aquatherms heat fusion connections are solid and able to absorb vibrations, so there is little to no risk of joints cracking during transport. Fittings cannot be unfused, so make sure the assembly will fit through the entrance of its destination. If you are uncertain about the final length of a transition, leave the pipe end long and unfused. You can cut and fuse for an exact fit on the jobsite. If you are building heavy equipment (valves, pumps, etc) into the assembly, make sure the pipe is properly supported around the equipment. Using machines that offer more support through the clamps will yield more consistent results.

3.5

Technical bulletins
Aquatherm works hard to deliver the best training and most accurate product information available to you, the installer. However, due to the wide vareity of applications that Aquatherm pipe is used in, and the ongoing development of third-party tools, clamps, insulations, and other solutions, the best practice for installing Aquatherm products can seem like a moving target. In order to keep you informed of new techniques and requirements, Aquatherm releases regular technical bulletins to fill in the gaps between editions of the installer manual. Technical bulletins also give more detailed explanations of installation techiques than will fit in the installer manual. As a result, in the event of a discrepancy between this installer manual and the current technical bulletins on the Aquatherm website, the bulletins should be considered correct. Aquatherm recommends reading the technical bulletins in addition to this manual. Notifications regarding new technical bulletins are sent out monthly with the Aquatherm Newsletter.

3.6

Clamps and hangers

When installing Aquatherm pipes, use only rubber- or felt-lined clamps, like the one shown here. You may use tape to pad the space between the PP-R and the metal on non-clamping hangers, such as clevis hangers.
Rubber-lined clamp

3.7

Metal clamps (even plastic-safe clamps) can damage hot water pipes, and can condensate when used on cold water pipe. When installing chilled water lines in high-humidity areas, use a non-crushable pipe shield (pictured above). Metal that is in direct contact with the Aquatherm pipe may sweat in certain chilled applications, even if the pipe itself shows no signs of condensation.

Fixed and sliding points

Pipe size (20 mm) (25 mm) 1 (32 mm) 1 (40 mm) 1 (50 mm) OD 1 1 1 2 2 3 3 4 5 Pipe size 6 (160 mm) 8 (200 mm) 10 (250 mm) 12 (315 mm) 14 (355 mm) 16 (400 mm) 18 (450 mm) 20 (500 mm) 22 (560 mm) 24 (630 mm) OD 6 8 10 12 14 15 17 19 22 24 Sliding point Fixed point

For the purposes of dealing with linear expansion, there are two types of supports: fixed points and sliding points. Fixed points are tight against the pipe and prevent movement through that point. Sliding points support the pipe, but are loose and allow movement through the joint. This table gives the actual imperial ID of the pipe, rounded to . The table on page 3.36 provides the best match of CTS and IPS sizes.

3.8

2 (63 mm) 2 (75 mm) 3 (90 mm) 3 (110 mm) 4 (125 mm)

Support intervals and hanger spacing (SDR 11 non-faser)

With PP-R, the hanger spacing varies with the expansion in the pipe. For cold water pipes, there is a negligible amount of expansion, or even some contraction, so only one spacing is given for non-faser installations. For heated or chilled applications, use a faser-composite pipe. The limited expansion helps increase hanger spacing. Use the difference between the installed temperature and the operating temperature (T) to determine proper spacing. In systems with a 0 or negative T, use the maximum spacing. Note: these support intervals are based on the pipes carrying water. If the pipes are carrying a material that is denser than water, additional support may be required. Alternative spacing should be confirmed in the chemical compatibility report. The instructions for submitting a chemical inquiry can be found on page 3.24. Also, the spacing given here does not supersede requirements given by the local authority having jurisdiction. 3.9
Pipe diameter
20 mm

25 mm

32 mm

40 mm

50 mm

63 mm

75 mm

90 mm

110 mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm

10

12

14

16

450 mm

18

Support intervals (ft) 4 4 4 4 4 4.6 4.9 5.2 5.9 6.6 7.2 7.5 7.9 8.4 9.5 10.5 11.2

Support intervals (SDR 7.4 and 11 faser-composite)

T
Difference in temp.

Pipe diameter
20 mm 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm 110 mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm

1 1

10

12

14

16

450 mm

18

Support intervals (ft) 4 4 4 4 4 4 4 4.6 4 4 4 4 4 4 5.2 4 4 4 4 4 4 5.9 4.4 4.4 4.1 4.1 4 4 6.7 5.1 5.1 4.8 4.8 4.4 4.3 7.5 5.7 5.7 5.4 5.4 5.1 4.8 8 6.1 6.1 5.7 5.7 5.4 5.1 8.5 6.4 6.4 6.1 6.1 5.7 5.4 9.5 7.1 6.9 6.6 6.2 5.9 5.6 10.5 7.9 7.4 7.1 6.4 6.1 5.7 11.2 8.9 8 7.7 6.7 6.4 6.1 11.3 9 8.2 7.9 6.9 6.6 6.2 11.5 9.2 8.4 8 7.1 6.7 6.4 12.5 10.1 9.2 8.7 7.8 7.1 6.7 13.5 11 10 9.5 8.5 7.5 7 15 14 12 11 10 9 8 16 15 13 12 11 10 8

0 F

(0 C)

36 F
(20 C)

54 F

3.10

(30 C)

72 F
(40 C)

90 F
(50 C)

108 F
(60 C)

126 F
(70 C)

Support intervals (SDR 17.6 faser-composite)

T
Difference in temp.

Pipe diameter
160 mm

200 mm

250 mm

10

315 mm

12

355 mm

14

400 mm

16

450 mm

18

500 mm

20

560 mm

22

630 mm

24

Support intervals (ft) 8.5 6.2 5.9 5.7 5.4 5.1 4.8 8.7 6.6 6.2 5.9 5.7 5.4 5.1 9.0 6.7 6.4 6.2 5.9 5.6 5.2 9.2 6.9 6.6 6.2 6.1 5.7 5.6 9.4 7.1 6.7 6.4 6.1 5.7 5.7 9.7 7.5 7.2 6.9 6.6 6.1 5.7 10.0 7.9 7.5 7.4 7.1 6.6 6.2 10.3 8.4 8.0 7.7 7.5 7.1 6.7 10.7 8.9 8.5 8.2 7.9 7.5 7.2 10.8 9.2 9.0 8.7 8.4 7.9 7.5

0 F

(0 C)

36 F
(20 C)

54 F
(30 C)

3.11

72 F
(40 C)

90 F
(50 C)

108 F
(60 C)

126 F
(70 C)

Increased hanger spacing

In some applications, the positioning of hangers is determined by outside factors, such as a retrofit with hangers from previous metal pipes. In order to accommodate for these variations, installers may use an in-line support, like the one shown here. The supported distance can be added to the hanger spacing. For example, a pipe with a 6 ft spacing requirement can be hung on 8 ft spacers if 2 ft of the pipe is supported in-line. The supports must clip securely to the pipe without damaging the outer wall. In-line supports will need to be installed under the insulation, but still need a non-metallic barrier layer (such as tape) between the metal surface of the in-line support and the pipe. Approved in-line supports* are available through Raywal. *Other manufacturers may provide a similar product that was not approved by Aquatherm at the time of printing. These supports, if acceptable, can be approved by Aquatherm upon request. 3.12

Fire rating
For fire-rated assemblies, such as return-air plenums, Aquatherm pipe will need to be protected by a fire-rated insulation or wrap. If the pipe needs to be insulated (HW, HWR, CHW), any material that meets the fire/smoke requirements of ASTM E84 or CAN/UL S102.2 can be used. If insulation is not required (DCW), a simple wrap meeting the fire/smoke requirements may be installed over the pipe. In areas requiring a listed system, recent changes to the model mechanical codes (2012 IMC and UMC) have made it clear that any product which is listed and labeled as meeting the flame and smoke requirements of ASTM E84 and CAN/UL S102.2 may be used to protect the pipe. Always obtain approval of your local authority having jurisdiction before installing any pipe insulation/wrap. Although the updated building codes allow for the use of any plenum-rated insulation to protect the pipe, it should be noted that the fittings will be required to be wrapped as well as the pipe in order to meet the fire/smoke standards. Again, confirm local authority approval before beginning. For fire-rated partition/assembly penetrations, Aquatherm recommends that installers work with the fire stopping manufacturer. The current list can be found at Aquatherm.com/firestopping By allowing the use of multiple materials to be installed with our product, the decision for insulation, flame/smoke wraps, and fire stopping can be made by the installer, engineer, and owner based on their preferences and the most cost-effective solutions for the project.

3.13

Linear expansion
Linear expansion occurs when the pipe is heated. The amount of expansion is determined by the difference in temperature. It is important to know how much expansion will occur during system operation and plan for it. Aquatherms faser-composite pipes use a combination of glass fibers and PP-R to reduce linear expansion and contraction by 75%. Pipe with a faser-composite layer can be fused without any special tools, treatment, or prep work. Fuse faser-composite pipes using the same techniques as non-faser pipe. For hot water, heating, and chilled applications, use a fasercomposite pipe, such as Greenpipe SDR 7.4 or Climatherm SDR 17.6 or 11. For ambient-temperature applications, such as greywater or DCW, use a non-faser pipe, like Greenpipe SDR 11 or Lilac.
The faser-composite layer is extruded with other layers during production. The percentage of PP-R is high enough to ensure a proper bonding between the layers, so the faser-composite cannot be separated from the inner and outer layers.

3.14

Calculating expansion
In order to deal with expansion properly, you will need to know how much expansion to expect. Expansion is based on the following factors: L Ti Tw T = the length of pipe = the temperature of the pipe at the time the pipe is clamped down = the temperature of the water inside the pipes during operation = the difference between the working temperature (Tw) and the installation temperature (Ti): = the coefficient of expansion = 0.0002367 in/ft F for faser-composite pipe = 0.001008 in/ft F for non-faser pipe 3.15

Multiply the length of the pipe (L) by the temperature difference (T), and again by the expansion coefficient (), as shown here: L x T x = L (Linear Expansion or change in length) This will give you the expected expansion in inches. The tables on the next two pages provide some of these calculations. Note that the length of expansion is the same for all diameters of pipe.

Linear expansion for non-faser pipe

Difference in temperature T = Toperating temperature - Tinstallation temperature Pipe length 10 ft 20 ft 30 ft 40 ft 50 ft 60 ft 70 ft 80 ft 90 ft 100 ft 150 ft 200 ft 10 F 20 F 30 F 40 F 50 F 60 F 80 F 100 F

Linear expansion L (in) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.5 2.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 3.0 4.0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3.0 4.5 6.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 6.0 8.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 7.5 10.0 0.6 1.2 1.8 2.4 3.0 3.6 4.2 4.8 5.4 6.0 9.0 12.0 0.8 1.6 2.4 3.2 4.0 4.8 5.6 6.4 7.2 8.0 12.0 15.9 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 14.9 19.9

3.16

Linear expansion for faser-composite pipe

Difference in temperature T = Toperating temperature - Tinstallation temperature Pipe length 10 ft 20 ft 30 ft 40 ft 50 ft 60 ft 70 ft 80 ft 90 ft 100 ft 150 ft 200 ft 10 F 20 F 30 F 40 F 50 F 60 F 80 F 100 F

Linear expansion L (in) 0.0 0.0 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.2 0.3 0.5 0.0 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.7 0.9 0.1 0.1 0.2 0.3 0.3 0.4 0.5 0.5 0.6 0.7 1.0 1.4 0.1 0.2 0.3 0.4 0.5 0.5 0.6 0.7 0.8 0.9 1.4 1.8 0.1 0.2 0.3 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.7 2.3 0.1 0.3 0.4 0.5 0.7 0.8 1.0 1.1 1.2 1.4 2.1 2.7 0.2 0.4 0.5 0.7 0.9 1.1 1.3 1.5 1.6 1.8 2.7 3.6 0.2 0.5 0.7 0.9 1.1 1.4 1.6 1.8 2.1 2.3 3.4 4.6

3.17

Expansion controls
To control linear expansion, you will need to isolate and direct the expansion in a safe way. Expansion will move away from fixed points and through sliding points until it reaches your expansion control or another fixed point. On long runs, you should use an expansion control every 120 ft. Remember that branches and other fittings cannot expand through a fixed or sliding point. Common expansion controls include: Sliding elbow: Expansion is directed to where the pipe changes direction. The force of the expansion is absorbed by the flexibility of the bending side. 3.18 Linear isolation: For vertical installations, expansion can be contained to each floor, leaving each 10 ft space with a fraction of an inch of expansion. This will cause a slight bowing of the pipe, which can be minimized using a midfloor guide (sliding point). Note: Only faser-composite pipes can absorb their expansion. Non-faser pipes in heated applications must have other expansion controls installed every 30 ft. Expansion should be handled by the engineer in the design documents and those documents must be followed. The information here is for reference and verification only.

Expanding side Bending side

Expansion controls
Expansion loop: Used on long, straight runs. Two distant fixed points direct expansion to a central loop. The loop can even be pre-stressed to accommodate additional expansion, or to give a square appearance during operation.

Expanding side

Expanding side

3.19

Bending side without pre-stress

Bending side with pre-stress

Sliding end: Used for short distances where the pipe ends with a cap. The distance between the end of the pipe and the wall (or other obstruction) must be less than the expansion. The pipe should be supported as closely to the end as possible.

Length of bending side

The following table gives the minimum distance between the elbow of the bending side and the first support on that pipe. The force of expansion can safely bend the pipe over this distance.
Pipe dimension in inches (mm) (20) (25) 1 (32) Linear expansion in inches () 1 13 15 17 19 21 24 26 28 31 34 2 19 21 24 27 30 34 37 40 44 47 3 23 26 29 33 37 41 45 49 54 58 4 27 30 34 38 42 48 52 57 63 67 5 30 34 38 42 47 53 58 64 70 70 6 33 37 42 46 52 58 64 70 77 82 7 35 40 45 50 56 63 69 75 83 89 8 38 42 48 54 60 67 73 80 89 95 9 40 45 51 57 64 71 78 85 94 101 10 42 47 54 60 67 75 82 90 99 106 11 44 50 56 63 70 79 86 94 104 111 12 46 52 59 66 73 82 90 99 109 116 Length of bending side (in)

3.20

1 (40) 1 (50) 2 (63) 2 (75) 3 (90) 3 (110) 4 (125)

Length of bending side

Pipe dimension in inches (mm) 6 (160) 8 (200) 10 (250) 12 (315) 14 (355) 16 (400) 18 (450) 20 (500) 22 (560) 24 (630) Linear expansion in inches () 1 38 42 47 53 56 60 63 67 71 75 2 54 60 67 75 79 84 89 94 100 106 3 66 73 82 92 97 103 109 115 122 130 4 76 85 95 106 112 119 126 133 141 150 5 85 95 106 119 126 133 141 149 158 167 6 93 104 116 130 138 146 155 163 173 183 7 100 112 125 141 149 158 167 176 187 198 8 107 120 134 151 159 169 178 188 199 212 9 114 127 142 160 168 179 190 200 212 224 10 120 134 150 168 178 188 200 211 223 237 11 126 141 157 177 186 198 210 221 234 248 12 131 147 164 184 194 Length of bending side (in)

3.21

206 219 231 244 259

Length of bending side with pre-stress

The following table gives the minimum distance between the elbow of the pre-stressed bending side and the first support on that pipe, splitting the expansion. Use the first table if you are pre-stressing for a square finish.
Pipe dimension in inches (mm) (20) (25) 1 (32) 1 (40) 1 (50) 2 (63) 2 (75) 3 (90) 3 (110) 4 (125) Linear expansion in inches () 1 9 11 12 13 15 17 18 20 22 24 2 13 15 17 19 21 24 26 28 31 34 3 16 18 21 23 26 29 32 35 39 41 4 19 21 24 27 30 34 37 40 44 47 5 21 24 27 30 34 38 41 45 50 53 6 23 26 29 33 37 41 45 49 54 58 7 25 28 32 35 40 45 49 53 59 63 8 27 30 34 38 42 48 52 57 63 67 9 28 32 36 40 45 51 55 60 67 71 10 30 34 38 42 47 53 58 64 70 75 11 31 35 40 44 50 56 61 67 74 79 12 33 37 42 46 52 58 64 70 77 82 Length of bending side (in)

3.22

Length of bending side with pre-stress

Pipe dimension in inches (mm) 6 (160) 8 (200) 10 (250) 12 (315) 14 (355) 16 (400) 18 (450) 20 (500) 22 (560) 24 (630) Linear expansion in inches () 1 27 30 34 38 40 42 45 47 50 53 2 38 42 47 53 56 60 63 67 71 75 3 46 52 58 65 69 73 77 82 86 92 4 54 60 67 75 79 84 89 94 100 106 5 60 67 75 84 89 94 100 105 112 118 6 66 73 82 92 97 103 109 115 122 130 7 71 79 89 100 105 112 118 125 132 140 8 76 85 95 106 112 119 126 133 141 150 9 80 90 101 113 119 126 134 141 150 159 10 85 95 106 119 126 133 141 149 158 167 11 89 99 111 125 132 140 148 156 165 175 12 93 104 116 130 138 146 155 163 173 183 Length of bending side (in)

3.23

Chemical compatibility
PP-R is safe with most chemicals, in most environments, and with nearly any quality of water. However, there are a few applications, such as high chlorine, that have adverse effects on the pipe and fittings. If you are installing the pipe in a chemically corrosive application, the engineer on the job should have already submitted a chemical compatibility report. If no report was submitted, go to Aquatherm.com/compatibility and follow the directions given there. Inquiries are submitted to Aquatherms testing laboratories in Germany for verification normally within 24-48 hours. More common applications will have information on file, and may be answered on the same day. Aquatherm pipe and fittings are safe to use with propylene and ethylene glycols at any concentration. Be aware that even if the Aquatherm pipe is compatible with the chemical being transported, other materials in the system may not be. Make sure that all parts of the system are compatible with the medium being carried before installing them. And, while Aquatherm pipe does not require treatment to protect it from corrosion, ferrous metals in the system will. Do not mix Aquatherm pipe with other piping systems in conditions that will cause the other system to fail.

3.24

Integration with copper tubing

When integrating Aquatherm piping systems with other systems, make sure that the operating parameters for PP-R wont damage the other materials. When there is extensive use of copper piping in conjunction with PP-R, care should be taken to ensure the operating conditions will not cause dissolution or corrosion of the copper. Aquatherm recommends following the Copper Development Agencys guidelines for sizing, temperature and flow speed in copper pipe. This will also help ensure that the copper levels in the water do not approach the regulatory action levels. Sustained high levels of copper ions in a water system can damage wetted surfaces within the system, even PP-R. Damage caused by unregulated copper ions may void the warranty. Alternatively, you can avoid using large amounts of new copper upstream of the PP-R in hot water recirculation lines. If the copper fails, it may degrade the PP-R as well, shortening its service life. Small amounts of copper from valves and other equipment will generally not cause an issue. For maximum longevity, recirculation lines for domestic hot water should not exceed a flowspeed of 4 ft/s unless the piping is all PP-R. If you are adding PP-R to an existing copper system, the level of copper in the water should be tested. These levels should not exceed 0.5 P.P.M., and are considered actionable by the EPA at 1.3 P.P.M. High levels of free copper indicate that the copper pipe is eroding due to system and/or water conditions. 3.25

Connecting to a boiler
When installing a boiler system, some codes may require a minimum of 18 of copper tubing from the boiler to the Aquatherm PP-R. (Note: this is not enough copper tubing to create an issue with copper ions as long as the copper is properly sized). It is always preferable to complete all heat producing connections, such as soldering copper tubing at the boiler, before making the Aquatherm piping connections to the copper piping. When this is not a possibility, one solution is to install a copper union that can be uncoupled until the soldering is complete. In any case, do not expose any PP-R piping and transition fittings to temperatures in excess of 170 F during the copper soldering process. Excessive heat may distort and deform any O-ring seals and fitting connections, resulting in a leak during testing or after system start-up. Perform all solder joints on copper piping at the following minimum distances from the PP-R piping along the copper tube: 10 from a or PP-R fitting or pipe; 18 from a 1 or 1 PP-R fitting or pipe; 20 from a 1 PP-R Pipe fitting or pipe; 22 from a 2 (or larger) PP-R fitting or pipe.

3.26

For additional safety, use a water soaked cloth or commercial heat blocking agent between the solder joint and the PP-R piping and immediately cool the copper tube and the transition fitting after the soldering is completed.

PP-R to copper transition fittings

To facilitate transitions to fixture units or copper components, Aquatherm now offers a PP-R to Copper stub out, intended for use with angle stops, flush valves, and other terminations. It is compatible with both compression and solder-type connections. These fittings are combination of a custom Aquatherm PP-R socket with a gasket and copper stub added by Sioux Chief Manufacturing. The fused PP-R portion is covered under Aquatherms warranty. The copper portion and gasket are covered under a warranty from Sioux Chief. Instructions are included with the fitting. Always follow those directions to avoid damaging the fitting.

3.27

Bushings, reducers, and reducing couplings

To help limit the number of reducing fittings that a wholesaler must stock, Aquatherm uses bushings which are designed to be inserted into another fitting, such as a socket, tee, or elbow. When reducing, the side being reduced from is male and acts like a piece of pipe in that size. The side being reduced to is female and acts like a socket in the smaller size. The female side (smaller pipe size) is labeled with the fitting dimension and has a stop on the inside, just like a regular socket fitting. The male side (larger pipe size) has a bevel on the face and a thicker wall than a normal socket connection. Bushings run from 4 down to 1/2. Reducers are used with larger pipes and are butt welded on both sides. They may go directly to a pipe or to a fitting. Aquatherm also provides reducing sockets to reduce the pipe during a straight run. Sizes under 4 are socket fused on both ends. Sizes that reduce from above 4 to 4 or smaller will butt fuse on the larger size and socket fuse on the smaller size. 3.28

male side

female side

Bushing

Threaded connections
To make integration with non-fusible system components easier, Aquatherm offers a wide range of threaded transitions. These transitions consist of a machined brass or stainless steel thread that has been mold-injected into a PP-R base for maximum strength. When installing these threaded connections, there are a few important things to remember: 1. The threads will not bottom out, so use pipe dope or plumbers tape to ensure a snug fit. Your sealant needs to be compatible with brass or stainless steel, as you will not be threading to the PP-R. 2. Always apply counter pressure on the fitting when tightening the connection. If the fitting has a hex head, place your wrench there (a crescent wrench may give you a more secure fit). For fittings without a hex head, use a pipe wrench on the PP-R body of the fitting. This will scratch up the fitting, but will not cause structural damage. 3. Use stainless steel fittings in chemically aggressive applications. Lead-free brass is acceptable in all states, unless zero-lead brass is specifically required (e.g. CA, VT).
Male Round SS

3.29

Female Hex Brass

Male Hex Brass

Flanges
To transition to other piping systems and mechanical equipment, Aquatherm provides a full range of flange adapters. Aquatherms flange rings are uniquely designed to have a metric center and an ANSI bolt pattern. For a flange transition, you will need both the adapter (fusible fitting) and the ring. Aquatherm recommends using a full face rubber (black EPDM or red SBR) gasket with its flanges. Viton gaskets may also be used if needed for chemical resistance. For lower pressure systems, and smaller diameters (4 and down), ring gaskets may be used but there may be blow-outs during pressure testing. Ring gaskets are also more susceptible to leaks if the flanges and connected piping are not aligned properly 1 during installation. The gasket should have an inside diameter consistent with the ID of 6 8 the flange adapter (see page 3.34).
3 5 2 7 4

3.30

Information on torque and bolt-tightening pattern can be found on the next page. Bolt tightening should follow the star pattern regardless of flange size and number of bolts. The pattern for an 8-bolt flange is shown in the example. Bolt length will depend on the thickness of gasket and flange ring, as well as any spacer if used with a butterfly valve. Do not overtighten the bolts.

Aquatherm flange bolt torque and size

Nominal pipe size (20mm) (25mm) 1 (32mm) 1 (40mm) 1 (50 mm) 2 (63mm) 2 (75mm) 3 (90mm) 3 (110mm) 4 (125mm) Torque N-m 10 15 15 20 30 35 40 40 50 50 ft-lb 14 20 20 27 41 47 54 54 68 68 Number 4 4 4 4 4 4 4 8 8 8 Bolts Diameter 1/2 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 Washers Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Nominal pipe size 6 (160mm) 8 (200mm) 10 (250mm) 12 (315 mm) 14 (355 mm) 16 (400 mm) 18 (450 mm) 20 (500 mm) 22 (560 mm) 24 (630 mm) Torque N-m 60 75 95 100 100 100 100 100 100 100 ft-lb 81 102 129 136 136 136 136 136 136 136 Number 8 8 12 12 12 16 16 20 20 20 Bolts Diameter 3/4 3/4 7/8 7/8 1 1 1-1/8 1-1/8 1-1/8 1-1/8 Washers Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

3.31

Butterfly valves
If you are using butterfly valves with Aquatherm pipe, you will need to make sure your valves can properly open. Aquatherms use of SDR means that the wall thickness will vary with the size and type of pipe. You can use a spacer to leave a wider opening, or you can use butterfly valves with a small enough clearance to open inside the flange. The following table gives the ID in inches of the flange adapters. Spacers can be made from a slice of larger pipe.
Flange adapters SDR 7.4 Part no. 15530 15534 15538 15531 15535 11 15539 15543 15545 Dimension ND 6 8 10 6 8 10 12 14 Flange ID 6.10 7.48 9.25 6.02 7.40 9.45 10.12 11.42 SDR Part no. 2515530 2515534 2515538 2515542 17.6 2515544 2515546 2515548 2515550 2515552 2515554 Flange adapters Dimension ND 6 8 10 12 14 16 18 20 22 24 Flange ID 6.18 7.64 9.45 10.98 12.36 13.94 15.67 17.44 19.53 21.97

3.32

Branch lines
Pipe size Thread size 1 Pipe size 1 1 2 2 3 F F F F F F F 3 4 6 8 10 12 14 16 18 24 Outlets available 1 1 1 1 2 3 4 4 2 6 2 8 2 10 2 12

1 M/F M/F 1 M/F M/F 2 M/F M/F

There are two ways to install branch lines on Aquatherm pipe: tees and outlets. Tees are full-sized fittings that either socket fuse or butt fuse in-line. These are usually used for branches that are within two sizes of the main line. Tees can be found on page 4.15 and reducing tees are on page 4.17. Outlets are smaller fittings that use outlet fusion to attach to the side of the pipe (see page 2.27). The table on the left gives the available branches for each pipe size. Fusion outlets are listed on page 4.23. The table on the far left shows the available outlets with metal threads, listed on page 4.37.

2 M/F M/F 3 M/F M/F

3.33

3 M/F M/F 4 6 8 10 M/F M/F M/F M/F F F F F

Buried applications
Unlike many other piping materials, PP-R is able to absorb the stress caused by expansion within certain limits. The faser-composite layer helps keep the pipe within these limits for most applications. In cases where the pipe needs to be buried in soil, sand, or concrete, PP-R is safe, non-leaching, and resistant to crushing or damage. Aquatherm pipe is also suitable for directional boring, if a properly sized pulling head is used. Buried installations generally do not require additional consideration for the expansion of faser-composite pipes. Resistance to movement from the concrete or backfill will restrict the natural expansion or contraction of the pipe. The expansive force of PP-R is much lower than metal pipes. Aquatherm pipe is safe to use with insulating backfills. Due to the thermal resistance of PP-R, dry sand is often acceptable as a backfill for insulation purposes. 6 of dry sand equates to roughly 1 of fiberglass insulation. When penetrating through concrete on an application where the pipe can expand and contract regularly, a shield or protective layer must be used and should be installed per local codes. It is best to anchor the pipe at that location.

3.34

Maximum pull force

The following table gives the maximum pull force for directional boring or similar applications. Make sure that the pull heads you are using are compatible with metric PP-R pipe. Max pull force (lb) SDR 11
11353 17739 27718 44005 55890 70958 89806 -

Pipe diameter
6 160 mm 8 200 mm 10 250 mm 12 315 mm 14 355 mm 16 400 mm 18 450 mm 20 500 mm 22 560 mm 24 630 mm

SDR 7.4
16055 25087 39198 62230 79038 -

SDR 17.6
7362 11503 17973

3.35

28534 36241 46012 58233 71893 90183 114137

Insulation sizing, thrust blocking, noise generation, and vibration isolation

Insulation sizing: Aquatherms pipes are made using a metric OD, so normal insulations do not always fit over the pipe. The table on the right gives the best (closest) fit between IPS and CTS sizes, and then the best fit using only the more common IPS size. These insulation sizes will go all the way around the pipe with minimal gaps. These sizes also work for clamps and hangers. Thrust blocking: Due to the inherent strength and integrity of fused connections, thrust blocking is not required. Noise generation: To avoid noise generation and water hammer, the calculated flow rate should not exceed 8 ft/s indoors. Buried pipe can be run faster (up to 12 ft/s) because noise generation is not an issue. At the higher flow velocity, the design engineer must still account for surge pressures and design accordingly. Vibration isolation: Due to Fusiolen PP-Rs natural ability to absorb vibration, isolators are not required if the pipe has some limited mobility on either side of the pump.

Pre-formed insulation Aquatherm ND 1 1 1 2 2 3 3 4 6 8 10 12 Best fit IPS IPS 1 IPS 1 CTS 1 IPS 2 IPS 2 3 CTS 4 IPS 5 CTS 6 IPS 8 CTS 10 CTS 12 IPS Best IPS fit 1 1 1 2 2 3 4 5 6 8 10 12

3.36

Flushing, grounding, and freeze protection

Flushing: Before beginning operation, flush the system to remove dust, pipe shavings, and other particles that may have fallen into the pipe. Make sure the system is flushed in a safe manner that doesnt damage or clog any components. Unless otherwise required, water is sufficient for flushing out the system. Grounding: Most building codes require that grounding be provided for all conductive components inside the structure. It is important to note that Aquatherm pipes do not carry electrical currents and cannot be used to provide grounding. Where metal pipes are replaced by PP-R pipes, the ground cannot be created by the piping system. An alternative ground system must be installed. Freeze protection: Aquatherm piping systems can be installed in applications and conditions where freezing may occur. Generally, freezing the pipes and the water in them will not cause problems for the piping materials, but they should not be frozen intentionally. Maintaining a minimum flow can prevent the pipes from freezing solid. All freeze protection products must be used in accordance with the manufacturers recommendations, the product listings, and in compliance with all applicable local codes. When using any type of external heat source applied to the piping such as heat tape or heating cables, the product must be suitable for use with plastic piping. Additionally, the heat system must be self-regulating and the surface temperature of the Aquatherm pipe and fittings must not exceed 160 F (71 C). 3.37

UV protection and painting

UV radiation can damage and weaken the polypropylene chains over time. Therefore, it is best to avoid exposing Aquatherm pipe and fittings to UV radiation. Transport and storage: Aquatherm pipes come in UV-resistant bags for storage and transport. Leave the pipes in these bags until you are ready to fuse or install them. Once the pipes are removed from the bags, try to store them inside or under an awning or tarp. Installation: Aquatherm offers its pipes with an extruded UV protective layer. This layer is ideal for pipes that are being installed outdoors, as the UV protective layer does not require upkeep. However, this UV layer will need to be removed before fusion can take place. Plastic-safe paint can be used to protect the pipe from UV damage, but most paints will not adhere well to PP-R. Painted pipe may need to be recoated or maintained. Aquatherm recommends using an elastomeric paint, which will expand and contract with the pipes, but does not endorse any particular brand of paint. You may also paint the pipe for non-UV reasons if needed. Standard acrylic, enamel, epoxy, and latex paints do not harm the pipe and will not leach through the pipe wall. Painting the pipe is considered an aftermarket modification to the Aquatherm pipe, so Aquatherm does not assume any responsibility for the performance of the paint. Damage caused by painting is not covered under the Aquatherm warranty.

3.38

Fusing UV pipe
In order to fuse the Aquatherm UV protected pipe, you will need to remove the outer layer. The outer layer is a black polyethylene and it is factory extruded over the top of normal Greenpipe and Climatherm pipes. You will still need to cover or paint the fittings.

Mark the pipe one size up from its actual size. This will protect the black layer from the heat fusion process.

Cut around the outside of the pipe through just the black layer. A rolling cutter works well. Do not cut into the pipe wall.

2
3.39

Cut from the mark to the edge of the pipe. Wear protective gloves and mind your fingers.

Use the knife to pry up the edge of the black layer. Rescore the cuts if they are not deep enough.

Peel back and remove the black layer. Fuse the pipe following the normal guidelines.

Pressure testing
Heat fusion is an all-or-nothing connection process, so pressure testing is an excellent way to be sure that every connection has been done correctly. Aquatherm piping systems must be pressure tested before beginning system operation. You may test sections in part or test the entire system at once. Documentation of the pressure test must be submitted to Aquatherm within 30 days of completion. You may use air, water, or a mix of the two. Stand clear when air testing, as damaged pipe may burst. The test pressure must be 150% of the system design operating pressure or 150 psi, whichever is higher. Do not test the pipe above 150 psi when using only air, unless the system is intended for compressed air. For smaller systems, the waiting times on the preliminary and principle tests may be reduced up to 50%. Pressure test instructions and forms may be found at Aquatherm.com/pressure-test Use a digital gauge or a gauge that is accurate to within 2 psi.

3.40

This test is designed to identify damaged pipe, manufacturers defects, and poor workmanship. It is required by the manufacturer for the validation of the Aquatherm warranty. This does not supersede or replace regulations placed by the local authority having jurisdiction. Aquatherms warranty does not cover failures caused by improper installation, operation outside of the recommended parameters, or damage from mishandling after the pipe has left the manufacturer.

Pressure test instructions

Preliminary & primary test
1. Bring test up to test pressure. 2. Wait and make sure the pressure stabilizes. 3. Top off the system if needed. 4. Wait 30 minutes. Pressure cannot drop more than 9 psi. 5. Wait 120 minutes. Pressure cannot drop more than 3 psi. 6. If the system cannot hold pressure, check for leaks. 7. If the system is leak free, move on to the final test.

Final test
1. Bring system up to 150 psi for 2 minutes. 2. Drop system to 15 psi for 2 minutes. 3. Depressurize and repeat steps 1 and 2 two more times. 4. Bring system to 150 psi for 5 minutes. 5. Drop system to 15 psi for 5 minutes. 6. Depressurize and submit test record to Aquatherm,

3.41

No leakage may appear at any point of the test. The final test exposes cracks and bad fusions. Stand clear of the pipe if pressure testing with air, as hidden damage could cause the pipe to burst. On large installations, make sure your pressure gauge is situated on the lowest point of the system. If the online pressure test instructions differ from the manual, follow the procedure given at Aquatherm.com/pressure-test as it is more current.

Preliminary and primary test visualization

150 % Max operating pressure or 150 psi which ever is greater

p max = 9 psi (0.6 bar) p max = 3 psi (0.2 bar)

Principle test

3.42

p in psi (bar)

Preliminary test

30 min

120 min

t in min

Final test visualization

150 psi

3.43

15 psi

2 min 4 min

2 min 4 min

2 min 4 min

5 min

10 min

t in min

Warranty claims
For any claims on the warranty, you will need to submit the following information using the Warranty Claim Form: The installer number(s) of the installer(s) A copy of the previously submitted pressure test or the submission date Pictures and/or samples of the damaged pipe (samples preferred) Information regarding operating pressures and temperatures leading up to the failure Additional information as specified on the Warranty Claim Form This information will be submitted to Aquatherm NA, and after testing and review, be forwarded on to Aquatherm GmbH for final analysis. This process may take several weeks. Appropriate coverage will be determined and issued accordingly. Submission for analysis is not a guarantee of compensation. The Aquatherm warranty does not cover the following issues*: Improperly assembled transitions (threads, flanges, copper stub outs, etc) unless the fitting was defective. Time lost due to poor planning, supplier issues, or failure to order the proper parts/tools. Connections that have not been properly fused according to Aquatherms requirements. Failures in systems that were not pressure tested before operation (evaluated on a case-by-case basis). Handling damage to pipe or fittings after they have left Aquatherms possession. *Not a comprehensive list

3.44

Chapter 4: Pipe and fittings

This chapter includes all the parts that Aquatherm offers as part of its piping systems. This chapter only gives the nominal imperial size so as to avoid confusion. A table giving the metric conversions can be found on page 1.8. Full dimensional data is not included in this manual. The dimensional data for all Aquatherm parts and fittings can be found on Aquatherms website.

4.1

aquatherm greenpipe SDR 7.4 faser-composite

Part no. 0670726 0670730 0670734 0670738 0670742 Part no. 0670708 0670710 0670712 0670714 0670716 0670718 0670720 0670722 0670724 Dimension ND 1 1 1 2 2 3 3 0670744 Dimension ND 4 6 8 10 12 14

aquatherm greenpipe SDR 11

Part no. 0610226 0610230 0610234 0610238 0610242 Part no. 0610208 0610210 0610212 0610214 0610216 0610218 0610220 0610222 0610224 Dimension ND 1 1 1 2 2 3 3 0610244 0610246 0610248 Dimension ND 4 6 8 10 12 14 16 18

The following items are supplied in coils: 0610308 0610310 0610312 1

4.2

climatherm SDR 7.4/11 faser-composite

Part no. 2670126 2670130 2670134 2670138 2070142 Part no. 2670708 2670710 2670112 2670114 2670116 2670118 2670120 2670122 2670124 Dimension ND SDR 7.4 SDR 7.4 1 SDR 11 1 SDR 11 1 SDR 11 2 SDR 11 2 SDR 11 3 SDR 11 3 SDR 11 2070144 2670146 2670148 Dimension ND 4 SDR 11 6 SDR 11 8 SDR 11 10 SDR 11 12 SDR 11 14 SDR 11 16 SDR 11 18 SDR 11

climatherm SDR 17.6 faser-composite

Part no. 2570148 2570150 2570152 2570154 Part no. 2570130 2570134 2570138 2570142 2570144 2570146 Dimension ND 6 8 10 12 Dimension ND 18 20 22 24

The following items are supplied in coils (non-faser) 2610308 2610310 2610312 SDR 11 SDR 11 1 SDR 11

4.3

14 16

aquatherm greenpipe UV SDR 7.4 faser-composite

Part no. 0670774 0670776 0670780 0670784 0670788 Part no. 0670758 0670760 0670762 0670764 0670766 Dimension ND 1 1 1 2 2 3 Dimension ND 3 4 6 8 10

climatherm UV SDR 7.4/11 faser-composite

Part no. 2670172 2670174 2670176 2670180 2670184 Part no. 2670758 2670760 2670762 2670162 2670164 2670166 2670168 2670170 Dimension ND SDR 7.4 SDR 7.4 1 SDR 7.4 1 SDR 11 1 SDR 11 1 SDR 11 2 SDR 11 2 SDR 11 2670188 Dimension ND 3 SDR 11 3 SDR 11 4 SDR 11 6 SDR 11 8 SDR 11 10 SDR 11

4.4

0670768 0670770 0670772

aquatherm lilac SDR 7.4/11

Part no. 9010224 9010226 9010230 9010234 9010238 Part no. 9010808 9010810 9010212 9010214 9010216 9010218 9010220 9010222 Dimension ND SDR 7.4 SDR 7.4 1 SDR 11 1 SDR 11 1 SDR 11 Dimension ND 3 SDR 11 4 SDR 11 6 SDR 11 8 SDR 11 10 SDR 11

4.5

2 SDR 11 2 SDR 11 3 SDR 11

aquatherm Advanced

wrap
Part no. Description 6 rolls of LPW 8" x 125' / Double bubble foil both sides with tape 4 rolls of LPW 12" x 125' /Double bubble foil both sides with tape 3 rolls of LPW 16" x 125' /Double bubble foil both sides with tape 2 rolls of LPW 24" x 125' /Double bubble foil both sides with tape 1 roll of LPW 36" x 125' /Double bubble foil both sides with tape 1 roll of LPW 48" x 125' /Double bubble foil both sides with tape For pipe sizes
38 /

DBLPW0812506 DBLPW1212504 DBLPW1612503 DBLPW2412502 DBLPW3612501 DBLPW4812501

" "

1" 1 " 2" 2 " 3" 4" 6" 8 10" 14

Foil tape required for aquatherm Advanced installations

4.6
Part no. FT25006 Dimension ND OD (6) Rolls 2 x 150 Foil Tape Total linear feet 900 Packing unit 6 per case Lb per case 8

Pricing and packing is per case of 6. Rolls not sold individually.

Coupling

Bushing
Part no. 0111130 0111131 0111132 0111134 0111136 0111138 0111143 0111144 0111145 0111139 0111140 0111142 0111151 0111152 0111153 Dimension ND 1 to 1 2 to 2 to 2 to 1 2 to 1 2 to 1 2 to 2 to 2 to 1 2 to 1 2 to 1 2 to 2 3 to 1 3 to 2 3 to 2 Part no. 0111155 0111157 0111159 0111161 0111163 0111165 Dimension ND 3 to 2 3 to 2 3 to 3 4 to 2 4 to 3 4 to 3

Part no. 0111008 0111010 0111012 0111014 0111016 0111018 0111020 0111022 0111024 0111026

Dimension ND 1 1 1 2 2 3 3 4

Part no. 0111112 0111114 0111116 0111118 0111120 0111122 0111124 0111126 0111128

Dimension ND to 1 to 1 to 1 to 1 to 1 to 1 1 to 1 to 1 to 1

4.7

Butt weld reducer

SDR Part no. 0111185 0111189 0111191 0111193 0111195 0111197 0111199 0111201 0111203 0111204 0111206 0111207 0111208 Dimension ND 8 to 6 10 to 6 10 to 8 12 to 8 12 to 10 14 to 10 14 to 12 16 to 10 16 to 12 16 to 14 18 to 12 18 to 14 18 to 16 SDR Part no. 2511184 2511188 2511190 2511193 2511195 2511197 2511199 2511201 2511203 2511204 2511206 2511207 2511208 2511209 2511210 Dimension ND 8 to 6 10 to 6 10 to 8 12 to 8 12 to 10 14 to 10 14 to 12 16 to 10 16 to 12 16 to 14 18 to 12 18 to 14 18 to 16 20 to 12 20 to 14 SDR Part no. 2511211 2511212 2511213 2511214 2511215 2511216 2511217 2511218 2511219 Dimension ND 20 to 16 20 to 18 22 to 16 22 to 18 22 to 20 24 to 16 24 to 18 24 to 20 24 to 22

17.6

SDR

Part no. 0111184 0111188 0111190

Dimension ND 8 to 6 10 to 6 10 to 8 12 to 8 12 to 10 14 to 10 14 to 12

11

17.6

7.4

0111192 0111194 0111196 0111198

4.8

Reducing couplings
female/female
Part no. 0111257 0111259 0111263 0111265 Dimension ND 3 to 2 3 to 3 4 to 3 4 to 3

Reducing couplings
butt weld/socket weld
SDR Part no. Dimension ND

2511174 6 to 3 17.6 2511176 6 to 4 2511182 8 to 4

Part no. 0111222 0111228 0111230 0111236 0111238 0111240 0111242 0111252 0111253

Dimension ND 1 to 1 1 to 1 1 to 1 2 to 1 2 to 1 2 to 1 2 to 2 3 to 2 3 to 2

SDR

Part no.

Dimension ND 6 to 4 8 to 4

0111174 6 to 3 7.4 0111176 0111182

0111175 6 to 3

4.9

11

0111177 0111183

6 to 4 8 to 4

One side is socket welded and the other is butt welded.

Elbow 90

aquatherm greenpipe - Elbow 90

SDR Part no. 0112131 112131LG 0112135 11 0112139 0112143 0112145 0112147 0112149 Dimension ND 6a 6b 8 10 12 14 16c 18c

Part no. 0112108 0112110 0112112 0112114 0112116 0112118

Dimension ND 1 1 1 2 2 3 3 4

SDR

Part no. 0112130 112130L 0112134 0112138 0112142 0112144

Dimension ND 6a 6b 8 10 12 14

7.4

4.10

0112120 0112122 0112124 0112126

Molded fitting, made from green Fusiolen. Molded fitting, made from green Fusiolen with 1 ft. extension on each end. c Mechanically stabilized with a faser-composite layer in the center of the pipe.
a b

climatherm - Elbow 90
SDR Part no. 2512130 2512134 2512138 2512142 17.6 SDR Part no. 0112131 112131LB 2612135 11 2612139 2012143 2012145 2012147 2012149
a b

Elbow 45
Dimension ND 6 8 10 12 14 16 18 20 22 24 Part no. 0112508 0112510 0112512 0112514 0112516 0112518 0112520 0112522 0112524 0112526 Dimension ND 1 1 1 2 2 3 3 4

2512144 2512146 2512148 2512150 2512152 2512154

Dimension ND 6 6
a b

8 10 12 14 16 18

4.11

Molded fitting, made from green Fusiolen. Molded fitting, made from green Fusiolen with 1 ft. extension on each end.

aquatherm greenpipe - Elbow 45

climatherm - Elbow 45
SDR Part no. 2512530 2512534 2512538 2512542 17.6 2512544 2512546 2512548 2512550 2512552 2512554 Dimension ND 6 8 10 12 14 16 18 20 22 24

SDR

7.4

11

Part no. 0112530 112530L 0112534 0112538 0112542 0112544 0112531 112531LG 0112535 0112539 0112543 0112545 0112547 0112549

Dimension ND 6a 6b 8 10 12 14 6a 6b 8 10 12 14 16c 18c

SDR

Part no. 0112531 112531LB 2612535 2612539 2012543 2012545 2012547 2012549

Dimension ND 6 6b 8 10 12 14 16 18
a

11

4.12

Molded fitting, made from green Fusiolen. Molded fitting, made from green Fusiolen with 1 ft. extension on each end. c Mechanically stabilized with a faser-composite layer in the center of the pipe.
a b

Street 90

Female/male

Street 45

Female/male

Cross

Part no. 0112308 0112310 0112312 0112314

Dimension ND 1 1

Part no. 0112708 0112710 0112712 0112714

Dimension ND 1 1

Part no. 0113708 0113710 0113712 0113714

Dimension ND 1 1

4.13

End cap

Butt weld end cap

SDR Part no. 0114131 0114135 0114139 0114143 0114145 0114147 0114149 Dimension ND 6 8 10 12 14 16 18 SDR Part no. 2514130 2514134 2514138 2514142 17.6 2514144 2514146 2514148 2514150 2514152 2514154 Dimension ND 6 8 10 12 14 16 18 20 22 24

11 Part no. 0114108 0114110 0114112 0114114 0114116 0114118 Dimension ND 1 1 1 2 2 3 3 4 7.4 SDR Part no. 0114130 0114134 0114138 0114142 0114144 Dimension ND 6 8 10 12 14

4.14

0114120 0114122 0114124 0114126

Tee

aquatherm greenpipe - Tee

SDR Part no. 0113131 113131LG 0113135 0113139 0113143 0113145 0113147 0113149 Dimension ND 6 6a 8 10 12 14 16b 18b

11 Part no. 0113108 0113110 0113112 0113114 0113116 0113118 0113120 0113122 0113124 0113126 Dimension ND 1 1 1 2 2 3 3 4
a

SDR

Part no. 0113130 0113130L 0113134 0113138 0113142 0113144

Dimension ND 6 6
a

7.4

8 10 12 14

4.15

Molded fitting, made from green Fusiolen with 1 ft. extension on each end. Mechanically stabilized with a faser-composite layer in the center of the pipe.

climatherm - Tee
SDR Part no. 25131310 2513134 2513138 2513142 SDR Part no. 0113131 113131LB 2613135 11 2613139 2013143 2013145 2013147 2013149 Dimension ND 6
a

Dimension ND 6 8 10 12 14 16 18 20 22 24

17.6

2513144 2513146 2513148 2513150 2513152 2513154

6b 8 10 12 14 16 18

4.16

Molded fitting, made from green Fusiolen. Molded fitting, made from green Fusiolen with 1 ft. extension on each end.

Reducing tee

inlet, outlet, branch

Part no. 0113546 0113547 0113548 0113550 0113551 Part no. 0113511 0113520 0113522 0113532 0113534 0113538 0113540 0113542 0113544 Dimension ND x x x x x x 1 x x 1 x 1 x 1 x x 1 x 1 x 1 x 1 x 1 x 1 x 0113552 0113554 0113556 0113558 0113560 0113561 0113562 0113564 0113566 0113568 Dimension ND 1 x 1 x 1 1 x 1 x 1 x 1 x 1 x 1 x 1 1 x 1 x 1 2 x 2 x 2 x 2 x 2 x 2 x 1 2 x 2 x 1 2 x 2 x 1 2 x 2 x 2 x 2 x 2 x 2 x 1 2 x 2 x 1 2 x 2 x 1 Part no. 0113570 0113576 0113578 0113580 0113582 0113584 0113586 0113588 0113590 0113592 0113594 0113596 Dimension ND 2 x 2 x 2 3 x 3 x 1 3 x 3 x 1 3 x 3 x 1 3 x 3 x 2 3 x 3 x 2 3 x 3 x 2 3 x 3 x 2 3 x 3 x 3 4 x 4 x 2 4 x 4 x 3 4 x 4 x 3

4.17

aquatherm greenpipe - Reducing tee

socket welding
SDR Part no. 0113628 7.4 0113630 0113904 0113916 SDR Part no. 0113601 0113603 113605LG 0113609 11 0113611 0113613 0113615 0113625 0113627 0113629 Dimension ND 10 x 10 3 10 x 10 x 4 12 x 12 x 4 14 x 14 x 4 Dimension ND 6 x 6 x 2 6 x 6 x 3 6 x 6 x 4a 8 x 8 x 2 8 x 8 x 3 8 x 8 x 3 8 x 8 x 4 10 x 10 x 2 10 x 10 x 3 10 x 10 x 3
a

SDR

Part no. 0113631 0113651 0113653 0113663 0113665 0113667 0113676 0113678 0113680 0113682 0113690 0113692 0113694 0113696 0113698

Dimension ND 10 x 10 x 4 12 x 12 x 4 12 x 12 x 6 14 x 14 x 4 14 x 14 x 6 14 x 14 x 8 16 x 16 x 4 16 x 16 x 6 16 x 16 x 8 16 x 16 x 10 18 x 18 x 4 18 x 18 x 6 18 x 18 x 8 18 x 18 x 10 18 x 18 x 12

SDR

Part no. 0113600 0113602 113604L 0113608

Dimension ND 6 x 6 x 2 6 x 6 x 3 6 x 6 x 4a 8 x 8 x 2 8 x 8 x 3 8 x 8 x 3 8 x 8 x 4 10 x 10 x 2 10 x 10 x 3

11

7.4

0113610 0113612 0113614 0113624 0113626

4.18

Molded fitting, made from green Fusiolen with 1 ft. extension on the inlet/outlet and a reducer on the branch.

aquatherm greenpipe - Reducing tee (continued)

butt welding
SDR Part no. 0113619 0113635 0113641 0113655 0113657 0113669 0113671 0113684 0113685 0113699 0113700 Dimension ND 8 x 8 x 6 10 x 10 x 6 10 x 10 x 8 12 x 12 x 8 12 x 12 x 10 14 x 14 x 10 14 x 14 x 12 16 x 16 x 12 16 x 16 x 14 18 x 18 x 14 18 x 18 x 16

11 SDR Part no. 0113618 0113634 0113640 0113906 7.4 0113908 0113910 0113918 0113920 0113922 0113924 Dimension ND 8 x 8 x 6 10 x 10 x 6 10 x 10 x 8 12 x 12 x 6 12 x 12 x 8 12 x 12 x 10 14 x 14 x 6 14 x 14 x 8 14 x 14 x 10 14 x 14 x 12

4.19

climatherm - Reducing tee

socket welding
SDR Part no. 2613631 2013651 2513653 2013663 2013657 2013669 2013676 2013678 2013680 2013682 2013690 2013692 2013694 2013696 2013698 Dimension ND 10 x 10 x 4 12 x 12 x 4 12 x 12 x 6 14 x 14 x 4 12 x 12 x 10 14 x 14 x 10 16 x 16 x 4 16 x 16 x 6 16 x 16 x 8 16 x 16 x 10 18 x 18 x 4 18 x 18 x 6 18 x 18 x 8 18 x 18 x 10 18 x 18 x 12

SDR

Part no. 0113601 0113603 113605LB 2613609 2613611 2613613 2613615 2613625 2613627 2613629

Dimension ND 6 x 6 x 2 a 6 x 6 x 3a 6 x 6 x 4b 8 x 8 x 2 8 x 8 x 3 8 x 8 x 3 8 x 8 x 4 10 x 10 x 2 10 x 10 x 3 10 x 10 x 3 11

11

4.20

Molded fitting, made from green Fusiolen. Molded fitting, made from green Fusiolen with 1 ft. extension on the inlet/outlet and a reducer on the branch.
a b

climatherm - Reducing tee (continued)

socket welding
SDR Part no. 2513630 2513651 2513653 2513663 2513665 2513667 2513676 2513678 17.6 2513680 2513682 2513690 2513692 2513694 2513696 2513698 2513804 2513806 Dimension ND 10 x 10 x 4 12 x 12 x 4 12 x 12 x 6 14 x 14 x 4 14 x 14 x 6 14 x 14 x 8 16 x 16 x 4 16 x 16 x 6 16 x 16 x 8 16 x 16 x 10 18 x 18 x 4 18 x 18 x 6 18 x 18 x 8 18 x 18 x 10 18 x 18 x 12 20 x 20 x 4 20 x 20 x 6 SDR Part no. Dimension ND 20 x 20 x 8 20 x 20 x 10 20 x 20 x 12 22 x 22 x 4 22 x 22 x 6 22 x 22 x 8 22 x 22 x 10 22 x 22 x 12 24 x 24 x 4 24 x 24 x 6 24 x 24 x 8 24 x 24 x 10 24 x 24 x 12 2513808 2513810 2513812 2513821 2513823 2513825 17.6 2513827 2513829 2513839 2513841 2513843 2513845 2513847

SDR

Part no. 2513600 2513602 2513608

Dimension ND 6 x 6 x 2 6 x 6 x 3 8 x 8 x 2 8 x 8 x 3 8 x 8 x 3 8 x 8 x 4 10 x 10 x 2 10 x 10 x 3 10 x 10 3

2513610 17.6 2513612 2513614 2513624 2513626 2513628

4.21

climatherm - Reducing tee

butt welding
SDR Part no. 2513618 2513634 2513640 2513655 2513657 2513669 SDR Part no. 2613619 2613635 2613641 2013655 2013657 2013665 2013671 2013684 2013685 2013699 2013700 Dimension ND 8 x 8 x 6a 10 x 10 x 6a 10 x 10 x 8 12 x 12 x 8 12 x 12 x 10 14 x 14 x 6 14 x 14 x 12 16 x 16 x 12 16 x 16 x 14 18 x 18 x 14 18 x 18 x 16 17.6 2513671 2513684 2513685 2513699 2513700 2513813 2513814 2513815 2513831 2513832 Dimension ND 8 x 8 x 6 10 x 10 x 6 10 x 10 x 8 12 x 12 x 8 12 x 12 x 10 14 x 14 x 10 14 x 14 x 12 16 x 16 x 12 16 x 16 x 14 18 x 18 x 14 18 x 18 x 16 20 x 20 x 14 20 x 20 x 16 20 x 20 x 18 22 x 22 x 16 22 x 22 x 18
a

SDR

Part no.

Dimension ND 20 x 20 x 20 24 x 24 x 16 24 x 24 x 18 24 x 24 x 20 24 x 24 x 22

2513833 2513849 17.6 2513850 2513851 2513852

11

4.22

Molded fitting, made from green Fusiolen.

Fusion outlet
Part no. 0115172 0115174 0115175 0115176 Part no. 0115156 0115158 0115160 0115162 0115164 0115166 0115168 0115170 Dimension ND (pipe x outlet) 1 x 1 x 1 x 1 x 2 x 2 x 2 x 1 2 x 0115178 0115180 0115181 0115182 0115184 0115186 0115188 0115189 0115190 0115192 Dimension ND (pipe x outlet) 2 x 2 x 1 2 x 1 3 x 3 x 3 x 1 3 x 1 3 x 3 x 3 x 1 3 x 1 3 x 1 4 x 4 x Part no. 0115194 0115196 0115197 0115198 0115206 0115208 0115210 0115212 0115214 0115216 0115218 0115220 0115228 0115229 Dimension ND (pipe x outlet) 4 x 1 4 x 1 4 x 1 4 x 2 6 x 6 x 6 x 1 6 x 1 6 x 1 6 x 2 6 x 2

4.23

6 x 3 8 to 10 x 8 to 10 x

Fusion outlet (continued)

Part no. 0115252 0115253 0115254 0115255 0115256 0115257 0115260 0115261 0115262 0115263 0115264 0115265 0115268 0115269 0115270 0115271 0115272 0115275 Dimension ND (pipe x outlet) 10 x 1 10 x 2 10 x 2 10 x 3 10 x 3 10 x 4 12 to 14 x 2 12 to 14 x 2 12 x 3 12 x 3 12 x 4 12 x 6 14 x 3 14 x 3 14 x 4 14 x 6 14 x 8 16 to 20 x 2 Part no. 0115277 0115278 0115280 0115288 0115290 0115292 0115298 0115300 0115303 0115306 0115312 0115315 0115316 0115318 0115331 0115334 0115340 Dimension ND (pipe x outlet) 16 to 18 x 3 16 x 4 16 x 6 to 10 16 to 20 x 3 18 to 20 x 4 18 x 6 to 10 18 x 12 16 to 24 x 2 20 to 22 x 3 20 x 6 to 10 20 x 12 22 to 24 x 2 22 to 24 x 3 22 to 24 x 4 24 x 3 24 x 6 to 10 24 x 12

Part no. 0115230 0115231 0115232 0115233 0115234

Dimension ND (pipe x outlet) 8 to 10 x 1 8 x 1 8 x 1 8 x 2 8 x 2 8 x 3 8 x 3 8 x 4 10 x 1

4.24

0115235 0115236 0115237 0115251

Cross-over

Flange adapterc
SDR Part no. 0115530 115530L 0115534 0115538 0115542 0115544 0115531 115531LB 115531LG 0115535 0115539 0115543 0115545 0115547 0115549 Dimension ND OD 6 6b 8 10 12 14 6 6b 6b 8 10 12 14 16 18 SDR Part no. Dimension ND OD 6 8 10 12 14 16 18 20 22 24

7.4

Part no. 0116108 0116110 0116112

Dimension ND 1

Part no. 0115512 0115514 0115516 0115518 0115520 0115522 0115524 0115526

Dimension ND 1 1 1 2 2 3 3 4a 11

2915530 2915534 2915538 2915542 2915544 17.6 2915546 2915548 2915550 2915552 2915554

4.25

Part no. 0115526 must be paired with a coupling (part no. 0111026, sold separately).

Gasket is not included. See page 3.33. b Molded fitting, made from green Fusiolen with 1 ft. extension on each end.

Flange ring
SDR Part no. 3315730 7.4 3315734 3315738 3315742 3315744 3315730 3315734 3315738 3315742 3315744 3315746 3315748 Dimension ND 6 8 10 12 14 6 8 10 12 14 16 18 # of bolt holes 8 8 12 12 12 8 8 12 12 12 16 16 SDR Part no. Dimension ND 6 8 10 12 14 16 18 20 22 24 # of bolt holes 8 8 12 12 12 16 16 20 20 20

Part no. 3315712 3315714 3315716 3315718 3315720 3315722 3315724 3315726

Nominal flange size 1 1 1 2 2 3 3 4

Dimension ND 1 1 1 2 2 3 3 4

# of bolt holes 4 4 4 4 4 8 8 8 11

3315730 3315734 3315738 3315742 3315744 17.6 3315746 3315748 3315750 3315752 3315754

4.26

Pump flange adapter ring

American bolt pattern

Union with brass nut

Union with PP-R nut

Part no. 5515712

Dimension ND OD 1 (32 mm) pump flange ring - blue, 3-1/8 to 3-5/32 bolt center used with #0115512 1.25 (40 mm) pump flange ring - black, 3-1/8 to 3-5/32 bolt center used with #0115514 1.25 (40 mm) pump flange ring - green, 3-/16 to 3-1/2 bolt center used with #0115514, fitted Grundfos model UP4375

Part no. 0115812 0115814 0115816 0115818 0115820

Dimension ND 1 1 1 2 2

Part no. 0115838 0115840 0115842 0115844 0115846 0115848 0115850

Dimension ND 1 1 1

5515713

4.27

2 2

5515714

Electrofusion coupling
Part no. 0117224 0117226 0117230 0117234 0117238 Part no. 0117208 0117210 0117212 0117214 0117216 Dimension ND 1 1 1 2 2 3
a

Wing back 90 elbow

Dimension ND 3 4 6a 8a 10a Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension 20 mm x F

0120158

0920158

0620158

4.28

0117218 0117220 0117222

Cannot be used in conjunction with UV pipe.

Back plate elbow

threaded

ISO plug for pressure tests

with gasket

Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x thread type x F x F x F x F

Part no. 0050708 0050710

Dimension M M

0120108 0120110 0120112 0120113

0920108 0920110 0920112 0920113

0620108 0620110 0620112 0620113

4.29

ISO transition piece

with counter nut, gasket and tension washer

with counter nut, gasket and tension washer

ISO transition elbow

ISO transition elbow

for dry construction

Part no. 0120204

Dimension 20 mm x F x M

Part no. 0120208 0120209

Dimension 20 mm x F x M 25 mm x F x M

Part no. 0120210

Dimension (ND OD) 20 mm x F x M

4.30

Transition fitting
round

NPT transition fitting

Lead-free brass
Part no. (NPT)

with hex-shaped threaded transition (female)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x thread type x F x F x F x F 1 x F 1 x 1 F 1 x 1 F 1 x 1 F 1 x 1 F 1 x 1 F 2 x 1 F 2 x 2 F 2 x 2 F

0121108 0121110 0121111 0121112 Lead-free brass

Part no. (NPT)

1121114 1121115 1121116 1121117 1121118 1121119 -

0621108 0621110 0621111 0621112 0621113 0621114 0621115 0621116 0621117 0621118 0621119 0621120 0621122

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x thread type x F x F x F x F 1 x F

0121113 0121114 0121115 0121116 0121117 0121118 0121119 0121120 0121122

0121008 0121010 0121011 0121012 0121013

0921008 0921010 0921011 0921012 0921013

0621008 0621010 0621011 0621012 0621013

4.31

Transition fitting
round (male)

NPT transition fitting

Lead-free brass
Part no. (NPT)

hex-shaped threaded transition (male)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x thread x M x M x M 1 x 1 M 1 x 1 M 1 x 1 M 1 x 1 M 1 x 1 M 1 x 1 M 2 x 1 M 2 x 2 M 2 x 2 M 2 x 2 M 3 x 3 M 3 x 4 M

0121308 0121310 0121312 0121314 0121316 Lead-free brass

Part no. (NPT)

0621308 0621310 0621312 0621314 0621316 0621317 0621318 0621319 0621320 0621321 0621322 0621323 0621324 0621325 -

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

0121317 Dimension PP-R (ND) x thread type x M x M x M x M 1 x M 0121318 0121319 0121320 0121321 0121322 0121323 0121324 0121325 0121327

0121208 0121210 0121211

0921208 0921210 0921211 0921212 0921213

0621208 0621210 0621211 0621212 0621213

4.32

0121212 0121213

NPT transition elbow

NPT transition street elbow

Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x Thread type x F x F x F x F

Lead-free brass
Part no. (NPT)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x Thread type x F

0123208

0623208

0123008 0123010 0123012 0123014 0123016 0123018

0923008 0923010 0923012 0923014 0923016 (NPT) 1123018

0623008 0623010 0623012 0623014 0623016 0623018

4.33

1 x F 1 x 1 F

NPT transition tee

(male)

Transition to compression fitting

(PP-R to brass)

Lead-free brass
Part no. (NPT)

Zero-lead brass
Part no. (NPT)

Dimension ND x M x

Part no. 0099013

Dimension ND PP-R to 3/ Compression 8

0125506

0625506

4.34

(PP-R to copper)

Stub out

PEX adaptor

Draining branch
to weld in valves

Part no. AA630P248E AA630P368E AA630P41110

Dimension ND 1

Part no. 0099840 0099841 0098742

Dimension ND 1

Part no. 0041408 0041410 0041412 0041414 0041416 0041418

Dimension ND 1 1

4.35

1 2

Transition elbow
(male)

Transition tee
(female)
Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R (ND) x thread type x x F x x F x x F x x F 1 x 1 x F

0125006 0125008 0125010 Lead-free brass

Part no. (NPT)

925006 925008 925010 925012 925014 (NPT)

0625006 0625008 0625010 0625012 0625014

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension PP-R ND x thread type x M x M x M 1 x M 1 x 1 M

0125012 0125014

0123506 0123508

0923506 0923508 0923510 0923512 -

0623506 0623508 0623510 0623512 0623514

0125016 0125022

1125016 -

0625016 0625022

1 x 1 x 1 F 1 x 1 x 1 F

4.36

0123510 0123512 0123514

NPT fusion outlet

with female thread
Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension pipe x outlet (thread) 1 x ( F) 1 x ( F) 2 x ( F) 2 x ( F) 3 x ( F) 3 x ( F) 4 x ( F) 6 x ( F) 8 to 10 x ( F) 1 x ( F) 1 x ( F) 2 x ( F) 2 x ( F)

0128214 0128216 0128218 0128220 0128222 0128224 0128226 0128230 0128232 0128234 0128236 0128238 0128240

0928214 0928216 0928218 0928220 0928222 0928224 0928226 0928230 0928232 0928234 0928236 0928238 0928240

0628214 0628216 0628218 0628220 0628222 0628224 0628226 0628230 0628232 0628234 0628236 0628238 0628240

4.37

NPT fusion outlet (continued)

with female thread
Lead-free brass
Part no. (NPT)

Stainless steel
Part no. (ISO)

Zero-lead brass
Part no. (NPT)

Dimension pipe x outlet (thread) 3 x ( F) 3 x ( F) 4 x ( F) 6 x ( F) 8 to 10 x ( F)

0128242 0128244 0128246 0128250 0128254

0928242 0928244 0928246 0928250 0928254 (NPT)

0628242 0628244 0628246 0628250 0628254

0128260 0128262 0128264 0128266

1128260 1128262 1128264 1128266 1128270 1128274

0628260 0628262 0628264 0628266 0628270 0628274

2 x 1 (1 F) 3 x 1 (1 F) 3 x 1 (1 F) 4 x 1 (1 F) 6 x 1 (1 F) 8 to 10 x 1 (1 F)

4.38

0128270 0128274

NPT fusion outlet

male thread
Lead-free brass
Part no. (NPT)

Zero-lead brass
Part no. (NPT)

Dimension pipe x outlet (thread) 4 x ( M) 6 x ( M) 1 x ( M) 1 x ( M) 2 x ( M) 2 x ( M) 3 x ( M) 3 x ( M) 4 x ( M) 6 x ( M)

0128326 0128330 0128334 Lead-free brass

Part no. (NPT)

0628326 0628330 0628334 0628336 0628338 0628340 0628342 0628344 0628346 0628350

Zero-lead brass
Part no. (NPT)

Dimension pipe x outlet (thread) 1 x ( M) 1 x ( M) 2 x ( M) 2 x ( M) 3 x ( M) 3 x ( M)

0128336 0128338 0128340 0128342 0128344 0128346 0128350

0128314 0128316 0128318 0128320 0128322 0128324

0628314 0628316 0628318 0628320 0628322 0628324

4.39

Distribution block plumbing

including 1 plug and 2 fasteners

Distribution block plumbing

with insulation block

Distribution pipe

Part no. 0130115

Dimension ND x

Part no. 0130130

Dimension ND x

Part no. 0130604

Dimension ND 1 x

4.40

Distributor end piece

with female thread NPT

Ball valve

(male/female)

Screw-down stop globe valve

for surface installation

Part no. 0130804

Dimension (ND) x Thread 1 x F

Part no. 0078000

Dimension ND 1 M/F

Part no. 0140808 0140810 0140812 0140814

Dimension ND 1 1

4.41

Concealed valve
chromium-plated

Concealed valve

chromium-plated, tamper proof, short design

Concealed valve
chromium-plated

Part no. 0140858 0140860 0140862

Dimension ND 1

Part no. 0140868 0140870 0140872

Dimension ND 1

Part no. 0140878 0140880 0140882

Dimension ND 1

4.42

Concealed valve

chromium-plated, tamper proof

Concealed valve

chromium-plated for part no. 0040858-0040862

Stop valve body ISO

Part no. 0140888 0140890 0140892

Dimension ND 1

Part no. 0140900 0140902

Dimension ND Length = 3.2 Length = 4.25

Part no. 0140908 0140910 0140912 0140914

Dimension PP-R (ND) x Thread x F x F 1 x 1F 1 x 1 F

4.43

Inclined valve
without drain

Inclined check valve

without drain

Ball valve

without drain

Part no. 0141108 0141110 0141112 0141114

Dimension ND 1 1

Part no. 0141208 0141210 0141212 0141214

Dimension ND 1 1

Part no. 0041308 0041310 0041312 0041314 0041316 0041318

Dimension ND 1 1 1 2

4.44

Extension for ball valve

Ball valve

polypropylene

Ball valve

Polypropylene (European flange ring)

Part no. 0141378 0141382 0141386

Dimension ND x length to 1 to 1 1 to 2

Part no. 0041388 0041390 0041392 0041394 0041396 0041398 0041400

Dimension ND 1 1 1 2 2

Part no. 0041602 0041604

*

Dimension ND 3 3 and 4 6

0041607

0141378 suitable for part no. 0041308 / 0041310. 0141382 suitable for part no. 0041312 / 0041314. 0141386 suitable for part no. 0041316 / 0041318.

*For a 4 connection, use part no. 0115526 and part no. 3315724. For a 3 connection, use part no. 0115524 and part no. 3315724.
Hexagon screw M16x60mm for Art.-No. 41602/41604 Hexagon screw M16x80mm for Art.-No. 41607 corresponding flat washer M16 Notice: These are not included in delivery.

4.45

Welding jig
Part no. 0450148 0450150 Dimension 2 - 4 -

Welding heads
Part no. 0050206 0050208 0050210 0050212 Dimension
38 /

Repair set
Part no. 0050307 0050311 Dimension
7 16

1 1 1 2 2 3 3 4

Temperature protective gloves

for welding head changing
Part no. 0050195 Dimension -

0050214 0050216 0050218 0050220 0050222

Repair plug
to close pipe holes up to 7 16 (repair stick part no. 0060600) Part no. 0060600 Dimension
7 16

4.46

0050224 0050226

Drill bit
Part no.

for boring fusion outlet holes Dimension & for pipes 1 - 6 & for pipes 2 - 10 1 1 1 2 2 a 3a 3 a 4a 6a 8a

Fusion outlet welding heads

Part no. 0050614 0050616 0050619 0050620 0050623 0050624 0050625 0050627 0050628 0050629 0050631 0050632 0050634 0050635 0050636 Dimension 1 x & 1 x & 2 x & 2 x 1 2 x & 2 x 1 2 x 1 3 x & 3 x 1 3 x 1 3 x & 3 x 1 3 x 1 3 x 1 4 x & Part no. 0050638 0050640 0050642 0050644 0050648 0050650 0050652 0050654 0050656 0050657 0050658 0050660 0050662 0050664 0050666 Dimension 4 x 1 4 x 1 4 x 1 4 x 2 6 x & 6 x 1 6 x 1 6 x 1 6 x 2 6 x 2 6 x 3 8 x & 8 x 1 8 x 1 8 x 1

0050940 0050941 0050942 0050944 0050946 0050948 0050950 0050952 0050954 0050956 0050958 0050960
a

4.47

Only fits into a drill press that can accommodate a Morse Taper shank.

Fusion outlet welding heads (continued)

Part no. 0050667 0050668 0050669 0050670 0050671 0050672 0050674 0050676 0050678 0050680 0050682 0050684 0050686 0050688 0050690 Dimension 8 x 2 8 x 2 8 x 3 8 x 3 8 x 4 10 x &. 10 x 1 10 x 1 10 x 1 10 x 2 10 x 2 10 x 3 10 x 3 10 x 4 12 x 2 Part no. 0050692 0050694 0050696 0050698 0050699 0050712 0050714 0050716 0050718 0050720 0050722 0050724 0050726 0050728 0050730 Dimension 12 x 2 12 x 3 12 x 3 12 x 4 12 x 6 14x 2 14 x 2 14 x 3 14 x 3 14 x 4 14 x 6 14 x 8 16 - 24 x 2 16 - 20 x 2 22 - 24 x 2 Part no. 0050732 0050734 0050736 0050738 0050740 0050742 0050744 0050746 Dimension 16 - 20 x 3 22 - 24 x 3 16 - 18 x 3 20 - 22 x 3 24 x 3 16 x 4 18 - x 4 22 - 24 x 4

4.48

Notes

4.49

Notes

4.50

Notes

4.51

Notes

4.52