Flowpex Technical Manual

FLOWPEX
PIPING
SYSTEMS
BY HYDROSTA
Flowpex
Technical Manual
GAS
LPG
HOT / COLD WATER
HYDRONIC HEATING
AIR
TM
Australian
Standard
AS4176 AS NZ4020
Lic SMkP021181
SAI Global
Index
Introduction....................................... 3
Characteristics................................... 4
Pipe.................................................. 5
Fittings.............................................. 6
Advantages....................................... 8
Installation Instructions...................... 10
Making a Bend................................. 12
Changing Crimping Heads................ 13
Hydronic Heating.............................. 14
Fittings List....................................... 16
Pipe Coils......................................... 20
Tools................................................ 21
Gas Tables....................................... 22
Worked Example.............................. 26
Sundry Regulations........................... 27
FLOWPEX
PIPING
SYSTEMS
BY HYDROSTA
Flowpex by Hydrosta is the most versatile
of all plumbing systems using a composite
(PEX-AL-HDPE) pipe with DR Brass fittings.
It is designed so that the same fittings and
tools can be used for all applications and
is priced to be competitive with PEX only
systems.
Our system has been independently tested
to meet the requirements of AS4176, AS
4020 and is listed in table 3.1 of the
Australian Standard for Gas Installations
AS5601.2004.
The Flowpex by Hydrosta system is so
simple and easy to use you will have so
much more time for other jobs, family or
doing the things you love.
3
Characteristics of Flowpex by Hydrosta
• UV stabilised
• Can be bent by hand
• Allows much tighter bends to be
made than with PEX
• Retains shape when bent
• 100% impermeability to oxygen and
other gases
• Eliminates water hammer
• Strong and durable
• Corrosion resistant; no denzo tape,
no sleeving required
• Butt laser welded—NOT overlapped
(pipe is circular and not oval in
shape)
• DR brass fittings and stainless steel
ferrules
• Smooth surface – no friction
• Lightweight and easy to use
• Smooth inner layer – lower pressure
loss, accurate use of sizing tables
• 2 Viton ‘o rings’ with a double crimp
PIPE
Flowpex pipe is a multi layered pipe of
five layers. It consists of a layer of food
grade cross-linked polyethylene, a layer
of longitudinally laser-welded aluminum
and an outer layer of UV stabilised
HDPE.
Between these layers are adhesive and bonding layers.
Our system is tested in accordance with AS4176 and
AS4020 and as such is fully approved for use in gas,
LPG, hot – cold water installations and hydronic heating.
The system is exactly the same for gas as it is for water,
except installers must ensure they use appropriately
marked pipes, depending on the installation.
For water and hydronic heating a black UV stabilised
pipe with blue markings is used displaying the
Watermark logo.
For gas instillations a black UV stabilised pipe with
yellow markings displaying the Standards mark logo
should be used.
5
FITTINGS
Our system uses crimp fittings which
are DR brass with stainless steel crimp
ferrules and Viton ‘O’ rings.
6
•
Constructed using high quality DR brass. This means
the fittings can be placed in the ground without
protection as they will not de-zincify.
•
The pipe and fittings are secured using a mechanical
crimper which deforms the stainless steel ferrule.
•
Uses specially designed crimping jaws for joining,
which lines up the jaws exactly with the holder on
the fitting. This guarantees a reliable and quick
connection - every time.
•
Each fitting has an isolation ring which separates
the brass fitting from the aluminium layer in the
pipe to prevent electrolysis.
•
The O-rings are made with Viton plastic which is a
fluoro-silicate plastic. This is impervious to attack by
olefants (hydrocarbons and petrochemicals found
in natural gas). Viton plastic is the only plastic that
will work universally for both water and gas.
CRIMPING TOOL
We use one hand crimping tool for all connections. It
is designed with an over-centre pivot point, allowing
greater pressure to be applied with the same amount
of force.
The crimping tool is non-adjustable and does not require
calibration or the use of gauges to check the effectiveness
of the crimp.
With our hand crimper you will easily crimp 32mm
fittings with a 100% durable crimp, something that you
can only achieve with an electric crimper using other
systems.
If you choose, our crimping jaws also connect to existing
power crimping tools.
Our tools are simple to use and
inexpensive!
7
ADVANTAGES
Flowpex is a premium brand utilising the latest technology
at the most competitive price.
Here are a number of significant advantages we can
offer over competitive systems.
Over
Copper
Over
PEX only systems
Cheaper - Our competitive
advantage
will
only
increase as the price of Price - We are so
copper increases.
competitive on price
Competitively
priced you will find us similarly
tools - The start up costs priced to other PEX only
to switch to Flowpex are systems.
not significant and are
well worth the benefits.
No Welding - The use of
crimp fittings completely
eliminates the needs for
welding. Imagine no
more lugging oxy around.
You’ll never have to refill
that gas bottle again!
Efficient installation - Its
simple use allows your
jobs to be installed in
around one-third of the
time, letting you take on
more jobs or even take
the afternoon off!
8
Once it’s bent it stays
bent - It won’t snap back
to its original shape like
PEX only systems. This
allows you to rough-in
your work before installing
and get into tighter
spaces. When hot water
is run through them they
can collapse and prevent
flow. Several systems have
bend restraining devices
which are not required by
Flowpex.
Malleable and light Allows plumbers to get
into tight spaces with
ease. It can also be bent
to make corners by hand
eliminating the need to
attach a corner or bend
piece.
Tighter bends can be
made - With Flowpex
you can make bends of
5X the radius of the pipe.
With PEX only products
the maximum allowable
bend is usually 10X - 15X
the radius of the pipe.
Eliminates water
hammer
100% oxygen tight - No
oxygen penetration.
ADVANTAGES
In terms of our competitors with similar composite pipe
systems our product brings a number of significant
advantages:
Advantages
Approved for gas AND hot/cold water - We believe
we are the most competitively priced composite pipe
that is approved for use in gas and hot/cold water
installations.
UV stabilized pipe – Our pipe is a black UV stabilised
pipe with a yellow stripe down the side when being
used for gas installations and with a blue stripe
for water. This allows the pipe to be placed in any
exposed area without having to be enclosed in a
protective covering or with UV protective paint.
Laser welded not overlapped – The aluminium layer in
our pipe is butted and laser welded NOT overlapped.
This means the product is of a much higher quality. In
overlapped systems the pipe takes on an oval shape
due to the two pieces of aluminium on one side of the
pipe. This means that the pipe doesn’t bend properly
if it is bent the wrong way. This can cause kinks in
the pipe. It also means that the pipe doesn’t fit into
the fitting exactly as it should, which may result in an
inaccurate or faulty crimp.
Fittings are DR brass – They can be placed within the
ground without protection. They also do not leech zinc
which would cause the fitting to ‘chalk’ and fail.
Quality and competitively priced tools – Our crimp
system uses a specially designed over-centre hand
crimping tool. This means that a hand crimper can
easily be used for all pipe sizes without the need to
buy an electric hand crimper. We also have electric
crimpers.
Flowpex uses the same fittings and pipe
for gas and hot/cold water, the only
difference being the markings on the
pipe.
9
INSTALLATION
MAKING A CRIMP
STEP 1 - Cutting Pipe
Cut the pipe using shears. Ensure that the shears are
square to the pipe. Rotate the shears around the pipe
when cutting to ensure a cleaner cut. Standard wheel
type cutters may also be used. The pipe has length
markings to assist in measuring.
STEP 2 - Gauging Pipe
Use the multi-step reamer to remove any oval distortion
and to chamfer the inside of the pipe. Make at least
two rotations.
STEP 2 - Assembling Joint
Push pipe into the fitting until the pipe is visible
through the indexing holes and the blue plastic antielectrolysis washer is visible through the Nylon ferrule
locator. Never crimp a fitting where the blue ring is
not visible or where the pipe cannot be seen through
the indexing holes.
10
INSTRUCTIONS
STEP 4 - Crimping
Place the assembled joint in the crimping jaws so that
the nylon ferrule support engages with the groove in
the jaws. This can be left or right. Move the handles
of the jaws together until the over centre limits on
the handles touch. You will feel resistance for this to
happen. Open the handles again and remove the
joint.
THE CRIMP IS COMPLETE!
11
MAKING A BEND
MAKING A BEND
STEP 1
Bends can be made by
hand. The pipe is quite
malleable and pulling the
pipe around obstructions,
through roof or other
small spaces should be
easy and can be made by
hand. When bending by
hand the minimum radius
of the bend should be
no less than 5 times the
diameter of the pipe.
STEP 2
Tighter bends should be
made with a bending
spring so as to maintain
the shape of the pipe
during the bend. To make
a bend using a bending
spring insert the correct
internal bending spring
for the pipe size you wish
to bend with the narrow
end first. The narrow end
is designed so that the
spring does not scratch
the inside of the pipe
during insertion.
STEP 3
STEP 4
Bend the pipe using your Remove
hands.
spring.
12
the
bending
CHANGING CRIMPING HEADS
CHANGING THE CRIMPING HEAD
With Flowpex you only need one crimping tool but
you will need to change the press tongs attached to
the end depending on the size of the pipe you wish
to crimp.
STEP 1
To attach the crimping head to the crimping tool,
line up a hole at the end of one of the tails on the
tongs with the hole on the crimping tool and place the
securing pin through this hole.
STEP 2
Open the handles slightly. You will not be able to insert
the other pin if the crimping jaws are fully closed.
STEP 3
Line up the hole on the other tongs tail and the other
hole in the crimping tool and insert the other pin.
STEP 4
You are now ready to crimp. Remove the crimping
head by following these steps in reverse.
13
HYRDONIC HEATING
Flowpex is a great option for use in hydronic heating.
Hydronic heating has three options:
1. Where hot water pipes are run throughout a concrete slab at intervals in a grid pattern. These pipes
are then attached to the water heater and hot water
is passed through them where under floor heating
is required.
2. Where the same grid like pattern is used but with a
sand/cement bed under tiles or carpet.
3. To heat wall mounted water radiators. Hydronic
heating is a fast and efficient way to provide under
floor heating.
Flowpex is a great option because:
•
Tighter bends can be made with Flowpex than with
PEX alternatives.
•
Flowpex pipe will maintain its shape during installation once it is bent. This means it is much easier to
work with while laying out the floor pattern.
•
Thermal expansion is lower than other pipes, meaning less stress on the pipe during heating.
•
Rated to 95*C.
•
DR brass fittings.
•
The same pipe that is used for drinking water is also
used for hydronic heating.
Use
Using Flowpex for hydronic under floor heating is easy.
You simply unroll some Flowpex water pipe on the concrete or tiling underlay. Fix the pipe to the floor or underlay using half saddles. These can be nail or screw fixed.
Over concrete slabs, holes should be drilled and either
spaghetti or rawl plugs used to take fixing screws.
14
HYDRONIC HEATING
Cover the whole sector in a grid pattern. Each sector of
approx 20 sq m will require a 100m roll of piping. The
flow and return lines should be laid in parallel, so that at
the centre of the sector, there is a loop.
Cover the pipe grid with chicken wire mesh, sand and
cement topping. Alternatively the chicken wire can be
laid before the piping.
Tile or carpet over.
Pipe work can also be set in concrete slabs before the
concrete is poured, by lashing it to the reinforcing steel
and leaving the flow and return tails protruding from
the slab.
We recommend the OLIN hot water system, as it not only
provides hot water for domestic use, but also hot water
for hydronic heating within the same unit. It is gas fired
- and hence very efficient.
Connection for hot and cold to and from the HWS should
be done using Flowpex composite piping.
Fast, efficient, economical and easy to
use!
15
FITTINGS
Cap
Size
CP16
CP20
CP26
Elbow
Size
E16
E20
E26
E32
Elbow Female
Size
FE1616
FE2020
FE2620
FE2626
FE3226
Elbow Male
Size
ME1616
ME2020
ME2626
ME3226
Lugged Elbow
Size
LE1616
LE2016
LE2020
LE2620
LE3226
16
FITTINGS
Connector
Size
C16
C20
C26
C32
Reducer
Size
R2016
R2616
R2620
R3226
Female Iron
Size
Adaptor
FI1616
FI2020
FI2620
FI2626
FI3226
FI3232
Male Iron
Size
Adaptor
MI1616
MI2020
MI2620
MI2626
MI3226
MI3232
Male Iron
Size
Union
MIU1616
MIU1620
MIU2020
17
FITTINGS
Tee
Size
T16
T20
T26
T32
Tee Female
Size
FT1616
FT2020
FT2626
FT3226
Tee Reducer
Size
RT201620
RT262026
RT322632
RT162016
RT201616
RT202016
RT262020
RT261620
RT322026
Copper
Size
Connector
CC16
CC20
BP19
Size
BP19-16 (short)
BP19-16 (long)
BP19-20
BP19-26
18
FITTINGS
Bath Breach
Size
BB01
Shower Breach
Size
SB01
Shower Breach - Top Entry
Size
SBT01
Solder Tail
Size
ST16
ST20
ST26
19
PIPE COILS
20
Gas Pipe
Roll (metres)
PG16
100
PG20
100
PG26
50
PG32
50
Water Pipe
Roll (metres)
PW16
100
PW20
100
PW26
50
PW32
50
TOOLS
Cutting Tool TPC01
Tool - Internal Spring
Crimping Tool CT01
Tool - Crimping Head
Size
Code
16
TIS16
20
TIS20
26
TIS26
32
TIS32
Tool - Reamer TR01
Size
Code
16
TCH16
20
TCH20
26
TCH26
32
TCH32
21
22
1119
2153
820
1611
3160
4870
20mm
26mm
32mm
40mm
4
16mm
1376
40mm
411
467
882
26mm
32mm
204
228
20mm
25
16mm
1222
823
104
20
115
Metres
3263
549
286
2
421
Metres
1010
723
386
183
95
30
2522
1639
920
453
231
5
Pressure Drop of 0.250 kPa (Meter Pressure 2.75 kPa )
8
1000
620
331
169
87
35
2266
1508
786
381
201
10
958
585
321
154
82
40
2012
1334
682
340
182
12
873
555
288
145
74
45
1832
1223
645
309
154
845
530
271
131
71
50
1681
1150
580
285
142
14
771
508
254
124
66
55
1552
1092
539
260
132
16
722
490
247
117
65
60
1457
994
496
242
124
18
N/A
+0.6
+0.8
+1.4
+1.7
Correction / Fittings All Cases
N/A
+0.6
+0.8
+1.4
+1.7
Correction / Fittings All Cases
LPG flow through PE-X/AL/HDPE Composite Pipe Crimped Fittings ( MJ/h )
Length of straight pipe in metres
FLOWPEX GAS PIPING TABLE LPG
Table 3a
205
400
165
310
20mm
26mm
4
16mm
271
40mm
76
83
158
44
20mm
26mm
23
16mm
32mm
40
20
Metres
255
136
20
25
650
599
1000
32mm
40mm
110
58
2
83
Metres
219
126
73
38
16
30
551
325
175
82
46
5
Pressure Drop of 0.075 kPa (Meter Pressure 1.1 kPa )
8
199
121
69
35
15
35
462
276
135
75
39
183
105
62
31
12
40
410
244
124
68
37
10
162
99
58
28
10
45
365
229
115
60
35
12
159
96
54
26
9
50
337
207
101
56
32
14
156
94
51
23
8.2
55
320
192
94
53
29
16
148
87
48
22
7.6
60
292
170
86
50
27
18
N/A
+0.5
+0.6
+1.2
+1.3
Correction / Fittings All Cases
N/A
+0.5
+0.6
+1.2
+1.3
Correction / Fittings All Cases
NATURAL GAS flow through PE-X/AL/HDPE Composite Pipe Crimped Fittings (MJ/h )
Length of straight pipe in metres
FLOWPEX GAS PIPING TABLE NG
Table 1a
23
24
720
1496
592
1050
20mm
26mm
4
16mm
140
256
20
83
162
299
596
1001
Metres
16mm
20mm
26mm
32mm
40mm
888
524
73
25
2444
2201
3511
32mm
40mm
392
221
2
316
Metres
800
471
237
125
68
30
1951
1222
610
316
165
5
Pressure Drop of 0.750 kPa (Meter Pressure 2.75 kPa )
8
754
436
205
119
63
35
1673
1002
501
270
140
10
689
406
191
110
58
40
1471
889
445
241
122
12
630
382
183
100
54
45
1352
796
401
216
110
594
361
176
95
51
50
1220
722
365
200
105
14
565
342
169
89
48
55
1105
671
340
184
96
16
541
334
160
83
47
60
1070
632
310
171
89
18
N/A
+0.6
+0.8
+1.4
+1.7
Correction / Fittings All Cases
N/A
+0.6
+0.8
+1.4
+1.7
Correction / Fittings All Cases
NATURAL GAS flow through PE-X/AL/HDPE Composite Pipe Crimped Fittings ( MJ/h )
Length of straight pipe in metres
FLOWPEX GAS PIPING TABLE NG
Table 1b
1664
3172
1210
2483
4680
8398
20mm
26mm
32mm
40mm
4
16mm
2574
40mm
571
650
1288
26mm
32mm
303
343
20mm
25
16mm
2301
1136
143
20
165.6
Metres
5889
827
484.2
2
768.7
Metres
2093
1026
513
274
126.7
30
4784
2535
1313
663
369.5
5
Pressure Drop of 1.500 kPa (Meter Pressure 4.0 kPa )
8
1937
941
469
251
114.2
35
4121
2158
1108
567
305.8
10
1807
874
434
234
104.6
40
3679
1898
974
502
263.3
12
1690
818
406
220
96.7
45
3354
1716
875
453
233.6
1612
771
381
207
90.2
50
3094
1573
800
417
210.9
14
1534
731
361
197
84.7
55
2886
1456
740
388
192.5
16
1469
696
343
188
79.9
60
2717
1365
692
362
174.4
18
N/A
0.6
1.1
1.4
2.9
Correction / Fittings All Cases
N/A
0.6
1.1
1.4
2.9
Correction / Fittings All Cases
NATURAL GAS flow through PE-X/AL/HDPE Composite Pipe Crimped Fittings ( MJ/h )
Length of straight pipe in metres
FLOWPEX GAS PIPING TABLE NG
Table 1c
25
SUNDRY REGULATIONS
Plumbers and gasfitters.
Plumbers and gasfitters working in South and Western
Australia should be aware that they are required to
undertake training before using any composite system
including Flowpex. One of our sales reps will be able to
instruct plumbers and gasfitters on the use of our system
and issue them with accreditation.
In the ground, in and under concrete slabs
Flowpex uses DR brass fittings and can therefore be
placed in the ground. The minimum depth of cover
required is 450mm when in the ground or 300mm when
placed under a concrete slab. Flowpex pipe can be
placed in concrete slabs providing the pressure does not
exceed 70 kPa.
Attaching Flowpex to other systems.
Flowpex cannot be crimped to other composite or PEX
only systems that appear to have similar pipes or fittings.
However, it can be attached to other systems using BSB
threaded fittings. Flowpex can also be attached to
copper systems using a copper flared connector fitting
or brazing tail. Only ever use Flowpex gas sizing tables
when using Flowpex.
UV Resistance
The outer layer of our pipe contains a carbon black
additive. It can therefore be used in areas exposed to
sunlight. The following is an extract from AS 4176.
“Polyethylene or cross linked polyethylene macro
composite pipes which are either natural or of colours
other than black are not suitable for use or extended
storage where exposed to direct sunlight”.
Permanent Joints
Flowpex crimped joints are classed as permanent joints
in AS 5601. It can therefore be used in concealed areas
such as a duct or stud wall
Excessive Heat
Flowpex should be kept away from sources of excessive
heat like combustion stoves, heating appliances, radiators
and recessed light fittings.
Flowpex should always be installed by a licensed gasfitter
or plumber in accordance with AS 3500 and AS 5601.
26
SUNDRY REGULATIONS
Notes
27
EXPERIENCE AND RELIABILITY. . .
WE MAKE IT EASY FOR YOU!
Unit 48
6 Jubilee Avenue
Warriewood NSW 2102
For all enquiries
1300 78 58 28
T: +612 9986 0605
F: +612 9979 2003
www.flowpex.com.au
TM
Australian
Standard
AS4176 AS NZ4020
Lic SMkP021181
SAI Global