K2 WaterTM - Iplex Pipelines
Transcription
K2 WaterTM - Iplex Pipelines
K2 Water PE-X Plumbing System TM IPLEX PIPELINES - THE COMPANY Iplex Pipelines (NZ) Limited manufactures a comprehensive range of plastic pressure and non-pressure pipe systems for the building, civil, rural, telecommunication, energy and export markets. Iplex is well supported on new and innovative products and technical innovation by Iplex Pipelines Australia and Wavin B.V. in the Netherlands. Access to international production equipment, product lines and support enables Iplex to offer specialised products to meet the needs of local specifiers, contractors and trade customers. For further information on our product range and added value services, please contact your local office of Iplex Pipelines or visit our website on www.iplex.co.nz. Quality Assurance All pipes and fittings produced by Iplex Pipelines are manufactured using a Quality Management System accredited to ISO 9001:2000. Market Segments Iplex Pipelines manufacture and supply pipe and fittings to the following four principal market segments. Plumbing: Pipe and fittings used within the property boundary for reticulation of potable and non-potable water, sanitary plumbing, wastewater, drainage and gas reticulation. Civil: Pipes and fittings for the development and maintenance of water and wastewater pipeline networks. Essentially the product produced for this segment covers any pipeline outside the property boundary line. Rural: Pipe and fittings for rural use, specifically irrigation, stock water reticulation, land drainage, effluent dispersal and culverts. Energy and Telecommunication: Pipe and fittings for the development and maintenance of gas, electrical and telecommunication pipeline networks. 2 CONTENTS PAGE 1 The System 4-5 2 K2TM PE-X Pipes 6-7 3 K2TM Fittings 8-9 4 Installation Tools 10 5 General Instructions 11 6 Jointing 11-15 7 Installation Guide 16-18 8 Limitations 18-19 9 Product & Tool range 20-24 10 Sustainability 25 Iplex Pipelines is dedicated to providing specifiers, plumbers, gasfitters and developers with a wide range of pipes and fittings that will satisfy residential, commercial and industrial plumbing requirements. All products are fully supported by Iplex senior mangement, product specialists, laboratory, and production facilities. Our plumbing products porfolio consists of innovative products that offer reassured performance and reliability, meeting the requirement of locally recognised standards. You can obtain further assistance and technical guidance by contacting any of our product specialists, Iplex territory managers or customer service representatives on 0800 800 262. 3 THE SYSTEM This manual details the features, benefits, technical information and installation guidelines for the Iplex K2 WaterTM PE-X pipes and DR brass fittings system: Iplex K2 WaterTM is a universal pipe and fittings system that is very flexible, extremely lightweight, corrosion resistant, and eliminates water hammer. The system consists of PE-X (cross-linked polyethylene) pipes and DR brass fittings with a retained copper crimp ring. Installation should be in accordance with the relevant sections of AS/NZS 3500 parts 1, 4 & 5. The system should only be installed by a registered plumber holding a current practising license. It is proven to be of high quality and because the fittings are crimped to the pipe (and not brazed) it is also very economical to install. Fields of Application K2 TM is designed for sanitary plumbing and heating applications, such as • potable water supply systems in residential & industrial buildings • food grade applications • heating systems 4 THE SYSTEM (cont.) Features & Benefits • Quick, easy and safe assembly by proven crimp technique Simple and effective crimp fittings • Abrasion resistant through the entire system High flow speeds of the transported liquids, without any risk of erosion • Reduced heat loss Condensation and heat dispersion of the transported fluids are considerably reduced • Extremely flexible and strong Pipes can easily be manipulated around obstructions • Economical to install • Light weight Quick and easy to install • Fittings have pipe depth insertion window Helps ensure pipe is pushed in to required depth. • Free of incrustations, corrosion resistant Maintains a smooth internal surface, hindering the build-up of deposits • Choice of manual or battery operated crimp tools • Excellent pressure and temperature resistance • Same tools can be used to install the Iplex K1 GasTM system • Iplex 25 year Warranty (conditions apply) Potable Water Pipes Heating Pipes Max operating temp 70˚c 90˚c Max malfunction temp 110˚c 110˚c Max permanent Operating pressure 10 bar 6 bar 5 K2 PE-X PIPES PE-X pipes have been used successfully in hot and cold water and heating applications for more than 25 years, and are internationally recognised for their pressure capabilities, and resistance against temperature and corrosion. PE-X pipes are very flexible and are the ideal option for potable water applications in residential and commercial buildings including multi-storey apartment blocks. PE-X heating pipes are additionally fitted wtih an EVOH-layer as an oxygen barrier. Technical Data Physical characteristics: Plumbing Pipe: Plumbing pipes are co-extruded with integral black coloured outer layer as a light inhibitor and UV Barrier. Maximum operating termperature Maximum short-term stress Maximum permanent operating pressure Thermal expansion coefficient (pipe) Thermal conduction (pipe) Pipe roughness k 70˚c 110˚c 10 bar 0.2 mm/mK 0.35 W/mK 0.007 mm Physical Characteristics: Heating pipes with EVOH-layer. (oxygen tight according to DIN 4726): Maximum operating termperature Maximum short-term stress Maximum permanent operating pressure Thermal expansion coefficient (pipe) Thermal conduction (pipe) Pipe roughness k 90˚c 110˚c 6 bar 0.2 mm/mK 0.35 W/mK 0.007 mm Colours Plumbing pipes Heating pipes Fittings black red DR Brass Raw material - Pipes Electron beam cross-linked polyethylene (PE-Xc) 6 K2 PE-X PIPES (cont.) Pipe Approvals The manufacture of K2 WaterTM pipe is carried out to the requirements of AS2492, and is approved under Australian Standard Mark Licence No. 2777. PE-X pipes conforming to AS 2492 are included in AS/NZS 3500.4 (Heated Water Services), and comply with the New Zealand Building Code Approved Document G12 VM1. Iplex Pipelines offer a 25 year warranty with the Iplex K2 WaterTM System (conditions apply). Supplied in 5 metre straight lengths and coils. Dimensions of Iplex K2TM PE-X pipe Nom. outside diameter Mean bore DN16 – 16 mm 10.8 – 11.9 mm DN20 – 20 mm 13.6 – 14.7 mm DN25 – 25 mm 17.0 – 18.3 mm 7 K2TM FITTINGS Iplex K2TM fittings are specially designed and engineered to complement Iplex K2 WaterTM pipes. Every fittings carton contains an installation instruction leaflet, which must be followed to ensure correct installation in accordance with Iplex Pipelines recommendations. Technical Data Raw material - fittings: Dezincafication resistant (DR) brass Retained copper crimp ring Fittings have pipe depth insertion window DR Brass Fittings Iplex K2TM DR brass fittings are fully dezincification resistant to AS 2345 and are precision CNC machined. Copper Crimp Rings All Iplex K2TM DR brass fittings have an annealed copper crimp ring with a pipe depth insertion window to provide visible assurance that the pipe has been pushed fully into fitting. Dimensions of Iplex K2TM fittings Nom. outside diameter Mean bore DN16 – 16 mm 8.4 mm DN20 – 20 mm 11.2 mm DN25 – 25 mm 14.6 mm Flow Charactersistics All fittings have been specially designed to optimise system flow performance. 8 K2TM FITTINGS (cont.) Designed for New Zealand Plumbers Several K2TM fittings have been designed to specifically meet the needs of the New Zealand Plumber. Fittings Approvals Iplex K2TM fittings are manufactured from dezincafication (DR) resistant brass compliant with AS 2345. Fittings are manufactured to AS 2537, and are approved under Australian Standards Mark License No. WMKA02801. Fittings conforming to AS 2537 are included in AS/NZS 3500.1 (Water Services) and AS/NZS 3500.4 (Heated Water Services), and comply with the New Zealand Building Code Approved Document G12 VM1. Iplex Pipelines offer a 25 year Warranty with the Iplex K2 WaterTM system (conditions apply). 9 INSTALLATION TOOLS Crimp tools are precision instruments engineered to ensure a simple, effective joint. The principle of this jointing method is well proven in many applications throughout Australia and New Zealand. It is used extensively around the world for connection of pipes and fittings for gas, hot and cold plumbing and in-floor heating systems. Care should be taken with crimp tools to ensure that moving parts are not damaged. Refer to individual tool instructions for maintenance and correct use. Calliper gauges are available to check that the copper crimp ring has been successfully crimped by the tool. Only the Iplex tools specified in this document can be used to crimp the Iplex K2 WaterTM system. See Product Range section for complete range of tooling options 10 GENERAL INSTRUCTIONS Connection and installation of the Iplex K2 WaterTM pipes and fittings system must be carried out by a registered, licensed plumber in accordance with Iplex Pipeline’s jointing and installation instructions.The installation must also meet the requirements of AS/NZS 3500 parts 1, 4 & 5 as well as any specific Local Authority and Regulatory codes and by-laws, and the New Zealand Building Code Approved Document G12. JOINTING Step 1 • Cut pipe squarely with the Iplex K2 TM pipe cutter (Iplex Part No. REMSPIPECUTTER or FK203064700). • Do not use a hack saw. 11 JOINTING (cont.) Step 2 • Slide the pipe onto the fitting until it stops. • If fitted correctly, the pipe should be visible through both copper crimp ring windows (arrowed below). • The fitting must be assembled with the copper crimp ring attached to the plastic retainer ring. • Ensure that the copper crimp ring is firmly attached to the plastic retainer ring. If the copper crimp ring has moved away from the plastic retainer ring, push it back onto the plastic retainer ring by hand before crimping. 12 JOINTING (cont.) Step 3 • Open crimp jaws / handles as wide as possible. • Position crimp jaws squarely over the copper crimp ring. i.e at 90 degrees to the pipe direction. • Hand tools - ensure that the full jaw width of the tool makes contact with the copper crimp ring prior to crimping. • Power tools - position the jaws over the full width of the copper crimp ring. • Avoid crimping over the plastic retainer ring. • Compress the crimp tool jaws fully over the copper crimp ring. • Once completed open the crimp tool jaws and remove tool from fitting. 13 JOINTING (cont.) Step 4 • Once crimp completed check every joint with the Iplex calliper gauge (code FKP64). • Gauge tips must slide freely over the crimped copper ring at 90° to the tool jaw split line. Connections can only be guaranteed if completed with Iplex approved tools. All tooling must to be protected against dirt and damage, and should be cleaned, checked regularly and serviced as required. Lubrication of any kind must not be used on pipe or fitting in jointing process. Under-crimping Under-crimping (i.e. when gauge does not pass freely over copper ring) can occur when: 1. The crimp tool has not been closed completely on copper ring. 2. The crimp tool is out of calibration (where possible, readjustment should be completed in accordance with instructions supplied with the tool). 14 JOINTING (cont.) If sufficient care is not taken when jointing, the consequences can be improper sealing, and potential leaks. The most likely causes of faulty connections are: 1. Copper crimp sleeve has separated from retaining ring and fitting. 2. Crimp tool has been incorrectly centred over copper crimp sleeve, resulting in partial crimp. 3. Pipe has not been pushed fully into fitting prior to crimp being completed. 4. Pipe has not been cut squarely. 5. Poorly maintained or damaged tool. If a faulty connection is detected: • Cut out the defective joint and replace with new fitting. If the pipe is kinked or damaged: • The faulty section of the pipe should be replaced. Testing and inspection Testing should be performed to the requirements of AS/NZS 3500 part 1, 4 & 5 and in accordance with Local Authority recommendations. While the system is under test, all joints and fittings should be inspected for leaks to ensure that pipe and fittings have been successfully joined. 15 INSTALLATION GUIDE Pipe bending Due to its flexibility, Iplex K2 WaterTM pipe can be easily formed around obstructions or correctly positioned through studs and plates minimising the number of fittings used. Care should be taken not to kink or damage the pipe. See Pipe Bending Guide noted in Product Range section. Note: Never apply bending forces to a crimped fitting. Pipe must always be bent prior to attaching pipe to fitting. It is recommended that the minimum bending radius is at least 8 times the outside diameter of the pipe. Minimum hand-bending radius 16mm pipe 128mm min. radius 20mm pipe 160mm min. radius 25mm pipe 200mm min. radius Fixing Clips In accordance with AS/NZS 3500, Iplex K2 WaterTM pipes installed above ground shall be retained in position by clips at intervals complying with the table below: The use of pipe clips Nom. pipe diameter Horizontal or graded pipes Vertical pipes 16mm 600mm 1,200mm 20mm 750mm 1,400mm 25mm 750mm 1,500mm 16 INSTALLATION GUIDE (cont.) Timber and metal framework Holes drilled in studs or plates etc shall be accurately sized to allow for longitudinal pipe movement, caused by thermal expansion and contraction. In metal framework suitable grommets or a sleeve must be installed to avoid abrasion and physical damage to the pipe. Note: Use of silicon and other such materials is not permitted and could cause damage to the pipe. Corrosive environment As per the requirements of AS/NZS 3500 and/or Local Authority requirements, PE-X pipes and fittings installed in a potentially corrosive environment must be protected, i.e. marine environment. Protection from physical damage As per the requirements of AS/NZS 3500 and any recognised Local Authority requirements, pipes and fittings must be protected against physical damage. This includes, but is not limited to, physical damage caused by exposure to direct sunlight, human activity, mechanical equipment, rodents or animals. When Iplex K2TM pipe is installed externally above the ground, it must be protected against degradation from exposure to ultraviolet light. Iplex recommends that the pipe be lagged or sleeved when exposed to UV. Pipe positioned underground should be buried to at least the minimum depth nominated in the relevant sections of AS/NZS 3500. Where appropriate, the pipe may be installed with marker tape, placed approximately 150mm above the pipe. Chases, ducts or conduits Pipes embedded in walls or floors shall comply with the requirements of the appropriate building authority or local regulations. 17 INSTALLATION GUIDE (cont.) Thermal expansion The linear thermal expansion rate of Iplex K2 WaterTM PE-X pipes is approximately 20mm for every 10°C temperature change for each 10 metres of pipe. Therefore, when pipes are installed in situations where they will be subjected to significant temperature change, provisions must be made for potential movement of the pipe. Iplex K2 WaterTM pipes should not be pulled tight between fixed points as this will prohibit movement if the pipe contracts, that will result in excessive tensile force on joints and fittings. LIMITATIONS Fire & excessive heat When cross-linked polyethylene pipe is installed and penetrates a fire resistant construction, the fire resistant integrity of the construction must be retained. This can commonly be achieved through the use of fire-stop collars and installers should seek definitive guidance by referencing local building installation recommendations. Light transmission The co-extruded outer sheath on Iplex K2TM PE-X pipes provide opacity, which prevents the transmission of light that would otherwise promote algae growth. The carbon black sheath also helps protect the pipe from the harmful effects of UV light. Lagging pipe is still recommended when exposed to UV. 18 LIMITATIONS (cont.) Thermal conductivity and lagging requirements The thermal conductivity of plastics is generally lower than that of metals (refer table below). It is the poor conductivity of cross-linked polyethylene that contributes to restricting the heat loss from hot water pipes. Thermal insulation (lagging) of cross-linked polyethylene water pipe is required to meet the energy efficiency requirements of AS/NZS 3500 Part 4, Section 8. Thermal Conductivity – watt per metre Kelvin (W/m.K.) Material PE-X COPPER WATER STEEL Conductivity 0.35 401 0.6 47–74 19 PRODUCT RANGE Product Item Code Minimum Order Quantity Description K2TM HOT & COLD WATER LENGTHS FK2.9300010 FK2.9300012 FK2.9300014 20 15 10 16mm x 5 metre length K2 20mm x 5 metre length K2 25mm x 5 metre length K2 K2TM HOT & COLD WATER COILS FK2.9301625 FK2.9300000 FK2.9302025 FK2.9300002 FK2.9300004 1 1 1 1 1 16mm x 25 metre coil K2 16mm x 100 metre coil K2 20mm x 25 metre coil K2 20mm x 100 metre coil K2 25mm x 50 metre coil K2 K2TM COILED DUCT PIPE FK2.9300020 FK2.9300022 FK2.9300024 1 1 1 16mm x 50 metre coil K2 20mm x 50 metre coil K2 25mm x 50 metre coil K2 K2TM HEATING PIPE* (Red) FK2.9300040 1 FK2.9300042 1 FK2.9300044 1 FK2.9300045 1 * With EVOH-layer K2 Heat Pipe 16mm x 100m K2 Heat Pipe 20mm x 100m K2 Heat Pipe 25mm x 50m K2 Heat Pipe 25mm x 5m K2TM RECYCLED WATER PIPE* (Lilac) FK2.9301000 FK2.9301002 FK2.9301004 1 1 1 K2 Lilac Pipe 16mm x 100m K2 Lilac Pipe 20mm x 100m K2 Lilac Pipe 25mm x 50m K2TM RAIN WATER PIPE* (Green) K216EG K21650G K220EG K22050G 1 1 1 1 K2 Green Pipe 16mm x 5m K2 Green Pipe 16mm x 50m K2 Green Pipe 20mm x 5m K2 Green Pipe 20mm x 50m STRAIGHT COUPLER K2501616 K2502020 K2502525 20 20 10 16mm K2 20mm K2 25mm K2 REDUCING COUPLER K2512016 K2512516 K2512520 25 10 10 20 20-16mm K2 25-16mm K2 25-20mm K2 PRODUCT RANGE (cont.) Product Item Code Minimum Order Quantity Description MALE ADAPTOR K2521615NZ K2522015NZ K2522020NZ K2522520NZ 1 1 1 1 90° BEND K2571616 K2572020 K2572525 20 10 5 16mm K2 x 1/2” 20mm K2 x 1/2” 20mm K2 x 3/4” 25mm K2 x 3/4” 16mm bend K2 20mm bend K2 25mm bend K2 WINGBACK ELBOW (MALE) K2601615 5 16mm x 15mm BSP x 70mm shaft Lugged K2601615100 5 16mm x 15mm BSP x 100mm shaft Lugged K2601615200 1 16mm x 1/2” BSP x 200mm shaft Lugged 90° TEE K255161616 K255202020 K255252525 10 10 5 16mm x 16mm x 16mm K2 20mm x 20mm x 20mm K2 25mm x 25mm x 25mm K2 REDUCING TEES (denotes branch size) K256162016 K256201616 K256201620 K256202016 K256202520 K256251625 K256252020 K256252025 K256252520 END PLUG K24011600NZ K24012000NZ K24012500NZ 10 10 5 5 5 5 5 5 5 16mm x (20mm) x 16mm K2 20mm x (16mm) x 16mm K2 20mm x (16mm) x 20mm K2 20mm x (20mm) x 16mm K2 20mm x (25mm) x 20mm K2 25mm x (16mm) x 25mm K2 25mm x (20mm) x 20mm K2 25mm x (20mm) x 25mm K2 25mm x (25mm) x 20mm K2 1 1 1 End Plug 16mm End Plug 20mm End Plug 25mm 21 PRODUCT RANGE (cont.) Product Item Code Minimum Order Quantity K2TM CRIMP RINGS K2CRING16 K2CRING20 K2CRING25 K2621615 K23622015NZ K23622034NZ Description 50 50 50 K2 Copper Crimp Ring 16mm K2 Copper Crimp Ring 20mm K2 Copper Crimp Ring 25mm WINGBACK ELBOW (FEMALE) 5 1 1 16mm K2 x 1/2” BSP Lugged 20mm K2 x 1/2” BSP Lugged 20mm K2 x 3/4” BSP Lugged K2TM FEMALE SWIVEL ADAPTOR CROXED K24001612NZ K24002012NZ K24002034NZ K24002501NZ 1 1 1 1 CLIPS with masonry nail per bag CLIPPEXM16 100 CLIPIT 16mm CLIPPEXM20 100 CLIPIT 20mm CLIPPEXM25 100 CLIPIT 25mm K2TM 90° FEMALE SWIVEL THREADED ADAPTOR K24901612NZ K24902012NZ 1 1 HOSEPLATE K25001612NZ 1 Brass Adapt 16mm x 1/2” Brass Adapt 20mm x 1/2” Brass Adapt 20mm x 3/4” Brass Adapt 25mm x 1” Brass Adapt Bend 16mm x 1/2” Brass Adapt Bend 20mm x 1/2” Brass Hose Plate 16mm x 1/2” PIPE BENDING GUIDE – 90° FK2.03064824 FK2.03064832 FK2.03064840 1 1 1 22 Guide to suit 16mm pipe Guide to suit 20mm pipe Guide to suit 25mm pipe TOOL RANGE Product Item Code Description ALBA HAND TOOLS FKPCR16 FKCR20 FKCR25 K1 / K2 Alba Crimp Tool 16mm K1 / K2 Alba Crimp Tool 20mm K1 / K2 Alba Crimp Tool 25mm BATTERY MINI CRIMP TOOL 7100060 FK17100074 FK17100076 FK17100078 7100090 7100092 K1 / K2 Battery Mini Crip Tool (in case) K1 / K2 Mini Crimp Jaws 16mm K1 / K2 Mini Crimp Jaws 20mm K1 / K2 Mini Crimp Jaws 25mm Battery (Mini Crimp Tool) Recharger Unit (Mini Crimp Tool) REMS BATTERY TOOL REMSBATTERYTOOL REMS Universal Battery Crimping Tool REMSBATTERY REMS 12V Battery Spare REMS TOOL JAWS REMSCRIMP16 REMSCRIMP20 REMSCRIMP25 23 K1 / K2 Crimp Jaws 16mm K1 / K2 Crimp Jaws 20mm K1 / K2 Crimp Jaws 25mm TOOL RANGE (cont.) Product Item Code Description PIPE CUTTER FK2.03064700 FK2.03052834 FK2.03064719 Pipe Cutting Tool for 16mm, 20mm and 25mm Additional blades for universal shears Additional blades for ducting pipe cutter PIPE CUTTER REMSPIPECUTTER REMS Universal Pipe Cutting Tool for 16mm, 20mm, 25mm and 32mm PIPE CUTTER REMSCUTTER63 REMS Pipe Cutting Tool for 16mm - 63mm CRIMP GAUGE FKP64 K1 / K2 Crimp Gauge 24 SUSTAINABILITY The NZ Building Code 2004 (section 3) provides for the setting of performance standards for buildings to ensure that, A) People that use building can do so safely and without endangering their health; B) Buildings have attributes that contribute appropriately to the Health, physical independence, and well being of the people who use them; C) People who use a building can escape from the building if it is on fire; D) Buildings are designed, constructed, and able to be used in ways that promote sustainable development. The following are ways that K2 WaterTM satisfies these core principles of the New Zealand Building Act 2004, which are, 1. HEALTH 2. SAFETY 3. WELFARE 4. SUSTAINABILITY • Health, Welfare, Sustainability - No impact on air quality during manufacture - No impact on water quality (no waste discharge) • Health & Safety - Chemically inert - No emissions from the product in normal use for its service life • Sustainability - Very low impact on water usage (fully recycled water cooling systems) - Low product weight means substantially less non-renewable energy in transport/delivery - 100% recyclable at the end of its service life - 100% recyclable or reusable cardboard boxes only used with these products - 100% recyclable during manufacture 25 NOTES 26 NOTES 27 DISCLAIMER All information contained in this literature is given in good faith. Whilst all reasonable care has been taken to ensure the information is accurate, this publication should not be used as the only source of information by the reader. Reference should be made to established textbooks and other published material, and readers should not rely on the information contained in this publication without taking appropriate professional advice for their particular circumstances. In case of uncertainty, the reader should contact Iplex Pipelines for clarification that the specific product is appropriate for their circumstances. Iplex Pipelines reserves the right to modify or extend any published information without any prior notification. No responsibility can be accepted by Iplex Pipelines for any error, omissions, or incorrect assumptions. Iplex Pipelines (NZ) Ltd. Supported by Iplex Pipelines NZ Limited. Call Centre - Phone: 0800 800 262 Call Centre - Fax: 0800 800 804 Web site - www.iplex.co.nz FREEPHONE 0800 800 262 Offices At: Auckland: Palmerston North: Christchurch: PO Box 13772 Onehunga 2 Rockridge Ave, Penrose. Private Bag 11019, 67 Malden Street. PO Box 16225, 22 Braeburn Drive, Sockburn. Distributed by FREEPHONE 0800 627 837 FREEPHONE 0800 101 999 VERSION 2
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