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Table of Contents
Wavin Pilsa System Introduction
Background ......................................................................................................................................... 4
Cross-Linked Polyethylene (PE-X) ................................................................................................ 4
PEX Production, an overview...................................................................................................... 5
Wavin Pilsa piping systems..... Your Unparalleled Advantage ................................... 5
Wavin Pilsa Piping Systems Features .......................................................................................... 5
Resistance to Temperature ............................................................................................................ 5
Recommended that the pipes, if stored outside, be shielded from dir ect sunlight. 6
Resistance to Chemicals ............................................................................................................ 6
Resistance to Pressure ....................................................................................................................... 6
Wavin Pilsa Systems........................................................................................................................ 7
1.
Wavin Pilsa Monolayer piping system ....................................................................... 7
2.
Oxygen Diffusion Barrier Systems:................................................................................... 8
Types of Wavin Pilsa Oxygen Diffusion Barrier Systems:................................................. 9
a. Wavin Pilsa EVOH Multilayer piping systems ................................................................... 9
Pipe Layers ................................................................................................................................... 9
Advantages of Wavin Pilsa Multilayer Piping System ......................................................... 10
b. Wavin Pilsa Aluminum Composite piping System ....................................................... 10
Pipe Layers ................................................................................................................................... 10
Advantages of Wavin Pilsa Aluminum Composite Piping System: ............................... 10
Quality Assurance ....................................................................................................................... 11
Quality Guarantee ........................................................................................................................ 11
Wavin Pilsa Standards and Regulations................................................................................ 11
Pressure Loss ................................................................................................................................... 22
Pressure Loss Diagram for Wavin Pilsa pipes .............................................................................. 22
Handling and Storing Wavin Pilsa Piping System ......................................................................... 22
Connecting the Wavin Pilsa Piping System ................................................................................... 22
Incorrect Connections .................................................................................................................... 24
Wavin Pilsa piping Supports: Selection and Inspection ...................................................... 25
Linear Expansion ............................................................................................................................ 25
Wavin Pilsa System Installation ................................................................................................... 28
Wood Floors .................................................................................................................................. 28
Wavin Pilsa Manifold Plumbing Systems .................................................................................. 29
Installing Manifolds: ....................................................................................................................... 29
The drawing below represents a typical Wavin Pilsa manifold system. ................................ 30
Connecting pipes to the manifold ................................................................................................ 30
Installed Piping Pressure Testing (DIN 1988, part 2) ............................................................... 30
Installation instruction for Pox Brass Fitting ........................................................................... 32
3
Wavin Pilsa System Introduction
Piping System
4
Wavin Pilsa System Introduction
Background
A wide range of plumbing and under - floor heating s y s t e m s have been developed
and produced by the name of Wavin Pilsa.
Wavin Pilsa systems are used in:
Domestic h o t and cold water installations.
Under - floor h e a t i n g .
Central heating.
Air-conditioning systems.
District heating.
Automotive and ship-building.
Transport of industrial gases/ compressed air and fluids (Including fuel oil, gases,
acids and alkalis)
• Process engineering and other specialized applications
• Natural gas supply in extreme or ambient conditions.
•
•
•
•
•
•
•
Cross-Linked Polyethylene (PE-X)
PE-X, which stands for cross-linked (X) Polyethylene (PE), is a modified and condensed
structure of the polyethylene molecule developed especially to improve its
physical properties. PE-X systems can be used independently or can complement the
equally wide range of PP-R system, produced and supplied by Pilsatherm.
Cross linked polyethylene (PE-X) results from chemically adjoining polyethylene
molecules in order to improve their properties, especially at high temperatures. This
results in a structure that does not soften when high temperature is applied, thus raising
the thermal stability of the material under load, which greatly increases the
environmental stress crack resistance and the resistance to slow crack growth due to
deterioration of the material under continuous temperature use.
The Molecule Structure of Polyethylene a n d Cross linked Polyethylene
5
Wavin Pilsa System Introduction
PEX Production, an overview
In today’s market, there are three cross-linking techniques used:
Peroxide Cross-linking, which entails adding peroxide into the base resin, and
through the application of a combination of high pressure and temperature, the crosslinking occurs as the tube is produced;
Silane Cross-linking, which entails grafting a reactive Silane molecule b a c k b o n e of
the polyethylene. The tubing i s then produced by blending this grafted co m p ou n d with a
catalyst during the production process. The tube is then exposed to steam or hot water, and
the cross-linking is thus achieved.
Electron Beam Cross-linking, takes place when very high energy radiation is used to
initiate molecular cross-linking in high density polyethylene.
The tube is extruded like
normal HOPE, then taken to an E-Beam facility and routed under a beam or ray in the
accelerator, where it is dosed with a specific amount of radiation to release hydrogen
atoms and cause polymer chains to bond to the open carbon sites.
In European standards, these three methods are referred to as PEX-A PEX-B, and
PEX-C respectively and are not related to any rating system. All the resulting PEX
tubing products perform similarly, and are rated for performance by the different
international standards, for which they are tested and certified.
Wavin Pilsa piping systems..... Your Unparalleled Advantage
When b u i l d e r s , contractors a n d h o m e o w n e r s choose W avi n Pil sa Piping Systems, they
are comforted to know that their plumbing system will last. The Wavin Pilsa piping system
includes the highest quality raw materials and processing, and a strong, reliable fitting
system, offering the following integrated advantages:







Increased maximum operating temperature.
Reduced deformation under load (creep).
Outstanding resistance to slow-crack growth.
Improved aging resistance.
Improved chemical resistance.
Improved impact strength Reducing Raid Crack Propagation (RCP), even at low
temperatures.
0 corrosion in the system, especially through the use of Multilayer and Aluminum
Composite Wavin Pilsa Piping.
Wavin Pilsa Piping Systems Features
Resistance to Temperature
Wavin Pilsa Cross linking polyethylene changes the polymer from a thermoplastic to a thermo
6
Wavin Pilsa System Introduction
Setting polymer. Once it is fully cross linked, polyethylene tends not to melt but merely to
become m o r e flexible at higher t e m p e r a t u r e s .
Low density polyethylene film grades which have been designed for medical applications,
for example, have been autoclaved at 130°C without l o s i n g their properties.
Although high temperature resistance of Wavin Pilsa piping system makes it particularly
suitable for hot and cold interior plumbing applications, it also makes an excellent
underground water service piping. The maximum c o n t i n u o u s application temperature i s
95°C. The permanent operating pressure is 1 0 bars at 70°C, which far exceeds any water
delivery a p p l i c a t i o n .
In rare instances during the lifetime of the piping s y s te m and due to malfunctioning under
abnormal circumstances in the installation, the highest temperature t h a t can be withstood
in the piping system for a short time during o p e ra ti o n is 1 1 0 degrees Celsius. This can
be sustained for a maximum of 100 hours per 50 years.
Wavin Pilsa piping system is designed f o r indoor a n d b u ri e d a p p l i c a t i o n s only and
i s not recommended for outdoor a b o v e g r o u n d use. Short exposures to sunlight not to
exceed
30 - 4 5 days are, however, permissible wh en storing Wavin Pilsa.
However, it
is
Recommended that the pipes, if stored outside, be shielded from d i rec t sunlight.
Resistance to Chemicals
The basic cross linked structure physically is resistant to the attack of aggressive chemicals.
The material
is thus r e n d e re d
more r e s i s t a n t to p e r m e a t i o n and s o f t e n i n g
by these chemicals.
Resistance to Pressure
Wavin Pilsa Cross linking im p ro ve s the resistance to pressure at room temperature,
reducing tendency to creep.
At high temperatures, this is achieved by reducing r e l a t i v e
molecular movement. At elevated temperatures c r o s s linking a l l o w s the properties o f
the original base polyethylene t o be preserved.
Moreover, cross linked high density
polyethylene, which has closer packing of the chains and an intrinsically higher pressure
resistance, is used for higher
pressure applications than
cross linked
low density
polyethylene.
According to DIN 16892 standards and in order to meet the pressure regulations for
flexible under floor heating pipes, a minimum density of 0.935 to 0.940 is necessary. As
for hot sanitary water pipes, which have to meet more stringent requirements, a minimum
density of 0.945 to 0.950 is required. All Wavin Pilsa cross linked polyethylene p i p e s
have a density in excess of 0.95, and therefore, meet or exceed DIN 16892 standards.
The following diagram shows the service life expectancy which depends on the installed
system pressure and pressure changes. Under normal circumstances, however, the service
7
Wavin Pilsa System Introduction
life expectancy of the pipes is more than 50 years.
MPa
3.0
2.0
1.0
0.8
0.6
0.5
0.4
0.3
0.2
0.1
0.08
0.06
0.05
10-1 100
101
102
103
104
105
106
Wavin
Pilsa
Systems
Copper piping has been the preferred choice i n plumbing systems for i t s quality a n d
durability. However, its disadvantages are numerous: It is relatively expensive; it cannot be
installed in long lengths without frequent j o i n t s ; it is relatively inflexible during i n s t a l l a t i o n ;
and it is prone to burst when frozen.
Polybutylene (PB) piping came as a transitional replacement to copper p i p e s , but proved
incompetent due to many f a i l e d connections between p i p e j o i n t s .
A variety of plastic piping systems have been developed in recent years, as a solid
replacement for conventional plumbing.
1.
Wavin Pilsa Monolayer piping system
Wavin Pilsa monolayer piping, designed to offer a very long service life, is made under very
strict quality c o n t r o l c o n d i t i o n s . Wavin Pilsa piping is superior i n mechanical and
th e rmal performance s h o w i n g
very good
resistance to crack propagation,
n o t c h i n g , a n d scratching, during storage, transport, and pipe installation.
8
Wavin Pilsa System Introduction
One of t h e m o r e unique features o f W a v i n P i l s a monolayer piping system is
its shape retention. During connection, pipe ends are expanded to insert the fittings.
After the connections are made, the material returns to its previous diameter forming
a tight seal around the fitting.
Wavin Pilsa Piping Systems are normally supplied with Wavin Pilsa Blue/Red
protective corrugated sleeve for concealed or exposed installations, to protect Wavin
Pilsa from abrasion inside the walls.
Also, these sleeves offer an easy way to
pull the pipes during maintenance jobs.
Advantages of Wavin Pilsa Monolayer Piping System:
•
•
•
•
•
•
•
•
2.
Flexible and easy to install.
Economic i n cost and installation.
Entirely chemical resistant.
High s o un d -insulation.
High r e s i s t a n c e to pressure and temperature.
Smooth surface, virtually no loss of pressure.
Light in weight.
Flexible, easy to bend even at low temperature.
Oxygen Diffusion Barrier Systems:
Wavin Pilsa Oxygen Diffusion Barrier pipe systems offer a comprehensive range of
plumbing and heating systems, recommended for high end installation requirements as
well as heating and under-floor heating applications.
Wavin Pilsa Oxygen Diffusion Barrier pipes are especially designed for general plumbing and
heating a p p l i c a t i o n s that require a long service life. These products i n c o r p o r a t e oxygen
diffusion barrier solutions virtually impervious to oxygen.
Corrosion, as is well known, is oxide formation on a non-inert metallic component, and
is made p o s s i b l e b y the combination of water and oxygen, accelerated by temperature.
Eliminating one of these components m e an s the elimination of corrosion. With the use
of Oxygen Diffusion B a r r i e r pipes this means that many metal components in the system
9
Wavin Pilsa System Introduction
Including fittings, tanks, boilers and other components in cold and hot water plumbing and
under floor heating systems, will not suffer corrosion made possible by the abundance of
oxygen in the closed circuit. This is particularly important in mixed systems where the
radiators and under-floor heating systems are supplied with the same water.
Under-floor heating is invisible and maintenance free consuming n o space for radiators or
other heat exchangers. Under-floor heating requires only warm temperature water and is ideal
for use with modern c o n d e n s i n g b o i l e r s . Comfort l e v e l s are high and running costs
are low.
Under - floor heating from the whole floor area of the house gently warms the air above,
eliminating cold spots. The warm air Convection from the floor surface losing 2°C
approximately at 2 meters above the floor makes Wavin Pilsa under-floor heating
system ideal for all ceiling heights.
Wavin Pilsa Under-Floor heating system is remarkably fuel-efficient, using 15-20%
less energy to achieve the some comfort conditions as other forms of heating in on
average height room. In areas with higher ceilings, the savings can be in excess of 50%.
Types of Wavin Pilsa Oxygen Diffusion Barrier Systems:
a. Wavin Pilsa EVOH Multilayer piping systems
In high-end and heating installations, PE-X pipe is equipped with a diffusion barrier EVOH
(Ethylene vinyl alcohol copolymer) which functions as an oxygen barrier.
The
pipe
measurements correspond to DIN 16892/16893. A major advantage concerning their
installation is the flexibility of these pipes. Therefore, Wavin Pilsa pipes are well suited for the
use in floor heating and radiant systems.
The multilayer (5 layer) pipe consists of five polymeric layers comprising the wall of the
pipe. This oxygen diffusion barrier is oxygen-diffusion tight conforming to DIN 4726:
Pipe Layers
• Inner pipe of cross linked polyethylene.
• Adhesive layer joining the outer pipe to the EVOH layer.
10
Wavin Pilsa System Introduction
• Uniform EVOH layer.
• Adhesive layer joining the EVOH layer to the outer protective layer.
• Outer layer of cross linked polyethylene protecting the EVOH layer from
damage.
Advantages of Wavin Pilsa Multilayer Piping System
•
•
•
•
•
•
•
•
•
•
Flexible and easy to install.
100% oxygen-tight and water vapor diffusion tight.
Lower coefficient of linear expansion.
Entirely corrosion-resistant and chemical resistant.
Sound-insulation similar to entirely plastic pipe.
Cross linked inner and outer pipe.
High resistance to pressure and temperature.
Smooth surface, less loss of pressure.
Light as plastic piping.
Flexible, easy to bend even at low temperature.
b. Wavin Pilsa Aluminum Composite piping System
Wavin Pilsa enclosed aluminum ensures that this multilayer pipe is 1 00% oxygen
diffusion
proof while maintaining very low expansion rates similar to other metal pipes.
The inner and outer polyethylene pipe prevents scaling and corrosion and its
unique combination of butt-welded aluminum and cross linked polyethylene ensure
that this composite pipe is an excellent alternative to copper. Aluminum composite Pipe
gives the installer the advantages of both metal and plastic. Wavin Pilsa Aluminum
composite pipe is now the first genuine pipe for all applications of plumbing, heating,
under - floor heating
or mains water supply.
Pipe Layers
• Inner pipe in cross linked polyethylene ace to DIN 16833.
• Adhesive layer homogeneously joining the inner pipe to the aluminum pipe.
• Uniform longitudinally welded, perfectly round, aluminum pipe.
• Adhesive layer homogeneously joining the outer pipe to the aluminum pipe.
• Outer pipe in cross linked polyethylene ace to DIN 16833.
Advantages of Wavin Pilsa Aluminum Composite Piping System:
• Perfectly welded and sealed aluminum layer, giving all the advantages of
metallic pipes.
11
Wavin Pilsa System Introduction
Quality Assurance
As stated in our Corporate Mission Statement, quality standards and policies of all
products and processes ensure that activities related to the eventual quality level desired
are implemented through clear operating procedures, work instructions, forms and records
throughout the company. These are always documented and stored in the system for future
tracing, if and when required. This means that all corporate and plant functions within
G PC I, whether commercial, or o p e r a t i o n a l , are r e q u i r e d to b e cl ea rl y stated a n d
documented, ensuring that the quality of your product is never compromised or been left
to chance.
G PC I is fully equipped with quality control labs that include state-of-the-art
measurement and performance evaluation instrumentation to aid in controlling and
achieving specification compliance.
Our engineers utilize ultra-modern hightech equipment to run dimensional, physical, and chemical property tests. For
example, accelerated hydrostatic testing on samples taken from production runs, using
technically advanced equipment, is just one of many tests that are conducted on a
continuous basis to stimulate the aging of piping systems under working conditions.
We also strongly believe and always nourish the environment of continuous quality
improvement in every aspect of our business and the enhancement of our employee
knowledge and skills to achieve their best in individual performance and teamwork.
This is just a glimpse of the meaning of quality at Wavin Pilsa which is committed to your
complete satisfaction through consistently exceeding your expectations through the
understanding of your needs and requirements.
Quality Guarantee
G PC I always maintains the highest standards of quality for its users. To support this,
Wavin Pilsa warrants a 1 0-year guarantee for all its piping network components from
the date of purchase. (Please ask your local representative for details)
Wavin Pilsa Standards and Regulations
Wavin Pilsa Pipes and Fittings are produced with the following standards and regulations:
•
•
•
•
•
•
DIN 16892 and DIN 16893 test method measuring resistance to
elevated temperature), (pipes made from cross-linked PE {PE-X).
BS EN 1055, ISO 13479 and ISO/TR 9080 resistance to crack propagation).
KTW-recommendations of the German Department of Public Health for all
ingredients which are used in the sense of the Food and Implement Regulation for
drinking water applications.
DIN 1988 the pipe insulation for cold and hot drinking water application.
Pipe joints in accordance with DIN 1988, this will be confirmed by the
examination performed corresponding to the DVGW-working paper W 534, and
by the DVGW- registration.
ISO 9000-2000 Quality Management System.
Product Range
14
Wavin Pilsa Product Range
Technical Specification
Working Temperature (0C)
0
Peak Temperature at ( C) *
Max. Working Pressure (bar)
Coeff. of Thermal Expansion (mm/m 0 C}
Internal texture (in mm)
Thermal Conductivity (W/m°K)
*for
0-95
110
10
0.026
0.007
0.340
br ief per iods of t i me
Wavin Pilsa Monolayer Pipes for sanitary and heating
systems, and floor radiating panel system.
(Max working temperature: 95°C)
Art – No.
Size
PX - 1620
16x2.0mm
100m
0.090Kg
PX - 1622
16x2.2mm
100m
0.098Kg
PX - 2020
20x2.0mm
100m
0.116Kg
PX - 2022
20x2.2mm
100m
0.126Kg
PX - 2523
25x2.3mm
100m
0.167Kg
PX - 3229
32x2.9mm
100m
0.269Kg
PX - 3230
32x3.0mm
100m
0.276Kg
Packing Wt/Mts
Wavin Pilsa EVOH Multilayer Pipes with Oxygen Barrier
for sanitary and heating systems, and floor radiating panel
system
(Max working temperature: 95°C)
Art – No.
Size
Packing
Wt/Mts
PXO – 1620
16x2.0mm
100m
0.091Kg
15
Wavin Pilsa Product Range
STRAIGHT NIPPLE MALE
Code
C0801
C0802
C0803
C0804
Measure
16x1/2
18x1/2
20x1/2
20x3/4
Box
125
125
75
75
BRASS FEMALE ELBOW
Code
C2101
C2102
C2103
C2104
Measure
16x2
18x2.2
18x2
18x2.5
Box
50
50
50
50
ROD CONNECTOR (one way)
Code
C0901
Measure
½” x 16
Box
100
RING + NUT + WINNY-PEX
Code
C2301
C2302
C2303
C2304
C2305
C2306
C2307
Measure
16x2
18x2.2
18x2
20x2
20x2.3
25x2.5
32x3
Box
300
300
300
300
300
300
300
ROD PIPE CONNECTOR
Code
C1001
Measure
½” x16
Box
100
FEMALE ELBOW SHORT
Code
C2401
C2402
Measure
16x2mm
16x2.2
Box
50
50
16
Wavin Pilsa Product Range
WALL PLATE ELBOW FEMALE
Code
C2101
C2102
C2103
C2104
Measure
16x2
18x2.2
18x2
18x2.5
Box
50
50
50
50
PLASTIC CASING
Code
C2501
Measure
25mm
Box
500
PIPE LID
Code
C1801
Measure
16-17mm
Box
100
17
Wavin Pilsa Product Range
Female Elbow with Box
Art – No.
Dimension
Description
PCS/CTN
EF1 – 161/2
16mm x ½”
Without Neck
200
EF1 – 201/2
20mm x ½”
With Neck
200
Female Elbow
Art – No.
Dimension
PCS/CTN
EF2 – 161/2
16mm x ½”
200
EF2 – 201/2
20mm x ½”
180
EF2 – 251/2
25mm x ½”
150
EF2 – 253/4
25mm x ¾”
120
EF2 – 251
25mm x 1”
100
EF2 – 321
32mm x 1”
80
32mm x 1 ¼”
80
Dimension
PCS/CTN
EM1 – 161/2
16mm x ½”
200
EM1 – 201/2
20mm x ½”
200
EM1 – 251/2
25mm x ½”
150
EM1 – 253/4
25mm x ¾”
120
EM1 – 251
25mm x 1”
100
EM1 – 321
32mm x 1”
80
32mm x 1 ¼”
80
EF2 – 3211/4
Male Elbow
Art – No.
EM1 – 3211/4
18
Wavin Pilsa Product Range
Male Adaptor
Art – No.
Dimension
PCS/CTN
AMP1 – 161/2
16mm x ½”
400
AMP1 – 201/2
20mm x ½”
250
AMP1 – 251/2
25mm x ½”
200
AMP1 – 253/4
25mm x ¾”
160
AMP1 – 251
25mm x 1”
120
AMP1 – 321
32mm x 1”
120
32mm x 1 ¼”
100
Dimension
PCS/CTN
IFP - 16
16mm x ½”
500
IFP - 20
20mm x ½”
400
IFP - 25
25mm x ½”
250
IFP - 32
32mm x ½”
160
Dimension
PCS/CTN
RSP – 3/41/2
¾” x ½”
600
RSP – 13/4
1” x ¾”
400
1 ¼” x 1”
200
Dimension
PCS/CTN
MMC1 – ½
½”
600
MMC1 – ¾
¾”
400
MMC1 – 1
1”
125
MMC1 – 11/4
1 ¼”
100
MMC1 – ¾ ½
½” x ¾”
500
AMP1 – 3211/4
Insert Fitting Set
Art – No.
Reducer Sleeve
Art – No.
RSP – 11/4 1
Male Coupling
Art – No.
19
Wavin Pilsa Product Range
T – Piece for Manifold
Art – No.
Dimension
PCS/CTN
EPM1 – 3/83/41/2
3/8” x ¾” x ½”
200
EPM1 – 1/23/41/2
½” x ¾” x ½”
200
EPM1 – 3/43/41/2
¾” x ¾” x ½”
200
EPM1 – 3/811/2
3/8” x 1” x ½”
170
EPM1 – 1/211/2
½” x 1” x ½”
170
EPM1 – 3/411/2
¾” x 1” x ½”
170
EPM1 – 3/811/41/2
3/8” x 1 ¼” x ½”
125
EPM1 – 3/211/41/2
½” x 1 ¼” x ½”
125
EPM1 – 3/411/41/2
¾” x 1 ¼” x ½”
125
Dimension
PCS/CTN
PPA - 16
16 x ½”
250
PPA – 20
20 x ½”
250
PPA – 25
25 x ½”
250
PPA – 32
32 x 1”
120
Dimension
PCS/CTN
3/8”
100
ARV1 – ½
½”
100
ARV1 – ¾
¾”
100
Pex Ppr Adaptor
Art – No.
Air Release Valve
Art – No.
ARV1 – 3/8
20
Wavin Pilsa Product Range
Ball Valve (Red Handle)
Art – No.
Dimension
PCS/CTN
V1 – 3/4R
¾” x 25mm
80
V1 – 1R
1” x 25mm
60
1 ¼” x 32mm
36
V1 – 11/4R
Ball Valve (Blue Handle)
Art – No.
Dimension
PCS/CTN
V1 – 3/4B
¾” x 25mm
80
V1 – 1B
1” x 25mm
60
1 ¼” x 32mm
36
V1 – 11/4B
Ball Valve (Red Handle)
Art – No.
V2 – 1/2R
Dimension
PCS/CTN
½”
200
Ball Valve (Blue Handle)
Art – No.
Dimension
PCS/CTN
½”
200
Dimension
PCS/CTN
EP1 – ½
½”
500
EP1 – ¾
¾”
500
EP1 – 1
1”
300
1 ¼”
144
V2 – 1/2B
End Plug
Art – No.
EP1 – 1 ¼
22
Wavin Pilsa System Installation
Pressure Loss
The pressure losses in PEX pipes can be assessed by the following chart. The chart
represents performance at 80°C. The deterioration curves indicate life of the piping system,
depending on the fluid pressure, temperature and hoop stress created in the pipe.
Due to smooth pipe surface, Wavin Pilsa pipes have very low coefficient of friction compared
to the metallic pipes. Moreover, no chemical reaction takes place between the pipe and
calcium and magnesium carbonates in the water and no reduction in cross section occurs,
thus giving constant pressure losses in long term use.
Pressure Loss Diagram for Wavin Pilsa pipes
Handling and Storing Wavin Pilsa Piping System





Wavin Pilsa pipes should be stored well covered in order to keep the pipes clean and
avoid exposure to sunlight. Consult Wavin Pilsa for recommended limits for outside
storage.
Wavin Pilsa pipes should be stored in a way to protect the system from mechanical
damage (slitting, puncturing, etc.).
Do not drag the Wavin Pilsa pipes over rough terrain, rocks, or any surface that can
cut, puncture, or damage the pipes wall.
Do not crush or kink the Wavin Pilsa pipes. Inspect all pipes before and after
installation.
Cut out and replace all damaged sections.
Connecting the Wavin Pilsa Piping System
There are several methods of connecting Wavin Pilsa piping all of which involve mechanical
fittings. The crimp fittings are the most widely used. Other fitting systems, including insert and
24
Wavin Pilsa System Installation
outside diameter compression fittings, are also available. Under - floor Heating
Systems are not difficult to design or to install but it is important that the guidelines and
instructions are carefully followed to ensure that the system performs correctly once installed
and has a long service life. This manual provides a guide to the principles and design of Wavin
Pilsa and also gives installation guidelines for the components and systems. Engineers
familiar with installing conventional central heating systems will be accustomed to working with
radiators, convectors, and copper pipes.
It is widely recommended that, in order to establish a consistent and leak free ioint, it is
necessary to follow Wavin Pilsa iointing procedure for screw
fittings.
1. Use Wavin Pilsa pipe cutter PC-O42 to cut the pipe.
Make sure that a straight and clean pipe end results a
correct positioning of the fittings.
2. Use a level for correct positioning of Elbow Box.
3. Select the right size Wavin Pilsa screw brass fitting
according to the pipe size. Put the nut on the pipe. Make
sure the female side of the nut and the pipe end are on ]
ts.- the same side. Slide the compression crimp ring over
the pipe.
4. Do not apply lubricant or pipe dope on the insert fitting.
Position crimp ring 3mm to 6mm from end of tubing. To
prevent ring from moving, squeeze the ring slightly with
spanner
5. Keeping both ring and tool square with tube. DO NOT
CRIMP TWICE. lt is recommended that each crimped
ring be checked with the appropriate gauge.
Incorrect Connections
The consequence of not following correct procedures is a potential for leaks. Incorrect fittings
should be cut out and replaced. Here are a few tips to trouble shoot incorrect connections:
01. Ring crimped over end of PE-X pipe.
02. Tool not at 90 degrees to pipe when crimped.
dented.
Result: Doesn't cover enough ribs.
Result: Insufficient rib coverage; pipe
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Wavin Pilsa System Installation
3. Ring not completely covered by crimp tool
Result: Ring distortion, non-uniform crimp.
4. Pipe not cut squarely
Result: Insufficient rib coverage.
5. Ring too far from pipe end.
Result: Insufficient rib coverage.
Wavin Pilsa piping Supports: Selection and Inspection
• Wavin Pilsa Plastic Brackets BC2- 16 and Straps are recommended. Although metal
supports which are designed for use with plastic pipes can be used.
• Do not use supports that pinch or cut the pipe. Support should allow free pipe
movement.
• Inspect all supports prior to installation to ensure that sharp edges do not exist that can
damage the pipe.
Linear Expansion
In exposed and unsupported pipe systems the pipe is subject to thermal expansion if
it undergoes a change of temperature. The expansion phenomenon is comparable to
that of metal pipe and must be taken into consideration when the system is installed.
Expansion of the Wavin Pilsa pipes varies in direct ratio with the temperature. The
linear expansion coefficient for the Wavin Pilsa pipes is:
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Wavin Pilsa System Installation
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Wavin Pilsa System Installation
Solid Floors
Wavin Pilsa under-floor heating can be permanently built into solid or concrete floors.
epending on the type of building, construction, standards, there are a number at methods of
laying the under floor heating pipes in concrete floor structures.
A concrete slab (or suspended beam and block construction) is laid over o damp proof
membrane. A 20mm thick piece of insulation is fixed to the perimeter (external) walls, to a
height to include the depth ot floor insulation and screed.
While the edging insulation may show, it is covered by wall plastering and skirting boards.
Floor insulation is laid to the whole area, joints are taped to prevent the ingress of screed
between the insulation boards The floor is now ready for the Wavin Pilsa under - floor heating
pipe network installation
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Wavin Pilsa System Installation
Wavin Pilsa System Installation
A 50mm layer of Polyurethane insulation sheet is recommended. If there is not enough space
for 50mm insulation, 30mm will suffice. Polyurethane outperforms polystyrene and its greater
density allows use of clip fittings, and therefore is preferred.
If polystyrene insulation (50mm) is used, it is recommended to install wire web on top of the
insulation and tie the pipe to the web. For other floor constructions please contact our technical
department.
Wood Floors
Wood suspended floors do not conduct heat as efficiently as solid floors. This means that the
heat output is less. Some manufacturers use heat emission plates to try to achieve an even
temperature on the floor. This is a very expensive way of installing under ~ floor heating in
wood suspended floors and at the end of the aluminium plate the temperature will be deflicient.
The Wavin Pilsa system is very simple and easy to install in timber suspended floors. Between
the joists, a 50mm polyurethane insulation board is cut tor a tight tit. It is advisable to use scrap
battens from the building site to support the insulation from below.
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Wavin Pilsa System Installation
Please Note:
Always check with the supplier if the floor covering can be used for under - floor heating.
Timber floors need to have moisture content below 10% to avoid shrinkage. The system must
be operated for 2i days with a very low temperature to dry the screed and then the floor
covering can be laid. Also note that the screed must be allowed to dry for 6 weeks before the
under-floor heating is operated.
Wavin Pilsa Manifold Plumbing Systems
The parallel manifold plumbing concept is relatively simple. Each faucet or water outlet is fed
by its own dedicated line which runs from a central manifold. By providing each outlet with its
own distribution line. The system offers quieter water flow, more balanced water pressure, a
dramatic reduction in the number of fittings required, and the ability to save both water and
energy, versus traditional system design.
Installing Manifolds:
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Manifolds can be installed in a horizontal or vertical position.
In larger installations, remote manifolds may be used to handle groups of remote
outlets.
Each tap or water outlet is fed by its own dedicated line from the manifold, which may
be located near the water supply or water heater.
Pipes should be run continuously and as direct as possible between fixture and
manifold locations. Approved fittings may be used to repair kinked or damaged PEX
distribution lines, or to add to a distribution line that was mistakenly cut too short during
installation. Excessive use of fittings should be avoided.
Shutoff valves can be placed at the manifold.
Pipes should not be pulled tight. Leave slack to allow for expansion and contraction.
Install Wavin Pilsa pipe cautiously to avoid bending, kinking, or abrasion.
Leave excess pipes at the beginning and end of runs for connection to fixtures and the
manifolds. When running lines to a group of fixtures, they may be bundled together,
but loose enough to allow individual pipe movement. Plastic ties may be used.
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Wavin Pilsa System Installation

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Do not use tape when bundling pipes as it may restrict movement of pipes runs.
When bundled lines pass through conventional structural members, cut a hole at the
centerline of the member.
Consult the applicable code for maximum allowable hole size.
Identify and mark all lines at the manifold.
The drawing below represents a typical Wavin Pilsa manifold system.
Connecting pipes to the manifold
1. When laying the under - floor heating loops, the first pipe end should be connected to
the manifold before the loop is laid. Make sure that a PRO ex i b d p p pe en support
BPSl -l 6 IS fitted where the pipe exits the floor and turns up to the manifold.
2. Line the pipe end up with the threaded port on the manifold and cut the pipe end square
by Wavin Pilsa pipe cutter.
3. Push the nut and olive onto the end of the pipe.
4. Push the insert fully into the pipe end and fit, the pipe end in order to get ci secure ioint.
5. Fit the pipe end into the manifold port.
6. Slide both the ring and nut onto the manifold port. Tighten the nut by hand, then a
further half turn with a spanner.
Installed Piping Pressure Testing (DIN 1988, part 2)
All pipes are should be subiected to a special pressure test during installation. The l t d b comp
e e ut not yet covered pipes should be filled with filtered tap water (protection against frost).
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Wavin Pilsa System Installation
The pressure measurement instrument is to be connected to the lowest part of the installation
which has to be tested. Please note that only pressure measurement instruments are to be
applied which allow a secure reading of pressure change of 0.1 bars. Valves are to be closed
upstream and downstream of the heating unit (e.g. boiler) to enable the test pressure to be
isolated from the rest of the network. The pipe system is then subjected to the test pressure
and then reduced to the operating pressure. The pressure for such an installation is the
permitted operating pressure plus 5 bars. With pressure increasing systems, the maximum
operating over-pressure is to be tested.
- Test pressure: maximum operating over-pressure plus 5 bars.
- Test period: alter temperature conditioning between pipe and test medium 2 hours.
- Test difference pressure: > 0.2 bar.
Alter the pressure test is conducted according to DIN l988, part 2, an additional pressure test
with 0.5 bars over a period ot one hour is recommended. Finally, all pipe joints are subject to
visual examination.
PR@pe>< Pipes Pressure Testing Graph
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Wavin Pilsa System Installation
Installation instruction for Pox Brass Fitting
Cut Wavin Pilsa pipe at the right angle using 0 pipe
cutter.
Choose the right size fitting according to the pipe, put
the nut over the pipe, slide the compression ring pipe,
and make sure the mouth of the nut direction.
Push the insert into the pipe up to the shoulder, take
care not to damage the O-ring.
Use Q spanner to tighten it up completely