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1. ND 2403126 2403130 6 17 6 2403134 8 o 2403138 10 a S Dimension ND Part no Dimension Part no Dimension gt SDR Part no SDR Part no SDR Part no yd 0113108 y ND ND L T 0113110 310 0113130 6 0113131 6 lt 2303726 4 2103126 4 2503126 4 p c 2303730 B 2103130 6 2503130 6 0113112 __ zu et 74 11 11 0113114 1 74 0113138 10 0113139 10 2303 34 8 2103134 8 2503134 8 zt 0113116 1 0113142 104 11 0113143 12 A 2303738 10 2103138 10 2503138 10 14 0113118 pu 0113144 14 e 0113120 0 0113147 16 0113149 18 0113122 27 i Mechanically stabilized with a faser dicis 2d composite layer in the center of the pipe 0113126 4 o e LL lt Lld Butt weld molded Dimension Part no 0113130 6 74 0113130106 6 0113131 6 11 0113131LG 6 aComes with a 1 ft extension on each end 74 Part no Dimension ND 0113604 6 x6 x4 0113618 8 xs xb 0113634 10 x 10 x 6 0113640 10 x 10 x 8 0113908 12 x 12 x8 0113910 12 x 12 x 10 0113922 14 x14 x10 0113924 aquatherm green pipe Reducing tee Butt weld Reducing tee Socket inlet outle
2. 0113631 10 x10 x4 0113651 12 x12 x4 01136539 12 x12 x6 0113663 14 x14 x4 Part no Dimension ND 01136057 M x 14 6 01136672 14 x14 x8 0113601 6 x6 x2 0113676 16 x16 x4 11 0113678 16 x16 x6 0113609 8 x8 x2 087007 EP 0113611 8 8 01136825 16 x 16 x 10 0113613 8 8 x3 0113690 18 18 4 0113615 8 8 4 01136928 18 18 6 0113625 10 x 10 2 0113694 18 x18 x8 0113627 10 x10 x3 0113696 18 x 18 x 10 0113629 10 x 10 x3 0113698 18 18 x 12 SDR Part no Dimension ND Partno Dimension ND 0113600 6x6 x2 0113602 6 x6 x3 0113608 8 x8 x2 0113610 8 x8 x3 0113612 8 x8 x3 0113614 8 x8 x 4 0113624 10 x 10 x2 0113626 10 x10 x 3 0113628 10 x 100 x 3 0113630 10 x10 x4 0113904 12 x12 x4 0113916 14 x14 x4 0113918 14 x14 x6 0113920 14 14 x 8 Branch outlet has a butt weld connection Branch outlet has a butt weld connection 5 Mechanically stabilized with a faser composite layer in the center of the pipe aquatherm blue pipe Tee Butt weld Part no 2613131 6 2613135 8 2613139 107 2013143 125 2013145 14 2013147 16 2013149 18 SDR Part no
3. Capacity w water Capacity w water gal Tt Ib ft gal ft Ib ft 0 01 0 11 0 22 125 4 20 17 24 52 23 0 02 0 16 0 36 147 3 9 22 16 67 03 1 0 04 0 19 0 55 16 6 79 27 77 84 31 14 0 07 0 29 0 85 187 0 07 35 15 106 56 1 0 11 0 45 1 32 The following items are supplied in coils 23 0 17 0 71 2 10 0 02 0 07 0 21 2 Va 0 24 1 00 2 97 4 0 03 0 11 0 33 9r 0 34 1 44 4 30 LA 0 04 0 17 0 53 32 0 51 2 13 6 39 4 0 66 2 76 8 27 6 1 08 4 51 13 52 8 1 69 7 03 21 12 10 2 65 10 93 32 97 aquatherm blue pipe SDR 17 6 MF aquatherm blue pipe weights and capacities Capacity Weight w water Ib ft 4 0 78 1 80 9 30 6 1 27 2 92 19257 8 1 99 4 56 21 10 10 3 11 7 09 32 95 12 4 93 11 23 52 30 14 6 27 14 23 66 43 16 7 95 18 06 84 30 18 10 07 22 02 106 69 20 12 42 28 22 131 70 22 15 60 02528 162 16 24 19 73 44 63 209 01 LoL WYAHLVNOV OL SINOITAM Aquatherm listings and approvals Reference standards e NSF 14 51 Green Pipe only 61 Green Pipe only e CSA B137 11 e CFIA A508 Green Pipe only e CSA B214 2 e ICC ESR 1613 PMG Listing 1014 e 150 15874 e PC 2009 Section 605 Green Pipe Lilac Pipe e ASTM F 2023 E e IMC 2009 Chapter 12 e ASTM D 635 e IRC 2009 Chapter 21 amp 56 e NFPA 13 D Green Pipe 7 4 only UMC 2009 Chapter 12 e DIN EN ISO 14001 e UPC 2012 Chapter 6 Green Pipe Lilac Pipe e DIN E
4. e B rr JJ cc lt et e LL e ol LL Identification Aquatherm has several lines of pipe that are specifically engineered for certain applications Stripes and color indicate the type of pipe aquatherm green pipe MF aquatherm blue pipe MF aquatherm green pipe 5 aquatherm lilac pipe S Expansion control label Material Relevant code listings not present on non MF pipes varies by pipe type Pipe name Production size and Wall thickness Additional only genuine Aquatherm pipe nomi ominal diameter Wo information and fittings are backed by our based on pipe diameter 10 year warranty incl timestamp Color Green Stripes Dark green Wall thickness SDR 74 Size range 12 14 Multi layer construction expansion controlled Yes Maximum operating pressure at 50 F 380 psi Maximum operating pressure at 180 F 100 psi Recommended applications Domestic potable hot water food processing light hazard fire sprinkler NFPA 13D Acceptable applications Domestic potable cold water heating cooling compressed air chemical transport and any other application suitable for PP R Hot water aquatherm green pipe MF gt rr RE e B rri ad cc EN lt et e LL e LL Cold water aquatherm green pipe S
5. 17 6 5 ft lbs 34 66 14 355 x 20 1 176 157 52 www mcelroy com _ 4 125 x 11 4 11 8 ft lbs 53 101 14 355 x 32 2 11 242 81 Installers should always use 6 160 x 9 1 17 6 9 ft lbs 60 108 60 32 14 355 x 48 0 74 243 114 67 160x146 11 14 ft lbs 93 167 93 49 2 with the butt welding machine d 16 400 x 22 7 176 199 66 T or the manufacturer s online 6 160 x 21 9 74 20 ft lbs 132 236 132 70 16 400x363 11 308 102 gt information to calculate the 8 200x114 176 94 94 50 17 m Li adjustment pressure This table 18 450 x 25 5 176 252 84 c is based on the information 8 200x 182 1 14 145 1 2 18 450403 11 389 129 N available to Aquatherm at the 8 200x274 74 207 207 109 36 e time of this manual s printing F 20 500 x 28 4 17 6 104 and may not be complete 10 250x 14 2 179 i a accurate or current If there is a 107 250x227 11 218 120 40 LESS ss discrepancy between this table 5 24 630 x 357 178 164 and any information provided by 10 200x382 26 the tool manufacturer the tool 12 315 x 17 9 176 124 41 manufacturers information shall 12 315x286 11 191 63 be considered correct 12 315 x 43 1 74 2 0 90 Ritmo adjustment and welding pressure Gamma Delta Dragon Delta Dragon Delta Dragon Delta Dragon 41 ITAA Cc Dimension 160 2508 3158 3558 ND OD mm Ritmo adjustment and welding pressure Di
6. et e e m LLI Getting started Before you get started you should know a little about the pipe you are installing Aquatherm s pipes and fittings are made from an engineered variation of polypropylene random copolymer or PP R Aquatherm PP R offers many benefits over metals and other plastics such as durability longevity and chemical purity Aquatherm s polypropylene pipes and fittings are produced in Germany and have been used around the world for over 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 don t have Aquatherm labels return them and don t install them Only genuine Aquatherm products are protected by Aquatherm s warranty and decades of expertise with PP R If you have not worked with Aquatherm s fusible pipe before It is best not to rush and get ahead of yourself Just as you were not able to make perfect welds your first day as an apprentice it will also take you some time to become proficient at heat fusion Fortunately you ll 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 Polypropylene is a thermoplastic similar to polyethylene pipe It is made from an oil by product 50 It naturally repels water This makes it ideal for a pip
7. m rm gt 2 N End cap Socket aquatherm blue pipe Elbow 45 SD Butt weld End cap Butt weld 9 e 2 LL ex TT a Dimension SDR Part no ND 7512530 6 7512534 8 7512538 107 11 7512542 125 7512544 147 7512546 16 7512548 18 17 6 Part no EM 7412530 6 7412534 8 7412538 107 7412542 128 7412544 147 7412546 1 7412548 18 7412550 20 7412552 22 7412554 24 Part no Dimension ND 0114108 12 0114110 4 0114112 1 0114114 a 0114116 TUE 0114118 28 0114120 2 Vr 0114122 9 0114124 Iy 0114126 4 74 Part no xi 0114130 6 0114134 8 0114138 107 0114142 12 0114144 14 Part no Part 0114131 6 2514130 6 0114135 8 2514134 8 0114139 10 2514138 10 0114143 12 2514142 12 UE MEE d 12514144 14 0114147 16 S onus 0114149 18 2514148 18 2514150 20 2514152 22 2514154 28 25 rri gt E C o aquatherm green pipe Wye Lateral 45 aquatherm blue pipe Wye Lateral 45 Tee Socket aquatherm green pipe Tee Butt weld Dimension SDR Part no
8. Damaged when exposed to innovations unique to Aquatherm high temperatures help address these minor Significant linear expansion shortfalls Aquatherm s special 020 blend of PP R is called Fusiolen which is used in each Aquatherm pipe and fitting Heat stabilization protects the pipe during brief exposure to extreme temperatures Aquatherm PP H Regular PP R The multi layer faser composite MF process yields a mix of PP R and glass fibers that reduces expansion but does not affect fusion properties Pipe integrity at 400 F 42 Time min Aquatherm is the world leader in PP R pressure piping systems When you work with our products you have decades of research and experience backing 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 manufacturer s warranty that doesn t just cover replacement parts it also covers the replacement labor incidental damages medical The world leader in PP R pipe costs and financial loss giving you and your customers real peace of mind Coverage begins upon submission of a successful pressure test record for the current coverage amount Exact coverage amounts are subject to the exchange rate with the Euro at the time cover
9. x Y 0121323 0621323 2 2 0123016 0923016 0623016 17 x ME 0121213 0921213 0621213 1 x M 0121324 0621324 2 x 2W M SaaS LS 0121325 0521325 3 0123018 1123018 0623018 1 x 1 F 0121327 0621327 3 x 4M NPT transition tee Draining branch Flow meter well Stub out Straight stub out male to weld in valves May also be used for thermometer well PP R to copper PP R to copper 22 o Lead free Industrial Lead free Part no Dimension ND Part no m potable b Dimension Di on ND notable b ion ND i gt Part NPT a able 91838 ND a ee AQ630P248E AQ638P211 Tm art no NPT Part no Part no 0638P41 1 ee QURE NE AQ630P41110 1 AQ638P418 LLJ cu 0628520 A toB x2 x2 F O 0041412 1 A 0041414 1 E 0041416 1 6 0041418 25 Transition elbow Transition tee female PEX adaptor expansion PP R to grooved transition ASTM F1960 standard with PP R street connection PEX adaptor crimp ASTM F1807 standard with PP R socket connection 0125022 0625022 1128 1 E LE un d P o 9 4 Industrial Stainless Lead free ae Lead free Lead free Lead
10. 0 0002367 in ft F for MF pipe 0 001008 in ft F for pipe Multiply the length of the pipe L by the temperature difference AT and again by the expansion coefficient a as shown here Lx AT xa AL 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 9NINNV ld LLY Linear expansion for non MF pipe Linear expansion for MF pipe Difference in temperature AT T i temperature instalation temperature Difference in temperature T i temperature installation temperature 20 F 40 F 50 F 60 F 80 F 100 F 10 F 20 F 40 F 50 F 60 F 80 F 100 F Linear expansion AL in Linear expansion AL in 0 1 0 2 0 3 0 4 0 5 0 6 0 8 1 0 0 0 0 0 0 1 0 1 0 1 0 1 0 2 0 2 0 2 0 4 0 6 0 8 1 0 1 2 1 6 2 0 0 0 0 1 0 1 0 2 0 2 0 3 0 4 0 5 0 3 0 6 0 9 1 2 1 8 2 4 30 0 1 0 1 0 2 0 3 0 3 0 4 0 5 0 7 0 4 0 8 172 1 6 2 0 24 32 4 0 0 1 0 2 0 3 0 4 0 5 0 5 0 7 0 9 0 5 1 0 15 2 0 205 3 0 4 0 5 0 0 1 0 2 0 3 0 5 0 6 0 7 0 9 1 1 0 6 1 2 1 8 24 3 0 3 6 48 6 0 0 1 0 3 0 4 0 5 0 7 0 8 1 1 1 4 0 7 1 4 2 1 2 8 35 4 2 5 6 7 0 0 2 0 3 0 5 0 6 0 8 1 0 1 6 5 0 8 1 6 24 2 4 0 4 8 6 4 8 0 0 2 0 4 0 5 0 7 0 9 1 1 1 5 1 8 0 9 1 8 2 7 3
11. 0115178 3 x M 0115206 B xv 0115234 8 0115263 12 x35 0115331 24 X3 __ imension ND a v MP 0115292 18 x 6 to 10 Partno nine x outlet 0115180 3 x1 0115208 7217 0115235 8 x3 12 x4 0115268 14 x 3 X 12 0115156 1 4 x14 0115181 3 x14 0115210 6 x1 0115236 8 x 3 nee ee 0115269 0115306 20 x 6 to 10 ca 0115158 14 x 34 0115182 3 x v 0115212 6x14 0115237 9 x 4 m Z 0115270 14 x4 0115312 20 x 12 et 0115160 15 xv 0115184 35 xA 0115214 6 x15 0115251 10 x14 E 0115275 16 to020 x2 aseo m a 0115162 xa 0115186 sA xT 0115216 KZ 0115252 1 x11 i 25 0115277 16 10 18 x3 mm JT L 0115164 2x V 0115188 3X x1 0115218 6x2 0115253 10 x2 115778 18 xd N 0115166 Du 0115189 522012 0115220 A XI 0115254 11 212 0115288 16 to 20 x 3 0115168 2 y1 0115190 Av xy 0115228 8 to 10 x 0115255 10 x3 0115290 18 to 20 x 4 0115170 2v xw 0115192 4 x 34 0115229 8 to 10 x34 0115256 10 x 3 0115300 16 to 24 x 2 Flange ring Flange adapter Butterfly Valve Dimension SDR ND OD 9 e 2 H LL et TT a 0115530BV 01155301 0115534 0115542BV 0115544BV 0115531BV 0115531 LBBV 115531LGBV 0115535BV 0115539BV Parco pis Dimension of bolt ND holes 3315
12. 17 6 39 to Aquatherm at the time of this manual s 10 250 x 22 7 11 32 28 12 printing and may not be complete accurate 10 250 x 34 2 74 45 40 17 Contact manufacturer for pressure or current If there 18 a discrepancy between this table and any information provided by 12 315 x 17 9 17 6 23 12 10 the tool manufacturer the tool manufacturer s 12 315 x 28 6 11 44 19 15 information shall be considered correct 12 315 x 43 1 7 4 62 26 4 c 22 lt Adjustment bead height 4 24 Size 4 125 mm 6 160 mm 8 200 mm 10 250 mm 12 315 mm 14 355 mm 006 som or esam oom nsnm wee Lar e om SDR 7 4 SDR 11 Bead height reference SDR 17 6 0 04 1 0 mm 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 1 mm 1 5 mm 2mm 2 5mm 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 and may also indicate a problem with fusion pressure 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
13. Dimension ND 25 0180 6 25 0184 8 25 0188 10 2570192 75 2570194 14 25 0196 16 25 0198 18 25 0200 20 Part no Dimension ND SDR 7 4 9010808 9010810 9010212 1 9010214 1A 9010216 11127 9010218 24 aquatherm lilac pipe SDR 74 11 S Part no Dimension ND 9010220 210 9010222 35 9010224 272 9010226 4 9010226x2 4 Double Length 9010226 3 4 Triple Length 9010230 6 9010230x2 6 Double Length 9010234 8 9010238 10 Pipe comes in 26 ft lengths PPipe comes in 39 ft legnths Pipe comes in 38 ft lenghts ar J mi I e 21 c e Coupling Reducing couplings Cross over Street 45 Street 90 female female female male female male Part no Dimension ND 0111253 3 t02 0111257 3 t021 0111259 3 to 3 0111263 4 to 3 0111265 47103 V Part no Dimension ND m Dimension ND 0116108 Dimension ND gt 0111008 y Part no Dimension ND 0116110 ye Part no Dimension ND 0112308 y 25 0111222 1 4 to 1 zs i 0111228 E 1 E E diis E 0111012 1 d 0112710 0112312 1 E et 0111014 14 0111230 172 to 174 0112712 i m ye 0112314 1 O 0111016 TA 0111236 2 to 1 0112714 i
14. not affect the outer wall of the pipe which will always be consistent gt m c 2 T c o LL lt 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 fuse in a new section Attach the repair head to a welding iron Heads If the hole is too small carefully drill it out Use are available in 5 16 and 7 16 sizes Use a size a 1 4 bit for the 5 16 head and a 3 8 bit for that is larger than the hole the 7 16 head Insert the repair head into the iron and insert the Remove the pin from the head and the welding Once the pin has set you may use cutters to repair pin into the repair head Heat for 5 seconds head from the pipe Insert the pin into the pipe remove the rest of the pin Pressure test the wall Do not overinsert the pin system to ensure a proper repair Chapter 3 Productivity Heat fusion is a fast and consistent way to join pipe but overall productivity depends on the build strategy being used Having the right crew and tooling mix will greatly increase the speed of your installation Proper prefabrication and field techniques can help you work even faster This chapter will help you apply the fusion techniques you ve learned in faster more productive ways ALIMLONGOdd gt fam e cc
15. 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 oc V Bushings reducers and reducing couplings Large PP R ball valve 3 6 To help limit the number of and a thicker wall than a normal Aquatherm also provides The benefits of an all polypropylene system can be realized up reducing fittings that a wholesaler socket connection Bushings run reducing couplings to reduce the through 6 with the large diameter PP R ball valves available from must stock Aquatherm uses from 4 down to 1 2 pipe during a straight run Sizes Aquatherm The valves flange in line and can be installed quickly and bushings which are designed to under 4 are socket fused on easily as long as the following items are addressed be inserted into another fitting Reducers are used with larger both ends Sizes that reduce from i j e Be aware that the bolt e At the time of print such as a socket tee or elbow pipes and are butt welded on above 4 to 4 or smaller will butt hole pattern is built to the Aquatherm does not source When reducing the side being both sides They may go directly fuse on the larger size and socket 2 ISO European standard gaskets or bolts We intend to reduced from is male and acts to a pipe or to a fitting fuse on the smaller size Therefore flange rings add
16. 2 7 0111144 2 t0 0113710 34 0111184 8 to 6 0111201 16 to 10 17 6 2511201 16 to 10 2511218 24 to 20 0111116 1 to 34 ae as m1 E m m 0111145 2 to 1 0113712 1 0111188 10 to 6 0111203 16 to 12 2511203 16 to 12 2511219 24 to 22 id 0111139 2X t01w 0113714 7 0111190 10 to 8 0111204 16 10 14 1A 34 n ue D 0111140 2X7 to1 4 74 0111192 12 01112068 18 to 12 2026 ME e 147 di EE to us 0111142 2 to 2 0111194 12 to 10 12 oe TNTUTUNE EET EU 0111124 1 to m ENS VENE MONEY 0111208 18 to 16 1 0111151 3 012 B 2511209 20 to 12 0111126 1 t0 0111152 4 19 2 0111198 14 to 12 2511210 20 to 14 vm 0111128 1 to 1 1111153 3 025 Elbow 90 Socket Elbow 90 Butt weld molded Reducin coupling butt weld socket wel aquatherm green pipe Elbow 90 SD Butt weld _ Dimension Part ND 2511174 6 1037 17 6 2511176 6 to 4 2511182 8 to 4 Part no Dimension ND Imension Z Dimension SDR Part no No rm Dimension 0112108 Part Part no n 4 ND us 0111174 6 to3 7 EI 2 7312130 7112130 6 74 0112130 6 74 0111176 6
17. 2513130 6 2513134 8 2513138 107 2519142 12 ne 2513144 14 2513146 16 2513148 18 2513150 208 2513152 227 2513154 24 m rm gt I 2 N o e LL et aquatherm blue pipe Reducing tee Butt weld Dimension ND 2613605 6 x6 x4 2613619 8 x 8 x6 2613635 10 x 10 x 6 2613641 2013655 12 x12 x8 2013657 12 x12 2013669 14 x 14 x 10 Part no Dimension ND 2013671 14 x 14 x 12 2013684 16 x 16 x 12 2013685 16 x 16 x 14 2013699 18 x 18 x 14 2013700 18 x18 x16 aquatherm blue pipe Reducing tee Butt weld continued SDR Part no 17 6 Dimension ND 25136049 6 x6 x 4 2513618 8 x 8 2513634 10 x 10 x 6 2513640 10 x 10 x8 2513657 12 x12 x10 2513669 14 x 14 x 10 2513671 14 x 14 x 12 2513684 16 x16 x12 17 6 Part no Dimension ND 2513685 16 x 16 x 14 2513699 18 x 18 x 14 2513700 18 x18 x 16 2513813 20 x 20 x 14 2513814 20 x 20 x 16 2513815 20 x 20 x 18 2513831 22 x22 x 16 2513832 22 22 X18 2513833 22 x 22 x 20 2513849 24 x 24 x 16 2513850 24 x 24 x 18 2513851 24 x 24 x 20 2513852 24 x 24 x 22 E m I e 21
18. 26 4 4 8 3315730 6 6 8 3315734 8 8 8 3315738 10 10 12 3315 42 125 12 12 3315744 14 14 12 3315746 16 16 16 3315748 18 18 16 3315750 20 20 20 3315752 22 22 20 3315 54 24 24 20 0115543BV Port Ho pis Dimension of bolt size ND holes 3315712 1 1 4 3315 14 1 114 4 3315716 15 16 4 3315 18 2 2 4 3315720 2 212 4 3319 22 3 3 8 3315 24 3A 317 8 0115545BV Part no 0115512 1 0115514 187 0115516 15 0115518 23 0115520 2 Vr 0115522 3 0115524 3h 0115526 4 0115547BV 0115549BV Part no Dimension ND OD 2915530BV 6 29152548 8 2915538BV 10 2915542BV 123 176 2915544BV 147 2915546BV 16 2915548BV 18 2915550BV 20 2915552 22 2915554BV Du Part no 0115526 must be paired with a coupling part no 0111026 sold separately Includes 1 ft extension of aquatherm green pipe Includes 1 ft extension of aquatherm blue pipe Not butterfly valve compatible E m rri gt E C n o e LL et 5515712 Pump flange adapter ring American bolt pattern Dimension ND OD 1 32 mm pump flange ring blue 3 1 8 to 3 5 32 bolt center used with 0115512 Union with brass nut Union with PP R nut 2919 13 2919 14 1 25 40 mm pump fl
19. 30 34 37 40 42 45 47 90 92 12 315 53 75 92 106 119 130 141 151 160 168 177 184 17 24 23 34 38 42 45 48 d 94 9 39 14 355 56 79 97 112 126 138 149 159 168 178 186 194 1 40 19 27 33 38 42 46 90 94 3 60 63 66 16 400 60 84 103 119 133 146 158 169 179 188 198 206 50 2 30 u 32 56 60 a 67 70 73 18 450 63 89 109 126 T 155 167 178 190 200 210 219 5 24 34 M 48 53 58 63 67 1 75 E n 20 500 67 94 115 133 149 163 176 188 200 211 271 231 2 2 75 26 37 49 32 58 54 2 73 i ap D 22 560 71 100 122 141 158 173 187 199 212 223 234 244 28 40 49 97 a s d 2 2 i iis 24 630 75 106 130 150 167 183 198 217 224 237 248 259 3 110 31 44 54 63 70 7 83 89 94 99 104 109 4 125 34 47 58 67 70 82 89 95 101 106 111 116 Length of bending side with pre stress 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 Pipe Linear expansion in inches square finish dimension in inches 2 2 4 5 6 2 8 g 10 i 12 mm Length of bending side in Pipe Linear expansion in inches dimension in inches 1 2 3 4 55 6 7 8 9 10 11 12 mm 6 160 2 38 46 04 60 66 7 76 80 89 89 93 ding side in 8 2
20. 6 4 5 5 4 12 9 0 0 2 0 4 0 6 0 8 1 0 1 2 1 6 2 1 1 0 2 0 3 0 4 0 5 0 6 0 8 0 10 0 0 2 0 5 0 7 0 9 1 1 1 4 1 8 2 3 1 5 30 45 6 0 15 9 0 120 14 9 0 3 0 7 1 0 1 4 1 7 2 1 2 7 3 4 2 0 4 0 6 0 8 0 10 0 12 0 159 19 9 0 5 0 9 1 4 1 8 23 21 30 4 6 Expansion controls Expansion controls To control linear expansion you will need to isolate and direct the expansion in a safe way Expansion will Expansion loop Used on long straight runs Two distant anchors direct expansion to a central loop The move away from anchors and through guides until it reaches your expansion control or another anchor On loop can even be pre stressed to accommodate additional expansion or to give a square appearance long runs you should use an expansion control every 120 ft Remember that branches and other fittings during operation cannot expand through an anchor or guide Common expansion controls include EXEC 4 lt i Sliding elbow Expansion is directed to Linear isolation For vertical installations expansion where the pipe changes direction The can be contained to each floor leaving each 10 ft space Expanding side Expanding side flexibility of the bending side slight bowing of the pipe which can be minimized using a midfloor guide force of the expansion is absorbed by the with a fraction of an inch of expansion This will cause a Bending side without pre stress Bending side with pre stress Note Only MF p
21. 638 281 information shall be considered correct i 12 315x 43 1 74 914 377 Rothenberger adjustment and welding pressure Rothenberger adjustment and welding pressure ROWELDG P ROWELD P ROWELD P ROWELD P a ROWELD P250B amp ROWELDO P 500 B amp _ROTHE NBERGER 250 A 160 250 amp 55 500 amp P630B Dimension SDR P355 B P630 B zipssncl technologies at work 00 OD mm 17 6 Adjustment pressure N Adjustment pressure bar Adjustment pressure bar 300 545 7698 4 263 394 14 42 12 176 26 7 11 8 www rothenberger usa com 11 407 610 115 65 _ 12 11 411 182 4 74 580 869 16 4 9 3 12 98 8 26 1 2 6 17 6 431 431 12 2 6 9 Ie ne 22 Installers should always use the 14 11 522 231 gt o operator s manual included with 6 I 667 667 18 9 10 7 s the butt welding machine or the m Y m m 14 7A 74 6 33 1 a manufacturer s online information to 16 176 _ 190 5 lt calculate the adjustment pressure g 17 6 675 10 8 48 l l This table is based on the information 16 11 37 2 gt available Aquatherm at the time of 8 11 1039 16 6 7 4 24 1 this manual s printing and may not be 18 17 complete accurate or current If there 8 74 J i 23 1 10 5 18 11 372 is a discrepancy between this table and i _ _ any information provided by the t
22. Not for potable applications 2 J m gt e I 2 N Ball valve Ball valve Extension for ball valve polypropylene Polypropylene with ISO bolt pattern Part no Dimension ND Part no Dimension ND 0041468 ke 0041602 3 0041588 y 00417028 z aaa 0041606 3 and 4 a 3 0041704 3 and co 0041492 1 E 0041607 6 5 0041592 ee D Dimension u art no 0041494 ND x length gt m 0041594 0041378 A to 4 Pa 7 2 et 0041496 1 0041382 1 to1 0041596 1 0041386 1 to 2 0041498 2 0041378 suitable for part no 0041308 0041310 e 00415988 2 0041382 suitable for part no 0041312 0041314 0041386 suitable for part no 0041316 0041318 D 0041400 2 Part comes with FKM FPM O ring in the color gray Repair plug Temperature protective Welding heads Drill bit to close pipe holes up to 16 repair stick gloves for boring fusion outlet holes part no 0060600 Dimension Part no Lr dia 2 22 0050948 nr 0050950 2 y 0050952 7 Partno Dimension Part no Dimension 0050954 3 Part Dimension 0050958 6 0050210 3 a 0050940 2 83 forpipes 14 6 uut 0050212 1
23. are sma e Ittings that use outlet TUSIO y wel TENE to attach to the side of the pipe see page 2 24 2 1 The table on the left gives the available branches 34 M F M F F 8 for each pipe size Fusion outlets are listed re ik a F 10 page 5 26 17 2 8 T e The table on the y far left shows the i lel available outlets 18 24 with metal threads listed on page 5 41 4 32 Buried applications Unlike many other piping materials PP R is able to absorb the stress caused by expansion within certain limits The multi layer faser MF construction helos 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 MF 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 in
24. back far enough for the electrofusion socket to be used as a slip coupling right Once the spool is in place the coupling is slid back to center below Joining spools Electrofusion GG ALIALLONGOYd gt gt e cc a Joining spools Flanges Flange adaptors can join the pipe to itself or another material Aquatherm flange connections consist of two parts the adaptor and the ring see page 4 26 Flange adaptors are a common connection method in areas where traditional fusion is difficult or impossible Flange transitions are available up to 24 Planning for flanged spools will include considerations for the thickness of the gasket and for any equipment such as valves being installed between the spools This affects both build length of the spool and the length of the bolts Chapter 4 Planning Beyond heat fusion there are a number of differences between installing Aquatherm pipe and installing other systems Your skill in planning and layout can help you take advantage of these differences and avoid common pitfalls This chapter will discuss important installation details such as pipe sizing hanger spacing expansion controls insulation and pressure testing PLANNING 4 2 Technical bulletins Aquatherm works hard to deliver the best training and most accurate product information available to you the installer However due to the w
25. 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 Electrofusion instructions page 3 of 3 Verify that the display matches the sticker If the label and the machine don t match rescan the fitting label or input manually Remove leads when heating 18 finished The pipe and fitting will get hotter before cooling down again Follow the directions on the machine Verify your prep work and then begin heating upon confirmation 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 LE c NOISN4 LV4H c 22 ert Butt welding Butt welding 15 the process of using heat and pressure to join the faces of two pieces of pipe together 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 Unit controls vary by manufacturer Carriage Aquatherm supports butt welding on sizes 6 and larger on all SDRs as well as 4 on S
26. free Industrial Stainless Lead free brass steel potable brass pp p ND x thread type un potable brass Dimension ND potable brass Dimension ND potable brass Dimension ND brass steel potable brass PP R ND x thread tvpe Part NPT Part no 150 Part no NPT Tm Part no Part no Part no Part no NPT Part no ISO Part no NPT 0125006 0925006 0625006 W x V x W F 0099840 20 mm PP R to 2 PEX 0098840 20 mm PP R to PEX 0627060 2W mm is to 0123506 0923506 0623506 Vy x M 0125008 0925008 0625008 7 2 2 groove z 0099841 94 25 mm PP R to 34 PEX 0098841 34 25 mm PP R to 34 PEX 111 Vm 2 2 a 0099842 1 32 mm PP R to 1 PEX 0098842 1 32 mm PP R to 1 PEX 0125012 0925012 0625012 X 4 x 34 C 0123510 0923510 0623510 4 x 4 M Te 0125014 0925014 0625014 1 xT x WF 0123512 0923512 0623512 1 x M 0123514 0623514 1 x I M 0125016 1125016 0625016 Xe NPT fusion outlet hex female NPT fusion outlet hex female continued Industrial brass otainless steel Lead free potable brass Dimension Part no NPT Part no ISO Part no NPT pipe x outlet thread o e LL et 5 44 Industrial brass Stainless steel Lead free potable brass Dimension Part no NPT Part no ISO Part no NPT pipe x outlet
27. machines are being Primary is always performing hot used Support preps a second work on a fusion machine Tools 2 3 butt fusion machines connection for the first machine welding irons and jigs if needed If three machines are being oupport can also work on adding CON Goal Maximize connections per La e ied 0 E hour by eliminating downtime for 1 deni zs the cooling phases and minimize in air connections Fusion Preparation J gt Unproductive time gt 22 Lo w T k Process Primary performs the SINGLE INSTALLER P FUSIONS PER HOUR hot work alignment facing i bead up heating and welding MW MW on first machine while one Support preps the second OPTIMIZED TEAM 9 FUSIONS PER HOUR 11277 machine for fusion Primary then performs the hot work 2 2 on the second machine while Ss es the first connection cools YU Oe a C co e ALIMLONGOdd Work example 5 Socket fusion Linear Crew 1 primary 1 2 support This process can also be done 4 g on the ground at which point Tools 1 iron 2 jigs ladders or lift the crew can lift the entire length 1 13 E Ta Goal Keep the single iron fusing cc n pipe as much as possible by ACTES 8 removing downtime 4 Process Support sets up f
28. of the pipe rr r e B gt rr z Flow rates and sizing Operating pressures 22 For most applications use the same size recommended GPM based on flow speed and head Systems with constant operating parameters 60 year expected minimum Aquatherm pipe as you use for other piping loss The maximum GPM may be higher in some materials The lower friction and higher flow speed cases Aquatherm pipe does not have internal aquatherm 22 00 2011 This table assumes constant of PP R compensates for the smaller ID which corrosion or ID loss so downsizing may be possible green pipe Mone pipe in pipe pipe operation using water or a water m occurs in some sizes The following table gives the in some cases at the discretion of the engineer Nem pipe na 7 a ime SDR11 ME SDR 17 6 MF glycol mix Seasonal operation my ADR TS or use of different mediums may omina omina i 2 Poli enm Toners SURE Permissible working pressure psi impact the pressure rating of 2 50 F 195 380 325 160 the pipe Aquatherm pipe is not E c E intended for use below 5 F 8 800 1000 1100 80 F 170 320 255 125 NI S 10 1200 1500 1800 100 F 135 255 210 95 OMIR SSE EA 12 2400 3000 3400 27 110
29. size Interfacial pressure Interfacial pressure is the force needed at the point of fusion to create a weld Aquatherm PP R butt welding always requires 14 5 pounds of pressure per square inch of surface area being fused Welding Pressure Welding pressure is the force needed by the machine to achieve proper interfacial pressure This varies by machine cylinder size and pipe dimension Welding pressures are available from the manufacturer and are included in this manual as well Welding pressure is measured by the machine s pressure gauge Full Pressure he drag pressure and welding pressure are added together to create full pressure which will be used twice during the fusion process Full pressure should be set on the machine during your post facing alignment inspection Each phase in the butt welding process takes the basic steps of facing adjusting heating and fusing and applies the previously calculated pressures to form a completed weld Each phase has a required time or visual cue to let you know when that phase is done Facing Phase he pressure for facing will vary based on the pipe size and condition of the blades Starting at drag pressure gradually increase the pressure between the pipe and the facing machine until two 360 continuous ribbons are removed from the pipe on both sides Adjustment Phase his phase pushes the exposed pipe surface out of the connection by pressing the pipe fac
30. the Aquatherm pipe and fittings must not exceed 160 F 71 C For any claims on the warranty you will need to submit the following information using the Warranty Claim Form e The installer number s of the installer s e Acopy of the previously submitted pressure test or the submission date Pictures and or samples of the damaged pipe samples preferred e 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 Please note that the Aquatherm warranty does not cover the following issues e Improperly assembled transitions threads flanges copper stub outs PEX etc unless the fitting was defective Time lost due to poor planning supplier issues or failure to order the proper parts tools e Connections that have not been properly fused according to Aquatherm s requirements e Failures in systems that were not pressure tested before operation Warranty claims evaluated on a case by case basis e Handling damage to pipe or fittings after they have left Aquatherm s possession e Use of defective tools a
31. the first connection 90 72 72 cools If two machines are 8 being used Support preps a z O1 ALIA LONGOdd Work example 3 Socket fusion prefabrication onsite Crew 1 primary 2 3 support can have a socket coupling sections could also be installed aqela added to them to reduce the by a second Primary Tools 1 benchtop 2 3 irons 2 3 number of in air connections 198 saw The remaining Supports take The exact mix and tasks of this f the fabricated sections to their iad depend on the skill of the o ord intended locations and install Primary ies and Support s and 3 them as directed Fabbed the layout of the jobsite Y 2 ground as much as possible m Pe Fusiofvvsvas Preparation J gt Unproductive time gt 27 Tl Process One Support E S measures and cuts pipe to SINGLE INSTALLER 2 FUSIONS PER HOUR gt length cleans and preps y l edges for fusion Primary uses MM 25 benchtop machine to perform f XN c E fusions on the main spool uses OPTIMIZED TEAM Q 1 PER HOUR i S T e iron and jig to fuse on additional if pipe fittings and outlets while 2 5 A the benchtop connection cools 2011 Saas eS m Simple straight lengths of pipe vn Work example 4 Butt fusion prefabrication onsite Crew 1 primary 1 3 support If two
32. them to our product line like a piece of pipe in that size The side being reduced to 15 female and acts like a socket in the smaller size and full face gaskets will in the near future need to match the pattern Aquatherm rings do match and the dimensions are available on the website The nuts inset in the valve are a coarse metric thread and do require metric bolting For bolt dimensions see page 5 49 4 24 ac Y The female side smaller pipe T 92201001 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 Bushing PLANNING 4 26 Threaded connections Aquatherm offers a wide range of threaded transitions to connect with non fusible system components These transitions have a machined brass or stainless steel thread mold injected into a PP R base for maximum strength Use stainless steel fittings in chemically aggressive applications Lead free brass is available for potable applications Industrial brass fittings are available for all other non potable applications Do not use the industrial transition fittings in applications that call for lead free brass When installing these threaded connections there are a few important things to remember e 1 2 turns past hand tight do not bottom out Tape only not pipe dope unless absolutely necesary Do NOT bottom out in
33. thread 0128242 0928242 0628242 J x 34 9 F 0128244 0928244 0628244 3 x 34 F 0128246 0928246 0628246 4 x 54 A4 F 0128250 0928250 0628250 6 x 4 WF 0128254 0928254 0628254 10 x34 34 F 0128214 0928214 0628214 14 x34 F 0128216 0928216 0628216 1 x 34 4 F 0128218 0928218 0628218 2 x 4 h F 0128220 0928220 0628220 2 x 347 F 0128222 0928222 0628222 3 x 4 4 F 0128224 0928224 0628224 3 x 4 0128226 0928226 0628226 4 x34 4 F 0128230 0928230 0628230 6 x34 878 0128232 0928232 0628232 8 to 10 x 34 4 F 0128234 0928234 0628234 14 x 34 34 F 0128236 0928236 0628236 1 x 34 34 F 0128238 0928238 0628238 X A IL Sy 0128240 0928240 0628240 2 x 9 0128260 1128260 0628260 2 x1 1 0128262 1128262 0628262 Sax ads 0128264 1128264 0628264 3 x1 1 F 0128266 1128266 0628266 0128270 1128270 0628270 6 x1 1 F 0128274 1128274 0628274 81010 1 1 F 2 18 a e 21 c e Distribution block plumbing Distribution block plumbing Distribution pipe with insulation block NPT fusion outlet including 1 plug and 2 fasteners Industrial Lead free Dimension pipe x outlet thread brass potable brass Part no NPT Part no NP
34. threaded fitting Your sealant needs to be compatible with brass or stainless steel as you are not threading to the PP R e Always apply counter pressure on the fitting when tightening the connection If the fitting has a hex head place your wrench there a Male Round SS 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 Female Hex Brass Male Hex Brass To comply with the new Reduction of Lead in Drinking Water Act Aquatherm offers two lines of brass fittings lead free potable and industrial non potable The two lines are identified by separate part numbers and the following distinctive visual cues Industrial e A double groove face of the female interior of the e cNSF us ind printed on the body male etched in the metal Brass identification Lead free e A single groove face of the female interior of the male etched in the metal e cNSF us pw G printed on the body 9NINNV Id Flanges Aquatherm flange bolt torque and size To transition to other piping Aquatherm recommends using Torque Torque systems and mechanical a full face rubber black EPDM Nominal pipe size Nominal pipe size N m ft lb Number Diam
35. way into the fitting within the welding time G but be careful not to overheat the pipe Column G Welding time This is the window of time between removing the PP R from the welding iron and inserting the pipe completely into the fitting before it cools If you exceed this time you risk having the connection cool off which could 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 H Cooling time Pipe should not be pressurized or stressed during this time You will need to fully immobilize the pipe for up to of this time while the connection sets Socket fusion heating and cooling times Pipe Welding Heating Welding Cooling diameter depth time in sec time time Actual OD above em AQ F o po pom 14 o wim 2 ee ee poer e e po Deme NIS NNCNNN 25 gt 7 c 2 c c o LL lt 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 manufacture
36. x 10 2913690 18 x18 x4 25136922 18 x18 x 6 2513694 18 x18 x8 2513696 18 x 18 x 10 2513698 18 x18 x 12 17 6 Part no Dimension ND 2513804 20 x20 x4 2513806 20 xu 2513808 20 x20 XB 2513810 20 x 20 x10 2513812 20 x 20 x12 2513821 22 x22 x4 2513839 24 x 24 x 4 2513841 24 x24 x6 2513843 24 x 24 x8 25138458 24 x 24 x 10 2513847 24 x 24 x12 eBranch outlet has a butt weld connection E m rri gt E C 72 Fusion outlet Socket Fusion outlet Butt weld Part no Dimension ND Dimension ND Dimension ND Dimension ND Dimension ND Dimension ND i pipe x outlet pipe x outlet pipe x outlet pipe x outlet pipe x outlet Part no pipe x outlet 0115172 2 Vy x34 0115194 4 x1 0115230 8 to 10 x 1 0115257 10 x 4 0115303 20 to22 x3 SEE TET 0115174 25 0115196 A x 1 0115231 8 x 114 0115260 0115315 22 1024 2 ES TS X 0115175 2 1 0115197 4 x19 0115232 8 x15 0115261 12 t0 14 x27 0115316 22 to 24 x3 TT VISUS F 0115176 3 x W 0115198 4 x2 0115233 8 x 2 Jr 25212 12 x3 0115318 22 1024 x4
37. 00 30 42 52 60 67 73 79 89 90 99 99 104 25 Length of ben 10 250 34 47 58 6 79 82 89 95 101 106 111 116 20 23 14872 12 315 38 53 65 15 84 92 100 106 113 119 125 130 14 355 40 56 69 19 89 97 105 112 He 126 132 138 14 40 11 50 16 400 42 60 73 84 94 103 112 119 126 133 140 146 6l Y 4 18 18 450 45 63 77 89 100 109 118 126 134 141 148 155 2 v 75 20 500 47 6 02 94 105 115 125 133 141 149 156 163 22 560 50 71 86 100 112 122 132 141 150 158 165 173 24 630 53 70 92 106 118 130 140 150 159 167 175 183 3 110 4 20 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 concentrations 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 provided there Inquiries are submitted to Aquatherm s testing laboratories in Germany for verification normally within 24 48 hours Many common applications are pre approved and may be answered on the same day
38. 0050214 114 0050941 Y amp 34 forpipes 2 10 zi 21 TUR i 0050942 T 0050218 2 e 0050944 1 0050220 2128 0050946 st 0050222 3 LO To 0050224 228 TE Only fits into a drill press that can 0050226 4 accommodate a Morse Taper shank 9 e 2 LL et TT a 5 56 Fusion outlet welding heads Part no 0050614 114 x V amp 34 0050616 14 xh amp 34 0050619 2 x Vo amp 34 0050620 2017 0050623 2 xA amp 34 0050624 25 x1 0050625 2 x114 0050627 3 xh amp 34 0050628 3 1 Part no 0050629 3 x1 a 0050631 3 amp 34 0050632 36 x1 0050634 3 x114 0050635 34 x15 0050636 4 x W RQA 0050638 4 x1 0050640 4 x1 Ya 0050642 4 0050644 4 x2 0050648 6 x 4 894 0050650 x1 0050652 3 x1 A 0050654 6 x14 0050656 6 x2 Part no 0050657 6 2 0050658 0050660 8 x amp 34 0050662 8 x1 0050664 8 x1 Ya 0050666 8 x 1 0050667 8 x24 0050668 0050669 8 x 3 0050670 8 x 34 0050671 8 x 4 0050672 10 2 8 34 0050674 10 x 1 0050676 10 x 1 A Fusion outlet welding heads continued Part no Part Dimension 0050
39. 010244 14 00102469 16 00102489 18 The following items are supplied in coils 0010308 Ve 0010310 0010312 1 0610808 V SDR 7 4 non MF 0610810 34 SDR 7 4 non MF 0610212 1 0610214 1 0610216 1 0610218 2 0610220 212 0610222 de 0610224 3 0610226 4 0610226x2 4 Double Length 0610226x3 4 Triple Length 0610230 6 0610230x2 6 Double Length Mechanically stabilized with a faser composite layer in the center of the pipe Dimension ND 0670758 Vo 0670760 0670762 1 0670764 1 0670766 1 0670768 2 0670770 25 E m rri gt E C 2 aquatherm blue pipe SDR 7 4 11 MF aquatherm blue pipe SDR 17 6 MF Part no Dimension ND Part no Dimension ND Part no Dimension ND Part no Dimension ND SDR 7 4 2670130x2 6 Double Length 25 0126 4 2570148 18 2670708 2670134 8 2570126x2 4 Double Length 2570148 2 18 Double Length 2670710 34 2670134 2 8 Double Length 2570126 3 4 Triple Length 2570150 21 SDR 11 2670138 10 29 0130 2570150 2 20 Double Length A 2670112 if 26701382 10 Double Length 2 2570152 22 0 2670114 14 2070142 12 is 2570154 24 gt 2670116 1 20
40. 2 Use the pressure from the higher SDR thinner wall pipe or fitting 3 Use the average bead height of the two SDRs The external bead should appear normal The internal bead will appear lop sided but this is not an issue The system will have the pressure rating of the highest SDR thinnest wall material that is fused into the section As a general rule you should avoid butt fusing different SDRs unless it is necessary You should never attempt to butt fuse pipes with different ODs 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 Internal alignment 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
41. 215 180 80 aque m 2 5 green pipe ue pipe M _ 2 19d d SDR7 4 MF 50811 25 24 160 F 120 100 45 SDR Pressure SDR Pressure i 180 F 100 62 30 74 200 1 125 200 F 45 30 15 27 sand 11 125 17 6 50 assumes air temp lt 100 F 24 1 16000 20 WELCOME TO AQUATHERM aquatherm green pipe and aquatherm lilac pipe weights and capacities aquatherm green pipe SDR 7 4 MF Capacity Weight w water lb ft y 0 01 0 11 0 22 0 02 0 17 0 34 1 0 03 0 26 0 51 14 0 05 0 41 0 83 16 0 08 0 64 1 31 25 0 13 1 00 2 08 2W 0 19 1 42 3 00 on 0 27 2 03 4 28 3A 0 40 3 04 6 37 AP 0 52 4 17 9 50 6 0 85 6 54 13 62 8 1 33 10 06 21 14 10 2 08 15 74 33 07 12 334 20 71 48 53 14 4 24 26 29 61 61 aquatherm green pipe pipe SDR 7 4 5 SDR 11 5 aquatherm lilac pipe SDR 7 45 SDR 115 Capacity Weight w water lb ft Capacity Weight w water Ib ft 10 2 09 10 42 32 49 125 4 20 17 24 52 20 14 5 34 20 99 65 47 16 6 79 27 11 84 33 18 8 57 99 19 106 54 The following items are supplied in coils 123 0 01 0 07 0 15 0 03 0 11 0 36 1 0 04 0 17 0 50 aquatherm blue pipe SDR 7 4 MF SDR 11 MF
42. 4 355 x 20 1 17 6 5 min 41 sec 9 sec 18 sec 32 min 14 355 x 32 2 11 7 min 28 sec 13 sec 28 sec 48 min 14 355 x 48 0 74 9 min 25 sec 17 sec 42 sec 70 min 16 400 x 22 7 17 6 6 min 7 sec 10 sec 20 sec 35 min 16 400 36 3 11 8 min 14 sec 31 Sec 54 min 18 450 x 25 5 17 6 6 min 35 sec 11 sec 22 sec 39 min 18 450 x 40 9 11 8 min 28 sec 15 sec 36 sec 59 min 20 500 x 28 4 17 6 6 min 59 sec 12 sec 24 sec 43 min 22 560 x 31 7 17 6 7 min 24 sec 12 sec 27 sec 48 min 24 630 x 35 7 17 6 7 min 55 sec 14 sec 31 sec 53 min Set up and inspect the machine Follow all of the manufacturer s directions Perform any maintenance if needed Inspect welding iron and turn it on Make sure that the iron is clean and set to 410 F 210 C 18 F Butt welding instructions 7 Setup Maintenance should only be performed by trained persons the manufacturer or authorized dealer Only refill the hydraulic oil according to the manufacturer s specifications Make sure that your power supply is fully compatible with the machine you are using any air bubbles by bringing the machine to full pressure and slowly releasing it set in the correct metric inserts if needed The Cut the pipe at least 1 2 longer than your manufacturer will know which clamps and inserts intended final length or longer if your cut is not are compatible perfectly squ
43. 40808 JA 0140868 5 0140888 0140878 y 0140858 y z a 0140810 34 0140870 94 0140890 34 0140880 34 0140860 34 0140812 0140872 V 0140892 0140882 17 0140862 i N 0140814 1 Not for potable applications Not for potable applications Not for potable applications Not for potable applications Not for potable applications 5 48 9 e 2 LL et TT a 9 90 Concealed valve chromium plated for part no 0040858 0040862 yeh Part no Dimension ND 0040900 Length 3 2 0040902 Length 4 25 Stop valve body ISO Industrial brass Dimension PP R ND x Thread Part no 0040908 V x WF 0040910 3 x WF 0040912 1 XE 0040914 1 x TW F Inclined valve without drain Inclined check valve without drain Industrial brass Dimension ND Part no 0041108 0 0041110 34 0041112 1 0041114 1 Not for potable applications Industrial brass Dimension ND Part no 0041208 5 0041210 34 0041212 1 0041214 1 Not for potable applications Ball valve without drain Industrial brass Part no 0041308 0041310 0041312 0041314 1 0041316 15 0041318 Ball valve male female Industrial brass Dimension ND Part no 0078000 1 M F Replacement parts available Not for potable applications Replacement parts available
44. 42 Adjustment bead height Butt welding heating and cooling times Butt welding instructions Reducing cooling times Fusing dissimilar SDRs Internal alignment Repairs Productivity Getting started Crew mix Tooling Hand irons socket fusion machines Four jaw butt fusion machines Modified machine configurations Manual butt fusion machines Larger crew vs more tools 2 44 2 45 2 4 2 53 2 04 2 55 2 56 Chapter 3 3 1 2 2 3 3 3 4 3 5 3 6 3 8 39 3 10 3 11 Work example Joining spools Planning Technical bulletins Clamps and hangers Anchors and guides Support intervals and hanger spacing Support intervals Increased hanger spacing Fire rating Linear expansion Expansion controls Chemical compatibility Integration with copper tubing PP R to copper transition fittings Connecting to a boiler Bushings reducers and reducing couplings 3 24 Chapter 4 4 1 4 7 4 3 4 4 4 0 4 0 4 8 4 3 4 10 4 14 4 20 4 21 4 22 4 23 4 24 Large PP R ball valve 4 25 Threaded connections 4 26 Brass identification 4 2 Flanges 4 28 Butterfly valves 4 30 Branch lines 4 31 Buried applications 4 32 Maximum pull force 4 33 Bending Aquatherm pipe 4 34 Insulation sizing thrust blocking noise generation and vibration isolation 4 35 UV protection and painting 4 36 Fusing UV pipe 4 37 Flushing grounding and freeze protection 4 38 Warranty claims 4 39 Pressure testing 4 40 Chapter 5 Pipe and fitti
45. 5 79 84 poni EN BEN o BEN o EIN o BE So 1 o 10 n 49 5 54 56 57 57 6 1 6 6 71 75 79 23 48 51 54 58 57 81 62 8 amp 4 67 7 8 8 16 48 5 52 56 57 57 6 2 6 7 72 75 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 surtace of the in line support and the pipe Approved in line Supports are available through Walraven 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 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 H
46. 620108 Ve xr 0117214 1 4 0120110 0920110 0620110 X F E O 0117216 1 0120112 0920112 0620112 X xA F 3 011 218 2 0120113 0920113 0620113 0117220 2 NPT transition piece female Transition piece with hex shaped threaded transition ISO transition elbow round female for dry construction ISO transition elbow with counter nut gasket and ISO transition piece with counter nut gasket and tension washer tension washer Industrial Stainless Lead free Di imension brass steel potable brass Part no NPT Part no NPT Part no NPT PP R ND x thread type 0121108 0621108 W x 0121110 0621110 x W F 0121111 0621111 4 x WF 2 0121112 0621112 347 x WF ES Industrial Stainless Lead free potable Dimension 0121113 0621113 1 XX F m Industrial EE brass steel brass PP R ND x thread I brass Dimension Part no NPT Part no ISO Part no type 0121114 1121114 0621114 Wx 0121008 0921008 0621008 0121145 1121115 0621115 1 x 1 F mn et 20 mm 2 Fx 4 M 0120208 20 mm x 2 Fx 44 M 20mm x 2 M 0121010 0921010 0621010 My x 34 F 0121116 1121116 0621116 0120209 25 M 0121011 0921011 0621011 W xw 0121117 1121117 0621117 IZ F a 0121012 0921012 0821012 x x 4F 0121118 1121118 0621118 1 x A
47. 696 0050698 12 4 0050699 12 x 6 0050712 14x 2 0050714 14 x25 0050716 14 x 3 0050718 14 x35 0050720 14 x 4 0050722 14 6 0050724 14 x 8 0050726 16 24 x2 0050728 16 20 x2 0050730 22 24 2 5 0050732 16 20 x3 0050678 10 x1 Kh 0050680 25 0050682 10 x2W 0050684 0050686 10 x3 Kh 0050688 10 x 4 0050690 12 x2 0050692 122275 0050694 12 X9 Part no 0050734 22 24 x3 0050736 16 18 3312 0050738 2 0050740 24 x 3h 0050742 16 x 4 0050744 18 12 0050746 22 24 x4 E m rri gt I C 2 Notes Notes Notes
48. 7142x2 12 Double Length diss dni 25 0154x2 24 Double Length 26 0118 pu 2070144 14 2570138 2 10 Double Length Pipe comes in 26 ft lengths gt 2670120 212 2070144x2 14 Double Length 2570142 12 PPipe comes in 39 ft legnths er Pipe comes in 38 ft lenghts Es 2670122 3 MEUM NN 25701422 12 Double Length i 2670124 35 2070148 18 2570144 14 a 2670126 4 The p ila In 2570144x2 14 Double Length N ee ee coils non faser 2670126x2 4 Double Length kc 2570146 16 2010308 Vo api in 26 ft lengths lt pe comes in engths i 2670126x3 4 Triple Length comes in 39 ft legnths 2570146 2 16 Double Length 2010310 4 2670130 Pipe comes in 38 ft lenghts 2010312 1 o e LL et 5 6 Dimension ND 2670758 SDR 7 4 2670760 SDR 7 4 2670162 1 SDR 11 2670164 3n 1 2670166 1 SDR 11 2670168 2 SUR T 2670170 25 SDR 11 2670172 aquatherm blue pipe SDR 7 4 11 MF UV Part no Dimension ND 2670174 3 SDR 11 2670176 A SDRT 2670180 6 SDR 11 2670184 8 SDR 11 2670188 10 SDR 11 aquatherm blue pipe SDR 176 MF UV Part no Dimension ND 25 0202 22 2570204 24 Part no
49. Aquatherm pipes 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 When integrating Aquatherm piping systems with other systems make sure that the operating parameters for PP R won t 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 Agency s guidelines for sizing temperature and flow speed in copper pipe This will also help Integration with copper tubing ensure that the copper levels in the water do not approach the regulatory action levels Sustained high levels of copper lions 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 recirc
50. Color Green Stripes Light blue Wall thickness SDR 11 74 347 or smaller only Size range 12 18 Multi layer construction expansion controlled No Maximum operating pressure at 50 F 195 psi Maximum operating pressure at 140 F 95 psi Recommended applications Domestic potable cold water food processing Acceptable applications Cooling chemical transport and any other lower temperature application suitable for PP R Color Blue Stripes Green Wall thickness SDR 11 74 347 or smaller only Size range 12 18 Multi layer construction expansion controlled Yes Maximum operating pressure at 50 F 325 psi Maximum operating pressure at 180 F 62 psi Recommended applications Heating and cooling distribution compressed air chemical transport swimming pools verify treatment levels in floor heating Acceptable applications Irrigation and any other non potable piping applications Thick wall aquatherm blue pipe MF gt rr RE e B gt j rri z cc EN lt et e LL e LL Thin wall aquatherm blue pipe Color Blue Stripes Green Wall thickness SDR 176 Size range 4 24 Multi layer construction 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 co
51. DR 17 6 and 11 Installers may decide to butt weld smaller sizes at their own risk Inserts for clamps not shown Compressor Hydraulic hoses The basic steps to successful butt welding are facing adjusting heating and fusing Facing Facing 15 Adjusting Building performed to square the adjustment bead the ends of the against the iron ensures pipe In doing so full contact of the pipe it also produces a face and also sets the contaminant free size of the resulting surface on which the fusion bead fusion will occur Explanation of butt welding Heating Commonly referred to as the heat soak this step fills the PP R with heat energizing the molecules for fusion Fusing Using the prescribed pressure push the two pipe faces together and let them cool under pressure gt 7 c 2 e lt 22 ert Butt welding pressures Each phase of butt welding requires a specific pressure The four pressures you will need to know are drag pressure interfacial pressure welding pressure and full pressure Calculate these pressures before starting your fusion Drag Pressure Drag pressure is the minimum hydraulic pressure needed to overcome the carriages inertia You identify the drag pressure by slowly Increasing the pressure control until the carriage begins to move Drag pressure varies by machine design machine orientation and pipe
52. 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 Aquatherm s MF pipes use a combination of glass fibers and PP R to reduce linear expansion and contraction by 7596 MF pipes can be fused without any special tools treatment or prep work Fuse MF pipes using the same techniques as non MF pipe For hot water heating and chilled applications use a MF pipe such as aquatherm green pipe SDR 74 or aquatherm blue pipe SDR 176 or 11 For ambient temperature applications such as gray water or DCW use a non MF pipe such as aquatherm green pipe SDR 11 or aquatherm lilac pipe The MF extrusion process produces a middle layer with expansion inhibiting properties The percentage of PP R is high enough to ensure a proper bonding between the layers so the middle layer cannot be separated from the inner and outer layers 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 the length of pipe Ti the temperature of the pipe at the time the pipe is clamped down lw the temperature of the water inside the pipes during operation AT the difference between the working temperature Tw and the installation temperature 11 a the coefficient of expansion
53. N ISO 9001 File M 6022 e ASTM F 2389 gt e File 5053 Green Pipe Lilac Pipe e FM 1635 Green Pipe 7 4 only e BNO 3660 950 Green Pipe only Chapter 2 Heat fusion Aquatherm is a rigid piping system similar to copper and steel Proper training helps ensure proper connections Your own care BE Once you learn how to heat fuse it and attention to detail will yield impressive results whereas will be up to you to provide the quality sloppy workmanship will yield poor results This chapter will labor that makes each installation a cover the basic techniques for heat fusing pipe work of art Butt fusion Outlet fusion Socket fusion Electrofusion gt m m 2 e ma 22 lt 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 Follow Aquatherm specific guidelines for proper material installation Wear OSHA approved steel toe shoes Wear a properly rated hard hat at all times Wear safety glasses Wear heat resistant gloves while handling welding irons Be careful when handling hot irons These are recommended cutting methods but you may use any method that doesn t damage the pipe Cuts should be as square as possible never more than 5 off and without jagged ed
54. T 0128326 0628326 4 x34 M e 0128330 0628330 6 x 34 x 0128334 0628334 1 x 34 34 M oa EE Dimension 0128336 0628336 1 W x 34 34 M Part no Dimension ND Part no Dimension ND Part no Dimension ND td bart NT 018067 08882 Pipe x outlet thread 0128338 0828338 2 x34 94 M 0130115 x Ww 0130130 x Ww 0130604 1x 0128314 0628314 1 x34 87 M 0128340 0628340 24 x3 347 a 0128316 0628316 172 x Y 07 M 0128342 0628342 3 x 4 amp 4 0128318 0628318 2 x3 2 0128344 0628344 3 x34 4 M 3 0128320 0628320 2 x 3 0128346 0628346 4 x M 34 M SUN 0128350 0628350 6 x 34 4 Lo 0128324 0628324 3 x Distributor end piece Screw down stop globe valve Concealed valve shor Concealed valve standard length Concealed valve extended Concealed valve anda with female thread NPT for surface installation chromium plated tamper proof chromium plated chromium plated tamper proof 54 e E X as E lt z Industrial i Industrial Industrial Industrial Industrial Industrial m Dimension gt brass ND x Thread brass Dimension ND brass Dimension ND brass Dimension ND brass Dimension ND brass 2 LL Part no Part no Part no Part no Part no Part no c 0130804 1 x 01
55. Unproductive gt YH Time spent moving around the jobsite setting up equipment waiting for cooling etc Note The Fusions per hour in the examples Preparation J gt are just for comparison Your actual productivity rates will vary with pipe size and installer experience SINGLE INSTALLER FUSIONS PER HOUR OPTIMIZED TEAM Q rusions PER HOUR a EUN RESINA Clee ALIMLONGOYd 3 14 PRODUCTIVITY Work example 2 Butt fusion prefabrication shop Crew 1 primary 1 Support second connection for the first The decision to use 2 or 3 machine If three machines are machines depends on the skill Tools 2 3 butt fusion machines being used Support sets up the of the Primary and the duration third machine during this time of the cool down time A longer Goal Maximize connection per The cycle continues so that the cool down allows for more hour by eliminating downtime for the cooling phases Primary is always performing hot simultaneous fusions work on a fusion machine Process Primary performs the hot work alignment Fusion Preparation Unproductive gt ZH facing bead up heating and welding on first machine SINGLE INSTALLER D FUSIONS PER HOUR while Support preps the second machine for fusion EXE LZ Wf Primary then performs the hot work on the second machine OPTIMIZED TEAM D FUSIONS PER HOUR while
56. W CHW any material that meets the fire smoke requirements of ASTM E84 or CAN UL 102 2 can be used If insulation is not required DCVV 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 15 listed and labeled as meeting the flame and smoke requirements of ASTM E84 and CAN UL 5102 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 Fire rating 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 PLANNING 4 10 Linear expansion
57. W F N 0121013 0921013 0621013 XXE 0121119 1121119 0621119 2ZXx1W F 0121120 0621120 2 x2 F 0121122 0621122 2 x2 F NPT transition street elbow male female NPT transition piece NPT transition elbow female hex shaped threaded transition Transition piece round male Industrial brass Lead free potable brass Dimension E Part no NPT Part no NPT PP R ND x thread 0121308 0621308 x WM 0121310 0621310 0 x 4M 0121312 0621312 4 x 0121314 0621314 u ES 2 0121316 0621316 1 x 1 M O Industrial Stainless pcb Dimension 0121317 0621317 IW xVM bros Dimension Industrial brass ae E Dimension T oss steel brass PP R ND x thread type 0121318 0621318 1A x 1A M Part no NPT Part no ISO Part no NPT PP R ND x Thread type Part no NPT PP R ND x Thread type Part NPT Part no ISO YP sal 0121319 0621319 I x WM 0123008 0923008 0623008 Wh x WF 0123208 0623208 W xw 7 et 112111 0121320 0621320 1 x I M 0123010 0923010 0623010 VORNE E 0121210 0921210 0621210 M 0121321 0621321 2 x1 M 0123012 0923012 0623012 X x 4 F i 3 1 uw n Hn O 0121211 0921211 0621211 4 x M 0121322 0621322 2 x2M 0123014 0923014 0623014 X e Bh 129708 0121217 0921212 0621212
58. Wall thickness Identification Hot water aquatherm green pipe MF Cold water aquatherm green pipe 5 Thick wall aquatherm blue pipe MF Thin wall aquatherm blue pipe MF aquatherm lilac pipe S Molded fittings segmented fittings Flow rates and sizing Chapter 1 1 1 1 2 1 3 1 4 1 9 1 6 1 8 1 0 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 19 Contents Operating pressures Compressed air Weights and capacities Listings and approvals reference standards Heat fusion Safety Cutting the pipe Inspecting the cut How heat fusion works Socket fusion Welding heads Welding irons Welding iron safety Tool assembly Marking the pipe Socket fusion heating and cooling times Socket fusion instructions 1 19 1 19 1 20 1 22 Chapter 2 2 1 2 3 2 0 2 5 21 2 8 2 9 2 10 2 12 2 13 2 14 2 16 Large diameter socket fusion Mechanically assisted fusions Inspection Avoiding improper fusions Troubleshooting bad connections Ovality in machine assisted fusions Fusion outlets Fusion outlet instructions Electrofusion Electrofusion instructions Butt welding Explanation of butt welding Butt welding pressures Butt welding phases McElroy adjustment and welding pressures Ritmo adjustment and welding pressure Rothenberger adjustment and welding pressure Widos adjustment and welding pressures 2 18 2 18 2 20 2 2 2 22 2 23 2 24 2 25 2 28 2 28 2 92 2 99 2 34 2 39 2 36 2 38 2 40 2
59. a Getting started There are several unique features of Aquatherm pipe that can help you accelerate your install times e Fusion outlets allow you to add branches after installing mains e Lightweight material is easier to carry in large amounts e Reduced contraction and expansion makes layout easier e Fused joints won t crack during transport e Flexible pipe can be fed into tight spaces e Fusion machines allow a single installer to work on multiple connections at one time As you continue installing Aquatherm pipe you will find a balance of prefab and in place installation that 1 works for you Looking for ways to help streamline the installation process can lead to significant savings in the overall installation time For each part of the installation you should decide what sections to build in a shop or on a workbench prefab and which sections need to be bullt in place Prefabrication gives you access to a wider range of fusion tools and makes it easier to work with multiple tools In general prefabricated Joints are also faster and more accurate An installer can become proficient at heat fusion in a very short period of time which can help make your less experienced installers more productive However more advanced concepts like build strategy and layout are best managed by more experienced installers Therefore a typical crew installing Aquatherm will have a few masters or journeyme
60. age is awarded PP R is durable both physically and chemically and is more resilient against oils freezing impact etc than other plastics and even metals 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 Full details of Aquatherm s warranty coverage can be found at Aquatherm com warranty Note Ihe Aquatherm warranty only applies to systems that are properly installed by 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 gt rr r e e B gt rr z Material handling Do 2 m i 3 NM WX Inspect pipe upon receiving it Aquatherm does Dont fuse damaged pipe Remove damaged Keep the pipe on a flat surface or close supports Don t run over the pipe with any type of vehicle or X Don t drop the pipe or handle it roughly PP R can Don t insert sharp or unpadded objects into the not accept responsibility for damage that occurs sections and install the remaining pipe Follow avoid bowing Use at least 3 supports for 13 crush t
61. ange ring black 3 1 8 to 3 5 32 bolt center used with 20115514 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 Dimension ND 0115812 1 0115814 1 0115816 16 0115818 22 0115820 212 Part no Dimension ND 0115838 n 0115840 3 0115842 1 0115844 0115846 Te 0115848 28 0115850 242 Flow through back plate elbow 90 20197 20 mm x 1 2 IG x 20 mm Flow through back plate elbow parallel 20198 20 mm x 1 2 IG x 20 mm E m I e 21 c e Wing back 90 elbow Electrofusion coupling Back plate elbow ISO plug for pressure tests threaded with gasket Part no Dimension ND Cannot be used in conjunction with UV pipe 0117222 0117224 319 0117226 4 01172308 6 x 01172349 8 Lead free Part no Dimension ND 0117238 10 Lead free potable m os brass Stainless steel potable brass Dimensin Industrial brass Stainless steel Dimension gt art no NPT Part no ISO 0117208 Part no NPT Part no ISO PP R ND x thread type 0050708 5M Ps Tm art no NPT Part no NPT 0117210 34 0050710 4X 0120158 0920158 0620158 20 mm x 2 F mu 1 0120108 0920108 0
62. aquatherm INSTALLER MANUAL 4th EDITION Owner Installer Number Trainer Name Trainer Contact Info 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 2015 aquatherm NA L C All rights reserved This manual was produced by Aquatherm 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 Also in the event of a discrepancy between this manual and the Aquatherm L C catalog the information published in the catalog will be considered correct The information in this manual is superseded by any subsequent editions of this manual Aquatherm L C retains the right to modify the proper installation procedures at any time via technical bulletins Welcome to Aquatherm Getting started Working with PP R Aquatherm innovations The world leader in PP R pipe Material handling Pipe sizes
63. are Se gt 7 c 2 2 48 HEAT FUSION Butt welding instructions 2 Alignment _ N set pipe and or fitting into the clamps If Leave a lip of 1 2 1 more if cut is uneven A Reposition clamps to accommodate fittings if possible use at least 2 clamps for each pipe thumbs width is normally a good measurement needed Some clamps slide and others can be Leave enough room for the facer removed entirely length Adjust configuration as needed Drag Pressure Find the drag pressure by Increasing the pressure control until the carriage beings to move Drag pressure varies by machine design and orientation and pipe size Welding Pressure Look up the welding pressure in the operating manual or in this book if no manual is available Welding pressure Tighten clamps and bring the pipe ends together Check alignment of pipe by running your finger varies by OD and SDR Make sure all hands are clear of the carriage or the end of a pen across the gap If one side 18 Full Pressure Add the drag and welding while it is in motion higher than the other tighten it down pressures to get the full pressure Butt welding instructions 3 Facing Open the carriage set and lock in facing tool Turn Close pipes on facer Increase the pressure until Drive the carriage forward whenever the on facer and let it reach full speed Never turn on the facer begins sh
64. aving off ribbons of PP R Don t use excessive pressure pressure drops or the facer stops facing Replace the facer if it is pinched between pipes the blades if they are too dull Proper facing will produce 360 full width strips Switch off and remove facer Don t turn off the on both sides At this point open pipes Adjust facer while the carriage is still closed as this can the facer if one side is ready before the other leave nicks on the pipe face 6v c NOISN4 LV4H 250 HEAT FUSION Butt welding instructions 4 Adjustment Close carriage and check for gaps Reface or realign if needed Wipe down the pipe face with rubbing alcohol Set your max pressure level welding drag Controls vary by manufacturer Don t change this pressure after setting it 4 Build your adjustment bead to the specified height The guide is on page 2 44 Do not let your bead get larger than required ee Close the pipes onto the heating iron under sure your heating iron is at or near 410 F 210 C full pressure to initiate construction of the adjustment bead Open carriage and insert the heating iron Make Butt welding instructions 5 Welding The heating phase requires as little pressure as possible Some machines lock in place only requiring the drag pressure Others require a slight positive pressure to keep them place but never more than drag 10 Ys N weldin
65. ay sweat In certain chilled applications even if the pipe itself shows no signs of condensation Clamps and hangers Rubber lined clamp 9NINNV Id cv Anchors and guides Support intervals and hanger spacing SDR 11 non MF For the purposes of dealing With PP R the hanger spacing The temperature difference with linear expansion there are varies with the expansion in is based on an ambient E on the pipes carrying water If the pipes two types of supports anchors the pipe For cold water pipes temperature of 68 F For are carrying a material that is denser than and guides Anchors are tight there is a negligible amount example a 100 F system in water additional support may be required against the pipe and prevent of expansion or even some a 100 F room should have Alternative spacing should be confirmed movement through that point contraction so only one spacing support spacing based on 100 oF 68 F 32 F t t instructions for submitting a chemical inquiry Guides support the pipe but Is given for non MF installations ik F emperature can be found on page 4 20 are loose and allow movement For heated or chilled differential not zero differential through the joint Guide Anchor applications use MF pipe The In systems with a 0 or negative limited expansion helps increase AT use the maximum spacing hanger spacing The table on page 4 35 provides the best mat
66. c e 9 e 2 LL et TT a aquatherm blue pipe Reducing tee Socket Part no Dimension ND 2613601 6 x6 x26 2613603 EO xo 2613609 0 x8 x2W 2613611 9 x8 x3 2613613 9 x8 x35 2613615 8 x8 x4 Part no Dimension ND 20136822 16 x 16 x 10 2013690 18 x18 x 4 20136922 18 18 x 6 2013694 18 x18 x8 2013696 18 x 18 x 10 20136989 11102212 Part no Dimension ND 2613625 10 x 10 x2 2613627 10 x 10 x 3 2613629 10 x 10 x 3 2613631 10 x 10 x 4 2013651 12 x 12 x 4 2013653 52251 2013663 14 x 14 x 4 20136659 14 x 14 x 6 20136674 14 x 14 x 8 2013676 16 x 16 x 4 2013678 16 16 x 6 2013680 16 x 16 x 8 aBranch outlet has a butt weld connection aquatherm blue pipe Reducing tee Socket continued 17 6 Part no Dimension ND 2513600 6 x6 x25 2513602 6 x6 x3 2513608 8 X6 x25 2513610 2513612 8 x6 x3 hh 2513614 8 x8 x4 2513624 10 x 10 x2 2513626 10 x 10 x 3 2513628 10 x 10 3 17 6 Part no Dimension ND 2513630 10 x 10 x4 2513651 12 x12 x4 25130537 sole 2513663 14 x 14 x 4 2513665 14 x 14 x6 25136673 14 x 14 x 8 2513676 16 x 16 x 4 2513678 16 x 16 x 6 25136809 16 x 16 x8 25136822 16 x 16
67. ch of CTS Pipe diameter and IPS sizes E s M 1 114 1 1 Yo 7 2 Yo 3 3 Yo 110 4 9 1 0 1 2 1 4 16 18 20 25mm 32 mm 40 mm 50 mm 63 mm 75mm 90 mm mm 125 mm 160 mm 200 mm 250 mm 315mm 355 mm 400 mm 450 mm Support intervals ft Support intervals SDR 7 4 and 11 MF Support intervals SDR 17 6 MF NI Pipe diameter NI Pipe diameter EE oc BENE oc BEND o BD o DM oc BU v 12 BIN BD 4 6 8 10 12 14 18 18 20 224 24 20mm 25mm 32mm 40mm 50mm 63mm 75mm 90mm mm 125mm 160mm 200mm 250mm 315mm 355mm 400 mm 450 mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm 500 mm 560 mm 630 mm Difference Difference in temp Support intervals ft Support intervals ft a 4 46 52 59 87 75 8 85 95 5 112 113 155 125 135 15 16 mi 84 8 5 87 9 0 92 94 97 10 0 10 3 10 7 10 8 i mE NEM 4 NEM 55 NM c 7o ES 9 o BI 14 15 x 6 1 62 6 6 6 7 6 9 71 75 7 9 8 4 8 9 92 2 4 4 4 144151 57 81 64 69 74 8 82 BEEN o v 13 57 5 9 6 2 6 4 6 6 6 7 72 75 8 0 8 5 9 0 0242 AC 1148 54 57 611688 71177 79 8 87 95 1 12 12 F 56 57 59 6 2 6 2 64 6 9 74 77 8 2 8 7 B 40 C 40 C am x 4 4 4 41 481 54 57 61 62 64 87 69 74 78 85 10 11 n 52 54 57 59 6 1 6 1 6 6 71 7
68. d saws Often or stress marks inside or outside the pipe damage to the pipe carbide teeth This will produce a cut that needs thinner blades leave a smooth cut but you will you can simply pull them out by hand You 72 little to no clean up also have some shavings to clean up may need to carefully cut them away with a Tw blade or reaming tool 2 E e Remove standing dirt and oil using an c isopropyl alcohol based cleaner 7096 by volume or greater Dirty pipe will not form i proper beads during fusion Be careful not to White stress marks and cracks indicate damage wipe off the printed label Reassess any cutting tools that leave cracks You l l m dt the end of the pipe t A wide toothed blade 24 40T will produce a A fine toothed blade 180T will overheat the Don t use power cutters if the pipe is 40 F or e gt jagged cut that is rough and not desirable for pipe as will cutting too slowly Make your cutas colder Cold pipe can crack and split Warm the socket fusion quickly and squarely as possible pipe before cutting It o lt How heat fusion works PP R plastic is made up of small chains of hydrogen and carbon When cold the chains are closed and won t 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 eliminati
69. duced the cooling time Butt welded connections need to cool under pressure to ensure a proper connection Cooling times for butt welded connections can be reduced by up to 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 Correct Whether on hangers or blocks the pipe should be supported on either side of the connection as well as further down the line to prevent deflection V Correct The pipe can also lay flat on the ground or a similar level surface Reducing cooling times 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 X Incorrect Failure to support the pipe near the connection can result in undue stress on the bottom of the joint X Incorrect NOISN4 LV4H Failure to support the pipe further away from the connection can result in undue stress at the top of the joint X Incorrect Failure to support the pipe on both sides of the connection can cause undue stress across the joint lt o ert Fusing dissimilar SDRs In order to fuse pipes with different SDRs you will need to make the following modifications to your fusion process 1 Use the heat time from the lower SDR thicker wall pipe or fitting
70. e fthe testing pressure exceeds 150 psi the test must be performed using water only or water with an air fill Compressed air alone is not approved for systems with a testing pressure higher than 150 psi unless those systems are intended for compressed air service Operating Medium Test Pressure Test Medium Choose One Air Service Pressure testing page 4 of 13 Water Service N 150 psi gt 150 psi N Test with air Test with water water over air system cvv 4 44 Pressure testing page 5 of 13 Step 3 Observe safety protocols The full Aquatherm warranty does not take effect until the pressure test is completed and submitted and the system is in operation Therefore it is important for the tester to observe all safety recommendations from Aquatherm and any other jobsite safey requirements until the testing 15 complete For all systems e Visually inspect the connections for signs of proper fusion following the guidelines given in the Aquatherm Installer Manual Socket connections should have two even rings of melted plastic and a visible depth mark Butt welded connections should have a single bead with a rounded top This inspection is most easily done during the fusion process The absence of these signs may be indicative of an improper fusion e Remove all fusion equipment from the system before starting the pressure test e Set your pressure gauge near the bottom of
71. e against the heating iron at full pressure This phase is complete when the displaced material forms a visible bead see page 2 44 Heating Phase During heating the pipe remains in contact with the heating iron under low pressure his allows the heat to soak into the pipe without displacing the PP R material Heating times and all other reference times can be found on pages 2 45 and 2 46 Butt welding phases Welding Phase After removing the iron the two heat soaked pipe surfaces are brought together under full pressure The pipes must be brought together within the transition time and brought to full pressure within the build up time Cooling Phase As the fusion occurs keep the joint under full pressure for a minimum of half of the cooling time After this the Joint may be removed from the jaws but must remain supported for the remainder of the cooling time Unsupported pipe must remain under pressure for the full cooldown gt 7 2 McElroy adjustment and welding pressures Pitbull 26 28 412 amp 618 824 amp 1236 uMcELROY E 1 ND OD mm 918 836 8611 Adjustment pressure psi McElroy adjustment and welding pressures 412 amp 618 824 amp 1236 Dimension Low Force Low Force ND OD mm Adjustment pressure psi fusion mcelroy com
72. e time spent loading and aligning the pipe Delta Dragon 315B Most fourjaw machines can be modified to accommodate different fusion situations Some machines allow a clamp to be removed 2x1 reducing weight and size Others allow for a 3x1 set up to accommodate shorter sections Clamping with a single Jaw generally requires additional alignment time Modified machine configurations m J e c mr lt gt e ec Manual butt fusion machines Manual machines lack a hydraulic system and instead use a mechanical device to generate the force required for fusion They can be advantageous in tight spaces and on smaller jobs Pit Bull 26 Ritmo Gamma 160 Tools should be viewed as a means to increase productivity rather than as an additional cost For example socket fusions from 2 4 are difficult to do with one installer and may require a second installer However a socket fusion machine makes larger socket fusions a one person job doubling productivity For larger sizes of pipe 6 and up cooling times occupy the time of the machine but not necessarily the installer With proper set up and planning a single installer can perform several fusions at once using multiple machines This can double or triple the output of an installer or team of installers The ratio of machines to installers will depend on the skill o
73. efore beginning operation flush the system to remove dust pipe shavings and other particles that may have fallen into the pipe Make sure the system 15 flushed in a safe manner that doesn t damage or clog any components Unless otherwise required water 15 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 VVhere 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 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 manufacturer s 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 use with plastic piping Additionally the heat system must be self regulating and the surface temperature of
74. eliver 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 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 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 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 7 partial bead in the pipe Inserting to the long side will leave a slight internal gap but this will not affect the connection strength 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 exceeds it the thermometer may When the iron is ho
75. enerally 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 fixed heating iron Heavier bench style machines offer increased Stability and accuracy but are less mobile Mechanically assisted fusions Other fusion processes such as butt welding and electrofusion require special tools to complete them These well as the tools for socket fusion are available from Aquatherm s approved tool manufacturers These manufacturers supply properly sized tools for Aquatherm s piping systems and have an established history of providing excellent support to Aquatherm installers A complete list of these manufacturers can be found starting on page 2 36 Do not use fusion tools from an unapproved manufacturer gt 7 2 22 ert 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 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 i
76. eter Washers N m ft lb Number Diameter Washers 05 NIE Nem Number Diameter Nem ftib Number Diameter 5 20mm 9 7 4 1 2 Yes 6 160mm 75 55 8 3 4 Yes a full range of flange adapters flanges Viton gaskets may also Aquatherm s flange rings are be used if needed for chemical 4 25mm lt 4 17 Yes 8 200mm 102 79 8 3 4 Yes uniquely designed to have a resistance For lower pressure 1 32mm 20 15 4 1 2 Yes 10 250mm 122 90 12 7 8 Yes metric center and an ANSI bolt systems and smaller diameters l 1 4 40mm 20 15 4 1 2 Yes 12 315 mm 142 105 12 7 8 Yes pattern For a flange transition 4 and down ring gaskets 134 50 mm 34 25 4 1 2 Yes 14 355mm 203 150 12 1 Yes adapter s used pur ida may A should c 2 63mm 4 30 4 5 8 Yes 167 400 mm 208 150 16 1 Yes 3 e star pattern regardless r A fusible fitting and the ring iis M 9 2 75mm 54 40 4 5 8 Yes 18 450 mm 237 175 16 1 1 8 Yes testing Ring gaskets are also flange size and number of bolts more susceptible to leaks if see example Tighten all bolts 3 90mm 54 40 8 5 8 Yes 20 500 mm 237 175 20 1 1 8 Yes piping are not aligned properly and repeat until fully tightened 4 125mm 54 40 8 5 8 Yes during installation The gasket Do not overtighten the bolts Note These are typical values for rubber gaskets with
77. f the crew the worksite conditions and the nature of the installation Having too few tools will slow down the job and leave installers standing around with nothing to do A good balance lets the crew stay engaged on productive work no waiting around while the fusion equipment is always being used on connections no idle machines Larger crew vs more tools Having the right number of tools will greatly impact your installation time To find the correct number of tools for the job evaluate the size and mix of the crew being used Each person fusing pipe will need at least one tool suitable for fusing the size of pipe being installed some installers may be able to operate multiple tools while installers in supporting roles may not need tools at all This next section will give you examples of tool selection and crew mix based on the type of work being done m C mur lt PRODUCTIVITY Work example 1 Socket prefabrication shop Crew 1 primary 1 support Tools 1 benchtop 1 iron 1 jig saw Goal Maximize connections per hour and eliminate unproductive time through specialization Process Support measures and cuts pipe to length cleans and preps edges for fusion Primary uses benchtop machine to perform fusions on the main spool uses iron and jig to fuse on additional pipe fittings and outlets while the benchtop connection cools o Fusion 944444
78. g and that your iron has sufficient power NOISN4 LV4H 22 eT m Troubleshooting bad connections 90000000009090900900000000909000000000000009000000009000000009 Y y Increase heating Fuse immediately after heat time time by up to 50 Marks no longer visible internal bead Fitting does not look square Y Y Y Verify marking depth and stop just before the marks Reduce 2 time slightly The pipe sheets back instead of forming a bead No ring visible Y Y Y Clean pipe before fusing ipe wont fully insert into fitting Y y Make sure temp gt 475 F Y Double check machine settings Hold pipe 2 at least 25 of the cooling time y Make sure both sides are heated The welding heads are designed to operate under very specific tolerances and compressing the end of the fitting can prevent proper contact and thus proper fusion This is referred to as ovaling Ovaling occurs when the clamps of a fusion machine exert too much force on the mouth of a fitting and bend it out of round To prevent this Issue avoid over tightening the clamp that holds the front of the fitting The clamps should be snug but not so tight that they distort the fitting Ovality in machine assisted fusions To prevent the fitting from slipping use a backstop or support the fitting with your hand during insertion Giving the iron time to heat the pipe and fitti
79. g pressure Excessive pressure B 3 E 1 Lal a r Adjustment bead complete drop the system to drag pressure If necessary to maintain contact add up to 10 of welding pressure Observe the entire heating time use a timer Too during the heating phase can create a little time will create an improper connection Do restriction in the pipe not exceed the heating time bd j Bring pipes together within the transition time and ensure the machine achieves full pressure within the pressure build up time have a safe place to set it down immediately if you can t hold it in one hand 220 NOISN4 c o lt Butt welding instructions 6 Cooling The cooling time can vary with the size and support of the pipe being fused Short sections and long sections that are properly supported can use a reduced cooling time Long sections that are not supported must use the full time A visual guide can be Observe the full cooling time Do not try and The final bead should look like one solid piece A shorten the cooling time by pouring water on bad PP R fusion will have a split bead with two found on the next page the connection distinct sides Release pressure and undo clamps Don t loosen Remove the connection from the machine the clamps until pressure has been fully released Remember to keep the pipe supported if you have re
80. ges Check for longitudinal cracks on the pipe wall after each cut i 4 p 4 E HLS PES a T Uu support the pipe while cutting to yield square ends and prevent bouncing or snapping Use ratchet cutters with a sharp pointed blade for smaller sizes The pointed blade prevents the pipe from ovaling during the cut Use tube cutters with a wheel taller than the pipe wall Smaller wheels might not reach through the entire pipe wall Cutting the pipe manual Hand saws are a safe alternative even in cold weather Dry chain saws can be used to cut larger pipe but will produce a jagged face gt 7 2 Cutting the pipe power Inspecting the cut When using hand saws use B A 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 Don t use any tool or method that causes 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 Remove any debris left from cutting the pipe A good cut is smooth square and has no cracks Use a circular hardwood blade 60 1007 with Band and reciprocating saws are safe to use The This is common with powere
81. han the OD of the branch line P y Siete long as they can cut a smooth even and properly sized hole a matches pipe wall NOISN4 LV4H c 22 LL et Pipe wall insert Fitting side Set up the welding iron following normal socket Don t forget to tighten the welding heads after Pipe side welding head procedures found on page 2 16 the plate is hot and check the temperature welding head before starting Fusion outlet instructions page 2 of 3 Fusion outlet instructions page 3 of 3 2 26 2210 Mark the pipe where you want the outlet Once Use the guide bit to start the hole to ensure The bore should pull the shavings out so that Look for a bead to form around the fitting This Ensure the welding head makes a full impression you begin drilling you cannot move the hole so accurate positioning Drill at a right angle to the they don t fall into the pipe Clear away any does not take much pressure Too much pressure on the pipe Check and adjust the head until the be sure of your placement pipe Quickly drill out the hole excess debris Flush any leftover shavings will cause internal restriction ring is complete HEAT FUSION NOISN4 LV4H 10 Set the fitting in the hole and hold in place Level and square the fitting as it cools Like the into the head Push down gently to keep the iron of the iron you may use a dowel or a board to Use only enough pressure to
82. he ends This is the most common cause of handle most impacts without issue butthereisno ends of the pipe These can gouge the inside of after the pipe is shipped your distributor s policy for returns pipes and 4 for 19 pipes pipe damage reason to risk damaging it the pipe and create weak spots 5 LH er lt e 5 Lid 5 gt um ing LLJ Keep the pipe in its protective bag or wrap until Handle the pipe carefully especially in freezing Cover unbagged pipe with a light colored tarp if Don t store pipe outside for more than 6 months Keep the fittings in their bags until you use them Don t use damaged pipe that is gouged deeper you are ready to install it The bag protects the weather Plastic may become brittle at cold storing it outside A dark tarp generates heat and uncovered The pipe should be stored under a tarp Bagged fittings will be easier to identify and than 10 of the wall thickness on the outside or pipe from dirt scratches and UV rays temperatures so treat it accordingly may cause warping or shade or in its factory packaging protected from contaminants 5 on the inside cc eT e al LLI Pipe sizes Aquatherm pipe 16 made to metric sizes millimeters This is part of its design and listings but it is easy to Socket fusion Butt welding learn the matching imperial sizes inches Factory Nomi
83. ide variety of applications that Aquatherm pipe is used in and the ongoing development of third party tools clamps insulations and other solutions staying up on the best practices requires a small bit of effort In order to keep you informed of new techniques and requirements Aquatherm frequently releases 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 can be found at http aquatherm com technical bulletins If you are installing metal clamps 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 Plastic clamps are safe without additional padding Metal clamps even plastic safe clamps can damage hot water pipes and can condense 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 18 in direct contact with Aquatherm pipe m
84. ing 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 Aquatherm s 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 15 covered in detail in Chapter 2 Working with PP R All of Aquatherm s pipes and fittings are made from PP R so they will have the same properties hey can be heat fused together without any strength loss and have the same densities durability and resistances Aquatherm s PP R has been engineered for improved performance and should not be mixed with other types of PP R PP R should never be fused to PP PVDE PE CPVC or any other type of plastic Never use solvent cements on Aquatherm s PP R as they may damage the pipe and won t bind properly gt rr r gt rr T WELCOME TO AQUATHERM Aquatherm innovations VS Aquatherm s Fusiolen PP R Normal plastic Every piping material has advantages and disadvantages Burns during fusion resulting PP R is proven to have very in strength loss few disadvantages and several
85. ion outlet 9 44 Street 90 5 9 aquatherm green pipe Tee Butt weld 5 19 ISO plug for pressure tests 5 35 Distribution block plumbing 9 47 Bushing 5 10 Tee Butt weld molded 5 20 ISO transition piece 5 36 Distribution pipe 9 47 Cross 5 10 aquatherm green pipe Reducing tee Butt weld 5 20 ISO transition elbow 5 36 Distributor end piece 9 40 Butt weld reducer 5 11 Reducing tee Socket 5 21 Transition piece 5 37 screw down stop globe valve 9 48 Reducing coupling 5 12 aquatherm green pipe Reducing tee Socket 5 22 NPT transition piece 5 37 Concealed valve 9 48 Elbow 90 Socket 5 12 aquatherm blue pipe Tee Butt weld 5 23 NPT transition elbow 5 39 Stop valve body ISO 9 90 Inclined valve Inclined check valve Ball valve Extension for ball valve Repair Set Repair Plug Temperature protective gloves Welding heads Drill bit Fusion outlet welding heads 0 00 5 51 0 01 909 5 53 0 04 0 04 0 04 0 00 0 06 Chapter 1 Welcome to Aquatherm This manual has been compiled to help ensure safe and consistent installation of Aquatherm s 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 teach you the proper techniques for fast reliable heat fusion connections and help you take full advantage of Aquatherm s many benefits AEN 01 ETN cc
86. ipes can absorb their expansion Non MF 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 4 14 al Y 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 Expanding side Bending side Length of bending side 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 Linear expansion in inches 7 Pipe dimension in i 2 4 5 6 7 8 g 10 12 Pipe Linear expansion in inches inches mm Length of bending side in dimension in p 2 om 4 ar 6 7 8 9 107 1 12 6 160 38 54 66 76 85 93 100 107 114 120 126 131 inches mm Length of bending side in 8 200 42 60 73 95 95 104 112 120 127 134 141 147 20 13 19 23 27 30 33 35 38 40 42 44 46 10 250 47 67 82 95 106 116 125 134 142 150 157 164 34 25 15 21 26
87. irst Jig Fusion Preparation J gt Unproductive time gt 27 5 t a Y a and then Primary performs the PA 51 actual fusion While Primary is RT 9 i AY gt performing the fusion Support SINGLE INSTALLER 3 FUSIONS PER HOUR aquaiherm 4 A A sets up the second jig Primary 2 7 mM then performs the second ZZ 222 1 connection while Support E x detaches the first Jig and sets OPTIMIZED TEAM Q rusions PER HOUR ee it up on another connection A 7 7 7 7 zm second Support may be needed 2 m to carry and hang pipe EE ee Yee ee ee 23 22 PRODUCTIVITY Work example 6 Butt fusion linear Crew 1 primary 1 2 support needed to minimize downtime This process can also be done on the ground at which point the crew can lift the entire length into the air Branch outlets can Tools 2 3 butt fusion machines If the pipe is fused on the M ground and hoisted into place Goal Maximize connections per ib ied two machines and one Support be added later hour by eliminating downtime for may be sufficient Branch outlets the cooling phases can be added later Process Primary performs the hot work alignment Fusion e Preparation gt Unproductive gt FY facing bead up heating and welding on first machine while SINGLE INSTALLER 2 1 2 Support prep the second FUSIDNS PER HOUR machine for fusio
88. it for you your company and the job you are working on Hand irons 12 2 socket fusion You will need 2 iron to do socket fusion work on 2 pipe and smaller When working in the it s easiest to use the smallest suitable welding iron 1 irons are also available for fusing small pipes in confined 2 iron spaces i 12 A socket fusion A 4 Iron can do all socket connections 4 and smaller Its weight and power usage make it better suited to prefab and connections that can t be done with a smaller iron 4 iron J mur gt e ec Socket fusion machines A jig style fusion machine eliminates the need for a second installer on 2 4 connections Designed for in air fusion it is minimalistic and nimble and requires a hand iron for use Prisma Jig A bench style fusion machine eliminates the need for a second installer on 2 A connections With Its larger frame and fixed iron it is not suitable for in air connections but does provide immense support and is very productive and efficient for fabrication Socket fusion machines Prisma 125 Widos 3511 m e c mr lt gt e cc Four jaw butt fusion machines Full size butt fusion machines have two jaws on each side of the fusion 2x2 reducing th
89. itions Waiting too long will let the pipe surface cool and make fusion impossible Se gt 7 c 2 c 22 lt Large diameter socket fusion Fusing pipe larger than 2 is difficult without help There are several tips for assisted two man fusions e 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 e Don t waste time Once the pipe and fitting are removed from the iron push them together immediately e PP R doesnt burn while heating 50 you can put the pipe and fitting back on the welding heads and start again if the connection 15 underheated Pipes and fittings may be safely reheated once after the initial heating e Ensure that the pipe end is cut square and mark the pipe on several sides This will help you line up the fitting squarely e f you can t push the pipe or fitting all the way onto the iron allow the heat to melt the PP R and then continue e Remember that the fitting welding heads are tapered they will not offer much resistance until the fitting 15 almost entirely on For larger fittings it is g
90. lubricated lightly greased or plated bolts Values may be increased for harder gaskets or plain un plated should have an inside diameter Bolt length will depend on the bolts consistent with the ID of the thickness of gasket and flange flange adapter see page 5 28 ring being used Butterfly valves Branch lines Pipe size Hitlets available There are two ways to Install branch lines on Aquatherm produces modified flange adapters for use with ANSI butterfly valves The part numbers for Aquatherm pipe tees and outlets Tees are these are distinguished by adding a BV to the end Note that these are available only for sizes 6 and Thread size 1 yu 4 2 above excluding 22 the ANSI and DIN dimensions overlap in smaller sizes The part numbers can be 2 a full sized fittings that either socket fuse or butt found on page 5 28 EMG fuse in line These are usually used for branches nee ae 2 5 V that are within two sizes of the main line Tees E Tolerances with some butterfly valves may be very tight Opening the valve before bolting it in place can 1 M E M F T ione can be found on page 5 17 and reducing tees on helo center the valve and ensure proper actuation 3511 3 page 5 19 F M F 3 W 16 ye Vile E o 200 re smaller fittin h let f n Modified flange adapter 2 T Outlets
91. maintain contact socket fittings you only have a few seconds in contact with the PP R help push the iron into the pipe between the heated surfaces before the fitting sets Insert the welding head into the hole and fitting Rather than putting excessive force on the neck 2 28 HEAT FUSION 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 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 installer s 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 Make
92. me rm 72 limitations of your gloves impact and damage accidentally burn themselves dropping the irons may break them irons and heads are hot until tested gt Tl Lia L p lt pF p c Post a sign near irons to warn that they are hot Be aware of where other people are at all times Keep the cord away from the heat surfaces Dont store multiple irons in a single box Irons Dont let the iron touch flammable or meltable Don t use the welding iron if the plate or heads Irons can remain hot for up to 30 minutes after while fusing Make sure they are clear before you Some cords are heat resistant but it s best to can easily damage each other and should be surfaces This is a fire hazard and can damage are dirty Clean the plate with a soft wire being turned off move the hot iron around keep everything away from the heating surface stored separately the plate or heads wheel and the heads with a cloth Tool assembly Marking the pipe The marking guide helps ensure proper insertion depth The green marking guide 2 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 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 d
93. mension snr Delta Dragon 355B Delta Dragon 500 Delta Dragon 630 ND OD mm Adjustment pressure psi FR rS Adjustment pressure psi 14 355x201 176 218 73 863 879 8655 M am 14 355x322 1 334 102 info ritmoamerica com 4 125 x 11 4 11 407 14 355 48 0 74 479 160 87 160 91 176 431 247 116 102 44 Ps i 16 400 x 22 7 17 6 174 87 E 6 160 x 14 6 11 667 392 189 160 73 16 400 x 36 3 1 276 131 22 Installers should always use the 6 160 x 21 9 74 950 551 276 232 102 18 450 25 5 176 218 116 o operator s manual included with 8 200 x 11 4 17 6 189 160 73 Tw the butt welding machine or the 18 430 x 403 38 TI manufacturer s online information to 8 200 x 18 2 230 261 102 20 500 x 28 4 17 6 276 145 n the adjustment pressure 8 200 x 27 4 74 42 363 160 22 560 31 7 176 174 is table is based on the information 10 250 x 14 2 176 305 261 102 available to Aquatherm at the time of j 24 630 35 7 17 6 218 this 5 printing and may not be 10 250 x 22 7 11 464 406 160 complete accurate or current If there 10 250 x 34 2 74 653 566 232 Is a discrepancy between this table and any information provided by the tool 12 1915 x 17 9 17 6 406 174 manufacturer the tool manufacturer s 12 315x286 1
94. n Primary Ey LZ 22222 then performs the hot work on the second machine while 1 2 Support set up the third OPTIMIZED TEAM f FUSIONS PER HOUR machine Pipe in the air may 2 9 7 2100 require the full cooldown time n so three machines will be 2 N 25 ALIAMLONGOdd 3 24 PRODUCTIVITY Joining spools Socket and butt fusion As part of using prefabrication you will need to have a plan for installing the spools once they are built Time saved by using prefabrication can be lost trying to rework sections that aren t easy to join together Traditional fusion methods socket and butt welding require a few inches of lateral movement If that movement is available then socket and butt fusion will be the most cost effective and secure means of joining the spools For straight lengths leave the moving spool unclamped until the fusion is complete Places where the pipe changes direction such as elbows allow the installer to take advantage of the pipe s flexibility See pages 4 16 and 4 17 for safe bending lengths Using a fusion machine the installer can force the pipe to bend perform the fusion and bring the pipe and fitting together for a square connection See series above In areas where lateral movement is not possible but fusion welding is still the preferred method electrofusion couplings can join sections up to 10 without lateral movement One side of the pipe is peeled
95. n primary assisted by multiple apprentices and laborers support Primary Focuses on the order of assembly complicated fusion work connection alignment and directing the support crew The primary uses experience and planning to make the installation fast and efficient Crew mix Support Focuses on handling measurement and cutting tool movement and set up and simple fusion work The support focuses on maximizing the productivity of the primary installer s m C mur lt gt e cc Tooling Fusing Aquatherm pipe requires tools that meet certain criteria The tools must comply with dimensional temperature and pressure requirements that are suitable for Aquatherm s PP R pipe Aquatherm s core focus is on pipe and fittings not tools so Aquatherm works with several tool manufacturers to promote the development and availability of these tools For better selection pricing and support installers are encouraged to use tools from an approved tool manufacturer As of the printing of this edition Aquatherm has approved tool lines from McElroy Ritmo Rothenberger and Widos Contact information for these manufacturers can be found starting on page 2 36 Each manufacturer has its own approach when it comes to tool function and design We recommend exploring your options and finding the tools that are the best f
96. nal Factory Nominal l metric OD diameter metric OD diameter This chart gives the matching sizes between metric 1 and imperial These sizes are based on factory settings and closest nominal diameters Use the 20m 8 nominal size when switching from imperial pipe if gpm requirements are not available Use the actual OD for sizing clamps and insulation SDR instead of schedules This means that the T5 wall thickness is proportional to the diameter of the pipe From a performance standpoint this makes the pressure rating of the pipe consistent through each size mm 12 4 pipes come in 13 ft 4 meter lengths 4 SDR 11 and SDR 17 6 may be butt welded 6 24 pipes come in 19 ft 5 8 meter lengths diameter SDR 7 4 A heavy wall provides increased pressure and temperature ratings for high stress applications such as hot water system piping aquatherm green pipe MF 1 Ay total diameter SDR 11 A balanced wall thickness provides higher flow rates while maintaining high pressures ouitable for most applications aquatherm green pipe 5 aquatherm blue pipe MF aquatherm lilac pipe S Wall thickness 1 16 total diameter SDR 17 6 A thinner wall provides maximum flow rate while minimizing material weight cost and fusion times For lower pressure systems such as chilled cooling or condenser applications aquatherm blue pipe MF gt rr r
97. nd equipment to make welded joints or fittings connections his list is not comprehensive 6E 1 Pressure testing page 7 of 13 E ES Pressure testing page 2 of 13 Aquatherm offers an extensive warranty to protect against damages caused by failure from manufacturer s defect Aquatherm requires that all installations be pressure tested in accordance with the following Pipe SDR SDR 17 6 SDR 11 or lower instructions and that proof of the pressure test be submitted to Aquatherm before the coverage can go into effect Warranty coverage begins only after the pressure test is properly completed and submitted Aquatherm s 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 Step 1 Determine your testing pressure In order to ensure the integrity of the heat fusion connections a pressure test must be performed on the completed system The amount of pressure used depends on the type of pipe and intended pressure of the application e f the piping system contains SDR 176 pipe and has an intended operating pressure of 65 psi or lower the system must be Operating Pressure 65 ps gt 65 ps lt 100 ps 100 psi tested at 100 psi If the piping system has an intended operating pressure higher than 65 psi the system must be tested at 150 of the intended operating pressure B e f the sy
98. ng 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 In socket fusion a fitting is fused over the outside of the pipe leaving the inside open and unrestricted 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 diameter between the fitting and pipe creates the required pressure for fusion Socket fusion During socket fusion the inside layer of the fitting is removed as is the outside layer of the pipe 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 gt m c 2 e ma c 22 lt 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 gt Only use heads from an approved tool manufacturer Threaded bolt Size markings Taper for easier fusion Heads store inside each other to avoid scratches Befo
99. ng can also reduce the chances of slippage To determine if your machine and technique are causing ovaling inspect the finished connection for two complete beads all the way around If the beads are present on two sides and absent on two sides this may indicate that the fitting was ovaled during fusion Ovaled fittings are not at full strength and may leak gt 7 c 2 T Fusion outlets 1 4 ES e Fusion outlet instructions page 1 of 3 Using a technique similar to socket fusion branches and outlets can be easily added to the walls of the When drilling out a fusion outlet Aquatherm s boring tools are properly Getting a properly sized hole is hole there are two important sized and designed to remove the crititcal An oversized hole will result ipe This technique helps save time and money while d ns for CNN Td zu things to remember shavings The smaller bores use a in an incomplete fusion and cause hand held drill with 1 2 chuck leaks An undersized hole will make Fusion outlet 1 Make sure to remove the material from Bores over 2 inches require a drill it difficult to insert the welding head Main size the hole so it will not clog the main line press with a Morse Taper shank You and can create a larger internal bead may also use hole saws or bores reducing flow performance Drilling bore n in 1 ides by other manufacturers as 1 D smaller t
100. ngs 5 1 aquatherm green pipe MF SDR 7 4 5 2 aquatherm green pipe Elbow 90 SD Butt weld 5 13 aquatherm blue pipe Reducing Tee Butt weld 5 24 NPT transition street elbow 9 39 aquatherm green pipe 5 SDR 11 5 2 Elbow 90 Butt weld molded 5 13 aquatherm blue pipe Reducing tee Socket 5 26 NPT transition tee 5 40 aquatherm green pipe UV SDR 7 4 5 3 Elbow 45 Socket 5 14 Fusion outlet Socket 5 28 Draining branch 5 40 aquatherm blue pipe SDR 7 4 11 5 4 aquatherm green pipe Elbow 45 SD Butt weld 5 14 Fusion outlet Butt weld 5 29 Flow meter well 9 40 aquatherm blue pipe MF SDR 17 6 5 5 Elbow 45 Butt weld molded 5 15 Flange ring 5 30 Stub out 3 41 aquatherm blue pipe MF UV SDR 7 4 11 5 6 aquatherm blue pipe Elbow 90 SD Butt weld 5 15 Flange adapter 5 31 Straight stub out 9 41 aquatherm blue pipe MF UV SDR 17 6 5 6 aquatherm blue pipe Elbow 45 SD Butt weld 5 16 Pump flange adpater ring 5 32 PEX adaptor crimp 9 42 aquatherm lilac pipe S SDR 7 4 11 5 7 End cap Socket 5 16 Union 5 32 PEX adaptor expansion 9 42 Coupling 5 8 End cap Butt weld 5 17 Flow through back plate elbow 90 5 33 PP R to grooved transition 9 42 Reducing couplings 5 8 aquatherm green pipe Wye Lateral 45 5 18 Wing back 90 elbow 5 34 Transition elbow 9 43 Cross over 5 9 aquatherm blue pipe Wye Lateral 45 5 18 Electrofusion coupling 5 34 Transition tee 9 43 Street 45 5 9 Tee Socket 5 19 Back plate elbow 5 35 NPT fus
101. nsertion depth was Information on the pressure test can reached be found on page 4 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 TU T ith the fitting If intentional pipe reaches the inside of the fitting The pipe should be square with the fitting If intentionally angled the angle per connection should not exceed 1 degree Don t 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 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 moisture cannot reach the fusion surfaces Avoiding improper fusions Use enough heat Don t 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 fusin
102. o 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 Aquatherm s website 25 RE I E A Q e LS 9 e 2 H LL et TT a 5 2 aquatherm green pipe SDR 7 4 MF Part no Dimension ND 0670708 12 0670710 0670712 1 0670714 1 0670716 15 0670718 28 0670720 218 0670722 37 0670724 35 0670726 4 Part no Dimension ND 0670730 6 0670730x2 6 Double Length 0670734 8 0670734 2 8 Double Length 0670738 10 0670738x2 10 Double Length 0670742 12 0670744 14 Comes in 26 ft lengths Comes in 38 ft lengths aquatherm green pipe SDR 74 11 S aPipe comes in 26 ft lengths PPipe comes in 39 ft legnths Pipe comes in 38 ft lenghts Part no Dimension ND aquatherm green pipe SDR 7 4 11 S continued aquatherm green pipe SDR 74 MF UV Part no Dimension ND Part no 0670772 0670774 Dimension ND 06 0776 06 0 80 0670784 0670788 0610234 8 0610234x2 8 Double Length 0610238 10 0610238x2 10 Double Length 0010242 12 0010242x2 12 Double Length 0
103. of 200 mm or 787 inches the bending radius is 787 inches or 66 feet This applies for all SDR s and pipe diameters for the Green and the Blue pipe with and without faser The only exceptions to this are Aquatherm s coiled tubing products When using coiled Aquatherm products for radiant floor snow melt field turf warming or similar applications the bending radius should be no less than 8 times the outside diameter of the tubing being used For example tubing OD 20 mm 8 x 20 160 mm bending radius 160 mm 6 3 inches bending radius or 12 inches on center Always bend the tubing in the coil direction and use a bending guide to prevent the tube from kinking Please note that considerable force may be required to field bend the pipe and the pipe may spring back forcibly if the restraints slip or are inadvertently released while bending or after installation Observe appropriate safety precautions during field bending Insulation sizing thrust blocking noise generation and vibration isolation Insulation sizing Aquatherm s pipes are made using a metric OD so standard 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 sizes also work for clamps and hangers Insulations with metric IDs and imperial ODs will use Aquatherm s ND Thrust blocking Due to the inheren
104. oling distribution condenser water piping to cooling towers Acceptable applications Any non potable low pressure low temperature applications suitable for PP R Color Purple Stripes None Wall thickness SDR 11 Size range 12 10 Multi layer construction expansion controlled No Maximum operating pressure at 50 F 195 psi Maximum operating pressure at 100 F 135 psi Recommended applications Rainwater greywater reclaimed water Irrigation aquatherm lilac pipe S gt rr RE e B rri ad cc EN lt LL e E LL Molded fittings Single piece 12 A fittings socket fuse over the pipe wall 6 24 fittings butt weld in line with the pipe All pipes use the same PP R fittings Minimal markings on the fittings Full labeling 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 Butt weld in line with the pipe 6 24 elbows amp tees Made from aquatherm green pipe or aquatherm blue pipe to match piping system Size marked on label otamped on the side to indicate origin aquatherm green pipe fittings may be used with aquatherm blue pipe installations do not use aquatherm blue pipe fittings in aquatherm green pipe installations Pressure rating meets the pressure rating
105. ool ij 1 me ee i 20 17 6 23 7 manufacturer the tool manufacturer s 11 25 9 115 27 176 _ 372 information shall be considered correct 10 74 37 0 16 4 24 17 6 47 2 Widos adjustment and welding pressures m Mapas W WI WI Wi5100 Dimension R 4400 4600 4900 8550 ND OD mm Widos adjustment and welding pressures Dimension WI 5100 amp 5500 WI 6100 ND OD mm Adjustment pressure bar Adjustment pressure bar 14 355 x 20 1 176 15 13 WSCA 17 6 11 14 355 x 32 2 11 24 19 4 125 x 11 4 11 89 17 8 14 355 x 48 0 74 37 6 160 x 9 1 17 6 94 18 9 8 16 400 x 22 7 176 20 16 678 376 4379 6 160 x 14 6 11 145 27 13 12 info widoswelding com z 16 400 x 36 3 11 30 24 T www widoswelding com 6 160 x 21 9 14 207 39 19 17 18 450 x 25 5 176 25 20 8 200 x 11 4 17 6 13 12 5 18 450 x 40 9 11 38 31 Eh LL Installers should always use the operator s 8 200 x 18 2 11 2 18 8 c manual included with the butt welding machine oe 20 500 x 28 4 17 6 30 25 en or the manufacturer s online information 8 200 x 27 4 74 29 26 11 22 580 x 31 7 176 31 O to calculate the adjustment pressure This 10 250 x 14 2 176 71 18 8 Pa table is based on the information available i 24 630 x 35 7
106. preparation Is needed for installation see 4 38 Another option 18 to paint the pipe Painted pipe may need to be recoated or maintained Aquatherm recommends using an elastomeric paint which will expand and contract with the pipes Visit for paint options You may also paint the pipe for non UV reasons Standard acrylic enamel epoxy and latex paints do not harm the pipe Painting the pipe is considered an aftermarket modification and Aquatherm does not assume any responsibility for the performance of the paint 4 ES 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 aquatherm green e pipe ana auan joh pipe Mark the pipe one size up from its actual size Cut around the outside of the pipe through just the pipes You will still need to cover This will protect the black layer from the heat _ black layer A rolling cutter works well Do not cut or paint the fittings fusion process into the pipe wall V Cut from the mark to the edge of the pipe Wear Use a knife to pry up the edge of the black layer Peel back and remove the black layer Fuse the protective gloves and mind your fingers Re score the cuts if they are not deep enough pipe following the normal guidelines 4 38 Flushing grounding and freeze protection Flushing B
107. re setting up the iron clean the welding heads with rubbing alcohol or a similar non corrosive agent if they are dirty Pipe female side Fitting male side Teflon coated Welding irons The welding heads can be interchangeably attached to a welding iron which provides the heat for the fusions Neck brace Power cord Heating plate Heat cycle indicator turns on while iron is heating turns off when iron reaches preset temperature NOISN4 LV4H Power indicator Heat sink Welding heads SS i Never carry welding iron by its power cord 1 inch iron 4 inch iron 2 inch iron Welding iron safety Do Welding iron safety Don t 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 E gt handling Never use water to cool an Wear heat resistant gloves while handling the After use return the iron to its case for Don t leave the iron unattended Passers by Don t drop the iron or hold it by its cord Don t touch the iron with bare hands unless r iron or head iron Few gloves are heat proof so know the storage The case will protect the iron from may not know if the iron is hot and could The cord is not intended to hold weight and you are certain the iron has cooled Assu
108. rs The heating times column E or F begin when the pipe and fitting are fully inserted onto the welding head Clean the pipe if needed and insert the pipe and fitting into the iron Pushing both sides at the same time helps hold the iron steady Stop the fitting when you reach the stopline page 2 8 Tapered heads will offer little resistance until just before the stop Stop the pipe when you hit the mark column D Over insertion will cause a restriction in the pipe and lower performance Observe the heating time column E or F A bead will form and become shiny as the fusion nears readiness Remove fitting and pipe from welding heads Use a clamped stand or an extra hand to hold the iron in place n IEE EU LP Rd 81344 ia d 5 seconds to make adjustments to the alignment depending on the pipe size Do not twist during adjustment alignment or insertion Socket fusion instructions page 2 of 2 the pipe until the rings meet within the welding time column G Align the pipe and observe cooling time column H You will need to provide full support for at least 1 4 of the cooling time Do not touch the face of the pipe to the edge of the fitting This flattens the beads and can cause an improper connection 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 cond
109. stem contains only SDR 11 or heavierwalled pipe lower SDR and has an intended operating pressure of 100 psi or less the system must be tested at 150 psi If the system has an intended operating pressure higher than 100 psi the system T 1 1 est Pressure 100 psi 150 150 psi 150 must be tested at 150 of the intended operating pressure e f you have concerns regarding your testing pressure please contact Aquatherm Exceptions to the required pressure test must be submitted via letter to Aquatherm e f the piping system has a mixture of SDR pipe the test should be performed to the higher SDR or thinner walled pipe testing requirements For example if the piping system contains SDR 176 pipe and SDR 11 piping you should test to the requirements of the SDR 176 piping Choose One 4 42 Pressure testing page 3 of 13 Step 2 Determine your testing medium Water is the preferred medium for testing purposes due to its incompressibility However in low pressure applications air testing may also be suitable You may use a different testing medium for different tests as long as the medium is acceptable with the test pressure e fthe system is intended for compressed air service only compressed air may be used for the pressure test regardless of the following restrictions e fthe testing pressure is equal to or less than 150 psi you may test with air only water only or with a water over air combination system
110. sulation purposes oix inches of dry sand equates to roughly one inch 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 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 Pull forces include a 4096 safety factor Max pull force Ib Pipe diameter oDR 17 6 6 160 mm 16055 11353 7362 8 200 mm 25087 17739 11503 10 250 mm 39198 27718 17973 12 315 mm 62230 44005 28534 14 355 mm 79038 55890 36241 2 16 400 mm 70958 46012 18 450 mm 89806 58233 20 500 mm 71893 22 560 90183 24 630 mm 114137 4 34 Bending Aquatherm pipe In general Aquatherm does not recommend bending Aquatherm pipe as a means of making a change in direction or going around obstacles However there are instances when the pipe is required to bend such as buried and trenchless applications The pipe may be bent or bowed a maximum of 5 off straight in a 20 foot section or to a bending radius of 100 x the pipe outside diameter For an 8 SDR 11 pipe with an outside diameter
111. sure during this p ma 29 psi 0 6 bar test is indicative of a leak If a leak occurs identify the leak and repair the system then repeat this test 6 psi 0 4 bar for SDR 17 6 systems e Asuccesstul version of this test must be completed before proceeding Fail Point p in psi bar e Aquatherm recommends using this test for progressive testing rather than completing the entire testing sequence he entire testing sequence must be completed on the whole system when it is finished Stabilization 30 min 4 48 Pressure testing page 9 of 13 Step 4 continued Principal test If the system has lost any pressure during the preliminary test bring the system back up to the test pressure Observe the system for 120 minutes The system should be able to hold the full test pressure during that time The loss of more than 3 psi or steadily decreasing pressure during this test is Indicative of a leak Identify the leak and repair the system before repeating this test A successful version of this test must be completed before proceeding Test Pressure p in psi bar Principal Test 120 min Pressure testing page 10 of 13 Ap mx 3 psi 0 2 bar Fail Point Pressure testing page 11 of 13 Pressure testing page 12 of 13 Step 4 continued 150 psi Final test e Release the pressure from the system e Bring the system up to test pressure for two minutes Reduce the
112. sure the pipe is cut exactly square to ensure proper contact Chamfer or ream the pipe to remove any rough edges Use a peeling tool or paint scraper to remove the AIV oo one more outside of the pipe Peel back at least half the E Inpeel the pipe length of the coupling being fused E 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 j um Clean the outside of the pipes with an isopropyl Don t open the fitting bag until you are ready to alcohol wipe Avoid touching those surfaces after fuse the connection This helps keep dirt off of cleaning them the fusion surface 6c NOISN4 LV4H 221 HEAT FUSION Electrofusion instructions page 2 of 3 Mark the pipe at half the depth of the fitting The two pipe sections will meet in the middle of the fitting Attach the leads to the fitting Most leads slide in with little resistance so don t force them Be careful not to bend them Insert pipe into the fitting The pipes should fit snugly but without any force You should be able pull them apart Make sure there is no gap in the middle You won t be able to see the gap so use your depth marks scan the tag on the fitting Rescan if needed On smaller couplings the tag can be removed and laid flat for better reading Make sure both sides of the pipe and
113. system pressure to 15 psi for two minutes e Release the pressure from the system e Bring the system up to test pressure for two minutes Reduce the system pressure to 15 psi for two minutes e Release the pressure from the system e Bring the system up to test pressure for two minutes Reduce the system pressure to 15 psi for two minutes e Release the pressure from the system e Bring the system up to test pressure for five minutes Reduce the system pressure to 15 psi for five minutes e Release the pressure from the system PLANNING 4 50 La Y a 15 psi tin min 2min 4min 2min 4min 2min 4min 5 min 10 min 4 52 Pressure testing page 13 of 13 Step 5 Complete and submit the pressure test record e Submit the form to Aquatherm within 30 days of completing the pressure test e f you are testing a system in sections save all the pressure test records and submit them together e Include the installer numbers of all the installers who fused connections on the system All information can be submitted electronically on Aquatherm s website at hito www aguatherm com pressure test submission A sample test record and set of instructions for recording in the field is also available on the submission page Chapter 5 Pipe and fittings This chapter includes all the parts that Aquatherm offers as part of its piping systems his chapter only gives the nominal imperial size so as t
114. t branch Part no Dimension ND Part no Dimension ND Part no Dimension ND 0113605 6 x6 x4 0113619 0 x 8 x6 0113635 10 x 10 x 6 0113641 10 x10 x8 0113655 IZ XIS KE 11 0113657 K o 0113669 14 x 14 x 10 0113671 HURK 0113684 16 x 16 x 12 01136859 16 x 16 x 14 01136999 18 x 18 x 14 0113700 18 x 18 x 16 Mechanically stabilized with a faser composite layer in the center of the pipe 0113546 220121 0113568 A 0113547 1 XT he 0113570 212 212 2 0113548 lA XTA 0113576 IK 0113550 15 x15 x1 01135 8 3 x3 x15 0113551 0113580 0113552 2 X2 XA 0113582 J x3 x2 0113554 Z2 KLA 0113584 XI 0113556 2 x2 x1 0113586 JW x3W x2 0113558 2 XZ x1 hh 0113588 QUOS SUN 0113560 2x2 x15 0113590 32 0113561 0113592 A xA x2 Ve 0113562 2W x2W x 0113584 4 x4 x3 0113564 0113596 A xA x3 he 0113566 LR x2W RTH Part no Dimension ND 0113511 Ya x Va xo 0113520 M K x Ve 0113522 XA xx 0113532 xh 0113534 Wx xh 0113538 1 x A XA 0113540 1x1 xx 0113542 TM 0113544 x 1A x 25 rri gt E C o 9 e 2 H LL et TT a aquatherm green pipe Reducing Tee Socket 74
115. t tighten the welding heads for be faulty Use a contact thermometer if you are unsure full contact Full contact will ensure uniform heating of the welding head 5 m 7 a o lt Socket fusion heating and cooling 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 diameter Aquatherm pipe based on flow rate Column B Metric OD in mm This is the manufactured size of the pipe Column C Actual OD in inches This is the actual size of the pipe in inches Use this for sizing clamps and penetrations 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 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 When using SDR 11 non faser pipe in small sizes 12 amp 34 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 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
116. t strength and integrity of fused connections thrust blocking is never required in buried applications Noise generation Due to the natural noise attenuation and the ability to absorb forces of water hammer the flow velocity of Aquatherm pipe can be higher between 8 and 14 ft s based on size 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 R s 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 Best IPS fit 227 IPS 12 74 IPS 1 1 IPS 1 114 CTS 14 132 118 1 2 201 23 Lye 2 212 53 3 CTS 5 3 4 IPS 4 47 BIS EU 6 6 IPS 6 en 8 CTS 8 107 10 CTS 107 12 123 GEV 4 36 UV protection and painting UV radiation can damage and weaken PP R chains over time 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 install them Installation Aquatherm offers Its pipes with an extruded UV protective layer his upgrade 15 ideal for UV protection because It does not require maintenance However extra
117. tem malfunction test of 8 760 hours 1 year at 230 F This does not mean the piping Is intended to be operated at this condition but rather that it can withstand temperatures above 180 F were this to occur due to a boiler malfunction This allows Aquatherm pipe to be connected directly to a boiler in many cases 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 safest to complete all heat producing connections such as soldering 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 Connecting to a boiler 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 34 PP R fitting or pipe 18 from a 1 or 14 PP R fitting or pipe 20 from a 172 PP R Pipe fitting or pipe 22 from a 2 or larger PP R fitting or pipe For additional safety use a water
118. 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 Dimension ND OD x Wall thickness in mm 4 125 x 11 4 Heating time Max transition time Time of pressure build up 2 min 56 sec Butt welding heating and cooling times 4 12 6 sec Welding Fusion 7 sec Cooling Cooling time 4 125 x 7 1 3 min 57 sec 7 sec 11 sec 6 160 x 9 1 3 min 24 sec 6 sec 9 sec 6 160 x 14 6 4 min 37 sec 0 sec 13 sec 6 160 x 21 9 6 min 1 sec 10 sec 19 sec 8 200 11 4 3 min 57 sec 7 sec 11 sec 8 200 18 2 5 min 20 sec 9 sec 16 sec 8 200 x 27 4 6 min 52 sec 11 sec 23 sec 10 250 x 14 2 4 min 32 sec 8 sec 13 sec 10 250 x 22 7 10 250 x 34 2 6 min 8 sec 7 min 46 sec 10 sec 20 sec 12 4315 x 17 9 5 min 17 sec 12 315 x 28 6 7 min 12 315 x 43 1 8 min 40 sec Se gt 7 c 2 22 et Butt welding heating and cooling times 74 24 Dimension Heating Welding Fusion Cooling ND 00 Heating time Max transition time Time of pressure build up Cooling time thickness in mm 1
119. the system where the pressure will be highest This reduces the risk of overpressurizing the system e Observe the joints during the test for any indications of leaks If a leak is found relieve all test pressure and repair the leak before continuing Pressure testing page 6 of 13 Step 3 continued When using compressed air e Stand clear of the pipe during testing and warn others nearby to do the same Take measures to secure loose sections of the pipe in case a rupture does occur e Do not perform the test if the ambient temperature is higher than 100 F Use water instead e Should any transition joints leak during testing check the joints for proper assembly and repeat the test using water before replacing any of the fittings avv Pressure testing page 7 of 13 Pressure testing page 8 of 13 Step 4 Perform the test Follow the steps as indicated below Use a digital pressure test gauge or an analog gauge that is accurate to within 0 5 psi Record the results on the pressure test form Preliminary test Preliminary test e Bring the system up to the test pressure The system will expand slightly once it is up to pressure Test Pressure so additional pressure may be required to help it stabilize e Once the system stabilizes observe it for 30 minutes The system should be able to hold the test pressure during that time e The loss of more than 9 psi 6 psi for SDR 176 systems or steadily decreasing pres
120. to 4 e 7312134 7112134 8 11 0112131 6 71 lt TE 74 7312138 7112138 10 O 17 7312142 12 11 7112142 12 a 7 0111175 671039 n c a 0112118 2 7312144 14 7112144 14 e 11 0111177 6 to4 0111183 8 to 4 7112146 16 0112122 3 7112148 18 d e IS un and the 0112124 3 t tt otner IS weide 0112126 o e LL et Elbow 45 Socket Part no Dimension ND 0112508 yo 0112510 4 0112512 0112514 1 0112516 15 0112518 2 0112520 2 0112522 37 0112524 3h 0112526 4 aquatherm green pipe Elbow 45 SD Butt weld 74 Dimension ND 7312530 6 7312534 8 7312538 10 7312542 28 7312544 14 Elbow 45 Butt weld molded Dimension 74 0112530 e 11 0112531 e Dimension ND 7112530 6 7112534 8 7112536 10 7112542 12 7112544 147 7112546 18 7112548 18 Dimension ND Part no 7912130 7912134 7912138 7512142 7512144 7512146 7512148 aquatherm blue pipe Elbow 90 SD Butt weld Dimension Part no ND 7412130 6 7412134 8 7412138 107 7412142 123 E 7412144 14 7412146 16 7412148 18 7412150 7412152 22 7412154 24
121. ulation 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 free copper in the water should be tested These levels should not exceed 0 5 PPM and are considered actionable by the EPA at 1 3 PPM High levels of free copper indicate that the copper pipe 15 eroding due to system and or water conditions LCV 222 PP R to copper transition fittings To facilitate transitions to fixture units or copper components Aquatherm 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 Aquatherm s 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 PP R to copper transitions are available in 1 7 34 and 1 sizes Aquatherm piping 15 required to pass a sys
122. ve a 0111018 28 0111238 2 10197 o 0111020 2 0111240 2 to1 0111022 3 0111242 2 V to 2 E Ji 0111024 35 0111252 Jor to 0111026 4 Butt weld reducer Cross Bushing Part no Dimension ND Dimension ND Dimension Dimension Dimension Part no Part no Part no 0111130 1 to 1A 0111155 3 4 to 2 ND ND ND 0111131 2 to 111 225022 0111185 9 to 6 2511184 9 to 6 217211 20 to 16 0111132 2 to 34 0111159 3 V to 3 0111189 10 to 6 2511188 10 06 2511212 20 to 18 0111134 2 t01 0111161 4 to 7 V 0111191 10 to 3 2911190 10 to 8 2511213 22810115 2 Xy 0111163 A tg 3 0111193 12 tog 2511193 12 to8 2511214 22 to 18 C9 imensi HET 2511195 12 to 10 17 6 2511215 22 to20 Part no Dimension ND 0111138 2 t011 0111165 4 tg 3 0111195 12 to 10 0 0 U 0111112 x to Y art no Dimension ND Dimension ig 10 2511197 14 to 10 2511216 24 to 16 fal 4 1072 0111143 214 to Part no 0111197 14 to 10 gt um mm 0113708 23 ND 11 0111199 11471012 2511199 14 to 12 2511217 24 to 18 5

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