Push-fit Plumbing System Installer Guide · (HD74, HD75, HD77 or HD78) should be used. Do not use a...

Installer GuidePush-fit Plumbing System

July 2009

APPROVED

PRODUCT

BS 7291

Contents

2

Page

Introduction 3 Introduction, Approvals4 Features & Benefits, Installation5 Performance, System Assembly

Basics 6-7 Pipe Selection, Standard Pipe, Barrier Pipe, Pipe Specification, Straight Lengths, Coils

8-9 Pipe Cutting10 Jointing

Standard 11-12Applications

Sitework 13-15 Cabling through Joists16-18 Pipe Support

18 Pipe Installation in Exposed Locations18 Pipe Installation in Concealed Locations19 Pipes through Walls and Floors19 Laying of Pipe in Floor Screeds19 Pipes Adjacent to Metalwork19 Piping Noise Reduction20 Manifolds/Microbore Plumbing 21 Underfloor Heating Pipe22 Routabout23 Conduit Systems

24-27 Installation Recommendations28-29 Hep2O® Within Dry Lined Walls

30 Hep2O® Within Internal Drywall Systems30-32 Hep2O® Within Timber Framed and Steel Framed

Buildings

Compatability 33-41 Metric Copper Pipe, Using Compression, Fittings, Adjacent& Connections to Capillary Joints, Imperial Copper, Chrome Plated Copper

or Stainless Steel Pipe, Incoming Service Pipe, Brass Spigots, Acorn System, Plastic Pipes, Steel pipes and Threaded Bosses, Connection to Appliances, Draw-off Taps, Ancillaries (Pumps, Valves, etc.), Storage Vessels and Radiators, Boilers and Heaters

System 42-43 Fitting Detachment, LubricationModifications 44 Alterations

General 45 Thermal InsulationInformation 45 Freezing for Maintenance/System Modification

45 Painting Hep2O®

45 Use of Corrrosion Inhibitors45 Antifreeze46 Electrical Safety46 Woodworm/Timber Treatment

Special 47 External InstallationsPrecautions 47 Vermin

47 Chlorine

Testing 48 Pressure Testing

Special 49 BoatsApplications 49 Caravans

49 Exhibitions49 Portable Buildings (site cabins, toilets etc.)50 Agricultural and Horticultural Use50 Air Conditioning Systems50 Where not to use Hep2O®

Handling & 51 Handling and StorageStorage

Hints & Tips 52 Hints and TipsFault Finding 53-54 Fault Finding

Information 55 Advisory Service55 Literature Service55 Other Sources of Information Literature

IntroductionThe mark of a professional tradesman isthat he understands and employs a widerange of materials and systems to achievethe best possible solution to individualinstallation situations.The notes in this Installer Guide areintended to assist professional plumbers toobtain the best results from using flexible push-fitplumbing, enhancing good plumbing practice.It is not sufficient to simply replace item for item, pipe length for pipelength, as this approach will not derive the maximum benefit from thesystem. It is necessary to design the system from the outset, embracing thebenefits the system offers to achieve maximum benefits.Enhanced Hep2O® flexibility means an opportunity to develop furtherskills when planning and installing plumbing, offering a comprehensive rangeof pipes and fittings to meet plumbing requirements.Greater pipe flexibility, long coil lengths and guaranteed joint performance,enables installations to be completed with fewer joints minimising systemcosts. Pipes can be cabled into position avoiding the awkward manoeuvringassociated with rigid straight lengths. Hep2O® fittings are designed toaccept copper as well as Hep2O® pipe, enabling systems to be mixed ifrequired.

Hep2O® is a tried and tested system, which has been in use in the UK forover 25 years.

ApprovalsHep2O® is manufactured and kitemarked to Class S of BS 7291, Parts 1 and 2 and is manufactured within a Quality Management System which satisfies BSEN ISO9002 requirements.

Hep2O® Barrier Pipe is covered by AgrémentCertificate 92/2823 to Class ‘S’ of BS 7291.

Hep2O® Is listed in the Water Fittings and MaterialsDirectory - Listing Number 0112066.

Hep2O® is suitable for use in domestic water distribution and centralheating systems including pressurised systems and combination boilers inaccordance with Table No. 1. It may also be used in buildings other thandwellings providing the service conditions are not exceeded.

The Hep2O® Installer Guide for Flexible Push-Fit Plumbing

3

Table No. 1 Peak Life Cycle Operating Temperatures/Pressures

20°C 30°C 40°C 50°C 60°C 70°C 80°C 95°C Short Malfunctionat 114°C

Safe pressures:

Bar 12 11.5 11 10.5 9 8 7 6 3

psi 174 167 160 152 131 116 102 87 43.5

Head of water (m) 120 115 110 105 90 80 70 60 29

BS 7291

1

APPROVED

PR�O�D�U�C�T�

Hep2O® has a minimum design life expectancy of 50years provided the system is installed in accordancewith the manufacturer’s recommendations. Theserecommendations include service temperatures andpressures. Peak life cycle operating temperatures /pressures are given in Table No. 1. As a result of itsrigorous Quality Management Programme Wavin offer a 50 year guaranteeagainst defects in materials or manufacturing of all Hep2O® pipe andfittings.

Features and BenefitsHep2O® has evolved over 25 years to offer improved installationadvantages, whilst maintaining proven long term performance benefits.Flexible pipe work and joint security are the key features of Hep2O®.

Pipe flexibility in conjunction with straight coils in SmartPackTM

dispensers enables pipe to be cabled into position, with fewer joints,minimising system costs. The Hep2O® fitting incorporates a high integritygrab wedge and robust pre-lubricated ‘O’ ring, offering the installersmoother pipe insertion and lower jointing forces.The re-usable grab wedge gives reliable jointing even when the fitting hasbeen dismantled and reassembled.

InstallationHep2O® introduces a new flexibility for the professional to exploit duringinstallation.

4


Cabling Ability Less Jointing Low Wastage

Measure and Cut In-situ

High Resistance toImpact

Rotatable Fittings

Easier Handling Less Risk Jointing, NoNaked Flame

PerformanceOnce installed Hep2O® offers considerable benefits over traditionalrigid systems.

5


No Scale Build-up No Burst Pipes Quieter

Cool to the Touch Solder Free Corrosion Free

1

System AssemblyIn skilled hands the flexible Hep2O® plumbing system guaranteesprofessional sitework.

Basics

6

Pipe SelectionHep2O® pipe is manufactured as two types, Standard and Barrier.

Their correct applications are as follows:-

Standard PipeStandard pipe is suitable for domestic hot and cold water services andheating applications. As standard pipe may allow the ingress of minuteamounts of oxygen molecules through the pipe wall when used for heating asuitable inhibitor (Sentinel or Fernox MB1) should be used.

Barrier PipeBarrier pipe is designed for central heating systems and incorporates anoxygen barrier to inhibit oxygen permeation. The use of inhibitors withbarrier pipe is still recommended as corrosion can occur in all types ofsystem regardless of pipe material.

Barrier pipe may be used for domestic hot and cold water services.

Both Hep2O® Standard and Barrier Pipe is accepted by BritishGas/ Scottish Gas Central Heating Care Contracts.

Pipe SpecificationThe 15mm, 22mm and 28mm pipe is available in straight lengths and coils.The 10mm pipe is only supplied in coils. Availability is clearly shown inTable 2 (see page 7).

Straight LengthsStraight lengths of Hep2O® are not rigid, and are as flexible as coiled pipe.Straight lengths are primarily for exposed pipework where neatness isimportant or for use where only short lengths are required.

CoilsCoiled Hep2O® is primarily suited to ‘first fix’work on site, where minimal pipe jointing isdesirable. Hep2O® is available in straight coils, inSmartPackTM dispensers.

Unlike other forms of coiled plastic pipe,Hep2O® does not tend to return to itscoiled state when uncoiled for installation.Hep2O® straight coiled pipe has a tendency toremain straight when uncoiled with no loss of flexibility.

Hep2O® Pipe in Pipe System incorporates Hep2O® Barrier Pipe in apre-sheathed conduit ready for underscreed installation, saving time, effortand complies with current regulations.

Note:Hep2O® pipe is not suitable for the conveyance of gas.

7

Basics

2

Table No. 2 Standard and Barrier Pipe Lengths

10mm 15mm 22mm 28mm

Straight Lengths

3m � � �

6m � � �

Coils

25m � � �

50m � � � �

100m � �

Pipe in Pipe

25m �

50m � � �

� Cut LengthStandard and BarrierStraight Cut Lengths.

� Standard Straight Coiled PipeStraight Coiled Lengths in SmartPackTM Dispenser.

� Barrier Straight Coiled PipeStraight Coiled Lengths in SmartPackTM Dispenser.

� Pipe in Pipe SystemHep2O® Barrier Pipe in Blue or Red Conduit.

Basics

8

Pipe CuttingBasic Jointing/Pipe CuttingWhen cutting Hep2O® pipe it is essential to use the correct tools.

Only the recommended cutters as shown in the current trade price list(HD74, HD75, HD77 or HD78) should be used. Do not use a hacksaw. (Figure No. 1)

Before making a joint ensure the pipe end is clean, cut square and freefrom burrs and surface damage. (Figure No. 2). Place the pipe in the jaws ofthe cutter and apply pressure, the pipe should be rotated whilstmaintaining the pressure until the pipe is severed. (Figure No. 3)

Figure No. 1

Do not use a hacksaw to cutHep2O® pipe.

Figure No. 2

Do not use damaged pipe. Ensure pipe is free from burrsand surface damage.�

DON’T

DON’T

�

To ensure adequate insertion, essential for a secure joint, cut the pipesquare at one of the cutting/insertion marks ‘ ’. The distance betweenthese marks indicates full socket depth (Figure No. 3).

V

Figure No. 3

When it may not be possible to use the ‘ ’ marks eg. badly lit areas,jointing copper pipe or where an exact length is required, mark theinsertion depth on the pipe using a pencil or suitable marker pen. Thecorrect insertion depth can be obtained by holding the pipe against thefitting or by measuring with a rule, as shown (Figure No. 4). The depthof insertion is shown in Table 3 at the end of this section.

V

Basics

Pipe Cutting cont.

9

Pipe depthinsertion marks

Pipe depthinsertion marks

Insertiondepth

Figure No. 4

Hep2O®

SlimLine FittingHep2O®

Demountable Fitting

Support SleeveALWAYS insert a Hep2O® support sleeve into the Hep2O® pipe end.(Figure No. 5).

It is essential to use a support sleeve in order to make a good joint. The support sleeve ensures that the pipe retains a circular section andprovides a leading edge to the pipe for easier insertion (the onlyexceptions to this rule are when using copper pipe, or the open spigotend of a Hep2O® fitting).

Table No. 3 Correct insertion depths forDemountable and SlimLine Hep2O® fittings

Pipe size Nominal insertion Depth inc. sleeve

10mm 23mm

15mm 28mm

22mm 31mm

28mm 40mm

Insertiondepth

2

Figure No. 5

Note:Support sleeve is an integral part of the system andshould NEVER be omitted when using Hep2O® pipe.

JointingProcedure - whichever type of fitting is used, the same jointingprocedure should be used. All fittings are pre-lubricated.

Figure No. 6

Use only purpose designed pipecutters. (HD74, HD75, HD77 orHD78) Cut the pipe at one of the‘ ’ marks. Ensure the pipe end isfree from burrs.

V

Figure No. 7

Insert a Hep2O® support sleeve(HX60) into the pipe end.

Figure No. 8

Push the pipe firmly into the fitting.A secure joint has been made whenthe end of the cap has reached thenext ‘ ’ mark on the pipe.

V

Figure No. 9

Tug back on the pipe to ensure thegrab wedge engages correctly.

��

DO� Use only Hep2O® cutters when cutting the pipe.� Cut the pipe at the ‘ ’ marks wherever possible.� Mark the pipe if not possible to cut to a ‘ ’.� When cutting rotate pipe whilst maintaining the pressure until the pipe

is severed. � Cut the pipe squarely.� Ensure pipe end is clean, free from burrs & surface damage.� Always use a support sleeve into a Hep2O®‚ pipe end.� Push the pipe and fitting together firmly.

DON’T� Use a hacksaw to cut the pipe.� Slacken the retaining cap prior to pipe insertion, this will not ease

jointing.� Knock fittings onto pipe.� Undo retaining cap after pipe insertion.

Basics

10

VV

Hep2O® is suitable for most domestic and commercial plumbingapplications.

With it’s extensive range of fittings, Hep2O® meets the requirements ofmodern systems ensuring secure connection.

Standard Applications

11

3

Figure No. 10

Wash Hand Basin 15mm

Figure No. 11

Wash Hand Basin 10mm

Figure No. 12

Bath

Figure No. 13

W.C.

Standard Applications

12

Figure No. 14

Sink

Figure No. 15

Boiler Connections

Figure No. 16

Cylinder Cupboard

Figure No. 17

Cylinder Cupboard

Figure No. 18

Washing Machine/Dishwasher

Cabling through Joists The 1992 Building Regulations Approved DocumentA allows for pipework to be installed in joists byone of two methods, notching or drilling.Traditionally joists have been notched and thepipework laid in as the rigidity of the pipedoes not easily allow for any other method ofinstallation. This means that the pipework mustbe installed prior to the floorboards being laid.

This has a number of disadvantages:� Plumber has to work on open joists increasing

risk of accident or injury.

� Plumber will have to return after floors are laid to connectradiators, etc.

� Plumber often finds that on his return, tails he left have been movedby other tradesmen thereby causing extra work to repositionpipework correctly for radiators.

Cabling through joists means pipework can be installed by working frombelow allowing exact positioning of ‘tails’ through floor.

Site safety is therefore enhanced and the plumber is not exposed to thedanger of falling or the discomfort of kneeling on open joists. Other tradesworking below are protected from the dangers of falling tools, molten solder,gas bottles etc.

As flooring can be laid prior to the plumber carcassing from below this willprogress the building schedule as other trades can work on the floor abovee.g. to form studwork etc.

Carcassing at a later stage in the construction programme is also morepleasant as the building is likely to be weatherproof.

Less Risk to Health and Site SafetyThe unique Hep2O® fitting ensure effective, leak-free pipe jointing withoutthe use of a naked flame.

Safety from fire, especially in restricted spaces, is greatly increased and theworking environment is improved. There is no need for flux and solder, thus eliminating any potentialcontamination of water supplies.

Push-fit jointing also has the following advantages for the installer:� No naked flame means that precautions such as obtaining a ‘hot work’

permit, having a fire extinguisher readily available, and remaining on sitefor a while after jointing are not necessary.

� No risk of infringement of Health and Safety recommendationsapplicable to some brands of flux. eg. means to control exposure tonoxious fumes when working in a confined space, and use of eyeprotection (where appropriate).

� After jointing the fitting is clean and safe to touch eg. after soldering joint, is hot and flux traces should be removed.

� Joint is rotatable after installation.

Sitework

13

4

Cabling through Joists cont.SummaryFlexible plumbing means that the installer can cable pipework more easilyutilising continuous runs of pipework. The flexibility does away with dryruns as the pipe can be cut and joints made in situ. As no solvents are usedin jointing, the system can be tested as soon as the installation is finished.Exposed pipework should use the recommended clipping distances asshown in Table 4 (see page 17).

Tails fitted through the floor for connections to sanitary ware can be leftlong enough for final connections. Straight connections and offset connections normally required for rigid connections are then unnecessary.Hep2O® can be trimmed to length and the natural flexibility used toovercome any mis-alignment.

The Hep2O® system incorporates a comprehensive range of spigot tees.These can be used individually or in groups to give manifold arrangementswith the benefit of 360 degree rotation.This facility means that systems based on conventional UK design can beenhanced by the addition of manifolds where beneficial.Joists can be drilled and pipework cabled through, rather than notchedwhich is the normal practice with rigid pipework systems. (This ispermitted by Building Regulations, NHBC Standards and several BritishStandards). This means that pipework no longer needs to be installed priorto floorboards being laid.The ability to install pipe through joists has specific advantages:Often eliminating the need for separate carcassing and second fixoperations.

When Hep2O® is cabled through joists it can be easily positioned to allowfor the installation of thermal insulation if required. Pipework can beexactly positioned for the radiators etc. avoiding the risk of being moved ordamaged by other trades. Safer working environment for all trades asupstairs floors are already in place. It is safer for the plumbing installer asthe drilling can be carried out from the floor below. There is less danger ofpuncturing the pipe with nails used for fixing the floorboards and there isno need to use protective devices such as ‘joist clips’.

Sitework

14

Note:

The Building Regulations 1992 Approved Document A gives exact instructions on the drilling of floor joists. Those regulations are detailed below:Hole diameters should be no greater than 0.25 of the depth of thejoist and should be drilled at the neutral axis. They should be not less than 3 diameters (centre to centre) apart andshould be located between 0.25 and 0.4 times the span from thesupport.These points are illustrated in Figure No. 19 (see page 15).

The value 0.25 is obviously one quarter and can easily be calculated onsite. The value 0.4 is less obvious and can be obtained from Figure No. 20(see page 15).

Sitework

15

Cabling through Joists cont.Engineered JoistsHep2O® is ideal in buildings incorporating timber ‘I’ joists. Piping can beproperly installed through holes in the web sectionwithout damaging flange members (eg. TJI Joist system, Trus Joist MacMillan Ltd.)even where the pre-formed holes do not alignon the plan. Pumps, Valves etc:

Where Hep2O® is connected to pumps,valves and similar devices considerationshould be given to adequately supporting theitem in question (bearing in mind the rotatabilityof the Hep2O® joint). Equipment should not besuspended from the pipe without adequate support.

HOLES SHOULD BE�LOCATED IN THIS�ZONE & DRILLED AT�THE NEUTRAL AXIS.

CENTRAL AXIS�OF JOIST

SPAN S �

NOT LESS THAN 3 DIAMETERS�APART CENTRE TO CENTRE.

MAX. DIAMETERS OF HOLES =�0.25 X DEPTH OF JOIST.

DEPTH.

0.4 x ‘S’�

0.25 x ‘S’�

1.5

0.5

1.0

1.5

2.0

2.0 2.5 3.0 3.5Span of Joist (m)

Maximum Distance from Support

Distance from Support (m)

Minimum Distance from Support

4.0 4.5 5.0

Figure No. 20 Graph Showing Dimension of Joist Drilling Zone from Support

Figure No. 19 Explanation of Drilling Joists in Accordance with Building Regulations 1992 - Approved Document A

NB: The minimum distance between a hole and a notch in the same joistshould not be less than 100mm.

Notes: This graph should be used in conjunction with Figure No. 19.

Example of use: Joist span is 4.5m.

Find value on horizontal scale and read-up to sloping line.

Transfer point of intersection to the vertical scale and read 1.8m.

4

Sitework

16

Pipe SupportThe Hep2O® system includes two types of pipe clip, the screw fix type(HX85) and the nail type (HX65). The nail type is primarily designed for useon concealed pipework, and allows for rapid fixing to timber. The screw typemay be used together with a spacer (HX86) which allows a greater spacingbetween the pipe and the fixing background. The spacer therefore allowsdifferent pipe fixing centres which can be used to facilitate pipe cross-oversor the installation of thermal insulation to the pipe (see Figure No. 22). Acold forming bend fixture (HX75) is available to allow the formation of abend on 15mm and 22mm pipes for situations where secure fixing andneatness are important. (See Figure No. 23).

Code Nominal Diameter

HX65/10 10

HX65/15 15

HX65/22 22

HX65/28 28Pipe Clip - Nail

Figure No. 21 Pipe Clips


HX85/15 15

HX85/22 22

HX85/28 28Pipe Clip - Screw


HX86/15 15

HX86/22 22

NB: The HX86/22 spacer can be used with both the HX85/22 and HX85/28 clip.

Pipe Clip - Spacer

CLCL

CL

A

B

Note: Fixing hole size is 5mm diameter.

Nominal Diameter Dimension A Dimension Bmm mm mm

15 17 40

22 21 43

28 24 46

Figure No. 22 Pipe Fixing Centres

Pipe Clip Pipe Clip and Spacer

The recommended support distances for general purpose use areshown in Table No. 4.

Where piping is adequately supported or is run within concealedspaces (eg. through suspended timber floors) clips can be reduced oromitted provided that:� Pipe does not form part of an open vent provided for safe operation of

heat source.

� Pipe does not form a distribution pipe or circuit where effective airventing might be impaired by poor pipe alignment.

� Hot pipe will not touch cold pipe or vice versa.

� There is no risk that pipes or fittings will come in contact with sharp,abrasive or other potentially damaging surfaces.

� There is no risk pipe will come in contact with materials which maysuffer damage or discoloration from transmitted heat.

Sitework

17

Pipe Support cont.

A

Fixing hole size is 5mm.Suitable for a No. 10woodscrew

Nominal Diameter mm Radius A mm

15 120

22 176

Figure No. 23 Cold Forming Bend Fixture Radii

Nominal Diameter Horizontal Runs Vertical Runsmm m

10 0.3 0.5

15 0.3 0.5

22 0.5 0.8

28 0.8 1.0

Table No. 4 Recommended Clipping Distances

For improved visual appearance support distances of 300mm aresuggested for Hep2O® in exposed locations.

NB: Where the pipe is concealed clipping may not be considerednecessary. Cable ties may be used for restraint.

The cabling ability of Hep2O® enables easy installation through noggins,studs etc., and in internal plasterboard/studding walls. Simply carried out,with tails left exposed prior to the plasterboard being installed, this isespecially useful for ‘microbore’ plumbing (see page 20).

4

Sitework

18

Partition systems on the market have the built-in facility for cablingelectrical wiring and this can be utilised for Hep2O® pipework.

Bending Radius:Hep2O® pipe can be easily manipulated by hand to form bends of anyangle. In order to prevent any long term detrimental effect on thematerial, the curvature of Hep2O® pipe should be not less than shownin Figure No. 24.

Pipe Support cont.

Figure No. 24 Minimum Bending Radii (8 x pipe diameter)

A

Nominal Diameter mm 10 15 16 20 22 28

A mm 80 120 128 160 176 224

Pipe Installation in Exposed LocationsHep2O® pipe expands as temperature increases causing it to undulatealong its length. This can be visually unacceptable in the case of long exposedruns. Long runs of exposed pipe are unusual in new build where pipework isgenerally concealed, but may occur in refurbishment.

� If the pipework is exposed there are a number of options open to theinstaller to ensure that a neat, tidy job is achieved:

� Hep2O® pipework, if exposed, can be boxed in (PVC-U trunking or preformed plywood profiles are generally used).

� Long runs of exposed Hep2O® may be unsightly as a result ofexpansion and therefore the installer may choose to use copper pipe inthis instance.

Pipe Installation in Concealed LocationsHep2O® pipework can easily be installed in concealed locations in floors,roof spaces etc. Any expansion which may occur will have little mechanicaleffect, this being absorbed within the pipe length as undulation which may beignored. Undulation of Hep2O® pipe which may occur naturally as a resultof expansion, or installation through joists, will not lead to airlocks.Installation in difficult locations is aided by the cabling ability of Hep2O®

pipe. If adequately supported, Hep2O® in concealed locations needs only tobe clipped for system alignment e.g. at changes in direction.

Where convenient, cable ties can be used to restrain pipes for systemneatness (care should be taken not to overtighten the tie.) The pipe shouldbe able to slide freely through the tie to facilitate thermal movement.

Pipes through Walls and FloorsWhenever Hep2O® passes through brickwork, stone or concrete the pipeshould be sleeved. The annular gap between the pipe and the sleeve shouldbe filled with a resilient material to provide effective fire stopping andprevention of noise transmission from one room to another.

Laying of Pipe in Floor ScreedsUnlike metal pipes Hep2O® is not affected by cement, limes, mortars,concrete and general corrosion. However, account should be taken of therequirements of the Water Byelaws which require distribution pipework tobe accessible - facilitating its removal and replacement. (See page 23 conduit system).

Pipes Adjacent to MetalworkWhen running Hep2O® adjacent to or through metalwork, it isimportant to ensure that the pipe cannot make contact with any sharpedges as this could cause damage during thermal movement. Any ofthe following preventative measures would be acceptable:

� For a pipe passing through a small hole drilled in metalwork, fix aresilient grommet in hole.

� For a pipe passing through a large hole in metalwork or adjacent toa sharp edge, fix an extruded flexible profile to metalwork.

� Provide sufficient local pipe clipping to prevent contact between pipeand metalwork.

� Run pipe within a conduit.

Piping Noise ReductionProblems with noise are frequently experienced with systems incorporatingrigid pipes. Hep2O® pipe does not transmit noise and with carefulinstallation to reduce the source of noise to a minimum, Hep2O® can beinstalled to run almost silently. For example:� Noise can be caused by friction between a pipe and an adjacent or

surrounding material, this often occurs with rigid pipes installed beneathtimber or chipboard flooring. The use of Hep2O® can greatly reducethis effect. Holes should be drilled through joists (see this section page13) of sufficient diameter to allow Hep2O® pipe to slide freely. This willprevent any friction between underside of floor, and more importantlyavoid ‘ticking’ and creaking normally associated with thermalmovement of rigid pipes.

� Noise can be caused by pipes knocking together or knocking on hardsurfaces in close proximity. Unlike rigid pipes, the inherent elasticity ofHep2O® would cushion the impact causing less impact noise andabsorbing vibrations, preventing the transmission of any sound along pipe.

� Similarly noise from ‘water hammer’ resulting from abrupt stoppage ofwater flow (typically by closure of quarter turn valves, solenoids andreverberating ball valves) is normally absorbed by Hep2O® and is nottransmitted along pipes.

NB: Noise generated by central heating pumps is rapidly absorbed by pipesand can be significantly reduced when compared with rigid systems.

19

Sitework

4

Manifolds/Microbore PlumbingHep2O® Manifolds are designed for use onmicrobore central heating systems and can alsobe used for hot and cold water.

The Hep2O® Manifold in one fitting bringstogether multiple 10mm pipe connections onthe flow or return pipework to one area of abuilding, enabling easy access when used inconjunction with the Hep2O® Routaboutsystem. Thus providing instant access below sheetflooring installations for future system modificationsor extension.

A comprehensive range of Hep2O® Manifolds is available (Figure No. 25)and these manifolds can be connected in series allowing any number ofoutlets.

Installation and Performance Benefits� The Hep2O® 2 Port and 4 Port Manifolds provide a cost effective way

of connecting 22mm pipe to 10mm pipe as they reduce the number offittings required.

� Fewer fittings reduces installation time.

� One of the main advantages of the new Hep2O® Manifolds is that theyare manufactured from polybutylene, an extremely robust yet lightweightmaterial and are therefore, much easier to install.

� The lightweight Hep2O® polybutylene manifolds enable the pipe to besuspended between joists without fear of dragging the pipe down.

� Blanking Pegs can be used to close off any unused sockets.

20

Sitework

Figure No. 25

Hep2O® Manifold Range

Underfloor Heating SystemsHep2O® Underfloor Heating Pipe is designed foruse in underfloor central heating systems. It issupplied with an oxygen diffusion barrieroffering maximum protection against oxygeningress.The design of the barrier within the wall ofthe pipe offers significant advantages overunderfloor pipes with an external coating.Hep2O® Underfloor Heating Pipe is available in16mm and 20mm diameters, in a variety of coillengths (Table 5).Hep2O® Underfloor Heating Pipe is manufactured principally frompolybutylene (PB) which is more flexible than other materialscommonly used for underfloor heating, such as crosslinkedpolyethylene (XLPE) or polypropylene (PP). The inherent flexibility ofpolybutylene allows sub-floor heating circuits to be installed quicklyand easily without the use of tools or heat sources. Hep2O®

Underfloor Pipe is available in a variety of coil lengths, enabling theinstallation of long continuous circuits, with minimal pipe wastage.Hep2O® Underfloor Heating Pipe is corrosion resistant andunaffected by corrosion inhibitors when used as recommended by themanufacturer.For further information on Hep2O® Underfloor Heating Systems visitwww.hep2O.co.uk

21

Sitework

4

Table No. 5 Underfloor Heating Pipe Lengths

16mm

60m �

80m �

100m �

150m �

200m �

500m �

Figure No. 26 Figure No. 27

Sitework

22

Hep2O® Routabout Hole Cutter This unique system solves the problem of underfloor access found by allbuilders, plumbers and other trades. A 250mm diameter opening can becut and made good in minutes. Designed for use in new or existing 18mm& 22mm chipboard or similar floors, the Routabout cuts only thethickness of the board, thus leaving no waste and the piece cut out isused to make good the floor.

You will also need:� 1 x 1/4 inch or 1/2 inch collet to fit a medium sized plunging type

router (not supplied).

� 1 x 30mm (outside dia) guide bush - fitted to router (not supplied).

� Router (750 watts or above).

� Routabout rotating template.

Routabout

Figure No. 28

� Router

� Tungsten router cutter

� Routabout rotating template

� Routabout spacer ring

Figure No. 29

� Routing the flooring sheet using the Routabout rotating template.

Figure No. 30

� The routabout spacer ring provides access in the floor sheet to the pipework.

Figure No. 31

� The chipboard cutout fits snuggly into the spacer ring, leaving a neat access.

Conduit SystemsThe Hep2O® Conduit system allows pipe andfittings to be installed directly into concretefloors or into walls whilst complying with therequirements of the Water Regulations.

The flexible conduit allows Hep2O® to bewithdrawn for inspection, and junction boxesallow maximum accessibility to fittings forinspection and possible removal.

To allow pipework to be easily replaced or terminated in the future onlyDemountable fittings should be used within the junction boxes. Hep2O®

22 x 10mm manifolds can be used in conjunction with spigot tees in 22x 15mm and 15 x 10mm sizes to build up various manifoldconfigurations. If any bent sections of conduit pipe are formed in aninstallation then future replacement of the Hep2O® is likely to requirethe use of a ‘draw cable’.

In this event the draw cable should be attached to one end of theHep2O® before it is pulled out from the other end. Replacement of anew section of Hep2O® pipe may require two operatives; one pullingthe draw cable which is attached to the pipe end and the other personfeeding-in the new length from the opposite end. Future replacement willbe easier if conduit bends are kept to a minimum and any radius kept aslarge as practicable.

The system consists of two sizes of flexible conduit, junction boxes withlids and terminal fittings.Holes can be cut in the sides of the junction box at the appropriateposition to accommodate the conduit which simply clicks into position.

Hep2O® Conduit Pipe is available in the sizes shown in Table No. 6.

Hep2O® Pipe in Pipe System (Figure No. 32) incorporates Hep2O®

Barrier Pipe in a pre-sheathed conduit ready for underscreed installation,thus allowing the installer to save time and effort whilst complying with the

current regulations. Hep2O® Pipe inPipe is available in the handy sitemanagable coil lengths shown in Table No. 6. The Pipe in Pipe systemis available in red and blue conduit toaid the identification of the pipe.

23

Sitework

Figure No. 32

Pipe in Pipe Coil

4

Table No. 6 Conduit and Pipe in Pipe Lengths10mm 15mm 22mm 28mm

Conduit Pipe (Black Conduit)

25m � �

50m � �

Pipe in Pipe (Red and Blue Conduit)

25m �

50m � � �

377mm

Sitework

24

Note:

Central heating pipework should not be run within thesame junction box as cold water pipework unless there issufficient space to fix adequate thermal insulation, inorder to prevent the warming of cold water.

202mm

End Section

SideSection

Plan

Figure No. 34Junction Box Dimensions

Figure No. 35Cut Junction Box

N.B:1. All dimensions are nominal.2. Lid recess is designed for 8mm thick plywood.

Installation RecommendationsThe Hep2O® pipe should be fed into position atthe same time as the conduit system is installedi.e. before screeding. The conduit system shouldnot be installed on sub-floors a long time inadvance of screeding as damage by site trafficcould occur.

The junction box is designed to gain access topipe fittings, and to allow pipe cross-overs (whichare normally undesirable within the floor screedmaterial). Dimensions are shown in Figure No. 34.

If required the junction box can be cut in half and installed up against a wall(Figure No. 35).

The junction box should be drilled using a hole cutter or spade bit, toallow the conduit to fit snugly and click into position to protrude not less

than 5mm inside the box. Conduitpipe OD’s are shown in Table No. 7.

NB: The prevention of cold waterbecoming warm is a WaterRegulations requirement.

Figure No. 33Conduit Junction Box HX100

170mm

Junction Box cut inhalf and secured tosub floor

Junction Box Lid

Hep2O pipe toradiator orsanitary appliance

Hep2O elbow

160mm

75mm

75mm

340mm

165mm

150mm

322mm

The junction box should be fixed to the sub-floor (in order to preventmovement or ‘floating’ during screeding) the fixings should be provided withsuitable washers. The junction box should be fixed so that the lid (whenfitted) will be level with the adjacent floor finish. For uneven sub-floors or where the screed depth exceeds the junctionbox height, the box should be provided with suitable packing supportunder the base.

25

Sitework

Installation Recommendations cont.Table No. 7 Drill Size for Conduit Box Holes

Hep2O Size Conduit Code Conduit(mm) OD (mm)

10 & 15 HXC25/15 - HXC50/15 - HXXC50/10 - HXXC50/15 25

22 HXC25/22 - HXC50/22 - HXXC50/22 34

28 HXXC25/28 42

4Figure No. 36 Typical Section Showing Junction Box Installed on

Hot and Cold Water Distribution Pipes at Tees

Finishedfloorlevel

ConduitPipe

Junction boxsecured to thesub-floor

Tee on coldwater pipe

Tee on hotwater pipe

Junction box lid,drilled and securedby fixing screws

Small insulatingpad, cut andplaced toseparate pipesat cross-over

Thermal insulationbarrier formedacross junction box.(if necessary).

Remember:

No thermal insulation would be necessary where thejunction box is used solely for central heating pipes.

To facilitate the possible removal and replacement of Hep2O® within theconduit system, conduit pipe should be installed without joints and shouldideally run in straight lines between junction boxes. Where bends areunavoidable there should be not more than two changes of directionbetween adjacent junction boxes.

Conduits carrying cold water pipes should not touch conduits carrying hotwater or central heating pipes. When running conduits within floor screeds the recommended gap betweensuch conduits should not be less than 50mm (see Figure No. 37, page 26) inorder to prevent the warming of cold water.

The conduit system should not contain unused water pipes which remainconnected to water systems. Redundant pipework will result in waterstagnation which would pose a risk to health.

Sitework

26

Installation Recommendations cont.

HX101/1515mm Conduit Terminal

HX103ATerminal Fitting Plate

Figure No. 38 Conduit Terminal Fittings

HX103Terminal Back Plate

Conduit pipes should be fixed to the sub-floor by using suitable straps toprevent movement. Conduit pipes for cold water systems should not berun in floor screeds which incorporate underfloor heating ‘loops’.

For terminating the conduit pipe at wall and floor finish level for direct15mm connections to appliances, a conduit terminal fitting is available(HX101/15). For floor terminations the plastic housing may be drilledthrough the base to allow fixing. Floor termination procedure is shown inFigure No. 39.

Figure No. 39 HX101/15 Conduit Terminal Installation Procedure

Figure No. 37 Minimum Spacing for Cold Water Conduit in Floor Screeds

Conduit for cold water pipe Conduit for hot water or central heating pipe

50mm

(min)

4

27

Sitework

Installation Recommendations cont.For wall terminations two alternative fixing plates are available. The HX102 Terminal Fitting Plate and HX103 Terminal Back Plate, shown inFigure No. 38. The HX103 can be used to mount two terminals side byside (Figure No. 40), or it can be easily split to form two single plates.The HX103 Terminal Back Plate can also be used to fix a maximum offour Wall Plate Elbows. (Figure No. 41).

Figure No. 40HX101/15, 15mm Conduit Terminal and HX103 Terminal Back Plate

Figure No. 41HX103, Terminal Back Plate and HX6/15 Wall Plate Elbow

Figure No. 42 Installation of HX102 Terminal Fitting Plate and HX101/15, 15mm Conduit Terminal

Hep2O® Within Dry Lined Walls

Installers have found that feeds to radiators run in microbore copper can beaccommodated behind ‘dot and dab’ plasterboard to give a pipe-freeappearance within the room. Pipes run in 10mm Hep2O® are equally suited to this application but will not be susceptible to damage such asdents or kinks which can be caused on ‘soft’ copper by followingtradesmen. The penetration through the plaster board for a radiatorconnection can be achieved by using a 10mm SlimLine elbow (HX5/10)together with a Fitting Clip (HX84/10 see Figure No. 44) or alternatively adry lining box can be used (see Figure No. 46).

Another method when using 10mm Hep2O® Pipe is to utilise the HX111or HX113 Radiator Outlet Cover Plates. The Cover Plates (HX111 &HX113) and Radiator Outlet Back Box (HX109 Plastic, for stud wall;HX110 Metal, for solid wall) allow for a superior and easy to install methodof connecting radiators. The box is fixed in a central position behind theradiator with the 10mm pipes dropping out to the radiator valves. This givesa smart professional finish where little or no pipe is seen and for new buildprovides an anchor point for the pipe work prior to plastering/boarding.

28

Sitework

Figure No. 43 Installation procedure of HX111 Cover Plate

Sitework

29

For fixing pipework to lightweight blockwork the HX65 pipe clip is notsuitable for fixing directly to such walls because ofthe low pull-out resistance of the nail. In suchcircumstances a more secure hold can beachieved by fixing wooden dowels at eachclip position. The dowels should be the solidtype with a serrated surface and of sufficientsize (not less than M8 x 30mm).

Holes should first be drilled in the blockworkusing a drill bit size which provides a tightfitting hole for the dowel, taking care not to over-drill the hole depth. After tapping in the dowels the pipeclips can then be fixed by knocking the nail into the centre of each dowel.

Figure No. 44 10mm Fitting Clip (HX84/10)

Two 5mmfixing holes,one eachside

Figure No. 45 Radiator Pipework in 10mm Hep2O®

Within Dry Lined Walls

ThermostaticRadiator Valve(HX71/10)

Skirtingboard

90° M & FElbows (HX4/10)

90° M & FElbow (HX4/10)

Pipe Clip(HX84/10)

90° Elbow(HX5/10)Radiator

Draincock (HX23/15)

The following is good practice for ‘first-fix’ pipework:� Radiator ‘drops’ should be run vertically, side by side, at one end of

the radiator position.

� Lateral pipes should be run horizontally in line with plasterboardpenetrations.

� Avoid running pipework along any obvious fixing zone ie. at skirting level.

Hep2O® Within Dry Lined Walls cont.

4

Sitework

30

Hep2O® Within Internal Drywall

SystemsHep2O® can easily be cabled within timber studwork and within wallsystems (eg. Paramount Board) during construction. This method is oftenused for running feeds to radiators or where concealed plumbing is necessary eg. supplies to a recessed shower mixer.

A connection for a radiator can be made by using a secured elbow in thewall and fixing a plastic snap-on escutcheon to neatly cover the holethrough the wall surface.

Alternatively for 10mm Hep2O® a dry lining box can be used which givesthe advantage of allowing minor alignment adjustment to the ‘tail’ during‘second-fix’ (see Figure No. 46) and allowing access to the elbow. ‘First-fix’pipework should follow the good practice advice in the text headed‘Hep2O® within Dry Lined Walls’ on this page, and ‘Pipes Adjacent toMetalwork’ on page 19.

10mmHep2O

Single socketelbow, useSlimLine type forneatness(HX4/10)

Dry lining box and cover plate(single gang electrical fitting)

Non-load bearinginternal drywall system

Demountable elbow (HX5/10)

Figure No. 46 Radiator Connection using 10mm Hep2O® and a Dry Lining Box within a Drywall

NB: This solution can also be used where the radiator is fed from belowin which case the risers should be located directly under each box.

Hep2O® Within Timber Framed and

Steel Framed BuildingsHep2O® is ideal for use within both timber framed and steel framedbuildings. For recommendations applicable to internal partition walls referto the text headed Hep2O® within Internal Drywall Systems’, on page 30.

Running pipework of any material within the external wall of framedbuildings should not be done without consideration of the following:-

� If a leak occurred on a pipe it should be discovered without delay asseepage within a wall may damage the structural frame and affect theperformance of insulating materials.

� Water Byelaws require that pipes should not be fixed in a situationwhere leaks could be undetected for long periods.

� Where a pipe passes through a vapour control layer the installationmethod should allow possible future replacement of pipe withoutaffecting the integrity of this layer.

� Pipework should be installed on ‘warm’ side of thermal insulation layer.

To comply with the foregoing criteria, pipework should be either run withina recessed duct designed by the Architect or run within a conduit system.Whichever method is used it is necessary to consider the detail at thejunction between the wall and floor to avoid floor joist problems and toagree pipe penetrations at header rails/bottom rails. For radiatorconnections, 10mm Hep2O® within conduit pipe may be used (seeFigure No. 47) The suggested installation sequence is as follows:

1. Prepare sketches showing setting-out dimensions for each dry liningbox including height and hole size.

2. Fix each conduit pipe to noggins using suitable straps or cable ties.Fixings at 1m centres are adequate for vertical conduit pipe.Horizontal runs and bends more than 45° should be avoided.

3. To allow future installation of dry lining boxes, each conduit pipe endshould be left approximately 100mm longer than box position andshould not be fixed closer than 600mm to the box.

4. Install the main ‘first-fix’ pipework leaving joints below floor accesscovers to allow connection to conduit pipework during ‘second fix’work.

31

Sitework

Figure No. 47 Radiator Connection Using 10mm Hep2O®

Within Timber or Steel Framed External Wall

15mm(nominal)Conduit Pipe

The conduitshould befirmlyterminatedwithin drylining box

Demountableelbow(HD5/10)

Dry Lining Boxand Cover Plate(single gangelectrical fitting)

Insulating material

Hep2O SingleSocket SlimLineElbow(HX4/10)

When cuttingvapour controlplasterboardcare should betaken not todisplace vapourcontrolmaterial

Plasterboard10mm Hep2O

4

Hep2O® within Timber Framed and

Steel Framed Buildings cont.

5. Using setting-out dimensions on sketches, holes in plasterboard can becut to allow each conduit pipe to be pulled out through the surfaceduring plasterboard fixing work.

6. During ‘second fix’ each dry lining box is installed by drilling a 26mmdiameter hole for 15mm (nominal) conduit pipe. The conduit can thenbe inserted through hole in box and should ‘click’ into position leavingone or two conduit ‘ribs’ inside box.

7. Slide a length of 10mm Hep2O® pipe through conduit pipe from thefloor access above. Pull out enough Hep2O® from dry lining box toallow a sufficient hand grip for jointing. Connect a demountable elbowto pipe then slide whole assembly through plasterboard hole andsecure box into position. Conduit pipe should ‘snake’ within void totake up slack leaving Hep2O® protruding out of box.

8. Pull Hep2O® pipe backwards from floor access panel until elbow iscentral within dry lining box. Cut pipe to length and connect toHep2O® joint left during ‘first fix’.

Timber or Steel Framed Buildings - General Advice:Holes through timber joists should be drilled in accordance with FigureNo. 19 & 20, on page 15. Holes through timber studs should be drilled inaccordance with Figure No. 48.

Within steel framed buildings pipework should be routed throughpreformed holes in steelwork wherever practicable (and where provided).No holes should be formed in steelwork without the approval of theArchitect. Pipeworkpassing throughsteelwork should beprotected from damage(refer to the text headed‘Pipes Adjacent toMetalwork’ on page 19).Do not lay pipework inareas where plasterboardis likely to be fixed.

Services withincompartment or partywalls should be avoidedso as not to impair fireresistance or acousticproperties.

Care should be takenthat pipework passingthrough compartmentwalls or floors does notimpair the fire resistanceof the property.

��QQ��

��

0.25

x H

0.4

x H

32

Sitework

Hep2O® within Timber Framed and

Steel Framed Buildings cont.

Figure No. 48 Limitations of Drilling Studwork

Holes shouldbe located inthese zonesand drilled atcentre of studdepth

Maximum Diameter of Holes = 0.25 Depth of Stud ‘D’

0.25

x H 0.4

x H

Stud

Hei

ght ‘

H’

D

�

Connection to Metric Copper PipeHep2O® fittings have been designed to form reliable joints with metriccopper tube which conforms to BS EN 1057 - R520. Copper pipes shouldbe cut with a wheel cutter. Before jointing, copper pipe ends should beinspected to ensure they are free from burrs or swarf (which could damagethe ‘O’ ring). It is also possible to connect 10mm BS EN 1057 - R220copper tube into Hep2O® fittings providing the tube end is carefullyprepared. R220 copper tube is ‘soft’ and therefore susceptible to becomingmisshaped or dented if it is not handled with care on site. Therefore theR220 tube end should be inspected for any signs of damage prior to jointing,as deformity of the tube could damage the ‘O’ ring whilst jointing, orotherwise affect the joint seal. R220 tube should be cut with a mini wheelcutter, and then a chamfer should be filed on the pipe. Rinse away theremainder of any copper filings and dry-off.

NB: Mark the joint depth on the copper pipe before jointing, refer to page9.

DO� Use a wheel cutter.

� Check ends free from burrs or swarf.

� Insert copper end protector (HX61/15 & HX61/22).

� Mark joint depth on copper pipe.

� File end of pipe if using a hacksaw.

Compatability and Connections

33

Cut copper pipe usinga wheel cutter

Inspect ends toensure free fromburrs or swarf

Insert copper endprotector

Mark joint depth oncopper pipe beforejointing

Push pipe firmly intofitting

Tug back on the pipeto ensure grab wedgeengages properly

5

��

DO� Use a support sleeve when making a compression joint.

� Ensure pipe is fully inserted.

� Use PTFE tape over olive if lubrication required.

� Copper olives are preferable to brass ones.

DON’T� Use oil based jointing compounds.

Connection Using Compression FittingsHep2O® pipe is suitable for connecting to compression fittings complyingwith BS EN 1254. Cut the Hep2O® pipe with the recommended cuttersand proceed as shown below.


Insert support sleeveinto pipe

Ensure pipe is fullyinserted

Apply PTFE if required

Tightening nut

Note:

Hep2O® pipe will not rotate in a compression fittingafter tightening

34

��

DO� Keep flame or soldering irons away from Hep2O®.

�DO� Use an adaptor (HD3A/22) or imperial ‘O’ ring (HX52)

when connecting to 3/4’’ imperial copper.

Connections Adjacent to Capillary JointsWhen using Hep2O® pipe or fittings adjacent to capillary joints it ispreferable to carry out the soldering work before the Hep2O® is installed. If it is not possible to undertake the work in this sequence then the followingprecautions should be observed:

Connection to ImperialCopperWhen connecting to 3/4’’ imperial copperHep2O® offers a special ‘O’ ring straightadaptor (HX3A/22) which accepts 22mm pipeat one end and 3/4’’ imperial at the other end.Special ‘O’ rings for use with 3/4’’ imperial pipe(HX52) are available. These can be used to replacethe standard ‘O’ in Hep2O® fittings. See Re-assembling a joint (page 42-43).

(3/8’’, 1/2 ‘’ & 1’’) imperial pipes can be connected using standard Hep2O®

fittings.


35

DON’T� Allow flux to run onto Hep2O®. Flux runs inside pipe

may occur during soldering, this effect can be reducedby not using excessive amounts of flux and by applyingflux to copper tube end only.

� Allow hot solder to come into contact with Hep2O®.

Note:

Systems should be flushed with water to remove anyinternal flux residues.

Trade Tip:

To prevent overheating of Hep2O® by conduction of heat alongcopper pipe, where necessary, wrap a damp cloth around copper pipeto minimise this effect.

5

Connection to Chrome Plated Copper orStainless Steel PipeHep2O® fittings cannot be connected directly to chromeplated copper or stainless steel, because of the relativesurface hardness of these materials.Therefore the following procedures must be followed:

Chrome Plated Copper: Use compression fittings as shown on page34.

Stainless Steel: Use compression fittings as shown on page 34.


36

Note:

Do not use Hep2O® fittings directly onto Stainless Steelor Chromium plated pipe.

Connection to Brass SpigotsThe only brass spigots which are suitable for jointing into Hep2O® fittingsare those within the Hep2O® Range. Brass spigots designed for compressionor capillary joints do not have the necessary joint grooves and are too short.

Connection to the Acorn® SystemHep2O® is fully compatible with its predecessor the Acorn® systempreviously manufactured by Bartol.Pre 1984 Acorn® 22mm pipe was manufactured with a thicker wall andrequires a different support sleeve. If carrying out remedial work on such anAcorn® system please contact our Technical Advisory Service Tel: 0870 460 5578 Fax: 0870 460 5579 for advice.

Remember:

Hep2O® Pipe is fully compatible with all versions ofHep2O® Fittings.

Connection to Plastic PipesHep2O® should not be used in conjunction with other manufacturersplastics pipe and fittings as dimensional tolerances and quality control cannotbe guaranteed by Wavin.

Note:

Internal components of the current Hep2O® Fitting (Cap, BiTite GrabWedge, Wedge Support Ring and ‘O’ ring) are not in any waycompatible with original Hep2O® Fitting components (Cap, ‘O’ ring,Spacer Washer and Grab Ring) and therefore bodies and componentsmust NOT be mixed.

For further information contact our Technical Advisory Service –Tel: 0870 460 5578.


37

Connection to Incoming Service PipesWater may enter a property through a variety of pipe materials. In recentlydeveloped properties the water is typically brought to a residence in blueMDPE (medium density polyethylene) pipe. However, in renovation of olderproperties this pipe may well be made of one of a number of metals. Themethod of converting from the service pipe to Hep2O® differs dependingon the pipe material of the service pipe.The following guidance is applicable to blue MDPE Pipe to BS 6572:-

� For 20mm MDPE use a polyethylene 20 x 1/2” BSP male adaptor (Code20PEAM05) together with a MDPE pipe liner (Code 20PELIN), Hep2O®

female adaptor (Code HX30/15) and Hep2O® stopcock (CodeHX36/15). (See Figure No. 49).

� For 25mm MDPE use a Hep2O® x MDPE stopcock (Code HX43/22)together with an MDPE pipe liner (Code 25PELIN). (See Figure No. 50).Alternatively if you wish to take advantage of the rotatability ofHep2O® joints by turning the stopcock towards the wall when notin use, then proceed as follows. Use a polyethylene 25 x 3/4” BSPmale adaptor (Code 25PEAM07) together with a MDPE pipe liner(Code 25PELIN), Hep2O® female adaptor (Code HX30/22) andHep2O® stopcock (Code HX36/22). (See Figure No. 51).

NB: Details of MDPE pipe, fittings and jointing instructions arecontained in separate literature which can be obtained by contactingour Literature Service Hotline Tel: 01249 766333 Fax: 01249 766332.

Figure No. 49

Rotatable StopcockHX36/15

HX30/15

Adaptor

20mm MDPE

HX36/22

HX30/22

Adaptor

25mm MDPE

HX43/22

25mm MDPE

Figure No. 50

Non-rotatable Stopcock

Figure No. 51

Rotatable Stopcock

5

NOTES:� Where a common supply pipe serves two or more dwellings a double

check valve (Code HX72) is required directly after stopcock in eachdwelling to comply with Water Byelaws.

� A drain-cock (Code HX32) should be fitted immediately after stopcock orafter double check valve where provided to comply with Water Byelaws.

� For sealing screwed joints on adaptors apply PTFE to threads.

Alternatively a PE (polyethylene) to copper compression stopcock can be used.The information on using compression fittings on Hep2O® pipe should becarefully noted. (See page 34).

For metal pipes an appropriate stopcock should be used with a compressionoutlet to 15 or 22mm copper. Hep2O® can then be fitted directly to theseoutlets carefully noting details in Connections to Compression Fittings (Seepage 34).

Connection to Steel Pipes and ThreadedBosses In order to facilitate connection to male and female iron threads, fouradaptors (HX28/HX29 Socket Adaptors, HX31/HX30 Spigot Adaptors) areavailable in the Hep2O® range. This enables connection to a wide range ofdifferent materials. (See Figure No. 52).

Connection to AppliancesWhen connecting to appliances and dishwashers always use Hep2O®

appliance valves (HX38C/15, HX38H/15). The Hep2O® pipework used toservice these appliances should be clipped in accordance with therecommended clipping distances (see page 17) using screw-type clips (HX85).


38

HX28 HX29 HX30 HX31

Figure No. 52

Adaptors for Connecting to Steel Pipes and Threaded Bosses

Figure No. 53

HX38C/15 (Cold) HX38H/15 (Hot)Connecting Appliance Valves

HX85Pipe Clip - Screw

Connection to Incoming Service Pipescont.

Figure No. 54 Tap Connectors

Demountable - Straight and Bent Tap Connectors15mm x 1/2” 15mm x 1/2”HD25A/15 HD27/15

15mm x 3/4”HD25B/15

22mm x 3/4”HD25B/22

Connection to Draw-off Taps When connecting to draw-off taps having a male threaded ‘tail’ use eitherthe Demountable or SlimLine Hep2O® tap connector. Do not use anyjointing compound on the jointing shoulder, use only the washer provided.When using the wall plate elbow or the 1/2” x 3/8” BSP adaptor the threadsshould be sealed by applying PTFE tape to the male threads.

Connection to Ancillaries (Pumps,Valves, etc.)When connecting Hep2O® to ancillaries it is important to follow theguidance in the section ‘Connection Using Compression Fittings’ (Page 34).Due to the flexibility of Hep2O® the pipework must be clipped adjacentto the outlets of the pumps and valves using Hep2O® screw pipe clips(code HX85). This ensures adequate support and reduces vibration in the

majority of cases. Where it is felt that the weightof the pump merits extra support, metalbrackets should be used. Where the size of thepump and/or valve requires fixing at a greaterdistance from the wall than can beaccommodated by the pipe clip alone, then thiscan be augmented with a pipe spacer (HX86),which will allow a greater ‘stand-off ’ distancewhilst maintaining security.


39

Wallplate Elbow - (HX6/15) used with Outside Taps

SlimLine - Straight and Bent Tap Connectors15mm x 1/2” 15mm x 1/2”HX25A/15 HX27/15

15mm x 3/4”HX25B/15

Figure No. 55

Connection to Pump

5

Connection to Storage Vessels andRadiators When connecting Hep2O® pipe to cylinders, radiators etc. it is alwaysrecommended that Hep2O® fittings are used wherever possible.

The Hep2O® range of fittings includes thermostatic, wheel head andlockshield radiator valves, double check valves, tank connectors, gate valves,stopcocks and cylinder connectors.

If the use of compression fittings is unavoidable then the jointing instructionsoutlined in the section, ‘Connection Using Compression Fittings’ (page 34)should be carefully followed.

Do not use any jointing compound on the jointing shoulder of the cylinderconnector, use only PTFE tape.

Do not use any jointing compound when fitting tank connectors, use onlysealing washers (not provided).


40

Figure No. 56 Tank and Cylinder Connectors

15mm and 22mmHX20/15 HX20/22

22mm x 1” BSPHX34/22

Figure No. 57

� Radiator or Lockshield Valve

� HX73/10

� HX73/15

Figure No. 58

� Thermostatic Radiator Valve

� HX71/10

� HX71/15

Figure No. 59

� Radiator or Lockshield Valve (HX73/10)

� Straight Radiator Connector(HX77/10)

� Radiator Draincock (HX23/15)


41

Connection to Boilers and HeatersWhere boilers incorporate a high limit cut out thermostat, pump overrundevice, and have connections outside the boiler casing 350mm from theheat source, direct connection can be made toHep2O®. Typically these boilers contain a copperheat exchanger and are low water contentboilers.

Where any one of the above criteria fordirect connection to a boiler cannot be met aminimum one metre run of copper pipeshould be installed between the boiler and thestart of the Hep2O® system.

In all cases (including instantaneous water heaters,caravan heaters etc.) care should be taken to ensurethat appliances have the appropriate thermostatic controls and cut outs toensure that operating conditions do not exceed the temperature andpressure limits laid down for Class S pipe (see Table No. 1, page 3). Forany type of back boiler all water connections should be extended fromthe appliance to the outside of the fireplace opening in copper tube.

In these instances, where the heat output may be uncontrolled, aminimum one metre run of copper pipe should be used between theboiler and the start of the Hep2O® system.

Any gravity circuit of a solid fuel boiler should always be installed incopper.

Regulations require that metal pipe be used as discharge pipe fromtemperature/pressure relief valves on unvented water heaters, to or from atundish or from safety valves on sealed central heating systems. On sealedsystems where the safety valve is not provided within the boiler casing, thepipe between the safety valve and the boiler should be in copper.

All boiler connections should be made in accordance with therequirements of BS 5955, Part 8.

On heating systems where normal circulation may be drastically reduced(eg. thermostatic radiator valves fitted throughout), then a bypass should befitted to the circulation pipework preferably controlled by an automaticdifferential pressure bypass valve.

During commissioning it is important to ensure that all trapped air ispurged from the heating system before the boiler is operated. ‘Pockets’ ofair can affect proper circulation and impair the correct operation of boilertemperature controls which could cause severe overheating.

5

System Modifications

42

Fitting DetachmentRe-using a demountable fitting

Re-assembling a Hep2O® jointTo re-assemble the fitting:

� If demounting a fitting, start with a fresh piece of pipe. cut off pipe at next full ‘ ’ mark from end.

� Check each component for damage. Replacement components are available. Refer to current Trade Price List.

� Ensure all components are clean.

� Apply a small amount of Hep2O® Silicone Lubricant (Code HX200) to ‘O’ ring before insertion of fitting.

� Insert the ‘O’ ring into the fitting body until it rests on the ledge at thebottom of the socket.

� Place the wedge support ring so it sits above the ‘O’ ring.

� Insert the grab wedge into the wedge support with the flat face of the grab wedge facing down.

� Replace the retaining cap and hand tighten.

� The fitting is now ready for use.

V

Figure 60

Unscrew the retaining cap andpull the pipe clear of the fitting.

Figure 61

Remove the ‘O’ ring and wedgesupport ring (if applicable) fromthe pipe.

Figure 62

Using the wedge removal tool,slide the grab wedge from thepipe. Provided it is undamaged itcan be re-used.

Figure 63

Re-assemble the fitting, insertingthe ‘O’ ring, the wedge supportring (if applicable) and then thegrab wedge, with the flat faceagainst the wedge support ring –replace the cap hand tight.

Retaining Cap

Grab Wedge

Wedge Support Ring

‘O’ Ring


43

LubricationAll ‘O’ ring seals contained in Hep2O® fittings have been pre-lubricatedduring factory assembly. During normal installation additional lubricationshould not be required. If however the fitting has been dismantled then thelubricant may have been removed by handling and may require replacing. Ifreplacement ‘O’ rings are being used (Code HX50, HX51 and HX52) theseare supplied dry and should be lubricated before jointing.Similarly in particularly difficult locations additional lubricant may assist inease of jointing. In these situations Hep2O® Silicone Lubricant Spray (CodeHX200) must be used to avoid contravention of Water Byelaws and ensurecompatibility with other system materials.

Remember:

Hep2O® Pipe is fully compatible with all versions ofHep2O® Fittings.

Remember:

If the grab wedge is inserted upside down the pipe willnot enter into the joint.

Figure 64

Note:

� Pipe should be rotated in cutters during operation.

� Support sleeve is an integral part of system and should NEVERbe omitted when using Hep2O® pipe.

� Once completed Hep2O® joints can be rotated even under pressure. Rotatability also enables fittings such as stopcocks and draincocks to be rotated close to the wall when not in use.

6


44

AlterationsBlanking a fitting is easy with Hep2O®

SlimLine Hep2O®

Insert a blanking plug (HX41)directly into the fitting. Whenready to continue, drain thesystem, cut off the top of theblanking plug where indicated andattach the next fitting.

Demountable Hep2O®

Remove the cap and grab wedgefrom the fitting. Push the openend of the blanking peg (HX44)into the ‘O’ ring. Replace the caphand tight.

Removing the Blanking Peg

Remove the cap and blanking peg,re-insert the ‘O’ ring and wedgesupport ring (if applicable) - checkthe grab wedge is undamaged.Insert the grab wedge into thefitting with the flat face againstthe wedge support ring. Replacethe cap hand tight.

Note:

Stainless steel blanking caps will not work correctly in Hep2O®

fittings with BiTite® grab wedges inside.

�

�DO� Check the fitting and components are clean.

� Lubricate ‘O’ ring before re-assembly of joint (use HX200 lubricant only).

� Replace end cap and tighten by hand.

DON’T� Keep new grab wedges loosely amongst tools or pipe

fittings. To avoid damage store in a separate compartment orcontainer, similarly with ‘O’ rings.

� Under NO circumstances should fitting components be individually fitted onto the pipe prior to assembly. It is important that components are correctly located and the Hep2O® fitting properly assembled prior to the insertion of the pipe.

Remember: Hep2O®‚ fittings are designed to push fit only andare NOT compression fittings.

Thermal InsulationAlthough Hep2O® pipe has lower thermaldiffusivity than copper, its insulationrequirements are the same as those of copperand should be in accordance with BS 5422,BS 6700, Water Byelaws and BuildingRegulations Approved Documents. Hep2O®

pipe is less likely to burst should the water inthe pipe freeze, however should Hep2O® beconnected to a metal pipe, a metal tap or a closeconfiguration of fittings (incorporating metal support sleeves) then thelikelihood of a failure due to the expansion of frozen water will beincreased.

Freezing for Maintenance/System ModificationHep2O® pipe can be frozen for maintenance/repairs without damage tothe system. Freezing equipment manufacturers instructions should befollowed. Freeze at a reasonable distance from where pipe is to be cut.

Painting Hep2O®

Hep2O® can be painted where this is felt to be necessary, e.g. outdoors toprotect the pipe from sunlight and the effects of ultra violet light.

It is preferable when painting Hep2O® to use emulsion paint, however, oilbased gloss paint can be used in conjunction with undercoat. Cellulosebased paints, paint strippers or thinners should not be used.Before painting, ensure all surfaces are clean, free of grease and dry.

Use of Corrosion InhibitorsCorrosion of metals is a hazard in all installations therefore it isessential that possible causes of corrosion are kept to an absoluteminimum.

Oxygen will almost always be present in any system as it can enterthrough a variety of points such as open header tanks, threaded joints,valves, pumps and above the bleed point on a radiator.

To provide maximum system protection independent of pipe material, allheating circuits should be protected by an inhibitor.

Hep2O® Barrier Pipe incorporates an additional oxygen barrier to reduceingress of oxygen through the pipe wall. It is accepted by British Gas and iseligible to be used in heating systems which specify SuperWarm, GasWarm orare covered by British Gas Contract Service.

Fernox MB1 and Betz Dearborne Sentinel Inhibitors have been tested and aresuitable for use with Hep2O®.

AntifreezeAntifreezes based on Ethylene Glycol mixtures will not have an adverse effecton Hep2O®, however if there is any doubt as to the suitability please contactthe Technical Advisory Service –Tel: 0870 460 5578 Fax: 0870 460 5579 for advice.

45

General Information

7

Electrical SafetyHep2O® does not conduct electricity therefore the risk of electric shockfrom contact with a Hep2O® installation is eliminated.

The practice of utilising the metal pipework system for earthing wasdiscontinued in 1966. However, when Hep2O® forms a break in thecontinuity of existing metal pipework which may have been used for earthingor bonding, then the electrical continuity should be reinstated by fixing thebonding lead permanently to both ends of the existing metal pipework.

46

General Information

For further information contact the Technical Advisory Service –Tel: 0870 460 5578 Fax: 0870 460 5579. For information on electrical safetyand the IEE regulations, contact a registered electrical contractor or your localelectrical provider.

Remember:

Equipotential BondingA Hep2O® installation requires no more and in many cases needs lessequipotential bonding than metal pipework.

Woodworm / Timber TreatmentWhen treating timber for woodworm or timber rot aqueous basedsolutions are generally accepted. But care should be taken to protect andcover Hep2O® pipe and fittings prior to any spraying.

It is preferable to carry out any spraying prior to Hep2O® installation.

Solvent based treatments should not be used.

For further information contact the Technical Advisory Service –Tel: 0870 460 5578.

External InstallationsIf Hep2O® is installed in an external application then the system willrequire protection from frost. Although Hep2O® has lower thermaldiffusivity than copper, insulation requirements are the sameas those of copper and should be in accordancewith BS 5422, BS 6700, Water Byelaws andBuilding Regulations Approved Document L.

Hep2O® pipe is less likely to burst shouldthe water in the pipe freeze, however shouldHep2O® be connected to a metal pipe, ametal tap or a close configuration of fittings(incorporating metal support sleeves) then thelikelihood of a failure due to the expansion offrozen water will be increased.

If Hep2O® is used externally it should be protected from the ultra-violetradiation in sunlight. If insulation has been installed to avoid freezing this issufficient. However, where insulation is not used, painting or covering isrecommended. (See page 45).

VerminExtensive testing has demonstrated that vermin do not show a preference forHep2O® over other materials. However, all items which are less hard than therodents teeth are liable to be gnawed in vermin infested property, includingelectric cables and Hep2O® pipe. If vermin infestation is suspected then areputable rodent exterminator should be consulted. If vermin are present theymay damage Hep2O® pipework.

ChlorineHigh sustained concentrations of chlorine will have an adverse effect on allplastics pipe. Hep2O® is not suitable for use in systems where the watercarried in the pipe contains a high concentration of chlorine e.g. swimmingpools or decorative water features. Hep2O® will not be affected by thelevels of chlorine expected in the UK water supply (typically less than0.5ppm) Short term chlorination for disinfection will not have an adverseeffect on the system.

If long term contact is suspected the Technical Advisory Service should beconsulted –Tel: 0870 460 5578 Fax: 0870 460 5579.

47

Special Precautions

8

Pressure TestingInstallers should ensure that all non-Hep2O® products can withstand thetest pressure by checking with other relevant manufacturers.

When testing Hep2O® pipework systems, the recommended test pressureis:� For Hep2O® fittings with grab wedges – 1.5 times working pressure.

� For Hep2O® grab ring and SlimLine fittings – a further test to 18 Bar.

If the system contains ANY grab ring or SlimLine fittings the further testto a maximum of 18 Bar should always be undertaken.

Care should be taken to disconnect any appliances or fittings that will notwithstand, or will be damaged by testing at 18 Bar.

For testing procedure see below. The duration of the test should be notless than 1 hour in accordance with BS 6700.

48

Testing

Figure No. 65 Pressure Testing Figure No. 66 Pressure TestingKit (HX81)

Pressure Test Procedure:1. Ensure any non-Hep2O® components in system will withstand test

pressure.

2. Blank off all open ends using Hep2O® Blanking Pegs (HX44) orBlanking Plugs (HX41).

3. Connect pressure hose to system at a convenient point using ademountable socket.

4. Close Valve V2 and open Valve V1.

5. Fill system to be tested with water ensuring system is completelyfull of water (purge all air).

6. Raise pressure to test pressure and close Valve V1.

7. At end of test duration, gently tap gauge with a finger (to ensure pointeris ‘free’). Read pressure on gauge, no appreciable drop in pressureshould be noticed to indicate the system is watertight.

8. Release Valve V1 and V2 to release pressure from system. Drain system ifnecessary.

9. Replace cap and components in socket used for connection to test kit.

Remember!

Pressure Testing is NOT a substitute for making sure theCorrect Insertion Depth of the Tube into the fitting usingeither the Chevron marks or a pencil mark has beenachieved. For correct method (see Fig 8, page 10).

GaugeValve 1

Valve 2

BoatsThe flexibility of Hep2O®

means it can be cabledaround the interior cavitiesof boats and easily hiddenbehind bulkheads. Light inweight, Hep2O® will notadd unduly to the draft ofthe vessel.

There are three keyproblems with traditional plumbing in marine craft:

� Prolonged and damaging vibration from engine and forces of sea maycause soldered or compression joints to crack or work themselves loose.Flexibility of Hep2O® pipe absorbs these damaging forces, and jointingtechnology ensures a secure joint will not come loose during its servicelife.

� Electrolytic corrosion may occur as a result of contact establishedbetween dissimilar metals in plumbing system and boat’s construction. Thiscan cause damage to both. This will not occur with Hep2O®.

� Salt water is itself extremely corrosive to most metal plumbing systemsbut has no effect on Hep2O® pipe or fittings.

CaravansHep2O® is ideal for caravan installation where its lightness and flexibilityallows fitting in confined spaces without damage to the fabric of the vehicle,or adding unduly to the kerbside weight. Resistance to corrosion and freezingmake Hep2O® an obvious choice for this application.

ExhibitionsThe temporary nature of most exhibitions combined with the requirementthat services be run for considerable distances with multiple take-off points,requires a plumbing system which is not only flexible, but also capable ofregular dismantling and remaking to different layouts. Hep2O® combiningflexible pipe with demountable joints, offers a unique solution to thisproblem, giving a positive cost saving (as little waste is incurred) with theopportunity to modify the overall design installation to suit short-termrequirements.

Portable Buildings (site cabins, toiletsetc.)Similar in many respects to caravans, portable homes often requireconnection to more permanent services.The Hep2O® range includes all the necessary items to ensurecompliance with local water byelaws (e.g. double check valves) whilstallowing the building to be moved to another location when required,with the minimum disruption to internal systems. Coupled with the ability toinstall in difficult spaces and the ability to rotate fittings to allow betteraccess to valves etc. Hep2O® is the ideal choice for these structures.

49

Special Applications

10

Where not to use Hep2O®

The Hep2O® system has been designed and tested to meet therequirements of modern heating and water distribution systems.

Testing has not been carried out to determine suitability for other purposesand therefore should not be used for instance, in the followingapplications:

� Conveyance of gas.

� Conveyance of fuel oil.

� In areas contaminated by petroleum and oil derivatives.

� Compressed air.

� Hep2O® is not suitable for use in systems where the water carried inthe pipe contains a high concentration of chlorine e.g. swimming pools ordecorative water features.

� Hep2O® will not be affected by those levels of chlorine expected in UKwater supply (typically less than 0.5ppm). Short term chlorination fordisinfection will not have an adverse effect on the system, (page 47).

� Hep2O® should not be used for primary circuit of a Solar HeatingSystem as temperature cannot be thermostatically controlled. Hep2O® issuitable for secondary circulation of these systems.

� Hep2O® should be protected at all times from exposure to directsunlight and ultra violet light.

� Hep2O® should not be installed in Ringmain Installations.A ringmain is a water-replenished circulating system maintained at aconstant high temperature to provide a permanent source of hot waterto its distributing pipes.Typical locations where ringmain systems are used are hospitals or hotelswhich distribute constant hot water to wards or rooms at a distancefrom heat source.This type of installation is very different from conventional domestic hotwater and central heating services.This restriction does not apply to domestic systems operatingintermittently at temperatures less than 65°C where a design life of 50 years as detailed in BS 7291 can be expected.

Agricultural and Horticultural UseBecause of its resistance to damage, corrosion and cold weather Hep2O®

has many applications in agricultural and horticultural environments. Typicalinstallations ideally suited to Hep2O® are the water supply to milkingparlours, drinking troughs and horticultural watering systems.

Air Conditioning SystemsHep2O® is ideal for the condensate pipes from air conditioning systems andchilling systems, and in many low pressure systems will also be suitable forthe primary circulation. If in doubt contact the Technical Advisory Service –Tel: 0870 460 5578 Fax: 0870 460 5579 for advice.

50

Special Applications

Hep2O® is an extremely tough and durable system however, as with allmaterials some care is required to ensure damage is not incurred duringstorage or installation which may impair its ultimate performance.Straight lengths of Hep2O® pipes may be laid flat or stacked vertically. Coilsmay be laid on their side or edge. Both are lightweightand easy to carry and handle.

Pipe and fittings wherever possible should bestored in their original packaging. This ensuresprotection from ultra violet light and willreduce the risk of contamination.Spare grab wedges and ‘O’ rings should not becarried loose amongst other fittings or toolswhere they may be damaged. They should be keptin their original packaging or in a separate containerwhich will protect them.

Hep2O® should be protected from contact with petroleum and oilderivatives.

When carrying or installing Hep2O® pipe, care should be taken to avoiddragging the pipe along the ground or damaging the pipe on other surfacessuch as walls.

When feeding pipe through holes in walls and brickwork the pipe endshould be taped over or the red cap included in the pipe coil be used toprevent damage to the jointing surface and debris entering the pipe.

Care should be taken to avoid kinking the pipe during installation.

51

Handling and Storage

Figure No. 67

Hep2O® Straight Coiled Pipe

11

52

Hints and Tips

For trouble free installation of Hep2O®

Most installers that have worked extensively with Hep2O® will haveexperienced the odd problem from time to time. Based on customerfeedback and over 20 years experience in dealing with such occurrences, thefollowing are simple but effective precautionary steps that when taken willensure trouble free installation. Potential joint problems can be divided intotwo main categories:

Pipe Derived By far the majority of problems occur because the pipe end inserted intothe fitting has been damaged in some way, this can create a leak pathway viathe scratch or indent for water to pass. This type of damage can occur atvarious points along the route to finally commissioning the plumbing system.But in general taking a few precautionary measures can eradicate any suchproblems.

� Take care in how and where the product isstored, retain pipe in protective packaging until itis to be used.

� Never use an open bladed knife to remove thepipe packaging.

� Always use the attached shielded blade tool toremove packaging and cut on the inside of thecoil, thus enabling the pipe to be containedwithin the packaging until the last metre. (FigureNo. 68).

� When threading pipe through holes in stone,brick and block walls always use a pipe sleeve oralternatively a small piece of foam pipe insulationto protect the pipe from the rough surface.

� Ensure exposed first fix pipework is protectedafter initial installation if further connections areto be made to the pipe. By simply pushing a temporary end protectoronto the pipe, it ensures that no debris will enter the pipe andfurthermore it will protect the pipe end from damage. (Figure No. 69).

Fitting DerivedProblems can arise for a number of reasons, grit or debris ingress into thejoint prior to coupling, or sometimes the inadvertent omission of an integralcomponent part of the joint due to past interference by the installer or apossible third party. Again taking a few general precautionary measures caneradicate any such incidents.

� Store materials in a secure place free from dust and dirt etc.

� Keep fittings in their bags until ready for use.

� When fittings are de-mounted ensure they are correctly re-assembled.

� Do not take joint components from new fittings to replace damaged orlost components in other fittings.

� Always follow the do’s and don’t guidelines leaflets included with all bagsof fittings.

Figure No. 68

Figure No. 69

53

Compared with traditional systems the possibility of a fault or leak occurring witha Hep2O® system is greatly reduced. However, in the unlikely event of a problemoccurring the following notes will help to identify the cause:

1. Problem: Pipe came out of fittingProbable Causes:a. Pipe had not been pushed into socket far enough to properly engage grab

wedge.Evidence: Lack of teeth marks on pipe or teeth marks only at tips of pipe.

b. Grab wedge has been damaged.

c. The fitting has been dismantled and reassembled incorrectly with the grabwedge the wrong way round.Evidence: The teeth of the grab wedge are pointing into the fitting (see pages42-43 for correct assembly detail).

d. The fitting has been dismantled and reassembled incorrectly with thecomponents in the wrong order.Evidence:The ‘O’ ring is next to the cap (see pages 42-43 for correct assembly detail).

e. The fitting has been dismantled and reassembled incorrectly with the grabwedge missing.Evidence: No grab wedge (see pages 42-43 for correct assembly detail).

2. Problem: Joint weepsProbable Causes:

a. Pipe has been inserted through grab wedge and not through ‘O’ ring.Evidence: Joint leaks but pipe remains in fitting.

b. Dust or burrs under ‘O’ ring seal (usually occurs if a hacksaw has been used tocut pipe).Evidence: Contamination evident on visual examination of components.

c. ‘O’ ring seal has been damaged (usually by insertion of a sharp ended copperpipe).

Evidence: Damage evident on visual examination of component.

d. Fitting may have been connected to old Imperial copper.Evidence: Measurement of pipe will reveal discrepancy with currentstandard diameter (BS 2871 Part: 1 1971).

e. Components from an old Hep2O® or Acorn® fitting may have beenused when ressembling a Hep2O® fitting. The cap, metal grab ring, ‘O’ ring and spacer washer from old Hep2O® or Acorn® fittings are not compatible with Hep2O® fittings.Evidence: Cap marked HBP (Hep2O® is marked Hepworth); Metal grab ring. (Hep2O® has a white grab wedge); ‘O’ ring not marked (theHep2O® is marked with the size); spacer washer (not needed inHep2O® fitting).

Fault Finding

12

3. Problem: Split fittingsProbable Cause:

Formation of ice within a system containing metal pipework, or adjacentto metal taps.NB: Water freezes at 0°C and increases in volume until it reaches –4°Cand 9% volume increase. Hep2O® pipe can absorb this volume increasewithout rupture, but if metal pipe or components are involved in thesystem, the extra pressure generated may occasionally be sufficient to splitthe fitting.Evidence: Splitting of fitting or fitting pulled off pipe after severe coldspell – deformation of grab wedge.

4. Problem: Pipe or fitting meltingProbable Causes:a. Melting point of polybutylene is approximately 125°C, direct contact

with any naked flame, electric fire, or hot flue pipe, etc., would cause thepipe to melt.

b. Water/steam within pipe reaches temperatures in excess of normal boilersafety and malfunction levels. (This is very rare and if found should initiate athorough investigation of both heating and electric systems. One cause has been found to be stray electric current passing through impurities in water).Evidence: Visual examination shows material to be deformed. Surface ofmaterial may appear ‘glossy’.

IMPORTANTIf in doubt then return the pipe and the fitting to the Technical AdvisoryDepartment for further analysis.

54

Fault Finding

Note:

Care should be taken not to cause any damage to the sample which mayhinder analysis.As much of the affected installation should be returned as possible andsufficient pipe should be left in fittings to allow pressure testing,(minimum requirement 50mm). If possible a full metre of pipe should bereturned complete with markings or a note made of all pipe markings.The above notes cover some possible malfunctions generally resultingfrom incorrect installation or service conditions. Careful attention tothe notes in this guide will avoid these problems.

Advisory ServiceWavin offer a comprehensive range of support services to ensure that anyqueries can be dealt with swiftly and efficiently.

Appointments for a demonstration can be made by telephoning RegionalHotlines.

To obtain guidance on planning installations and to receive immediate adviceof a technical nature telephone the Technical Advisory Service –Tel: 0870 460 5578 Fax: 0870 460 5579

Literature ServiceHep2O® is only distributed through builders’ and plumbers’ merchants andcan be obtained nationwide.For details of your nearest Hep2O® stockist contact our customer servicesteam – Tel: 0870 460 5578 Fax: 0870 460 5579

To receive a Product Guide or Consumer Information Leaflet, please ring theLiterature Hotline –Tel: 01249 766333 Fax: 01249 766332.

Other Sources of Information LiteratureThe Plumbing Engineering Services Design Guide published by The Institute ofPlumbing.

Building Regulations - Approved Documents A, G and L.

BS 5449: Code of Practice for Central Heating for Domestic Premises.

BS 5955: Part 8: Specification for the installation of themoplastics pipes andassociated fittings for use in domestic hot and cold water services and heatingsystems.

BS 6700: Design, Installation, Testing and Maintenance of services supplyingwater for domestic use within buildings and their curtilages.

Hep2O® is manufactured and kitemarked to Class S of BS 7291, Parts 1 and 2 and is manufactured within a Quality Management System which satisfies BSEN ISO9002requirements.

Hep2O® Barrier Pipe is Covered by Agrément Certificate 92/2823 to

class ‘S’ of BS 7291.

The Water ByelawsListed in the Water Fittings and Materials Directory Listing Number 0112066.

55

Information

BS 7291

This Guide follows requirements stated inthe standards, byelaws and regulations listedpreviously. Should it differ from any new UKor European requirements issued since wewent to print, please obtain clarification bycalling the appropriate Enquiry Hotline.

APPROVED

PR�O�D�U�C�T�

Hotlines

2903 – Hep2O IG 08/09Printed on paper sourcedfrom sustainable forests.

Orders:Fax 0870 443 8000(for all orders & additions)

Enquiries:Tel 0870 443 6000

Technical Advisory Service:Tel 0870 460 5578Fax 0870 460 5579

Literature Service:Tel 01249 766333Fax 01249 766332

Email:[email protected]

Web Site:www.hep2o.co.uk

WavinEdlington Lane Edlington Doncaster DN12 1BY UK

© Wavin 2009. ® Hep2O is a registered trademark of Wavin. Wavin operates a programme ofcontinuous improvement, and reserves the right to modify or amend the specification of productswithout notice. All information in this publication is believed correct at the time of going to press.However, no responsibility can be accepted for any errors or omissions.

Wavin has industrial affiliation with:

Institute of Plumbing Scottish & Northern IrelandPlumbing Employers’ Federation

National Association of Plumbing Heating & Mechanical Services Contractors

Push-fit Plumbing System Installer Guide · (HD74, HD75, HD77 or HD78) should be used. Do not use a...

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