Contents Overview. Pipe. Fittings. Features & benefits. Installation considerations. Tools & terminology

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1 pexplus manual

2 1 pexplus Contents Overview Pipe Fittings Features & benefits Installation considerations Tools & terminology Jointing instructions FAQ Pex fitting range

3 2 Overview The Pex Plus system has been developed to deliver plumbers, builders and home owners a high quality yet cost effective pipe system for use with hot and cold water, rainwater, hydronic heating and recycled water distribution. The Pex Plus product range is based on a premium quality cross-linked polyethylene pipe which is used in conjunction with either of the two available ranges of dzr brass fittings. When installed in accordance with the Pex Plus installation guidelines and the relevant Australian standards the Pex Plus system will provide years of trouble free service.

4 3 Pipe Pex Plus pipe is a high quality Pex-a cross linked pipe. Pex is an industry accepted name for cross linked polyethylene pipe. In general terms polyethylene in its normal state is not capable of handling high pressure or temperature loads. However once subjected to the cross-linking process, its ability to handle these conditions is increased substantially. Pex Plus pipe consists of an inner section of Pex-a material encased in an outer layer of tough hdpe. Pex Plus also offers a pipe specifically for use in hydronic heating. This pipe is identified by its bright pink colour. Pex Plus pink is a similar construction to the standard Pex Plus pipes. However it also incorporates a layer of evoh material which acts as an oxygen barrier, thus preventing the entry of additional oxygen into the sealed heating system. Pex Plus pipe is available in sizes 16, 20, 25 & 32mm, in either coils or straight lengths.

5 4 Pex Plus pipe dimensions Nom size Mean OD (mm) Mean ID (mm) 16mm mm mm mm Pex Plus pipe standard supply units Nom pipe size Straight lengths (all) Coil length (black) Coil length (green, lilac) Coil length (pink) 16mm 5m 100m 50m 200m 20mm 5m 100m 50m 100m 25mm 5m 50m 50m 32mm 5m 25m 16mm black + conduit 50m 20mm black + conduit 50m The Pex Plus pipe is colour coded to assist the installer in avoiding cross connections. BLACK GREEN LILAC PINK CONDUIT Hot & cold potable water Rainwater Recycled water (non-potable) Hydronic heating In/under slab hot & cold water

6 5 Performance The use of Pex Plus pipe provides users with many advantages over traditional piping materials. It has excellent flexibility, is not adversely affected by freezing, offers excellent pressure and temperature resistance, is lightweight and also has low noise and heat transmission qualities. The Pex Plus pipe provides very low levels of friction loss and therefore can often save users needing to upsize piping when installing long runs. As jointing methods are mechanical it does not require the use of solvents. Nor does it require soldering, welding or brazing. Pex Plus pipe heat & pressure performance Recommended working pressure relative to pipe material temperature Temp (ºC) Pressure (Kpa)

7 6 Cross-section Black, green, lilac pipe Inner layer (PEX-a) 1. Inner layer: combination of hdpe & crosslinking agent. 2. Outer layer: hdpe compound. Pink pipe Outer layer (coloured HDPE) Inner layer (PEX-a) Middle layer (red adhesive) Outer layer (EVOH) 1. Inner layer: the same Pex layer as standard Pex Plus pipe. 2. Middle layer: adhesive to bind internal pex-a layer to the external evoh layer(<0.01mm) 3. Oxygen barrier (<0.01mm). Clear outer layer which prevents oxygen from entering the pipe system from the outside atmosphere.

8 7 Fittings The Pex Plus system offers two ranges of fittings. Pex Plus is an axial crimp system (more commonly known as a compression system) which involves drawing a sleeve along the pipe and over a barbed fitting to form a reliable and leak-proof joint. Crimp Plus is a radial crimp system which has a similar barbed fitting but is secured by crimping or squeezing a copper sleeve which in turn compresses the pipe over the barbed fitting to produce a secure joint. Further information and descriptions of the jointing methods for Pex Plus can be found later in this guide. Both ranges of fittings are manufactured from high quality dezincification resistant (dzr) brass (In the case of Crimp Plus it also incorporates a solid copper crimp ring). It will generally come down to the installer s individual preference as to which system to use, as both comply fully with the relevant Australian Standards and are Watermark approved. Pex Plus pipe fitting dimensions Nom size 16mm 10 20mm mm mm 20 Mean bore (mm)

9 8 Features & benefits Secure & easy jointing system less time on the job. Same pipe for Crimp Plus or Pex Plus system carry less stock. Simple hand tool compression method less capital outlay on tooling. Minimal need for brazing less outlay on gas and consumables. Low noise transmission in pex pipe quieter, reduced water hammer. Internal sealing method reduced chance of leaks due to scratched/scuffed pipe. Installation considerations Proximity to flame/external heat sources The Pex Plus system should not be installed in positions where it is likely to be exposed to a naked flame. If it is, there s a danger the pipe could ignite and continue to burn even after the source of the flame is extinguished. In accordance with as/nzs 3500 all plastic pipes for water supply must be protected from excessive ambient heat.

10 9 Thermal expansion The Pex Plus pipe has an expansion rate of approx. 0.3mm per metre for every 10 C change in temperature. Care should be taken not to pull the pipe tightly between fixed points during installation as this may later contract and apply excessive tensile force to any joints. This could cause a possible joint failure. Heat & Pressure performance As with all plastic pipe systems the ability of the pipe to withstand pressure decreases as the pipe temperature increases. (Refer to table on page 5) Protection from physical damage Due care should be taken to protect pipe and fittings from any physical damage both prior to, during and after installation. Possible causes of physical damage may include (but are not limited to) sharp edges/ implements, machinery, rodents, excessive heat, long term uv exposure, radiation, mechanical forces. Pipe Bending Pex pipe is very flexible and as such can save the need to use additional fittings. Due care should be taken during bending to ensure that pipe is not kinked or damaged. If you do encounter a kinked section of pipe it should be cut out and replaced as a precaution.

11 10 Pex Plus pipe may be subjected to a minimum bending radius of approx. 8 times the od of the pipe. Clipping Clipping requirements are outlined in the relevant Australian standards. The recommended clip spacings for Pex Plus pipe are: Pipe size Horizontal pipe work Vertical pipe work 16mm 0.6m 1.2m 20mm 0.7m 1.4m 25mm 0.75m 1.5m 32mm 0.85m 1.7m Framework penetrations Where pipe is required to pass through timber or steel studs/frames, holes should be sized to allow for adequate pipe movement due to thermal expansion or contraction. In all cases, steps should be taken to protect the pipe from any possible physical damage (particularly due to abrasion) where it passes through studs or frames. This can be achieved by installing grommets, sleeves or stud clips as applicable.

12 11 UV exposure Both Pex Plus black and Pex Plus green pipes are able to be installed in direct sunlight with no degradation likely to occur. Pex Plus lilac should be protected from long term exposure to uv by way of either lagging or enclosing in a conduit. Note: The above does not completely exclude the need for lagging to protect any of the pipes from temperature extremes. TESTING It is essential that appropriate pressure testing (in accordance with AS/NZS 3500 or relevant local requirements) is carried out prior to burying or concealing the Pex Plus system.

13 12 Tools Jointing tool Expanding tool Pipe shears Terminology Bevelled end Barb Grooved ring Pipe stop Shoulder

14 Jointing instructions Cut pipe Ensure that the pipe is cut squarely using universal pipe shears. Ensure that the pipe is deburred if necessary (Pipe shouldn t need deburring if cut using universal shears.) The cut must be clean and square for a leak-proof joint. When cutting pipe for connection to a fitting, measure to the fitting shoulder. Pipe expansion Pipe must be expanded by using the Pex Plus expander. Ensure that the expander heads are not faulty or broken as this may lead to the joint eventually leaking. i. Holding the levers of the Expanding Tool fully open, screw on the expander head.

15 14 ii. Slip the jointing sleeve over the pipe with its bevelled end facing towards the fitting being joined. iii. Insert the expander head into pipe, ensuring that the expander is at right angles to the pipe. Ensure that the jointing sleeve is well clear of the area that is to be expanded iv. To expand the pipe, fully close the levers of the expanding tool. Hold them in position momentarily then release and rotate pipe or expander approximately 30 and repeat the process. This ensures that the inside pipe surface is expanded evenly. Note: it should not be necessary to expand more than twice. Over or under expansion of the pipe can lead to possible joint failure.

16 Joint assembly Insert the fitting into the expanded pipe until the pipe reaches the pipe stop. (It does not need to reach to the shoulder) After a few moments the pipe will shrink and grip the fitting. Slide the jointing sleeve as far as you can towards the fitting. Completion of joint The recommended Pex Plus compression tool is to be used. Ensure that the tool is not damaged. Use of a damaged or non-complying tool will void warranty. i. Position the jointing sleeve and fitting squarely within the jaws of the jointing tool. ii. Draw the sleeve towards the fitting by closing the jaws of the jointing tool.

17 iii. The jointing sleeve is drawn over the pipe until it reaches the shoulder of the fitting. Joint inspection All joints are to be inspected once installation is complete. Ensure that the sleeves are drawn all the way to the fitting shoulder and that they are secured with the bevelled end closest to the fitting and the grooved ring at the furthest point from the fitting shoulder. Pressure test At completion, carry out pressure testing as required per as/nzs 3500 and or any requirements specified by local authorities.

18 17 FAQ 1. What are some possible causes for joints leaking? When installed in accordance with the installation instructions, Pex Plus should prove a very simple and effective piping system. However certain conditions may increase the possibility of a faulty or leaking joint. i. Pipe has not been cut squarely. ii. Pipe is not fully engaged on fitting barb. iii. Compression sleeve has not been drawn completely up to fitting shoulder. iv. Pipe has been over-expanded (beyond the point where its memory can return it to original size). v. Teeth of expander are faulty or damaged leaving indentations inside the tube. 2. What do I do if the pipe kinks during installation? If during installation you encounter a kink in the pipe the kinked section should be cut out and replaced.

19 Can I braze adaptors after the pex pipe has been fitted? No, all brazing or soldering must be performed on the fittings prior to the pex pipe being connected. Sufficient time should be allowed for the fitting to cool prior to attaching the pex pipe. Is the Pex Plus system approved? Yes, the Pex Plus system is approved under the following as/nzs standards. Fittings as/nzs 2537 and Pipe as/nzs 2492 Can I use Pex Plus to connect solar panels to the storage tank? No, the Australian Standards do not allow pex pipe to be used on the flow or return lines between solar panels and solar storage vessels.

20 Pex fittings Compression Sleeve 16mm Compression Sleeve 20mm Compression Sleeve 25mm Compression Sleeve 32mm No.1 Straight Coupling 16mm No.1 Straight Coupling 20mm No.1 Straight Coupling 25mm No.1 Straight Coupling 32mm No.1 Reducing Coupling 20-16mm No.1 Reducing Coupling 25-16mm No.1 Reducing Coupling 25-20mm No.1 Reducing Coupling 32-25mm No.2 Straight Connector 16mm ½ FI No.2 Straight Connector 20mm ½ FI No.2 Straight Connector 20mm ¾ FI

21 No.3 Straight Connector 16mm ½ MI No.3 Straight Connector 16mm ¾ MI No.3 Straight Connector 20mm ½ MI No.3 Straight Connector 20mm ¾ MI No.3 Straight Connector 25mm ½ MI No.3 Straight Connector 25mm ¾ MI No.3 Straight Connector 25mm 1 MI No.3 Straight Connector 32mm ¾ MI No.3 Straight Connector 32mm 1 MI No.12 Elbow 16mm No.12 Elbow 20mm No.12 Elbow 25mm No.12 Elbow 32mm No.13 Elbow 16mm ½ MI No.13 Elbow 20mm ½ MI No.13 Elbow 20mm ¾ MI No.13 Elbow 25mm ¾ MI No.14 Elbow 16mm ½ FI No.14 Elbow 20mm ½ FI No.14 Elbow 20mm ¾ FI

22 No.15BP Elbow 16mm ½ FI No.15BP Elbow 20mm ¾ FI No.19BP Elbow 16mm ½ MI 65mm long No.19BP Elbow 16mm ½ MI 90mm long No.19BP Elbow 20mm ½ MI 95mm long No.19BP Elbow 16mm ½ MI 150mm long No.19BP Elbow 16mm ½ MI 200mm long No.19BP Elbow 20mm ¾ MI 150mm long No.24 Tee 16mm No.24 Tee 20mm No.24 Tee 25mm No.24 Tee 32mm

23 No. 25 tee reduced centre 20x20x16mm No. 25 tee reduced centre 25x25x16mm No. 25 tee reduced centre 25x25x20mm No. 25 tee reduced centre 32x32x25mm No 26 tee reduced end 20x16x20mm No 26 tee reduced end 25x16x25mm No 26 tee reduced end 25x20x25mm No 27 tee reduced centre+end 20x16x16mm No 27 tee reduced centre+end 25x16x16mm No 27 tee reduced centre+end 25x20x20mm No 27 tee reduced centre+end 32x25x25mm No.61 Stopper 16mm No.61 Stopper 20mm No.62 Straight Tap Connector 16mm ½ FI nut (flat seal) 16mm ½ FI nut (cone seal) 20mm ¾ FI nut (flat seal) 20mm ¾ FI nut (cone seal)

24 No.63 Bent Tap Connector 16mm ½ FI nut No.63 Bent Tap Connector 20mm ¾ FI nut Connecting Barb 16mm Connecting Barb 20mm Connecting Barb 25mm Connecting Barb 32mm Flared Copper Comp. Union 16mm ½ Flared Copper Comp. Union 20mm ¾ Profile Bend Bracket 90 5D 16mm Profile Bend Bracket 90 5D 20mm Profile Bend Bracket 90 5D 25mm

25 Bath/Laundry Assembly R/A 8 Bath/Laundry Assembly R/A Bath/Laundry Assembly 12 Straight Shower Assembly R/A 6 Shower Assembly R/A Shower Assembly R/A Barbs up 6 Shower Assembly R/A Barbs up 8

26 Shower Assembly 6 Straight Open Clip Masonry Nail 16mm Open Clip Masonry Nail 20mm Open Clip Masonry Nail 25mm Open Clip Metal screw 16mm Open Clip Metal screw 20mm Open Clip Metal screw 25mm

27 25 year warranty The Pex Plus hot & cold water plumbing system carries a 25 year warranty against defects in materials or manufacturing of pipe and fittings produced under the Pex Plus name. This warranty is restricted by the following clauses: i. Installation must have been carried out by a licenced plumber. ii. Installation must be carried out in accordance with the Pex Plus installation instructions. iii. Installation must be in full accordance with the relevant local and national plumbing codes and standards. The Plumbing Plus merchant from whom you purchase Pex Plus product supports the warranty on this product and as such may request suitable information or evidence from the installer to support any warranty claim. The Plumbing Plus merchant concerned also reserves the right to engage a nominated outside agent of its own choice to assess any faulty product before honouring any warranty claim.

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