Rifeng PEX Piping System Installation Guidelines. (Updated June 2008)

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1 Rifeng PEX Piping System Installation Guidelines (Updated June 2008)

2 Index 1. Rifeng PEX pipe descriptions... P-3 2. Marking and explanation... P-3 Explanation... P-3 3. Rifeng PEX System fittings and tools... P Fittings available... P Tools available... P-5 4. Making a connection...p-5 4.1Connecting PF1 screw fittings with Rifeng PEX pipes...p Connecting PF2 axial-press fittings with Rifeng PEX pipes... P Connecting PF5 radial-press fittings with Rifeng PEX pipes... P-8 5. Installation...P Manifold System...P Pipe-in-corrugated pipe... P Fixing the corrugated pipe...p Pipe-in-insulation pipe...p Termination Box Sets... P Expansion and Contraction...P Bend pipe with/without Supports... P Pipe fixing... P Pipework... P Test system... P Pipe line flushing... P-16 Contact us at: page: 2

3 Rifeng PEX Piping System Installation guidelines Notice: This manual contains recommended installation instructions for Rifeng PEX piping system. Failure to observe these installation instructions may result in substandard performance of the system. Rifeng Piping Systems expressly disclaim any responsibility or liability for substandard performance resulting from failure to comply with installation instructions. 1. Rifeng PEX pipe descriptions Rifeng PEX pipes are produced from crosslinkable polyethylene. We provide PEX pipes with diameter ranging from 10 to 40 mm for European standard sizes or up to 1 1/2" for American standard sizes; the maximal pressure and temperature range could reach 10 bar and 90. Rifeng PEX pipes with EVOH oxygen barrier could be made into 3-layer or 5-layer structure. The layer of adhesive bonds the layer of cross-linked polyethylene and barrier layer by a thermal reaction. The barrier layer is on outside for 3-layer pipe and is right in the center for 5-layer. Following pictures show their structures. 3-layer Rifeng PEX pipe 5-layer Rifeng PEX pipe 2. Marking and explanation All Rifeng PEX pipes are marked with nominal size, wall thickness, pressure/temprature ratings, applicable standards and other information. See following example for marking. 012A RIFENG PEX-b/EVOH OXYGEN BARRIER Class A EN ISO Tmax=90 P D =10bar 000m Explanation 012A0111 Batch number Production time (YYYY-MM-DD-HH-MM-SS) RIFENG PEX-b/EVOH OXYGEN BARRIER Manufacturer and logo Pipe materials/structure (PEX-c/EVOH, PEX-b/EVOH/PEX-b etc. are also available) With oxygen barrier function Outer diameter wall thickness by mm Class A Dimension class Contact us at: page: 3

4 EN ISO Tmax=90 P D =10bar Reference Standard number Maximum design temperature Design pressure 3. Rifeng PEX System fittings and tools Fittings: Made of strong brass by forging, PF1 screw fitting, PF2 axial-press fitting and PF5 radial-press fitting are available for PEX pipe. PF1 and PF2 fittings are dimensionally designed according to European EN ISO PEX piping system standards, popular in Europe, Oceania,South America and other areas where European standard is prevailing, while PF5 is dimensionally designed to American ASTM F1807 and ASTM F876/877 PEX piping system standards. 3.1 Fittings available PF1: series: Special tool is not necessary. PF2 series: Special tool is necessary. PF5 series: Special tool is necessary Contact us at: page: 4

5 3.2 Tools available Cutter : GJ2-2 Designed for smooth, even cutting, the tool's jaw should fit firmly over the pipe to allow a square, burr-free cut. Expander tool: (KKQ-16, KKQ-20, KKQ25, KKQ-32) The expanding adapter is to expand the pipe end in order to insert the PF2 fitting into the pipe. It s better to expand the pipe end twice. The Axial-pressing Tool: (KYQ-16, KYQ-20,KYQ25, KYQ-32) for PF2 fitting installation Small, light and very handy, complete assortment of Rifeng compression heads, quick and interchangeable 15" Manual pressing crimp: (SYQ2-3/8-3/4 ), for PF5 fitting(copper crimp ring style) installation, including crimp ring and crimp gage. 19" Manual pressing crimp: (SYQ /4 ), for PF5 fitting(copper crimp ring style) installation, including crimp ring and crimp gage. 4. Making a connection IMPORTANT:Rifeng Piping Systems disclaim any responsibility or liability failures due to unauthorized tools,components or fittings application in Rifeng PEX piping system.user can consult us for suitable fittings or tools at or by tel: Connecting PF1 screw fittings with Rifeng PEX pipes 1. Cut the pipe vertically with a pipe cutter(gj2-2), make sure to cut in a proper way. Contact us at: page: 5

6 2. Choose the correct fitting according to PEX pipe dimension. 3. Slide the compression nut onto the pipe first, then the split ring (pay attention to the direction of nut) 4. Aim and straight push the fitting into the pipe until the pipe reach the end of fitting corner. 5. Screw-tighten the compression nut with the fitting body by hand 6. Screw-tighten the fitting lastly (Spanners are recommended). Contact us at: page: 6

7 4.2 Connecting PF2 axial-press fitting with Rifeng PEX pipes 1, Cut the pipe vertically by PEX pipe cutter(gj2-2), make sure to cut in a proper way. 2, Choose right size of expander head for the expanding adapter. Note: There are different sizes of expander head for pipe and fitting installation in the kit, make sure select the right head before expanding. The two handles of the expander must remain 90-degree open for installing the head. 3, Expand the pipe end a) Slide the fitting sleeve on to the pipe firstly but do not too close to the pipe end which is to be expanded and connected with fitting insert, keep the handles of the expander 90-degree open while fully inserting the expander head into the pipe end. b) Close the handles until they are locked with 30-degree open between them, then return to 90-degree position and pull the head out off the pipe. 4, Installation of fitting a) After expanding the pipe end, fully straight push the fitting insert into the pipe and move the sleeve towards the expanded pipe end position. Contact us at: page: 7

8 b) Choose the right size of compression heads for the axialpressing tool and install the heads by following the tool instruction. c) Place the fitting and the sleeve in the compression groove at the right position(as shown from the picture), then close and open up the handles repeatedly along the ratchet bar until the sleeve is stopped by the metal block on the fitting. d) Remove the tool head and check the compressing. 4.3 Connecting PF5 radial-press fittings with Rifeng PEX pipes 1, Cut the pipe vertically by PEX pipe cutter(gj2-2), make sure to cut in a proper way. 2, Choose the right size of fitting and jaw of the crimping tool. Contact us at: page: 8

9 3, Slide the copper crimp ring onto the pipe at the open end. then insert the ribbed end of the fitting into the pipe until the pipe reaches the shoulder of the fitting, make sure the insert is completely inside the pipe, and the contact between fitting and pipe is clean and free of impurity. 4 The crimp ring should be positioned on the pipe so the edge of the crimp ring is 1/8 to 1/4 inch(3.2 to 6.4mm)from the end of the pipe. 5. The jaws of the crimping tool should be centered over the crimp ring, and the tool should be held so that the crimping jaws are perpendicular to the axis of the barb. The jaws of the crimping tool should be closed around the crimp ring,compressing the crimp ring onto the pipe. Warning:The crimp ring should not be crimped more than once. Contact us at: page: 9

10 Important:Crimping tools should be checked and adjusted before use. Users could make a testing crimp connection and check it with the crimp gage. If the connection is proper, the tool is regarded as good for work. We recommend checking each crimp connection with the Gage. 6. Crimp gage is included in the kit of Rifeng Manual pressing tools(syq2-3/8-3/4 ) and (SYQ /4 ), please see below picture of the gage, and read the note for which section is "Go" Gage or "No-Go" Gage. After making crimp connections, users should use the appropriate opening of this flat "Go/No-Go" Gage to check your finished crimp.if the crmped ring slides into the "Go" slot section,but stops at the scale(see below picture) between "Go"and "No-Go" section,then the pressing is acceptable. If the crimped ring fails to go across the "Go"slot section,or if the crimped ring goes across the scale,the crimped joint must be replaced,additionally,the crimp tool may need adjustment,follow the recommendations of the tool manufacturers. There is a scale on each tooth,each tooth is for one diameter's crimp check. The section below the scale is "Go" area. The section above the scale is "No-Go" area Crimp gage included in the kit of Rifeng Manual pressing tool SYQ2-3/8-3/4 5. Installation The Rifeng PEX Plumbing System is widely used in potable water system, under floor heating system and snow melting system etc. Each of them could be made from Manifold System, Pipe-in-Pipe System etc. Users should read below guidelines. If you have any questions, please do not hesitate to consult us. Contact us at: page: 10

11 5.1 Manifold System The basic principle of the Rifeng manifold system is to provide joint free pipe runs from a centrally positioned manifold to each radiator valve or tap or water outlet. The system can be designed with one single pipe dimension from the manifold to the draw-off point, which simplifies design and installation work. With joints only at the manifold and the radiator, taps, the risk of leakage from joints is considerably reduced and there are no connections within the walls. Since also there are no other draw-off points on the same pipe, pressure and temperature variations are minimal when taps are turned on and off. Small pipe diameters and fewer fittings save on installation time and labour costs. 5.2 Pipe-in-corrugated pipe system Rifeng Pipe-in-Corrugated Pipe allows the pipe to be withdrawn and replaced particularly in solid floors or walls. Supplied to site with the pipe already threaded into the corrugated pipe, this system saves time and money on site. Any leakage is retained within the corrugated pipe and can be detected. In addition, in a concealed pipe run without any Tee-joints, an accidentally damaged section of pipe can be withdrawn and replaced whilst minimizing structural damage. 5.3 Fixing the corrugated pipe Corrugated pipe should be properly fixed to simplify any subsequent pipe replacement. Rifeng Pipe-in- Corrugated pipe should be laid with the fewest possible bends and the largest possible bend radii. This will also make it easier to remove the pipe at a later stage if necessary. In concrete structures, corrugated pipes Contact us at: page: 11

12 should be fixed to the reinforcing steel with metal or plastic ties. In a floor screed, corrugated pipe should be fixed to the surface of the concrete slab with suitably sized plastic clips. Fixings must not deform or damage the pipe or the corrugated pipe. Where the pipe bends, the Corrugated pipe should be supported using a pipe bend support or fixed at either side of the bend using suitable clips. 5.4 Pipe-in-insulation pipe For those occasions where it is necessary to keep certain temperature or to avoid heat-loss during transport, Rifeng provide Pipe-in-insulation pipe. The coefficient of thermal conductivity of the insulation layer is no more than 0.040W/(m K). The pipe in insulation pipe is not allowed to be withdrawn and replaced as pipe-incorrugated pipe, but is similar in installation, it also should be laid with the fewest possible bends and the largest possible bend radii. To achieve better insulating effect, the insulated pipe should be laid as continuous as possible,and connections should be ensured with insulation too. 5.5 Termination Box Sets The pipe is terminated in the floor or wall and final connection to the radiator is made using a radiator connection pipe. Termination boxes are positioned so the face of the box is at the finished floor level directly below each radiator valve or tap. They are designed so that the joint is accessible and so that the pipe can be removed and replaced without damage to the building structure. Contact us at: page: 12

13 5.6 Expansion and Contraction As is common with all plastic materials, Rifeng PEX pipe has a higher coefficient of expansion than metal. This must be considered when installing plastic pipework. All hot water pipes should be laid in soft serpentine bends or with expansion loops to accommodate the expansion. Allow for 1.5% expansion & contraction of the pipe when installed at 20 C for use at 80 C. Contraction or shrinkage up to 1.5% of the pipe length occurs when the pipes have been in use and the temperature and pressure drops. The grip of a correctly installed fitting is greater than that of the shrinkage force, and if the pipe has been installed allowing for expansion, there should be no problem. After about 15 temperature cycles the pipe will stabilize and no more shrinkage will occur. 5.7 Bend pipe with/without Supports Rifeng PEX pipes may normally be bent without the need for any special tool. To make a bend in Rifeng PEX pipe, fix the pipe at one end and gently curve the pipe by hand and fix the pipe at the other end. Use pipe bend supports to hold the pipe in position. The minimum bend radius is given below table and care should be taken not to bend the pipe beyond this radius since this may cause the pipe to kink. Pipes that have been damaged during bending should not be used. Table for bend radius Bend radius Bend radius Dimension Dimension Without support With support Without support With support Bending with support 1 Bending with support 2 Contact us at: page: 13

14 5.8 Pipe fixing Rifeng PEX pipes are not self-supporting and should be fixed using pipe clips to provide adequate support whilst allowing for thermal expansion. A certain degree of sagging is to be expected in horizontal pipe runs, this will not affect the performance of the pipe. Rifeng supply a variety of plastic pipe clips to fix Rifeng pipe products into position. U-clip Plastic socket closed/open aluminium socket fixed/slide socket Supports should always be installed at either side of a bend. It is recommended that pipes be supported at not more than 150 mm from connections, junctions, valves and other controls. Additional support must always be provided for pumps and other heavy items. Below table is recommended spacing of fixing points for internal pipework. Table for recommended spacing of fixing points Diameter Horizontal Vertical runs Diameter Horizontal Vertical (mm) rums (mm) (mm) (mm) rums (mm) runs (mm) Pipework Pipes which pass through walls, floors, concrete or brickwork must be protected by a suitable pipe sleeve, such as Rifeng pipe in corrugated pipe. Pipes laid in floors or walls should be run in soft serpentine bends to allow for thermal movement of the pipe. This also applies to pipe-in-corrugated pipe and pipe-in-insulation pipe. Where pipes cross-over, do not allow hot and cold water pipes to come into contact with each other. The relative positions of cold water pipes to hot water pipes should be such that the cold water pipes are not warmed, particularly when pipes are running parallel. Do not allow pipe to make contact with any sharp or abrasive surfaces which could damage the pipe. Pipe at high level or in ceiling voids can be laid on a metal tray which will allow for thermal movement. Caution:Pressure testing should be performed right after piping installation,if there is no leakage found Contact us at: page: 14

15 after pressure testing, the piping system can then be buried with concretes,for maximum allowed diameters and shapes of hard blocks which might be included in the burying concretes,please follow local codes or regulations.rifeng Piping Systems expressly disclaim any responsibility or liability for any damage on the established piping system resulting from hard blocks included in buring concretes with exceeding diameters or out-of-regulation sharp shapes. The following pressure testing with water is just for installer s reference,installer can use local installation practices or codes for intallation checking. 6. Test system Hydraulic pressure testing shall be undertaken before the Rifeng PEX pipes system is taken into operation. Hydraulic pressure testing is not a substitute for the correct installation of the PEX pipe and associated fittings. It is essential that the correct size, inserts and fittings are used for the pipe and that thermal movements are taken into account when installing the pipe. The test pressure applied to the system should be 10 bar or 1.5 times of the maximum pressure rating of the lowest rated component in the system.the maximum test pressure applied to Rifeng PEX pipe should not exceed 15 bar at 20 C. Other equipment in the system, such as boilers, valves, etc. should be checked with manufacturer as to their maximum pressure rating before any pressure test of the complete system is performed. A pressure gage must be connected at the lowest point of the installation being tested and a visual inspection of all pipe connections is to be made before pressure testing with water. Vent and fill the system with potable drinking water. Visually inspect the whole system for leaks. Pressurize the installation to a test pressure of not less than 1.5 times the maximum working pressure. The maximum test pressure applied to Rifeng PEX pipe should not exceed 15 bar at 20 C. Apply the test pressure by pumping for a period of 30 times. Inspect for leaks. Reduce the pressure in the pipework by bleeding water from the system to 0.5 times the maximum working pressure. Contact us at: page: 15

16 Close the bleed valve. Visually check for leakage and monitor for 90 minutes. If there is no reduction in pressure the system is regarded as leak tight. 7. Pipe line flushing Total system is to be flushed thoroughly as soon as possible after installation of the piping and following the pressure test. To ensure a sufficient flushing effect, this procedure could be based on pulsating flow of water or water and air. Warning: Once the pressure test and flush complete, you should expel water with compressed air. Because the test water might cause freezing or damage of the piping system in winter prior to use. Rifeng Piping Systems claim this Rifeng PEX Piping System Installation Guidelines does not include all cases possibly met during Rifeng PEX piping system s services. If users meet any new case or have any questions on above guidelines, please contact us by or by tel: Contact us at: page: 16

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