Push-fit Plumbing System Installer Guide

BS 7291

ED V T A RO C PP DU PRO

July 2009 Contents

Page Introduction 3 Introduction, Approvals 4 Features & Benefits, Installation 5 Performance, System Assembly Basics 6-7 Pipe Selection, Standard Pipe, Barrier Pipe, Pipe Specification, Straight Lengths, Coils 8-9 Pipe Cutting 10 Jointing Standard 11-12 Applications Sitework 13-15 Cabling through Joists 16-18 Pipe Support 18 Pipe Installation in Exposed Locations 18 Pipe Installation in Concealed Locations 19 Pipes through Walls and Floors 19 Laying of Pipe in Floor Screeds 19 Pipes Adjacent to Metalwork 19 Piping Noise Reduction 20 Manifolds/Microbore Plumbing 21 Underfloor Heating Pipe 22 Routabout 23 Conduit Systems 24-27 Installation Recommendations ® 28-29 Hep2O Within Dry Lined Walls ® 30 Hep2O Within Internal Drywall Systems ® 30-32 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, Lubrication Modifications 44 Alterations General 45 Thermal Insulation Information 45 Freezing for Maintenance/System Modification ® 45 Painting Hep2O 45 Use of Corrrosion Inhibitors 45 Antifreeze 46 Electrical Safety 46 Woodworm/Timber Treatment Special 47 External Installations Precautions 47 Vermin 47 Chlorine Testing 48 Pressure Testing Special 49 Boats Applications 49 Caravans 49 Exhibitions 49 Portable Buildings (site cabins, toilets etc.) 50 Agricultural and Horticultural Use 50 Air Conditioning Systems ® 50 Where not to use Hep2O Handling & 51 Handling and Storage Storage Hints & Tips 52 Hints and Tips Fault Finding 53-54 Fault Finding Information 55 Advisory Service 55 Literature Service 55 Other Sources of Information Literature 2 ® The Hep2O Installer Guide for Flexible Push-Fit Plumbing Introduction The mark of a professional tradesman is that he understands and employs a wide 1 range of materials and systems to achieve the best possible solution to individual installation situations. The notes in this Installer Guide are intended to assist professional plumbers to obtain the best results from using flexible push-fit plumbing, enhancing good plumbing practice. It is not sufficient to simply replace item for item, pipe length for pipe length, as this approach will not derive the maximum benefit from the system. It is necessary to design the system from the outset, embracing the benefits the system offers to achieve maximum benefits. ® Enhanced Hep2O flexibility means an opportunity to develop further skills when planning and installing plumbing, offering a comprehensive range of 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 system costs. Pipes can be cabled into position avoiding the awkward manoeuvring ® associated with rigid straight lengths. Hep2O fittings are designed to ® accept copper as well as Hep2O pipe, enabling systems to be mixed if required.

® Hep2O is a tried and tested system, which has been in use in the UK for over 25 years. Approvals ® Hep2O is manufactured and kitemarked to Class S of BS 7291, Parts 1 and 2 and is manufactured within a BS 7291 Quality Management System which satisfies BSEN ISO9002 requirements.

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

® Hep O Is listed in the Water Fittings and Materials ED 2 V T A RO C PP DU Directory - Listing Number 0112066. PRO

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

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 Malfunction at 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

3 ® The Hep2O Installer Guide for Flexible Push-Fit Plumbing

® Hep2O has a minimum design life expectancy of 50 years provided the system is installed in accordance with the manufacturer’s recommendations. These recommendations include service temperatures and pressures. Peak life cycle operating temperatures / pressures are given in Table No. 1. As a result of its rigorous Quality Management Programme Wavin offer a 50 year guarantee ® against defects in materials or manufacturing of all Hep2O pipe and fittings. Features and Benefits ® Hep2O has evolved over 25 years to offer improved installation advantages, 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 integrity grab wedge and robust pre-lubricated ‘O’ ring, offering the installer smoother pipe insertion and lower jointing forces. The re-usable grab wedge gives reliable jointing even when the fitting has been dismantled and reassembled. Installation ® Hep2O introduces a new flexibility for the professional to exploit during installation.

Cabling Ability Less Jointing Low Wastage

Measure and Cut High Resistance to Rotatable Fittings In-situ Impact

Easier Handling Less Risk Jointing, No Naked Flame 4 ® The Hep2O Installer Guide for Flexible Push-Fit Plumbing Performance ® Once installed Hep2O offers considerable benefits over traditional rigid systems. 1

No Scale Build-up No Burst Pipes Quieter

Cool to the Touch Solder Free Corrosion Free

System Assembly ® In skilled hands the flexible Hep2O plumbing system guarantees professional sitework.

5 Basics Pipe Selection ® Hep2O pipe is manufactured as two types, Standard and Barrier. Their correct applications are as follows:- Standard Pipe Standard pipe is suitable for domestic hot and cold water services and heating applications. As standard pipe may allow the ingress of minute amounts of oxygen molecules through the pipe wall when used for heating a suitable inhibitor (Sentinel or Fernox MB1) should be used. Barrier Pipe Barrier pipe is designed for central heating systems and incorporates an oxygen barrier to inhibit oxygen permeation. The use of inhibitors with barrier pipe is still recommended as corrosion can occur in all types of system 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 British Gas/ Scottish Gas Central Heating Care Contracts.

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

Pipe Specification The 15mm, 22mm and 28mm pipe is available in straight lengths and coils. The 10mm pipe is only supplied in coils. Availability is clearly shown in Table 2 (see page 7). Straight Lengths ® Straight lengths of Hep2O are not rigid, and are as flexible as coiled pipe. Straight lengths are primarily for exposed pipework where neatness is important or for use where only short lengths are required. Coils ® Coiled Hep2O is primarily suited to ‘first fix’ work on site, where minimal pipe jointing is desirable. ® Hep2O is available in straight coils, in SmartPackTM dispensers. Unlike other forms of coiled plastic pipe, ® Hep2O does not tend to return to its coiled state when uncoiled for installation. ® Hep2O straight coiled pipe has a tendency to remain straight when uncoiled with no loss of flexibility. ® ® Hep2O Pipe in Pipe System incorporates Hep2O Barrier Pipe in a pre-sheathed conduit ready for underscreed installation, saving time, effort and complies with current regulations.

6 Basics

Table No. 2 Standard and Barrier Pipe Lengths 10mm 15mm 22mm 28mm Straight Lengths 3m  6m  Coils 2 25m  50m    100m  Pipe in Pipe 25m  50m  

G Cut Length Standard and Barrier Straight Cut Lengths.

G Standard Straight Coiled Pipe Straight Coiled Lengths in SmartPackTM Dispenser.

G Barrier Straight Coiled Pipe Straight Coiled Lengths in SmartPackTM Dispenser.

G Pipe in Pipe System ® Hep2O Barrier Pipe in Blue or Red Conduit.

7 Basics

Pipe Cutting Basic Jointing/Pipe Cutting ® When 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 free from burrs and surface damage. (Figure No. 2). Place the pipe in the jaws of the cutter and apply pressure, the pipe should be rotated whilst maintaining the pressure until the pipe is severed. (Figure No. 3) DON’T Figure No. 1 Do not use a hacksaw to cut ®  Hep2O pipe.

DON’T Figure No. 2 Do not use damaged pipe. Ensure pipe is free from burrs

 and surface damage. To ensure adequate insertion, essential for a secureV joint, cut the pipe square at one of the cutting/insertion marks ‘ ’. The distance between these marks indicates full socket depth (Figure No. 3).

Figure No. 3

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

8 Basics Pipe Cutting cont.

Figure No. 4

® ® Hep2O Hep2O SlimLine Fitting Demountable Fitting

Pipe depth 2 insertion marks

Insertion depth

Insertion depth

Pipe depth insertion marks

Support Sleeve ® ® ALWAYS 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 and provides a leading edge to the pipe for easier insertion (the only exceptions to this rule are when using copper pipe, or the open spigot ® end of a Hep2O fitting). Figure No. 5

Table No. 3 Correct insertion depths for ® Demountable and SlimLine Hep2O fittings Pipe size Nominal insertion Depth inc. sleeve 10mm 23mm 15mm 28mm 22mm 31mm 28mm 40mm

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

9 Basics

Jointing Procedure - whichever type of fitting is used, the same jointing procedure should be used. All fittings are pre-lubricated.

Figure No. 6 Use only purpose designed pipe

cutters. (HD74, HD75, HD77 or HD78)V Cut the pipe at one of the ‘ ’ marks. Ensure the pipe end is free from burrs.

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 when the endV of the cap has reached the next ‘ ’ mark on the pipe.

Figure No. 9 Tug back on the pipe to ensure the grab wedge engages correctly.

DO G ®

Use only Hep2O cutters when cutting the pipe.

G Cut the pipe at the ‘V ’ marks wherever possible. G Mark the pipe if not possible to cut to a ‘ V ’. G When cutting rotate pipe whilst maintaining the pressure until the pipe is severed. G Cut the pipe squarely. G  Ensure pipe end is clean, free from burrs & surface damage. G ® Always use a support sleeve into a Hep2O ‚ pipe end. G Push the pipe and fitting together firmly. DON’T G Use a hacksaw to cut the pipe. G Slacken the retaining cap prior to pipe insertion, this will not ease jointing. G  Knock fittings onto pipe. G Undo retaining cap after pipe insertion.

10 Standard Applications

® Hep2O is suitable for most domestic and commercial plumbing applications.

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

Figure No. 10 Wash Hand Basin 15mm

3

Figure No. 11 Wash Hand Basin 10mm

Figure No. 12 Bath

Figure No. 13 W.C .

11 Standard Applications

Figure No. 14 Sink

Figure No. 15 Boiler Connections

Figure No. 16 Figure No. 17 Cylinder Cupboard Cylinder Cupboard

Figure No. 18 Washing Machine/Dishwasher

12 Sitework

Cabling through Joists The 1992 Building Regulations Approved Document A allows for pipework to be installed in joists by one of two methods, notching or drilling. Traditionally joists have been notched and the pipework laid in as the rigidity of the pipe does not easily allow for any other method of installation. This means that the pipework must be installed prior to the floorboards being laid. This has a number of disadvantages: G Plumber has to work on open joists increasing risk of accident or injury. G Plumber will have to return after floors are laid to connect radiators, etc. 4 G Plumber often finds that on his return, tails he left have been moved by other tradesmen thereby causing extra work to reposition pipework correctly for radiators. Cabling through joists means pipework can be installed by working from below allowing exact positioning of ‘tails’ through floor. Site safety is therefore enhanced and the plumber is not exposed to the danger of falling or the discomfort of kneeling on open joists. Other trades working 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 will progress the building schedule as other trades can work on the floor above e.g. to form studwork etc. Carcassing at a later stage in the construction programme is also more pleasant as the building is likely to be weatherproof. Less Risk to Health and Site Safety ® The unique Hep2O fitting ensure effective, leak-free pipe jointing without the use of a naked flame. Safety from fire, especially in restricted spaces, is greatly increased and the working environment is improved. There is no need for flux and solder, thus eliminating any potential contamination of water supplies. Push-fit jointing also has the following advantages for the installer: G No naked flame means that precautions such as obtaining a ‘hot work’ permit, having a fire extinguisher readily available, and remaining on site for a while after jointing are not necessary. G No risk of infringement of Health and Safety recommendations applicable to some brands of flux. eg. means to control exposure to noxious fumes when working in a confined space, and use of eye protection (where appropriate). G After jointing the fitting is clean and safe to touch eg. after soldering joint, is hot and flux traces should be removed. G Joint is rotatable after installation.

13 Sitework Cabling through Joists cont. Summary Flexible plumbing means that the installer can cable pipework more easily utilising continuous runs of pipework. The flexibility does away with dry runs as the pipe can be cut and joints made in situ. As no solvents are used in jointing, the system can be tested as soon as the installation is finished. Exposed pipework should use the recommended clipping distances as shown in Table 4 (see page 17). Tails fitted through the floor for connections to sanitary ware can be left long 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 to overcome any mis-alignment.

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

® When Hep2O is cabled through joists it can be easily positioned to allow for the installation of thermal insulation if required. Pipework can be exactly positioned for the radiators etc. avoiding the risk of being moved or damaged by other trades. Safer working environment for all trades as upstairs floors are already in place. It is safer for the plumbing installer as the drilling can be carried out from the floor below. There is less danger of puncturing the pipe with nails used for fixing the floorboards and there is no need to use protective devices such as ‘joist clips’.

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 the joist and should be drilled at the neutral axis. They should be not less than 3 diameters (centre to centre) apart and should be located between 0.25 and 0.4 times the span from the support. These points are illustrated in Figure No. 19 (see page 15).

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

14 Sitework Cabling through Joists cont. Engineered Joists ® Hep2O is ideal in buildings incorporating timber ‘I’ joists. Piping can be properly installed through holes in the web section without damaging flange members (eg. TJI Joist system, Trus Joist MacMillan Ltd.) even where the pre-formed holes do not align on the plan. Pumps, Valves etc:

® Where Hep2O is connected to pumps, valves and similar devices consideration should be given to adequately supporting the item in question (bearing in mind the rotatability ® of the Hep2O joint). Equipment should not be suspended from the pipe without adequate support. 4 Figure No. 19 Explanation of Drilling Joists in Accordance with Building Regulations 1992 - Approved Document A

SPAN S

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

0.4 x ‘S’

0.25 x ‘S’ CENTRAL AXIS OF JOIST

DEPTH.

NOT LESS THAN 3 DIAMETERS APART CENTRE TO CENTRE.

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

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

Figure No. 20 Graph Showing Dimension of Joist Drilling Zone from Support Distance from Support (m) 2.0

1.5

1.0 Maximum Distance from Support

0.5 Minimum Distance from Support

1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Span of Joist (m) 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.

15 Sitework Pipe Support ® The 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 use on concealed pipework, and allows for rapid fixing to timber. The screw type may be used together with a spacer (HX86) which allows a greater spacing between the pipe and the fixing background. The spacer therefore allows different pipe fixing centres which can be used to facilitate pipe cross-overs or the installation of thermal insulation to the pipe (see Figure No. 22). A cold forming bend fixture (HX75) is available to allow the formation of a bend on 15mm and 22mm pipes for situations where secure fixing and neatness are important. (See Figure No. 23).

Figure No. 21 Pipe Clips Code Nominal Diameter HX65/10 10 HX65/15 15 HX65/22 22 Pipe Clip - Nail HX65/28 28

Code Nominal Diameter HX85/15 15 HX85/22 22 Pipe Clip - Screw HX85/28 28

Code Nominal Diameter HX86/15 15 HX86/22 22 Pipe Clip - Spacer NB: The HX86/22 spacer can be used with both the HX85/22 and HX85/28 clip.

Figure No. 22 Pipe Fixing Centres CL

CL B A

Pipe Clip Pipe Clip and Spacer

Note: Fixing hole size is 5mm diameter.

Nominal Diameter Dimension A Dimension B mm mm mm 15 17 40 22 21 43 28 24 46

16 Sitework Pipe Support cont. Figure No. 23 Cold Forming Bend Fixture Radii

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

A

Nominal Diameter mm Radius A mm 15 120 4 22 176

The recommended support distances for general purpose use are shown in Table No. 4. Where piping is adequately supported or is run within concealed spaces (eg. through suspended timber floors) clips can be reduced or omitted provided that: G Pipe does not form part of an open vent provided for safe operation of heat source. G Pipe does not form a distribution pipe or circuit where effective air venting might be impaired by poor pipe alignment. G Hot pipe will not touch cold pipe or vice versa. G There is no risk that pipes or fittings will come in contact with sharp, abrasive or other potentially damaging surfaces. G There is no risk pipe will come in contact with materials which may suffer damage or discoloration from transmitted heat. Table No. 4 Recommended Clipping Distances

Nominal Diameter Horizontal Runs Vertical Runs mm m 10 0.3 0.5 15 0.3 0.5 22 0.5 0.8 28 0.8 1.0

For improved visual appearance support distances of 300mm are ® suggested for Hep2O in exposed locations. NB: Where the pipe is concealed clipping may not be considered necessary. 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 is especially useful for ‘microbore’ plumbing (see page 20).

17 Sitework Pipe Support cont. Partition systems on the market have the built-in facility for cabling ® electrical wiring and this can be utilised for Hep2O pipework. Bending Radius: ® Hep2O pipe can be easily manipulated by hand to form bends of any angle. In order to prevent any long term detrimental effect on the ® material, the curvature of Hep2O pipe should be not less than shown in Figure No. 24.

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 Locations ® Hep2O pipe expands as temperature increases causing it to undulate along its length. This can be visually unacceptable in the case of long exposed runs. Long runs of exposed pipe are unusual in new build where pipework is generally concealed, but may occur in refurbishment. G If the pipework is exposed there are a number of options open to the installer to ensure that a neat, tidy job is achieved: G ® Hep2O pipework, if exposed, can be boxed in (PVC-U trunking or preformed plywood profiles are generally used). G ® Long runs of exposed Hep2O may be unsightly as a result of expansion and therefore the installer may choose to use copper pipe in this instance. Pipe Installation in Concealed Locations ® Hep2O pipework can easily be installed in concealed locations in floors, roof spaces etc. Any expansion which may occur will have little mechanical effect, this being absorbed within the pipe length as undulation which may be ® ignored. Undulation of Hep2O pipe which may occur naturally as a result of 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 to be clipped for system alignment e.g. at changes in direction. Where convenient, cable ties can be used to restrain pipes for system neatness (care should be taken not to overtighten the tie.) The pipe should be able to slide freely through the tie to facilitate thermal movement.

18 Sitework Pipes through Walls and Floors ® Whenever Hep2O passes through brickwork, stone or concrete the pipe should be sleeved. The annular gap between the pipe and the sleeve should be filled with a resilient material to provide effective fire stopping and prevention of noise transmission from one room to another. Laying of Pipe in Floor Screeds ® Unlike metal pipes Hep2O is not affected by cement, limes, mortars, concrete and general corrosion. However, account should be taken of the requirements of the Water Byelaws which require distribution pipework to be accessible - facilitating its removal and replacement. (See page 23 conduit system). Pipes Adjacent to Metalwork ® When running Hep2O adjacent to or through metalwork, it is important to ensure that the pipe cannot make contact with any sharp 4 edges as this could cause damage during thermal movement. Any of the following preventative measures would be acceptable: G For a pipe passing through a small hole drilled in metalwork, fix a resilient grommet in hole. G For a pipe passing through a large hole in metalwork or adjacent to a sharp edge, fix an extruded flexible profile to metalwork. G Provide sufficient local pipe clipping to prevent contact between pipe and metalwork. G Run pipe within a conduit. Piping Noise Reduction Problems with noise are frequently experienced with systems incorporating ® rigid pipes. Hep2O pipe does not transmit noise and with careful ® installation to reduce the source of noise to a minimum, Hep2O can be installed to run almost silently. For example: G Noise can be caused by friction between a pipe and an adjacent or surrounding material, this often occurs with rigid pipes installed beneath ® timber or chipboard flooring. The use of Hep2O can greatly reduce this effect. Holes should be drilled through joists (see this section page ® 13) of sufficient diameter to allow Hep2O pipe to slide freely. This will prevent any friction between underside of floor, and more importantly avoid ‘ticking’ and creaking normally associated with thermal movement of rigid pipes. G Noise can be caused by pipes knocking together or knocking on hard surfaces in close proximity. Unlike rigid pipes, the inherent elasticity of ® Hep2O would cushion the impact causing less impact noise and absorbing vibrations, preventing the transmission of any sound along pipe. G Similarly noise from ‘water hammer’ resulting from abrupt stoppage of water flow (typically by closure of quarter turn valves, solenoids and ® reverberating ball valves) is normally absorbed by Hep2O and is not transmitted along pipes. NB: Noise generated by central heating pumps is rapidly absorbed by pipes and can be significantly reduced when compared with rigid systems.

19 Sitework Manifolds/Microbore Plumbing ® Hep2O Manifolds are designed for use on microbore central heating systems and can also be used for hot and cold water.

® The Hep2O Manifold in one fitting brings together multiple 10mm pipe connections on the flow or return pipework to one area of a building, enabling easy access when used in ® conjunction with the Hep2O Routabout system. Thus providing instant access below sheet flooring installations for future system modifications or extension.

® A comprehensive range of Hep2O Manifolds is available (Figure No. 25) and these manifolds can be connected in series allowing any number of outlets. Installation and Performance Benefits G ® 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 of fittings required. G Fewer fittings reduces installation time. G ® One of the main advantages of the new Hep2O Manifolds is that they are manufactured from polybutylene, an extremely robust yet lightweight material and are therefore, much easier to install. G ® The lightweight Hep2O polybutylene manifolds enable the pipe to be suspended between joists without fear of dragging the pipe down. G Blanking Pegs can be used to close off any unused sockets.

Figure No. 25

® Hep2O Manifold Range

20 Sitework Underfloor Heating Systems ® Hep2O Underfloor Heating Pipe is designed for use in underfloor central heating systems. It is supplied with an oxygen diffusion barrier offering maximum protection against oxygen ingress. The design of the barrier within the wall of the pipe offers significant advantages over underfloor pipes with an external coating. ® Hep2O Underfloor Heating Pipe is available in 16mm and 20mm diameters, in a variety of coil lengths (Table 5). ® Hep2O Underfloor Heating Pipe is manufactured principally from polybutylene (PB) which is more flexible than other materials commonly used for underfloor heating, such as crosslinked polyethylene (XLPE) or polypropylene (PP). The inherent flexibility of 4 polybutylene allows sub-floor heating circuits to be installed quickly ® and easily without the use of tools or heat sources. Hep2O Underfloor Pipe is available in a variety of coil lengths, enabling the installation of long continuous circuits, with minimal pipe wastage. ® Hep2O Underfloor Heating Pipe is corrosion resistant and unaffected by corrosion inhibitors when used as recommended by the manufacturer. ® For further information on Hep2O Underfloor Heating Systems visit www.hep2O.co.uk

Figure No. 26 Figure No. 27

Table No. 5 Underfloor Heating Pipe Lengths 16mm 60m  80m  100m  150m  200m  500m 

21 Sitework Routabout ® Hep2O Routabout Hole Cutter This unique system solves the problem of underfloor access found by all builders, plumbers and other trades. A 250mm diameter opening can be cut and made good in minutes. Designed for use in new or existing 18mm & 22mm chipboard or similar floors, the Routabout cuts only the thickness of the board, thus leaving no waste and the piece cut out is used to make good the floor. You will also need: G 1 1 1 x /4 inch or /2 inch collet to fit a medium sized plunging type router (not supplied). G 1 x 30mm (outside dia) guide bush - fitted to router (not supplied). G Router (750 watts or above). G Routabout rotating template.

Figure No. 28 G Router G Tungsten router cutter G Routabout rotating template G Routabout spacer ring

Figure No. 29 G Routing the flooring sheet using the Routabout rotating template.

Figure No. 30 G The routabout spacer ring provides access in the floor sheet to the pipework.

Figure No. 31 G The chipboard cutout fits snuggly into the spacer ring, leaving a neat access.

22 Sitework Conduit Systems ® The Hep2O Conduit system allows pipe and fittings to be installed directly into concrete floors or into walls whilst complying with the requirements of the Water Regulations.

® The flexible conduit allows Hep2O to be withdrawn for inspection, and junction boxes allow maximum accessibility to fittings for inspection and possible removal. To allow pipework to be easily replaced or terminated in the future only ® Demountable fittings should be used within the junction boxes. Hep2O 22 x 10mm manifolds can be used in conjunction with spigot tees in 22 x 15mm and 15 x 10mm sizes to build up various manifold configurations. If any bent sections of conduit pipe are formed in an ® installation then future replacement of the Hep2O is likely to require 4 the use of a ‘draw cable’. In this event the draw cable should be attached to one end of the ® Hep2O before it is pulled out from the other end. Replacement of a ® new section of Hep2O pipe may require two operatives; one pulling the draw cable which is attached to the pipe end and the other person feeding-in the new length from the opposite end. Future replacement will be easier if conduit bends are kept to a minimum and any radius kept as large as practicable. The system consists of two sizes of flexible conduit, junction boxes with lids and terminal fittings. Holes can be cut in the sides of the junction box at the appropriate position to accommodate the conduit which simply clicks into position.

® Hep2O Conduit Pipe is available in the sizes shown in Table No. 6. Table No. 6 Conduit and Pipe in Pipe Lengths 10mm 15mm 22mm 28mm Conduit Pipe (Black Conduit) 25m  50m  Pipe in Pipe (Red and Blue Conduit) 25m  50m  

® ® 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 in Pipe is available in the handy site managable coil lengths shown in Table No. 6. The Pipe in Pipe system is available in red and blue conduit to aid the identification of the pipe. Figure No. 32 Pipe in Pipe Coil

23 Sitework Installation Recommendations ® The Hep2O pipe should be fed into position at the same time as the conduit system is installed i.e. before screeding. The conduit system should not be installed on sub-floors a long time in advance of screeding as damage by site traffic could occur. The junction box is designed to gain access to pipe fittings, and to allow pipe cross-overs (which are normally undesirable within the floor screed material). 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, to allow the conduit to fit snugly and click into position to protrude not less than 5mm inside the box. Conduit pipe OD’s are shown in Table No. 7. NB: The prevention of cold water becoming warm is a Water Regulations requirement.

Figure No. 33 Conduit Junction Box HX100

Note: Central heating pipework should not be run within the same junction box as cold water pipework unless there is sufficient space to fix adequate thermal insulation, in order to prevent the warming of cold water.

Figure No. 34 Figure No. 35 Junction Box Dimensions Cut Junction Box 377mm Plan Hep2O pipe to radiator or sanitary appliance 202mm Junction Box Lid 170mm

340mm Side Hep O elbow 75mm 2 Section 322mm

165mm 160mm End 75mm Section

150mm N.B: Junction Box cut in 1. All dimensions are nominal. half and secured to 2. Lid recess is designed for 8mm thick plywood. sub floor 24 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

The junction box should be fixed to the sub-floor (in order to prevent movement or ‘floating’ during screeding) the fixings should be provided with suitable washers. The junction box should be fixed so that the lid (when fitted) will be level with the adjacent floor finish. For uneven sub-floors or where the screed depth exceeds the junction box height, the box should be provided with suitable packing support under the base. 4

Figure No. 36 Typical Section Showing Junction Box Installed on Hot and Cold Water Distribution Pipes at Tees

Small insulating Thermal insulation Finished Junction box lid, pad, cut and barrier formed floor drilled and secured placed to across junction box. level by fixing screws separate pipes (if necessary). at cross-over

Conduit Junction box Tee on cold Tee on hot Pipe secured to the water pipe water pipe sub-floor

Remember: No thermal insulation would be necessary where the junction box is used solely for central heating pipes.

® To facilitate the possible removal and replacement of Hep2O within the conduit system, conduit pipe should be installed without joints and should ideally run in straight lines between junction boxes. Where bends are unavoidable there should be not more than two changes of direction between adjacent junction boxes. Conduits carrying cold water pipes should not touch conduits carrying hot water or central heating pipes. When running conduits within floor screeds the recommended gap between such conduits should not be less than 50mm (see Figure No. 37, page 26) in order to prevent the warming of cold water. The conduit system should not contain unused water pipes which remain connected to water systems. Redundant pipework will result in water stagnation which would pose a risk to health.

25 Sitework Installation Recommendations cont. Figure No. 37 Minimum Spacing for Cold Water Conduit in Floor Screeds

50mm (min)

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

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

Figure No. 38 Conduit Terminal Fittings

HX101/15 HX103A HX103 15mm Conduit Terminal Terminal Fitting Plate Terminal Back Plate

For terminating the conduit pipe at wall and floor finish level for direct 15mm connections to appliances, a conduit terminal fitting is available (HX101/15). For floor terminations the plastic housing may be drilled through the base to allow fixing. Floor termination procedure is shown in Figure No. 39. Figure No. 39 HX101/15 Conduit Terminal Installation Procedure

26 Sitework Installation Recommendations cont. For wall terminations two alternative fixing plates are available. The HX102 Terminal Fitting Plate and HX103 Terminal Back Plate, shown in Figure No. 38. The HX103 can be used to mount two terminals side by side (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 of four Wall Plate Elbows. (Figure No. 41).

Figure No. 40 Figure No. 41 HX101/15, 15mm Conduit Terminal HX103, Terminal Back Plate and and HX103 Terminal Back Plate HX6/15 Wall Plate Elbow

4

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

27 Sitework

® Hep2O Within Dry Lined Walls Installers have found that feeds to radiators run in microbore copper can be accommodated behind ‘dot and dab’ plasterboard to give a pipe-free ® appearance within the room. Pipes run in 10mm Hep2O are equally suited to this application but will not be susceptible to damage such as dents or kinks which can be caused on ‘soft’ copper by following tradesmen. The penetration through the plaster board for a radiator connection can be achieved by using a 10mm SlimLine elbow (HX5/10) together with a Fitting Clip (HX84/10 see Figure No. 44) or alternatively a dry lining box can be used (see Figure No. 46).

® Another method when using 10mm Hep2O Pipe is to utilise the HX111 or 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 method of connecting radiators. The box is fixed in a central position behind the radiator with the 10mm pipes dropping out to the radiator valves. This gives a smart professional finish where little or no pipe is seen and for new build provides an anchor point for the pipe work prior to plastering/boarding.

Figure No. 43 Installation procedure of HX111 Cover Plate

28 Sitework

® Hep2O Within Dry Lined Walls cont. The following is good practice for ‘first-fix’ pipework: G Radiator ‘drops’ should be run vertically, side by side, at one end of the radiator position. G Lateral pipes should be run horizontally in line with plasterboard penetrations. G Avoid running pipework along any obvious fixing zone ie. at skirting level.

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

Two 5mm fixing holes, one each side 4 For fixing pipework to lightweight blockwork the HX65 pipe clip is not suitable for fixing directly to such walls because of the low pull-out resistance of the nail. In such circumstances a more secure hold can be achieved by fixing wooden dowels at each clip position. The dowels should be the solid type with a serrated surface and of sufficient size (not less than M8 x 30mm). Holes should first be drilled in the blockwork using a drill bit size which provides a tight fitting hole for the dowel, taking care not to over- drill the hole depth. After tapping in the dowels the pipe clips can then be fixed by knocking the nail into the centre of each dowel.

® Figure No. 45 Radiator Pipework in 10mm Hep2O Within Dry Lined Walls

Thermostatic Radiator Valve (HX71/10)

90° M & F Elbow Pipe Clip (HX4/10) (HX84/10)

Skirting board 90° Elbow Radiator (HX5/10) Draincock (HX23/15) 90° M & F Elbows (HX4/10)

29 Sitework

® Hep2O Within Internal Drywall Systems ® Hep2O can easily be cabled within timber studwork and within wall systems (eg. Paramount Board) during construction. This method is often used 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 the wall and fixing a plastic snap-on escutcheon to neatly cover the hole through the wall surface. ® Alternatively for 10mm Hep2O a dry lining box can be used which gives the 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 to Metalwork’ on page 19.

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

10mm Hep2O

Single socket elbow, use SlimLine type for neatness (HX4/10)

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

Demountable elbow (HX5/10) Non-load bearing internal drywall system NB: This solution can also be used where the radiator is fed from below in which case the risers should be located directly under each box.

® Hep2O Within Timber Framed and Steel Framed Buildings ® Hep2O is ideal for use within both timber framed and steel framed buildings. For recommendations applicable to internal partition walls refer ® to the text headed Hep2O within Internal Drywall Systems’, on page 30. Running pipework of any material within the external wall of framed buildings should not be done without consideration of the following:- G If a leak occurred on a pipe it should be discovered without delay as seepage within a wall may damage the structural frame and affect the performance of insulating materials. G Water Byelaws require that pipes should not be fixed in a situation where leaks could be undetected for long periods. 30 Sitework

® Hep2O within Timber Framed and Steel Framed Buildings cont. G Where a pipe passes through a vapour control layer the installation method should allow possible future replacement of pipe without affecting the integrity of this layer. G Pipework should be installed on ‘warm’ side of thermal insulation layer. To comply with the foregoing criteria, pipework should be either run within a recessed duct designed by the Architect or run within a conduit system. Whichever method is used it is necessary to consider the detail at the junction between the wall and floor to avoid floor joist problems and to agree pipe penetrations at header rails/bottom rails. For radiator ® connections, 10mm Hep2O within conduit pipe may be used (see Figure No. 47) The suggested installation sequence is as follows: 4 1. Prepare sketches showing setting-out dimensions for each dry lining box 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 end should be left approximately 100mm longer than box position and should not be fixed closer than 600mm to the box. 4. Install the main ‘first-fix’ pipework leaving joints below floor access covers to allow connection to conduit pipework during ‘second fix’ work.

® Figure No. 47 Radiator Connection Using 10mm Hep2O Within Timber or Steel Framed External Wall

Plasterboard 10mm When cutting Hep2O vapour control plasterboard 15mm care should be (nominal) taken not to displace vapour Conduit Pipe control material The conduit should be firmly terminated within dry lining box

Demountable elbow Hep2O Single (HD5/10) Socket SlimLine Elbow (HX4/10) Dry Lining Box and Cover Plate (single gang electrical fitting)

Insulating material

31 Sitework

® Hep2O within Timber Framed and Steel Framed Buildings cont. 5. Using setting-out dimensions on sketches, holes in plasterboard can be cut to allow each conduit pipe to be pulled out through the surface during plasterboard fixing work. 6. During ‘second fix’ each dry lining box is installed by drilling a 26mm diameter hole for 15mm (nominal) conduit pipe. The conduit can then be inserted through hole in box and should ‘click’ into position leaving one or two conduit ‘ribs’ inside box. ® 7. Slide a length of 10mm Hep2O pipe through conduit pipe from the ® floor access above. Pull out enough Hep2O from dry lining box to allow a sufficient hand grip for jointing. Connect a demountable elbow to pipe then slide whole assembly through plasterboard hole and secure box into position. Conduit pipe should ‘snake’ within void to ® take up slack leaving Hep2O protruding out of box. ® 8. Pull Hep2O pipe backwards from floor access panel until elbow is central within dry lining box. Cut pipe to length and connect to ® Hep2O joint left during ‘first fix’. Timber or Steel Framed Buildings - General Advice: Holes through timber joists should be drilled in accordance with Figure No. 19 & 20, on page 15. Holes through timber studs should be drilled in accordance with Figure No. 48. Within steel framed buildings pipework should be routed through preformed holes in steelwork wherever practicable (and where provided). No holes should be formed in steelwork without the approval of the Architect. Pipework Figure No. 48 Limitations of Drilling passing through Studwork steelwork should be protected from damage

(refer to the text headed ‘Pipes Adjacent to Metalwork’ on page 19). Do not lay pipework in areas where plasterboard 0.25 x H

is likely to be fixed. 0.4 x H Services within Holes should compartment or party be located in walls should be avoided these zones D and drilled at so as not to impair fire centre of stud resistance or acoustic depth ‘H’ Stud Height properties. Care should be taken that pipework passing 0.4 x H through compartment walls or floors does not 0.25 x H impair the fire resistance of the property.

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

32 Compatability and Connections Connection to Metric Copper Pipe ® Hep2O fittings have been designed to form reliable joints with metric copper tube which conforms to BS EN 1057 - R520. Copper pipes should be cut with a wheel cutter. Before jointing, copper pipe ends should be inspected to ensure they are free from burrs or swarf (which could damage the ‘O’ ring). It is also possible to connect 10mm BS EN 1057 - R220 ® copper tube into Hep2O fittings providing the tube end is carefully prepared. R220 copper tube is ‘soft’ and therefore susceptible to becoming misshaped or dented if it is not handled with care on site. Therefore the R220 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, or otherwise affect the joint seal. R220 tube should be cut with a mini wheel cutter, and then a chamfer should be filed on the pipe. Rinse away the remainder of any copper filings and dry-off. NB: Mark the joint depth on the copper pipe before jointing, refer to page 9.

5

Cut copper pipe using Inspect ends to Insert copper end a wheel cutter ensure free from protector burrs or swarf

Mark joint depth on Push pipe firmly into Tug back on the pipe copper pipe before fitting to ensure grab wedge jointing engages properly

DO G Use a wheel cutter. G Check ends free from burrs or swarf. G Insert copper end protector (HX61/15 & HX61/22). G Mark joint depth on copper pipe. G File end of pipe if using a hacksaw. 

33 Compatability and Connections

Connection Using Compression Fittings ® Hep2O pipe is suitable for connecting to compression fittings complying ® with BS EN 1254. Cut the Hep2O pipe with the recommended cutters and proceed as shown below.

Insert support sleeve Ensure pipe is fully Apply PTFE if required into pipe inserted

Tightening nut

Note:

® Hep2O pipe will not rotate in a compression fitting after tightening

DO G Use a support sleeve when making a compression joint. G Ensure pipe is fully inserted. G Use PTFE tape over olive if lubrication required. G Copper olives are preferable to brass ones.

DON’T G Use oil based jointing compounds. 

34 Compatability and Connections Connections Adjacent to Capillary Joints ® When using Hep2O pipe or fittings adjacent to capillary joints it is ® preferable 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 following precautions should be observed:

DO G ® Keep flame or soldering irons away from Hep2O . DON’T G ® Allow flux to run onto Hep2O . Flux runs inside pipe may occur during soldering, this effect can be reduced by not using excessive amounts of flux and by applying 5 flux to copper tube end only. G ® Allow hot solder to come into contact with Hep2O .

Trade Tip:

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

Note: Systems should be flushed with water to remove any internal flux residues.

Connection to Imperial Copper When connecting to 3/4’’ imperial copper ® Hep2O offers a special ‘O’ ring straight adaptor (HX3A/22) which accepts 22mm pipe at 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 replace ® the standard ‘O’ in Hep2O fittings. See Re-assembling a joint (page 42-43). 3 1 ® ( /8’’, /2 ‘’ & 1’’) imperial pipes can be connected using standard Hep2O fittings.

DO G Use an adaptor (HD3A/22) or imperial ‘O’ ring (HX52) when connecting to 3/4’’ imperial copper.  35 Compatability and Connections Connection to Chrome Plated Copper or Stainless Steel Pipe

® Hep2O fittings cannot be connected directly to chrome plated copper or stainless steel, because of the relative surface hardness of these materials. Therefore the following procedures must be followed: Chrome Plated Copper: Use compression fittings as shown on page 34. Stainless Steel: Use compression fittings as shown on page 34.

Note:

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

Connection to Brass Spigots ® The only brass spigots which are suitable for jointing into Hep2O fittings ® are those within the Hep2O Range. Brass spigots designed for compression or capillary joints do not have the necessary joint grooves and are too short. Connection to the Acorn® System

® ® Hep2O is fully compatible with its predecessor the Acorn system previously manufactured by Bartol. Pre 1984 Acorn® 22mm pipe was manufactured with a thicker wall and requires a different support sleeve. If carrying out remedial work on such an Acorn® 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 of ® Hep2O Fittings.

Note:

® Internal components of the current Hep2O Fitting (Cap, BiTite Grab Wedge, Wedge Support Ring and ‘O’ ring) are not in any way ® compatible with original Hep2O Fitting components (Cap, ‘O’ ring, Spacer Washer and Grab Ring) and therefore bodies and components must NOT be mixed. For further information contact our Technical Advisory Service – Tel: 0870 460 5578.

Connection to Plastic Pipes ® Hep2O should not be used in conjunction with other manufacturers plastics pipe and fittings as dimensional tolerances and quality control cannot be guaranteed by Wavin.

36 Compatability and Connections Connection to Incoming Service Pipes Water may enter a property through a variety of pipe materials. In recently developed properties the water is typically brought to a residence in blue MDPE (medium density polyethylene) pipe. However, in renovation of older properties this pipe may well be made of one of a number of metals. The ® method of converting from the service pipe to Hep2O differs depending on the pipe material of the service pipe. The following guidance is applicable to blue MDPE Pipe to BS 6572:-

G For 20mm MDPE use a polyethylene 20 x 1/2” BSP male adaptor (Code ® 20PEAM05) together with a MDPE pipe liner (Code 20PELIN), Hep2O ® female adaptor (Code HX30/15) and Hep2O stopcock (Code HX36/15). (See Figure No. 49). G ® 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 of ® Hep2O joints by turning the stopcock towards the wall when not in use, then proceed as follows. Use a polyethylene 25 x 3/4” BSP male adaptor (Code 25PEAM07) together with a MDPE pipe liner ® (Code 25PELIN), Hep2O female adaptor (Code HX30/22) and 5 ® Hep2O stopcock (Code HX36/22). (See Figure No. 51). NB: Details of MDPE pipe, fittings and jointing instructions are contained in separate literature which can be obtained by contacting our Literature Service Hotline Tel: 01249 766333 Fax: 01249 766332.

Figure No. 49 Rotatable Stopcock HX36/15 HX30/15

Adaptor

20mm MDPE

HX43/22 HX36/22

HX30/22

Adaptor

25mm MDPE 25mm MDPE

Figure No. 50 Figure No. 51 Non-rotatable Stopcock Rotatable Stopcock

37 Compatability and Connections Connection to Incoming Service Pipes cont. NOTES: G Where a common supply pipe serves two or more dwellings a double check valve (Code HX72) is required directly after stopcock in each dwelling to comply with Water Byelaws. G A drain-cock (Code HX32) should be fitted immediately after stopcock or after double check valve where provided to comply with Water Byelaws. G 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 be carefully noted. (See page 34). For metal pipes an appropriate stopcock should be used with a compression ® outlet to 15 or 22mm copper. Hep2O can then be fitted directly to these outlets carefully noting details in Connections to Compression Fittings (See page 34).

Connection to Steel Pipes and Threaded Bosses In order to facilitate connection to male and female iron threads, four adaptors (HX28/HX29 Socket Adaptors, HX31/HX30 Spigot Adaptors) are ® available in the Hep2O range. This enables connection to a wide range of different materials. (See Figure No. 52).

HX28 HX29 HX30 HX31 Figure No. 52 Adaptors for Connecting to Steel Pipes and Threaded Bosses

Connection to Appliances ® When connecting to appliances and dishwashers always use Hep2O ® appliance valves (HX38C/15, HX38H/15). The Hep2O pipework used to service these appliances should be clipped in accordance with the recommended clipping distances (see page 17) using screw-type clips (HX85).

Figure No. 53

HX85 HX38C/15 (Cold) HX38H/15 (Hot) Pipe Clip - Screw Connecting Appliance Valves 38 Compatability and Connections Connection to Draw-off Taps When connecting to draw-off taps having a male threaded ‘tail’ use either ® the Demountable or SlimLine Hep2O tap connector. Do not use any jointing 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 threads should be sealed by applying PTFE tape to the male threads. Figure No. 54 Tap Connectors Demountable - Straight and Bent Tap Connectors

15mm x 1/2” 15mm x 1/2” HD25A/15 HD27/15

15mm x 3/4” HD25B/15

22mm x 3/4” HD25B/22

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

5

SlimLine - Straight and Bent Tap Connectors

15mm x 1/2” 15mm x 1/2” HX25A/15 HX27/15

15mm x 3/4” HX25B/15

Connection to Ancillaries (Pumps, Valves, etc.) ® When connecting Hep2O to ancillaries it is important to follow the guidance in the section ‘Connection Using Compression Fittings’ (Page 34). ® Due to the flexibility of Hep2O the pipework must be clipped adjacent ® to 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 weight of the pump merits extra support, metal brackets should be used. Where the size of the pump and/or valve requires fixing at a greater distance from the wall than can be accommodated by the pipe clip alone, then this can be augmented with a pipe spacer (HX86), which will allow a greater ‘stand-off’ distance whilst maintaining security.

Figure No. 55 Connection to Pump

39 Compatability and Connections Connection to Storage Vessels and Radiators ® When connecting Hep2O pipe to cylinders, radiators etc. it is always ® recommended that Hep2O fittings are used wherever possible. ® The Hep2O range of fittings includes thermostatic, wheel head and lockshield radiator valves, double check valves, tank connectors, gate valves, stopcocks and cylinder connectors. If the use of compression fittings is unavoidable then the jointing instructions outlined 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 cylinder connector, use only PTFE tape. Do not use any jointing compound when fitting tank connectors, use only sealing washers (not provided). Figure No. 56 Tank and Cylinder Connectors

15mm and 22mm 22mm x 1” BSP HX20/15 HX20/22 HX34/22

Figure No. 57 G Radiator or Lockshield Valve G HX73/10 G HX73/15

Figure No. 58 G Thermostatic Radiator Valve G HX71/10 G HX71/15

Figure No. 59 G Radiator or Lockshield Valve (HX73/10) G Straight Radiator Connector (HX77/10) G Radiator Draincock (HX23/15)

40 Compatability and Connections Connection to Boilers and Heaters Where boilers incorporate a high limit cut out thermostat, pump overrun device, and have connections outside the boiler casing 350mm from the heat source, direct connection can be made to ® Hep2O . Typically these boilers contain a copper heat exchanger and are low water content boilers. Where any one of the above criteria for direct connection to a boiler cannot be met a minimum one metre run of copper pipe should be installed between the boiler and the ® start of the Hep2O system. In all cases (including instantaneous water heaters, caravan heaters etc.) care should be taken to ensure that appliances have the appropriate thermostatic controls and cut outs to ensure that operating conditions do not exceed the temperature and pressure limits laid down for Class S pipe (see Table No. 1, page 3). For any type of back boiler all water connections should be extended from the appliance to the outside of the fireplace opening in copper tube. 5 In these instances, where the heat output may be uncontrolled, a minimum one metre run of copper pipe should be used between the ® boiler and the start of the Hep2O system. Any gravity circuit of a solid fuel boiler should always be installed in copper. Regulations require that metal pipe be used as discharge pipe from temperature/pressure relief valves on unvented water heaters, to or from a tundish or from safety valves on sealed central heating systems. On sealed systems where the safety valve is not provided within the boiler casing, the pipe between the safety valve and the boiler should be in copper. All boiler connections should be made in accordance with the requirements 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 be fitted to the circulation pipework preferably controlled by an automatic differential pressure bypass valve. During commissioning it is important to ensure that all trapped air is purged from the heating system before the boiler is operated. ‘Pockets’ of air can affect proper circulation and impair the correct operation of boiler temperature controls which could cause severe overheating.

41 System Modifications Fitting Detachment Re-using a demountable fitting Figure 60 Unscrew the retaining cap and pull the pipe clear of the fitting.

Figure 61 Remove the ‘O’ ring and wedge support ring (if applicable) from the pipe.

Figure 62 Using the wedge removal tool, slide the grab wedge from the pipe. Provided it is undamaged it can be re-used.

Figure 63 Re-assemble the fitting, inserting the ‘O’ ring, the wedge support ring (if applicable) and then the grab wedge, with the flat face against the wedge support ring – replace the cap hand tight.

® Re-assembling a Hep2O joint To re-assemble the fitting:

G If demountingV a fitting, start with a fresh piece of pipe. cut off pipe at next full ‘ ’ mark from end. G Check each component for damage. Replacement components are available. Refer to current Trade Price List. G Ensure all components are clean. G ® Apply a small amount of Hep2O Silicone Lubricant (Code HX200) to ‘O’ ring before insertion of fitting. G Insert the ‘O’ ring into the fitting body until it rests on the ledge at the bottom of the socket. G Place the wedge support ring so it sits above the ‘O’ ring. G Insert the grab wedge into the wedge support with the flat face of the grab wedge facing down. G Replace the retaining cap and hand tighten. G The fitting is now ready for use.

42 System Modifications

Note: G Pipe should be rotated in cutters during operation. G Support sleeve is an integral part of system and should NEVER ® be omitted when using Hep2O pipe. G ® 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.

Remember: If the grab wedge is inserted upside down the pipe will not enter into the joint.

Figure 64 Retaining Cap

‘O’ Ring

6

Wedge Support Ring

Grab Wedge

Lubrication ® All ‘O’ ring seals contained in Hep2O fittings have been pre-lubricated during factory assembly. During normal installation additional lubrication should not be required. If however the fitting has been dismantled then the lubricant may have been removed by handling and may require replacing. If replacement ‘O’ rings are being used (Code HX50, HX51 and HX52) these are supplied dry and should be lubricated before jointing. Similarly in particularly difficult locations additional lubricant may assist in ® ease of jointing. In these situations Hep2O Silicone Lubricant Spray (Code HX200) must be used to avoid contravention of Water Byelaws and ensure compatibility with other system materials.

Remember:

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

43 System Modifications Alterations ® Blanking a fitting is easy with Hep2O

® SlimLine Hep2O Insert a blanking plug (HX41) directly into the fitting. When ready to continue, drain the system, cut off the top of the blanking plug where indicated and attach the next fitting.

Note:

® Stainless steel blanking caps will not work correctly in Hep2O fittings with BiTite® grab wedges inside.

® Demountable Hep2O Remove the cap and grab wedge from the fitting. Push the open end of the blanking peg (HX44) into the ‘O’ ring. Replace the cap hand tight.

Removing the Blanking Peg Remove the cap and blanking peg, re-insert the ‘O’ ring and wedge support ring (if applicable) - check the grab wedge is undamaged. Insert the grab wedge into the fitting with the flat face against the wedge support ring. Replace DO the cap hand tight. G Check the fitting and components are clean. G Lubricate ‘O’ ring before re-assembly of joint (use HX200 lubricant only). G  Replace end cap and tighten by hand. DON’T G Keep new grab wedges loosely amongst tools or pipe fittings. To avoid damage store in a separate compartment orcontainer, similarly with ‘O’ rings. G 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 and are NOT compression fittings.

44 General Information Thermal Insulation ® Although Hep2O pipe has lower thermal diffusivity than copper, its insulation requirements are the same as those of copper and should be in accordance with BS 5422, BS 6700, Water Byelaws and Building ® Regulations Approved Documents. Hep2O pipe is less likely to burst should the water in ® the pipe freeze, however should Hep2O be connected to a metal pipe, a metal tap or a close configuration of fittings (incorporating metal support sleeves) then the likelihood of a failure due to the expansion of frozen water will be increased. Freezing for Maintenance/ System Modification ® Hep2O pipe can be frozen for maintenance/repairs without damage to the system. Freezing equipment manufacturers instructions should be followed. 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 to protect the pipe from sunlight and the effects of ultra violet light. ® It is preferable when painting Hep2O to use emulsion paint, however, oil based gloss paint can be used in conjunction with undercoat. Cellulose based paints, paint strippers or thinners should not be used. Before painting, ensure all surfaces are clean, free of grease and dry. Use of Corrosion Inhibitors 7 Corrosion of metals is a hazard in all installations therefore it is essential that possible causes of corrosion are kept to an absolute minimum. Oxygen will almost always be present in any system as it can enter through 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, all heating circuits should be protected by an inhibitor. ® Hep2O Barrier Pipe incorporates an additional oxygen barrier to reduce ingress of oxygen through the pipe wall. It is accepted by British Gas and is eligible to be used in heating systems which specify SuperWarm, GasWarm or are covered by British Gas Contract Service. Fernox MB1 and Betz Dearborne Sentinel Inhibitors have been tested and are ® suitable for use with Hep2O . Antifreeze Antifreezes based on Ethylene Glycol mixtures will not have an adverse effect ® on Hep2O , however if there is any doubt as to the suitability please contact the Technical Advisory Service – Tel: 0870 460 5578 Fax: 0870 460 5579 for advice.

45 General Information Electrical Safety ® Hep2O does not conduct electricity therefore the risk of electric shock ® from contact with a Hep2O installation is eliminated. The practice of utilising the metal pipework system for earthing was ® discontinued in 1966. However, when Hep2O forms a break in the continuity of existing metal pipework which may have been used for earthing or bonding, then the electrical continuity should be reinstated by fixing the bonding lead permanently to both ends of the existing metal pipework.

Remember: Equipotential Bonding ® A Hep2O installation requires no more and in many cases needs less equipotential bonding than metal pipework.

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

Woodworm / Timber Treatment When treating timber for woodworm or timber rot aqueous based solutions are generally accepted. But care should be taken to protect and ® cover 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.

46 Special Precautions External Installations ® If Hep2O is installed in an external application then the system will ® require protection from frost. Although Hep2O has lower thermal diffusivity than copper, insulation requirements are the same as those of copper and should be in accordance with BS 5422, BS 6700, Water Byelaws and Building Regulations Approved Document L.

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

® If Hep2O is used externally it should be protected from the ultra-violet radiation in sunlight. If insulation has been installed to avoid freezing this is sufficient. However, where insulation is not used, painting or covering is recommended. (See page 45). Vermin Extensive testing has demonstrated that vermin do not show a preference for ® Hep2O over other materials. However, all items which are less hard than the rodents teeth are liable to be gnawed in vermin infested property, including ® electric cables and Hep2O pipe. If vermin infestation is suspected then a reputable rodent exterminator should be consulted. If vermin are present they ® may damage Hep2O pipework. Chlorine High sustained concentrations of chlorine will have an adverse effect on all ® plastics pipe. Hep2O is not suitable for use in systems where the water carried in the pipe contains a high concentration of chlorine e.g. swimming ® pools or decorative water features. Hep2O will not be affected by the 8 levels of chlorine expected in the UK water supply (typically less than 0.5ppm) Short term chlorination for disinfection will not have an adverse effect on the system. If long term contact is suspected the Technical Advisory Service should be consulted – Tel: 0870 460 5578 Fax: 0870 460 5579.

47 Testing Pressure Testing

® Installers should ensure that all non-Hep2O products can withstand the test pressure by checking with other relevant manufacturers. ® When testing Hep2O pipework systems, the recommended test pressure is: G ® For Hep2O fittings with grab wedges – 1.5 times working pressure. G ® 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 test to a maximum of 18 Bar should always be undertaken. Care should be taken to disconnect any appliances or fittings that will not withstand, or will be damaged by testing at 18 Bar. For testing procedure see below. The duration of the test should be not less than 1 hour in accordance with BS 6700.

Gauge Valve 1 Valve 2 Figure No. 65 Pressure Testing Figure No. 66 Pressure Testing Kit (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) or Blanking Plugs (HX41). 3. Connect pressure hose to system at a convenient point using a demountable socket. 4. Close Valve V2 and open Valve V1. 5. Fill system to be tested with water ensuring system is completely full 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 pointer is ‘free’). Read pressure on gauge, no appreciable drop in pressure should be noticed to indicate the system is watertight. 8. Release Valve V1 and V2 to release pressure from system. Drain system if necessary. 9. Replace cap and components in socket used for connection to test kit.

Remember! Pressure Testing is NOT a substitute for making sure the Correct Insertion Depth of the Tube into the fitting using either the Chevron marks or a pencil mark has been achieved. For correct method (see Fig 8, page 10).

48 Special Applications Boats ® The flexibility of Hep2O means it can be cabled around the interior cavities of boats and easily hidden behind bulkheads. Light in ® weight, Hep2O will not add unduly to the draft of the vessel. There are three key problems with traditional plumbing in marine craft: G Prolonged and damaging vibration from engine and forces of sea may cause soldered or compression joints to crack or work themselves loose. ® Flexibility of Hep2O pipe absorbs these damaging forces, and jointing technology ensures a secure joint will not come loose during its service life. G Electrolytic corrosion may occur as a result of contact established between dissimilar metals in plumbing system and boat’s construction. This ®. can cause damage to both. This will not occur with Hep2O G Salt water is itself extremely corrosive to most metal plumbing systems ® but has no effect on Hep2O pipe or fittings. Caravans ® Hep2O is ideal for caravan installation where its lightness and flexibility allows fitting in confined spaces without damage to the fabric of the vehicle, or adding unduly to the kerbside weight. Resistance to corrosion and freezing ® make Hep2O an obvious choice for this application. Exhibitions The temporary nature of most exhibitions combined with the requirement that services be run for considerable distances with multiple take-off points, requires a plumbing system which is not only flexible, but also capable of ® regular dismantling and remaking to different layouts. Hep2O combining flexible pipe with demountable joints, offers a unique solution to this problem, giving a positive cost saving (as little waste is incurred) with the opportunity to modify the overall design installation to suit short-term requirements. Portable Buildings (site cabins, toilets etc.) 10 Similar in many respects to caravans, portable homes often require connection to more permanent services. ® The Hep2O range includes all the necessary items to ensure compliance with local water byelaws (e.g. double check valves) whilst allowing the building to be moved to another location when required, with the minimum disruption to internal systems. Coupled with the ability to install in difficult spaces and the ability to rotate fittings to allow better ® access to valves etc. Hep2O is the ideal choice for these structures.

49 Special Applications Agricultural and Horticultural Use ® Because of its resistance to damage, corrosion and cold weather Hep2O has many applications in agricultural and horticultural environments. Typical ® installations ideally suited to Hep2O are the water supply to milking parlours, drinking troughs and horticultural watering systems. Air Conditioning Systems ® Hep2O is ideal for the condensate pipes from air conditioning systems and chilling systems, and in many low pressure systems will also be suitable for the primary circulation. If in doubt contact the Technical Advisory Service – Tel: 0870 460 5578 Fax: 0870 460 5579 for advice.

® Where not to use Hep2O ® The Hep2O system has been designed and tested to meet the requirements of modern heating and water distribution systems. Testing has not been carried out to determine suitability for other purposes and therefore should not be used for instance, in the following applications: G Conveyance of gas. G Conveyance of fuel oil. G In areas contaminated by petroleum and oil derivatives. G Compressed air. G ® Hep2O is not suitable for use in systems where the water carried in the pipe contains a high concentration of chlorine e.g. swimming pools or decorative water features. G ® Hep2O will not be affected by those levels of chlorine expected in UK water supply (typically less than 0.5ppm). Short term chlorination for disinfection will not have an adverse effect on the system, (page 47). G ® Hep2O should not be used for primary circuit of a Solar Heating ® System as temperature cannot be thermostatically controlled. Hep2O is suitable for secondary circulation of these systems. G ® Hep2O should be protected at all times from exposure to direct sunlight and ultra violet light. G ® Hep2O should not be installed in Ringmain Installations. A ringmain is a water-replenished circulating system maintained at a constant high temperature to provide a permanent source of hot water to its distributing pipes. Typical locations where ringmain systems are used are hospitals or hotels which distribute constant hot water to wards or rooms at a distance from heat source. This type of installation is very different from conventional domestic hot water and central heating services. This restriction does not apply to domestic systems operating intermittently at temperatures less than 65°C where a design life of 50 years as detailed in BS 7291 can be expected.

50 Handling and Storage

® Hep2O is an extremely tough and durable system however, as with all materials some care is required to ensure damage is not incurred during storage or installation which may impair its ultimate performance. ® Straight lengths of Hep2O pipes may be laid flat or stacked vertically. Coils may be laid on their side or edge. Both are lightweight and easy to carry and handle. Pipe and fittings wherever possible should be stored in their original packaging. This ensures protection from ultra violet light and will reduce the risk of contamination. Spare grab wedges and ‘O’ rings should not be carried loose amongst other fittings or tools where they may be damaged. They should be kept in their original packaging or in a separate container which will protect them.

® Hep2O should be protected from contact with petroleum and oil derivatives.

® When carrying or installing Hep2O pipe, care should be taken to avoid dragging the pipe along the ground or damaging the pipe on other surfaces such as walls. When feeding pipe through holes in walls and brickwork the pipe end should be taped over or the red cap included in the pipe coil be used to prevent damage to the jointing surface and debris entering the pipe. Care should be taken to avoid kinking the pipe during installation.

Figure No. 67

® Hep2O Straight Coiled Pipe

11

51 Hints and Tips

® For trouble free installation of Hep2O

® Most installers that have worked extensively with Hep2O will have experienced the odd problem from time to time. Based on customer feedback and over 20 years experience in dealing with such occurrences, the following are simple but effective precautionary steps that when taken will ensure trouble free installation. Potential joint problems can be divided into two main categories: Pipe Derived By far the majority of problems occur because the pipe end inserted into the fitting has been damaged in some way, this can create a leak pathway via the scratch or indent for water to pass. This type of damage can occur at various points along the route to finally commissioning the plumbing system. But in general taking a few precautionary measures can eradicate any such problems. G Take care in how and where the product is stored, retain pipe in protective packaging until it is to be used. G Never use an open bladed knife to remove the pipe packaging. G Always use the attached shielded blade tool to remove packaging and cut on the inside of the Figure No. 68 coil, thus enabling the pipe to be contained within the packaging until the last metre. (Figure No. 68). G When threading pipe through holes in stone, brick and block walls always use a pipe sleeve or alternatively a small piece of foam pipe insulation to protect the pipe from the rough surface. G Ensure exposed first fix pipework is protected Figure No. 69 after initial installation if further connections are to be made to the pipe. By simply pushing a temporary end protector onto the pipe, it ensures that no debris will enter the pipe and furthermore it will protect the pipe end from damage. (Figure No. 69). Fitting Derived Problems can arise for a number of reasons, grit or debris ingress into the joint prior to coupling, or sometimes the inadvertent omission of an integral component part of the joint due to past interference by the installer or a possible third party. Again taking a few general precautionary measures can eradicate any such incidents. G Store materials in a secure place free from dust and dirt etc. G Keep fittings in their bags until ready for use. G When fittings are de-mounted ensure they are correctly re-assembled. G Do not take joint components from new fittings to replace damaged or lost components in other fittings. G Always follow the do’s and don’t guidelines leaflets included with all bags of fittings.

52 Fault Finding

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

1. Problem: Pipe came out of fitting Probable 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 grab wedge the wrong way round. Evidence: The teeth of the grab wedge are pointing into the fitting (see pages 42-43 for correct assembly detail). d. The fitting has been dismantled and reassembled incorrectly with the components 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 grab wedge missing. Evidence: No grab wedge (see pages 42-43 for correct assembly detail).

2. Problem: Joint weeps Probable 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 to cut pipe). Evidence: Contamination evident on visual examination of components. c. ‘O’ ring seal has been damaged (usually by insertion of a sharp ended copper pipe). 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 current standard diameter (BS 2871 Part: 1 1971).

® ® e. Components from an old Hep2O or Acorn fitting may have been ® used 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 (the ® Hep2O is marked with the size); spacer washer (not needed in ® Hep2O fitting). 12

53 Fault Finding

3. Problem: Split fittings Probable Cause: Formation of ice within a system containing metal pipework, or adjacent to metal taps. NB: Water freezes at 0°C and increases in volume until it reaches – 4°C ® and 9% volume increase. Hep2O pipe can absorb this volume increase without rupture, but if metal pipe or components are involved in the system, the extra pressure generated may occasionally be sufficient to split the fitting. Evidence: Splitting of fitting or fitting pulled off pipe after severe cold spell – deformation of grab wedge. 4. Problem: Pipe or fitting melting Probable 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 the pipe to melt. b. Water/steam within pipe reaches temperatures in excess of normal boiler safety and malfunction levels. (This is very rare and if found should initiate a thorough 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 of material may appear ‘glossy’.

IMPORTANT If in doubt then return the pipe and the fitting to the Technical Advisory Department for further analysis.

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

54 Information Advisory Service Wavin offer a comprehensive range of support services to ensure that any queries can be dealt with swiftly and efficiently. Appointments for a demonstration can be made by telephoning Regional Hotlines. To obtain guidance on planning installations and to receive immediate advice of a technical nature telephone the Technical Advisory Service – Tel: 0870 460 5578 Fax: 0870 460 5579 Literature Service ® Hep2O is only distributed through builders’ and plumbers’ merchants and can be obtained nationwide. ® For details of your nearest Hep2O stockist contact our customer services team – Tel: 0870 460 5578 Fax: 0870 460 5579 To receive a Product Guide or Consumer Information Leaflet, please ring the Literature Hotline – Tel: 01249 766333 Fax: 01249 766332. Other Sources of Information Literature The Plumbing Engineering Services Design Guide published by The Institute of Plumbing. 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 and associated fittings for use in domestic hot and cold water services and heating systems. BS 6700: Design, Installation, Testing and Maintenance of services supplying water 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 ISO9002 requirements. BS 7291 ® Hep2O Barrier Pipe is Covered by Agrément Certificate 92/2823 to class ‘S’ of BS 7291.

The Water Byelaws Listed in the Water Fittings and

ED Materials Directory Listing Number 0112066. V T A RO C PP DU PRO

This Guide follows requirements stated in the standards, byelaws and regulations listed previously. Should it differ from any new UK or European requirements issued since we went to print, please obtain clarification by calling the appropriate Enquiry Hotline.

55 Hotlines

Orders: Fax 0870 443 8000 (for all orders & additions) Enquiries: Tel 0870 443 6000 Technical Advisory Service: Tel 0870 460 5578 Fax 0870 460 5579 Literature Service: Tel 01249 766333 Fax 01249 766332 Email: [email protected] Web Site: www.hep2o.co.uk

Wavin Edlington Lane Edlington Doncaster DN12 1BY UK

Wavin has industrial affiliation with:

Institute of Plumbing Scottish & Northern Ireland Plumbing Employers’ Federation

National Association of Plumbing Heating & Mechanical Services Contractors

® © Wavin 2009. Hep2O is a registered trademark of Wavin. Wavin operates a programme of continuous improvement, and reserves the right to modify or amend the specification of products without 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.

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