Emmeti Gerpex Press Fit Installations- und Betriebshandbuch

Installation and Commissioning Instructions

Gerpex Press Fit System

Reduced Installation time

Linear expansion similar to copper

Minimal tooling required

No hot works - no permits

Less wastage

High quality raw materials

Stable material costs

No scrap value

Low heat losses through pipe

WRAS approved

Easy to transport

Double O-ring technology

www.emmeti.co.uk

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

Contents

1. Equipment Checks....................................................................................................................2

1.1 Press Tool and Jaws

1.2 Calibration Tool

1.3 Pipe Cutting Tool

2. Installation ................................................................................................................................4

2.1 Removal of Pipe Packaging

2.2 Surface Installation

2.3 Embedded Installation

2.4 Bend Radius

2.5 Thermal Expansion

2.6 Pressure Drops

2.7 Pipe Cutting

2.8 Pipe Preparation

2.9 Pipe/Fitting Assembly

3. Press Fitting ..............................................................................................................................9

 3.1PressFittings16–63(THProle)

4. Compression Fittings.............................................................................................................10

4.1 Pipe Preparation

4.2 Pipe Connection

5. System Testing.......................................................................................................................10

6. Notes .......................................................................................................................................10

7. Warranty..................................................................................................................................11

The Gerpex Multi-Layer Composite Pipe System and the Gerpex Press Fittings are designed for use in heating,

hot and cold water, compressed air and chilled water systems.

Please always use the correct tooling and follow the instructions, as detailed to ensure correct operation of the

system.Thepurposeoftheseinstructionsistoensurethatthecorrecttoolselection,pipepreparation,tting

assembly and installation methods are used.

1. Equipment Checks - BEFORE CARRYING OUT ANY WORK

1.1 Press machine and jaws

PleaseensurethatthejawpressingproleiscompatiblewiththeEmmetiGerpexttingrange,byreferringto

Fig1.1andtable1below.Jawprolesarenormallyprintedontothejawbody.Ifindoubtpleaserefertojaw

manufacturerforconrmation.

Profile and dimensions of the jaws that can be used with Multi-Jaw Gerpex Fittings

16 20 26 32 40 50 63

TH OK OK OK OK OK OK OK

BOK OK OK OK - - -

UOK OK - - - - -

HOK OK - - - - -

FOK OK - - - - -

TH - KSP 11

B - KSP 1

U - KSP 5H- KSP 7F- KSP 2

TH - KSP 11 B - KSP 1

U - KSP 5H- KSP 7F

- KSP 2

TH - KSP 11 B - KSP 1

U - KSP 5H- KSP 7F- KSP 2

TH - KSP 11 B - KSP 1

U - KSP

5H- KSP 7F- KSP 2

TH - KSP 11 B - KSP 1

U - KSP 5H

- KSP

7F- KSP 2

Fig 1.1

Table 1.

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

1. Equipment Checks - BEFORE CARRYING OUT ANY WORK

1.1 Press machine and jaws

• Pleaseensurethatthereisnodamagetothe

pressing face of the press jaws. If damaged,

please replace as this could result in an incorrect

pressofthetting.

• Pleaserefertothetoolmanufacturer’sinstructions

when preparing the press machine for use.

•

Please ensure that the jaw size corresponds with the

ttingsize,thepressingmachineisingoodworking

order and that the batteries are fully charged.

ATTENTION: If the incorrect sized pressing jaw

is used for the fitting you have it will result in an

incorrectly pressed fitting and could therefore leak

1.2 Calibration Tools

• Pleaseensurethatcalibrationtoolhasnodamage

to its face or cutter. If so please dispose of and

replace.

YES NO

Cutter

• Pleaseensurethatthetoolbulbandcutterdonot

rotate when in use. If so please retighten locknut

or holding screw

1.3 Pipe Cutting Tool

• Checkcuttingbladetoensurefreefromdamage

and replace if necessary

ATTENTION:Keepngersawayfromcuttingblade

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

2. Installation

All installation must be carried out at temperatures

above -10oC and below 45oC to avoid any potential

distortion to the materials. In case of temperatures

below 0oC,pipeandttingswillneedtobestoredat

a higher temperature immediately prior to use.

2.1 Removal of pipe packaging

• Takecarenottodamagepipewhenremovingthe

packaging

• Takecarenottodamagepipeinsulationwhen

removing the packaging

YES NO

2.2 Surface mounted installation

• Forsurfacemountedpipeorpipeinstalledinto

falseceilings/oorsandductsthepipewillneed

to be adequately supported at regular intervals

depending on pipe diameter.

• Forreferencetomaximumclipspacing’splease

refer to table 2 and image Fig 2.2

Pipe

dimension

Maximum Distance (S)

for bracketing (cm)

14 x 2 100

16 x 2 100

20 x 2 125

26 x 3 150

32 x 3 200

40 x 3.5 200

50 x 4 250

63 x 4.5 250

Table 2.

Fig 2.2

A = max 800mm

B = 300mm

C = 300mm

D = max 800mm

2.3 Embedded installation

• Forembeddedinstallationsthepipemustbe

securely fastened with ties spaced at the minimum

of 800mm and 300mm either side of bends or

joints,seeg2.3

• Forthistypeofsystemitisrecommendedtouse

pre-insulated pipe to minimise heat loss and gain

ortopassthroughexibleconduitasaminimum

•

 Forsurfaceembeddedpressttingswerecommend

thattheentirettinginprotectedfromcorrosionby

using purpose designed adhesive tapes

or expanding

plastic materials that have been adequately sealed.

Fig 2.3

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

2. Installation

2.4 Bend radius

• Whenformingbendsinthepipepleasereferto

table 3 to obtain the minimum bend radius.

Pipe

dimension

(Ø x S)

Minimum

radius

of bend R

Min. radius

of bend R

with spring

pipe bender

Min.radius

of bend R

with

hydraulic

bender

14 x 2 5 x Ø 3 x Ø

16 x 2 5 x Ø 3 x Ø

20 x 2 5 x Ø 3 x Ø

26 x 3 8 x Ø 4 x Ø 4 x Ø

32 x 3 4 x Ø

40 x 3.5 4 x Ø

50 x 4 4 x Ø

63 x 4.5 4.5 x Ø

• FortoolingtoformbendsinGerpexpipeplease

refer to our pricelist.

• Itispreferabletousettingsratherthanbendsfor

pipe with greater than 26mm diameter

• Whenbendingpipepleaseavoidplacingany

existingttingsunderunduepressure.Please

refertog2.4whichshowstheminimumdistance

betweenattingandthebeginningofabend.

Minimum distance is 5 x pipe diameter.

2.5 Thermal Expansion

• Duringinstallationpleasepayattentiontothe

thermal expansion characteristics of Gerpex pipe.

The longitudinal expansion of the pipe is affected

by a variation in temperature and can be calculated

using the following data found in table 4 and Fig. 2.5.

Copper

PE-X polyethylene mesh

PP polypropylene

PB polybutylene

Steel

Inox Steel

Gerpex

ΔT 10 20 30 40 50 60 70

LΔL

0.1 0.026 0.052 0.078 0.104 0.130 0.156 0.182

0.2 0.052 0.104 0.156 0.208 0.260 0.312 0.364

0.3 0.078 0.156 0.234 0.312 0.390 0.468 0.546

0.4 0.104 0.208 0.312 0.416 0.520 0.624 0.728

0.5 0.130 0.260 0.390 0.520 0.650 0.780 0.910

0.6 0.156 0.312 0.468 0.624 0.780 0.936 1.092

0.7 0.182 0.364 0.546 0.728 1.910 1.092 1.274

0.8 0.208 0.416 0.624 0.832 1.040 1.248 1.456

0.9 0.234 0.468 0.702 0.936 1.170 1.404 1.638

1.0 0.260 0.520 0.780 1.040 1.300 1.560 1.820

2.0 0.520 1.040 1.560 2.080 2.600 3.120 3.640

3.0 0.780 1.560 2.340 3.120 3.900 4.680 5.460

4.0 1.040 2.080 3.120 4.160 5.200 6.240 7.280

5.0 1.300 2.600 3.900 5.200 6.500 7.800 9.100

6.0 1.560 3.120 4.680 6.240 7.800 9.360 10.920

7.0 1.820 3.640 5.460 7.280 9.100 10.920 12.740

8.0 2.080 4.160 6.240 8.830 10.400 12.480 14.560

9.0 2.340 4.680 7.020 9.360 11.700 14.040 16.380

10.0 2.600 5.200 7.800 10.400 13.000 15.600 18.200

In order to calculate the longitudinal expansion please

use the following formula:

ΔL=αxLxΔT

where:

αisthecoefcientoflinearexpansion,equalto0.026

mm/m K for insulated pipes;

Listheinitiallengthofthepipe(m);

ΔTisthetemperaturedifference(K).

Example:

Length of pipe: 12 m

Temperature difference: 50 K

ΔL=0.026x12x50=15.6mm

Fig 2.4

Table 3

Table 4

Fig 2.5

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

2.5 Thermal Expansion

For surface mounted installation or when installed in

shafts, voids etc, longitudinal thermal expansion can

becompensatedforwithconsiderationofxedand

sliding brackets depending on type of installation.

These sliding brackets allow the pipe to expand and

contract without sagging and/or putting any undue

stress on the pipe and brackets. Please see Fig 2.6,

2.7 and 2.8 for example:

Where:

Ls =Cx√(ØxΔL)

Ls =Lengthofcompensator(mm)

Ø =Externaldiameterofpipe(mm)

C =Materialconstant

 (forinsulatedpipesC=33)

With

ΔL=15.6mm(previousexample),

Ø=26mm

the result will be:

Ls=33x√(26x15.6)=665mm

FP FP

∆L∆L

FP SP

∆L∆L

To allow expansion for pipes installed vertically in

shafts or risers with horizontal branches, the branch

musthaveaminimumfreelength(LS)andthe

transition through the wall of the shaft should not

be sealed so as to allow for movement and the pipe

should also be sleeved. See Fig 2.9 and 3.0.

If the size of the shaft does not allow for the

compensationlength(LS)thetransitionalholeinthe

wall of the shaft should be increased in diameter

and the tube should be protected with an insulating

sheath of thickness; see Fig 3.1.

Wherepipesarebeinglaidwithinscreededoors

thermal expansion can be allowed for by creating an

insulated curve at 10m intervals. This can be done

byenclosingwithininsulationorexibleconduit,see

Fig 3.2.

Note:Ifthepipeisbeingusedforunderoorheating

and is using spiral or serpentine loops this method

need not apply.

2. Installation

FP: Fixed Point

SP: Sliding Point

Fig 2.6

Fig 2.7

Fig 2.8

Fig 2.9 Fig 3.0 Fig 3.1

Fig 3.2

Installation & Commissioning Instructions

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Gerpex Press Fit System

2. Installation

2.6 Pressure drops

Pressure drops across Gerpex and Gerpex Press

Fittings can be calculated using data shown in the

GERPEX System Technical Product Guide which can

be found at www.emmeti.co.uk

2.7 Pipe cutting

The pipe must be cut at a 90

angle and be cut

perfectly straight. A rotary pipe slice is recommended

for sizes 26mm and greater to ensure that the pipe is

not deformed by the ratchet shear, see Fig 3.3 and 3.4.

Anunevencutwillmakecalibrationdifcult.

2.8 Pipe preparation

Pipe preparation includes calibration and bevelling of

the cut end of pipe with a purpose designed tool in

readinessforthepipetobeinsertedintothetting.

Failure to prepare the pipe in this way can lead to

damageoftheO-ringandthepossiblefailureofatting.

To calibrate the pipe the tool must be rotated into the

end of the pipe in a clockwise motion as shown in Fig

3.5 and 3.6:

To bevel the internal edge of the pipe the tool must

be rotated clockwise which will remove and bevel

the inner edge of the pipe. This prepares the pipe for

insertionintothetting.

Fig 3.3

Fig 3.4

Fig 3.5

Fig 3.6

TheEmmeticalibrationtoolcanbettedtoabattery

powered drill to speed up the process. Please take care

not to place undue pressure if calibrating in this way.

Installation & Commissioning Instructions

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Gerpex Press Fit System

2.9 Pipe/Fitting Assembly

Once the cut end of pipe has been prepared and

calibratedpleaseinspecttheGerpexpressttingfor

anysignsofdamage.Ensurettingiscleanandfree

of dust or debris prior to insertion. Take care when

insertingthepipeintothetting,ensurebothare

aligned and push together to engage. Do not rotate as

this can dislodge the O-rings, see Figs 3.7, 3.8 and 3.9.

✔

✘

CouplingPipe

Pipe outof

alignment

YES

2.9 Pipe/Fitting Assembly

Note: Do not lubricate with grease or oil as this

can corrode the O-rings. Please use clean water to

lubricate only.

Asthepipeispushedintothetting,fullinsertioncan

beconrmedwiththesightholelocatedintheblue

collar. See Fig 4.0.

CouplingPipe

Pipe outof

alignment

YES

✘

✔

2. Installation

Fig 3.7

Fig 3.8

Fig 3.9

Fig 4.0

Pipe fully inserted

Rounded edge to show

pipe has been calibrated

correctly

Double O-ring

Fig 4.1

Fig 4.1 shows how the pipe has been fully inserted

intothetting.Theroundededgeoftheinternalface

of the pipe can be seen showing that calibration has

been carried out correctly and double O-rings can be

seen intact.

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

3. Press Fitting

3.1 Press fitting 16mm – 63mm (TH Profile)

Place jaws around steel sleeve and ensure jaw

alignment collar is inserted into the jaw groove as

showng4.2.Itisimportanttoensurethatthe

groove is engaged with the blue collar as this will lock

thettingintothejawsandwillpreventthejawsfrom

movingduringthepressingoperation,seeg4.3:

PleaseensurethatthejawpressingproleiscompatiblewiththeEmmetiGerpexttingrange,seediagrams

on page 3 and in table 4.

Once aligned, press and hold the pressing tool trigger

untilanaudibleclickcanbeheard,thiswillconrm

thatafullpresshasbeencompleted,seeg.4.4.Do

not attempt to abort a press once started.

If the machine fails or the battery drains mid-press

pleasereplaceandcontinuetoconrmthatthepress

hasbeencompletedsatisfactorily.Avisualconrmation

of the press can be carried out once the jaws are

removedseeg4.5andrefertog1.1toconrm.

CLICK

Profile and dimensions of the jaws that can be used with Multi-Jaw Gerpex Fittings

16 20 26 32 40 50 63

TH OK OK OK OK OK OK OK

BOK OK OK OK - - -

UOK OK - - - - -

HOK OK - - - - -

FOK OK - - - - -

Table 4

Fig 4.2

Fig 4.3

Fig 4.4

Fig 4.5

Visual indication of

TH press

Installation & Commissioning Instructions

For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk

Gerpex Press Fit System

Oncethepipeandttinghavebeeninstalledasystem

integrity test should be carried out in accordance with

current regulations prior to any permanent coverings

being applied.

6. Notes

• DONOTexceedmaximumrecommended

operation time or number of presses for the

chosen press tool (refer to press tool instructions

fordetail)

• DONOTattempttoreuseapartiallypressedtting

• DONOTattempttomodifyortamperwiththe

toolingorttings

• DOchecktoolsconditionregularlyandrepair/

replace where necessary

• DOreadthisdocumentcarefullybeforecarrying

out any works

• DOalwayskeeptools,pipeandttingsstoredina

clean and dry environment

• DOprotectttingsagainstcorrosionwheninstalled

in embedded screed or concrete

• DOensuresystemcompatibilitywiththeGERPEX

System

• DOensureEMMETIapprovedtoolingandpressing

prolesareusedatalltimes

• DOensurethatanypresstoolsarecalibrated

at recommended manufacturer intervals and by

approved test facilities.

5. Testing of the System

Gerpex Multi-Layer Pipe can also be used with

Emmetidevelopedcompressionttingstoconnect

to heating or plumbing manifolds and also to

compressionttingsincluding15,22and28mm

coppercompression.Thesettingsenablethe

installer to connect to tap connectors, isolation valves

and radiator valves or to transition onto copper pipe

with no requirement for hot works.

4.1 Preparation of Pipe

Pipe preparation is carried out in the same way for

compressionaswithpressttings.Pleasereferto

section 2.7 and 2.8

4.2 Pipe Connection

Once the pipe has been prepared it should be inserted

intothemonobloccotting.Pleaseensurethatpipeis

alignedandpushontotting,donotturnoninsertion

as this could potentially disturb or damage the double

O-ring.Seeg4.6

The pipe is clamped onto the brass insert of the

ttingbythesplitolivewhentightenedontothe

compressionttingasshown.Takecarenottoover

tightenthettingontothecompressionconnection

as this could damage the O-ring seal on the face of

thetting.

4. Compression Fittings

EMMETI-GERPEX PEXb/AL/PEXb 16x2 PER

15mm Copper Pipe

15mm Compression

Lever Valve

16 x 2 mm Gerpex Pipe

EmmetidevelopedMLCPtocoppercompressiontting.Suppliedasasingle

piece unit to connect onto any copper compression thread up to 28mm.

Fig 4.6

Inhaltsverzeichnis

Andere emmeti Sanitärprodukte Handbücher

emmeti

emmeti KEV 2 07514110 Leitfaden

Beliebte Sanitärprodukte Handbücher anderer Marken

Weka

Weka 506.2020.00E Betriebsanleitung

American Standard

American Standard DetectLink 6072121 Bedienungsanleitung

Kohler

Kohler K-6228 Montageanleitung

Uponor

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