Watts Radiant R-Flex Installation Manual

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Page 1

insulated piping systems

installation manual

Page 2

insulated piping system

Table of Contents

Description . . . . . . . . . . . . . . 2

Speciﬁcations ............. 3

Warnings ............... 3

Transportation . . . . . . . . . . . . 4

Connections . . . . . . . . . . . . . 5

Utility Trenches ............ 6

Wall Penetrations . . . . . . . . . . 8

Intersections . . . . . . . . . . . . 11

Inspection Chamber . . . . . . . 15

Repairs ................ 19

Appendix

A - System Design . . . . . . . . 20

B - Pressure Drops ........ 25

Description

Well insulated piping systems equate to energy savings. Watts Radiant’s R-ﬂex™ series is a pre-insulated piping system composed of a thermal insulated jacket surrounding the carrier pipe(s). Each foot of R-ﬂex is protected by a double wall high density polyethylene outer jacket.

R-ﬂex is an SDR-11 PEX ﬂuid transfer piping system suitable for use in heating or cooling applications. Each foot of R-ﬂex is protected with an EVOH oxygen diffusion layer. Low weight and superior ﬂexibility means R-ﬂex can be installed easily and rapidly, even over obstacles or around corners.

R-ﬂex is available with either a single or double carrier pipe in a wide variety of sizes, all offering superior insulation properties. The insulating material consists of microcellular, cross-linked polyethylene foam. The closed-cell structure of the foam provides excellent insulation values, ensures minimal water absorption, and is CFC free.

Corrugated twin wall outer jacket (PE-HD)

Carrier Pipe (cross-linked barrier PEX)

Insulation (cross-linked PE foam)

C - Pressure Test Logs . . . . . 30

D - Installation Times ....... 31

Carrier pipes in Dual R-ﬂex are marked with a single dash line and a double dashed line to provide easy identiﬁcation at transition points.

The outer shell of R-ﬂex is constructed of double-wall, high density corrugated polyethylene. A durable, watertight seal is provided between the inner and outer surface, ensuring that moisture ingress is prevented in the event that the outer casing is damaged. This unique combination of inner and outer layers also allows the corrugated design of the outer shell to bend easier, providing greater ﬂexibility.

PEX ID

PEX OD

Jacket OD

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Speciﬁcations (conforms to DIN 16892, SDR-11)

insulated piping system

Order # Description

81012929 160/40 R-ﬂex

81012886 160/50 R-ﬂex

81012887 160/63 R-ﬂex

Single

81012889 200/75 R-ﬂex

81012890 200/90 R-ﬂex

81012891 200/110 R-ﬂex

81012879 125/2x1 R-ﬂex*

81012880 125/2x32 R-ﬂex

81012882 160/2x40 R-ﬂex

Dual

81012884 200/2x50 R-ﬂex

81012885 200/2x63 R-ﬂex

PEX

32.6 mm

(1.28")

40.8 mm

(1.61")

51.6 mm

(2.03")

61.4 mm

(2.42")

73.6 mm

(2.90")

90.0 mm

(3.55")

0.863"

(21.92 mm)

26.2 mm

(1.03")

32.6 mm

(1.28")

40.8 mm

(1.61")

51.6 mm

(2.03")

PEX

40 mm

(1.57")

50.0 mm

(1.97")

63.0 mm

(2.48")

75.0 mm

(2.95")

90.0 mm

(3.54")

110.0 mm

(4.33")

1.125"

(28.58 mm)

32.0 mm

(1.26")

40.0 mm

(1.57")

50.0 mm

(1.97")

63.0 mm

(2.48")

JacketODBend

Radius

350 mm

(13.8")

160 mm

(6.30")

200 mm

(7.90")

4.90"

(125 mm)

125 mm

(4.90")

160 mm

(6.30”)

200 mm

(7.90")

450 mm

(17.80")

550 mm

(21.7”)

800 mm

(31.5")

1100 mm

(43.4”)

1200 mm

(47.3")

11.80"

(300 mm)

300 mm

(11.80")

600 mm

(23.70")

800 mm

(31.50")

1200 mm

(47.30")

Coil

Length

100 m**

(328 ft)

100 m**

(328 ft)

Coil

Diameter

2300 mm

(90.6")

82.70"

(2100 m

2100 mm

(82.70")

2300 mm

(90.60")

Coil

Height

850 mm

(33.50")

1400 mm

(55.20")

27.60"

(700 mm)

700 mm

(27.60")

850 mm

(33.50")

1400 mm

(55.20")

Coil

Weight

232 kg

(512 lbs)

248 kg

(547 lbs)

278 kg

(613 lbs)

416 kg

(917 lbs)

473 kg

(1,043 lbs)

564 kg

(1,244 lbs)

358 lbs

(162 kg)

182 kg

(402 lbs)

263 kg

(580 lbs)

403 kg

(889 lbs)

464 kg

(1,023 lbs)

Fluid Cap.

/ 100m (328ft)

83.00 L

(21.93 gal)

131.31 L

(34.69 gal)

208.76 L

(55.15 gal)

296.67 L

(78.37 gal)

426.02 L

(112.55 gal)

638.41 L

(168.65 gal)

19.94 gal

(75.46 L)

107.48 L

(28.40 gal)

166.00 L

(43.86 gal)

262.62 L

(69.38 gal)

417.52 L

(110.30 gal)

Insulation Thickness

47.5 mm

(1.88")

42.5 mm

(1.68")

37.0 mm

(1.46")

52.0 mm

(2.05")

44.0 mm

(1.74")

34.0 mm

(1.33")

1.11"

(28.0 mm)

22.3 mm

(0.88")

34.0 mm

(1.34")

46.0 mm

(1.81")

33.0 mm

(1.30")

Casing

R-Value

6.79

6.07

5.27

7.4

6.28

4.84

4.01

3.18

4.84

6.57

4.69

Pex pipe is certied to ASTM F876, SDR-9 dimensions.

Custom lengths are available upon request. Contact distributor for details.

WARNINGS

General Handling & Storage

If R-ﬂex connections must be made in temperatures lower than 30°F, caution must be taken to allow the tubing to form a proper seal against the barb. Apply the connection slowly to ensure the PEX material conforms to the barb.

In order to prevent property damage, serious injury and/or death...

1. Do not allow the ﬂuid temperature to exceed:

• 200°F at 80psi

• 180°F at 100psi

• 73.4°F at 160psi

2. Do not allow the inner PEX tubing to be exposed to sunlight, or direct UV

exposure for more than 30 days maximum. Outer casing of R-ﬂex protects

the inner PEX tubing from UV exposure.

3. Do not allow the tubing to come in contact with any of the following: – Petroleum based products – Pipe sealants – Firewall sealants (except those approved to be used with PEX)

– Kerosene – Gasoline – Fuel oils – Cutting oils – Asphalt – Contaminated soils or building materials.

4. Do not use if the tubing has visible gouges, cuts, cracks, abrasions, signs of

physical damage, or other defects.

5. Do not use in swimming pools or other systems that use high levels of chlorine.

6. Do not kink. If kinking occurs, use a repair coupling.

7. Do not expose tubing to rough terrain that may cause punctures, cuts, or

other damage.

8. Do not use tubing to transfer natural gas or any unapproved substances.

9. Do not use Crimp, Cinch, or Compression connections designed for RadiantPEX or RadiantPEX+ with metric size R-ﬂex tubing.

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insulated piping system

General Installation Cautions

1. When installing R-ﬂex, use a serpentine pattern to account for expansion and contraction. Failure to do so may result in damage to connections.

2. Do not install directly to a heat source. A metallic adapter, minimum 18" in

length, must be used between the heat source and tubing.

3. Do not support ﬁxtures directly from the tubing, such as hose bibs or shut-off valves.

4. Protect the tubing via sleeves where it transitions through a concrete slab,

concrete wall or other framing material.

5. Do not use this manual to install Watts Radiant Onix™, RadiantPEX™, RadiantPEX

™

, or RadiantPEX-AL™.

Transport and Storage

R-ex pipelines are supplied in coils with a maximum length of 328 ft (100

meters). Pipe ends are factory sealed with protective end caps to prevent dirt and debris from entering the tubing.

In storage, care must be taken to ensure that the PEX carrier pipe is protected from sunlight and that no undesirable deformation of the coil occurs.

Pipes must be transported and stored in such a way that sharp objects, like stones and tree roots cannot damage them. Pipes must not be dragged along the ground. Only nylon or textile straps should be used for fastening the

coils during transport.

Connections

R-ﬂex connections are speciﬁcally designed and engineered for hydronic heating and cooling applications. They are available in PEX x NPT adapters. Tees and elbows can be constructed with the use of an NPT tee or elbow.

R-flex Barb

Compression Collar

Steel Plate

Compression Bolt

Standard NPT Tees, Elbows, and Couplings are used with R-ﬂex ﬁttings to create a wide range of ﬁtting conﬁgurations.

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insulated piping system

Assembly instructions

1 Cut the PEX pipe at a right angle with a pair of

PEX cutters.

2 If the tubing is cut by a saw, deburr the pipe

with an appropriate tool.

4 The compression fitting comes with a nut and

steel plate. Use these to open the compression

collar and allow the collar to slide off of the NPT base.

5 Slide the compression collar over the pipe.

Ensure the notch on the inside of the clamping ring is facing the fitting.

6 Push the pipe COMPLETELY over

the coupling.

7 Slide the clamping ring back to COMPLETELY

cover the fitting.

8 Remove the bolt and the steel plate.

10 Assemble the bolt, washer and nut provided

and tighten the compression collar to the following torque recommendations:

R-ﬂex Diameter Bolt Size Torque

1” (USA / Canada) M 8 8 Nm (5.9 ft-lbf)

32 mm M 8 8 Nm (5.9 ft-lbf)

40 mm M 8 10 Nm (7.38 ft-lbf)

50 mm M 10 40 Nm (29.50 ft.lbf)

63 mm M 12 70 Nm (51.63 ft-lbf)

75 mm M 12 70 Nm (51.63 ft-lbf)

90 mm M 16 110 Nm (81.13 ft-lbf)

110 mm M 16 110 Nm (81.13 ft-lbf)

Test Connections:

1. Preliminary test

The preliminary test involves applying a test pressure equal to 1.5 times the admissible operating pressure. This pressure must be regenerated twice within the space of 30 minutes at intervals of 10 minutes. Following a test period of another 30 minutes, the test pressure must not

have fallen by more than 9 psi. Leaks must not occur at

any points in the system being tested.

2. Main test

The main test has to be conducted immediately after the preliminary test. The test takes 2 hours. At the end

of this period, the test pressure recorded after the preliminary test must not have fallen by more than 3 psi. Leaks must not occur at any point in the system being tested.

(See Appendix C on page 30 for time-pressure curve of test method and log for test results)

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insulated piping system

Utility Trench Proﬁle

Trenches 4ft (120 cm) or less can be dug with vertical walls. If the trench is to be deeper than 4 ft (120 cm), a V-shaped trench should be dug to prevent

accidental wall-collapse.

Excavation work must be carried out in the approved manner, according to the rules and regulations of local authorities.

The depth of the trench must be in accordance with the guidelines relating to the laying of R-ﬂex.

1 Backﬁll 2 Route warning tape - to indicate buried pipe underfoot 3 Sand ﬁll 4 Sandbed 5 R-ﬂex

Proﬁle of trench for R-ﬂex Dual (twin) pipe

jacket Ø

125

(5.00 in)

160

(6.23 in)

200

(7.87 in)

mm B mm C mm D mm

150

(6.00 in)

100

150

(6.00 in)

180

(4.00 in)

(7.10 in)

It is recommended to consult with the local utility company to have the area marked for public utilities such as water, gas, electrical, and phone.

After completion of the pipe-laying process, the route can be marked with warning tape.

Minimum laying temperature for R-ﬂex is 23°F (- 5°C).

Proﬁles of Typical Utility Trenches

Trench depth should allow the R-ﬂex to rest below normal frost line. Failure to do so will accelerate heat loss through the tubing. Check local codes to determine minimum pipe depth with relation to surface loads. Local codes may require different depths than those illustrated in this manual.

pedestrian

250

(9.85")

vehicular

650

(25.60")

width

425

(16.75 in)

520

(20.50 in)

560

(22.05 in)

depth

pedestrian

625

(24.61 in)

660

(25.98 in)

700

(27.56 in)

depth

vehicular

1025

(40.35 in)

1060

(41.73 in)

1100

(43.31 in)

Excavation

approx

0.27

(9.53 ft

0.34

(12.00 ft

0.39

(13.75 ft

/ft)

Sandﬁll

m3/m

approx

0.17

(6.00 ft3/ft)

0.22

(7.77 ft3/ft)

0.25

(8.83 ft3/ft)

Proﬁle of trench for (2) R-ﬂex single pipes (2x Dual) WITHOUT underground connection

depth

vehicular

1025

(40.35 in)

1060

(41.73 in)

1100

(43.31 in)

Excavation

approx

0.41

(14.50 ft

0.51

(18.01 ft

0.60

(21.12 ft

jacket Ø

125

(5.00 in)

160

(6.23 in)

200

(7.87 in)

mm B mm C mm D mm

pedestrian

150

(6.00 in)

100

150

(6.00 in)

180

(4.00 in)

(7.10 in)

250

(9.85")

vehicular

650

(25.60")

width

650

(25.60 in)

780

(30.71 in)

860

(33.86 in)

depth

pedestrian

625

(24.61 in)

660

(25.98 in)

700

(27.56 in)

Proﬁle of trench for (2) R-ﬂex single pipes WITH underground connection

depth

vehicular

1200

(47.24 in)

Excavation

approx

0.72

(25.43 ft

300

(12.00 in)

mm B mm C mm D mm

pedestrian

150

(6.00 in)

100

(4.00 in)

150

(6.00 in)

250

(9.85")

vehicular

650

(25.60")

width

900

(36.00 in)

depth

pedestrian

800

(31.50 in)

Install R-ﬂex in accordance to local code requirements. Depth of R-ﬂex should be compliant with intended loads.

/ft)

Sandﬁll

m3/m

approx

0.26

(9.20 ft3/ft)

0.32

(11.30 ft3/ft)

0.38

(13.42 ft3/ft)

Sandﬁll

m3/m

approx

0.45

(15.90 ft3/ft)

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insulated piping system

Instructions for Laying R-ﬂex

R-ﬂex can easily be placed in earth-contact trenches. The corrugated jacket provides the necessary protection for the insulating material and the PEX pipe. Groundwater has no inﬂuence on the R-ﬂex system. When laying the R-ﬂex directly into the trench, be careful not to pull the piping by the outer jacket. Doing so may cause damage to the corrugation of the jacket. Pull R-ﬂex by

grabbing the carrier pipes – never pull the jacket.

When uncoiling the pipe, please take care to ensure the pipe is not dragged along the ground. Doing so can cause the R-ﬂex to be damaged by sharp objects. It is important to maintain control of the ends of each R-ﬂex coil to prevent pipe ends from whipping back when untying the textile straps. The bending radii (see product data sheet) must not fall below the prescribed minimum during installation or when positioning the pipeline. Pipes must be laid in a serpentine course and may be covered with sand at regular intervals to prevent unwanted movement. General guidelines for laying underground pipes must be followed.

When laying larger dimensions and lengths, pulling devices such as winches or tail-end rollers may be used. Always connect these devices to the carrier pipe.

The carrier pipe ships from the factory with ﬁtted protective end caps to prevent the entry of dirt and debris into the R-ﬂex. Do not remove these caps until ready to connect the R-ﬂex to a ﬁxed connection.

Since the R-ﬂex pipe is laid in a serpentine pattern, it is necessary to design for more pipe length than the measured trench length.

backll has been brought to about 20" (50 cm) above the top of the pipe, a

vibrating tamper may be used to compact the remainder of the soil. Do not use a backhoe or other mechanical device to ﬁll the ﬁrst layer of the trench as damage to the R-ﬂex may occur.

Transitions

When transitioning R-ﬂex across a structural wall, be sure to keep the Dual pipe oriented in the vertical plane, as shown. Failure to do this will cause connection issues at necessary intersections.

The point where the R-ﬂex penetrates the structure must be sealed. This can be done in a variety of ways, depending on the wall construction.

Backﬁlling Guidelines

Carefully place the R-ex pipeline on a compacted 4.0” (10 cm) bed of sand on the bottom of the trench. The quality of this sand bed providing uniform support for the pipe line has a decisive inﬂuence on the compressive stress of the system. Make sure that the pipes are fully covered with sand

(granularity of 0-3mm).

Backﬁlling should be in layers of

about 8.0" (20 cm) and compacted

by hand. Care should be taken to remove any sharp objects from the backﬁll material. When the backﬁll has

been brought to about 20.0" (50 cm)

above the top of the pipe, a vibrating tamper may be used to compact the remainder of the soil. There should also be a warning tape bearing the legend “water pipe” laid directly above the pipe.

Once the trenches are excavated, the ﬁrst layer of backﬁll should be carefully compacted with a shovel. When the

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insulated piping system

Wall seals are available in two styles: a Link Sleeve, and a Wall Sleeve. The Link Sleeve is designed to be used when transversing existing walls. The Wall Sleeve is to be used when a concrete wall is to be poured around the R-ﬂex.

Link Sleeves

1. Drill a hole according to minimum and

maximum dimensions (see column wall opening).

Center the pipe, cable or conduit in wall opening or casing. Make sure the pipe will be adequately supported on both ends.

2. Loosen rear pressure plate with nut

just enough so links move freely. Check to be sure all bolt heads are facing the installer. Extra slack or sag is normal.

Make sure the pipe is held straight

for at least 2 ft (60 cm) before and

after the belt. Bends are not allowed.

Link Belt Description Links

Order #

81012948

81012949

81012950

LinkBelt, 125mm

outer casing

LinkBelt, 160mm

outer casing

LinkBelt, 200mm

outer casing

3. Slide belt assembly into annular space. Start inserting Link-Seal

modular seal assembly at the 6

o’clock position and work both sides

up toward the 12 o’clock position

Req’d

15 125 mm

15 160 mm

17 200 mm

outer

jacket

wall opening

152 mm (6.00 in)

203.3 mm (8.00 in)

254 mm

(10.00 in)

4. Using a hand socket or offset wrench ONLY, start at 12 o’clock. Do not tighten any bolt more than 4 turns

at a time. Continue in a clockwise manner until links have been

uniformly compressed. (Approx. 2 or

3 rotations)

5. Make 2 or 3 more passes at 4 turns per bolt MAXIMUM, tightening

all bolts clockwise until all sealing elements “bulge” around all pressure plates.

Link-Seal® Modular Seal - Do’s

1. Make sure pipe is centered.

2. Install the belt with the pressure

plates evenly spaced.

3. Make sure seal assembly and pipe surfaces are free from dirt.

4. For tight ts, use non-polluting liquid

detergent to assist installation.

Link-Seal® Modular Seal - Don’ts

1. Don’t Install the belt with the pressure plates aimed in irregular directions. (Staggered)

2. Don’t torque each bolt completely

before moving on to the next.

3. Don’t use high speed power tools

(450 rpm or more)

4. Don’t use grease installing Link-Seal

modular seals.

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insulated piping system

Ø D1

Ø D2

430

Wall Sleeves

Where pipes must pass through walls and ﬂoors of new structures, molded nonmetallic high density polyethylene CS sleeves can be installed.

Molded-in waterstop and reinforcing ribs serve to anchor the sleeve in the wall and resist pour forces. Nailer end caps are provided to make placement in forms simple and accurate. In the event of a ﬁeld change they can be shortened with ordinary hand tools.

The sleeve is purposely molded with a texture on the outside surface to assure a much better bond than most plastic-to-concrete interfaces.

Each Wall Sleeve comes complete with corresponding sizes LinkBelts to complete the seal between the R-ﬂex and the Wall Sleeve.

R-ﬂex Wall sleeve

Order #

81012931 125 mm

81012932 160 mm

81012933 200 mm

Ø pipe jacket D1 L

(4.92 in)

(6.30 in)

(7.87 in)

208.5 mm

(8.21 in)

208.5 mm

(8.21 in)

258.8 mm

(10.19 in)

406.4 mm

(16.in)

406.4 mm

(16 in)

406.4 mm

(16 in)

Wall Sleeves come complete with end caps and corresponding Link Belts.

1 Nailer end caps are installed at

each end of the sleeve to prevent deformation during the initial concrete pour and hold sleeve in exact location. Place one end cap at each end of the sleeve.

2 Remaining end cap is inserted

into sleeve. Wide ﬂange area on cap provides good surface against wall form, and resists weight of concrete pour.

3 Workman checks sleeve

installation prior to erecting outside form wall.

4 Keep end caps in place after wall

is poured and the form has been removed. The end caps seal sleeve against dirt and debris.

5 Just before pipe penetration,

caps are removed to reveal clean inside surface of sleeve.

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insulated piping system

On the interior side of the wall, secure an “L” bracket to the wall to support the R-ﬂex as it transitions through the wall. Install either a dust cap or a shrinkable end cap to the protruding end of the R-ﬂex to keep dirt, debris, and possibly water from entering the inner casing. Do this before installing any connections or ﬁttings.

R-ﬂex must be supported at transition points to hard piping in the structure. Failure to do so may void the warranty. There can be signiﬁcant

expansion and contraction movement of the PEX carrier pipe which may cause connection leaks and/or damage to hard piping. R-ﬂex can not be run internally (run inside the building). Transition from R-ﬂex to a suitable carrier pipe rated for interior applications.

Guidelines for installing shrinkable end caps.

Slide the cap over the carrier pipe and the jacket.

Use a heat gun or mini

torch with soft yellow ﬂame (DO NOT use a blue ﬂame!) to gently shrink the cap. Extra care should be taken not to damage the outer jacket.

Non waterproof dust caps Waterproof shrink caps.

R-ﬂex must be supported at transition points into the structure. R-ﬂex can not be run inside the building. Transition from R-ﬂex to a suitable carrier pipe rated for interior applications.

Press the cap, wearing protective gloves.

The tail end of the pipe is now sealed watertight.

WARNING

Keep hands away from any open flame. Do not touch – surface of shrink-

wrap will be hot. Wear gloves when handling.

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insulated piping system

Intersections

Intersections generally consist of (1) branch tees, (2) elbows, or (3) mid-run

couplings used to extend a run of R-ﬂex. Each of these connections need to be encased in a connection casing - a waterproof protective shell.

When creating an intersection, make sure to follow these guidelines fully in order to maintain the warranty.

Keep R-ﬂex Dual systems oriented in the vertical plane, as illustrated below. This will allow for proper assembly of the internal connections. This is especially critical when installing Tee intersections.

Casings provide additional insulation and seal outer jacket where ﬁeld connections are made. The set comes with stone wool (insulation), a ready to use bitumen rubber kit, stainless steel bolts and an instruction leaﬂet. Heat shrinkable caps to be ordered separately.

Make sure the area where casings are to be installed is square with the R-ﬂex entering and exiting the casing. Failure to do so will cause complications later when trying to assemble the upper half of the casing, and may create an improper seal at the transition points.

Holes in both shell-shaped casings (top and bottom) are identical and are pre-drilled allowing for quick, easy installation.

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insulated piping system

All casings have a series of stepped collars at each point of entry. These are designed to ﬁt each of the three main outer jacket sizes of R-ex – 125 mm, 160 mm, and 200 mm respectively. These steps are to be cut to accommodate the size of pipe being used.

Trim the casings before installing them in the trench. Inserting the R-ﬂex into the lower half of the casing will facilitate gauging of ﬁt and trim points on the R-ﬂex.

Do not cut a step intended for larger R-ﬂex than being used. Doing so will cause an improper seal at the transition point.

(4 in)(4 in)

The end of the R-ﬂex pipe must be positioned in the noted area of the casing.

Use the casing as a guide when determining how much of the outer jacket to remove. The outer jacket must extend 4” (10cm) past the last step (marked for 200mm). Mark the R-ex and carefully remove the outer jacket and insula-

tion – taking care not to damage the internal PEX piping.

Replace the R-ﬂex in the casing and mark where to trim the PEX pipe.

Apply the shrink caps, using the techniques described in the Transition section of the manual.

Apply connections to the PEX tubing. Make sure the outer Jacket remains

within the 200 mm step of the casing.

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insulated piping system

Each casing kit comes with bitumen strips (2 with couplings and elbows, 3 with

tees) and an insulation blanket. Cut the strips to ﬁt the pipe size. Do not cut the strips so they overlap as an improper ﬁt will result at the entry point.

Remove the protective layer and ﬁt the bitumen strips to the outside of the R-ex jacket and inside of the insulation casings at the (2 or 3) pipe entry points.

Ø 125 mm

Ø 160 mm

It is not necessary to cut for 200 mm

Wrap the insulating blanket, cut to the desired size, around the carrier pipe so that the connections are properly covered. Make sure to cover the shrink cap. Tape the insulated blanket in place.

Apply a uniform bead of sealant to the grooves of both the upper and lower shell casings. Keep the bead to a thickness of

about 5/32" (4 mm) to 3/16" (5 mm wide).

Insert the R-ﬂex into the lower casing.

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insulated piping system

Apply sealant at a uniform rate along ﬂanges of top and bottom casing (next to

the drilled holes) to yield a thickness of about 1/4" (6 mm).

Carefully align the two casing halves and insert the stainless steel bolts. Tighten the stainless bolts.

Check that the sealant is being squeezed through the side of the casing. This will indicate proper distribution of the sealant across the casing ﬂange.

Page 15

insulated piping system

Inspection Chamber

Inspection chambers allow access to connections and valves after R-ﬂex is installed and can be used as an alternative to the individual connection casings. Each chamber

is equipped with 6 marked entries that can be cut to suit various opening sizes (125, 160 or 200 mm).

Each inspection chamber comes with a top lid, stainless bolts, and an instruction sheet.

The following steps will lead to establishing a waterproof connection.

Installation

Entries are marked and are to be cut off to suit the desired opening sizes. Carefully lower the inspection chamber on a level bed of sand, free of sharp objects.

Ø 160mm

Ø 125mm

Ø 200mm

100

4.0"

100

4.0"

100

4.0"

Ø 455mm Ø 18.0"

Ø 380mm Ø 15.0"

270mm

10.5"

Ø 810mm Ø 32.0" 1010mm 40.0" 1210mm 47.5" 1410mm 55.5"

220mm

8.5"

65mm

2.5"

23.5"600mm

30.3"770mm

Page 16

insulated piping system

Connections

Before connecting the R-ﬂex in the inspection chamber, slide a shrink cap

(1) over the jacket and the carrier pipe. Use a heat gun (2) or mini torch with

soft yellow ﬂame (do NOT use a blue ﬂame!) to gently shrink the cap. Further information on applying the shrink caps can be found in the section

Guidelines for installing shrinkable end caps.

The use of the shrink cap is mandatory for any casing installation.

Slide a shrink sleeve (3) over the jacket, prior to pushing (4) the R-ex pipe

into the inspection chamber.

Make all necessary connections in the chamber.

Slide the shrink sleeve back over the edge of the inspection chamber (5) so it covers both the chamber and the R-ﬂex outer jacket. Gently shrink the sleeve onto the jacket, using a heat gun or a mini torch to ensure a waterproof connection between jacket and inspection chamber.

The use of the shrink sleeve is mandatory for any casing installation.

3 Shrink sleeve

WARNING

Keep hands away from any open flame. Do not touch – surface of shrink

wrap will be hot. Wear gloves when handling.

Page 17

insulated piping system

Branching possibilities

The inspection chamber, made of shock-resistant polyethylene, is very solid. It offers the possibility of:

• branching from Single to Dual R-ex pipes

Sealing of inspection chamber

Apply sealant at a uniform rate, to edge of chamber body part to yield a thickness

of about 0.4" x 0.4" (10 mm by 10 mm wide).

Place the pitched top on the body part.

Install the 6 stainless screws.

• branching from Dual to Dual R-ex pipes

• branching of several Dual pipes having various diameters

Install the screws

Carefully turn the lid clockwise to lock it. Do not damage the black gasket between body and top part.

Do not use excessive force.

Page 18

100 mm

150 mm

≥ 250 mm

≥ 400 mm

insulated piping system

Covering

The type of surface loading expected over the inspection chamber and R-ﬂex pipe will determine the necessary installation depth. Refer to section Backﬁlling Guidelines for further information on depth and covering requirements. Check local codes to determine minimum pipe depth with relation to surface loads. Local codes may require different depths than those illustrated in this manual.

The inspection chamber needs to be positioned to allow the R-ﬂex to enter the chamber without stress or bending. This may result in the chamber being below grade.

Always consider where the frost line is when determining trench depth. R-ﬂex should always be installed below frost line.

9.85"

15.75"

5.90"

3.95"

5.90"

Covering of the inspection chamber

Cement stabilized sand

3.95"

Check local code to determine minimum pipe depth with relation to surface loads.

Concrete ring

Page 19

Outer Jacket Repairs

For Repairs Using Shrink Sleeve For Repairs Using Shrink Tape

Locate damaged area. Locate damaged area.

insulated piping system

Make sure the jacket of the pipe is dry and clean.

Slide the shrink sleeve over the damaged R-ﬂex pipe.

NEVER CUT THE SLEEVE LENGTHWISE!

Use a heat gun or mini torch with soft yellow ame (do NOT use

a blue ﬂame!) to gently shrink the repair sleeve.

Make sure the jacket of the pipe is dry and clean.

7cm

Wrap the repair tape around the damaged jacket, overlap-

ping each preceding layer by about 7 cm (2.75").

Use a heat gun or mini torch with soft yellow ame (do NOT use

a blue ﬂame!) to gently shrink the repair sleeve.

Press the sleeve, wearing protective gloves.

The damaged jacket is now sealed watertight.

Keep hands away from any open flame. Do not touch – surface of

shrink wrap will be hot. Wear gloves when handling.

WARNING

Press the sleeve, wearing protective gloves.

The damaged jacket is now sealed watertight.

Page 20

insulated piping system

Appendix A system design

R-ﬂex U.S. equivalents

Metric 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm 110 mm

US Equivalent 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 3-1/2" 4"

Single

Dual

Required calculation steps:

1. Select the right pipe diameter:

-Calculate the heat transfer.

-Select the (carrier) pipe dimension for which the ow velocity does not exceed 7 ft/sec.

-Choose either Single or Dual pipe system.

160 mm 81012929 81012886 81012887

200 mm 81012889 81012890 81012891

125 mm 81012879 81012880

160 mm 81012882

200 mm 81012884 81012885

2. Determine the total physical pipe length:

-Split the pipe length into straight and angled segments.

- Calculate the equivalent length of the angled segments (as a function of the tightest suitable bends achievable with the speciﬁc pipe dimension.

-After the length of all segments have been determined, simply add them all together and add 5%.

Rule of Thumb

To accommodate for the thermal expansion forces and minimize the forces on the ﬁttings:

-A 5% add-on on the total length is required

-To be distributed over the total length (serpentine)

Bending angle into equivalent length:

L = a/180 x π x (R + d/2) a = the angle of the bend from its center R = bending radius based on the inside radius d = outer diameter HDPE-outer jacket

Example 45° turn: L = 45/180 x 3.14 x (12 + 8/2) L = 12.5 inches

L = 1.05 ft

Example 90° turn: L = 90/180 x 3.14 x (12 + 8/2) L = 25.13 inches L = 2.09 ft

a=90 a=180

Example 180° turn: L = 180/180 x 3.14 x (12 + 8/2) L = 50.27 inches L = 4.19 ft

Page 21

Single

Dual

insulated piping system

Description Jacket OD Bend Radius 45° Bend 90° Bend

160/40 160/50 450 mm (17.8 in) 160/63 550 mm (21.7 in) 200/75 200/90 1100 mm (43.4 in) 491 mm (1.61 ft.) 981 mm (3.22 ft)

200/110 1200 mm (47.3 in) 539 mm (1.77 ft.) 1079 mm (3.54 ft)

125/2x1” 4.9 in (125 mm) 11.8” (300 mm) 0.85 ft (259 mm) 1.7 ft (518 mm) 125/2x32 125 mm (4.9 in) 300 mm (11.8 in) 259 mm (0.85 ft.) 518 mm (1.7 ft) 160/2x40 160 mm (6.3 in) 600 mm (23.7 in) 512 mm (1.66 ft.) 1024 mm (3.36 ft) 200/2x50 200/2x63 1200 mm (47.3 in) 850 mm (2.79 ft.) 1700 mm (5.58 ft)

160 mm (6.3 in)

200 mm (7.9 in)

350 mm (13.8 in) 305 mm (1.00 ft.) 610 mm (2.00 ft)

433 mm (1.42 ft.) 866 mm (2.84 ft)

800 mm (31.5 in) 485 mm (1.59 ft.) 969 mm (3.18 ft)

800 mm (31.5 in) 639 mm (2.10 ft.) 1278 mm (4.19 ft)

3. Calculate the heat load at the source (as a function of the target heat capacity at recipient side)

Determine heat transfer losses:

- Calculate ΔT as the temperature differential between the surrounding soil temperature and the temperature in the carrier pipe(s).

- Locate this ΔT along the X axis of the corresponding graph

- Read the heat loss at the corresponding coordinate.

- Multiply the heat loss per unit with the total pipe length to obtain the total transfer losses.

Heat load at source = required capacity + transfer losses

Rule of Thumb

Ground temperature: for planning purposes a ground temperature of about 50°F (10°C) is a realistic assumption [minimum laying

depth of 2.0 ft (600 mm) to 3.2 ft (1000 mm)

4. Determine pressure loss in the system Calculate the total equivalent length of the system, by including the length equivalent of all brass ﬁttings

Use the “Pressure Loss Table” to determine the pressure loss per 100 feet of Single R-ex or per 50 feet of Dual R-ex.

Complete Pressure Loss Tables are found in the back of this Manual.

Single R-ﬂex Divide the total length (supply, return, bends, ﬁttings, etc) by 100. Multiply this length of the system with the pressure drop per 100’ found in the table to obtain the system’s overall pressure loss (head loss).

Dual R-ﬂex Divide the total length (supply, return, bends, ﬁttings, etc) by 50. Multiply this length of the system with the pressure drop per 50’ found in the table to obtain the system’s overall pressure loss (head loss).

Page 22

Heat losses in W/m

Δ T

10 20 30 40 50 60 70 80 90

160/2 x 40

200/2 x 63

200/2 x 50

∅ jacket

125/2 x 32 and 1”

Appendix A cont’d

Heat losses

The values used in calculating the heat loss are:

insulated piping system

– Insulation 0.0365 W/m.K (0.0211 BTU/hr.sq.ft.°F)

– Ground 1.2 W/m.K (0.693 BTU/hr.sq.ft.°F)

– PEX pipe: 0.35 W/m.K (0.202 BTU/hr.sq.ft.°F)

Depth of cover over top of pipe: 50 cm (20")

With the ΔT being calculated, the heat loss per length of piping can easily be read along the corresponding line of the table.

R-ﬂex Dual

(BTU/hr.ft)

(26.0)

(23.1)

(20.2)

(17.3)

(14.4)

(11.6)

For Dual

+Tr)

- T

ΔT =

: Fluid supply temperature

: Fluid return temperature

: Ground temperature

(8.7)

(5.8)

(2.9)

(0)

18 36 54 72 90 108 126 144 162 ∆T °F

** May not currently be offered.

°C

Page 23

insulated piping system

Heat losses in W/m

Δ T

10 20 30 40 50 60 70 80 90

200/110

200/90

∅ jacket

160/63 200/75

160/50

160/40

For Single

ΔT = T

- T

Tv : Fluid supply temperature

: Ground temperature

R-ﬂex Single

(26.0)

(23.1)

(20.2)

(17.3)

(14.4)

(11.6)

(8.7)

(5.8)

(2.9)

(BTU/hr.ft)

(0)

18 36 54 72 90 108 126 144 162 ∆T °F

°C

Page 24

500 mbh

1500 mbh

Supply Return

Segment A

Segment B Segment C

Segment T

Segment D

Segment E

Segment F

D 1

D 2

insulated piping system

Appendix A cont’d design example

Calculating length to order: Suppose:

A = 100 ft; B = C = 6 ft; D1 = 30 ft GPM: 200

T = 100 ft GPM = 50

D2 = 100 ft; E = 6 ft; F = 40 ft GPM = 150

Segment A – D1 requires 110 mm R-ﬂex Single

Segment T requires 63 mm R-ex Single Segment D2 – F requires 110 mm R-ex Single.

Supply Temp: 140°F (60°C)

Ground Temp: 50°F (10°C)

Total length to order:

(100+6+6+30) x 1.05 = 150 ft of 110 mm. x 2 (for supply/return) = 300 ft. 100 x 1.05 = 105 ft of 63 mm x 2 (for supply/return) = 210 ft. (100+6+40) x 1.05 = 154 ft of 90 mm. x 2 (for supply/return) = 308 ft.

Heat Loss: (supply and return)

-For all sectors: ∆T-ground = 90° F (50°C)

-A thru D1: 20 BTU/ft x 300 ft = 6,000 BTU/hr

-T: 7 BTU/ft x 210 ft = 1,470 BTU/hr

-D2 thru F: 9.5 BTU/ft x 308 ft = 2,926 BTU/hr

-TOTAL HEAT LOSS = 10,396 BTU/hr

-TOTAL LOAD: 2,000,000 BTU

Heat Lost through R-ex is less than .25% of the total load!

Pressure Loss through pipe with 140°F Water:

-A thru D1: 300 ft; 200 gpm

3.23 ft hd / 100 ft x 300 = 9.69 ft hd.

-T: 210 ft; 50 gpm

3.89 ft hd / 100 x 210 = 8.17 ft. hd.

-D2 thru F: 308 ft; 150 gpm

1.92 ft hd / 100 x 308 = 5.91 ft hd

MAX HEAD PRESSURE = 17.86 + LOSS THROUGH “T”

(Does not include ﬁttings)

Page 25

insulated piping system

Appendix B pressure drop charts

Pressure Drop Methodology

Calculating pressure drop through a tube or circuit is dependent on a wide range of factors – viscosity, density, ﬂow rate, and tube conditions.

Pressure drop (loss) in the circuits is determined using the Darcy-Weisback equation.These equations are referenced in ASHRAE's 2005 Handbook Fundamentals, section 2.0, equations 5, 18, 30, 32a, 32b, and 32c.

Glycol values referenced are based on DowFrost™ Technical Specication (form no. 180-01272-402AMS). Different glycol concentrations, types, and

formats will result in different pressure drop calculations. The data points provided should only be used as a reference point.

Data

DowFrost™ 50% Solution (extrapolated data)

Density

°F

(lbs/cu.ft.)

40 65.670 14.280

60 65.210 12.394

80 64.750 10.509

100 64.290 8.623

120 63.830 6.737

140 63.370 4.851

160 62.910 2.966

180 62.450 1.080

* derived equation used for extrapolation: y = 8473.8x

The table shown assume an approximate mixture of water/glycol of 50% concentration. Actual pressure drop values will change depending on actual concentrations and fluid temperature.

Dynamic Viscosity

(cps)*

Dynamic Viscosity

(lb/ft-s)

0.0096

0.0048

0.0029

0.0020

0.0014

0.0011

0.0009

0.0007

(-1.7307)

Calculations

Where: HL = Head Loss in feet per 100 feet of pipe f = Friction factor L = Length of pipe (ft) V = Fluid velocity (ft/sec) d = Pipe inside diameter (ft) g = Gravity (32.2 ft/sec2) Re = Reynold's number e = Pipe roughness factor (est. 3.0E-6)

Water

Density

°F

(lbs/cu.ft.)

80 62.22 0.858 0.00058

100 61.99 0.681 0.00046

120 61.71 0.557 0.00037

140 61.38 0.466 0.00031

160 61.00 0.398 0.00027

180 60.58 0.345 0.00023

Dynamic Viscosity

(cps)

HL = f

d2g

f = 8

A = 2.457 ln

37,530

B =

(7/Re)

(A+B)

0.9

Dynamic Viscosity

(lb-ft-s)

1/12

1.5

+ (0.27e/d)

Page 26

insulated piping system

50 mm R-flex Single, Pressure Drop per 100' (1.79" Nom. ID)

11.00

12.00

13.00

14.00

15.00

16.00

17.00

°F

(1.78)

(1.94)

0.90

80°

100°

120°

140°

160°

180°

1.04

1.37 1.59 1.82

0.85 0.99 1.14

1.23 1.43 1.64 1.86

0.81

0.95

1.13 1.31 1.50

0.78

0.91

1.05 1.22 1.41

0.75

0.88

0.99 1.16 1.33

0.73

0.86

0.95 1.10 1.27

(2.11)

(2.27)

(2.43)

(2.59)

1.20 1.37 1.55 1.74 1.93 2.14 2.35 2.58 3.84 5.31 7.00 8.89

2.07 2.33 2.60 2.88 3.18 3.49 3.81 5.61 7.70 10.07 12.72

1.30 1.47 1.65 1.84 2.03 2.24 2.45 3.65 5.07 6.68 8.50

2.09 2.34 2.60 2.87 3.15 3.45 5.08 6.99 9.17 11.59

1.09 1.25 1.41 1.58 1.76 1.95 2.15 2.35 3.51 4.87 6.42 8.17

1.71 1.93 2.16 2.40 2.65 2.91 3.19 4.71 6.49 8.52 10.79

1.05 1.20 1.36 1.52 1.70 1.88 2.07 2.27 3.39 4.70 6.21 7.91

1.60 1.81 2.02 2.25 2.48 2.73 2.99 4.43 6.11 8.03 10.18

1.02 1.16 1.31 1.47 1.64 1.82 2.01 2.20 3.29 4.57 6.03 7.69

1.51 1.71 1.91 2.13 2.35 2.59 2.83 4.20 5.81 7.64 9.69

0.99 1.13 1.28 1.43 1.60 1.77 1.95 2.14 3.20 4.45 5.88 7.50

1.45 1.63 1.83 2.04 2.25 2.48 2.72 4.03 5.58 7.34 9.32

(2.75)

18.00

(2.92)

19.00

(3.08)

20.00

(3.24)

25.00

(4.05)

30.00

(4.86)

35.00

(5.67)

40.00

(6.48)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

63 mm R-flex Single, Pressure Drop per 100' (2.25" Nom. ID)

15.00

20.00

25.50

30.00

35.00

40.00

45.00

°F

(1.53)

(2.04)

0.52

80°

100°

120°

140°

160°

180°

0.86

0.78 1.28 1.88

0.49 0.81 1.21

0.70 1.15 1.70 2.34

0.47

0.78

0.65 1.06 1.57

0.45

0.75

0.60 1.00 1.47

0.43

0.73

0.57 0.94 1.40

0.42

0.71

0.54 0.90 1.34

(2.55)

(3.08)

(3.57)

(4.08)

1.27 1.76 2.31 2.94 3.63 4.38 5.20 6.08 7.02 8.02

2.58 3.37 4.25 5.22 6.27 7.41 8.63 9.93 11.32

1.67 2.20 2.80 3.46 4.18 4.97 5.81 6.71 7.67

3.06 3.86 4.75 5.72 6.76 7.88 9.08 10.36

1.16 1.61 2.12 2.69 3.33 4.02 4.78 5.59 6.46 7.39

2.16 2.83 3.59 4.41 5.32 6.30 7.35 8.47 9.66

1.12 1.55 2.04 2.60 3.22 3.89 4.62 5.41 6.26 7.16

2.03 2.67 3.38 4.16 5.02 5.94 6.94 8.00 9.13

1.08 1.50 1.98 2.52 3.12 3.78 4.49 5.26 6.09 6.97

1.93 2.53 3.21 3.96 4.78 5.66 6.61 7.63 8.72

1.05 1.46 1.93 2.46 3.05 3.69 4.38 5.14 5.94 6.80

1.85 2.43 3.08 3.80 4.59 5.45 6.37 7.35 8.39

(4.59)

50.00

(5.10)

75 mm R-flex Single, Pressure Drop per 100' (2.69" Nom. ID)

30.00

35.00

40.00

45.00

50.00

55.00

60.00

°F

(2.15)

(2.50)

0.75

80°

100°

120°

140°

160°

180°

0.99

1.11 1.45 1.83

0.71 0.94 1.19

1.01 1.31 1.66 2.04

0.68

0.90

0.93 1.22 1.54

0.66

0.87

0.87 1.14 1.45

0.64

0.84

0.83 1.08 1.37

0.62

0.82

0.79 1.04 1.32

(2.86)

(3.22)

(3.58)

(3.93)

1.25 1.55 1.87 2.21 2.59 2.99 3.41 3.86 4.34 4.84 5.37

2.25 2.70 3.18 3.71 4.27 4.86 5.48 6.14 6.83 7.55

1.47 1.78 2.11 2.47 2.85 3.26 3.69 4.15 4.63 5.13

2.45 2.90 3.38 3.89 4.43 5.01 5.61 6.25 6.92

1.15 1.42 1.71 2.03 2.38 2.75 3.14 3.56 4.00 4.46 4.95

1.89 2.28 2.70 3.14 3.62 4.13 4.67 5.25 5.83 6.46

1.11 1.37 1.65 1.96 2.30 2.66 3.04 3.44 3.87 4.32 4.79

1.78 2.15 2.54 2.96 3.42 3.90 4.41 4.95 5.51 6.11

1.07 1.33 1.61 1.91 2.23 2.58 2.95 3.35 3.76 4.20 4.66

1.69 2.04 2.42 2.82 3.26 3.72 4.20 4.72 5.26 5.83

1.04 1.29 1.56 1.86 2.18 2.52 2.88 3.27 3.67 4.10 4.55

1.62 1.96 2.32 2.71 3.13 3.58 4.05 4.54 5.07 5.61

(4.29)

65.00

(4.65)

55.00

(5.61)

70.00

(5.01)

60.00

(6.13)

75.00

(5.37)

65.00

(6.64)

80.00

(5.72)

70.00

(7.15)

85.00

(6.08)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

90.00

(6.44)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

Page 27

insulated piping system

90 mm R-flex Single, Pressure Drop per 100' (3.22" Nom. ID)

50.00

55.00

60.00

65.00

70.00

75.00

80.00

°F

(2.49)

(2.74)

0.78

80°

100°

120°

140°

160°

180°

0.93

1.14 1.35 1.57

0.75 0.89 1.04

1.04 1.22 1.43 1.64

0.72

0.85

0.96 1.14 1.32

0.69

0.82

0.90 1.07 1.25

0.67

0.80

0.86 1.02 1.19

0.65

0.78

0.82 0.98 1.14

(2.99)

(3.24)

(3.49)

(3.73)

1.09 1.25 1.43 1.62 1.82 2.03 2.25 2.71 3.22 3.77 4.36 4.98

1.80 2.05 2.32 2.59 2.88 3.19 3.84 4.54 5.29 6.09 6.94

1.20 1.37 1.55 1.74 1.94 2.15 2.60 3.08 3.61 4.17 4.77

1.87 2.11 2.37 2.63 2.91 3.51 4.15 4.85 5.59 6.38

0.99 1.15 1.31 1.49 1.67 1.86 2.07 2.50 2.97 3.48 4.02 4.60

1.53 1.74 1.97 2.20 2.45 2.72 3.27 3.88 4.53 5.23 5.96

0.96 1.11 1.27 1.44 1.62 1.80 2.00 2.42 2.88 3.37 3.90 4.46

1.44 1.64 1.85 2.08 2.32 2.56 3.09 3.67 4.29 4.95 5.65

0.93 1.08 1.23 1.40 1.57 1.75 1.94 2.35 2.80 3.28 3.80 4.35

1.37 1.56 1.77 1.98 2.21 2.44 2.95 3.50 4.09 4.73 5.40

0.91 1.05 1.20 1.36 1.53 1.71 1.90 2.30 2.73 3.20 3.71 4.25

2.31 1.50 1.70 1.90 2.12 2.35 2.84 3.37 3.94 4.55 5.21

(3.98)

85.00

(4.23)

90.00

(4.48)

100

(4.98)

110

(5.48)

120

(5.97)

130

(6.47)

140

(6.97)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

110 mm R-flex Single, Pressure Drop per 100' (3.94" Nom. ID)

100

110

120

130

140

150

°F

(3.00)

(3.33)

0.86

80°

100°

120°

140°

160°

180°

1.03

1.23 1.47 1.74

0.82 0.99 1.17

1.12 1.34 1.59 1.86

0.78

0.95

1.04 1.25 1.48

0.76

0.92

0.98 1.18 1.40

0.74

0.89

0.93 1.13 1.33

0.72

0.87

0.90 1.08 1.28

(3.66)

(4.00)

(4.33)

(4.66)

(4.99)

1.23 1.43 1.66 1.89 2.14 2.83 3.61

2.03 2.34 2.66 3.01 3.95 5.00

1.37 1.58 1.81 2.05 2.71 3.46

2.14 2.44 2.76 3.62 4.60

1.13 1.32 1.53 1.74 1.98 2.62 3.34

1.73 2.00 2.28 2.57 3.39 4.31

1.09 1.28 1.48 1.69 1.92 2.54 3.23

1.64 1.89 2.15 2.44 3.21 4.08

1.06 1.24 1.44 1.64 1.86 2.47 3.15

1.56 1.80 2.06 2.33 3.07 3.90

1.03 1.21 1.40 1.60 1.82 2.41 3.08

1.50 1.73 1.98 2.24 2.96 3.77

175

(5.83)

Pressure drop through R-ﬂex ﬁttings

Equivalent ft. R-ﬂex

Coupling 1.0 Elbow 5.0 Tee-Run 1.0 Tee-Branch 3.3

200

(6.67)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

Page 28

insulated piping system

1" R-flex Dual, Pressure Drop per 50' (0.86" Nom. ID)

2.50

3.00

3.50

4.00

4.50

5.00

°F

(1.36)

(1.64)

1.21

80°

100°

120°

140°

160°

180°

1.66

1.20 2.23 3.36

1.14 1.56 2.05

1.71 2.34 3.04 3.81

1.08

1.49

1.56 2.13 2.77

1.04

1.43

1.45 1.97 2.57

1.00

1.38

1.35 1.85 2.41

0.97

1.33

1.29 1.76 2.30

(1.91)

(2.18)

(2.46)

(2.73)

2.17 2.74 3.36 4.04 4.78 5.57 6.42 7.31 9.26 11.40 13.75 16.29 19.02

4.28 5.22 6.24 7.34 8.50 9.75 11.06 13.89 17.00 20.38 24.02 27.92

2.29 3.18 3.83 4.53 5.28 6.08 6.94 8.79 10.84 13.08 15.51 18.11

4.66 5.57 6.56 7.61 8.74 9.92 12.50 15.32 18.39 21.71 25.26

1.95 2.47 3.04 3.66 4.33 5.05 5.82 6.64 8.42 10.39 12.54 14.88 17.39

3.48 4.26 5.10 6.01 6.99 8.03 9.13 11.51 14.13 16.99 20.07 23.37

1.87 2.37 2.92 3.51 4.16 4.86 5.60 6.39 8.11 10.02 12.10 14.36 16.79

3.23 3.96 4.75 5.61 6.52 7.50 8.53 10.77 13.24 15.93 18.83 21.95

1.80 2.29 2.82 3.40 4.02 4.70 5.42 6.19 7.86 9.71 11.73 13.93 16.29

3.04 3.73 4.48 5.29 6.16 7.08 8.06 10.19 12.54 15.09 17.86 20.83

1.75 2.22 2.73 3.30 3.91 4.56 5.27 6.01 7.64 9.44 11.42 13.56 15.87

2.90 3.56 4.28 5.06 5.89 6.78 7.72 9.76 12.02 14.48 17.14 20.00

5.50

(3.00)

6.00

(3.28)

6.50

(3.55)

7.00

(3.82)

8.00

(4.37)

9.00

(4.91)

10.00

(5.46)

11.00

(6.01)

12.00

(6.55)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

32 mm R-flex Dual, Pressure Drop per 50' (1.15" Nom. ID)

5.00

5.50

6.00

6.50

7.00

8.00

9.00

°F

(1.96)

1.85

80°

2.89 3.39 3.93

1.75 2.07 2.41

100°

2.57 3.02 3.51

1.67

120°

2.35 2.77 3.21

1.60

140°

2.18 2.58 2.99

1.55

160°

2.06 2.43 2.82

1.50

180°

1.96 2.31 2.69

(2.16)

(2.36)

(2.55)

(2.75)

(3.14)

2.19

2.55 2.93 3.34 4.22 5.20 6.26 7.41 8.65 9.98 11.38 12.87 14.44 16.09

4.50 5.10 6.40 7.83 9.37 11.04 12.82 14.72 16.73 18.85 21.08 23.42

2.77 3.16 4.00 4.93 5.95 7.05 8.23 9.49 10.84 12.26 13.76 15.34

4.02 4.47 5.74 7.04 8.44 9.96 11.58 13.31 15.14 17.07 19.11 21.25

1.97

2.30 2.65 3.02 3.83 4.72 5.70 6.75 7.89 9.11 10.40 11.77 13.22 14.74

3.69 4.19 5.28 6.48 7.78 9.19 10.70 12.30 14.01 15.81 17.71 19.70

1.90

2.21 2.55 2.91 3.69 4.55 5.49 6.51 7.61 8.79 10.04 11.37 12.77 14.24

3.44 3.91 4.94 6.06 7.29 8.61 10.03 11.55 13.16 14.86 16.65 18.53

1.83

2.14 2.46 2.81 3.57 4.40 5.32 6.31 7.38 8.52 9.74 11.03 12.39 13.83

3.25 3.69 4.66 5.73 6.90 8.16 9.51 10.95 12.48 14.10 15.81 17.61

1.78

2.07 2.39 2.73 3.47 4.28 5.17 6.14 7.18 8.30 9.48 10.74 12.07 13.47

3.10 3.53 4.46 5.48 6.60 7.81 9.11 10.50 11.97 13.53 15.18 16.90

(3.54)

10.00

(3.93)

40 mm R-flex Dual, Pressure Drop per 50' (1.43" Nom. ID)

7.00

8.00

9.00

10.00

11.00

12.00

13.00

°F

(1.78)

(2.03)

1.18

80°

100°

120°

140°

160°

180°

1.49

1.83 2.29 2.80

1.12 1.41 1.74

163 2.05 2.51 3.00

1.06

1.35

1.49 1.88 2.30

1.02

1.30

1.39 1.75 2.15

0.99

1.25

1.31 1.65 2.03

0.96

1.22

1.25 1.58 1.94

(2.28)

(2.54)

(2.79)

(3.05)

1.83 2.21 2.61 3.05 3.51 4.00 4.52 5.07 5.65 6.25 6.89 7.55 11.24

3.35 3.94 4.57 5.24 5.96 6.71 7.50 8.32 9.19 10.09 11.02 16.24

2.09 2.49 2.89 3.33 3.80 4.30 4.83 5.38 5.95 6.56 7.19 10.73

3.54 4.11 4.72 5.37 6.05 6.77 7.53 8.31 9.14 9.99 14.77

1.66 2.00 2.37 2.77 3.19 3.64 4.12 4.63 5.16 5.71 6.30 6.90 10.31

2.76 3.26 3.79 4.36 4.96 5.59 6.26 6.96 7.70 8.46 9.26 13.71

1.60 1.93 2.28 2.67 3.08 3.51 3.98 4.46 4.98 5.51 6.08 6.67 9.97

2.58 3.05 3.55 4.08 4.65 5.24 5.87 6.54 7.23 7.95 8.70 12.91

1.55 1.86 2.21 2.58 2.98 3.40 3.85 4.33 4.83 5.35 5.90 6.47 9.68

2.44 2.88 3.36 3.86 4.40 4.97 5.57 6.20 6.86 7.55 8.27 12.28

1.50 1.81 2.15 2.51 2.90 3.31 3.75 4.21 4.70 5.21 5.74 6.30 9.44

2.33 2.76 3.21 3.70 4.22 4.76 5.34 5.94 6.58 7.24 7.93 11.80

(3.30)

14.00

(3.55)

11.00

(4.32)

15.00

(3.81)

12.00

(4.71)

16.00

(4.06)

13.00

(5.11)

17.00

(4.31)

14.00

(5.50)

18.00

(4.57)

15.00

(5.89)

19.00

(4.82)

16.00

(6.29)

20.00

(5.08)

17.00

(6.68)

25.00

(6.34)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

Page 29

insulated piping system

50 mm R-flex Dual, Pressure Drop per 50' (1.79" Nom. ID)

11.00

12.00

13.00

14.00

15.00

16.00

17.00

°F

(1.78)

(1.94)

0.90

80°

100°

120°

140°

160°

180°

1.04

1.37 1.59 1.82

0.85 0.99 1.14

1.23 1.43 1.64 1.86

0.81

0.95

1.13 1.31 1.50

0.78

0.91

1.05 1.22 1.41

0.75

0.88

0.99 1.16 1.33

0.73

0.86

0.95 1.10 1.27

(2.11)

(2.27)

(2.43)

(2.59)

1.20 1.37 1.55 1.74 1.93 2.14 2.35 2.58 3.84 5.31 7.00 8.89

2.07 2.33 2.60 2.88 3.18 3.49 3.81 5.61 7.70 10.07 12.72

1.30 1.47 1.65 1.84 2.03 2.24 2.45 3.65 5.07 6.68 8.50

2.09 2.34 2.60 2.87 3.15 3.45 5.08 6.99 9.17 11.59

1.09 1.25 1.41 1.58 1.76 1.95 2.15 2.35 3.51 4.87 6.42 8.17

1.71 1.93 2.16 2.40 2.65 2.91 3.19 4.71 6.49 8.52 10.79

1.05 1.20 1.36 1.52 1.70 1.88 2.07 2.27 3.39 4.70 6.21 7.91

1.60 1.81 2.02 2.25 2.48 2.73 2.99 4.43 6.11 8.03 10.18

1.02 1.16 1.31 1.47 1.64 1.82 2.01 2.20 3.29 4.57 6.03 7.69

1.51 1.71 1.91 2.13 2.35 2.59 2.83 4.20 5.81 7.64 9.69

0.99 1.13 1.28 1.43 1.60 1.77 1.95 2.14 3.20 4.45 5.88 7.50

1.45 1.63 1.83 2.04 2.25 2.48 2.72 4.03 5.58 7.34 9.32

(2.75)

18.00

(2.92)

19.00

(3.08)

20.00

(3.24)

25.00

(4.05)

30.00

(4.86)

35.00

(5.67)

40.00

(6.48)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

63 mm R-flex Dual, Pressure Drop per 50' (2.25" Nom. ID)

15.00

20.00

25.50

30.00

35.00

40.00

45.00

°F

(1.53)

(2.04)

0.52

80°

100°

120°

140°

160°

180°

0.86

0.78 1.28 1.88

0.49 0.81 1.21

0.70 1.15 1.70 2.34

0.47

0.78

0.65 1.06 1.57

0.45

0.75

0.60 1.00 1.47

0.43

0.73

0.57 0.94 1.40

0.42

0.71

0.54 0.90 1.34

(2.55)

(3.08)

(3.57)

(4.08)

1.27 1.76 2.31 2.94 3.63 4.38 5.20 6.08 7.02 8.02

2.58 3.37 4.25 5.22 6.27 7.41 8.63 9.93 11.32

1.67 2.20 2.80 3.46 4.18 4.97 5.81 6.71 7.67

3.06 3.86 4.75 5.72 6.76 7.88 9.08 10.36

1.16 1.61 2.12 2.69 3.33 4.02 4.78 5.59 6.46 7.39

2.16 2.83 3.59 4.41 5.32 6.30 7.35 8.47 9.66

1.12 1.55 2.04 2.60 3.22 3.89 4.62 5.41 6.26 7.16

2.03 2.67 3.38 4.16 5.02 5.94 6.94 8.00 9.13

1.08 1.50 1.98 2.52 3.12 3.78 4.49 5.26 6.09 6.97

1.93 2.53 3.21 3.96 4.78 5.66 6.61 7.63 8.72

1.05 1.46 1.93 2.46 3.05 3.69 4.38 5.14 5.94 6.80

1.85 2.43 3.08 3.80 4.59 5.45 6.37 7.35 8.39

(4.59)

50.00

(5.10)

55.00

(5.61)

60.00

(6.13)

65.00

(6.64)

70.00

(7.15)

GPM

(ft/sec)

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

100% Water

50% Water/Glycol

Page 30

insulated piping system

Appendix C pressure test results

Test the nished pipe-work before concealing! The execution and documentation of the pressure test for the entire piping system is a warranty requirement!

psi

2 Preliminary test

2.1 Operating pressure x 1,5

2.2 After 10 min (restore 2,1)

2.3 After 20 min (restore 2,1)

2.4 After 30min

2.5 After 60 min admissible pressure drop < 0,6 bar

psi

3 Main test

3.1.1 Beginning

3.1.2 End

3.2 Test pressure

3.3 After120 min

3.4 Remarks admissible pressure drop < 0,2 bar

Page 31

insulated piping system

Appendix D installation times

The installation time is highly dependant on local conditions. Obstacles, use of tools and weather can have a signicant impact on the installation time.

Outside casing

out

mm mm minutes*

Single (100m)

160 40 60 3

160 50 60 3

160 63 60 4

200 75 75 4

200 110 90 5

Double (100m)

125 1 inch/32mm 40 3

160 40 60 3

200 50 60 3

200 63 60 4

* All installation times are approximate. Transport and digging not included.

Accessories Time Number of Workers

Terminal connections 15-20 min. 1

Tees PEX 30-40 min. 1

Insulation casings 20-30 min. 1

Shrink caps 15 min. 1

* All installation times are approximate. Transport and digging not included.

PEX

out

Time per coil Number of Workers

minutes*

Page 32

4500 E. Progress Place

Springﬁeld, MO 65803

ph: 417.864.6108

800.276.2419 fax: 417.864.8161

www.wattsradiant.com

Watts Industries - Canada

5435 North Service Road

Burlington, ON L7L-5H7

ph: 888.208.8927

905.332.4090

fax: 888.882.1979

905.332.7068

www.wattscanada.ca

In Canada