Handbook products, design and installation

Transcription

1 Handbook products, design and installation Version

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3 LOGSTOR FlexPipe handbook General Introduction This section describes LOGSTOR s solutions for heating and domestic water systems primarily for community heating projects. Contents System description 1.1 Fields of application 1.2 Component solutions 1.3 Design 1.4 LOGSTOR A/S Tel FlexPipe

4 LOGSTOR FlexPipe handbook General - system description System description This LOGSTOR handbook is primarily directed at the community heating/low temperature (up to 95 C) market with the products: PexFlex and AluFlex for heating PEX DW for domestic water Community heating as a concept does not differ essentially from district heating as regards the technical solutions, but primarily as regards the facts that: the system is connected to a local energy source either by utilising: - existing systems or - new community heating systems the ownership is rooted locally the system, by its nature, has a limited size the pipe dimensions are small, making flexible pipe systems an obvious choice the temperatures are low, enabling optimisation of the product choice and thus reducing the construction costs. LOGSTOR FlexPipe systems contribute to this with: good insulating properties. Certified thermal conductivity, lambda = W/mK few buried joints no welding or soldering. Only mechanical joints. narrow trenches = minimise the excavation and restoration costs also due to: --the possibility to use TwinPipe --the small bending radii --self-compensating systems. No expansion components LOGSTOR FlexPipe handbook This handbook is based on excerpts from LOGSTOR s Product Catalogue, Design, and Handling & Installation manual. Refer to these, if additional documentation and instructions are required. All rights reserved. The English version on is the original. All other language versions are made according to the best knowledge of the translators. FlexPipe LOGSTOR Fredericia A/S Tel

5 LOGSTOR FlexPipe handbook General - fields of application Typical fields of application for community heating projects System types: Distribution: Consumers: Biogas Horticultural farms Landfill gas Terraced and cluster houses Biomass (Wood chips/straw) Detached houses Heat pump (Air/ground) LOGSTOR Schools Industry Sports centres Geothermal energy Small- and medium-sized enterprises Solar system Villages BIO LOGSTOR A/S Tel FlexPipe

6 LOGSTOR FlexPipe handbook General - component solutions Component solutions In addition to choosing the pipe system there are only a few other choices to make. The primary choices are: A. Branching components B. Connection to the consumer C. Straight joint of two lengths of FlexPipe A B C Solution A A. Branching components: - Preinsulated T-pieces and straight casing joints - T-press couplings and T-casing joints Illustration Components Component No. T-piece straight with couplings fitted onto it 3400 FXJoint (single pipe) 5057 SXJoint (TwinPipe) for foaming 5012 T-coupling, press T-coupling, compression 6062 Pex/Alu 6160 PEX DW T-straight (single pipe) 5140 T-straight (TwinPipe) for foaming 5140 FlexPipe LOGSTOR Fredericia A/S Tel

7 LOGSTOR FlexPipe handbook General - component solutions Solution B B. Connection to the consumer: - In the cellar - Tilted bore - Embedded inlet pipe Illustration Components Component No. Wall entry sleeve 5800 End cap 5600 End cap 5600 or protective cap 1230 Inlet pipe 1236 End cap 5600 Protective cap 1230 Solution C C. Straight joint between two lengths of FlexPipe: - Jointing single pipes - Jointing TwinPipe/DoublePipe (PEX DW) Illustration Components Component No. Press coupling 6000 PexFlex 6001 AluFlex Compression coupling 6100 PEX DW and PexFlex FXJoint (insulated) 5057 Press coupling 6000 PexFlex 6001 AluFlex Compression coupling 6100 PEX DW and PexFlex SXJoint (foamed) 5012 LOGSTOR A/S Tel FlexPipe

8 Design with General Introduction This section describes general and product specific rules for designing and dimensioning with PexFlex, AluFlex, and PEX DW. Design and piping The design of the pipeline is very simple, because the pipes are self-compensating. That means that expansion movements in the soil shall not be taken into account. in the design phase the following shall be decided upon: -- The design of the trench, see page Bending radius of the relevant dimensions, see page Introduction in buildings, see section (If are to be connected to existing systems with steel service pipes special rules apply! (see section 11.3 and ). FlexPipe LOGSTOR Fredericia A/S Tel

9 Design with Heat loss Conditions The tables in this section are based on the following and are consequently only guiding: --Flow temperature 80 C --Return temperature 40 C --Soil temperature 10 C -- Soil cover 0.6 m --Distance between pipes (in connection with single pipes) 0.15 m -- Lambda value of the soil 1.6 W/mK If exact calculations with other condistions are required, please refer to LOGSTOR Calculator at (use the quick link). PexFlex The heat loss is the total heat loss of flow and return pipe. Pipe pair: Service pipe ø mm Series 1 Outer casing ø mm Heat loss W/m Service pipe ø mm Series 2 Outer casing ø mm Heat loss W/m TwinPipes: Service pipe ø mm Series 1 Outer casing ø mm Heat loss W/m 2x x x x x x Service pipe ø mm Series 2 Outer casing ø mm Heat loss W/m 2x x x x x LOGSTOR A/S Tel FlexPipe

10 Design with Heat loss AluFlex The heat loss is the total heat loss of flow and return pipe. Pipe pair: Service pipe ø mm Series 1 Outer casing ø mm Heat loss W/m Service pipe ø mm Series 2 Outer casing ø mm Heat loss W/m TwinPipes: Service pipe ø mm Series 1 Outer casing ø mm Heat loss W/m 2x x x x Service pipe ø mm Series 2 Outer casing ø mm Heat loss W/m 2x x x x FlexPipe LOGSTOR Fredericia A/S Tel

11 Design with Pressure loss charts General In order to establish the correct pipe dimension it is necessary to know the water flow and the maximum allowable pressure loss. Small pipelines are often dimensioned after the available pressure difference, thereby minimising the dimension and the heat loss as much as possible as well as assuring the consumer the highest possible flow temperature. In addition, it must be ensured that the water speed will not be too high. For flexible pipelines it is recommended that the speed does not exceed 2 m/s in couplings and that the speed in house connections does not exceed 1 m/s to minimise the risk of noise. It is recommended that the system is dimensioned after the available pressure difference. In case it is not known, a value corresponding to 150 Pa/m is often used. As a dimensioning tool LOGSTOR Calculator can be used. It is available on: As an alternative to a hand calculation the graphs in the following can be used. Inter-related values between output (kw) and cooling as well as water flow (kg/h) appear from the graphs. The required output is found with the inter-related cooling, or the water flow can be found after the formula: q Q 860 T q = Mass flow [ kg/h] Q = Output [kw] DT = Cooling The following graphs are based on: Water temperature of 80 C for heat pipes and 60 for domestic water pipes. Absolute PEX roughness = 0.01 mm LOGSTOR A/S Tel FlexPipe

12 Design with Pressure loss charts PexFlex kw 2000 kg/h ,0 m/s ø 110 ø 90 ø ,0 m/s ø ,50 m/s ø 50 ø ,25 m/s ø 32 ø 25 ø 20 ø ΔT 40 C 30 C Pa/m AluFlex kw kg/h ,0 m/s ø ,25 m/s 0,50 m/s 1,0 m/s ø 32 ø 26 ø 20 ø ΔT 40 C 30 C Pa/m FlexPipe LOGSTOR Fredericia A/S Tel

13 Design with Pressure loss charts PEX DW kg/h 2,0 m/s ø ,0 m/s ø 50 0,50 m/s ø 40 ø 32 0,25 m/s ø 28 ø ø Pa/m LOGSTOR A/S Tel FlexPipe

14 Product Catalogue Introduction This section contains a presentation of the LOGSTOR products: -- pipes -- fittings --casing joints --accessories -- tools available to the following systems: -- heating: PexFlex AluFlex --domestic water: PEX DW Contents Technical description of 2.1 PexFlex 2.2 AluFlex 2.3 PEX DW 2.4 Casing joint types 2.5 Terminations with General PexFlex AluFlex Tools for 2.7 FlexPipe LOGSTOR Fredericia A/S Tel

15 Technical description Overview Materials, properties etc. for LOGSTOR Service pipe (1) PexFlex AluFlex PEX DW PEXb ø mm EVOH diffusion barrier 3.1 certificate is available PEX/Alu/PE (out.) ø mm PEX ø mm Polyurethane foam, PU Insulation (2) Blowing agent: Cyclopentane Certified thermal conductivity: l 50 = W/mK Diffusion barrier (3) Multilayer polymer foil - Outer casing (4) Polyethylene PELD Standards/approvals EN EN Service pipe: - EN DVGW K 178 and 183 Pressure, P bar PN 6: ø 16 mm PN 10: ø mm PN 10 PN 10 Temperature, C - Continuous max. - Max. at 100 h/year Delivered lengths: Standard lengths Fixed lengths min max. 90 m and 100 mm Yes and 100 mm Yes and 100 mm Measurements of FlexPipe coil Apply to series 1, 2, and TwinPipe D i D e H Measure approx. Outer casing, ø out. mm D i D e H H LOGSTOR A/S Tel FlexPipe

16 PexFlex - pipes in coils Single pipe Component No Lengths: 50 or 100 m PN 6, SDR 11. PEX service pipe ø out. mm Wall t. mm Series 1 Outer casing ø out. mm Wall t. mm Series 2 Outer casing ø out. mm Wall t. mm 16** * 3.0 * Series 0. Note! Preinsulated components have casing pipes ø 180 mm. ** PN 10. TwinPipe Component No Lengths: 50 or 100 m PN 6, SDR 11. PEX service pipe ø out. mm Wall t. mm Series 1 Outer casing ø out. mm Wall t. mm Series 2 Outer casing ø out. mm Wall t. mm 16/16* / / / / / * PN 10. Order example System - Component - Component No. - Dim. service/casing pipe - Length: PexFlex - pipe /77-50 m PexFlex Twin - pipe x2/ m FlexPipe LOGSTOR Fredericia A/S Tel

17 PexFlex - preinsulated bends Application PexFlex 90 bends are used, when a sharper curvature than allowed by the minimum bending radius is required. 90 preinsulated bend PexFlex bends have PEX service pipes. Do not shorten! Are available without free ends. Component overview Component No Single pipe PEX pipe Outer casing ø out. mm ø out. mm Series 1 Series *180 * PexFlex in coils is delivered as ø 110 mm in a ø 160 mm casing pipe. TwinPipe PEX pipe Outer casing ø out. mm ø out. mm Series 1 Series 2 20/ / / / / Order example System - Component - Component No. - Dimension: PexFlex - 90 bend /90 LOGSTOR A/S Tel FlexPipe

18 PexFlex - preinsulated branches Description Preinsulated branches for PexFlex are straight branches with steel service pipes. They are delivered with press couplings already welded on to them. As an alternative they can be ordered with compression couplings. Single pipes Component No mm 605 mm PexFlex, main pipe, D 1 Branch ø out. mm, D 2 Service pipe Outer casing, ø out. mm Dim. outer casing = main pipe ø out. mm Series 1 Series x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x TwinPipes Component No mm 605 mm FlexPipe LOGSTOR Fredericia A/S Tel

19 PexFlex - preinsulated branches TwinPipes, continued PexFlex, main pipe, D 1 Branch, ø out. mm, D 2 Service pipe Outer casing, ø out. mm Dim. outer casing = main pipe ø out. mm Series 1 Series 2 16/16 20/20 25/25 32/32 40/40 50/50 16/ x 20/ x x 25/ x x x 32/ x x x x 40/ x x x x x 50/ x x x x x x Order example System - Component - Component No. - D 1 - D 2 : PexFlex - Straight branch / / LOGSTOR A/S Tel FlexPipe

20 PexFlex - transition pipes, TwinPipe - single pipe Application Preinsulated transition pipes are used in connection with straight transition from a single pipe system to a TwinPipe system. As a standard series 2 dimensions for single pipe ends and series 1 dimensons for TwinPipe ends are delivered for PexFlex. As the flow pipe is always placed at the bottom, the transition is available in a type 1 as well as a type 2 version. Description "Type 1" and "type 2" are defined by viewing the transition pipe from the single pipe end perspective. Type 1 Type 2 C/C = 245 mm 1700 mm Possible combinations Component No Single pipe ø out. mm TwinPipe ø out. mm 16/77 20/77 25/77 32/77 40/90 50/110 16/90 20/90 25/110 32/110 40/125 50/160 Order example System - Component - Component No. - Dim. single - Dim. Twin - Type: PexFlex - Overgangsrør /77-25/110-1 FlexPipe LOGSTOR Fredericia A/S Tel

21 PexFlex - press couplings Coupling types For PexFlex-systems the three most commonly used coupling types are: -- Straight press coupling: Same dimension -- Reducing press coupling: 1-3 dimensional offsets dependent on the dimension --Straight branch with press coupling Press couplings ensure a permanent sealing at all temperature variations. Alternative: Straight couplngs as well as T-couplings are also available as compression couplings, see page Straight and reducing couplings Component No Dimension = PEX ø out. mm ø1 ø1 ø1 ø2 Coupling end ø Coupling end ø2 16 x x 20 x x x 22 x x 25 x x x 28 x 32 x x 40 x x 50 x x 63 x x 75 x x 90 x x 110 x Order example System - Coupling type - ø1 - ø2: PexFlex - Press/reducing LOGSTOR A/S Tel FlexPipe

22 PexFlex - press couplings T-branch with press couplings Component No ø2 ø1 ø3 PEX main pipe ø1 = ø3 ø out. mm PEX branch, ø2 ø out. mm x 25 x x x 32 x x x x 40 x x x x 50 x x x x x 63 x x x x x x 75 x x x x x x x 90 x x x x x x x x 110 x x x x x x x x x PEX main pipe with reduction ø1 - ø3 ø out. mm x x x PEX branch, ø2 ø out. mm x x x x x x x x Order example System - Coupling type - Comp. No. - ø1 - ø2 - ø3: PexFlex - T-branch PexFlex - T-branch with reduction Other coupling types -- Transition coupling for steel service pipe. From steel/pex: ø 26.9/16 mm to ø 114.3/110 mm. FlexPipe LOGSTOR Fredericia A/S Tel

23 PexFlex - compression couplings Coupling types For PexFlex compression couplings can also be used. They are available as straight couplings and T-couplings. Please note that in some countries special rules apply to the use of not visible compression couplings. Straight connections Straight compression coupling: Component No PEX pipe diameter d, mm Component No PEX pipe diameter d, mm Order example: ø20-32 ø System - Component - Component No. - Dim. service pipe: PexFlex - Straight compression coupling Branches Compression-T-coupling, component No In principle ø2 and ø3 are optional, provided that they are ø1. ø2 ø1 ø3 PEX main pipe ø1 = ø 3 ø out. mm PEX-branch, ø2 ø out. mm x 25 x x 32 x x 40 x x x 50 x x x x x 63 x x x x x x 75 x x x x x x x 90 x x x x x x x 110 x x x x x x x Order example: System - Component - Component No. - Dimension from/to: PexFlex - Compression-T-coupling /28 LOGSTOR A/S Tel FlexPipe

24 AluFlex - pipes in coils Single pipe Component No AluPEX Series 1 Series 2 Casing pipe Casing pipe ø out. Wall t. ø out. Wall t. ø out. Wall t. mm mm mm mm mm mm TwinPipe Component No AluPEX Series 1 Series 2 Casing pipe Casing pipe ø out. Wall t. ø out. Wall t. ø out. Wall t. mm mm mm mm mm mm 16/ / / / Order example System - Component - Component No. - Dim. service pipe/outer casing - Length: AluFlex - Single pipe / AluFlex - TwinPipe / FlexPipe LOGSTOR Fredericia A/S Tel

25 AluFlex - preinsulated branches Description Preinsulated branches for AluFlex are straight branches with steel service pipes. They are delivered with press couplings already welded on to them. Single pipe Component No mm 605 mm AluFlex, main pipe, D 1 Branch ø out. mm, D 2 Service pipe Outer casing, ø out. mm Dim. outer casing = main pipe ø out. mm Series 1 Series x x x x x x x x x x TwinPipes Component No mm 605 mm AluFlex, main pipe, D 1 Branch, ø out. mm, D 2 Service pipe Outer casing, ø out. mm Dim. outer casing = main pipe ø out. mm Series 1 Series 2 16/16 20/20 26/26 32/32 16/ x 20/ x x 26/ x x x 32/ x x x x Order example System - Component - Component No. - D 1 - D 2 : AluFlex - Straight branch / /125 LOGSTOR A/S Tel FlexPipe

26 AluFlex - press couplings Coupling types For AluFlex systems the three most commonly used coupling types are: -- Straight press coupling: Same dimension -- Reducing press coupling: 1-3 dimensional offsets dependent on the dimension --Straight branch with press coupling Press couplings ensure a permanent sealing at all temperature variations. Please note that press couplings for AluFlex are equipped with O-rings and insulator rings. See "Installation of press couplings". Straight and reducing couplings Component No Dimension = PEX ø out. mm ø1 ø1 Coupling end ø Coupling end ø2 16 x x 20 x x 26 x x 32 x ø1 ø2 Order example System - Coupling type - ø1 - ø2: AluFlex - Press/reducing T-branch with press couplings Component No Main pipe Branch, ø 2 ø1 = ø3 AluFlex, ø mm AluFlex x 20 x x 26 x x x 32 x x x x ø1 ø2 ø3 Order example System - Coupling type - ø1 - ø2 - ø3: AluFlex - T-press coupling Other coupling types -- Transition coupling for steel service pipe. From steel/pex: ø 26.9/16 mm to ø 33.7/32 mm. -- End coupling, closed press coupling. Also see "Terminations with AluFlex", page FlexPipe LOGSTOR Fredericia A/S Tel

27 PEX DW - pipes in coils Application The FlexPipe system PEX DW for domestic water is a complete distribution and house entry system. Single pipe, PN 10 SDR 7.4 Distribution pipe, component No PEX service pipe Outer casing (series 1) ø out. Wall thick. ø out. Wall thick. mm mm mm mm DoublePipe, PN 10 SDR 7.4 Circulation pipe, component No PEX service pipe Outer casing (series 1) ø out. Wall thick. ø out. Wall thick. mm mm mm mm 28/22 4.0/ /22 4.4/ /28 5.5/ /32 6.9/ Order example System - Component - Component No. - Dim. service/casing pipe - Length: PEX DW - DoublePipe / LOGSTOR A/S Tel FlexPipe

28 PEX DW - preinsulated bends Preinsulated 90 bend PEX DW bends have PEX service pipes. Do not shorten them! They are delivered without free ends. Component overview Component No PEX pipe ø out. mm Outer casing ø out. mm Order example System - Component - Component No. - Dimension: PEX DW - 90 bend /110 FlexPipe LOGSTOR Fredericia A/S Tel

29 PEX DW - compression couplings Connection types PEX DW pipes are connected by means of compression couplings. When ordering, please state 10 bar. Straight connections Straight compression coupling: Component No PEX pipe diameter d, mm ø22-32 ø40-63 Component No PEX pipe diameter d, mm Order example: System - Component - Component No. - Dim. service pipe: PEX DW - Straight compression coupling, 10 bar Compression coupling with male thread, component No PEX pipe Male thread ø out. mm 3 / / 4 1½ 2 22 x x 28 x x 32 x x 40 x x 50 x x 63 x Compression coupling with female thread, component No PEX pipe Female thread ø out. mm 3 / / 4 1½ 2 22 x x 28 x x 32 x x 40 x x 50 x x 63 x Order example: System - Component - Component No. - Dimension (mm/"): PEX DW - Compression coupling, male, 10 bar /1 1 / 4 LOGSTOR A/S Tel FlexPipe

30 PEX DW - compression couplings Bends Compression coupling. Union elbow with male thread, component No PEX pipe Male thread ø out. mm 3 / / 4 1½ 2 22 x x 28 x x 32 x 40 x 50 x 63 x Compression coupling. Union elbow with female thread, component No PEX pipe Female thread ø out. mm 3 / / 4 1½ 2 22 x x 28 x x 32 x 40 x 50 x 63 x Order example: System - Component - Comp. No. - Dimension (mm/"): PEX DW - Compression coupling, 90 male, 10 bar /1 1 / 4 Branches Compression-T-coupling, component No Main pipe Branch ø out. mm ø out. mm x 28 x x x 32 x x x 40 x x x x 50 x x x x x 63 x x x x x x Order example: System - Component - Component No. - Dimension from/to: PEX DW - Compression-T-coupling, 10 bar /28 FlexPipe LOGSTOR Fredericia A/S Tel

31 Casing joint types Casing joint types From LOGSTOR s casing joint assortment 4 types have been selected which ensure simple and efficient connections of. For single pipes shrink joints with insulation shells are used. Alternatively, casing joints for foaming may be used. For TwinPipe shrink joints for foaming with foam packs are used. Overview Pipe type Straight connections Branches Insulation Single pipe FXJoint T-joint, straight F Insulation shells TwinPipe SXJoint T-joint, straight Foam packs LOGSTOR A/S Tel FlexPipe

32 Casing joints for - FXJoint Application The shrink joint FXJoint with insulation shells is used for connections on single pipe ø mm. The sleeve is pre-installed on the pipes, before they are connected. FXJoints are installed by means of a soft gas flame. (See installation instructions section 3.5). Description The FXJoint set consists of: 1. Insulation shells with flexible core for couplings 2. Shrink sleeve with integrated mastic 3. Cleaning tissue Materials Sleeve Cross-linked PE (PEX) with mastic, embedded in the ends Insulation shells Hard PU, polyurethane, furnished with soft PU Component overview Component No FXJoint is available in 2 dimensions, covering the following two intervals: - Dimension ø mm - Dimension ø mm Order example Casing joint type - Component No. - Outer casing dimension: FXJoint (No distinction is made between series 1 and 2). FlexPipe LOGSTOR Fredericia A/S Tel

33 Casing joints for - T-joint, straight F Application The shrink joint T-joint, straight F with insulation shells is used for straight connections on single pipe ø mm. Collar, shrink wrap and T-shoe are pre-installed on the branch prior to connection to the main pipe. Description A complete set consists of: 1. Closure patch 2. Shrink wrap 3. Insulation shells with marking for branch 4. T-shoe 5. Insulation shells 6. Collar 7. Cleaning tissue Materials - T-shoe PE with hotmelt in the branch - Shrink wrap and collar PE with mastic - Closure patch Cross-linked polyolefin with fibreglass reinforcement - Insulation shells Hard PU, polyurethane with soft PU embedded Component overview Component No Main pipe, outer casing ø mm Branch, outer casing ø mm x 90 x x 110 x x x 125 x x x x 140 x x x x x 160 x x x x x x Order example Casing joint type - Component No. - From dimension - To dimension: T-joint, straight F No distinction is made between series 1 and 2. LOGSTOR A/S Tel FlexPipe

34 Casing joints for - SXJoint Application The shrink joint SXJoint for foaming is used for straight connections of Twin ø mm. The sleeve is pre-installed on the pipes prior to their connection. The SXJoint is installed by means of a soft gas flame, see installation instructions section 3.7. The joint is for foaming and consequently shrinkable at the ends and not in the middle. Description The SXJoint set consists of: 1. Shrink sleeve (The joint ends contain mastic) 2. Venting plugs 3. Expansion plugs 4. Wedge plugs 5. Patches 6. Collars (to be ordered separately) The joint set is wrapped in white PE foil on delivery. Store the shrink sleeve vertically. Max. temperature during transportation and storage: 80 C L Materials Shrink sleeve: Crosslinked PE (PEX) Venting plugs: LDPE Expansion plugs: PEX with a butyl mastic ring Wedge plugs: PEX Patches: PEX with water-resistant hotmelt Component overview/data Component No Outer casing dim. Shrinkable to L ø mm ø mm mm For outer casing dimension ø 77 mm a ø 90 mm sleeve is used. Order example Casing joint type - For outer casing dmension - Foam pack - Series: SXJoint - ø 125 mm - incl. - 2 Accessories Foam packs are used for foaming. When ordering, simply state the insulation series and that the casing joint must be delivered including foam packs, then the correct dosage will be delivered automatically. The foam pack size appears from the table on page FlexPipe LOGSTOR Fredericia A/S Tel

35 Casing joints for - T-joint, straight branch Application The shrink joint T-joint for foaming is used for branching single pipe ø mm. Collar, shrink wrap and T-shoe are pre-installed on the branch prior to connection to the main pipe. Description A complete set consists of: 1. Closure patch 2. Shrink wrap 3. T-shoe 4. Collar 5. Venting, expansion, and wedge plugs 1 2 L 2 L Materials T-shoe: PE with hotmelt in the branch Shrink wrap and collar: PE with mastic Closure patch: Cross-linked polyolefin with fibreglass reinforcement Venting plugs: LDPE Expansion plugs: PEX with mastic Wedge plugs: PEX Component overview Component No Main pipe, outer casing ø mm Branch, outer casing ø mm x 110 x x 125 x x x 140 x x x x 160 x x x x x Order example Casing joint type - Comp. No. - From dim. - To dim. - Foam pack - Series: T-joint, straight ø 160 mm - ø 125 mm - incl. - 1 Accessories Foam packs are used for foaming. When ordering, simply state the insulation series and that the casing joint must be delivered including foam packs, then the correct dosage will be delivered automatically. The foam pack size appears from the table on page LOGSTOR A/S Tel FlexPipe

36 Terminations with General Possible terminations. Description In principle there are 4 methods to introduce through a wall: - Straight lead-in through the base - Tilted bore in the base - 90 lead-in through the base with embedded inlet pipe - External lead-in through the wall, covered by a cabinet For internal use a number of possible mountings and valves, adjusted to the pipe type and expansion stress (see under the different FlexPipe types) are offered. Consequently, it is possible to find a solution which fits the specific task precisely. Straight lead-in throug the base. Wall entry sleeve Is used by direct introduction into e.g. service space, cellar etc. Component No Dependent on whether bore or core has been used a wall entry sleeve may be required. Outer casing ø out. mm Sealing ring 77 x 90 x 110 x 125 x 140 x 160 x Order example System - Component - Component No. - Dim. service/casing pipe - Length: - - Wall entry pipe / Tilted bore in the base Is used in connection with existing buildings, where boring is preferred to cutting a hole. A projected FlexPipe end may be covered by a tight-fitting protective cap. Component No As for TwinPipes the conical connecting pieces are adjusted to the service pipe end. FlexPipe LOGSTOR Fredericia A/S Tel

37 H Terminations with General Tilted bore in the base, component overview for protective cap Component No. of protective cap for single pipe: General for all FlexPipe types. Dimension internal/external mm System 20/77 25/77 26/77 32/77 22/90 26/90 32/90 40/90 50/110 PexFlex x x x x x AluFlex x x x x x x Order example System - Component - Component No. - Dimension: AluFlex - Protective cap /77 Lead in through base by means of embedded inlet pipe Is used in connection with new buildings to facilitate later introduction of FlexPipe without drawbacks for the building. 1. Inlet pipe 2. Sealing reduction 2 / 3 or 3. End-cap 1 Use a special pulling tool to pull the pipe through the inlet pipe, see page Inlet pipe (1) Component No FlexPipe R H L ø ø out. mm mm mm mm mm R ø L Order example System - Component - Component No. - Dimension: FlexPipe - Inlet pipe /140 LOGSTOR A/S Tel FlexPipe

38 Terminations with General Protective cap (2) The introduction may be terminated with a protective cap (see section about tilted introduction) or an end-cap. End-cap (3) Shrinkable end-cap for single pipe. Component No Service pipe Outer casing DHEC ø out. mm ø out. mm No Shrinkable end-cap for Twin FlexPipe. Component No Service ppe Outer casing DHEC ø out. mm ø out. mm No. 16/16-20/ /22-25/ / / Order example System - Component - Component No. - Dimension: Twin FlexPipe - End-cap / or DHEC 3200 Description. Internal fixing. Connection to house installation There are a lot of suitable individual solutions, but LOGSTOR offers a number of possibilities which make allowance for the material properties of the individual pipe type and the pure pipestatic influences. Mounting type A Applicable for all types of introduction in connection with screw couplings. Used for: - PexFlex - AluFlex Product No FlexPipe LOGSTOR Fredericia A/S Tel

39 Terminations with General Accessories for mounting type A For installation on this mounting an adapter coupling with ex- and internal thread respectively is available for threaded couplings, screw couplings and loose ball valves. Thread Product No. 3/ In connection with mounting type A (or for individual solutions) a 3/4 ball valve with internal thread is available. Component No Design Flow (red) Return (blue) All-welded steel x x Nickeled brass x x Mounting type C If expansion movements occur in the through the wall, the pipe bending must be ensured by means of a matrix (especially in connection with cooling of the pipes). Primarily used for: - PexFlex (max. ø 28 mm) - AluFlex Service pipe Product No. ø out. mm Order example System - Component - Component No. - Dimension: FlexPipe - Mounting type C LOGSTOR A/S Tel FlexPipe

40 Terminations with PexFlex Internal wall installation (with relief) Mounting type A is used for all introductions where there is some kind of expansion absorption. Product No See Terminations, general. Termination in cabinet (relieved) Press coupling with male thread. Material: Brass Component No To be used relieved (in cabinet or indoors). PEX pipe Male thread ø out. mm 1 / 2 3 / / / x 20 x 22 x 25 x x 28 x 32 x x 40 x 50 x 63 x 75 x 90 x 110 x Order example System - Component - Component No. - Dimension: PexFlex - Press coupling with male thread /1 1 / 4 Internal installation Compression coupling with male thread can be used for internal installation. Component No The coupling is made of brass. FlexPipe LOGSTOR Fredericia A/S Tel

41 Terminations with PexFlex Internal installation, continued PEX pipe Male thread ø out. mm 3/ /4 1 1/ x 22 x x 25 x x 28 x x 32 x x 40 x 50 x 63 x 75 x 90 x 110 x Order example System - Component - Component No. - Dimension: PexFlex - compression coupling with male thread /1 1 / 2 Internal wall installation (without relief) ø 22 and 28 mm Mounting type A combined with mounting type C is used, when the PexFlex pipe is installed directly through the wall without any absorption of the expansion movement. See page A C Internal wall installation (without relief), ø 32 and 40 mm In connection with PexFlex ø 32 mm mounting type C cannot be used, as the radius will be too large. Instead a 90 bend coupling is used. Component Nos. 6100, see page (Naturally, this solution can also be used in cellars). A LOGSTOR A/S Tel FlexPipe

42 Terminations with PexFlex Inlet pipe Component No For casing ød, mm Pipe K, mm R = 6 ød Order example System - Component - Component No. - Dimension: PexFlex - Inlet pipe /125 End fitting Component No The outmost 100 mm of the end fitting is shrinkable. 1. End fitting 2. Shrink sleeve PEX pipe ø out. mm Outer casing ø out. mm Order example System - Component - Component No. - Dimension: PexFlex - End fitting /77 FlexPipe LOGSTOR Fredericia A/S Tel

43 Terminations with AluFlex Internal wall installation (partial relief) In connection with introduction with partial absorption of the expansion movement - Tilted bore - Embedded inlet pipe mounting type A is used. Internal wall installation (with relief) If the AluFlex pipe is installed through the wall after the expansion movement has been absorbed, mounting type A can be used. Product No See Terminations, general. Straight screw couplings (with relief) When the lead-in has been relieved, straight couplings can be used to connect to internal installations. 1 Dimension ø out. mm Product No (3/4 ) (3/4 ) (1 ) 2 Order example System - Component - Component No. - Dimension: AluFlex - Screw coupling /1 Internal wall installation (without relief) Mounting type A combined with mounting type C is used, when the AluFlex pipe is installed directly through the wall without any absorption of the expansion movement. C A min. 300 mm LOGSTOR A/S Tel FlexPipe

44 Tools for, general Introduction This section describes the tools which can be used generally for: - PexFlex - AluFlex Pulling tool If concrete cast pipes or tilted bore in the base is used, then pulling tool and pulling sleeve are used. LOGSTOR Service Department can refer to a supplier. Transport and uncoiling To transport or uncoil it is possible to hire or buy special FlexPipe trailers from various suppliers. Especially for major dimensions of AluFlex and major numbers of house entries, the FlexPipe wagon with motorized straightener and remote control are recommended. Please contact our Service Department. FlexPipe LOGSTOR Fredericia A/S Tel

45 Tools for PexFlex Introduction This section describes the tools which are used especially in connection with Pexflex pipes. Installation equipment Joints When installing compression couplings for PexFlex pipes a tool set, containing compression tool and accessories for PEXservice pipe dimensions ø 16, 22, 25, 28, 32, 40 and 50 mm, is used. Available in a sturdy carrying case, product No Compression tool 2. Exchangeable compression inserts 3. Saw 4. Plastic pipe cutter for ø 40 mm 5. Plastic pipe cutter for ø 63 mm 6. Stripping knife 7. Deburring tool 8. Special lubricating grease For the installation a hydraulic pump must also be used. Product No Stripping tools Stripping tools Type PEX dimension ø mm Product No. A B A B LOGSTOR A/S Tel FlexPipe

46 Tools for AluFlex Introduction This section describes the tools which are used in connection with AluFlex pipes. Hydraulic pump Carrying case for hydraulic pump, product No Contents: 1. Hydraulic pump, complete 2. Bottle with reserve oil 1 2 Compression tool for service pipe dimensions ø mm Sturdy carrying case for compression tool and accessories for service pipe dimensions ø 20, ø 26 and ø 32 mm. Available in sturdy carrying case, product No Contents: 1. Compression tool 2. Exchangeable compression inserts 3. Hacksaw 4. Pipe cutter 5. Stripping knife 6. Deburring tool, internal 7. Deburring tool, external 8. Special lubricating agent Alternative stripping tool Alu-PEX ø mm Product No FlexPipe LOGSTOR Fredericia A/S Tel

47 Tools for AluFlex Alternatively compression tool for service pipe dim. ø mm Complete tool set in carrying case with all necessary tools and accessories for service pipe dimensions ø 20, ø 26 and ø 32 mm. Part no REMS REMS LOGSTOR Service Department sells this tool set or can refer to suppliers of it. LOGSTOR A/S Tel FlexPipe

48 Tools for shrink joints Introduction This section describes the tools and accessories to use, when installing shrink joints and other shrink materials: end-caps, shrink sleeves, and shrink wrap for repairs. Burner set for shrinking Burner set for propane gas with 10 m hose and 50 mm burner head and union for regulator: Product No Burner set for propane gas with 10 m hose and hose union with ½ thread: Product No Also used to dry joint locations and preheat joints. Roller Used to compress overlap etc. on shrink joints and shrink sleeves. Component No Heat protection LOGSTOR Heat Shield is wrapped around the outer casings, when shrinking joints. Product No Dimension: L x W = 120 x 15 cm FlexPipe LOGSTOR Fredericia A/S Tel

49 Handling & Installation Introduction This section describes the most important requirements to and instructions for handling, adapting and installing the FlexPipe system. Contents Storage and transport 3.1 Installation, general 3.2 Installing press couplings 3.3 Installing compression couplings 3.4 Installing casing joints: -- FXJoint T-joint, straight F SXJoint T-joint, straight 3.8 Insulating joints with foam packs: -- Foam packs, general Storage and handling Foam packs for shrink joints Foam pack numbers 3.12 LOGSTOR A/S Tel FlexPipe

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51 max. 2 m General Storage and transport Delivery Delivery takes place in accordance with the sales and delivery terms of the supplier, see Heating/Sales & Delivery. Storage Stock pipes in such a way that they are not damaged. Stack the pipes on a level surface of stoneless sand with cushions of sand as it appears from the illustration. Stack the FlexPipe coils so the maximum height is 2 m. Store pallets with foam liquids indoors at Likewise store shrink materials indoors or under cover. All casing joints of plastic materials must be stored vertically, resting on one end in order to avoid ovalization. Unloading Do not throw or roll pipes and other components directly on to the ground. They must be lifted into place and NOT dragged - neither on the truck bed nor on the ground. Handling, Only use lifting straps with a width of min. 100 mm. When using a truck protect the forks with casing pipe, rubber pads etc. 100 mm LOGSTOR A/S Tel FlexPipe

52 Installation, general Installation methods are installed in trenches either horizontally or vertically in accordance with the minimum trench dimensions in the illustration below. Trench installation This sectional view of the trench shows the minimum dimensions for: - The sand layer The pipes must be surrounded by min. 50 mm sand or other stonefree backfill material. - The distance between outer casing pipes, 50 mm - The cover H 1 = In areas with heavy traffic min. 400 mm from the top of the pipe to the bottom of the asphalt or concrete layer H 2 = In areas with no or only light traffic min. 300 mm! = Warning tape or net The cross section of the trench must allow sufficient space for proper installation of pipes and casing joints and compacting of backfilling. Note! The minimum cover also applies to branching, if any, from the illustrated cross section. H 1 H 2!!! 50 mm D 50 mm 50 D 50 D 50 mm 50 mm D 50 mm 50 D 50 mm 50 mm D 50 mm D 50 mm 50 D 50 mm Shortening are delivered in coils. The required length is cut perpendicularly, using a suitable saw. The casing of the FlexPipe has a metre indication, facilitating the cutting of exact lengths. Example of marking: LOGSTOR PEXFLEX :: VARME - HEAT - HEIZUNG :: EN :: 20x20/77 MM :: MAX 95 C :: 6 BAR :: PELD :: MADE IN DK :: 198 m LOGSTOR PEXFLEX :: VARME-HEAT-HEIZUNG :: EN :: 20x20/77 MM :: MAX 95 C :: 6 BAR :: PELD :: MADE IN DK :: 198 m LOGSTOR PEXFLEX :: VARME-HEAT-HEIZUNG :: EN :: 20x20/77 MM :: MAX 95 C :: 6 BAR :: PELD :: MADE IN DK :: 199 m FlexPipe LOGSTOR Fredericia A/S Tel

53 Installation, general Unwinding Do not cut all fixation strings at the same time. Place the coil at the start of the trench. Cut the first string. Unwind the pipe till the next string and then cut that etc Straightening Adapt the FlexPipe end, so that min. 500 mm of it is straight and plane-parallel with the welded branch pipe piece or the adjoining pipe end. This adaptation is important and necessary to ensure that subsequent installation of the casing joint can be carried out according to instructions. 500 L Please keep the bounce effect of the free pipe ends in mind when cutting. Auxiliary tools In case of major tasks and very large dimensions it is advantageous to use a waggon with motorized straightener (not obligatory). The LOGSTOR Service Department can refer to relevant suppliers of the FlexPipe-waggon. NOTE! 1. At temperatures below +5 C the outer casing must be preheated to lukewarm, immediately before it is inserted in the straightener head (soft gas flame during the entire straightening process). 2. It is recommended to store the coil in a heated room at least 24 hours before use - this does not however exclude item 1, if the coil becomes cold again. LOGSTOR A/S Tel FlexPipe

54 Installation, general Bending radius The minimum radius of the curve is determined by the dimension (see table below). Do not bend the pipes over a sharp edge. R min. Outer casing Bending radius ø out. mm R min. m The rigidity of PexFlex pipes depends on the temperature of the pipe. On installation it may be necessary to ensure the pipe position e.g. by partial backfilling. Prior to bending/installation in the pipe trench it is advantageous to preheat the casing pipe in order to reduce the stresses. Bending Winter measures Unrolling and straightening do not normally require preheating, only common caution. Preheating is however recommended, if the material (FlexPipe) has a temperature below 5 C, see page Auxiliary tools. Ordinarily bending of the outer casing at temperatures below 5 C, requires preheating of the section which is influenced by the bending to lukewarm, The preheating rule also applies to tilted bores in the base or inlet pipes. Bend the pipe slowly and smoothly, not jerkily. Avoid to bend the utmost cm of the pipe because of the bounce effect. FlexPipe LOGSTOR Fredericia A/S Tel

55 Installing press couplings Press couplings PexFlex and AluFlex The service pipe of PexFlex and AluFlex is joined by means of press couplings, ensuring a permanent tightness of all joints made at all temperature variations. 1. Base unit 2. Compression ring 3. Squeezing ring AluFlex only: 4. O-ring 5. Insulating ring Note! For PEX DW 10 bar compression couplings are used. (They can also be used for PexFlex, but then in 6 bar design). Hydraulic pump: Carrying case, product No Press couplings are fitted with compression tools, activated by means of a hydraulic pump. The tools and accessories are delivered in sturdy carrying cases, containing the following: 1. Hydraulic pump, complete 2. Bottle with reserve oil 2 1 PexFlex tool box: Service pipe dimensions ø 16, ø 20, ø 22, ø 25, ø 28, ø 32, ø 40, ø 50 and 63 mm. 3 Carrying case, complete with contents, product No Compression tool 2. Exchangeable compression inserts 3. Saw 4. Plastic cutter for ø 40 mm 5. Plastic cutter for ø 63 mm 6. Stripping knife 7. Deburring tool 8. Special lubricating agent For PexFlex service pipe dimensions ø 75, ø 90 and ø 110 mm a special tool set with a compression tool which is universal for all three dimensions is available. LOGSTOR A/S Tel FlexPipe

56 Installing press couplings Press couplings, PexFlex and AluFlex continued AluFlex tool box: Service pipe dimensions ø 20, ø 26, ø 32 and ø 40 mm. Carrying case, complete with contents, product No Compression tool 2. Exchangeable compression inserts 3. Hacksaw 4. Stripping knife 5. Deburring tool, internal 6. Deburring tool, external 7. Special lubricating agent General: All tools can be rented from LOGSTOR's Service Department. Alternatively compression tool for service pipe dim. ø mm Complete tool set in carrying case with all necessary tools and accessories for service pipe dimensions ø 20, ø 26 and ø 32 mm. Part no REMS REMS LOGSTOR Service Department sells this tool set or can refer to suppliers of it. FlexPipe LOGSTOR Fredericia A/S Tel

57 Installing press couplings, general Preparations for pipe ends Remove the insulation from the FlexPipe end for the lengths, stated in the installation instructions, using the stripping knife. Reckon with a general additional length of 30 mm for a later cutting of the service pipe end in order to obtain a clean and perpendicular end. Remove the insulation from the FlexPipe end for the prescribed length L with cutting tool, component No L + 30 Cut the pipe perpendicularly, using: a. PexFlex plastic cutter b. AluFlex hacksaw a b L 30 L-measurements Service pipe, ø mm L mm Deburr the inside and outside of the perpendi cularly cut service pipe end, using deburring tool, product No Remove the foam remnants on the service pipe with emery cloth, grain size 150. L LOGSTOR A/S Tel FlexPipe

58 Installing press couplings Preparing first pipe end Push the compression ring and the squeezing ring on to one of the pipe ends. Thrust the base unit into the pipe to stop. AluFlex only: Make sure that the insulating ring (1) and the O-ring (2) are placed correctly. 1 2 Preparing second pipe end Push the compression ring and the squeezing ring on to the other pipe end. Push the other pipe end on to the base unit to stop. AluFlex only: Make sure that the insulating ring (1) and the O-ring (2) are placed correctly. 1 2 FlexPipe LOGSTOR Fredericia A/S Tel

59 Installing press couplings Preparing compression tool General: Follow the instructions in the tool box. Fit compression inserts, corresponding to the service pipe dimension, on to the compression tool. Place the pipe joint in the compression tool. Prior to compression make sure that the joint is placed correctly. Connecting hydraulic pump General: Follow the instructions in the tool box. Connect the hydraulic pump to the compression tool. 1. Stop, hydraulic hose coupling 2. Pull the locking ring back 2 1 LOGSTOR A/S Tel FlexPipe