emmeti Gerpex Press Fit Installation and operation manual

Installation and Commissioning Instructions
Gerpex Press Fit System
Reduced Installation time
Linear expansion similar to copper
Minimal tooling required
No hot works - no permits
Less wastage
High quality raw materials
Stable material costs
No scrap value
Low heat losses through pipe
WRAS approved
Easy to transport
Double O-ring technology
£
£
£
£
£
www.emmeti.co.uk

2
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
Contents
1. Equipment Checks....................................................................................................................2
1.1 Press Tool and Jaws
1.2 Calibration Tool
1.3 Pipe Cutting Tool
2. Installation ................................................................................................................................4
2.1 Removal of Pipe Packaging
2.2 Surface Installation
2.3 Embedded Installation
2.4 Bend Radius
2.5 Thermal Expansion
2.6 Pressure Drops
2.7 Pipe Cutting
2.8 Pipe Preparation
2.9 Pipe/Fitting Assembly
3. Press Fitting ..............................................................................................................................9
 3.1PressFittings16–63(THProle)
4. Compression Fittings.............................................................................................................10
4.1 Pipe Preparation
4.2 Pipe Connection
5. System Testing.......................................................................................................................10
6. Notes .......................................................................................................................................10
7. Warranty..................................................................................................................................11
The Gerpex Multi-Layer Composite Pipe System and the Gerpex Press Fittings are designed for use in heating,
hot and cold water, compressed air and chilled water systems.
Please always use the correct tooling and follow the instructions, as detailed to ensure correct operation of the
system.Thepurposeoftheseinstructionsistoensurethatthecorrecttoolselection,pipepreparation,tting
assembly and installation methods are used.
1. Equipment Checks - BEFORE CARRYING OUT ANY WORK
1.1 Press machine and jaws
PleaseensurethatthejawpressingproleiscompatiblewiththeEmmetiGerpexttingrange,byreferringto
Fig1.1andtable1below.Jawprolesarenormallyprintedontothejawbody.Ifindoubtpleaserefertojaw
manufacturerforconrmation.
Profile and dimensions of the jaws that can be used with Multi-Jaw Gerpex Fittings
16 20 26 32 40 50 63
TH OK OK OK OK OK OK OK
BOK OK OK OK - - -
UOK OK - - - - -
HOK OK - - - - -
FOK OK - - - - -
TH - KSP 11
B - KSP 1
U - KSP 5H- KSP 7F- KSP 2
TH - KSP 11 B - KSP 1
U - KSP 5H- KSP 7F
- KSP 2
TH - KSP 11 B - KSP 1
U - KSP 5H- KSP 7F- KSP 2
TH - KSP 11 B - KSP 1
U - KSP
5H- KSP 7F- KSP 2
TH - KSP 11 B - KSP 1
U - KSP 5H
- KSP
7F- KSP 2
Fig 1.1
Table 1.

3
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
1. Equipment Checks - BEFORE CARRYING OUT ANY WORK
1. Equipment Checks - BEFORE CARRYING OUT ANY WORK
1.1 Press machine and jaws
• Pleaseensurethatthereisnodamagetothe
pressing face of the press jaws. If damaged,
please replace as this could result in an incorrect
pressofthetting.
NO
• Pleaserefertothetoolmanufacturer’sinstructions
when preparing the press machine for use.
•
Please ensure that the jaw size corresponds with the
ttingsize,thepressingmachineisingoodworking
order and that the batteries are fully charged.
ATTENTION: If the incorrect sized pressing jaw
is used for the fitting you have it will result in an
incorrectly pressed fitting and could therefore leak
1.2 Calibration Tools
• Pleaseensurethatcalibrationtoolhasnodamage
to its face or cutter. If so please dispose of and
replace.
YES NO
Cutter
• Pleaseensurethatthetoolbulbandcutterdonot
rotate when in use. If so please retighten locknut
or holding screw
1.3 Pipe Cutting Tool
• Checkcuttingbladetoensurefreefromdamage
and replace if necessary
ATTENTION:Keepngersawayfromcuttingblade

4
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
2. Installation
All installation must be carried out at temperatures
above -10oC and below 45oC to avoid any potential
distortion to the materials. In case of temperatures
below 0oC,pipeandttingswillneedtobestoredat
a higher temperature immediately prior to use.
2.1 Removal of pipe packaging
• Takecarenottodamagepipewhenremovingthe
packaging
• Takecarenottodamagepipeinsulationwhen
removing the packaging
YES NO
2.2 Surface mounted installation
• Forsurfacemountedpipeorpipeinstalledinto
falseceilings/oorsandductsthepipewillneed
to be adequately supported at regular intervals
depending on pipe diameter.
• Forreferencetomaximumclipspacing’splease
refer to table 2 and image Fig 2.2
Pipe
dimension
Maximum Distance (S)
for bracketing (cm)
14 x 2 100
16 x 2 100
20 x 2 125
26 x 3 150
32 x 3 200
40 x 3.5 200
50 x 4 250
63 x 4.5 250
S
S
Table 2.
Fig 2.2
A
D
C
A = max 800mm
B = 300mm
C = 300mm
D = max 800mm
B
2.3 Embedded installation
• Forembeddedinstallationsthepipemustbe
securely fastened with ties spaced at the minimum
of 800mm and 300mm either side of bends or
joints,seeg2.3
• Forthistypeofsystemitisrecommendedtouse
pre-insulated pipe to minimise heat loss and gain
ortopassthroughexibleconduitasaminimum
•
 Forsurfaceembeddedpressttingswerecommend
thattheentirettinginprotectedfromcorrosionby
using purpose designed adhesive tapes
or expanding
plastic materials that have been adequately sealed.
Fig 2.3

5
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
2. Installation
2.4 Bend radius
• Whenformingbendsinthepipepleasereferto
table 3 to obtain the minimum bend radius.
Pipe
dimension
(Ø x S)
Minimum
radius
of bend R
Min. radius
of bend R
with spring
pipe bender
Min.radius
of bend R
with
hydraulic
bender
14 x 2 5 x Ø 3 x Ø
16 x 2 5 x Ø 3 x Ø
20 x 2 5 x Ø 3 x Ø
26 x 3 8 x Ø 4 x Ø 4 x Ø
32 x 3 4 x Ø
40 x 3.5 4 x Ø
50 x 4 4 x Ø
63 x 4.5 4.5 x Ø
R
Ø
S
x
• FortoolingtoformbendsinGerpexpipeplease
refer to our pricelist.
• Itispreferabletousettingsratherthanbendsfor
pipe with greater than 26mm diameter
• Whenbendingpipepleaseavoidplacingany
existingttingsunderunduepressure.Please
refertog2.4whichshowstheminimumdistance
betweenattingandthebeginningofabend.
Minimum distance is 5 x pipe diameter.
2.5 Thermal Expansion
• Duringinstallationpleasepayattentiontothe
thermal expansion characteristics of Gerpex pipe.
The longitudinal expansion of the pipe is affected
by a variation in temperature and can be calculated
using the following data found in table 4 and Fig. 2.5.
Copper
PE-X polyethylene mesh
PP polypropylene
PB polybutylene
Steel
Inox Steel
.
.
.
.
Gerpex
ΔT 10 20 30 40 50 60 70
LΔL
0.1 0.026 0.052 0.078 0.104 0.130 0.156 0.182
0.2 0.052 0.104 0.156 0.208 0.260 0.312 0.364
0.3 0.078 0.156 0.234 0.312 0.390 0.468 0.546
0.4 0.104 0.208 0.312 0.416 0.520 0.624 0.728
0.5 0.130 0.260 0.390 0.520 0.650 0.780 0.910
0.6 0.156 0.312 0.468 0.624 0.780 0.936 1.092
0.7 0.182 0.364 0.546 0.728 1.910 1.092 1.274
0.8 0.208 0.416 0.624 0.832 1.040 1.248 1.456
0.9 0.234 0.468 0.702 0.936 1.170 1.404 1.638
1.0 0.260 0.520 0.780 1.040 1.300 1.560 1.820
2.0 0.520 1.040 1.560 2.080 2.600 3.120 3.640
3.0 0.780 1.560 2.340 3.120 3.900 4.680 5.460
4.0 1.040 2.080 3.120 4.160 5.200 6.240 7.280
5.0 1.300 2.600 3.900 5.200 6.500 7.800 9.100
6.0 1.560 3.120 4.680 6.240 7.800 9.360 10.920
7.0 1.820 3.640 5.460 7.280 9.100 10.920 12.740
8.0 2.080 4.160 6.240 8.830 10.400 12.480 14.560
9.0 2.340 4.680 7.020 9.360 11.700 14.040 16.380
10.0 2.600 5.200 7.800 10.400 13.000 15.600 18.200
In order to calculate the longitudinal expansion please
use the following formula:
ΔL=αxLxΔT
where:
αisthecoefcientoflinearexpansion,equalto0.026
mm/m K for insulated pipes;
Listheinitiallengthofthepipe(m);
ΔTisthetemperaturedifference(K).
Example:
Length of pipe: 12 m
Temperature difference: 50 K
ΔL=0.026x12x50=15.6mm
Fig 2.4
Table 3
Table 4
Fig 2.5

6
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
2.5 Thermal Expansion
For surface mounted installation or when installed in
shafts, voids etc, longitudinal thermal expansion can
becompensatedforwithconsiderationofxedand
sliding brackets depending on type of installation.
These sliding brackets allow the pipe to expand and
contract without sagging and/or putting any undue
stress on the pipe and brackets. Please see Fig 2.6,
2.7 and 2.8 for example:
Where:
Ls =Cx√(ØxΔL)
Ls =Lengthofcompensator(mm)
Ø =Externaldiameterofpipe(mm)
C =Materialconstant
 (forinsulatedpipesC=33)
With
ΔL=15.6mm(previousexample),
Ø=26mm
the result will be:
Ls=33x√(26x15.6)=665mm
FP FP
FP
LL
∆L∆L
FP SP
SP
L
FP
SP
∆L∆L
Ls
Ls
To allow expansion for pipes installed vertically in
shafts or risers with horizontal branches, the branch
musthaveaminimumfreelength(LS)andthe
transition through the wall of the shaft should not
be sealed so as to allow for movement and the pipe
should also be sleeved. See Fig 2.9 and 3.0.
If the size of the shaft does not allow for the
compensationlength(LS)thetransitionalholeinthe
wall of the shaft should be increased in diameter
and the tube should be protected with an insulating
sheath of thickness; see Fig 3.1.
Wherepipesarebeinglaidwithinscreededoors
thermal expansion can be allowed for by creating an
insulated curve at 10m intervals. This can be done
byenclosingwithininsulationorexibleconduit,see
Fig 3.2.
Note:Ifthepipeisbeingusedforunderoorheating
and is using spiral or serpentine loops this method
need not apply.
2. Installation
FP: Fixed Point
SP: Sliding Point
Fig 2.6
Fig 2.7
Fig 2.8
Fig 2.9 Fig 3.0 Fig 3.1
Fig 3.2

7
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
2. Installation
2.6 Pressure drops
Pressure drops across Gerpex and Gerpex Press
Fittings can be calculated using data shown in the
GERPEX System Technical Product Guide which can
be found at www.emmeti.co.uk
2.7 Pipe cutting
The pipe must be cut at a 90
o
angle and be cut
perfectly straight. A rotary pipe slice is recommended
for sizes 26mm and greater to ensure that the pipe is
not deformed by the ratchet shear, see Fig 3.3 and 3.4.
Anunevencutwillmakecalibrationdifcult.
2.8 Pipe preparation
Pipe preparation includes calibration and bevelling of
the cut end of pipe with a purpose designed tool in
readinessforthepipetobeinsertedintothetting.
Failure to prepare the pipe in this way can lead to
damageoftheO-ringandthepossiblefailureofatting.
To calibrate the pipe the tool must be rotated into the
end of the pipe in a clockwise motion as shown in Fig
3.5 and 3.6:
To bevel the internal edge of the pipe the tool must
be rotated clockwise which will remove and bevel
the inner edge of the pipe. This prepares the pipe for
insertionintothetting.
Fig 3.3
Fig 3.4
Fig 3.5
Fig 3.6
TheEmmeticalibrationtoolcanbettedtoabattery
powered drill to speed up the process. Please take care
not to place undue pressure if calibrating in this way.

8
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
2.9 Pipe/Fitting Assembly
Once the cut end of pipe has been prepared and
calibratedpleaseinspecttheGerpexpressttingfor
anysignsofdamage.Ensurettingiscleanandfree
of dust or debris prior to insertion. Take care when
insertingthepipeintothetting,ensurebothare
aligned and push together to engage. Do not rotate as
this can dislodge the O-rings, see Figs 3.7, 3.8 and 3.9.
✔
✘
CouplingPipe
Pipe outof
alignment
YES
YES
NO
NO
2.9 Pipe/Fitting Assembly
Note: Do not lubricate with grease or oil as this
can corrode the O-rings. Please use clean water to
lubricate only.
Asthepipeispushedintothetting,fullinsertioncan
beconrmedwiththesightholelocatedintheblue
collar. See Fig 4.0.
CouplingPipe
Pipe outof
alignment
YES
YES
NO
NO
✘
✔
2. Installation
Fig 3.7
Fig 3.8
Fig 3.9
Fig 4.0
Pipe fully inserted
Rounded edge to show
pipe has been calibrated
correctly
Double O-ring
Fig 4.1
Fig 4.1 shows how the pipe has been fully inserted
intothetting.Theroundededgeoftheinternalface
of the pipe can be seen showing that calibration has
been carried out correctly and double O-rings can be
seen intact.

9
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
3. Press Fitting
3.1 Press fitting 16mm – 63mm (TH Profile)
Place jaws around steel sleeve and ensure jaw
alignment collar is inserted into the jaw groove as
showng4.2.Itisimportanttoensurethatthe
groove is engaged with the blue collar as this will lock
thettingintothejawsandwillpreventthejawsfrom
movingduringthepressingoperation,seeg4.3:
PleaseensurethatthejawpressingproleiscompatiblewiththeEmmetiGerpexttingrange,seediagrams
on page 3 and in table 4.
Once aligned, press and hold the pressing tool trigger
untilanaudibleclickcanbeheard,thiswillconrm
thatafullpresshasbeencompleted,seeg.4.4.Do
not attempt to abort a press once started.
If the machine fails or the battery drains mid-press
pleasereplaceandcontinuetoconrmthatthepress
hasbeencompletedsatisfactorily.Avisualconrmation
of the press can be carried out once the jaws are
removedseeg4.5andrefertog1.1toconrm.
CLICK
Profile and dimensions of the jaws that can be used with Multi-Jaw Gerpex Fittings
16 20 26 32 40 50 63
TH OK OK OK OK OK OK OK
BOK OK OK OK - - -
UOK OK - - - - -
HOK OK - - - - -
FOK OK - - - - -
Table 4
Fig 4.2
Fig 4.3
Fig 4.4
Fig 4.5
Visual indication of
TH press

10
Installation & Commissioning Instructions
For more information please call us on 01993 824900 or view our website at www.emmeti.co.uk
Gerpex Press Fit System
Gerpex Press Fit System
Oncethepipeandttinghavebeeninstalledasystem
integrity test should be carried out in accordance with
current regulations prior to any permanent coverings
being applied.
6. Notes
• DONOTexceedmaximumrecommended
operation time or number of presses for the
chosen press tool (refer to press tool instructions
fordetail)
• DONOTattempttoreuseapartiallypressedtting
• DONOTattempttomodifyortamperwiththe
toolingorttings
• DOchecktoolsconditionregularlyandrepair/
replace where necessary
• DOreadthisdocumentcarefullybeforecarrying
out any works
• DOalwayskeeptools,pipeandttingsstoredina
clean and dry environment
• DOprotectttingsagainstcorrosionwheninstalled
in embedded screed or concrete
• DOensuresystemcompatibilitywiththeGERPEX
System
• DOensureEMMETIapprovedtoolingandpressing
prolesareusedatalltimes
• DOensurethatanypresstoolsarecalibrated
at recommended manufacturer intervals and by
approved test facilities.
5. Testing of the System
Gerpex Multi-Layer Pipe can also be used with
Emmetidevelopedcompressionttingstoconnect
to heating or plumbing manifolds and also to
compressionttingsincluding15,22and28mm
coppercompression.Thesettingsenablethe
installer to connect to tap connectors, isolation valves
and radiator valves or to transition onto copper pipe
with no requirement for hot works.
4.1 Preparation of Pipe
Pipe preparation is carried out in the same way for
compressionaswithpressttings.Pleasereferto
section 2.7 and 2.8
4.2 Pipe Connection
Once the pipe has been prepared it should be inserted
intothemonobloccotting.Pleaseensurethatpipeis
alignedandpushontotting,donotturnoninsertion
as this could potentially disturb or damage the double
O-ring.Seeg4.6
The pipe is clamped onto the brass insert of the
ttingbythesplitolivewhentightenedontothe
compressionttingasshown.Takecarenottoover
tightenthettingontothecompressionconnection
as this could damage the O-ring seal on the face of
thetting.
4. Compression Fittings
EMMETI-GERPEX PEXb/AL/PEXb 16x2 PER
1
15mm Copper Pipe
15mm Compression
Lever Valve
16 x 2 mm Gerpex Pipe
EmmetidevelopedMLCPtocoppercompressiontting.Suppliedasasingle
piece unit to connect onto any copper compression thread up to 28mm.
Fig 4.6