LK Systems PE-X User manual

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LK Heat pipe / LK Universal PE-X pipe
LK PE-X Universal pipe with conduit and extra insulated
conduit
LK PAL Universal pipes A, in straight lengths
TABLE OF CONTENTS
General 1
Storage and handling 1
Pipe range 1
Pipe properties 2
Marking and identication 2
Bending 2
Joining 3
Assembly of LK Universal System 4
Pipelaying 5
Replacement of pipes in conduits 8
Checks 9
Assembly of LK Underoor Heating System 9
Tightness testing 9
Excess materials/recycling 10
General
These assembly instructions relate to installations
implemented using LK PE-X, LK PAL and LK Heat
pipes in the PE-X and PE-RT execution.
• The designation “LK Universal PE-X pipe”
refers to pipes of homogeneous PE-Xa.
• The designation “LK Heat pipe” is avail-
able in two variants, homogeneous PE-Xa or
homogeneous PE-RT.
• The designation “LK Universal PAL pipe”
refers to composite pipes of PE-RT/Alumini-
um/PE-RT.
All types of pipes are diffusion-tight for use in
heating and cooling systems. Refer to the table
on page 2 for designation, pipe dimension, pipe
material, design, pressure class, temperature range
as well as manufacturing standard.
Storage and handling
LK pipes may not be stored or installed in a way
that they are exposed to direct sunlight (max. 3
months). This is also applicable to LK Pipe-in-
pipe. Packaging provides sufcient protection
against UV radiation. Once installation is com-
plete the pipes should not be exposed to direct
sunlight other than occasionally. Window panes
provide sufcient protection against UV ra-
diation and so do not affect the good long-term
properties of the pipe.
Pipe range
For the complete range of pipes, see each respec-
tive product range for Underoor Heating and
Universal on our website www.lksystems.se
The LK PE-X Pipe-in-Pipe system, with compo-
nent parts as stated in installation solutions NT
VVS 129, is tested and approved in accordance
with NT VVS 129 and the Sintef Test method for
conduits. More information is available at: www.
lksystems.se (support/dokumentation/lkuni-
versal)
LK Tappvattensystem är godkänt
enligt Nordtestmetoden NT VVS 129.
Assembly instructions for LK PE-X, PAL and PE-RT pipes
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes

2 (10)
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Cold bending without fixture
Where space permits large bend radii, we recom-
mend that the pipe bends be formed without a
xture/support. Large radii facilitate any re-
placement of the pipe in inner pipe (pipe-in-pipe)
without causing structural damage. See section
Replacement of pipes in conduits.
NOTE!
The instructions concerning clamping and x-
ing in the section entitled Pipe laying in tim-
ber frames on page 5 must be followed for
pipes in inner pipes that are to be replaced.
Bending PE-X pipes directly after press tting
is not recommended. The distance between
the coupling and the PE-X pipe should be a 1
x the pipe’s diameter before the bending, at a
minimum. This instruction is provided due to
the risk of stress corrosion.
Pipe properties
Designation Pipe
dim.
(mm)
Material Pipe range, design Pres-
sure
class
Temperature range Standard
Except
con-
duit
PiP PiP
Extra
Insula-
tion
Max.
con-
tinuous
tempera-
ture
Max. mo-
mentary
tempera-
ture
Mini-
mum
permit-
ted
tem-
pera-
ture
LK Under Floor
Heating Pipe
8x1.0
12x2.0
PE-Xa X PN6 70 °C 95 °C -20 °C EN ISO 15875
(DIN16892/3)
LK Under Floor
Heating Pipe
16x2.0
20x2.0
PE-RT X PN6 60 °C 70 °C -20 °C EN ISO 22391
(DIN16833/4)
LK Heating pipe 25x2.3
32x2.9
PE-Xa X PN6 70 °C 95 °C -20 °C EN ISO 15875
(DIN16892/3)
LK Universal
Pipe PE-X
16x2.0
20x2.5
25x3.5
PE-Xa X X X PN10 70 °C 95 °C -20 °C EN ISO 15875
(DIN16892/3)
LK Universal
Pipe PAL
16x2.0
20x2.5
25x3.5
32x3.0
40x3.5
50x4.0
63x4.5
75x7.5
PE-RT/
AI/
PE-RT
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
PN10 70 °C 95 °C -20 °C EN ISO 15875
(DIN16892/3)
LK Pal Universal Pipe A16 (16x2,0) 10 bar 95°C Oxygen barrier acc. to DIN 4726 Certification body Date Time Metre
Example of markings for identication of a pipe
Marking and identification
LK pipes can always be identied as they are
marked repeatedly at every metre.
Bending
Bending of LK PE-X and PE-RT
Minimum recommended bend radii:
Bending method Minimum bend radius at
pipe dim.
16 20 25 32
Cold bending without xture 80 130 180 260
Cold bending with xture 55 110 140 210
Hot bending with bending
support
34 45 60 95
Precautions must be taken when installing PE-X
and PE-RT pipes at temperatures below -5 ˚C, par-
ticularly when bending.

3 (10)
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Minimum recommended bend radii:
When bending with LK bending tools 4 x OD
When bending manually 5 x OD
Precautions must be taken when installing PAL
pipes at temperatures below -5 ˚C, particularly
when bending.
Joining
LK PE-X, LK PE-RT and LK PAL pipes for PN10
are joined with couplings as follows:
• LK PressPex press tting coupling system.
See separate assembly instructions.
• LK Compression ttings.
See separate assembly instructions.
• LK PushFit couplings.
See separate assembly instructions.
Please note the choice of couplings for LK PE-X
and LK PE-RT, pipes intended for pressure class
PN6.
LK PressPex, LK PushFit and LK PI Tube adapter AX.
Example of jointing PE-X and PAL pipes using a LK PI
Tube Adapter.
Cold bending with fixture
Pipe bending supports are recommended where
PE-X and PE-RT pipes are to be secured in bent
position and where the space requires small bend
radii. The product range includes a number of
different bend xtures for e.g. connection of radi-
ators, installations against oor heating distribu-
tors or for pipe exits from walls.
Hot bending PE-X pipes
Hot bending is recommended if small radii are
required. The pipe must be heated using a hot
air gun, not a naked ame. The pipe is heated at
the bend location until it becomes colourless and
transparent. This occurs at a temperature of be-
tween 120 ºC and 130 ºC.
LK Bending springs are threaded outside the
pipe, which is then bent to the preferred angle.
The pipe is cooled in water or air, the bending
spring is pulled off and bending is complete. The
oxygen diffusion-sealing layer on the pipe is af-
fected during heating and bending, but this is
only of signicance in terms of appearance.
Thanks to the thermal memory of the PE-X ma-
terial, a nished hot bend can easily be straight-
ened out again by reheating the pipe.
NOTE!
LK PE-RT and LK PAL pipes should not be
hot bent.
Bending of LK PAL Universal pipes
The bends are made by using a LK Bending
Spring (Bockfjäder) (up to 40 mm dimension) or
a LK Bending Tool (Bockverktyg) (up to 40 mm
dimension). Larger dimensions up to dim 75 can
be bent using special bending tools; contact an
LK representative.
LK Bending Spring INV, LK Bending Spring UTV, LK
Bending Tool 16-32 and LK Bending Tool PAL Multi 16-32.

4 (10)
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Assembly of LK Universal System
The following headings primarily relate to LK
Universal Systems however relevant parts are
also applicable for LK Floor Heating Systems. See
also the separate heading Assembly of LK Under-
oor Heating System.
Suspension, clamping and fixing
LK PAL Universal pipes in straight lengths are
used for visible installation. PE-X Universal pipes
on rings are recommended for concealed instal-
lation and for installation on cable racks, for ex-
ample.
Suspension must take place using rubber-coated
clips, LK Clip PE-X/PAL, and be tightened to
“sliding position”, i.e. so that axial movements
are possible. Pendulum-type roof brackets are
used for attachment to the building structure.
Pendulum lengths should not exceed 150 mm.
LK Clip PE-X/ PAL is also used for xing, but
with the clip tightened to “xed position” to pre-
vent the pipe moving axially. Please see the pipe
wholesalers’ ranges for parts for robust, move-
ment-inhibiting mounting to the building struc-
ture.
Clamping between suspension and xing points
must be made if there is a risk of movement in
the piping network, for instance upon rapid shut-
off of e.g. mixers and closing of solenoid valves.
Clamping is intended to prevent damage to the
piping and to prevent movement noise spreading
to the building structure.
Horizontal laying
With horizontal installation, xing must
be located at branch pipes unless the
shank length of the branch pipe is sufcient ac-
cording to the section entitled Expansion-absorb-
ing devices in the project planning and design
guidance.
However, it is always recommended to make the
shank long enough to provide room for expan-
sion, this is accomplished for example by making
extra bends on the branch as shown in the exam-
ple below.
Fixings must also be made at points where expan-
sion movements need to be directed to special
expansion loops. When laying in cable racks or
similar, we only recommend clamping between
any xed points.
Example of clamping, horizontal installation.
Suspension between xed points must take place
as follows.
Visible installation:
LK Universal
Pipe
Maximum distance between suspen-
sion points
X16 - X25 0.5 m
A16 and A20 1.0 m
A25 and A32 1.5 m
A40 to A75 1.8 m
Concealed installation (in pipe recesses, etc.):
LK Universal
Pipe
Maximum distance between suspen-
sion points
X16 - X25 1.5 m
A16 - A75 2.0 m
EN.29.C.41.191217

5 (10)
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Vertical laying
With vertical installation, xing must be locat-
ed at T-junctions unless the shank length of the
branch pipe is sufcient according to the section
entitled Expansion-absorbing devices in the proj-
ect planning and design guidance.
Example of clamping, vertical installation.
Suspension between xed points must take place
as follows.
Visible installation:
LK Universal
Pipe
Maximum distance between suspen-
sion points
X16 - X25 0.5 m
A16 - A25 1.5 m
A32 - A75 2.0 m
Concealed installation:
LK Universal
Pipe
Maximum distance between suspen-
sion points
X16 - X25 2.5 m
A16 - A75 2.5 m
Example of clamping, visible installation
Pipelaying
• Always use the system products in the
LK range and never mix different product
makes.
• There must be no unused outlets for cold
water, hot water or hot water circulation
pipes
• Cold and hot water pipes must be installed
such that they do not come into contact with
one another.
• Hot water circulation pipes must not be adja-
cent to cold tapwater without the requisite
insulation.
• Pipes for heating systems must not be adja-
cent to cold tapwater without the requisite
insulation.
• No water pipes may be placed in uninsu-
lated areas such as crawl space foundations
or attics. Pipes may be laid in special installa-
tion areas in oors, exterior walls or loft oor
structures on the warm side of the structure,
inside the airtight foil, or in a frost-free space
below ground level.
• See the relevant section in the project plan-
ning and design guidance with regard to
heat emission from pipelines.
Pipe lead-throughs in floors
There must be no pipe lead-throughs in oors
with sealing layers in bathrooms or shower
rooms.
Pipe lead-throughs in the oors of laundry rooms,
equipment rooms or other areas for water heat-
ers, heat pumps or similar may be installed using
grommets. In smaller houses, without a laundry
room or other utility rooms, the pipe inlets to the
water heater, heat pump, etc. can be tted with
a pipe sleeve in the bath or shower room oor,
though not at the location of the bath or shower.
Use grommets with OD 40 and 50 mm (e.g.
drainage pipes). Install a LK Sealing sleeve on the
outside of the grommet and the inner pipe. Suit-
able for both corrugated and smooth inner tubes
with OD 20, 25, 32 and 34 mm.
EN.29.C.41.191217

6 (10)
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Pipe routing in timber frames/stud work
When installing Pipe-in-Pipe in timber frames,
the conduit must always be xed against wall
studs or oor joists as follows:
• At the beginning and at the end of each
bend.
• In straights with at least 1 xing every two
metres for PAL pipe-in-pipe.
• For PE-X pipe-in-pipe, xings must be
provided every 0.6 m so that they can be
replaced. The pipes should not be drawn
completely straight between the connection
points. Soft curves give the inner tubes the
required expansion space, thereby reducing
expansion movements at the tube ends.
In addition to xing, clamping must take place
so that any movements in the pipe network, for
instance due to rapid pressure changes, do not
cause disruptive noise or abrasion of the conduit.
Conduit xing and clamping must take place us-
ing LK Fixing Plate, LK Plastic Clip for Sleeve
Pipe, LK Metal Clip for Sleeve Pipe 25, coil, LK
Fixing Plate metal or LK Wall Support. LK Nail
Protection Plate are recommended to protect
against nailing damage. To protect ducts from
sharp sheet edges when laying in a sheet metal
walls, LK Tube Protector can be used. Always in-
sulate potable water pipes from any underoor
heating or hot tap water by placing the pipes
deep in the oor insulation. However, make sure
that the tapwater pipes are laid in compliance
with the requirements for laying to prevent dam-
age due to freezing
LK Fixing Plate, LK Plastic Clip for Sleeve Pipe, LK Metal
Clip for Sleeve Pipe 25 coil, LK Feed-through Holder,
Sleeve Pipe Support, and LK Sleeve Pipe protection.
LK Fixing Plate
every 0,6 metres
on straight
streches and
in bends.
Fixing of Pipe-in-Pipe in timber frames.
EN.29.C.41.191217

7 (10)
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Pipe installation in concrete structures
In concrete structures, conduits may be clamped
to reinforcements using cable ties or similar. The
distance between the attachment points should
not exceed 1 m to prevent the risk of the pipes
moving up during casting. The cable ties must
not be tightened excessively in a manner that
would deform or damage the conduit. When us-
ing LK PE-X pipes for concealed Pipe-in-Pipe lay-
ing in concrete, it is extremely important to con-
sider expansion-absorbing devices.
If the pipes are not laid with sufcient enough
room to expand, radiators/mixers may come
loose from their brackets in the event of high
temperature differences between the time of in-
stallation and when the system becomes fully op-
erational. Pipe expansion may also occur at mani-
folds, leading to a risk of the pipes coming loose
from their couplings. Ensure that the PE-X pipes
are pulled up into the couplings to the manifolds
or radiators/mixers in order to provide space for
expansion in the conduit/sleeve pipe. No expan-
sion-absorbing devices are needed for concealed
laying of “naked” LK PE-X and LK PAL pipes in
concrete as the pipes are secured in position in
the concrete.
Example of expansion-absorbing bends for concealed lay-
ing of Pipe-in-Pipe.
If underoor heating is installed in the concrete
slab, the tapwater pipes must be placed at least 100
mm beneath the top edge of the topmost layer of
insulation. Alternatively, Pipe-in-Pipe Extra (insu-
lated pipes) may be laid beneath the insulation.
Tap water pipes and hot water circulation pipes
which are installed in concrete constructions with-
out oor heating should be placed in the insulation
or alternatively as Pipe-in-Pipe Extra above the
insulation.
Lashing
against reinforcement
at a maximum distance of 1 m.
Clamping against reinforcement.
Concrete
Pipe-in-Pipe
Pipe-in-Pipe Extra
Insulation
LK Clip Rail
LK Underfloor Heating Pipe
Reinforcement
Laying of Pipe-in-Pipe in a concrete slab with underoor
heating.
Pipe laying using LK PE-X
and LK PAL to kitchen faucet
LK PE-X and PAL Universal pipe
Expansion space
Copper pipes
Dish washer
connection
Acceptable solution when installing kitchen mixers with
copper connecting pipes with LK PE-X and PAL Universal
pipes Pipe-in-Pipe.
EN.29.C.41.191217

8 (10)
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Dish washer
connection
LK PE-X and PAL Universal pipe
Expansion space
Soft-pex
Acceptable solution when installing kitchen mixers with
Soft-pex with LK PE-X and PAL Universal pipes Pipe-in-
Pipe.
When penetrations for LK PE-X and PAL Universal pipes
Pipe-in-Pipe without a wall box are to connect to a kitchen
or washbasin mixer, for example, the angle at the transi-
tion between the LK PE-X – LK PAL pipe and the mixer’s
connecting pipe must be xed. This is preferably done
using a wall washer tted with thread connection.
Replacement of pipes in conduits
A damaged LK Universal PE-X pipe (size 16x2.0
mm) can usually be replaced without causing
structural damage. Provided that installation has
been carried out according to the instructions and
that LK Fixing plates and LK Clip for Sleeve Pipe
have been used to the extent prescribed by the as-
sembly instructions.
LK recommends a maximum of 4 bends from
manifold to termination/tap location; up to 2 of
these may have a radius of less than 100 mm.
LK PAL Pipe-in-Pipe is generally regarded as not
replaceable; however it can be replaced if only 2
bends with a radius of 100 mm are to be installed.
Replacement of pipe in conduit using LK Exchange nipple.
LK Pipe extractor PE-X 16.
Use LK Exchange nipple, RSK 187 37 91 for 16
mm PE-X pipes, to secure the damaged pipe to
the new pipe. Screw LK Pipe extractor, RSK 188
07 73, into the other end of the pipe, then pull out
the damaged pipe and replace it with the new
pipe. Replacement of Pipe-in-Pipe PE-X dim.
20 to 32 mm normally requires a maximum of
2 bends of large radius. Note that Pipe-in-Pipe
PE-X of dim. 20 mm xed with LK Angle Wall
box 20 mm cannot be replaced.
Extracting a damaged inner pipe is facilitated by
means of the following measures:
• Softening of the pipe by ushing through
with hot water or hot air.
• Lubrication between media carrier pipes and
empty pipes with a mineral oil solution or
similar lubricant which reduces the friction.
Note that the conduit/sleeve pipe must be blown
clean after the change of the pipe.

9 (10)
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes
Checks
The following must be checked:
• laying of pipes and pipe connections
• location of joints and pipes
• connecting of mixers/taps and appliances to
the pipe system
• pipe lead-throughs
• attachments of connecting parts in walls with
watertight seals
• freezing-safe installation (freeze protection)
• leak tightness of the installation.
Assembly of LK Underfloor Heating
System
See the respective oor heating system’s installa-
tion instructions, for example LK Floor Heating
Strip 16, LK HeatFloor 22 and LK Heat circuit dis-
tributor RF , etc.
Tightness testing
Tightness testing of press fittings
To check that a press tting is compressed, a tight-
ness test must be performed before the nal pres-
sure test takes place. Pressurise the pipe to a test
pressure of 3 bar for at least 30 minutes. All joints
must be inspected. The pressure must not drop
during the inspection period.
NOTE! This tightness test is not a substitute for the
mandatory pressure and tightness test described
below.
Tapwater and heating pipes
When carrying out pressure and tightness tests
on pipes carrying water, the water pipe must be
lled slowly up to the control pressure. The pipes
must be completely lled with water and air
bled. To facilitate air bleeding, the pipe should be
lled from its lowest point. The tapwater system
must be tested with water of drinking water qual-
ity. The temperature difference between the room
temperature and the water temperature may not
exceed 10 °C.
Once a tapwater system has undergone pressure
and leak testing with water, this must be put in to
use within seven days at the latest or completely
emptied of water in order to reduce the risk of
bacterial growth.
Guidance
During tightness testing all joints should be in-
spected for hidden leaks. This inspection is impor-
tant because such leaks cannot always be identied
by the manometer on the pressure equipment.
Pressure and tightness testing of plastic pipe sys-
tems and pipe systems involving a mix of plastic
and metal pipes
Phase 1
Pressurize the pipe system to a test pressure of 1.43
x the calculation pressure for at least 30 minutes.
The test pressure must be 14.3 bar for tapwater
systems and 8.6 bar for heating systems. The test
pressure should be maintained for 30 minutes.
Phase 2
After 30 minutes, the test pressure is reduced rap-
idly to 7.5 bar for tapwater systems and 4.5 bar for
heating systems. This pressure must be maintained
for at least 90 minutes. The pressure should nor-
mally increase somewhat during the test period.
The entire pipe system must be inspected.
Pressure and tightness testing with air.
Pressure and tightness testing with air or another
gas must be performed by a Swedac-accredited
company as per the requirements in AFS 2006.
Tightness testing with air, low pressure
- A method devised by VVS Företagen (the Swedish Associa-
tion of Plumbing and HVAC Contractors) and Säker Vatten AB
If there is a risk of freezing or bacterial growth
before a pipe system is to be commissioned, carry-
ing out tightness testing using water is impracti-
cal. Industry regulations Säker Vatteninstallation
displays on its website www.sakervatten.se how a
simplied tightness test with air can be performed.
NOTE! Under no circumstances may this method
be performed with a test pressure higher than 1.1
bar, and it does NOT replace the mandatory tight-
ness test.

10 (10)
EN.29.C.41.191217
Assembly instructions | LK PE-X, PAL and PE-RT pipes
LK Universal system, with type-approved prod-
ucts, is ideal for this procedure. LK’s Type ap-
provals can be used as certicates showing that
they have been tested in respect of strength.
LKUnderoor heating pipes (6 or 10 bar) can be
used for this method together with LK Under-
oor heating manifolds as they are manufactured
for a pressure of 6 bar. Manufacturer certicates
can be obtained from LK Systems AB.
Carefully follow the document “Förenklad täthet-
skontroll med luft för vissa rörsystem” (Simpli-
ed tightness testing with air for certain piping
systems). Use testing protocols, that are available
to download from www.sakervatten.se.
NOTE! The system must be depressurized imme-
diately when tightness testing is complete.
Overmolding of underfloor heating pipe
The pipe system must be pressurised when em-
bedding the pipes in screed and concrete. This is
to ensure that no damage occurs during the work.
Pay attention to the danger of freezing when em-
bedding PE-X pipes in concrete.
NOTE!
While the concrete cures, high temperature
are present in the concrete. In order to avoid
damage to the pipe caused by excessive
high pressure in connection with the curing of
the concrete, a 10 bar safety valve must be
mounted on the manifold/distributor. It is sug-
gested that a LK 514 Multisafe G15, 10 bar is
used, which is a mounted where a manual air
vent is located/tted. Prior to commissioning,
remove the safety valve from the manifold/
distributor.
Existing tapwater and heating system
Guidance
Existing tapwater systems should undergo pres-
sure and tightness testing with the existing water
pressure of the tapwater system. Existing heating
systems should undergo pressure and tightness
testing with the existing operating pressure of the
heating system.
• Appoint a qualied person to lead
the work and set up testing protocol.
• Ensure that the installation and all fasteners,
xings, supports, etc. are capable of with-
standing the loads during the test.
• Freezing risks must be eliminated.
• All joints must be visible and dry.
• Make sure that the measuring equipment is
working correctly.
Leftover excess materials/recycling
LK does not accept the return of packaging mate-
rials or surplus materials, except for materials in
unbroken and undamaged packaging.
Within the framework and scope of the produc-
er’s responsibility, we are afliated with to Pack-
aging and Newspaper Collection (FTI), which is
the industry’s collection system for recycling of
packaging.
No pipes in the LK Universal System and the LK
Floor Heating Systems are classied as hazard-
ous waste, but rather these are handled as com-
bustible waste.
LK Systems AB, Box 66, 161 26 Bromma, Sweden | www.lksystems.se/en