wirsbo ProPEX User manual

ProPEX®Battery Expander Tool
Installation Guide
Contact Information
and UL Listee for United States:
Uponor Wirsbo, Inc.
5925 148th Street West
Apple Valley, MN 55124
T: [phone]
F: [phone]
E: [email protected]
www.wirsbo.com
Contact Information
and C-UL Listee for Canada:
Uponor Wirsbo
Div of Uponor Canada Inc
655 Park Street
Regina, Saskatchewan
S4N 5N1
T: [phone]
F: [phone]
E: [email protected]
www.wirsbo.ca
Copyright © 2003 Uponor Wirsbo, Printed in the United States BTHB_0603

ProPEX®Battery Expander Tool
Installation Guide

ProPEX®Battery Expander Tool
Installation Guide
Published by Uponor Wirsbo
5925 148th Street West
Apple Valley, MN 55124
[phone]
© 2003 Uponor Wirsbo
All rights reserved
First Edition
First Printing June 2003
Printed in the United States of America

i
Table of Contents
Section 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 3
Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Charging the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section 4
Tool Operating Instructions and Guidelines . . . . . . . . . . 5
Tool Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 5
Making ProPEX®Connections . . . . . . . . . . . . . . . . . . . . . 8
Important Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Making ³⁄₈" AQUAPEX ProPEX Connections . . . . . . . . . 10
ProPEX Connection Troubleshooting Guide. . . . . . . . . 12
Cold Weather Expansions. . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning the ProPEX Expander Tool Heads . . . . . . . . . 13
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ii

1
------------------------------------------------------------------ Section 1 ----------------------------------------------------------------
Overview
Wirsbo's
ProPEX®Battery
Expander (Part
No. Q6251500), an
electro-hydraulic tool,
makes fast, easy
connections to ³⁄₈", ¹⁄₂",
⁵⁄₈", ³⁄₄", 1", 1¹⁄₄" and 1¹⁄₂"
AQUAPEX®and hePEX™ plus
tubing. The tool eliminates the
need for air compressors, air hoses
and generators — making ProPEX
connections easier than ever.
Tool Components
The ProPEX Battery Expander comes with
the following components.
• ProPEX Battery Expander
• Battery charger
• Two batteries
• Tool lubricant
• Operating instructions
• Carrying case
Keep all tool components in the carrying case, which can store
several expander heads. To protect the internal driver, store
the tool with an expansion head in place. Purchase expander
heads separately.

2
------------------------------------------------------------------ Section 2 ----------------------------------------------------------------
Technical Data
ProPEX Battery Expander
Dimensions 11.8" x 12.6" x 3.3"
Weight 7 lbs. with battery
Max. tubing size 1¹⁄₂"
Power supply 12 V, 2.0 Ah, 20 A
Noise emission 73 decibels
Vibration <2,5 m/s2
Rapid Charger
Power supply 120V, 60 Hz, 2 A
Output voltage 9.6 to 18 V
Recharging time 1 hour
Weight 3 lbs.
Battery
Output 12 VDC, 2.0 Ah
Number of cells 10
Cell construction NiCd with thermal overcharge protection
Weight 1.5 lbs.
Expander Head
Weight 0.3 lb. (average)
Working Range
³⁄₈" tubing ~125-150 fittings/charge
¹⁄₂" tubing ~125-150 fittings/charge
⁵⁄₈" tubing ~80-100 fittings/charge
³⁄₄" tubing ~45-60 fittings/charge
1" tubing ~20-30 fittings/charge
1¹⁄₄" tubing ~20-30 fittings/charge
1¹⁄₂" tubing ~20-30 fittings/charge

3
------------------------------------------------------------------ Section 3 ----------------------------------------------------------------
Battery Operation
Charging the Battery
• Charge the battery before initial operation.
• Only use the rapid charger to charge the ProPEX Battery
Expander Tool.
• Remove charger from case.
• Insert battery into the charger (+pole to +pole) with
minimum force.
• The flashing red light indicates the battery is charging.
• Recharge time takes about one hour (the red indicator light on the
charger stops flashing and remains on when charge is complete).
Battery Handling
The ProPEX Battery Expander uses rechargeable batteries
containing nickel cadmium (NiCd) cells. For the most effective
and proper use of the battery, keep the following in mind.
• Only recharge cool batteries.
• The battery can recharge 1,000 times, and reaches full capacity
after several charges.
• Store batteries at temperatures greater than 40ºF, but less than
100ºF to optimize battery life.
• Only recharge after the battery is completely drained of power.
• Do not use the charger if dropped or damaged.
• Do not connect two chargers together.
• To prevent damage to the battery, do not use the charger at
ambient temperatures of less than 40°F (5°C) or greater than
105°F (40°C).
• Keep the battery in a frost-free and dry place.
• It is normal for the battery and charger to become warm during
the charge cycle.

4
• To avoid shorting the battery contacts, do not allow metal
objects (e.g., screws, cutlery, nails) to come in contact.
• Only use the provided charger to charge the battery. Use of any
battery other than the provided battery will void the warranty.
• Use Wirsbo-recommended charging procedures. Incorrect use
can lead to short circuits, overheating or battery fluid leakage.
• To prolong the battery's life, avoid overcharging. Do not charge
for more than two days.
• Replace the battery if you notice a substantially reduced
operating time after proper charging.
• When this symbol appears, discharge the battery
completely and dispose in accordance to local
environmental regulations. Do not incinerate or
dispose in common waste-removal methods.

5
------------------------------------------------------------------ Section 4 ----------------------------------------------------------------
Expander Tool Operation and Guidelines
Operating Instructions
• Check the cone for dirt and clean as described below
(Proper Tool Maintenance).
• Attach the correctly sized ProPEX expander head onto the
Expander Tool. Screw on the expander head snugly.
• Insert the battery into the tool.
• Use tool for expanding Wirsbo PEX tubing only.
• Refer to the Making Proper ProPEX Connections section.
Proper Tool Maintenance
• Periodically remove the head and clean the cone of the ProPEX
Battery Expander Tool using a dry cloth.
• Periodically clean the inside of the expander heads using a dry
cloth. This will remove any debris trapped between the head
and cone.
• Apply a small amount of lubricant to the expander cone before
use or daily to ensure a good connection.
Caution: Excessive lubrication may result in improper
connections. Only use a small amount of lubrication to
keep the tool working properly.
• Store the ProPEX Battery Expander in a dry location to
prevent rust.
• Store the tool with an expander head attached to the cone to
prevent damage.
Troubleshooting
If you experience difficulty making connections:
• Ensure the battery is fully charged.
• Do not overload the tool's capacity. (Do not expand tubing
larger than 1¹⁄₂".)

6
• Check if the expander head needs lubrication.
If the red light on the handle is on:
• The battery may need to be charged.
• The expander may be overloaded.
Note: A continuous red light on the tool indicates a problem.
Return the tool to the distributor or manufacturer for repair.
Safety Guidelines
To reduce the risk of electric shock, personal injury and fire,
always follow basic safety precautions. Read and comply with all
these guidelines before operating the ProPEX Battery Expander.
Failure to follow the instructions and installation guidelines as
defined in this handbook can result in the failure of the ProPEX
Battery Expander.
• Keep fingers and hands away from the moving head area.
• Remove the battery when tool is not in use, before servicing
and when changing expander heads.
• Lay the tool on its side when not in use. Tool is not designed
to sit upright.
• Do not operate or expose the tool and the charger to moisture,
combustible fluids or gases (danger of explosion).
• Do not use the tool for any function other than
expanding tubing.
• Do not obstruct or place anything in the vent holes in the
tool housing.
• Always wear protective eyewear and clothing when
operating the tool.
• Use original replacement parts only.
• Only professional contractors should operate the ProPEX
Battery Expander. Keep away from children.
• Keep the ProPEX Battery Expander clean. Dirt and rust may
hinder proper and safe tool operation.

• If the tool is not functioning properly, return the tool to the
distributor or manufacturer.
Important: The ProPEX Battery Expander complies with
relevant safety regulations. All maintenance and repair
work, particularly when involving electrical systems, may
only be performed by an authorized expert or by trained
personnel using genuine spare parts, otherwise injuries
may result. All unauthorized modifications to the
equipment are prohibited for safety reasons.
Repairs
Warranty repairs are offered by the manufacturer only.
Repairs outside the warranty should only be carried out by
trained personnel.
Warranty
• The Wirsbo ProPEX Battery Expander Tool carries a two-year
warranty for the tool and a six-month warranty for batteries.
• All warranties are effective from delivery date (proven by
invoice or delivery note).
• Damage due directly or indirectly to misuse, abuse, and
negligence or lack of proper maintenance is not included in
this warranty.
• Damage caused by material or manufacturing faults will be
covered by this warranty, and the product should be returned
to the manufacturer for repairs.
• Claims are only acceptable if the complete ProPEX Battery
Expander Tool is returned to Wirsbo or to the distributor.
• If a warranty claim is necessary, return the product to Wirsbo
with transportation charges prepaid.
• Include proof of purchase date and an explanation of the
complaint with the product.
7

8
------------------------------------------------------------------ Section 5 ----------------------------------------------------------------
Making ProPEX Connections
Tools Needed
• ProPEX Battery Expander Tool
• Properly sized expander head, hand-tightened on the tool
• Tubing cutter designed for plastic tubing
1. Square cut the PEX tubing perpendi-
cular to the length of the tubing.
Remove all excess material or
burrs that might affect the fitting
connection.
2. Slide the PEX ring over the end of the
tubing. Extend the end of the ring
over the end of the tubing no more
than ¹⁄₁₆" (1mm).
max ¹⁄₁₆"
3. Slide the expander head into the
tubing until it stops. Full expansions
are necessary to make a proper con-
nection. Press the trigger to expand.
Release the trigger, remove the head
from the tubing and rotate it ¹⁄₈ turn.
Slide the tool head into the tubing
in the newly rotated position and
expand again.
Important: Rotate the tool ¹⁄₈ turn after
each expansion to provide smooth and
even expansion of the tubing. If the
head is not repositioned after each
expansion, the segments on the tool
head may cause deep grooves in the
tubing. These grooves can result in
potential leak paths.

Important Tips for a Proper ProPEX Connection
• Rotate the tool after every expansion. If the tool is not rotated
after EACH expansion, the segments on the tool head may
cause deep grooves in the tubing. These grooves can result in
potential leak paths.
• If the fitting does not slide into the tubing all the way to the
stop, immediately remove it from the tubing and expand the
tubing one final time. To avoid over-expanding the tubing,
do not hold the tubing in the expanded position.
9
4. Repeat the expansion process until
the tubing and ring are snug against
the shoulder on the expander head.
See Chart A for the recommended
number of expansions for each
tubing size. 5. Immediately remove the ProPEX
Expander Tool. As you slide the tubing
over the fitting, you should feel some
resistance. If the tubing reaches the
shoulder of the fitting without any
resistance, the tubing may be over-
expanded and may require additional
time to fully shrink over the fitting.
The tubing and PEX ring should seat
against the shoulder of the fitting for a
proper connection.
Tubing Size Ring Marking Head Marking # of Expansions
Manual Air Exp Battery Exp Manual Air Exp Battery Exp
³⁄₈"³⁄₈"³⁄₈"³⁄₈"—4-5 4-5 6-7
¹⁄₂"¹⁄₂"¹⁄₂"¹⁄₂"—3-4 3-4 3-4
³⁄₄"³⁄₄"³⁄₄"³⁄₄"³⁄₄"H 7-9 7-9 6-7H
1" 1" 1" 1" 1"H 12-14 12-14 6-7H
1¹⁄₄"1¹⁄₄"——1¹⁄₄"H — — 6-7H
1¹⁄₂"1¹⁄₂"——1¹⁄₂"H — — 6-7H
Chart A

10
• The number of expansions in Chart A is the recommended
number of expansions. Experience, technique and weather
conditions influence the actual number of expansions. Fewer
expansions may be necessary under certain conditions. The
correct number of expansions is the amount necessary for the
tubing and the shoulder of the fitting to fit snugly together.
• Good connections result when the PEX ring rests snugly against
the stop of the ProPEX fitting shoulder. If there is more than ¹⁄₁₆"
between the ring and the shoulder of the fitting, square cut the
tubing 2 inches away from the fitting, and make another
connection using a new PEX ring.
³⁄₈" AQUAPEX ProPEX Connections
The ³⁄₈" PEX ring is smaller and thicker than the PEX rings used for
other tubing sizes. The ³⁄₈" PEX ring must expand once on each
side to properly fit over the tubing. Expansion of the PEX ring is
only necessary for ³⁄₈" AQUAPEX.
1. Square cut the ³⁄₈" AQUAPEX tubing
perpendicular to the length of the tubing.
2. Expand each side of ³⁄₈" PEX ring with
the ProPEX Expander Tool once.
3. Slide the expanded ³⁄₈" ring
over the end of the tubing.
Extend the end of the ring
over the end of the tubing
no more than ¹⁄₁₆" (1mm).
Once the ³⁄₈" PEX ring is properly expanded and on the tubing,
refer to Steps 3-5 on pages 8-9 for further instruction.
Important Tips for a Proper ³⁄₈" ProPEX Connection
• When the temperature is above 40°F, ProPEX connections to ³⁄₈"
AQUAPEX tubing require four to five expansions. When the
temperature is below 40°F, only four expansions are necessary.
• The thicker PEX ring used for ³⁄₈" ProPEX connections shrinks
over the fitting faster than other size PEX rings.
max ¹⁄₁₆"

11
Rotating Tool After Each Expansion
Rotate the tool ¹⁄₈ turn after EACH expansion to provide smooth
and even expansion of the tubing. If the head is not repositioned
after each expansion, the segments on the tool head may cause
deep grooves in the tubing. These grooves could result in
potential leak paths.
Note: The photos above show enlarged views inside
expanded tubing.
Improper Connections
In the event of an improper connection, square cut the tubing
2 inches from the PEX ring, and begin the steps for making a
ProPEX connection.
Expansion with
proper rotation
Expansion without
proper rotation

12
ProPEX Connection
Troubleshooting Guide
Trouble-free ProPEX installations begin with a ProPEX Expander
Tool that is maintained in proper working condition. If the tool
or segment fingers are damaged, it is very difficult to make a
proper connection. The following troubleshooting guide is
designed to assist with problems in the field.
For Fittings That Will Not Seal:
• Make sure the expander head is securely screwed onto the tool
(hand-tightened).
• Make sure the segment fingers are not bent. If the head does not
completely close when the electro-hydraulic drive unit is fully
retracted, replace the head.
• Examine the tool for excess grease on the segment fingers.
Remove excess grease prior to making ProPEX connections.
• Examine the fitting for any damage. Nicks and gouges on the
fitting will cause the fitting to leak.
• Make sure the internal driver is not damaged or bent.
• Make sure the last expansion is not held in the expanded
position for more than three seconds before the fitting is
inserted. The longer the tubing and ring are held in the
expanded position, the greater the chance for a leak.
• Be sure to rotate the tool ¹₈ turn after EACH expansion.
If Expansion is Difficult:
• Make sure the internal cone is properly greased.
If the Expansion Head Slips out of the Tubing
When Making Expansions:
• Ensure the tubing and ring are dry.
• Make sure that grease is not getting into the tubing.
• Examine the segment fingers to make sure that none are bent.

13
If More Than the Recommended Number of Expansions
are Needed to Make a Connection:
• Make sure that the head is hand-tightened to the expander tool.
• Examine the segment fingers to make sure that none are bent.
• Be sure to completely cycle the tool on each expansion.
Cold Weather Expansions
• Temperature affects the time required for the tubing and ring to
shrink onto the fitting. The colder the temperature, the slower
the contraction time.
• Operating the tool in temperatures below 40ºF will reduce the
number of connections that can be made per charge.
• When using the tool in temperatures below 40ºF, keep the
batteries warm to optimize battery life.
• Warming ProPEX fittings and ProPEX Rings reduces contraction
time. Put fittings and rings in your pockets prior to installation to
keep them warm.
• In temperatures below 40°F, do not hold the tubing in the
expanded position after the final expansion.
• ProPEX connections must be made at temperatures above 5°F
(-15°C).
Cleaning the ProPEX Expander Tool Head
The ProPEX Expander Tool head comes in different sizes
ranging from ³₈" to 1¹⁄₂". All heads contain six segment fingers,
one attachment ring and one spring. It is very important to keep
the heads on the tool or in the tool case at all times as dirt and
other debris can affect the connection process.
1. Remove and clean the segment fingers once a week. Remove
the segments from the attachment ring by pushing the
segment finger down toward the opening in the ring. Once the
first segment is removed, the rest follow easily.
2. Place the segments on a flat surface with the ridges facing up.
The fingers should lay flat without any curve in the middle.
If the segments are bent, replace the head immediately.

14
3. To reassemble, replace the segment fingers one at a time to the
attachment ring by sliding the grooved portion of the segment
fingers over the spring in the attachment ring. The narrow end
of the segment fingers points away from the solid side of the
attachment ring. Hold these segment fingers in place with your
thumb as the remaining segment fingers are inserted.
4. Once the expander head is cleaned and reassembled, apply a
light coat of graphite grease to the expander cone prior to
making any ProPEX connections.
Product Information
• Do not install Wirsbo AQUAPEX and hePEX plus tubing where
temperatures and pressure exceed their ratings.
• Store AQUAPEX and hePEX plus in their original boxes.
Exposure to direct sunlight for more than 30 days can cause
damage to the tubing.
• Do not weld or glue AQUAPEX or hePEX plus.
• Do not apply an open flame to AQUAPEX or hePEX plus tubing.
• Do not install AQUAPEX or hePEX plus within 6" of any single
wall gas appliance vent or within 12" of any uninsulated
recessed light fixture.
• Do not use AQUAPEX or hePEX plus for an electrical ground.