Aquatherm Installer Manual

aquatherm INSTALLER MANUAL
825 W 600 N | Lindon, UT | 84042 | 801.805.6657
aquatherm
4 ed.
support@aquatherm.com
www.aquatherm.com
This manual is designed to accompany the Aquatherm Installer
INSTALLER MANUAL
Training Course and act as a reference for trained installers. It is
not a substitute for taking the Installer Training Course.
10.15
© 2015 aquatherm NA L.C. All rights reserved

4 Edition
Printed in USA 4th EDITION
Owner Aquatherm Installer Manual
- -
Installer Number For the proper installation of PP-R and PP-RP (RCT)
pipe and fittings manufactured exclusively by
Trainer Name Aquatherm
Required for the Aquatherm Installer

Trainer Contact Info.
and Aquatherm Butt Welding and
Hot Tapping Courses
© 2015 aquatherm, LP. All rights reserved

Contents
Contents Segmented fittings 1.17

Chapter 1 Flow rates and sizing 1.18
Welcome to Aquatherm 1.1 Operating pressures 1.19
Getting started 1.2 Compressed air 1.19
Working with PP-R 1.3 Weights and capacities 1.20
Aquatherm innovations 1.4 Listings and approvals, reference standards 1.22
The world leader in PP-R pipe 1.5 Chapter 2
Material handling 1.6 Heat fusion 2.1
Pipe sizes 1.8 Safety2.2
Wall thickness 1.9 Cutting the pipe 2.3
Identification1.10 Inspecting the cut 2.5
Hot water aquatherm green pipe® MF1.11 How heat fusion works 2.6
This manual was produced by Aquatherm, LP. and is intended strictly for the North American market. It combines information published by Aquatherm GmbH with Cold water aquatherm green pipe® S1.12 Socket fusion 2.7
accepted fusion practices in the USA and Canada. Aquatherm GmbH assumes no responsibility for the content of this manual beyond what they have specifically Welding heads 2.8
published. Aquatherm, LP. does not warranty the completeness or accuracy of the information contained herein. In the event of a discrepancy between this manual
Thick-wall aquatherm blue pipe® MF1.13
and information published by Aquatherm GmbH, the information published by Aquatherm GmbH will be considered correct. Also, in the event of a discrepancy Thin-wall aquatherm blue pipe® MF1.14 Welding irons 2.9
between this manual and the Aquatherm, LP. catalog, the information published in the catalog will be considered correct. The information in this manual is aquatherm lilac pipe® S1.15 Welding iron safety 2.10
superseded by any subsequent editions of this manual. Aquatherm, LP retains the right to modify the proper installation procedures at any time via technical Molded fittings 1.16 Tool assembly 2.12
bulletins. Marking the pipe 2.13
Socket fusion heating and cooling times 2.14 Rothenberger adjustment and welding pressure 2.40 Manual butt fusion machines 3.10 Connecting to a boiler 4.23
Socket fusion instructions 2.16 Widos adjustment and welding pressures 2.42 Larger crew vs. more tools 3.11 Bushings, reducers, and reducing couplings 4.24
Large diameter socket fusion 2.18 Adjustment bead height 2.44 Work example 3.12 Large PP-R ball valve 4.25
Mechanically assisted fusions 2.19 Butt welding heating and cooling times 2.45 Joining spools: 3.24 Threaded connections 4.26
Inspection2.20 Butt welding instructions: 2.47 Chapter 4 Brass identification 4.27
Avoiding improper fusions 2.21 Reducing cooling times 2.53 Planning4.1 Flanges4.28
Troubleshooting bad connections 2.22 Fusing dissimilar SDRs 2.54 Technical bulletins 4.2 Butterfly valves 4.30
Ovality in machine-assisted fusions 2.23 Internal alignment 2.55 Clamps and hangers 4.3 Branch lines 4.31
Fusion outlets 2.24 Repairs2.56 Anchors and guides 4.4 Buried applications 4.32
Fusion outlet instructions 2.25 Chapter 3 Support intervals and hanger spacing 4.5 Maximum pull force 4.33
Electrofusion2.28 Productivity3.1 Support intervals 4.6 Bending Aquatherm pipe 4.34
Electrofusion instructions 2.29 Getting started 3.2 Increased hanger spacing 4.8 Insulation sizing, thrust blocking, noise generation, and
Butt welding 2.32 Crew mix 3.3 Fire rating 4.9 vibration isolation 4.35
Explanation of butt welding 2.33 Tooling3.4 Linear expansion 4.10 UV protection and painting 4.36
Butt welding pressures 2.34 Hand irons 3.5 Expansion controls 4.14 Fusing UV pipe 4.37
Butt welding phases 2.35 Socket fusion machines 3.6 Chemical compatibility 4.20 Flushing, grounding, and freeze protection 4.38
McElroy adjustment and welding pressures 2.36 Four-jaw butt fusion machines 3.8 Integration with copper tubing 4.21 Warranty claims 4.39
Ritmo adjustment and welding pressure 2.38 Modified machine configurations 3.9 PP-R to copper transition fittings 4.22 Pressure testing 4.40
Chapter 5 Butt weld reducer 5.11 Union5.32 Transition elbow (male)5.43
Pipe and fittings 5.1 Elbow 90° (Socket) 5.12 Wing back 90° elbow 5.34 Transition tee (female)5.43
aquatherm green pipe® SDR 7.4 MF 5.2 Elbow 90° (Butt-weld) 5.13 Electrofusion coupling 5.34 NPT fusion outlet hex (female)5.44
aquatherm green pipe® SDR 7.4/11 S 5.2 molded5.13 Back plate elbow 5.35 Distribution block plumbing 5.47
aquatherm green pipe® SDR 7.4 MF UV 5.3 Elbow 45° (Socket) 5.14 ISO plug for pressure tests 5.35 Distribution pipe 5.47
aquatherm blue pipe® SDR 7.4/11 MF 5.4 Elbow 45° (Butt-weld) 5.15 ISO transition piece 5.36 Distributor end piece 5.48
aquatherm blue pipe® SDR 17.6 MF 5.5 (molded)5.15 Transition piece 5.37 Screw-down stop globe valve 5.48
aquatherm blue pipe® SDR 7.4/11 MF UV 5.6 End cap (Socket) 5.16 NPT transition piece (female)5.37 Concealed valve (standard)5.49
aquatherm blue pipe® SDR 17.6 MF UV 5.6 aquatherm green pipe® Wye (Lateral 45) 5.18 NPT transition elbow (female)5.39 Stop valve body ISO 5.50
aquatherm lilac pipe® SDR 7.4/11 S 5.7 aquatherm blue pipe® Wye (Lateral 45) 5.18 NPT transition street elbow (male/female)5.39 Inclined valve 5.50
Coupling5.8 Tee (Socket) 5.19 NPT transition tee 5.40 Inclined check valve 5.51
Reducing couplings 5.8 Tee (Butt-weld) molded5.20 Draining branch 5.40 Ball valve 5.51
Cross-over5.9 Reducing tee (Socket) 5.21 Flow meter well 5.40 Ball valve 5.51
Street 45° 5.9 aquatherm blue pipe® - Reducing tee (Butt-weld) 5.24 Stub out 5.41 Repair plug 5.54
Street 90° 5.9 Fusion outlet (Socket) 5.28 Straight stub out 5.41 Temperature protective gloves5.54
Bushing5.10 Fusion outlet (Butt-weld) 5.29 PEX adaptor (crimp)5.42 Welding heads 5.54
Cross5.10 Flange ring 5.30 PEX adaptor (expansion)5.42 Drill bit 5.55
Flange adapter 5.31 PP-R to grooved transition 5.42 Fusion outlet welding heads 5.56
Chapter 1: Welcome to Aquatherm
1.1
This manual has been compiled to help ensure safe and
consistent installation of Aquatherm’s piping materials.
Please read all instructions before beginning installation.
WELCOME TO AQUATHERM
Installers must take the appropriate training course from an
authorized Aquatherm trainer before beginning installation.
This training will teach you

the proper techniques for
fast, reliable heat fusion
connections and help you take
full advantage of Aquatherm’s
many benefits.
Getting started Working with PP-R
1.2
1.3
Before you get started, you standards of quality, so you can find that learning fusion is quick Polypropylene is a thermoplastic, durability, rigidity and flexibility. All of Aquatherm’s pipes and
should know a little about trust the material every time you and easy. This manual will act as similar to polyethylene pipe. It is PP-R is connected using heat fittings are made from PP-R
the pipe you are installing. install it. If the pipe and fittings your guide while you learn, and made from an oil by-product, so it fusion, which involves heating, or PP-RP, so they will have the
Aquatherm’s pipes and fittings don’t have Aquatherm labels, as you continue to fuse pipe for naturally repels water.This makes pressure and cooling the pipe to same properties. They can be
are made from an engineered return them and don’t install years to come. it ideal for a piping material, as join it to an identical material. This heat fused together without
variation of polypropylene- them. Only genuine Aquatherm it does not affect, and is not is covered in detail in Chapter 2. any strength loss, and have the
random copolymer, or PP-R. products are protected by affected by, the water it carries. same densities, durability, and
Aquatherm’s warranty and resistances.
Aquatherm PP-R offers many decades of expertise with PP-R. PP is made from chains of
benefits over metals and other hydrogen and carbon, so there Aquatherm’s PP-R has been
plastics, such as durability, If you have not worked with are no toxic chemicals that can engineered for improved
longevity, and chemical purity. Aquatherm’s fusible pipe before, affect drinking water. performance and should not be
it is best not to rush and get mixed with other types of PP-R.
Aquatherm’s polypropylene ahead of yourself. Just as you PP-R is polypropylene PP-R should never be fused to
pipes and fittings are produced were not able to make perfect copolymerized (combined) with PVDF, PE, CPVC, or any other
in Germany and have been used welds your first day as an a small amount of ethylene. type of plastic. Never use solvent
around the world for over four apprentice, it will also take you This combination, enhanced by cements on Aquatherm’s PP-R,
decades. The pipe and fittings are some time to become proficient Aquatherm’s proprietary formula, as they may damage the pipe
made to the highest international at heat fusion. Fortunately, you’ll gives the material a balance of and won’t bind properly.
Aquatherm innovations The world leader in PP-R pipe
Normal plastic VS Aquatherm’s Fusiolen PP-R
1.4
1.5
Every piping material has Aquatherm is the world leader in costs, and financial loss, giving warranty does not cover
advantages and disadvantages. • Burns during fusion, resulting • Does not burn during PP-R pressure piping systems. you and your customers real damage caused by post-factory
PP-R is proven to have very in strength loss fusion, for 100% strength When you work with our peace of mind. Coverage begins mishandling, jobsite abuse, UV
• Damaged when exposed to • Heat-stabilized to withstand

few disadvantages, and several products, you have decades of upon submission of a successful damage, or improper installation.
high temperatures high temperatures
innovations unique to Aquatherm • Multi-layer faser technology
research and experience backing pressure test record for the Full details of Aquatherm’s
• Significant linear expansion
help address these minor cuts expansion by 75% you up. All Aquatherm products current coverage amount. Exact warranty coverage can be found
when heated
shortfalls. Aquatherm’s special • Completely inert to water are thoroughly tested before, coverage amounts are subject to at Aquatherm.com/warranty.
• Chemically reactive, resulting
blend of PP-R is called Fusiolen®, in failures and most chemicals during, and after production by the exchange rate with the Euro
which is used in each Aquatherm the best equipment and experts at the time coverage is awarded. Note: The Aquatherm warranty only applies
pipe and fitting. in the industry. This quality control to systems that are properly installed by
PP-R is durable, both physically an Aquatherm-trained installer. Improper
helps ensure consistency in
Pipe integrity (at 400 oF)

installation or fusing to non-Fusiolen parts
The multi-layer faser Aquatherm PP-R Heat stabilization every Aquatherm pipe and fitting. and chemically, and is more will void the warranty for those connections.
composite (MF) process Regular PP-R protects the resilient against oils, freezing, Following all the procedures in this manual
yields a mix of PP-R and pipe during brief Aquatherm backs its products impact, etc. than other plastics will minimize the risk of material failure
glass fibers that reduces exposure to extreme and help ensure coverage in the event of a
with a 10-year manufacturer’s and even metals.
expansion but does not temperatures. problem. Pressure testing is required to verify
warranty that doesn’t just cover proper installation.
affect fusion properties. Proper care should be taken
replacement parts — it also
covers the replacement labor, when working with Aquatherm
0 7 42
Time (min.) incidental damages, medical pipes and fittings. The Aquatherm
Material handling: Do Material handling: Don’t
1.6
1.7
Inspect pipe upon receiving it. Aquatherm does Don’t fuse damaged pipe. Remove damaged Keep the pipe on a flat surface or close supports Don’t run over the pipe with any type of vehicle or Don’t drop the pipe or handle it roughly. PP-R can Don’t insert sharp or unpadded objects into the
not accept responsibility for damage that occurs sections and install the remaining pipe. Follow to avoid bowing. Use at least 3 supports for 13’ crush the ends. This is the most common cause of handle most impacts without issue, but there is no ends of the pipe. These can gouge the inside of
after the pipe is shipped. your distributor’s policy for returns. pipes and 4 for 19’ pipes. pipe damage. reason to risk damaging it. the pipe and create weak spots.
Keep the pipe in its protective bag or wrap until Handle the pipe carefully, especially in freezing Cover unbagged pipe with a light-colored tarp if Don’t store pipe outside for more than 6 months Keep the fittings in their bags until you use them. Don’t use damaged pipe that is gouged deeper
you are ready to install it. The bag protects the weather. Plastic may become brittle at cold storing it outside. A dark tarp generates heat and uncovered. The pipe should be stored under a tarp Bagged fittings will be easier to identify and than 10% of the wall thickness on the outside or
pipe from dirt, scratches, and UV rays. temperatures, so treat it accordingly. may cause warping. or shade, or in its factory packaging. protected from contaminants. 5% on the inside.
Pipe sizes Wall thickness
Aquatherm pipe is made to metric sizes (millimeters).
1.8
1.9
This is part of its design and listings, but it is easy to Socket fusion Butt welding
learn the matching imperial sizes (inches). Factory Nominal Factory Nominal
metric OD diameter metric OD diameter
/7.4
FPO /17.6
1 1
This chart gives the matching sizes between metric 1
/9 1/11
20 mm ½” 160 mm 6” of the of the of the of the
and imperial. These sizes are based on factory
25 mm ¾” 200 mm 8” total total total total
settings and closest nominal diameters. Use the
diameter diameter diameter diameter
nominal size when switching from imperial pipe if 32 mm 1” 250 mm 10”
gpm requirements are not available. Use the actual 40 mm 1 ¼” 315 mm 12” SDR 7.4 SDR 9 SDR 11 SDR 17.6
OD for sizing clamps and insulation.
50 mm 1 ½” 355 mm 14” A heavy wall provides increased A medium thick wall composed A balanced wall thickness to A thinner wall provides maximum
Aquatherm pipes use standard dimension ratios 63 mm 2” 400 mm 16” pressure and temperature of PP-RCT provides increased provide higher flow rates while flow rate while minimizing material
(SDR) instead of schedules. This means that the ratings for high-stress temperature and pressure maintaining high pressures. weight, cost, and fusion times. For
75 mm 2 ½” 450 mm 18”
wall thickness is proportional to the diameter of the applications such as hot water capabilities for higher-stress Suitable for most applications. chilled, cooling, and condenser
pipe. From a performance standpoint, this makes 90 mm 3” 500 mm 20” recirulation. applications such as mechanical (all ½” and ¾” pipes are SDR 7.4 applications.
the pressure rating of the pipe consistent through 110 mm 3 ½” 560 mm 22” heating hot water systems. unless otherwise indicated)
each size. aquatherm green pipe® MF aquatherm blue pipe® MF
125 mm 4” 630 mm 24” aquatherm blue pipe® MF-RP aquatherm green pipe® S, MF
½” – 4” pipes come in 13 ft (4 meter) lengths. aquatherm blue pipe® MF
4" SDR 11 and SDR 17.6 may be butt welded.
aquatherm lilac pipe® S
6” – 24” pipes come in 19 ft (5.8 meter) lengths.
Identification Product Selection
IS THIS A POTABLE/DOMESTIC SYSTEM?
1.10
1.11
YES NO
Aquatherm has several lines of pipe that are specifically aquatherm blue pipe®
aquatherm green pipe®
engineered for certain applications. Stripes and color aquatherm lilac pipe®
indicate the type of pipe. NON-POTABLE NON-POTABLE
POTABLE COLD POTABLE HOT
reclaimed water (Select SDR based on Temp and Pressure Requirements)
aquatherm aquatherm
aquatherm green pipe® MF aquatherm blue pipe® MF aquatherm green pipe® S aquatherm lilac pipe® S green pipe®
aquatherm
lilac pipe®
aquatherm aquatherm aquatherm
green pipe® blue pipe® blue pipe® blue pipe®
Temperature SDR 11 SDR 11
SDR 7.4 (MF) SDR 9 (MF-RP) SDR 11 (MF) SDR 17.6 (MF)
(non-MF) (non-MF)
Aquatherm Green pipe® faser-composite pipe 63x8.6mm (2” N.D.) PP-R80 SDR 11 cNSF CSA b137.11 ASTM F2389 ICC ESR-1613 Made in Germany
Permissible working pressure (psi)
50 °F 195 380 195 385 285 160
80 °F 170 320 170 305 220 125
Expansion control label Material Relevant code listings 100 °F 135 255 135 255 185 95
(not present on non-MF pipes) (varies by pipe type)
120 °F 110 215 110 215 155 80
140 °F 95 180 95 180 130 70
Pipe name Production size and Additional 160 °F - 120 - 150 100 45
(only genuine Aquatherm pipe Wall thickness
nominal diameter (based on pipe diameter) information 180 °F - 100 - 125 62 -
and fittings are backed by our
10-year warranty) (incl. timestamp)
200 °F - 45 - 100 30 -
Hot water aquatherm green pipe® MF Cold water aquatherm green pipe® S
1.12
1.13
Color: Green Color: Green
Stripes: Dark green Stripes: Light blue
Wall thickness: SDR 7.4 Wall thickness: SDR 11, 7.4 (¾” or smaller only)
Size range: ½” - 14” Size range: ½” - 18”
Multi-layer construction (expansion-controlled): Yes Multi-layer construction (expansion-controlled): No
Maximum operating pressure at 50 °F: 380 psi Maximum operating pressure at 50 °F: 195 psi
Recommended applications: Domestic (potable) Recommended applications: Domestic (potable) cold
hot water, food processing, light-hazard fire sprinkler water, food processing
(NFPA 13D) Acceptable applications: Cooling, chemical
Acceptable applications: Domestic (potable) cold transport, and any other lower temperature application
water, heating, cooling, compressed air, chemical suitable for PP-R
transport, and any other application suitable for PP-R
Thick-wall aquatherm blue pipe® MF Thick-wall aquatherm blue pipe® MF
1.14
1.15
Color: Blue Color: Blue
Stripes: Green Stripes: Green
Wall thickness: SDR 9 Wall thickness: SDR 11, 7.4 (¾” or smaller only)
Size range: ½” - 14” Size range: ½” - 18”
Multi-layer construction (expansion-controlled): Yes Multi-layer construction (expansion-controlled): Yes
Recommended applications: Heating and cooling Recommended applications: Heating and cooling
distribution, compressed air, chemical transport, swimming distribution, compressed air, chemical transport, swimming
pools (verify treatment levels), in-floor heating pools (verify treatment levels), in-floor heating
Acceptable applications: Irrigation and any other Acceptable applications: Irrigation and any other
non-potable piping applications non-potable piping applications
Thin-wall aquatherm blue pipe® MF aquatherm lilac pipe® S
1.16
1.17
Color: Blue Color: Purple
Stripes: Green Stripes: None
Wall thickness: SDR 17.6 Wall thickness: SDR 11

Size range: 4”- 24” Size range: ½” - 10”
Multi-layer construction (expansion-controlled): Yes Multi-layer construction (expansion-controlled): No
Recommended applications: Geothermal, district Recommended applications: Rainwater, greywater,
cooling, low-pressure cooling distribution, condenser reclaimed water, irrigation
water piping to cooling towers
Acceptable applications: Any non-potable, low
pressure, low temperature applications suitable for
PP-R
Molded fittings Segmented fittings
1.18
1.19
• Single piece • Usually 2 - 4 fused pieces
• ½” - 4” fittings socket fuse over the pipe wall
• Butt weld in-line with the pipe
• 6”- 24” fittings butt weld in-line with the pipe

• All pipes use the same PP-R fittings • 6” - 24” (elbows & tees)
• Minimal markings on the fittings • Made from aquatherm green pipe® or aquatherm blue pipe®
to match piping system
• Full labeling on the bag
• Keep fittings in their bags until ready for use • Size marked on label
• Pressure rating meets or exceeds the pressure rating of • Stamped on the side to indicate origin
the pipe
• aquatherm green pipe® fittings may be used with aquatherm
blue pipe installations -- do not use aquatherm blue pipe
fittings in aquatherm green pipe installations
• Pressure rating meets the pressure rating of the pipe

Flow rates and sizing Operating pressures
1.20
1.21
For most applications, use the same size Aquatherm on flow speed and head loss. The maximum GPM Systems with constant operating parameters (60-year expected minimum)
pipe as you use for other piping materials. The lower may be higher in some cases. Aquatherm pipe does
friction and higher flow speed of PP-R compensates not have internal corrosion or ID loss, so downsizing aquatherm This table assumes constant
aquatherm aquatherm aquatherm aquatherm operation using water or a water/

for the smaller ID which occurs in some sizes. The may be possible in some cases, at the discretion of green pipe®
green pipe® blue pipe® blue pipe® blue pipe®
following table gives the recommended GPM based the engineer. Use Flow Rate Table.xlsx Temperature aquatherm lilac pipe®
SDR 7.4 (MF) SDR 9 (MF) SDR 11 (MF) SDR 17.6 (MF) glycol mix. Seasonal operation
SDR 11 (S) or use of different mediums may
Nominal GPM GPM GPM GPM Nominal GPM GPM GPM GPM Permissible working pressure (psi) impact the pressure rating of
diameter SDR 7.4 SDR 9 SDR 11 SDR 17.6 diameter SDR 7.4 SDR 9 SDR 11 SDR 17.6
50 °F 195 380 385 285 160 the pipe. Aquatherm pipe is not
½” 6 - 8 - 6” 400 500 500 600
intended for use below -5 °F.
¾” 9 12 12 - 8” 800 700 1000 1100 80 °F 170 320 305 220 125
100 °F 135 255 255 185 95 Compressed air
1” 16 19 20 - 10” 1200 1100 1500 1800
1 ¼” 24 29 32 - 12” 2400 1800 3000 3400 120 °F 110 215 215 155 80 aquatherm aquatherm
green pipe® blue pipe®
1 ½” 40 46 50 - 14” 3000 2300 3800 4500 140 °F 95 180 180 130 70 SDR 7.4 (MF) SDR 11 (MF)
2” 60 70 80 - 16” - - 4500 5750 160 °F - 120 150 100 45 7.4 200 11 125
2 ½” 90 100 110 - 18” - - 6000 7250
180 °F - 100 125 62 25
3” 130 150 160 - 20” - - - 10000 (assumes air temp < 100 °F)
200 °F - 45 100 30 15
3 ½” 190 220 240 - 22” - - - 13000
4” 240 290 300 350 24” - - - 16000
aquatherm green pipe and aquatherm lilac pipe® weights and capacities aquatherm blue pipe® weights and capacities
1.22
1.23
aquatherm green pipe® SDR 7.4 MF aquatherm green pipe® pipe SDR 7.4 S / SDR 11 S aquatherm blue pipe® aquatherm blue pipe® aquatherm blue pipe®
aquatherm lilac pipe® SDR 7.4 S / SDR 11 S SDR 7.4 MF / SDR 11 MF SDR 9 MF SDR 17.6 MF
Pipe Capacity Weight w/water
Pipe Capacity Weight w/water Pipe Capacity Weight w/water
ND gal/ft lb/ft lb/ft Pipe Capacity Weight w/ water Pipe Capacity Weight w/ water
Pipe Capacity Weight w/ water Pipe Capacity Weight w/ water

½” 0.01 0.11 0.22 ND gal/ft lb/ft lb/ft ND gal/ft lb/ft lb/ft ND gal/ft lb/ft lb/ft ND gal/ft lb/ft lb/ft ND gal/ft lb/ft lb/ft ND gal/ft lb/ft lb/ft
¾” 0.02 0.17 0.34 ½” 0.02 0.10 0.24 10” 2.65 10.42 32.49 ½” 0.01 0.11 0.22 12” 4.20 17.24 52.23 1” 0.039 0.22 0.55 4” 0.78 1.80 8.30
1” 0.03 0.26 0.51 ¾” 0.03 0.16 0.38 12” 4.20 17.24 52.23 ¾” 0.02 0.16 0.36 14” 5.39 22.16 67.03 1 ¼” 0.061 0.35 0.85 6” 1.27 2.92 13.52
1 ¼” 0.05 0.41 0.83 1” 0.04 0.18 0.51 14” 5.34 20.99 65.47 1” 0.04 0.19 0.55 16“ 6.79 27.77 84.31 1 ½” 0.095 0.54 1.33 8” 1.99 4.56 21.10
1 ½” 0.08 0.64 1.31 1 ¼” 0.07 0.28 0.86 16“ 6.79 27.77 84.33 1 ¼” 0.07 0.29 0.85 18“ 8.57 35.15 106.56 2” 0.151 0.85 2.11 10” 3.11 7.09 32.95
2” 0.13 1.00 2.08 1 ½” 0.11 0.43 1.35 18“ 8.57 35.15 106.54 1 ½” 0.11 0.45 1.32 The following items are supplied in coils 2 ½” 0.214 1.20 2.99 12” 4.93 11.23 52.30
2 ½” 0.19 1.42 3.00 2” 0.17 0.68 2.10 The following items are supplied in coils
2” 0.17 0.71 2.10 ½” 0.02 0.07 0.21 3” 0.308 1.73 4.30 14” 6.27 14.23 66.43
3” 0.27 2.03 4.28 2 ½” 0.24 0.95 2.95 ½” 0.01 0.07 0.15 2 ½” 0.24 1.00 2.97 ¾” 0.03 0.11 0.33 3 ½” 0.461 2.56 6.41 16“ 7.95 18.06 84.30
3 ½” 0.40 3.04 6.37 3” 0.34 1.37 4.20 ¾” 0.03 0.11 0.36 3” 0.34 1.44 4.30 1” 0.04 0.17 0.53 4” 0.595 3.31 8.27 18“ 10.07 22.82 106.69
4” 0.52 4.17 8.50 3 ½” 0.51 2.10 6.35 1” 0.04 0.17 0.50 3 ½” 0.51 2.13 6.39 6” 0.975 5.41 13.50 20“ 12.42 28.22 131.70
6” 0.85 6.54 13.62 4” 0.66 2.63 8.13 4” 0.66 2.76 8.27 8” 1.522 8.45 21.20 22“ 15.60 32.25 162.16
8” 1.33 10.06 21.14 6” 1.08 4.30 13.30 6” 1.08 4.51 13.52 10” 2.384 13.20 33.00 24“ 19.73 44.63 209.01
10” 2.08 15.74 33.07 8” 1.70 6.70 20.86 12” 3.782 20.90 52.50
8” 1.69 7.03 21.12
12” 3.34 20.71 48.53 10” 2.65 10.93 32.97 14” 4.801 26.50 66.60
14” 4.24 26.29 61.61
Chapter 2: Heat fusion
Aquatherm is a rigid piping system, similar to copper and steel.
Proper training helps ensure proper connections. Your own care Once you learn how to heat fuse, it
and attention to detail will yield impressive results, whereas will be up to you to provide the quality
sloppy workmanship will yield poor results. This chapter will labor that makes each installation a
2.1
cover the basic techniques for heat fusing pipe. work of art.
Butt fusion Outlet fusion
HEAT FUSION
Electrofusion Socket fusion
Safety Cutting the pipe : manual
There are procedures that should be These are recommended cutting

followed to work safely with Aquatherm methods, but you may use any
pipe. These include: method that doesn’t damage the
pipe. Cuts should be as square
2.2
2.3
Take proper precautions Wear safety glasses. as possible (never more than 5°
around electrical equipment off) and without jagged edges.
and follow all instructions. Check for longitudinal cracks on Use ratchet cutters with a sharp, pointed blade Don’t use ratchet cutters with a dull or flat
HEAT FUSION
HEAT FUSION
the pipe wall after each cut. for smaller sizes. The pointed blade prevents blade. Dull or flat blades can oval the pipe and
Wear heat-resistant the pipe from ovaling during the cut. cause it to crack.
Follow Aquatherm-specific gloves while handling
guidelines for proper welding irons.
material installation.
Wear OSHA-approved steel- Be careful when handling

toe shoes. hot irons.
Support the pipe while cutting to yield square Use tube cutters with a wheel taller than the Hand saws are a safe alternative, even in cold
Wear a properly rated hard
ends and prevent bouncing or snapping. pipe wall. Smaller wheels might not reach weather.
hat at all times. through the entire pipe wall.
Cutting the pipe: power Inspecting the cut
When using hand saws, use Upon receiving the pipe, and after cutting it,
plastic or metal-safe teeth. With inspect the ends for cracks or damage. Mark
and remove damaged sections, cutting a few
powered saws, blades that are intended inches past the damage. Fusing pipe that is
for hardwood will yield the best results. cracked will result in joints that leak.
2.4
2.5
Avoid jagged or angled cuts, as these
require additional prep to fuse. Don’t
use any tool or method that causes Remove any debris left from cutting the pipe. A good cut is smooth, square, and has no cracks
Use a circular hardwood blade (60-100T) with Band and reciprocating saws are safe to use. The This is common with powered saws. Often,
HEAT FUSION
HEAT FUSION
damage to the pipe. or stress marks inside or outside the pipe.
carbide teeth. This will produce a cut that needs thinner blades leave a smooth cut, but you will you can simply pull them out by hand. You
little to no clean-up. also have some shavings to clean up. may need to carefully cut them away with a
blade or reaming tool.
Remove standing dirt and oil using an

isopropyl alcohol-based cleaner (70% by
volume or greater). Dirty pipe will not form
proper beads during fusion. Be careful not to White stress marks and cracks indicate damage.
wipe off the printed label. Reassess any cutting tools that leave cracks. You
may need to squeeze the end of the pipe to see
A wide-toothed blade (24-40T) will produce a A fine-toothed blade (180T) will overheat the Don’t use power cutters if the pipe is 40 °F or small cracks.
jagged cut that is rough and not desirable for pipe, as will cutting too slowly. Make your cut as colder. Cold pipe can crack and split. Warm the
socket fusion. quickly and squarely as possible. pipe before cutting it.
How heat fusion works Socket fusion
PP-R plastic is made up of small As the pipe is heated, the When they cool, the chains close In socket fusion, a fitting is fused over During socket fusion, the inside layer of
chains of hydrogen and carbon. chains open and can be pressed again, forming a connection the outside of the pipe, leaving the the fitting is removed, as is the outside
When cold, the chains are closed together to form a connection. that is identical to the original inside open and unrestricted. layer of the pipe.
and won’t react or bind with Pressure causes the chains to material. This makes for a perfect
2.6
2.7
most common chemicals. cross the gap, eliminating any connection with no foreign
leak path. materials or leak path.
HEAT FUSION
HEAT FUSION
The fittings are sized to be too small to fit The heating process removes surface impurities
over the pipe unheated. This makes dry- and allows the pipe to be inserted into the fitting.
fitting impossible, so connections cannot be The inner wall of the fitting fuses to the outer
accidentally left unfused. Also, the difference in wall of the pipe, forming a bond that is stronger
diameter between the fitting and pipe creates than the pipe wall itself. The connection forms on
the required pressure for fusion. the entire fused surface.
Welding heads Welding irons
Socket fusions are made using welding heads. Welding heads The welding heads can be interchangeably
are specifically sized to match the pipe and fittings for a perfect attached to a welding iron, which provides
fit. Different welding head sets are required for each size of pipe. the heat for the fusions. Heat shield
Only use heads from an approved tool manufacturer. Neck brace
Threaded bolt
2.8
2.9
Power cord Heating plate
Taper for easier fusion

HEAT FUSION
HEAT FUSION
Size markings
Heat cycle indicator
(turns on while iron is heating, turns off
when iron reaches preset temperature)
Power indicator
Heads store inside each other to Heat sink
avoid scratches.
Welding heads
Before setting up the iron, clean the Stopline
Teflon-coated Never carry a
welding heads with rubbing alcohol or
a similar non-corrosive agent if they welding iron by its
are dirty. Pipe (female) side Fitting (male) side power cord!
1-inch iron 4-inch iron 2-inch iron
Welding iron safety : Do Welding iron safety: Don’t
Compared to open flames or

noxious glues, a welding iron
is fairly safe to use. However, the iron
is hot enough to burn on contact and
2.10
2.11
can remain hot for 30 minutes after it
is unplugged. Take care in its use and
handling. Never use water to cool an Wear heat-resistant gloves while handling the After use, return the iron to its case for Don’t leave the iron unattended. Passers-by Don’t drop the iron or hold it by its cord. Don’t touch the iron with bare hands unless
HEAT FUSION
HEAT FUSION
iron or head. iron. Few gloves are heat-proof, so know the storage. The case will protect the iron from may not know if the iron is hot and could The cord is not intended to hold weight and you are certain the iron has cooled. Assume
limitations of your gloves. impact and damage. accidentally burn themselves. dropping the irons may break them. irons and heads are hot until tested.
Post a sign near irons to warn that they are hot. Be aware of where other people are at all times Keep the cord away from the heat surfaces. Don’t store multiple irons in a single box. Irons Don’t let the iron touch flammable or meltable Don’t use the welding iron if the plate or heads
Irons can remain hot for up to 30 minutes after while fusing. Make sure they are clear before you Some cords are heat-resistant, but it’s best to can easily damage each other and should be surfaces. This is a fire hazard and can damage are dirty. Clean the plate with a soft wire
being turned off. move the hot iron around. keep everything away from the heating surface. stored separately. the plate or heads. wheel and the heads with a cloth.
Tool assembly Marking the pipe
The marking guide helps ensure

Plug in the iron early, as it will take 5-10 minutes to heat proper insertion depth. The
up. Make sure that you have sufficient power for the iron. green marking guide (½” - 4”) is
Low-gauge extension cords can be used to deliver power ideal for smaller pipes and the
2.12
2.13
over long distances if needed. Be aware of other devices blue marking guide is designed
drawing power if you are using a limited power source, for larger pipes (2 - 4”). Marking
as this can cause fluctuations in temperature. Use a
compatible power source for your iron. A surge protector 2 on several sides can help you
line up the connection.
HEAT FUSION
HEAT FUSION
will protect the iron from on-site power surges. Set welding heads loosely in place while the iron Under-inserting will weaken the Over-inserting will form a bead inside the
1 heats up. The plate will expand as it heats and leave

indentations if the heads are too tight.
connection by reducing the amount of
fusing surface.
fitting, causing a restriction in the pipe.
Check the temperature using a digital thermometer. Test on When using the blue marking If the cut is slightly angled (but not
the inside of the welding heads (at close range if using an guide, insert the fitting to the enough to prohibit fusion), make only
infrared thermometer). The temperature for socket fusion beginning of the mark, not the one mark on the long side. Use this mark
should always be around 500 °F (+/- 18 °F). If the iron middle. The bead may roll over to prevent over-insertion. Inserting to
constantly cycles on and off, or if the heating phase takes during fusion and cover the a mark on the shorter side will leave a
When the iron is hot, tighten the welding heads for

3 a long time, there may be a power supply issue. If the iron
does not reach 500 °F or exceeds it, the thermometer may
be faulty. Use a contact thermometer if you are unsure.
initial mark, so the tail shows
that the pipe was properly
marked upon inspection.
partial bead in the pipe. Inserting to the
long side will leave a slight internal gap,
but this will not affect the connection
full contact. Full contact will ensure uniform heating
of the welding head. 4 strength.
Socket fusion heating and cooling times Socket fusion heating and cooling times
Column A: Nominal diameter in Column E: Heating time for normal Column G: Welding time
inches weather This is the window of time between
Pipe Welding Heating Welding Cooling
This is the size of standard pipe that the Usually 40 - 100 °F. Reduce this time removing the PP-R from the welding
diameter depth time in sec. time time
Aquatherm pipe normally replaces. In slightly if working in extreme heat (100 iron and inserting the pipe completely
into the fitting before it cools. If you ND OD Actual OD above below
2.14
2.15
some cases, it may be possible to use a °F+). Never use less than 80% of the inch sec. min.
smaller diameter Aquatherm pipe based on heat time in these circumstances. exceed this time, you risk having the (inch) (mm) (inch) 40 °F 40 °F
flow rate. connection cool off, which could cause A B C D E F G H
When using SDR 11 non-faser pipe in an incomplete insertion. If you cannot
fully insert the pipe into the fitting in this ½” 20 0.79 ⁄ ” (14.5mm)
9 16 5 8 4 2
Column B: Metric OD in mm small sizes (½” & ¾”), reduce the
HEAT FUSION
HEAT FUSION
observed time by 1 second to avoid time, get another installer or a fusion ¾” 25 0.98 ⁄ ” (16mm)
58 7 11 4 2
This is the manufactured size of the pipe.
overheating and collapsing the pipe wall. machine to help you.
1” 32 1.26 ⁄ ” (18mm)
11 16 8 12 6 4
Insert the pipe into the fitting as quickly
Column C: Actual OD in inches as possible. Column H: Cooling time 1 ¼” 40 1.57 ⁄ ” (20.5mm)
13 16 12 18 6 4
This is the actual size of the pipe in
Pipe should not be pressurized or
inches. Use this for sizing clamps and 1 ½” 50 1.97 ⁄ ” (23.5mm)
15 16 18 27 6 4
Column F: Heating time for cold stressed during this time. You will need
penetrations.
to fully immobilize the pipe for up to ¼ of 2” 63 2.48 1 ⁄ ” (27.5mm)
1 16 24 36 8 6
weather this time while the connection sets.
Column D: Welding depth in inches For 40 °F or colder, use these times. 2 ½” 75 2.95 1 3 ⁄16” (30mm) 30 45 8 8
This is the depth the pipe should be You may also use these times if you are
having a hard time inserting the pipe 3” 90 3.54 1 5 ⁄16” (33mm) 40 60 8 8
inserted into the socket fitting. Use this
for planning the length of a cut and if no all the way into the fitting within the 110 4.33 50 75 10 8
3 ½” 1 7 ⁄16” (37mm)
marker is available. welding time (G) but be careful not to
overheat the pipe. 4” 125 4.92 1 ⁄ ” (40mm)
9 16 60 90 10 8
Socket fusion instructions (page 1 of 2) Socket fusion instructions (page 2 of 2)
In socket fusion, you are heating

the outside of the pipe and fusing
it to the inside of the fitting. This
creates a large joining surface
2.16
2.17
with no leak path, so proper
connections will never leak or
blow off.
1 2 5 6
Clean the pipe (if needed) and insert the pipe and Stop the pipe when you hit the mark (column D). Remove fitting and pipe from welding heads. Use Immediately* insert the pipe into the fitting. Push Do not touch the face of the pipe to the edge
HEAT FUSION
HEAT FUSION
fitting into the iron. Pushing both sides at the Over-insertion will cause a restriction in the pipe a clamped stand or an extra hand to hold the iron the pipe until the rings meet within the welding of the fitting. This flattens the beads and can
You must use the properly sized same time helps hold the iron steady. and lower performance. in place. time (column G). cause an improper connection.
welding heads for a proper fusion.
These heads are available through *You will normally have 5-10
Aquatherm and approved tool seconds to begin joining the
manufacturers. connection after you remove it
from the iron. This time will vary
with pipe size and conditions.
The heating times (column E
or F) begin when the pipe and 3 4 Once the rings meet, you will have 5 to 15
7 8 Waiting too long will let the pipe
fitting are fully inserted onto the Stop the fitting when you reach the stopline . Observe the heating time (column E or F). A
seconds to make adjustments to the alignment,
Align the pipe and observe cooling time (column surface cool and make fusion
welding head. Tapered heads will offer little resistance until bead will form and become shiny as the fusion H). You will need to provide full support for at impossible.
just before the stop. (see page 2.8) depending on the pipe size. Do not twist during
nears readiness. least 1/4 of the cooling time.
adjustment, alignment, or insertion.
Large diameter socket fusion Mechanically assisted fusions
Fusing pipe larger than 2” is • Don’t waste time. Once the For larger fittings, it is These, as well as the tools for
difficult without help. There pipe and fitting are removed generally faster and more socket fusion, are available
are several tips for assisted from the iron, push them accurate to use a fusion from Aquatherm’s approved
(two man) fusions: together immediately. machine. Fusion machines tool manufacturers. These
2.18
2.19
• Increase the heating time • PP-R doesn’t burn while act as an additional set of manufacturers supply properly
by up to 50% if needed. It heating, so you can put the hands during the fusion, sized tools for Aquatherm’s
can take longer to fuse the pipe and fitting back on the aligning the pipe and fitting piping systems and have
HEAT FUSION
HEAT FUSION
pipe and fitting by hand, so welding heads and start while providing a mechanical an established history of
overheating them makes the again if the connection is advantage. providing excellent support to
connection easier and prevents underheated. Pipes and fittings Aquatherm installers.
• If you can’t push the pipe or There are many different types
it from sticking midfusion. The may be safely reheated once fitting all the way onto the
ideal amount of overheating after the initial heating. of fusion machines. Some lighter A complete list of these
iron, allow the heat to melt the machines are easier to operate manufacturers can be found
depends on the ambient • Ensure that the pipe end is cut PP-R and then continue.
temperature, the size of the overhead, but may not offer starting on page page 2.36. Do
square and mark the pipe on • Remember that the fitting additional support or have a fixed not use fusion tools from an
pipe, and the strength of several sides. This will help you welding heads are tapered; heating iron. Heavier bench- Other fusion processes, such as unapproved manufacturer.
the installers. Use your best line up the fitting squarely. they will not offer much style machines offer increased butt welding and electrofusion,
judgment to prevent the pipe
resistance until the fitting is stability and accuracy, but are require special tools to
from becoming too soft.
almost entirely on. less mobile. complete them.
Inspection Avoiding improper fusions
The following indicators will allow you

to know that your connections have Both rings of PP-R should be
been performed properly. However, visible and joined all the way
around.
you will still need to do a pressure test
2.20
2.21
The edge of the mark
to confirm the integrity of the joint. should be visible to
indicate that the proper
Information on the pressure test can insertion depth was
reached.
HEAT FUSION
HEAT FUSION
be found on page 4.31.
Certain fusion assistance machines Don’t twist the fitting Prevent water contact Use enough heat/Don’t wait to fuse
have integrated depth controls. These Never twist a fusion connection. Twisting Like oil, PP-R is hydrophobic and repels Insufficient heat will cause the chains to
controls should be used for their breaks the chains while they cool and will water. Any water contact on the fusion close early, preventing a full connection. This
accuracy, but it is best to mark the lead to a weakened connection. You may area will cause the chains to close and can be caused by the iron being too cold, an
pipe for inspection. Some machines make some minor adjustments early in the prevent a proper fusion. Make sure the pipe extended delay after removing from the iron,
cooling process, but avoid turning the fitting is dry before beginning the fusion and that or insufficient heat time. Make sure that you
will not bring rings completely more than 2 degrees. moisture cannot reach the fusion surfaces. follow all the instructions while fusing and
together, but this is acceptable as that your iron has sufficient power.
long as the gap is consistent and the
The pipe should be square with the fitting. If intentionally angled,
pipe reaches the inside of the fitting. the angle per connection should not exceed 3 degrees.
Troubleshooting bad connections Ovality in machine-assisted fusions
Pipe won’t fully insert into fitting
The welding heads are designed To prevent the fitting from
to operate under very specific slipping, use a backstop, or
Welding heads are too cold Extended delay after Insufficient heating time Fusion machine depth control is tolerances, and compressing support the fitting with your
removing from iron set to the wrong size the end of the fitting can hand during insertion. Giving
2.22
2.23
Make sure temp > 475 °F Increase heating prevent proper contact, and the iron time to heat the pipe
Fuse immediately after heat time time by up to 50% Double-check machine settings thus proper fusion. This is and fitting can also reduce the
referred to as ovaling. chances of slippage.
Marks no longer visible/internal bead Fitting does not look square
HEAT FUSION
HEAT FUSION
Ovaling occurs when the To determine if your machine
clamps of a fusion machine and technique are causing
Over-insertion Insufficient support during cooling Fitting was overheated
exert too much force on the ovaling, inspect the finished
Verify marking depth and stop just before Hold pipe squarely for at least 25% of Reduce heating time slightly mouth of a fitting and bend it connection for two complete
the marks the cooling time out of round. To prevent this beads all the way around. If the
issue, avoid over-tightening the beads are present on two sides,
The pipe sheets back instead of forming a bead No ring visible clamp that holds the front of the and absent on two sides, this
fitting. The clamps should be may indicate that the fitting was
Pipe too dirty for fusion snug, but not so tight that they ovaled during fusion. Ovaled
Only one side heated
distort the fitting. fittings are not at full strength
Clean pipe before fusing Make sure both sides are heated and may leak.
Fusion outlets Fusion outlet instructions (page 1 of 3)
Using a technique similar to socket fusion, branches
and outlets can be easily added to the walls of the When drilling out a fusion outlet Aquatherm’s boring tools are properly Getting a properly-sized hole is
hole, there are two important sized and designed to remove the crititcal. An oversized hole will result
pipe. This technique helps save time and money while shavings. The smaller bores use a in an incomplete fusion and cause
providing flexibility for expansion following installation. things to remember:
hand-held drill with a 1/2” chuck. leaks. An undersized hole will make
2.24
2.25
Fusion outlet 1. Make sure to remove the material from Bores over 2 inches require a drill it difficult to insert the welding head
Main size the hole so it will not clog the main line. press with a Morse Taper shank. You and can create a larger internal bead,
Guide bit Branch size may also use hole saws or bores reducing flow performance.
Drilling bore 2. The hole needs to be 1-3 mm (1⁄24” - 1⁄8”)
smaller than the OD of the branch line.
provided by other manufacturers, as
HEAT FUSION
HEAT FUSION
long as they can cut a smooth, even,
and properly-sized hole.
Curvature matches
pipe wall
2
1 2
Pipe-wall insert Fitting-side Set up the welding iron following normal socket Don’t forget to tighten the welding heads after The welding head should not stick out past the
Pipe-side welding head procedures, found on page page 2.16. the plate is hot and check the temperature iron. This will lead to uneven heat transfer and
welding head before starting. can prevent proper fusion.
Fusion outlet instructions (page 2 of 3) Fusion outlet instructions (page 3 of 3)
Pro tip:
Make sure the welding head you are
using matches the pipe and fitting. In an
2.26
2.27
emergency, it is possible to use a head
Mark the pipe where you want the outlet. Once

3 Use the guide bit to start the hole to ensure
4 The bore should pull the shavings out so that
5 with the wrong curvature, but you must
have the right branch size. Tilting the
welding head slightly from side to side can Look for a bead to form around the fitting. This
8 Ensure the welding head makes a full impression
9
HEAT FUSION
HEAT FUSION
you begin drilling you cannot move the hole, so accurate positioning. Drill at a right angle to the they don’t fall into the pipe. Clear away any help ensure contact at all points. does not take much pressure. Too much pressure on the pipe. Check and adjust the head until the
be sure of your placement. pipe. Quickly drill out the hole. excess debris. Flush any leftover shavings. will cause internal restriction. ring is complete.
Pro tip:
For branches smaller than 2”, don’t use
the fitting to push the iron into the pipe.
This overheats the fitting. Instead, push
6
Insert the welding head into the hole and fitting Rather than putting excessive force on the neck
7
the welding head into the pipe, and then
set the fitting on the iron. For larger sizes,
you may use the fitting to push the welding
If the welding head has not made a full
10
Set the fitting in the hole and hold in place.
11
Level and square the fitting as it cools. Like the
head into the pipe.
into the head. Push down gently to keep the iron of the iron, you may use a dowel or a board to impression, do not set the fusion outlet into the Use only enough pressure to maintain contact socket fittings, you only have a few seconds
in contact with the PP-R. help push the iron into the pipe. hole. It will not form a proper fusion. between the heated surfaces. before the fitting sets.
Electrofusion Electrofusion instructions (page 1 of 3)
Pro tip:
Multiple passes may be necessary.
Peeling tools are available from approved
2.28
2.29
manufacturers. Make sure that you use
1 2 metric or metric-compatible peelers.

Avoid over-peeling the pipe. You can
always make one more pass, but you
Electrofusion is another technique is particularly useful for situations be integrated with traditional Make sure the pipe is cut exactly square to Use a peeling tool or paint scraper to remove the
HEAT FUSION
HEAT FUSION
cannot unpeel the pipe.
for fusing a socket onto a pipe. where there is not enough socket fusion and butt welding if ensure proper contact. Chamfer or ream the pipe outside of the pipe. Peel back at least half the
to remove any rough edges. length of the coupling being fused.
Rather than using contact heat, space or mobility to perform necessary.
electrofusion uses electrical a traditional socket fusion.
Electrofusion machines are
resistance heat from a copper However, electrofusion has more
available from approved tool
coil inside the fitting. The fitting steps and is more difficult to
manufacturers.
is attached to an electrofusion visually inspect. Therefore, the
machine using a pair of leads, choice to use electrofusion over It is best to plug in the machine
and a set voltage is applied to
the coil for a set time. The time
traditional socket fusion depends
on the physical restrictions of
and familiarize yourself with the
controls and interface before
Repeat with the other pipe. If you are using the
3 4
Clean the outside of the pipes with an isopropyl
5
Don’t open the fitting bag until you are ready to
and voltage can be found on the the installation and the installer’s beginning the electrofusion fitting as a slip coupling, peel one side back the alcohol wipe. Avoid touching those surfaces after fuse the connection. This helps keep dirt off of
label of the fitting. Electrofusion preferences. Electrofusions may process. entire length of the coupling. cleaning them. the fusion surface.
Electrofusion instructions (page 2 of 3) Electrofusion instructions (page 3 of 3)
2.30
2.31
Mark the pipe at half the depth of the fitting.
6 Do not touch the peeled pipe or inside the fitting.
7
Insert pipe into the fitting. The pipes should fit
9
Scan the tag on the fitting. Rescan if needed. On
10
Verify that the display matches the sticker. If the
11
Follow the directions on the machine. Verify
HEAT FUSION
HEAT FUSION
The two pipe sections will meet in the middle Any oils, dirt, dust, or other contaminants may snugly, but without any force. You should be able smaller couplings, the tag can be removed and label and the machine don’t match, rescan the your prep work and then begin heating upon
of the fitting. ruin the connection. pull them apart. laid flat for better reading. fitting label or input manually. confirmation.
Pro tip: The black indicator on the top of

Make sure both sides of the pipe
If the fitting cannot be pushed into the the fitting will drop in after the
and fitting are fully supported
coupling without a significant amount of connection is done heating, as
for the entire fusion process. The fitting
force, make another pass with the peeling long as the electrical leads are
will become extremely soft after it is
8 12
tool. Remember to wipe the welding pointing up. You will only be able
surface with rubbing alcohol, as the peeler heated and will lose its shape if subject
may be dirty. to verify the fusion during the
Attach the leads to the fitting. Most leads slide Make sure there is no gap in the middle. You to any stresses. Remove leads when heating is finished. The pressure test. All electrofusion
in with little resistance, so don’t force them. Be won’t be able to see the gap, so use your pipe and fitting will get hotter before cooling
careful not to bend them. depth marks. down again. sockets are rated to 300 psi.
Butt welding Explanation of butt welding
The basic steps to successful butt welding are:
Butt welding is the process of facing, adjusting, heating and fusing.
using heat and pressure to join Compressor
the faces of two pieces of pipe Unit controls Facing: Facing is Adjusting: Building Heating: Commonly Fusing: Using the
together. This eliminates the need (vary by manufacturer)
performed to square the adjustment bead referred to as the prescribed pressure,
Hydraulic cylinders
2.32
2.33
for a socket-type fitting while the ends of the against the iron ensures “heat soak”, this step push the two pipe faces
maintaining the full strength pipe. In doing so, full contact of the pipe fills the PP-R with together and let them
of the connection. As with any it also produces a face and also sets the heat, energizing the cool under pressure.
fusion, the primary elements are contaminant-free size of the resulting molecules for fusion.
HEAT FUSION
HEAT FUSION
Carriage
heat and pressure. Therefore, a surface on which the fusion bead.
butt welding machine is designed fusion will occur.
to provide both, as well as
support the pipe and prepare the
pipe face for fusion.
Clamps Inserts for clamps
(not shown) Hydraulic hoses
Aquatherm supports butt welding on sizes 6”

and larger on all SDRs as well as 4” on SDR
17.6 and 11. Installers may decide to butt weld smaller
sizes at their own risk.
Butt welding pressures Butt welding phases
Each phase of butt welding Interfacial pressure: Interfacial Full Pressure: The drag pressure Each phase in the butt welding Adjustment Phase: This phase Welding Phase: After removing
requires a specific pressure. pressure is the force needed and welding pressure are added process takes the basic steps pushes the exposed pipe the iron, the two heat-soaked
The four pressures you will at the point of fusion to create together to create full pressure, of facing, adjusting, heating surface out of the connection by pipe surfaces are brought
need to know are drag pressure, a weld. Aquatherm PP-R butt which will be used twice and fusing and applies the pressing the pipe face against together under full pressure. The
2.34
2.35
interfacial pressure, welding welding always requires 14.5 during the fusion process. Full previously calculated pressures the heating iron at full pressure. pipes must be brought together
pressure, and full pressure. pounds of pressure per square pressure should be set on the to form a completed weld. Each This phase is complete when the within the transition time and
Calculate these pressures before inch of surface area being fused. machine during your post-facing phase has a required time or displaced material forms a visible brought to full pressure within
visual cue to let you know when bead (see page page 2.42). the build-up time.
HEAT FUSION
HEAT FUSION
starting your fusion. alignment inspection.
Welding Pressure: Welding that phase is done.
Heating Phase: During heating, Cooling Phase: As the fusion
Drag Pressure: Drag pressure pressure is the force needed
Facing Phase: The pressure for the pipe remains in contact occurs, keep the joint under
is the minimum hydraulic by the machine to achieve
facing will vary based on the with the heating iron under low full pressure for a minimum of
pressure needed to overcome proper interfacial pressure. This
pipe size and condition of the pressure. This allows the heat half of the cooling time. After
the carriage’s inertia. You identify varies by machine cylinder size
blades. Starting at drag pressure, to soak into the pipe without this, the joint may be removed
the drag pressure by slowly and pipe dimension. Welding
gradually increase the pressure displacing the PP-R material. from the jaws but must remain
increasing the pressure control pressures are available from the
between the pipe and the Heating times (and all other supported for the remainder of
until the carriage begins to manufacturer and are included
facing machine until two 360o reference times) can be found the cooling time. Unsupported
move. Drag pressure varies in this manual as well. Welding
continuous ribbons are removed on pages 2.45 and 2.46. pipe must remain under
by machine design, machine pressure is measured by the
from the pipe on both sides. pressure for the full cooldown.
orientation, and pipe size. machine’s pressure gauge.
McElroy adjustment and welding pressures McElroy adjustment and welding pressures
Pitbull 26 28 412 & 618 824 & 1236 412 & 618 824 & 1236
Dimension Acrobat 160 DM 250 EP Dimension
SDR 15” Lever Low Force Low Force Low Force SDR Low Force Low Force
ND (OD mm) ND (OD mm)
Adjustment pressure (psi) Adjustment pressure (psi)
918-836-8611
fusion@mcelroy.com 4” (125 x 7.1) 17.6 5 ft-lbs 34 66 - - - 14” (355 x 20.1) 17.6 157 52
www.mcelroy.com
2.36
2.37
4” (125 x 11.4) 11 8 ft-lbs 53 101 - - -
4” (125 x 14.0) 9 14” (355 x 32.2) 11 242 81
Installers should always use 6” (160 x 9.1) 17.6 9 ft-lbs 60 108 60 32 - 14” (355 x 39.7) 9
the operator’s manual included 6” (160 x 14.6) 11 14 ft-lbs 93 167 93 49 -
with the butt welding machine, 14” (355 x 48.0) 7.4 343 114
HEAT FUSION
HEAT FUSION
6” (160 x 17.9) 9
or the manufacturer’s online 6” (160 x 21.9) 7.4 20 ft-lbs 132 236 132 70 - 16” (400 x 22.7) 17.6 199 66
information, to calculate the 8” (200 x 11.4) 17.6 - 94 - 94 50 17
adjustment pressure. This table 16” (400 x 36.3) 11 308 102
8” (200 x 18.2) 11 - 145 - 145 77 26
is based on the information
8” (200 x 22.4) 9 18” (450 x 25.5) 17.6 252 84
available to Aquatherm at the
time of this manual’s printing 8” (200 x 27.4) 7.4 - 207 - 207 109 36
18” (450 x 40.9) 11 389 129
and may not be complete, 10” (250 x 14.2) 17.6 - - - 142 78 26
accurate, or current. If there is a 10” (250 x 22.7) 11 - - - 218 120 40 20” (500 x 28.4) 17.6 - 104
discrepancy between this table 10” (250 x 27.9) 9
22” (560 x 31.7) 17.6 - 130
and any information provided by 10” (250 x 34.2) 7.4 - - - 309 170 56
the tool manufacturer, the tool 12” (315 x 17.9) 17.6 - - - - 124 41 24” (630 x 35.7) 17.6 - 164
manufacturer’s information shall 12” (315 x 28.6) 11 - - - - 191 63
be considered correct. 12” (315 x 35.2) 9
12” (315 x 43.1) 7.4 - - - - 270 90
Ritmo adjustment and welding pressure Ritmo adjustment and welding pressure
Gamma Delta Dragon Delta Dragon Delta Dragon Delta Dragon Dimension Delta Dragon 355B Delta Dragon 500 Delta Dragon 630
Dimension 160 160 250B 315B 355B SDR
SDR ND (OD mm) Adjustment pressure (psi)
ND (OD mm)
[N] Adjustment pressure (psi)
14” (355 x 20.1) 17.6 218 - 73
4” (125 x 7.1) 17.6 263 - - -
863-679-8655 4” (125 x 11.4) 11 407 - - -
14” (355 x 32.2) 11 334 - 102
2.38
2.39
info@ritmoamerica.com
4” (125 x 14.0) 9 14” (355 x 39.7) 9
www.ritmoamerica.com
6” (160 x 9.1) 17.6 431 247 116 102 44 14” (355 x 48.0) 7.4 479 - 160
6” (160 x 14.6) 11 667 392 189 160 73
6” (160 x 17.9) 9 16” (400 x 22.7) 17.6 - 174 87
HEAT FUSION
HEAT FUSION
Installers should always use the 6” (160 x 21.9) 7.4 950 551 276 232 102 16” (400 x 36.3) 11 - 276 131
operator’s manual included with 8” (200 x 11.4) 17.6 - - 189 160 73
the butt welding machine, or the 18” (450 x 25.5) 17.6 - 218 116
8” (200 x 18.2) 11 - - 290 261 102
manufacturer’s online information, to 18” (450 x 40.9) 11 - 334 174
8” (200 x 22.4) 9
calculate the adjustment pressure.
8” (200 x 27.4) 7.4 - - 421 363 160 20” (500 x 28.4) 17.6 - 276 145
This table is based on the information
available to Aquatherm at the time of 10” (250 x 14.2) 17.6 - - 305 261 102 22” (560 x 31.7) 17.6 - - 174
this manual’s printing and may not be 10” (250 x 22.7) 11 - - 464 406 160
10” (250 x 27.9) 9 24” (630 x 35.7) 17.6 - - 218
complete, accurate, or current. If there
is a discrepancy between this table and 10” (250 x 34.2) 7.4 - - 653 566 232
any information provided by the tool 12” (315 x 17.9) 17.6 - - - 406 174
manufacturer, the tool manufacturer’s 12” (315 x 28.6) 11 - - - 638 261
information shall be considered correct. 12” (315 x 35.2) 9
12” (315 x 43.1) 7.4 - - - 914 377
Widos adjustment and welding pressures Widos adjustment and welding pressures
WI WI WI WI 5100 WI Dimension WI 5100 & 5500 WI 6100
Dimension Maxiplast SDR
SDR 4400 4600 4900 & 5500 6100 ND (OD mm)
ND (OD mm) Adjustment pressure (bar)
lbs Adjustment pressure (bar)
14” (355 x 20.1) 17.6 15 13
4” (125 x 7.1) 17.6 58 11 6 - - -
14” (355 x 32.2) 11 24 19
2.40
2.41
4” (125 x 11.4) 11 89 17 8 - - -
4” (125 x 14.0) 9 14” (355 x 39.7) 9
6” (160 x 9.1) 17.6 94 18 9 8 - - 14” (355 x 48.0) 7.4 37 *
678-376-4379 6” (160 x 14.6) 11 145 27 13 12 - -
info@widoswelding.com 6” (160 x 17.9) 9 16” (400 x 22.7) 17.6 20 16
HEAT FUSION
HEAT FUSION
www.widoswelding.com 6” (160 x 21.9) 7.4 207 39 19 17 - - 16” (400 x 36.3) 11 30 24
8” (200 x 11.4) 17.6 - - 13 12 5 - 18” (450 x 25.5) 17.6 25 20
Installers should always use the operator’s 8” (200 x 18.2) 11 - - 20 18 8 -
manual included with the butt welding machine, 8” (200 x 22.4) 9 18” (450 x 40.9) 11 38 31
or the manufacturer’s online information,
8” (200 x 27.4) 7.4 - - 29 26 11 - 20” (500 x 28.4) 17.6 30 25
to calculate the adjustment pressure. This
10” (250 x 14.2) 17.6 - - 21 18 8 - 22” (560 x 31.7) 17.6 - 31
table is based on the information available
to Aquatherm at the time of this manual’s 10” (250 x 22.7) 11 - - 32 28 12 -
10” (250 x 27.9) 9 24” (630 x 35.7) 17.6 - 39
printing and may not be complete, accurate,
or current. If there is a discrepancy between 10” (250 x 34.2) 7.4 - - 45 40 17 -
this table and any information provided by 12” (315 x 17.9) 17.6 - - - 29 12 10 * Contact manufacturer for pressure
the tool manufacturer, the tool manufacturer’s 12” (315 x 28.6) 11 - - - 44 19 15
information shall be considered correct. 12” (315 x 35.2) 9
12” (315 x 43.1) 7.4 - - - 62 26 *
Adjustment bead height (4” - 24”) Butt welding heating and cooling times (4” - 12”)
Dimension Heating Welding (Fusion) Cooling
Size SDR 7.4 SDR 11 SDR 17.6 The height of the bead is important during the
ND (OD x Wall
4” (125 mm) - 0.04” (1.0 mm) 0.04” (1.0 mm)
fusion, as too small of a bead may lead to an thickness in mm)
SDR Heating time Max. transition time Time of pressure build-up Cooling time
improper connection, whereas too large of a 4” (125 x 11.4) 17.6 2 min. 56 sec 6 sec. 7 sec. 12 min.
6” (160 mm) 0.06” (1.5 mm) 0.04” (1.0 mm) 0.04” (1.0 mm)
bead can create a flow restriction and may also
2.42
2.43
4” (125 x 7.1) 11 3 min. 57 sec 7 sec. 11 sec. 19 min.
8” (200 mm) 0.08” (2.0 mm) 0.04” (1.0 mm) 0.04” (1.0 mm) indicate a problem with fusion pressure. You 4” (125 x 7.1) 9
10” (250 mm) 0.08” (2.0 mm) 0.06” (1.5 mm) 0.04” (1.0 mm) will need to carefully watch the bead during 6” (160 x 9.1) 17.6 3 min. 24 sec. 6 sec. 9 sec. 15 min.
12” (315 mm) 0.1” (2.5 mm) 0.08” (2.0 mm) 0.04” (1.0 mm) the adjustment phase and reduce the pressure 6” (160 x 14.6) 11 4 min. 37 sec. 8 sec. 13 sec. 24 min.
6” (160 x 17.9) 9
HEAT FUSION
HEAT FUSION
14” (355 mm) 0.1” (2.5 mm) 0.08” (2.0 mm) 0.06” (1.5 mm) once the bead reaches its required height.
6” (160 x 21.9) 7.4 6 min. 1 sec. 10 sec. 19 sec. 34 min.
16” (400 mm) - 0.08” (2.0 mm) 0.06” (1.5 mm) 8” (200 x 11.4) 17.6 3 min. 57 sec. 7 sec. 11 sec. 19 min.
Remember that 1 mm is only 1/25th of an 8” (200 x 18.2) 11 5 min. 20 sec. 9 sec. 16 sec. 29 min.
18” (450 mm) - 0.1” (2.5 mm) 0.06” (1.5 mm)
inch and is difficult to measure. Generally, 8” (200 x 22.4) 9
20” (500 mm) - - 0.08” (2.0 mm)
when you can first see the bead, that is 8” (200 x 27.4) 7.4 6 min. 52 sec. 11 sec. 23 sec. 42 min.
22” (560 mm) - - 0.08” (2.0 mm) when it is at the 1 mm height. If your final 10” (250 x 14.2) 17.6 4 min. 32 sec. 8 sec. 13 sec. 23 min.
24” (630 mm) - - 0.08” (2.0 mm) bead (when the connection is all finished) 10” (250 x 22.7) 11 6 min. 8 sec. 10 sec. 20 sec. 35 min.
looks too large, try reducing the size of 10” (250 x 27.9) 9
Bead height reference 10” (250 x 34.2) 7.4 7 min. 46 sec. 13 sec. 30 sec. 52 min.
your adjustment bead slightly.
12” (315 x 28.6) 11 7 min. 12 sec. 24 sec. 44 min.
1 mm 1.5 mm 2 mm 2.5 mm 12” (315 x 35.2) 9
Butt welding heating and cooling times (14” - 24”) Butt welding instructions: 1. Setup
Dimension Heating Welding (Fusion) Cooling Maintenance should only be

ND (OD x Wall
performed by trained persons,
SDR Heating time Max. transition time Time of pressure build-up Cooling time the manufacturer or authorized dealer.
thickness in mm)
Only refill the hydraulic oil according
2.44
2.45
14” (355 x 32.2) 11 7 min. 28 sec. 13 sec. 28 sec. 48 min. to the manufacturer’s specifications.
14” (355 x 39.7)
14” (355 x 48.0)
9
7.4 9 min. 25 sec. 17 sec. 42 sec. 70 min. Set up and inspect the machine. Follow all
1.1 Make sure that your power supply is
fully compatible with the machine you Check and tighten seals if needed. Release
1.2
HEAT FUSION
HEAT FUSION
16” (400 x 22.7) 17.6 6 min. 7 sec. 10 sec. 20 sec. 35 min. of the manufacturer’s directions. Perform any are using. any air bubbles by bringing the machine to full
16” (400 x 36.3) 11 8 min. 14 sec. 31 sec. 54 min. maintenance if needed. pressure and slowly releasing it.
18” (450 x 40.9) 11 8 min. 28 sec. 15 sec. 36 sec. 59 min.
20” (500 x 28.4) 17.6 6 min. 59 sec. 12 sec 24 sec 43 min.
1.3
Inspect welding iron and turn it on. Make sure
1.4
Set in the correct metric inserts, if needed. The
1.5
Cut the pipe at least 1/2” longer than your
that the iron is clean and set to 410 °F (210 °C) manufacturer will know which clamps and inserts intended final length, or longer if your cut is not
+/- 18 °F. are compatible. perfectly square.
Butt welding instructions: 2. Alignment Butt welding instructions: 3. Facing
2.46
2.47
2.1
Set pipe and/or fitting into the clamps. If
2.2
Leave a lip of 1/2” - 1” (more if cut is uneven). A
2.3
Reposition clamps to accommodate fittings if
3.1
Open the carriage set and lock in facing tool. Turn
3.2
Close pipes on facer. Increase the pressure until Drive the carriage forward whenever the
3.3
HEAT FUSION
HEAT FUSION
possible, use at least 2 clamps for each pipe thumb’s width is normally a good measurement. needed. Some clamps slide and others can be on facer and let it reach full speed. Never turn on the facer begins shaving off ribbons of PP-R. pressure drops or the facer stops facing. Replace
length. Adjust configuration as needed. Leave enough room for the facer. removed entirely. the facer if it is pinched between pipes. Don’t use excessive pressure. the blades if they are too dull.
Drag Pressure: Find the drag pressure by

increasing the pressure control until the carriage Pro tip:
beings to move. Drag pressure varies by machine If one side begins facing before the other
design and orientation, and pipe size. one, try opening and closing the jaws again
Welding Pressure: Look up the welding to give the facer a “bump.” You can also try
inserting wood blocks between the clamps
2.4
Tighten clamps and bring the pipe ends together.
2.5
Check alignment of pipe by running your finger
pressure in the operating manual (or in this book
if no manual is available). Welding pressure
varies by OD and SDR.
and the planing tool in order to force the facer
to shave the opposite side. Facing to a pre-
3.4
Proper facing will produce 360o, full-width strips
3.5
Switch off and remove facer. Don’t turn off the
marked point can ensure proper length of the
Make sure all hands are clear of the carriage or the end of a pen across the gap. If one side is Full Pressure: Add the drag and welding finished connection. on both sides. At this point, open pipes. Adjust facer while the carriage is still closed, as this can
while it is in motion. higher than the other, tighten it down. pressures to get the full pressure. the facer if one side is ready before the other. leave nicks on the pipe face.
Butt welding instructions: 4. Adjustment Butt welding instructions: 5. Welding
The heating phase requires as

Pro tip: little pressure as possible. Some
machines lock in place only requiring
Make sure that the two pieces being the drag pressure. Others require a
2.48
2.49
connected are still approximately 1/4” longer
than your desired final length. You will lose slight positive pressure to keep them in
4.1
Close carriage and check for gaps. Reface or
roughly 1/8” off each side of the connection
during the adjustment and welding phases.
4.2
Set your max pressure level (welding + drag).
5.1
Adjustment bead complete, drop the system to
place, but never more than drag + 10%
welding pressure. Excessive pressure
5.2
Observe the entire heating time (use a timer). Too
Measure and track your average loss to
HEAT FUSION
HEAT FUSION
realign if needed. Wipe down the pipe face with Controls vary by manufacturer. Don’t change this drag pressure. If necessary to maintain contact, during the heating phase can create a little time will create an improper connection. Do
increase accuracy.
rubbing alcohol. pressure after setting it. add up to 10% of welding pressure. restriction in the pipe. not exceed the heating time.
4.3
Open carriage and insert the heating iron. Make
4.4
Close the pipes onto the heating iron under
4.5
Build your adjustment bead to the specified
5.3
Open carriage and remove iron. Make sure you
5.4
Bring pipes together within the transition time
sure your heating iron is at or near 410 °F (210 °C). full pressure to initiate construction of the height. The guide is on page 2.42. Do not let have a safe place to set it down immediately if and ensure the machine achieves full pressure
adjustment bead. your bead get larger than required. you can’t hold it in one hand. within the pressure build-up time.
Butt welding instructions: 6. Cooling Reducing cooling times
The cooling time can vary with Butt welded connections need to cool under reduced from 24 minutes to 12 minutes if the
the size and support of the pipe pressure to ensure a proper connection. Cooling joint is not subjected to any undue stress for the
being fused. Short sections and long times for butt-welded connections can be reduced remaining 12 minutes. The following images show
sections that are properly supported by up to 50% if the joint is properly supported for proper and improper support for the pipe.
2.50
2.51
can use a reduced cooling time. Long the remainder of the cooling time. For example,
6.1
Observe the full cooling time. Do not try and The final bead should look like one solid piece. A
sections that are not supported must
use the full time. A visual guide can be
the cooling time for 6” SDR 11 pipe can be
Incorrect
HEAT FUSION
HEAT FUSION
shorten the cooling time by pouring water on bad PP-R fusion will have a split bead with two found on the next page. Failure to support the pipe near the connection can result in
the connection. distinct sides. undue stress on the bottom of the joint.
Correct Incorrect
Whether on hangers or blocks, the pipe should be

supported on either side of the connection, as well as Failure to support the pipe further away from the connection
further down the line to prevent deflection. can result in undue stress at the top of the joint.
6.2
Release pressure and undo clamps. Don’t loosen Remove the connection from the machine.
6.3 Incorrect
Correct
the clamps until pressure has been fully released. Remember to keep the pipe supported if you have
The pipe can also lay flat on the ground or a similar level Failure to support the pipe on both sides of the connection
reduced the cooling time.
surface. can cause undue stress across the joint.
Fusing dissimilar SDRs Internal alignment
In order to fuse pipes with highest SDR (thinnest wall) Due to gravity and the physics This difference is not enough to on the side, as the label is always in
different SDRs, you will need to material that is fused into the of extrusion, larger pipes tend cause problems with the flow the same relative position to the top
make the following modifications section. to be slightly thicker on the calculations or to require a change in of the pipe. Aligning the labels will
to your fusion process: bottom than they are on the top. fusion pressures. The only concern help eliminate internal misalignment.
2.52
2.53
However, the top will always be is simply an aesthetic one, where If aligning the labels does not fix this
As a general rule, you should
at least as thick as the production the internal bead will be misshapen issue, use your best judgment when
1. Use the heat time from the avoid butt fusing different SDRs SDR, so there is no concern over if a thinner top is fused to a thicker aligning the pipe. The issue does
lower SDR (thicker wall) unless it is necessary. pressure and temperature ratings. bottom. To avoid this, line up the not affect the outer wall of the pipe,
HEAT FUSION
HEAT FUSION
pipe or fitting. tops and bottoms of the pipe before which will always be consistent.
2. Use the pressure from the You should never attempt to butt fusing them. The easiest way to align
higher SDR (thinner wall) fuse pipes with different ODs. the pipes is using the printed label
pipe or fitting.
3. Use the average bead
height of the two SDRs. 1.5”
The external bead should appear

0.25”
normal. The internal bead will
appear lop-sided, but this is not 1.75”
an issue. The system will have
the pressure rating of the
Repairs
For small holes in the pipe, such

as holes from nails or screws,
you can use the repair pin
shown here. For larger holes,
2.54
install and cap an outlet or

remove the pipe and fuse in a
new section.
1 2
Attach the repair head to a welding iron. Heads If the hole is too small, carefully drill it out. Use
HEAT FUSION
are available in 5/16” and 7/16” sizes. Use a size a 1/4” bit for the 5/16” head, and a 3/8” bit for
that is larger than the hole. the 7/16” head.
3 4 5
Insert the repair head into the iron and insert the Remove the pin from the head and the welding Once the pin has set, you may use cutters to
repair pin into the repair head. Heat for 5 seconds. head from the pipe. Insert the pin into the pipe remove the rest of the pin. Pressure test the
wall. Do not overinsert the pin. system to ensure a proper repair.
Chapter 3: Productivity
Heat fusion is a fast and
consistent way to join pipe, but
overall productivity depends on
the build strategy being used.
Having the right crew and tooling

mix will greatly increase the
speed of your installation. Proper
prefabrication and field techniques
3.1
can help you work even faster.
This chapter will help you apply
the fusion techniques you’ve
PRODUCTIVITY
learned in faster, more productive
ways.
Getting started Crew mix
There are several unique As you continue installing An installer can become
features of Aquatherm pipe that Aquatherm pipe, you will proficient at heat fusion in
can help you accelerate your find a balance of prefab and a very short period of time,
install times. in-place installation that which can help make your less
works for you. experienced installers more
• Fusion outlets allow you to add productive.
branches after installing mains Looking for ways to help
• Lightweight material is easier streamline the installation However, more advanced
to carry in large amounts
3.2
3.3
For each part of the installation, process can lead to significant concepts like build strategy
• Reduced contraction and
expansion makes layout easier you should decide what savings in the overall and layout are best managed
• Fused joints won’t crack during sections to build in a shop or installation time. by more experienced
Primary: Support:
PRODUCTIVITY
PRODUCTIVITY
transport on a workbench (prefab) and installers. Therefore, a typical Focuses on the order of assembly, Focuses on handling, measurement
• Flexible pipe can be fed into which sections need to be built crew installing Aquatherm complicated fusion work, and cutting, tool movement and set-
tight spaces in place. Prefabrication gives will have a few masters or connection alignment, and directing up, and simple fusion work.
• Fusion machines allow a single you access to a wider range of journeymen (primary) assisted the support crew.
installer to work on multiple fusion tools and makes it easier by multiple apprentices and The support focuses on
connections at one time to work with multiple tools. In laborers (support). The primary uses experience and maximizing the productivity of the
general, prefabricated joints are planning to make the installation fast primary installer(s).
also faster and more accurate. and efficient.
Tooling Hand irons
1” iron
pressure requirements that are Contact information for these ½”-2” socket fusion:
suitable for Aquatherm’s PP-R manufacturers can be found You will need ½”-2” iron to do socket fusion
pipe. Aquatherm’s core focus is starting on page 2.36. work on 2” pipe and smaller. When working
on pipe and fittings, not tools, so in the air, it’s easiest to use the smallest
Aquatherm works with several Each manufacturer has its own suitable welding iron. 1” irons are also
tool manufacturers to promote approach when it comes to available for fusing small pipes in confined 2” iron
the development and availability tool function and design. We spaces.
of these tools. recommend exploring your
½”-4” socket fusion:
3.4
3.5
options and finding the tools
For better selection, pricing, that are the best fit for you, your A ½”- 4” iron can do all socket connections 4”
and support, installers are company, and the job you are and smaller. Its weight and power usage make
PRODUCTIVITY
PRODUCTIVITY
encouraged to use tools working on. it better suited to prefab and connections that
from an approved tool can’t be done with a smaller iron.
4” iron
manufacturer.
Fusing Aquatherm pipe requires
tools that meet certain criteria. As of the printing of this edition,
The tools must comply with Aquatherm has approved tool
dimensional, temperature, and lines from McElroy, Ritmo,
Rothenberger, and Widos.
Socket fusion machines Socket fusion machines
A jig-style fusion machine eliminates A bench-style fusion machine

the need for a second installer on eliminates the need for a second
2”-4” connections. Designed for in-air installer on 2”-4” connections. With
fusion, it is minimalistic and nimble, Spider its larger frame and fixed iron, it is Prisma 125
and requires a hand iron for use. not suitable for in-air connections, Widos 3511
but does provide immense support
and is very productive and efficient
for fabrication.
Prisma Jig
3.6
3.7
PRODUCTIVITY
PRODUCTIVITY
Four-jaw butt fusion machines Modified machine configurations
Full-size butt fusion machines W 4400 Most four-jaw machines can

W 4400
have two jaws on each side of the be modified to accommodate
fusion (2x2), reducing the time different fusion situations. Some
spent loading and aligning the pipe. machines allow a clamp to be
removed (2x1), reducing weight
and size. Others allow for a 3x1
set-up to accommodate shorter
Delta Dragon 315B sections. Clamping with a single
Acrobat 160
3.8
3.9
Acrobat 160 jaw generally requires additional
alignment time.
PRODUCTIVITY
PRODUCTIVITY
Manual butt fusion machines Larger crew vs. more tools
Manual machines lack Ritmo Gamma 160 Tools should be viewed as a multiple machines. This can Having the right number of
a hydraulic system, and means to increase productivity, double or triple the output of an tools will greatly impact your
instead use a mechanical rather than as an additional installer, or team of installers. installation time.
device to generate the cost. For example, socket
force required for fusion. fusions from 2”-4” are difficult The ratio of machines to To find the correct number
They can be advantageous to do with one installer and installers will depend on the of tools for the job, evaluate
in tight spaces and on may require a second installer. skill of the crew, the worksite the size and mix of the crew
smaller jobs. However, a socket fusion conditions, and the nature of being used. Each person fusing
3.10
3.11
Pit Bull® 26 machine makes larger socket the installation. Having too few pipe will need at least one
fusions a one-person job, tools will slow down the job, tool suitable for fusing the
doubling productivity. and leave installers standing size of pipe being installed.
PRODUCTIVITY
PRODUCTIVITY
around with nothing to do. A Some installers may be able
Widos Maxiplast For larger sizes of pipe (6” and good balance lets the crew stay to operate multiple tools,
up), cooling times occupy the engaged on productive work while installers in supporting
time of the machine, but not (no waiting around) while the roles may not need tools at all.
necessarily the installer. With fusion equipment is always This next section will give you
proper set-up and planning, being used on connections (no examples of tool selection and
a single installer can perform idle machines). crew mix, based on the type of
several fusions at once, using work being done.
Work example #1: Socket prefabrication (shop)
Crew: 1 primary, 1 support Unproductive time

Fusion
Tools: 1 benchtop, 1 iron, 1 jig, saw (Time spent moving around the
jobsite, setting up equipment, waiting
for cooling, etc.)
Goal: Maximize connections per
hour and eliminate unproductive Note: The “Fusions per hour” in the examples
time through specialization. Preparation are just for comparison. Your actual productivity
rates will vary with pipe size and installer
Process: Support measures experience.
3.12
3.13
and cuts pipe to length, cleans
and preps edges for fusion.
Primary uses benchtop machine SINGLE INSTALLER
3FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
to perform fusions on the main
spool, uses iron and jig to fuse
on additional pipe, fittings, and
outlets while the benchtop
connection cools.
OPTIMIZED TEAM 8FUSIONS PER HOUR
Work example #2: Butt fusion prefabrication (shop)
Crew: 1 primary, 1 support second connection for the first The decision to use 2 or 3
machine. If three machines are machines depends on the skill
Tools: 2-3 butt fusion machines being used, Support sets up the of the Primary and the duration
third machine during this time. of the cool-down time. A longer
Goal: Maximize connection per
The cycle continues so that the cool down allows for more
hour by eliminating downtime for
Primary is always performing hot simultaneous fusions.
the cooling phases.
work on a fusion machine.
Process: Primary performs
3.14
3.15
Fusion Preparation Unproductive time
the hot work (alignment,
facing, bead-up, heating, and
welding) on first machine SINGLE INSTALLER
2 FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
while Support preps the
second machine for fusion.
Primary then performs the hot

work on the second machine
while the first connection
cools. If two machines are
being used, Support preps a
Work example #3: Socket fusion prefabrication (onsite)
Crew: 1 primary, 2-3 support can have a socket coupling sections could also be installed
added to them to reduce the by a second Primary.
Tools: 1 benchtop, 2-3 irons, 2-3 number of in-air connections.
jigs, saw The remaining Supports take The exact mix and tasks of this
the fabricated sections to their crew depend on the skill of the
Goal: Minimize in-air Primary(ies) and Support(s) and
intended locations and install
connections by building on the the layout of the jobsite.
them as directed. Fabbed
ground as much as possible.
3.16
3.17
Process: One Support
measures and cuts pipe to
length, cleans and preps
SINGLE INSTALLER
2FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
edges for fusion. Primary uses
benchtop machine to perform
fusions on the main spool, uses
iron and jig to fuse on additional
pipe, fittings, and outlets while
the benchtop connection cools.
Simple straight lengths of pipe
Work example #4: Butt fusion prefabrication (onsite)
Crew: 1 primary, 1-3 support If two machines are being Primary is always performing hot
used, Support preps a second work on a fusion machine.
Tools: 2-3 butt fusion machines, connection for the first machine.
welding irons and jigs if needed If three machines are being Support can also work on adding
used, Support sets up the third outlets and other connections as
Goal: Maximize connections per needed or take finished sections
machine during this time. The
hour by eliminating downtime for and install them as directed.
cycle continues so that the
the cooling phases and minimize
in-air connections. Fusion Preparation Unproductive time
3.18
3.19
Process: Primary performs the
hot work (alignment, facing,
SINGLE INSTALLER
2FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
bead-up, heating, and welding)
on first machine while one
Support preps the second
machine for fusion. Primary
then performs the hot work
on the second machine while
the first connection cools.
Work example #5: Socket fusion (Linear)
Crew: 1 primary, 1-2 support This process can also be done

on the ground, at which point
Tools: 1 iron, 2 jigs, ladders or lift the crew can lift the entire length
into the air. Branch outlets can
Goal: Keep the single iron fusing
be added later.
pipe as much as possible by
removing downtime.
Process: Support sets up first jig

3.20
3.21
and then Primary performs the
actual fusion. While Primary is
performing the fusion, Support SINGLE INSTALLER
3FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
sets up the second jig. Primary
then performs the second
connection while Support
detaches the first jig and sets
it up on another connection. A
second Support may be needed
to carry and hang pipe.
Work example #6: Butt fusion (linear)
Crew: 1 primary, 1-2 support needed to minimize downtime. This process can also be done
on the ground, at which point
Tools: 2-3 butt fusion machines If the pipe is fused on the the crew can lift the entire length
ground and hoisted into place, into the air. Branch outlets can
Goal: Maximize connections per two machines and one Support be added later.
hour by eliminating downtime for may be sufficient. Branch outlets
the cooling phases. can be added later.
Process: Primary performs
3.22
3.23
the hot work (alignment, Fusion Preparation Unproductive time
facing, bead-up, heating, and
welding) on first machine while SINGLE INSTALLER
2FUSIONS PER HOUR
PRODUCTIVITY
PRODUCTIVITY
1-2 Support prep the second
machine for fusion. Primary
then performs the hot work
on the second machine while
1-2 Support set up the third
machine. Pipe in the air may
require the full cooldown time,
so three machines will be
Joining spools: Socket and butt fusion Joining spools: Electrofusion
In areas where lateral movement is

not possible, but fusion welding is still
the preferred method, electrofusion
couplings can join sections up to 10”
without lateral movement.
One side of the pipe is peeled back

far enough for the electrofusion
3.24
3.25
socket to be used as a slip coupling
As part of using Traditional fusion the spools. For straight flexibility. (See pages (right). Once the spool is in place, the
prefabrication, you will methods (socket and lengths, leave the moving 4.16 and 4.17 for safe coupling is slid back to center (below).
PRODUCTIVITY
PRODUCTIVITY
need to have a plan for butt welding) require spool unclamped until the bending lengths). Using
installing the spools a few inches of lateral fusion is complete. a fusion machine, the
once they are built. movement. If that installer can force the
Time saved by using movement is available, Places where the pipe to bend, perform the
prefabrication can be then socket and butt pipe changes direction fusion, and bring the pipe
lost trying to rework fusion will be the most (such as elbows) allow and fitting together for a
sections that aren’t easy cost-effective and the installer to take square connection (See
to join together. secure means of joining advantage of the pipe’s series above).
Joining spools: Flanges
Flange adaptors can join the

pipe to itself or another material.
Aquatherm flange connections
consist of two parts: the adaptor
and the ring (see page 4.26).
Flange adaptors are a common
connection method in areas
where traditional fusion is
3.26
difficult or impossible. Flange

transitions are available up to 24”.
PRODUCTIVITY
Planning for flanged spools will

include considerations for the
thickness of the gasket and for
any equipment (such as valves)
being installed between the
spools. This affects both build-
length of the spool and the
length of the bolts.
Chapter 4: Planning
Beyond heat fusion, there are a number of

differences between installing Aquatherm
pipe and installing other systems. Your skill
in planning and layout can help you take
advantage of these differences, and avoid
PLANNING
common pitfalls. This chapter will discuss
important installation details, such as pipe
sizing, hanger spacing, expansion controls,
insulation, and pressure testing.
Remember that, when using an

engineered system like PP-R, planning
4.1
and finesse will yield better results than
brute force.
Technical bulletins Clamps and hangers
Aquatherm works hard to bulletins to fill in the gaps Notifications regarding new If you are installing metal clamps, use only rubber- or felt-lined
deliver the best training between editions of the installer technical bulletins can be found at: clamps, like the one shown here. You may use tape to pad the space
and most accurate product manual. Technical bulletins also http://aquatherm.com/technical-bulletins between the PP-R and the metal on non-clamping hangers, such as Rubber-lined clamp
information available to you, give more detailed explanations clevis hangers. Plastic clamps are safe without additional padding.
the installer. of installation techiques than will
fit in the installer manual.
PLANNING
PLANNING
However, due to the wide
variety of applications that As a result, in the event of
Aquatherm pipe is used in, a discrepancy between this
and the ongoing development installer manual and the current
of third-party tools, clamps, technical bulletins on the
insulations, and other solutions, Aquatherm website, the bulletins
staying up on the best practices should be considered correct.
4.2
4.3
requires a small bit of effort. Metal clamps (even plastic-safe clamps) Metal that is in direct contact with
Aquatherm recommends reading can damage hot water pipes, and can Aquatherm pipe may sweat in certain
In order to keep you informed the technical bulletins in addition condense when used on cold water chilled applications, even if the pipe
of new techniques and to this manual. pipe. When installing chilled water itself shows no signs of condensation.
requirements, Aquatherm lines in high-humidity areas, use a non-
frequently releases technical crushable pipe shield (pictured above).
Anchors and guides Support intervals and hanger spacing (SDR 11 non-MF)
For the purposes of dealing With PP-R, the hanger spacing The temperature difference
Note: These support intervals are based
with linear expansion, there are varies with the expansion in is based on an ambient
on the pipes carrying water. If the pipes
two types of supports: anchors the pipe. For cold water pipes, temperature of 68 °F. For are carrying a material that is denser than
and guides. Anchors are tight there is a negligible amount example, a 100 °F system in water, additional support may be required.
against the pipe and prevent of expansion, or even some a 100 °F room should have Alternative spacing should be confirmed in
the chemical compatibility report.
movement through that point. contraction, so only one spacing support spacing based on (100
PLANNING
PLANNING
Guides support the pipe, but is given for non-MF installations. °F - 68° F= 32°F) temperature
are loose and allow movement For heated or chilled differential, not zero differential.
through the joint. Guide Anchor applications, use MF pipe. The In systems with a 0 or negative
limited expansion helps increase ∆T, use the maximum spacing.
The table on page 4.27 hanger spacing.
provides the best match of CTS
Pipe diameter
and IPS sizes.
4.4
4.5
½” ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 110 4” 6” 8” 10” 12” 14” 16” 18”
20 mm 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm
Support intervals (ft)
4 4 4 4 4 4.6 4.9 5.2 5.9 6.6 7.2 7.5 7.9 8.4 9.5 10.5 11.2
Support intervals (SDR 7.4 MF) Support intervals (SDR 9 MF)
Pipe diameter Pipe diameter

∆T ½” ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 110 4” 6” 8” 10” 12” 14” 16” 18”
∆T 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 110 4” 6” 8” 10” 12” 14”
20 mm 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm
Difference Difference
in temp. in temp.
Support intervals (ft) Support intervals (ft)
PLANNING
PLANNING
0 °F 4 4.6 5.2 5.9 6.7 7.5 8 8.5 9.5 10.5 11.2 11.3 11.5 12.5 13.5 15 16 0 °F 5.2 5.9 6.7 7.5 8.0 8.5 9.5 9.9 10.2 10.3 10.7 11.0 11.2
(0 °C) (0 °C)
36 °F 4 4 4 4.4 5.1 5.7 6.1 6.4 7.1 7.9 8.9 9 9.2 10.1 11 14 15 36 °F 4.0 4.4 5.1 5.7 6.1 6.4 7.1 7.4 7.4 7.9 8.0 8.2 8.4
(20 °C) (20 °C)
54 °F 4 4 4 4.4 5.1 5.7 6.1 6.4 6.9 7.4 8 8.2 8.4 9.2 10 12 13 54 °F 4.0 4.4 5.1 5.7 6.1 6.4 6.9 6.9 7.1 7.4 7.6 7.9 8.0
(30 °C) (30 °C)
72 °F 4 4 4 4.1 4.8 5.4 5.7 6.1 6.6 7.1 7.7 7.9 8 8.7 9.5 11 12 72 °F 4.0 4.1 4.8 5.4 5.7 6.1 6.6 6.6 6.7 7.1 7.4 7.4 7.6
4.6
4.7
(40 °C) (40 °C)
90 °F 4 4 4 4.1 4.8 5.4 5.7 6.1 6.2 6.4 6.7 6.9 7.1 7.8 8.5 10 11 90 °F 4.0 4.1 4.8 5.4 5.7 6.1 6.2 6.1 6.4 6.7 7.1 7.2 7.2
(50 °C) (50 °C)
108 °F 4 4 4 4 4.4 5.1 5.4 5.7 5.9 6.1 6.4 6.6 6.7 7.1 7.5 9 10 108 °F 4.0 4.0 4.4 5.1 5.4 5.7 5.9 5.7 6.1 6.4 6.6 6.7 6.9
(60 °C) (60 °C)
126 °F 4 4 4 4 4.3 4.8 5.1 5.4 5.6 5.7 6.1 6.2 6.4 6.7 7 8 8 126 °F 4.0 4.0 4.3 4.8 5.1 5.4 5.6 5.4 5.7 6.1 6.2 6.6 6.7
(70 °C) (70 °C)
Support intervals (SDR 11 MF) Support intervals (SDR 17.6 MF)
Pipe diameter Pipe diameter

∆T ½” ¾” 1” 1 ¼” 1 ½” 2” 2 ½” 3” 3 ½” 110 4” 6” 8” 10” 12” 14” 16” 18”
∆T 4” 6” 8” 10” 12” 14” 16” 18” 20” 22” 24”
20 mm 25 mm 32 mm 40 mm 50 mm 63 mm 75 mm 90 mm mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm 125 mm 160 mm 200 mm 250 mm 315 mm 355 mm 400 mm 450 mm 500 mm 560 mm 630 mm
Difference Difference
in temp. in temp.
Support intervals (ft) Support intervals (ft)
PLANNING
PLANNING
0 °F 4 4.6 5.2 5.9 6.7 7.5 8 8.5 9.5 10.5 11.2 11.3 11.5 12.5 13.5 15 16 0 °F 8.4 8.5 8.7 9.0 9.2 9.4 9.7 10.0 10.3 10.7 10.8
(0 °C) (0 °C)
36 °F 4 4 4 4.4 5.1 5.7 6.1 6.4 7.1 7.9 8.9 9 9.2 10.1 11 14 15 36 °F 6.1 6.2 6.6 6.7 6.9 7.1 7.5 7.9 8.4 8.9 9.2
(20 °C) (20 °C)
54 °F 4 4 4 4.4 5.1 5.7 6.1 6.4 6.9 7.4 8 8.2 8.4 9.2 10 12 13 54 °F 5.7 5.9 6.2 6.4 6.6 6.7 7.2 7.5 8.0 8.5 9.0
(30 °C) (30 °C)
72 °F 4 4 4 4.1 4.8 5.4 5.7 6.1 6.6 7.1 7.7 7.9 8 8.7 9.5 11 12 72 °F 5.6 5.7 5.9 6.2 6.2 6.4 6.9 7.4 7.7 8.2 8.7
4.8
4.9
(40 °C) (40 °C)
90 °F 4 4 4 4.1 4.8 5.4 5.7 6.1 6.2 6.4 6.7 6.9 7.1 7.8 8.5 10 11 90 °F 5.2 5.4 5.7 5.9 6.1 6.1 6.6 7.1 7.5 7.9 8.4
(50 °C) (50 °C)
108 °F 4 4 4 4 4.4 5.1 5.4 5.7 5.9 6.1 6.4 6.6 6.7 7.1 7.5 9 10 108 °F 4.9 5.1 5.4 5.6 5.7 5.7 6.1 6.6 7.1 7.5 7.9
(60 °C) (60 °C)
126 °F 4 4 4 4 4.3 4.8 5.1 5.4 5.6 5.7 6.1 6.2 6.4 6.7 7 8 8 126 °F 4.6 4.8 5.1 5.2 5.6 5.7 5.7 6.2 6.7 7.2 7.5
(70 °C) (70 °C)
Increased hanger spacing Linear expansion
In some applications, the Linear expansion occurs when For hot water, heating, and
positioning of hangers is the pipe is heated. The amount chilled applications, use a MF
determined by outside factors, of expansion is determined by pipe, such as aquatherm green
such as a retrofit with hangers the difference in temperature. It pipe® SDR 7.4 or aquatherm blue
from previous metal pipes. is important to know how much pipe® SDR 17.6, 11 or 9.
In order to accommodate for expansion will occur during
PLANNING
PLANNING
these variations, installers may system operation and plan for For ambient-temperature
use an in-line support, like the it. Aquatherm’s MF pipes use a applications, such as gray water
one shown here. combination of glass fibers and or DCW, use a non-MF pipe,
the outer wall. In-line supports *Other manufacturers may provide a similar PP-R to reduce linear expansion such as aquatherm green pipe
The supported distance can be will need to be installed under product that was not approved by Aquatherm and contraction by 75%. SDR 11 or aquatherm lilac pipe®.
added to the hanger spacing. the insulation, but still need a at the time of printing. These supports, if
4.10
4.11
For example, a pipe with a 6 non-metallic barrier layer (such acceptable, can be approved by Aquatherm MF pipes can be fused without any To determine the sizes for
ft spacing requirement can be as tape) between the metal
upon request. special tools, treatment, or prep various types of expansion
The MF extrusion process produces a middle layer
hung on 8 ft spacers if 2 ft of the surface of the in-line support work. Fuse MF pipes using the controls, consult the Aquatherm with expansion-inhibiting properties. The percentage
pipe is supported in-line. and the pipe. Approved in-line same techniques as non-MF pipe. product catalog. of PP-R is high enough to ensure a proper bonding
between the layers, so the middle layer cannot be
supports* are available through separated from the inner and outer layers.
The supports must clip securely Walraven.
to the pipe without damaging
Expansion controls Expansion controls
To control linear expansion, you will need to isolate and direct the expansion in a safe way. Expansion will Expansion loop: Used on long, straight runs. Two distant anchors direct expansion to a central loop. The
move away from anchors and through guides until it reaches your expansion control or another anchor. On loop can even be pre-stressed to accommodate additional expansion, or to give a square appearance
long runs, you should use an expansion control every 120 ft. Remember that branches and other fittings during operation.
cannot expand through an anchor or guide. Common expansion controls include:
PLANNING
Sliding elbow: Expansion is directed to Linear isolation: For vertical installations, expansion
PLANNING
where the pipe changes direction. The can be contained to each floor, leaving each 10 ft space Expanding side Expanding side
force of the expansion is absorbed by the with a fraction of an inch of expansion. This will cause a
flexibility of the bending side. slight bowing of the pipe, which can be minimized using a
midfloor guide.
Bending side without pre-stress Bending side with pre-stress
Note: Only MF pipes can absorb their expansion.
4.12
4.13
Non-MF pipes in heated applications must have Sliding end: Used for short distances where the pipe
other expansion controls installed every 30 ft. Expansion ends with a cap. The distance between the end of the
Expanding side should be handled by the engineer in the design pipe and the wall (or other obstruction) must be less
Bending side documents and those documents must be followed. The than the expansion. The pipe should be supported as
information here is for reference and verification only. closely to the end as possible.
Integration of other systems or components with Aquatherm piping PP-R to copper transition fittings
When integrating Aquatherm independent institutions. system operation and/or water To facilitate transitions to fixture the fitting. Always follow those
piping systems with other conditions. units, Aquatherm offers a PP-R to directions to avoid damaging the
systems or componenets not Sustained high levels of copper copper stub out, intended for use fitting. PP-R to copper transitions
made of PP-R (e.g. components in DHWR piping can damage For additional information, see with angle stops, flush valves, and are available in ½”, ¾”, and 1” sizes.
not made of PP-R like valves, components within the system, the Aquatherm Technical Bulletin other terminations. It is compatible
pumps, other piping, check valves, even PP-R. Damage caused by 201207C - AQTTB and product with both compression and solder-
PLANNING
strainers, etc.), care must be copper in the water resulting catalog.
PLANNING
type connections.
taken to ensure the operating from erosion/corrosion or
parameters for PP-R won’t other degradation of copper
These fittings are combination
damage the other materials or vice components in the DHWR system
of a custom Aquatherm PP-R
versa. will void the Aquatherm warranty.
socket with a gasket and
Aquatherm recommends following When adding PP-R to an existing copper stub added by Sioux
4.14
4.15
the Copper Development Agency’s copper system in a DHWR- Chief Manufacturing. The fused
guidelines for sizing, temperature application, the level of copper in PP-R portion is covered under
and flow speed in copper pipe. the water should be tested. These Aquatherm’s warranty. The
This will also help ensure that levels should not exceed 0.1 copper portion and gasket are
the copper levels in the water mg/L (ppm). Higher levels of total covered under a warranty from
do not approach the regulatory copper indicate that the copper Sioux Chief.
action levels recommended by pipe is corroding/eroding due to Instructions are included with
Connecting to a boiler Bushings, reducers, and reducing couplings
Aquatherm piping is required to Aquatherm piping connections the PP-R piping along the copper tube: To help limit the number of and a thicker wall than a normal Aquatherm also provides
pass a system malfunction test to the metal piping. When this reducing fittings that a wholesaler socket connection. Bushings run reducing couplings to reduce the
of 8,760 hours (~1 year) at 230°F. is not a possibility, one solution 10” from a ½” or ¾” PP-R fitting or pipe;
18” from a 1” or 1¼” PP-R fitting or pipe; must stock, Aquatherm uses from 4” down to 1/2”. pipe during a straight run. Sizes
This does not mean the piping is is to install a union that can be bushings which are designed to under 4” are socket fused on
intended to be operated at this uncoupled until the metal piping 20” from a 1½” PP-R Pipe fitting or pipe;
22” from a 2” (or larger) PP-R fitting or be inserted into another fitting, Reducers are used with larger both ends. Sizes that reduce from
condition, but rather that it can installation is complete. In any such as a socket, tee, or elbow. pipes and are butt welded on above 4” to 4” or smaller will butt
pipe.
PLANNING
withstand temperatures above case, do not expose any PP-R
PLANNING
When reducing, the side being both sides. They may go directly fuse on the larger size and socket
180°F were this to occur due to piping and transition fittings to For additional safety, use a water reduced from is male and acts to a pipe or to a fitting. fuse on the smaller size.
a boiler malfunction. This allows temperatures in excess of 170 °F soaked cloth or commercial heat
Aquatherm pipe to be connected during the metal piping installation like a piece of pipe in that size.
blocking agent between the solder
directly to a boiler in many cases. process. Excessive heat may The side being reduced to is
joint and the PP-R piping and
distort and deform any O-ring seals immediately cool the copper tube
female and acts like a socket in
Some codes may require a and fitting connections, resulting and the transition fitting after the the smaller size.
4.16
4.17
minimum of 18” of metal pipe in a leak during testing or after soldering is completed.
from the boiler to the Aquatherm system start-up. The female side (smaller pipe male side female side
PP-R. Copper tubing is not size) is labeled with the fitting
Where copper is used in a mechanical recommended for use with dimension and has a stop on the
It is safest to complete all heat- system or dometic cold water, perform
Aquatherm piping in a domestic inside, just like a regular socket
producing connections, such all solder joints on copper piping at
hot water recirculating system. fitting. The male side (larger pipe
as welding, before making the the following minimum distances from
size) has a bevel on the face Bushing
Large PP-R ball valve (3”-6”) Threaded connections
The benefits of an all polypropylene system can be realized up Aquatherm offers a wide range When installing these crescent wrench may give
through 6” with the large diameter PP-R ball valves available from of threaded transitions to threaded connections, there you a more secure fit). For
Aquatherm. The valves flange in-line, and can be installed quickly and connect with non-fusible system are a few important things to fittings without a hex head,
easily as long as the following items are addressed: components. These transitions remember: use a pipe wrench on the
have a machined brass or • 1-2 turns past hand-tight, PP-R body of the fitting. This
• Be aware that the bolt • Valves are provided with
stainless steel thread mold- do not bottom out. Tape will scratch up the fitting,
PLANNING
hole pattern is built to the gaskets and bolt kids, or these
PLANNING
injected into a PP-R base for only, not pipe dope unless but will normally not cause
ISO (European) standard. can be ordered separately as
maximum strength. absolutely necesary. Do structural damage.
Therefore, flange rings needed.
NOT bottom out in threaded
and full face gaskets will
Use stainless steel fittings fitting.
need to match the pattern.
in chemically aggressive • Your sealant needs to be
Aquatherm rings do match,
applications. Lead-free compatible with brass or
and the dimensions are
4.18
4.19
brass is available for potable stainless steel, as you are Female Hex Brass
available on the website. 3 2 6 1 5
l 4
applications. Industrial brass not threading to the PP-R.

• The nuts inset in the valve D D
fittings are available for all other • Always apply counter

are a coarse metric thread,
h1
non-potable applications. Do pressure on the fitting when
and do require metric d
not use the industrial transition tightening the connection.
bolting. For bolt dimensions,
C C
h2
fittings in applications that call If the fitting has a hex head,
see page 5.49.
D
z
for lead-free brass. place your wrench there (a Male Round SS Male Hex Brass
B B
Flanges Aquatherm flange bolt torque and size
To transition to other piping Aquatherm recommends using Torque Bolts Torque Bolts
systems and mechanical a full face rubber (black EPDM Nominal pipe size Nominal pipe size
N-m ft-lb Number Diameter Washers N-m ft-lb Number Diameter Washers
equipment, Aquatherm provides or red SBR) gasket, minimum
1” (32mm) 15 11 4 1/2 Yes 10” (250mm) 95 70 12 7/8 Yes
a full range of flange adapters. 1/8 inch thickness, with its
Aquatherm’s flange rings are flanges. Viton® gaskets may 1 ¼” (40mm) 20 15 4 1/2 Yes 12” (315 mm) 142 105 12 7/8 Yes
uniquely designed to have a also be used if needed for 1 ½” (50 mm) 30 22 4 1/2 Yes 14” (355 mm) 203 150 12 1 Yes
PLANNING
PLANNING
metric center and an ANSI bolt chemical resistance. The gasket 2” (63mm) 35 26 4 5/8 Yes
16” (400 mm)
244- 180-
16 1 Yes
pattern. For a flange transition, should have an inside diameter 366 270
2 ½” (75mm) 40 30 4 5/8 Yes
you will need both the adapter consistent with the ID of the Bolt tightening should follow 3” (90mm) 40 30 8 5/8 Yes
271- 200-
18” (450 mm) 16 1-1/8 Yes
(fusible fitting) and the ring. flange adapter. the “star” pattern regardless of 407 300
3 ½” (110mm) 50 37 8 5/8 Yes
flange size and number of bolts 20” (500 mm)
271- 200-
20 1-1/8 Yes
(see example). Tighten all bolts 4” (125mm) 50 37 8 5/8 Yes 407 300
1
4.20
4.21
to a third of the torque rating, 6” (160mm) 60 44 8 3/4 Yes 393- 290-
8 6 24” (630 mm) 20 1-1/8 Yes
and repeat until fully tightened. 8” (200mm) 75 55 8 3/4 Yes 590 435
3 4
Bolt length will depend on the
thickness of gasket and flange Note: These are typical values for rubber gaskets with lubricated (lightly greased) or plated bolts. Values may be increased for
ring being used. harder gaskets or plain/un-plated bolts.
5 7
2
Butterfly valves Branch lines
Aquatherm produces modified flange adapters for use with ANSI butterfly valves. The part numbers for Pipe size Outlets available There are two ways to install branch lines on
Thread size
these are distinguished by adding a “BV” to the end. Note that these are available only for sizes 6” and Pipe
1 ¼” ½” — ¾”
Aquatherm pipe: tees and outlets. Tees are full-
size
above, excluding 22”, as the ANSI and DIN dimensions overlap in smaller sizes. ½” ¾” 1” sized fittings that either socket fuse or butt fuse
1 ½” ½” — ¾”
in-line. These are usually used for branches that
1 ¼” M/F M/F 2” ½” — 1”
Tolerances with some butterfly valves may be very tight. Opening the valve before bolting it in place can are within two sizes of the main line.
help center the valve and ensure proper actuation. 1 ½” M/F M/F 2 ½” ½” — 1 ¼”
PLANNING
PLANNING
3” ½” — 1 ¼” Outlets are smaller fittings that use outlet fusion
2” M/F M/F
3 ½” ½” — 1 ½” to attach to the side of the pipe, see fusion outlet
2 ½” M/F M/F F welding installation in Chapter 2. The table on
Modified flange adapter 4” ½” — 2”
the left gives the available branches for each pipe
3” M/F M/F F 6” ½” — 3” size.
3 ½” M/F M/F F 8” ½” — 4”
4.22
4.23
4” M/F M/F F 10” ½” — 4” The table on the
12” 2” — 6” far left shows the
6” M/F M/F F available outlets
14” 2” — 8”
8” F F F with metal threads.
16” 2” — 10”
10” F F F 18” — 24” 2” — 12”
Buried applications Maximum pull force
In cases where the pipe needs Aquatherm pipe is safe to use The following table gives the maximum pull force for directional boring or similar applications. Make
to be buried in soil, sand, or with insulating backfills. Due to sure that the pull heads you are using are compatible with metric PP-R pipe. Pull forces include a
concrete, PP-R is safe, non- the thermal resistance of PP-R, 40% safety factor.
leaching, and resistant to dry sand is often acceptable as
crushing or damage. Aquatherm a backfill for insulation purposes. Max pull force (lb)
pipe is also suitable for When penetrating through Pipe diameter
PLANNING
SDR 7.4 SDR 9 SDR 11 SDR 17.6
PLANNING
directional boring, if a properly concrete on an application where
sized pulling head is used. the pipe may expand or contract, 6” — 160 mm 16060 13570 11350 7360
or otherwise be subjected to 8” — 200 mm 25090 21200 17740 11500
Buried installations generally movement or lateral forces, a 10” — 250 mm 39200 33120 27720 17970
do not require additional shield or protective layer must
12” — 315 mm 62230 52590 44010 28530
Unlike many other piping consideration for the expansion be used and should be installed
4.24
4.25
of MF pipes. Resistance to per local codes. It is best to 14” — 355 mm 79040 66790 55890 36240
materials, PP-R is able to absorb
the stress caused by expansion movement from the concrete or anchor the pipe at that location. 16” — 400 mm - - 70960 46010
within certain limits. The multi- backfill will restrict the natural 18” — 450 mm - - 89810 58230
layer faser (MF) construction expansion or contraction of the 20” — 500 mm - - - 71890
helps keep the pipe within these pipe. The expansive force of PP-R
22” — 560 mm - - - 90180
limits for most applications. is much lower than metal pipes.
24” — 630 mm - - - 114140
Bending Aquatherm pipe Insulation sizing, thrust blocking, noise generation, and vibration isolation
In general Aquatherm does not This applies for all SDR’s and Always bend the tubing in Insulation sizing: Aquatherm’s Noise generation: Due to the Pre-formed insulation
recommend bending Aquatherm pipe diameters for the Green and the coil direction and use a pipes are made using a metric natural noise attenuation and Aquatherm ND Best fit Best IPS fit
pipe as a means of making a the Blue pipe, with and without bending guide to prevent the OD, so standard insulations do the ability to absorb forces of
½” ½” IPS ½”
change in direction or going faser. The only exceptions to this tube from kinking. not always fit over the pipe. water hammer, the flow velocity
around obstacles. However, are Aquatherm’s coiled tubing The table on the right gives of Aquatherm pipe can be ¾” ¾” IPS ¾”
there are instances when products. Please note that considerable the best (closest) fit between higher (between 8 and 14 ft/s, 1” 1” IPS 1”
PLANNING
PLANNING
the pipe is required to bend, force may be required to field IPS and CTS sizes, and then based on size) because noise 1 ¼” 1 ½” CTS 1 ¼”
such as buried and trenchless When using coiled Aquatherm bend the pipe, and the pipe may the best fit using only the generation is not an issue. At the 1 ½” 1 ½” IPS 1 ½”
applications. products for radiant floor, snow spring back forcibly if the restraints more common IPS size. These higher flow velocity, the design 2” 2” IPS 2”
melt, field/turf warming or similar slip or are inadvertently released sizes also work for clamps and engineer must still account for
2 ½” 2 ½” 2 ½”
The pipe may be bent or bowed applications, the bending radius while bending or after installation. hangers. Insulations with metric surge pressures and design
3” 3” CTS 3”
a maximum of 5° off straight in should be no less than 8 times Observe appropriate safety IDs and imperial ODs will use accordingly.
4.26
4.27
a 20-foot section or to a bending the outside diameter of the precautions during field bending. Aquatherm’s ND. 3 ½” 4” IPS 4”
radius of 100 x the pipe outside tubing being used. For example, Vibration isolation: Due to 4” 5” CTS 5”
diameter. For an 8” SDR 11 pipe ½” tubing (OD = 20 mm) 8 x 20 Thrust blocking: Due to the Fusiolen® PP-R’s natural ability 6” 6” IPS 6”
with an outside diameter of 200 = 160 mm bending radius. 160 inherent strength and integrity to absorb vibration, isolators 8” 8” CTS 8”
mm (or 7.87 inches), the bending mm = 6.3 inches bending radius of fused connections, thrust are not required if the pipe has 10” 10” CTS 10”
radius is 787 inches or 66 feet. or 12 inches on center. blocking is never required in some limited mobility on either
12” 12” IPS 12”
buried applications. side of the pump.
UV protection and painting Fusing UV pipe
UV radiation can damage and Another option is to paint the In order to fuse the Aquatherm
weaken PP-R chains over time. pipe. Painted pipe may need UV protected pipe, you will need
Avoid exposing Aquatherm pipe to be recoated or maintained. to remove the outer layer. The
and fittings to UV radiation. Aquatherm recommends using outer layer is a black polyethylene
an elastomeric paint, which and it is factory extruded over the
Transport and storage: will expand and contract with top of normal aquatherm green 1 2
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PLANNING
Aquatherm pipes come in UV- the pipes. Visit aquatherm. pipe® and aquatherm blue pipe® Mark the pipe one size up from its actual size. Cut around the outside of the pipe through just the
resistant bags for storage and com/ancillary-products for paint pipes. You will still need to cover This will protect the black layer from the heat black layer. A rolling cutter works well. Do not cut
transport. Leave the pipes in options. or paint the fittings. fusion process. into the pipe wall.
these bags until you are ready to
install them. You may also paint the pipe
for non-UV reasons. Standard
4.28
4.29
Installation: Aquatherm offers acrylic, enamel, epoxy, and latex
its pipes with an extruded UV paints do not harm the pipe.
protective layer. This upgrade is
ideal for UV protection because
Painting the pipe is considered
an aftermarket modification and 3 4 5
it does not require maintenance. Aquatherm does not assume Cut from the mark to the edge of the pipe. Wear Use a knife to pry up the edge of the black layer. Peel back and remove the black layer. Fuse the
However, extra preparation is any responsibility for the protective gloves and mind your fingers. Re-score the cuts if they are not deep enough. pipe following the normal guidelines.
needed for installation (see 4.30). performance of the paint.
Flushing, grounding, and freeze protection Pressure testing (page 1 of 14)
Flushing: Before beginning be used to provide grounding. All freeze protection products Aquatherm offers an extensive warranty to protect against damages caused by failure from
operation, flush the system to Where metal pipes are replaced must be used in accordance manufacturer’s defect. Aquatherm requires that all installations be pressure tested in accordance
remove dust, pipe shavings, by PP-R pipes, the ground with the manufacturer’s with the following insturctions and that proof of the pressure test be submitted to Aquatherm before
and other particles that may cannot be created by the piping recommendations, the product the coverage can go into effect. Warranty coverage begins only after the pressure test is properly
have fallen into the pipe. system. An alternative ground listings, and in compliance with completed and submitted. Aquatherm’s warranty does not cover failures caused by improper
Make sure the system is system must be installed. all applicable local codes. When installation of the Aquatherm piping or mechanical connections to other materials, operation outside of
PLANNING
PLANNING
flushed in a safe manner that using any type of external heat the recommended parameters, or damage from mishandling after the pipe has left the manufacturer.
doesn’t damage or clog any Freeze protection: Aquatherm source applied to the piping
components. Unless otherwise piping systems can be installed such as heat tape or heating
required, water is sufficient for in applications and conditions cables, the product must be
flushing out the system. where freezing may occur. suitable for use with plastic
Generally, freezing the pipes piping. Additionally, the heat
4.30
4.31
Grounding: Most building and the water in them will not system must be self-regulating
codes require that grounding cause problems for the piping and the surface temperature of
be provided for all conductive materials, but they should not be the Aquatherm pipe and fittings
components inside the structure. frozen intentionally. Maintaining must not exceed 160 °F (71 °C).
It is important to note that a minimum flow can prevent the
Aquatherm pipes do not carry pipes from freezing solid.
electrical currents and cannot
Pressure testing (page 2 of 14) Pressure testing (page 3 of 14)
Step 1: Determine your testing pressure. In order to ensure the integrity of the heat fusion connections, a Pipe SDR SDR 17.6 SDR 11 or lower
pressure test must be performed on the completed system. The amount of pressure used depends on the
type of pipe and intended pressure of the application.
• If the piping has a mixture of SDR pipe, you should test to the higher SDR’s (thinner walled pipe’s) testing requirements). For
PLANNING
PLANNING
example, if the piping system contains SDR 17.6 pipe and SDR 11 piping, you should test to the requirements of the 17.6 piping.
• If the piping system contains SDR 17.6 pipe and has an intended operating pressure of 65 psi or lower, the system must be
tested at 100 psi.
• If the piping system contains SDR 17.6 and has an intended oeprating pressure higher than 65 psi, the system must be tested
at 150% of the intended operating pressure.
• If the system contains only SDR 11 or heavier-walled pipe (lower SDR) and has an intended operating pressure of 100 psi or less, Operating Pressure < 65 psi >65 psi < 100 psi >100 psi
the system must be tested at 150 psi.
• If the system contains only SDR 11 or heavier-walled pipe (lower SDR) and has an intended operating pressure higher than 100 psi,
4.32
4.33
the system must be tested at 150% of the intended operating pressure.
• If you have concerns regarding your testing pressure, please contact Aquatherm. Exceptions to the required pressure test must be
given from Aquatherm. Test Pressure 100 psi 150% 150 psi 150%
Choose One:
Step 2: Determine your testing medium. Water is the preferred medium for testing purposes, due to its
incompressibility. However, in low pressure applications, air testing may also be suitable. You may use a Operating Medium Air Service Water Service
different testing medium for different tests, as long as the medium is acceptable with the test pressure.
• If the system is intended for compressed air service, only compressed air may be used for
the pressure test, regardless of the following restrictions. See Aquatherm Technical Bulletin
PLANNING
PLANNING
201705A-AQTTB for proper safety precautions when testing with air.
• If the testing pressure is equal to or less than 150 psi and the piping is SDR 11 or heavier wall Test Pressure < 150 psi >150 psi
thickness (lower SDR), you may test with air only, water only, or with an air-over-water system
(piping filled with water, pressure source is air).
SDR < 11 SDR ≥ 11
• If the testing pressure exceeds 150 psi, the test must be performed using water only, or an air-
4.34
4.35
over-water system (piping filled with water, pressure source is air). Compressed air alone is not
approved for systems with a testing pressure higher than 150 psi. Test Medium Test with air Test with water or air over water system
Choose One:
Step 3: Observe safety protocols. The full Aquatherm warranty does not take effect until the pressure Step 3 (continued):
test is completed and submitted and the system is in operation. Therefore, it is important for the tester to
observe all safety recommendations from Aquatherm until the testing is complete. When using compressed air:
• It is recommended that the system be leak-tested at 25-30 psi before conducting the full pressure
For all systems: test.
• See Aquatherm Technical Bulletin 201705A-AQTTB for proper safety precautions when testing with
PLANNING
PLANNING
• Visually inspect the connections for signs of proper fusion, following the guidelines given in the air.
Aquatherm Installer Manual. Socket connections should have two even rings of melted plastic, • Stand clear of the pipe during testing and warn others nearby to do the same. Take measures to
and a visible depth mark. Butt welded connections should have a single bead with a rounded top. secure loose sections of the pipe in case a rupture does occur.
This inspection is most easily done during the fusion process. The absence of these signs may be
• Do not perform the test if the ambient temperature is higher than 100 °F. Use water instead.
indicative of an improper fusion.
• Should any transition joints leak during testing, check the joints for proper assembly and repeat the
• Remove all fusion equipment from the system before starting the pressure test.
4.36
4.37
test using water before replacing any of the fittings.
• Set your pressure gauge near the bottom of the system, where the pressure will be highest. This Warning - Failure of a compressed gas (air or inert gas) system can be extremely violent and dangerous.
reduces the risk of over-pressurizing the system. In a compressed gaseous media test or piping system, energy is applied to compress the gaseous
• Observe the joints during the test for any indications of leaks. If a leak is found, relieve all test media in addition to pressurizing the system. If failure occurs, both energies can be suddenly released
pressure and repair the leak before continuing. and can be extremely violent compread to failure duing leak testing or system operation with an
incompressible liqiud testing media.
Step 4: Perform the test. Follow the steps as indicated below. Use a digital pressure test gauge or an
analog gauge that is accurate to within 0.5 psi. Record the results on the pressure test form. Preliminary test
Preliminary test:
• Bring the system up to the test pressure. The system will expand slightly once it is up to pressure, Test Pressure
PLANNING
so additional pressure may be required to help it stabilize.
PLANNING
• Once the system stabilizes, observe it for 30 minutes. The system should be able to hold the test
pressure during that time.
• The loss of more than 9 psi (6 psi for SDR 17.6 systems) or steadily decreasing pressure during this p max = 9 psi (0.6 bar)
p in psi (bar)
test is indicative of a leak. If a leak occurs, identify the leak and repair the system then repeat this test. 6 psi (0.4 bar) for SDR 17.6 systems
4.38
4.39
• A successful version of this test must be completed before proceeding. (Fail Point)
• Aquatherm recommends using this test for progressive testing, rather than completing the entire testing
sequence. The entire testing sequence must be completed on the whole system when it is finished.
Stabilization 30 min
Step 4 (continued):
Principal Test
Principal test:
• If the system has lost any pressure during the preliminary test, bring the system back up to the
test pressure. Test Pressure p max = 3 psi (0.2 bar)
PLANNING
(Fail Point)
PLANNING
• Observe the system for 120 minutes. The system should be able to hold the full test pressure
during that time.
p in psi (bar)
• The loss of more than 3 psi or steadily decreasing pressure during this test is indicative of a leak.
Identify the leak and repair the system before repeating this test.
• A successful version of this test must be completed before proceeding.
4.40
4.41
120 min
Step 4 (continued):
150 psi
Final test:
• Release the pressure from the system.

• Bring the system up to test pressure for two minutes. Reduce the system pressure to 15 psi for
PLANNING
PLANNING
two minutes.
two minutes.
4.42
4.43
two minutes.
• Bring the system up to test pressure for five minutes. Reduce the system pressure to 15 psi for 15 psi
five minutes.
t in min
2 min 4 min 2 min 4 min 2 min 4 min 5 min 10 min
Pressure testing (page 14 of 14)
Step 5: Complete and submit the pressure test record.
• Submit the form to Aquatherm within 30 days of completing the pressure test.
• If you are testing a system in sections, save all the pressure test records and submit them
together.
PLANNING
• Include the installer numbers of all the installers who fused connections on the system.
All information can be submitted electronically on Aquatherm’s website at http://www.aquatherm.com/

pressure-test-submission. There is no one at the Aquatherm headquarters that will submit the form for
you.
4.44
A sample test record and set of instructions for recording in the field is also available on the
submission page.
Chapter 5: Pipe and fittings
This chapter includes all the parts that

Aquatherm offers as part of its piping
systems. This chapter only gives the
nominal imperial size so as to avoid
confusion. A table giving the metric
conversions can be found on page 1.8.
PIPE AND FITTINGS

Full dimensional data is not included in
this manual. The dimensional data for all
Aquatherm parts and fittings can be found
on Aquatherm’s website.
5.1
aquatherm green pipe® SDR 7.4 MF aquatherm green pipe® SDR 7.4/11 S aquatherm green pipe® SDR 7.4/11 S (continued) aquatherm green pipe® SDR 7.4 MF UV
Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND Dimension
Part no.
0610808 ½” SDR 7.4 (non-MF) 0610234 8” ND
0670730 6”
0670730x2a 6” (Double Length) 0610810 ¾” SDR 7.4 (non-MF) 0610234x2c 8” (Double Length) 0670772 3”
0670734 8” 0610212 1” 0610238 10” 0670774 3 ½”

0670734x2 b
8” (Double Length) 0610214 1 ¼” 0610238x2c 10” (Double Length) 0670776 4”
Part no. Dimension ND 0610216 1 ½” 0010242 12”
0670738 10” 0670780 6”
PIPE AND FITTINGS
PIPE AND FITTINGS

0670708 ½” 0610218 2” 0010242x2c 12” (Double Length)
0670738x2b 10” (Double Length) 0670784 8”
0670710 ¾” Dimension
0610220 2 ½” 0010244 14” Part no.
ND 0670788 10”
0670712 1” Comes in 26 ft lengths.
a
Comes in 38 ft lengths.
b 0610222 3” 0010246d 16”
0670758 ½”
0670714 1 ¼” 0610224 3 ½” 0010248d 18”
0670760 ¾”
0670716 1 ½” 0610226 4” The following items are supplied in coils:
0670718 2” 0670762 1”
0610226x2a 4” (Double Length) 0010308 ½”
0670720 2 ½” 0670764 1 ¼”
0610226x3b 4” (Triple Length) 0010310 ¾”
0670722 3” 0610230 6” 0010312 1” 0670766 1 ½”
a
Pipe comes in 26 ft lengths.
0670724 3 ½” b
Pipe comes in 39 ft legnths. 0610230x2c 6” (Double Length) d
Mechanically stabilized with a faser-composite 0670768 2”
5.2
5.3
0670726 4” c
Pipe comes in 38 ft lenghts. layer in the center of the pipe. 0670770 2 ½”
aquatherm blue pipe® SDR 7.4/9/11 MF aquatherm blue pipe® SDR 17.6 MF
Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND
2670116 1½ ” 10” (Double 2570126 4” 2570148 18”
2670138x2 c
Length)
2670118 2” 2570126x2a 4” (Double Length) 2570148x2 c
18“ (Double Length)
2070142 12”
2670120 2 ½” 2570126x3b 4” (Triple Length) 2570150 20”
12” (Double
2670122 3” 207142x2c 2570130 6”
Length) 2570150x2 c
2670124 3 ½” 2570130x2c 6“ (Double Length)
2070144 14” 2570152 22”
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND Part no. Dimension ND 2670126 4” 2570134 8”
14” (Double 2570154 24”
1970724 3 ½” 2070144x2c
SDR 7.4 4” (Double Length) 2570134x2c 8“ (Double Length)
2670126x2a 2570154x2c 24“ (Double Length)
2670708 ½” 1970726 4” Length) 2070146 16” 2570138 10”
2670710 ¾” 1970730 6” 2670126x3b 4” (Triple Length) 2070148 18” 2570138x2c 10“ (Double Length) a
2670130 6” The following items are supplied 2570142 12”
b
Pipe comes in 39 ft legnths.
SDR 9 1970734 8”
in coils (non-faser)
c
Pipe comes in 38 ft lenghts.
1970712 1” 1970738 10” 6” (Double 2570142x2c 12“ (Double Length)
2670130x2c
Length) 2010308 ½”
1970714 1 ¼” 1970742 12” 2570144 14”
2670134 8” 2010310 ¾”
1970716 1½ ” 1970744 14” 2570144x2c 14“ (Double Length)
8” (Double 2010312 1”
1970718 2” SDR 11 2670134x2c 2570146 16”
Length)
5.4
5.5
1970720 2 ½” 2670112 1” 2670138 10”
a
Pipe comes in 26 ft lengths. 2570146x2 c
b
1970722 3” 2670114 1 ¼” c
aquatherm blue pipe® SDR 7.4/11 MF UV aquatherm blue pipe® SDR 17.6 MF UV aquatherm lilac pipe® SDR 7.4/11 S
Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND
2670174 3 ½” — SDR 11 2570202 22” SDR 7.4 9010220 2 ½”
2670176 4” — SDR 11 2570204 24” 9010808 ½” 9010222 3”
2670180 6” — SDR 11 9010810 ¾” 9010224 3 ½”
2670184 8” — SDR 11 SDR 11 9010226 4”
2670188 10” — SDR 11 9010212 1” 9010226x2 4” (Double Length)
PIPE AND FITTINGS
PIPE AND FITTINGS

a
Part no. Dimension ND 9010214 1 ¼” 9010226x3b 4” (Triple Length)

Part no. Dimension ND
2670758 ½” — SDR 7.4 9010216 1 ½” 9010230 6”
2570180 6”
2670760 ¾” — SDR 7.4 9010218 2” 9010230x2c 6” (Double Length)
2570184 8”
2670162 1” — SDR 11
2570188 10” a
2670164 1 ¼” — SDR 11 b
2570192 12” c
2670166 1 ½” — SDR 11
2570194 14”
2670168 2” — SDR 11
2570196 16”
2670170 2 ½” — SDR 11
2570198 18”
5.6
5.7
2670172 3” — SDR 11
2570200 20”
Coupling Reducing couplings Cross-over Street 45° Street 90°
female/female female/male female/male

0111253 3” to 2 ½”
0111257 3 ½” to 2 ½”
0111259 3 ½” to 3”
0111263 4” to 3”
PIPE AND FITTINGS
PIPE AND FITTINGS

0111265 4” to 3 ½”
Part no. Dimension ND 0116108 ½” Part no. Dimension ND
Part no. Dimension ND Part no. Dimension ND
0111008 ½” 0116110 ¾” 0112308 ½”
0111222 1 ¼” to 1” 0112708 ½”
0111010 ¾” 0116112 1” 0112310 ¾”
0111012 1” 0111228 1 ½” to 1” 0112710 ¾” 0112312 1”
0111014 1¼” 0111230 1 ½” to 1 ¼” 0112712 1” 0112314 1 ¼”
0111016 1½” 0111236 2” to 1 ¼” 0112714 1 ¼”
0111018 2” 0111238 2” to 1 ½”
0111020 2½” 0111240 2 ½” to 1 ½”
0111022 3” 0111242 2 ½” to 2”
5.8
5.9
0111024 3½” 0111252 3” to 2”
0111026 4”
Bushing Cross Butt weld reducer

Dimension Dimension Dimension
0111130 1 ½” to 1 ¼” 0111155 3 ½” to 2” SDR Part no. SDR Part no. SDR Part no.
ND ND ND
0111131 2” to ½” 0111157 3 ½” to 2 ½” 0311184 8” to 6” 0111185 8” to 6” 2511184 8” to 6”
2511188 10” to 6”
0111132 2” to ¾” 0111159 3 ½” to 3” 0311188 10” to 6” 0111189 10” to 6” 2511190 10” to 8”
0111161 4” to 2 ½” 0311190 10” to 8” 0111191 10” to 8” 2511193 12” to 8”
0111134 2” to 1” 2511195 12” to 10”
0111136 2” to 1 ¼” 0111163 4” to 3” 9 0311192 12” to 8” 0111193 12” to 8” 2511197 14” to 10”
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND 0311194 12” to 10” 0111195 12” to 10” 2511199 14” to 12”
0111138 2” to 1 ½” 0111165 4” to 3 ½” 2511201 16” to 10”
Part no. Dimension ND Dimension
0111112 ¾” to ½” SDR Part no. 0311196 14” to 10” 0111197 14” to 10” 2511203 16” to 12”
0111143 2 ½” to ½” 0113708 ½” ND 2511204 16” to 14”
0111114 1” to ½” 0311198 14” to 12” 11 0111199 14” to 12”
0111144 2 ½” to ¾” 0111184 8” to 6” 2511206 18” to 12”
0113710 ¾” 0111201 16” to 10” 2511207 18” to 14”
0111116 1” to ¾” 17.6
0111145 2 ½” to 1” 0113712 1” 0111188 10” to 6” 0111203 16” to 12” 2511208 18” to 16”
0111118 1 ¼” to ½” 2511209 20” to 12”
0111139 2 ½” to 1 ¼” 0113714 1 ¼” 0111190 10” to 8” 0111204 16” to 14” 2511210 20” to 14”
0111120 1 ¼” to ¾” 7.4 0111206 18” to 12” 2511211 20” to 16”
0111140 2 ½” to 1 ½” 0111192 12” to 8”
2511212 20” to 18”
0111122 1 ¼” to 1” 0111194 12” to 10” 0111207 18” to 14” 2511213 22” to 16”
0111142 2 ½” to 2”
0111124 1 ½” to ½” 0111208 18” to 16” 2511214 22” to 18”
0111151 3” to 1 ½” 0111196 14” to 10” 2511215 22” to 20”
5.10
5.11
0111126 1 ½” to ¾” 0111198 14” to 12” 2511216 24” to 16”
0111152 3” to 2” 2511217 24” to 18”
0111128 1 ½” to 1” 2511218 24” to 20”
0111153 3” to 2 ½”
2511219 24” to 22”
Reducing coupling Elbow 90° (Socket) aquatherm green pipe® Elbow 90° SD Elbow 90° (Butt-weld)
butt weld/socket weld molded
(Segmented, Butt-weld)
Dimension
SDR Part no.
ND
0111175 6” to 3 ½”
11 0111177 6” to 4”
0111183 8” to 4”
2511174 6” to 3 ½”
PIPE AND FITTINGS
PIPE AND FITTINGS

17.6 2511176 6” to 4”
Part no. Dimension ND Dimension
2511182 8” to 4” Dimension Dimension SDR Part no.
Dimension 0112108 ½” SDR Part no. SDR Part no. No.
SDR Part no. ND ND
ND
0112110 ¾” 7312130 6” 6” 7.4 0112130 6”
7112130
0111174 6” to 3 ½”
0112112 1” 7312134 8” 7112134 8” 0312130 6”
7.4 0111176 6” to 4”
0112114 1 ¼” 7312138 10” 7112138 10”
0111182 8” to 4” 7.4 9 0312134 8”
0112116 1 ½” 7312142 12” 11 7112142 12”
0311174 6” to 3 ½” 0312138 10”
0112118 2” 7312144 14” 7112144 14”
9 0311176 6” to 4” 11 0112131 6”
0112120 2 ½” 7112146 16”
0311182 8” to 4”
0112122 3” 7112148 18”
5.12
5.13
One side is socket welded and the 0112124 3 ½”
other is butt welded.
0112126 4”
Elbow 45° (Socket) aquatherm green pipe® Elbow 45° SD Elbow 45° (Butt-weld) aquatherm blue pipe® Elbow 90° SD
(molded)
(Segmented, Butt-weld) (Segmented, Butt-weld)
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND Dimension Dimension Dimension
SDR Part no. SDR Part no. SDR Part no.
Dimension Dimension ND ND ND
0112508 ½” SDR Part no. SDR Part no.
ND ND 7412130 6”
0112510 ¾” 7.4 0112530 6” 7212142 12”
7312530 6” 7112530 6” 9 7412134 8”
0112512 1” 7212144 14”
7.4 7312534 8” 7112534 8” 11 0112531 6” 7412138 10”
0112514 1 ¼” 7512130 6”
7312538 10” 7112538 10” 7412142 12”
0112516 1 ½” 7512134 8”
11 7112542 12” 7412144 14”
0112518 2” 7512138 10” 17.6
7112544 14” 7412146 16”
0112520 2 ½” 11 7512142 12“
7112546 16” 7512144 14“ 7412148 18”
0112522 3”
7112548 18” 7512146 16“ 7412150 20”
5.14
5.15
0112524 3 ½”
7512148 18“ 7412152 22”
0112526 4”
7412154 24”
aquatherm blue pipe® Elbow 45° SD End cap (Socket) End cap (Butt-weld)
(Segmented, Butt-weld)
Dimension Dimension Dimension Dimension
SDR Part no. SDR Part no. SDR Part no. SDR Part no.
ND ND ND ND
7512530 6” 0314130 6” 0114131 6” 2514130 6”
7512534 8” 0314134 8” 0114135 8” 2514134 8”
7512538 10” 9 0314138 10” 0114139 10” 2514138 10”
11 7512542 12” 0314142 12” 11 0114143 12” 2514142 12”
PIPE AND FITTINGS
PIPE AND FITTINGS

7512544 14” 0314144 14” 0114145 14” 2514144 14”
7512546 16” Part no. Dimension ND Dimension 0114147 16” 17.6
SDR Part no. 2514146 16”
Dimension 7512548 18” 0114108 ½” ND 0114149 18”
SDR Part no.
ND 2514148 18”
7412530 6” 0114110 ¾” 0114130 6”
7212530 6” 2514150 20”
7412534 8” 0114112 1” 0114134 8”
7212534 8” 2514152 22”
7412538 10” 0114114 1 ¼” 7.4 0114138 10”
9 7212538 10” 2514154 24”
7412542 12” 0114116 1 ½” 0114142 12”
7212542 12”
7412544 14” 0114118 2”
7212544 14” 17.6 0114144 14”
7412546 16”
0114120 2 ½”
7412548 18”
0114122 3”
5.16
5.17
7412550 20”
0114124 3 ½”
7412552 22”
0114126 4”
7412554 24”
aquatherm green pipe® Wye (Lateral 45) aquatherm blue pipe® Wye (Lateral 45) Tee (Socket) aquatherm green pipe® Tee (Segmented, Butt-weld)
Dimension
SDR Part no.
ND
2403126 4”
2403130 6”
17.6
2403134 8”
2403138 10”
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND Dimension Dimension
Dimension Dimension Dimension SDR Part no. SDR Part no.
SDR Part no. SDR Part no. SDR Part no. 0113108 ½” ND ND
ND ND ND
0113110 ¾” 0113130MF 6” 0113131MF 6”
2303726 4” 2103126 4” 2503126 4”
0113112 1” 7.4 0113134 8” 0113135 8”
2303730 6” 2103130 6” 2503130 6”
7.4 11 11 0113138 10” 0113139 10”
0113114 1 ¼”
2303734 8” 2103134 8” 2503134 8” 11 0113143 12”
0113116 1 ½”
2303738 10” 2103138 10” 2503138 10” 0113145 14”
0113118 2”
0113147a 16”
0113120 2 ½”
0113149a 18”
0113122 3”
5.18
5.19
a
Mechanically stabilized with a faser-
0113124 3 ½”
composite layer in the center of the pipe.
0113126 4”
Tee (Butt-weld) molded aquatherm green pipe® Reducing tee (Segmented, Butt-weld) Reducing tee (Socket)
(inlet, outlet, branch) molded (inlet, outlet, branch)
0113546 1 ¼” x 1 ¼” x 1” 0113568 2 ½” x 2 ½” x 1 ½”
0113547 1 ½” x 1 ½” x ½” 0113570 2 ½” x 2 ½” x 2”
0113548 1 ½” x 1 ½” x ¾” 0113576 3” x 3” x 1”
SDR Part no. Dimension ND
0113550 1 ½” x 1 ½” x 1” 0113578 3” x 3” x 1 ¼”
Dimension SDR Part no. Dimension ND 0113605 6“ x 6“ x 4“
SDR Part no. 0113551 1 ½” x 1 ½” x 1 ¼” 0113580 3” x 3” x 1 ½”
No. 0113604 6“ x 6“ x 4“
PIPE AND FITTINGS
PIPE AND FITTINGS

0113619 8” x 8” x 6”
0113618 8” x 8” x 6” 0113552 2” x 2” x ½” 0113582 3” x 3” x 2”
0113130 6” 7.4 0113635 10” x 10” x 6” Part no. Dimension ND
7.4 0113634 10” x 10” x 6” 0113641 10” x 10” x 8” 0113554 2” x 2” x ¾” 0113584 3’’ x 3” x 2 ½”
0113130LGa 6” 0113511 ½” x ½” x ¾”
0113640 10” x 10” x 8” 0113655 12” x 12” x 8” 0113556 2” x 2” x 1” 0113586 3 ½” x 3 ½” x 2”
0113520 ¾” x ½” x ½”
9 0313130 6” 0113657 12” x 12” x 10” 0113558 2” x 2” x 1 ¼” 0113588 3 ½” x 3 ½” x 2 ½”
11 0113522 ¾” x ¾” x ½”
0113131 6” 0113669 14” x 14” x 10” 0113560 2” x 2” x 1 ½” 0113590 3 ½” x 3 ½” x 3”
11 0113532 1” x ½” x ½”
0113131LGa 6” 0113671 14” x 14” x 12”
0113561 2 ½” x 2 ½” x ½” 0113592 4” x 4” x 2 ½”
0113684a 16” x 16” x 12” 0113534 1” x 1” x ½”
Comes with a 1-ft extension on each end.
a 0113562 2 ½” x 2 ½” x ¾” 0113594 4” x 4” x 3”
0113685a 16” x 16” x 14” 0113538 1” x ¾” x ¾”
0113699a 18” x 18” x 14” 0113564 2 ½” x 2 ½” x 1” 0113596 4” x 4” x 3 ½”
0113540 1” x 1” x ¾”
5.20
5.21
0113700a 18” x 18” x 16” 0113566 2 ½” x 2 ½” x 1 ¼”
0113542 1 ¼” x 1 ¼” x ½”
a
Mechanically stabilized with a faser-composite 0113544 1 ¼” x 1 ¼” x ¾”
layer in the center of the pipe.
aquatherm green pipe® Reducing Tee (Socket) (inlet, outlet, branch) aquatherm blue pipe® Tee (Segmented, Butt-weld)
SDR Part no. Dimension ND 0113631 10” x 10” x 4” Dimension Dimension
SDR Part no. SDR Part no.
0113651 12” x 12” x 4” ND ND
0113600 6” x 6” x 2 ½”
0113653a 12” x 12” x 6” 2613131 6” 2513130 6”
0113602 6” x 6” x 3”
0113663 14” x 14” x 4” 2613135 8” 2513134 8”
0113608 8” x 8” x 2 ½”
0113665ab 14” x 14” x 6” 2613139 10” 2513138 10”
0113610 8” x 8” x 3” SDR Part no. Dimension ND
0113667a 14” x 14” x 8” 11 2513142 12”
0113601 6” x 6” x 2 ½” 2013143 12“
0113612 8” x 8” x 3 ½” 0113676b 16” x 16” x 4”
PIPE AND FITTINGS
PIPE AND FITTINGS

7.4 0113603 6” x 6” x 3” 2013145 14“ 2513144 14”
0113614 8” x 8” x 4” 11 0113678ab 16” x 16” x 6” Dimension 17.6
0113609 8” x 8” x 2 ½” SDR Part no. 2013147 16“ 2513146 16”
0113624 10” x 10” x 2 ½” 0113680ab 16” x 16” x 8” ND
0113611 8” x 8” x 3” 2013149 18“ 2513148 18”
0113626 10” x 10” x 3” 0113682ab 16” x 16” x 10” 0813134 8”
11 0113613 8” x 8” x 3 ½” 2513150 20”
0113628 10” x 10” x 3 ½” 0113690 18” x 18” x 4” 0813138 10”
0113615 8” x 8” x 4” 9 2513152 22”
0113630 10” x 10” x 4” 0113692 ab
18” x 18” x 6” 0813142 12“
0113625 10” x 10” x 2 ½” 0113694 ab
18” x 18” x 8” 2513154 24”
0813144 14“
0113627 10” x 10” x 3” 0113696 ab
18” x 18” x 10”
0113629 10” x 10” x 3 ½” 0113698ab 18” x 18” x 12”
a
Branch outlet has a butt-weld connection.
5.22
5.23
b
Mechanically stabilized with a faser-
composite layer in the center of the pipe.
a
aquatherm blue pipe® Reducing tee (Segmented, Butt-weld) aquatherm blue pipe® Reducing tee (Segmented, Butt-weld) (continued)

2513685 16” x 16” x 14”
2613605 6“ x 6“ x 4“
2513699 18” x 18” x 14”
2613619 8” x 8” x 6”
2513700 18” x 18” x 16”
2613635 10” x 10” x 6”
2513813 20” x 20” x 14”
2613641 10” x 10” x 8”
PIPE AND FITTINGS
PIPE AND FITTINGS

2513814 20” x 20” x 16”
SDR Part no. Dimension ND 2013655 12” x 12” x 8“ 2513604a 6” x 6” x 4”
2513815 20” x 20” x 18”
0813618 8” x 8” x 6” 2013657 12” x 12” x 10” 2513618 8” x 8” x 6”
11 17.6 2513831 22” x 22” x 16”
0813634 10” x 10” x 6” 2013669 14” x 14” x 10” 2513634 10” x 10” x 6”
2513832 22” x 22” x 18”
0813640 10” x 10” x 8” 2013671 14” x 14” x 12” 2513640 10” x 10” x 8”
2513833 22” x 22” x 20”
17.6
9 0813908 12” x 12” x 8“ 2013684 16” x 16” x 12”
2513657 12” x 12” x 10” 2513849 24” x 24” x 16”
0813910 12” x 12” x 10” 2013685 16” x 16” x 14”
2513669 14” x 14” x 10” 2513850 24” x 24” x 18”
0813922 14” x 14” x 10” 2013699 18” x 18” x 14”
5.24
5.25
2513671 14” x 14” x 12” 2513851 24” x 24” x 20”
0813924 14” x 14” x 12” 2013700 18” x 18” x 16”
2513684 16” x 16” x 12” 2513852 24” x 24” x 22”
aquatherm blue pipe® Reducing tee (Socket) (inlet, outlet, branch) aquatherm blue pipe® Reducing tee (Socket) (continued)
SDR Part no. Dimension ND SDR Part no. Dimension ND

SDR Part no. Dimension ND SDR Part no. Dimension ND
0813630 10” x 10” x 4” 2613631 10” x 10” x 4”
2513630 10” x 10” x 4” 2513804 20” x 20” x 4”
0813904 12” x 12” x 4” 2013651 12” x 12” x 4”
2513651 12” x 12” x 4” 2513806a 20” x 20” x 6”
0813906a 12” x 12” x 6“ 2013653a 12” x 12” x 6“
9 2513653a 12” x 12” x 6” 2513808a 20” x 20” x 8”
0813916 14” x 14” x 4” 2013663 14” x 14” x 4”
2513663 14” x 14” x 4” 2513810a 20” x 20” x 10”
0813918 a
14” x 14” x 6” 2013665 a
14” x 14” x 6”
2513665a 14” x 14” x 6”
PIPE AND FITTINGS
PIPE AND FITTINGS

2513812a 20” x 20” x 12”
0813920a 14” x 14” x 8” 2013667a 14” x 14” x 8”
2513667a 14” x 14” x 8” 17.6 2513821 22” x 22” x 4”
SDR Part no. Dimension ND 2613601 6” x 6” x 2 ½” 2013676 16” x 16” x 4” SDR Part no. Dimension ND
2513676 16” x 16” x 4”
0813600 6” x 6” x 2 ½” 2613603 6” x 6” x 3” 11 2013678 a
16” x 16” x 6” 2513600 6” x 6” x 2 ½” 2513839 24” x 24” x 4”
17.6 2513678a 16” x 16” x 6”
0813602 6” x 6” x 3” 2613609 8” x 8” x 2 ½” 2013680 a
16” x 16” x 8” 2513602 6” x 6” x 3” 2513841a 24” x 24” x 6”
2513680a 16” x 16” x 8”
0813608 8” x 8” x 2 ½” 2613611 8” x 8” x 3” 2013682a 16” x 16” x 10” 2513608 8” x 8” x 2 ½” 2513843 a
24” x 24” x 8”
2513682a 16” x 16” x 10”
0813610 8” x 8” x 3” 11 2613613 8” x 8” x 3 ½” 2013690 18” x 18” x 4” 2513610 8” x 8” x 3” 2513845a 24” x 24” x 10”
2513690 18” x 18” x 4”
9 0813612 8” x 8” x 3 ½” 2613615 8” x 8” x 4” 2013692a 18” x 18” x 6” 17.6 2513847a 24” x 24” x 12”
2513612 8” x 8” x 3 ½” 2513692a 18” x 18” x 6”
0813614 8” x 8” x 4” 2613625 10” x 10” x 2 ½” 2013694 a
18” x 18” x 8” 2513614 8” x 8” x 4” Branch outlet has a butt-weld connection.
a
2513694a 18” x 18” x 8”
0813624 10” x 10” x 2 ½” 2613627 10” x 10” x 3” 2013696a 18” x 18” x 10” 2513624 10” x 10” x 2 ½” 2513696a 18” x 18” x 10”
5.26
5.27
0813626 10” x 10” x 3” 2613629 10” x 10” x 3 ½ 2013698a 18” x 18” x 12” 2513626 10” x 10” x 3” 2513698a 18” x 18” x 12”
0813628 10” x 10” x 3 ½
a 2513628 10” x 10” 3 ½”
Fusion outlet (Socket) Fusion outlet (Butt-weld)
Dimension ND Dimension ND Dimension ND Dimension ND Dimension ND Dimension ND

Part no. Part no. Part no. Part no. Part no. Part no.
(pipe x outlet) (pipe x outlet) (pipe x outlet) (pipe x outlet) (pipe x outlet) (pipe x outlet)
0115172 2 ½” x ¾” 0115194 4” x 1” 0115230 8 to 10” x 1” 0115257 10” x 4” 0115303 20” to 22” x 3 ½”
0115265 12“ x 6“
0115174 2 ½” x 1” 0115196 4” x 1 ¼” 0115231 8” x 1 ¼” 0115260 12” to 14” x 2” 0115315 22” to 24” x 2 ½”
0315265 12“ x 6“
0115175 2 ½” x 1 ¼” 0115197 4” x 1 ½” 0115232 8” x 1 ½” 0115261 12” to 14” x 2 ½” 0115316 22” to 24” x 3”
0315271 14“ x 6“
0115176 3” x ½” 0115198 4” x 2’’ 0115233 8” x 2” 0115262 12” x 3” 0115318 22” to 24” x 4”
0115271 14“ x 6“
PIPE AND FITTINGS
PIPE AND FITTINGS

0115263 12” x 3 ½” 0115331 24” x 3 ½”
0115178 3” x ¾’’ 0115206 6” x ½” 0115234 8” x 2 ½” 0115272 14“ x 8“
Dimension ND 0115264 12” x 4”
Part no. 0115180 3” x 1” 0115208 6” x ¾” 0115235 8” x 3”
(pipe x outlet) 0115280 16“ x 6“ to 10“
0115268 14” x 3”
0115156 1 ¼” x ½” 0115181 3” x 1 ¼” 0115210 6” x 1” 0115236 8” x 3 ½”
0115269 14” x 3 ½” 0115292 18“ x 6“ to 10“
0115158 1 ¼” x ¾” 0115182 3 ½” x ½” 0115212 6” x 1 ¼” 0115237 8” x 4”
0115270 14” x 4” 0115298 18“ x 12“
0115160 1 ½” x ½” 0115184 3 ½” x ¾” 0115214 6” x 1 ½” 0115251 10” x 1 ¼”
0115275 16” to 20” x 2 ½” 0115306 20“ x 6“ to 10“
0115162 1 ½” x ¾” 0115186 3 ½” x 1” 0115216 6” x 2” 0115252 10” x 1 ½”
0115277 16” to 18” x 3 ½” 0115312 20“ x 12“
0115164 2 x ½” 0115188 3 ½” x 1 ¼” 0115218 6” x 2 ½” 0115253 10” x 2” 0115278 16” x 4” 0115334 24“ x 6“ to 10“
0115166 2” x ¾” 0115189 3 ½” x 1 ½” 0115220 6” x 3” 0115254 10” x 2 ½” 0115288 16” to 20” x 3” 0115340 24“ x 12“
0115190 4” x ½” 0115228 8 to 10” x ½” 0115255 10” x 3”
5.28
5.29
0115168 2” x 1” 0115290 18” to 20” x 4”
0115170 2 ½” x ½” 0115192 4” x ¾” 0115229 8 to 10” x ¾” 0115256 10” x 3 ½” 0115300 16” to 24” x 2”
Flange ring Flange adapter Flange adapter (Butt-weld)
Nominal Butterfly Valve Dimension Dimension

Dimension # of bolt SDR SDR Part no.
Part no. flange Part no. ND — OD ND — OD
ND holes
size 0315530BV 6” 2915530BV 6”
3315726 4” 4” 8 0315534BV 8“ 2915534BV 8”
3315730 6” 6” 8 9 0315538BV 10” 2915538BV 10”
3315734 8” 8” 8 0315542BV 12” 2915542BV 12”
2915544BV 14”
0315544BV 14”
PIPE AND FITTINGS
PIPE AND FITTINGS

Nominal 3315738 10” 10” 12 17.6
Dimension # of bolt Dimension Dimension 2915546BV 16”
Part no. flange Part no. SDR Part no.
ND holes 3315742 12” 12” 12 ND ND — OD 0115531BV 6” 2915548BV 18”
size
3315744 14” 14” 12 0115512 1” 0115530BV 6” 0115531LBBVc 6” 2915550BV 20”
3315712 1” 1” 4
3315746 16” 16” 16 0115514 1 ¼” 0115530LBVb 6“ 115531LGBVb 6” 2915552d 22”
3315714 1 ¼” 1 ¼” 4 0115534BV 8” 2915554BV 24”
3315748 18” 18” 16 0115516 1 ½” 7.4 0115535BV 8”
3315716 1 ½” 1 ½” 4 0115538BV 10”
3315750 20” 20” 20 0115518 2” 11 0115539BV 10”
3315718 2” 2” 4 0115542BV 12” a
Part no. 0115526 must be paired
0115520 2 ½” 0115543BV 12” with a coupling (part no. 0111026,
3315752 22” 22” 20 0115544BV 14”
3315720 2 ½” 2 ½” 4 sold separately).
0115522 3” 0115545BV 14”
3315754 24” 24” 20 b
Includes 1-ft extension of
3315722 3” 3” 8 0115524 3 ½” 0115547BV 16” aquatherm green pipe.
3315724 3 ½” 3 ½” 8 0115549BV 18” c
Includes 1-ft extension of
5.30
5.31
0115526 a
4”
aquatherm blue pipe.
d
Not butterfly valve compatible.
Pump flange adapter ring Union with brass nut Union with PP-R nut Flow through back plate elbow 90° Flow through back plate elbow parallel
American bolt pattern
Part No. Dimension

PIPE AND FITTINGS
PIPE AND FITTINGS

Part No. Dimension
20197 20 mm x 1/2" IG x 20 mm 20198 20 mm x 1/2" IG x 20 mm
Dimension Part no. Dimension ND Part no. Dimension ND
Part no.
ND — OD
0115812 1” 0115838 ½”
1” (32 mm) pump flange ring - blue,
5515712 3-1/8” to 3-5/32” bolt center
0115814 1 ¼” 0115840 ¾”
used with #0115512 0115816 1 ½” 0115842 1”
1.25” (40 mm) pump flange ring - black, 3-1/8” to 0115818 2” 0115844 1 ¼”
5515713 3-5/32” bolt center
used with #0115514 0115820 2 ½” 0115846 1 ½”
1.25” (40 mm) pump flange ring - green, 3-/16” to 0115848 2”
3-1/2” bolt center 0115850 2 ½”
5515714
5.32
5.33
used with #0115514, fitted Grundfos model
UP4375
Wing back 90° elbow Electrofusion coupling Back plate elbow ISO plug for pressure tests
threaded with gasket

0117222 3”
0117224 3 ½”
0117226 4”
0117230a 6”
PIPE AND FITTINGS
PIPE AND FITTINGS

0117234 a
8”
Lead-free Part no. Dimension ND 0117238a 10” Lead-free (potable) Part no. Dimension
Stainless steel Stainless steel Dimension
(potable) brass Dimension brass
Part no. (ISO) 0117208 ½” Part no. (ISO) PP-R (ND) x thread type 0050708 ½” M
Part no. (NPT) Part no. (NPT)
0117210 ¾” 0050710 ¾” M
0920158 0620158 20 mm x ½” F 0920108 0620108 ½” x ½” F
0117212 1”
0117214 1 ¼” 0920110 0620110 ½” x ¾” F
0117216 1 ½” 0920112 0620112 ¾” x ¾” F

0117218 2” 0920113 0620113 ¾” x ½” F
0117220 2 ½”
5.34
5.35
Cannot be used in conjunction with UV pipe.
a
Transition piece NPT transition piece (female) Transition piece NPT transition piece (male)
round (female) with hex-shaped threaded transition round (male) hex-shaped threaded transition
Stainless Lead-free Lead-free (potable) brass Dimension

Dimension Part no. (NPT) PP-R (ND) x thread
steel (potable) brass
PP-R (ND) x thread type
Part no. (NPT) Part no. (NPT) 0621308 ½” x ½” M
- 0621108 ½” x ½” F 0621310 ½” x ¾”M
- 0621110 ½” x ¾” F 0621312 ¾” x ¾” M
- 0621111 ¾” x ½” F 0621314 1” x 1” M
PIPE AND FITTINGS
PIPE AND FITTINGS

- 0621112 ½” x ¾” F 0621316 1” x 1 ¼” M
Stainless Lead-free (potable) Dimension - 0621113 ½” x ¾” F Lead-free 0621317 1 ¼” x 1” M
Stainless
steel brass PP-R (ND) x thread (potable) Dimension
1121114 0621114 1” x 1” F steel 0621318 1 ¼” x 1 ¼” M
Part no. (ISO) Part no. (NPT) type brass PP-R (ND) x thread type
Part no. (ISO)
1121115 0621115 1 ¼” x 1” F Part no. (NPT) 0621319 1 ½” x 1 ¼” M
0921008 0621008 ½” x ½” F
1121116 0621116 1 ¼” x 1 ¼” F 0921208 0621208 ½” x ½” M 0621320 1 ½” x 1 ½” M
0921010 0621010 ½” x ¾” F
1121117 0621117 1 ½” x 1 ¼” F 0921210 0621210 ½” x ¾” M 0621321 2” x 1 ½” M
0921011 0621011 ¾” x ½” F
1121118 0621118 1 ½” x 1 ½” F 0921211 0621211 ¾” x ½” M 0621322 2” x 2” M
0921012 0621012 ¾” x ¾” F
1121119 0621119 2” x 1 ½” F 0921212 0621212 ¾” x ¾” M 0621323 2 ½” x 2” M
0921013 0621013 1” x ¾” F
01121120 0621120 2” x 2” F 0921213 0621213 1” x ¾” M 0621324 2 ½” x 2 ½” M
5.36
5.37
0621325 3” x 3” M
- 0621122 2 ½” x 2” F
0621327 3 ½” x 4” M
NPT transition elbow (female) NPT transition street elbow NPT transition tee Draining branch Flow meter well May also be used for thermometer well.
(male/female) (male) to weld in valves
Lead-free Lead-free
PIPE AND FITTINGS
PIPE AND FITTINGS

Dimension Dimension
(potable) brass (potable) brass
pipe x outlet x thread x ID pipe x outlet x thread x ID
Stainless Lead-free Lead-free (potable) Lead-free Industrial Part no. Part no.
Dimension Dimension Dimension
steel (potable) brass brass (potable) brass brass Dimension ND
PP-R (ND) x Thread type PP-R (ND) x Thread type ND 0628480 2” x 1 ¼” x 1 ¼” F x 1” 0628501 6” x 1 ½” x 1 ½” F x 1 ¼”
Part no. (ISO) Part no. (NPT) Part no. (NPT) Part no. (NPT) Part no.
0923008 0623008 ½” x ¾” F 0623208 ½” x ½” F 0625506 ½” x ½” M x ½” 0628481 2 ½” x 1 ¼” x 1 ¼” F x 1” 0628502 8” x 1 ½” x 1 ½” F x 1 ¼”
0041408 ½”
0923010 0623010 ½” x ½” F 0628482 3” x 1 ¼” x 1 ¼” F x 1” 0628503 10” x 1 ½” x 1 ½” F x 1 ¼”
0041410 ¾” 0628483 3 ½” x 1 ¼” x 1 ¼” F x 1” 0628520 4” x 2” x 2” F x 1 5/8”
0923012 0623012 ¾” x ¾” F
0923014 0623014 ¾” x ½” F 0041412 1” 0628484 4” x 1 ¼” x 1 ¼” F x 1” 0628521 6” x 2” x 2” F x 1 5/8”
0923016 0623016 1” x ¾” F 0041414 1 ¼” 0628485 6” x 1 ¼” x 1 ¼” F x 1” 0628522 8” x 2” x 2” F x 1 5/8”
(NPT) 0628486 8” x 1 ¼” x 1 ¼” F x 1” 0628523 10” x 2” x 2” F x 1 5/8”

5.38
5.39
0041416 1 ½”
1123018 0623018 1” x 1” F 0628487 10” x 1 ¼” x 1 ¼” F x 1” 0628524 12” to 14” x 2” x 2” F x 1 5/8”
0041418 2” 0628525 16” to 24” x 2” x 2” F x 1 5/8”
0628500 4” x 1 ½” x 1 ½” F x 1 ¼”
Stub out Straight stub out PEX adaptor (crimp) PEX adaptor (expansion) PP-R to grooved transition
(PP-R to copper) (PP-R to copper) ASTM F1807 standard with PP-R socket connection. ASTM F1960 standard with PP-R street connection.
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND Part no. Dimension ND Lead-free Lead-free Lead-free
(potable) brass Dimension ND (potable) brass Dimension ND (potable) brass Dimension ND
AQ630P248E ½” AQ638P211 ½”
Part no. Part no. Part no.
AQ630P368E ¾” AQ638P311 ¾”
0099840 ½” (20 mm) PP-R to ½” PEX 0098840 ½” (20 mm) PP-R to ½” PEX 2 ½” (75 mm) PP-R to
0627060
AQ630P41110 1” AQ638P418 1” 2” grooved
0099841 ¾” (25 mm) PP-R to ¾” PEX 0098841 ¾” (25 mm) PP-R to ¾” PEX
0099842 1” (32 mm) PP-R to 1” PEX 0098842 1” (32 mm) PP-R to 1” PEX
5.40
5.41
Transition elbow (male) Transition tee (female) NPT fusion outlet hex (female)
Lead-free (potable) Dimension Lead-free (potable) Dimension

Stainless steel Stainless steel
brass pipe x outlet brass pipe x outlet
Part no. (ISO) Part no. (ISO)
Part no. (NPT) (thread) Part no. (NPT) (thread)
0928214 0628214 1 ¼” x ¾” (½” F) 0928242 0628242 3” x ¾” (¾” F)
0928216 0628216 1 ½” x ¾” (½” F) 0928244 0628244 3 ½” x ¾” (¾” F)
0928218 0628218 2” x ¾” (½” F) 0928246 0628246 4” x ¾” (¾” F)
PIPE AND FITTINGS
PIPE AND FITTINGS

Stainless Lead-free 0928220 0628220 2 ½” x ¾” (½” F) 0928250 0628250 6” x ¾” (¾” F)
Dimension
Stainless Lead-free steel (potable) brass
Dimension PP-R (ND) x thread type 0928222 0628222 3” x ¾” (½” F) 0928254 0628254 8 to 10” x ¾” (¾” F)
steel (potable) brass Part no. (ISO) Part no. (NPT)
PP-R ND x thread type (NPT)
Part no. (ISO) Part no. (NPT) 0925006 0625006 ½” x ½” x ½” F 0928224 0628224 3 ½” x ¾” (½” F)
0923506 0623506 ½” x ½” M 0925008 0625008 ½” x ½” x ¾” F 0928226 0628226 4” x ¾” (½” F) 1128260 0628260 2 ½” x 1” (1” F)
0925010 0625010 ¾” x ¾” x ½” F 0928230 0628230 6” x ¾” (½” F) 1128262 0628262 3” x 1” (1” F)

0923508 0623508 ½” x ¾” M
0925012 0625012 ¾” x ¾” x ¾” F 0928232 0628232 8 to 10” x ¾” (½” F) 1128264 0628264 3 ½” x 1” (1” F)
0923510 0623510 ¾” x ¾” M
0925014 0625014 1” x 1” x ¾” F 0928234 0628234 1 ¼” x ¾” (¾” F) 1128266 0628266 4” x 1” (1” F)
0923512 0623512 1” x ¾” M 1128270 0628270 6” x 1” (1” F)
(NPT) 0928236 0628236 1 ½” x ¾” (¾” F)
5.42
5.43
- 0623514 1” x 1” M 1125016 0625016 1” x 1” x 1” F 0928238 0628238 2” x ¾” (¾” F) 1128274 0628274 8 to 10” x 1” (1” F)
- 0625022 1 ½” x 1 ½” x 1” F 0928240 0628240 2 ½” x ¾” (¾” F)

NPT fusion outlet (male) Distribution block plumbing Distribution block plumbing Distribution pipe
including 1 plug and 2 fasteners with insulation block
Lead-free Lead-free
Dimension Dimension
(potable) brass (potable) brass
pipe x outlet (thread) pipe x outlet (thread)
Part no. (NPT) Part no. (NPT)
0628314 1 ” x ¾” (½” M) 0628326 4” x ¾” (½” M)

0628316 1 ½” x ¾” (½” M) 0628330 6” x ¾” (½” M)
0628318 2” x ¾” (½” M)
PIPE AND FITTINGS
PIPE AND FITTINGS

0628334 1 ” x ¾” (¾” M)
0628320 2 ½” x ¾” (½” M)
0628336 1 ½” x ¾” (¾” M) Part no. Dimension ND Part no. Dimension ND Part no. Dimension ND
0628322 3” x ¾” (½” M) 0130115 ¾” x ½” 0130130 ¾” x ½” 0130604 1” x ½”
0628338 2” x ¾” (¾” M)
0628324 3 ½” x ¾” (½” M)
0628340 2 ½” x ¾” (¾” M)
0628342 3” x ¾” (¾” M)
0628344 3 ½” x ¾” (¾” M)
0628346 4” x ¾” (¾” M)
0628350 6” x ¾” (¾” M)
5.44
5.45
Distributor end piece Screw-down stop globe valve Concealed valve (short) Concealed valve (standard length) Concealed valve (extended) Concealed valve (standard)
with female thread NPT for surface installation chromium-plated, chromium-plated, tamper proof chromium-plated chromium-plated,
tamper proof tamper proof
PIPE AND FITTINGS
PIPE AND FITTINGS

Industrial Industrial Industrial Industrial Industrial Industrial
Dimension brass Dimension ND
brass brass Dimension ND brass Dimension ND brass Dimension ND brass Dimension ND
(ND) x Thread Part no.
Part no. Part no. Part no. Part no. Part no.
0130804 1” x ½” F 0140808 ½” 0140868 ½” 0140888 ½” 0140878 ½” 0140858 ½”
0140810 ¾” 0140870 ¾” 0140890 ¾” 0140880 ¾” 0140860 ¾”
0140812 1” 0140872 1” 0140892 1” 0140882 1” 0140862 1”
0140814 1 ¼” Not for potable applications Not for potable applications Not for potable applications Not for potable applications
5.46
5.47
Not for potable applications
Concealed valve Stop valve body ISO Inclined valve Inclined check valve Ball valve Ball valve
chromium-plated for without drain without drain without drain (male/female)
part no. 0040858-0040862
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension ND Industrial Industrial Industrial Industrial Industrial
Dimension
brass brass Dimension ND brass Dimension ND brass Dimension ND brass Dimension ND
0040900 Length = 3.2” PP-R (ND) x Thread
Part no. Part no. Part no. Part no. Part no.
0040902 Length = 4.25” 0040908 ½” x ¾”F 0041108 ½” 0041208 ½” 0041308 ½” 0078000 1” — M/F
0040910 ¾” x ¾”F 0041110 ¾” 0041210 ¾” 0041310 ¾” Replacement parts available
0040912 1” x 1”F
0041112 1” 0041212 1” Not for potable applications
0041312 1”
0040914 1 ¼” x 1 ¼”F
0041114 1 ¼” 0041214 1¼” 0041314 1¼”
5.48
5.49
Not for potable applications Not for potable applications 0041316 1 ½”
Replacement parts available
0041318 2”
Not for potable applications
Ball valve Ball valve Replacement bolt/gasket Ball valve
polypropylene Polypropylene with ISO bolt pattern kit for ball valves Polypropylene construction with ISO bolt pattern. Comes with 2 gaskets, 16 bolts,
Kit includes the following replacement and 16 washers. Contact Aquatherm to order parts individually.
parts for the polypropylene Aquatherm ball
valves: 2 gaskets, 16 bolts, and 16 washers.
Part no. Dimension ND Part no. Dimension (ND — OD)
0041602 3”
0041488 ½” 0041802 3”
0041702a 3”
0041588 a
½” 0041804 a
3 ½” to 4”
0041604b 3 ½” and 4”
0041490 ¾” 0041807 6”
PIPE AND FITTINGS
PIPE AND FITTINGS

0041704a 3 ½” and 4”
0041590 a
¾”
Part no. Dimension (ND — OD) a
For a 4” connection, use part no. 0115526 and
0041607 6”
0041492 1” part no. 3315726. For a 3 ½” connection, use part
0041707a 6” 4160218(S)a 3” no. 0115524 and part no. 3315724.
0041592a 1”
Note: A full-faced flange gasket should be used
4160418(S) b
3 ½” to 4”
0041494 1 ¼” a
Part comes with FKM/FPM O-ring with these valves. Do not use an O-ring with or
and in the color gray. See catalog p 4160718(S)c 6” without the flange gasket or leakage may occur.
0041594a 1 ¼” 5.57 for reference and what order to Discard any O-ring that may come with the valve.
0041496 1 ½” add the parts.
a
Replacement kit for part no. 0041602 and 0041702.
b
0041596a 1 ½” c
0041498 2”
5.50
5.51
0041598a 2” a
Part comes with FKM/FPM O-ring
0041400 2 ½” in the color gray.
Extension for ball valve Split flange ring Repair plug Temperature protective Welding heads
Carbon steel with green epoxy powder coating, American bolt pattern. For flange bolt size and to close pipe holes up to 7⁄16” (repair stick gloves
torque, refer to Appendix A. ASME B16.5, Class 150 bolt pattern. part no. 0060600)
Part no. Dimension Part no. Dimension Part no. Dimension

0050195 - 0050206 ”
PIPE AND FITTINGS
PIPE AND FITTINGS

3/8
0060600 ⁄
7 16” x ¼”
Part no. Dimension (ND — OD) Part no. Dimension (ND — OD) 0050208 ½”
Dimension
Part no. 0615734 8”
ND x length 0615712 1” 0050210 ¾”
0041378 ½” to ¾” 0615714 1 ¼” 0615738 10” 0050212 1”
0615716 1 ½” 0615742 12”
0041382 1” to 1¼” 0050214 1 ¼”
0615718 2” 0615744 14”
0041386 1 ½” to 2” 0050216 1 ½”
0615720 2 ½” 0615746 16”
0050218 2”
0041378 suitable for part no. 0041308 / 0041310. 0615722a 3” 0615748 18”
0041382 suitable for part no. 0041312 / 0041314. 0050220 2 ½”
0615750 20”
0041386 suitable for part no. 0041316 / 0041318. 0615724a 3 ½” 0050222 3”
0615754 24”
5.52
5.53
0615726 4” 0050224 3 ½”
0615730 6” 0050226 4”
Drill bit Replacement pilot bits Fusion outlet welding heads
for boring fusion outlet holes
Part no. Dimension Part no. Dimension

Part no. Dimension (ND — OD)
0050629 3” x 1 ¼” 0050657 6” x 2 ½”
0099910 ½” to 1” — 20 to 32 mm
0050631 3 ½” x ½” & ¾” 0050658 6” x 3”
0099911 1 ¼” to 2” — 40 to 63 mm
0050632 3 ½” x 1” 0050660 8” x ½” & ¾”
0050634 3 ½” x 1 ¼” 0050662 8” x 1”
PIPE AND FITTINGS
PIPE AND FITTINGS

Part no. Dimension Part no. Dimension 0050635 3 ½” x 1 ½” 0050664 8” x 1 ¼”
0050950a 2 ½” Part no. Dimension 0050636 4” x ½” & ¾” 0050666 8” x 1 ½”
0050940 ½” & ¾” for pipes 1¼” - 6”
0050952 a
3” 0050614 1 ¼” x ½” & ¾” 0050638 4” x 1” 0050667 8” x 2 ½”
0050941 ½” & ¾” for pipes 2” - 10” 0050954a 3 ½” 0050616 1 ½” x ½” & ¾” 0050640 4” x 1 ¼” 0050668 8” x 2”
0050956 a
4” 0050619 2” x ½” & ¾” 0050642 4” x 1 ½” 0050669 8” x 3”
0050942 1”
0050958 a
6” 0050620 2” x 1” 0050644 4” x 2” 0050670 8” x 3 ½”
0050944 1 ¼”
0050960 a
8” 0050623 2 ½” x ½” & ¾” 0050648 6” x ½” & ¾” 0050671 8” x 4”
0050946 1 ½”
0050624 2 ½” x 1” 0050650 6” x 1” 0050672 10” x ½” &. ¾”
0050948 2” a
Only fits into a drill press that can
accommodate a Morse Taper shank. 0050625 2 ½” x 1 ¼” 0050652 6” x 1 ¼” 0050674 10” x 1”
5.54
5.55
0050627 3” x ½” & ¾” 0050654 6” x 1 ½” 0050676 10” x 1 ¼”
0050628 3” x 1” 0050656 6” x 2”
Fusion outlet welding heads (continued)
Notes
Part no. Dimension Part no. Dimension

0050696 12” x 3 ½” 0050734 22” - 24” x 3”
0050698 12” x 4” 0050736 16” - 18” x 3 ½”
0050699 12” x 6” 0050738 20” - 22” x 3 ½”
0050712 14”x 2” 0050740 24” x 3 ½”
PIPE AND FITTINGS
PIPE AND FITTINGS

0050714 14” x 2 ½” 0050742 16” x 4”
Part no. Dimension 0050716 14” x 3” 0050744 18” - ½” x 4”
0050678 10” x 1 ½” 0050718 14” x 3 ½” 0050746 22” - 24” x 4”
0050680 10” x 2” 0050720 14” x 4”
0050682 10” x 2 ½” 0050722 14” x 6”
0050684 10” x 3” 0050724 14” x 8”
0050686 10” x 3 ½” 0050726 16” - 24” x 2”
0050688 10” x 4” 0050728 16” - 20” x 2 ½”
0050690 12” x 2” 0050730 22” - 24” x 2 ½”
5.56
5.57
0050692 12” x 2 ½” 0050732 16” - 20” x 3”
0050694 12” x 3”
Notes

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aquatherm INSTALLER MANUAL

825 W 600 N | Lindon, UT | 84042 | 801.805.6657

© 2015 aquatherm NA L.C. All rights reserved

Required for the Aquatherm Installer

© 2015 aquatherm, LP. All rights reserved

Contents Segmented fittings 1.17

This training will teach you

• Damaged when exposed to • Heat-stabilized to withstand

Pipe integrity (at 400 oF)

reclaimed water (Select SDR based on Temp and Pressure Requirements)

Wall thickness: SDR 17.6 Wall thickness: SDR 11

• 6”- 24” fittings butt weld in-line with the pipe

• Pressure rating meets the pressure rating of the pipe

aquatherm aquatherm aquatherm aquatherm operation using water or a water/

Pipe Capacity Weight w/ water Pipe Capacity Weight w/ water

Butt fusion Outlet fusion

There are procedures that should be These are recommended cutting

Wear OSHA-approved steel- Be careful when handling

Remove standing dirt and oil using an

Taper for easier fusion

Compared to open flames or

The marking guide helps ensure

1 heats up. The plate will expand as it heats and leave

When the iron is hot, tighten the welding heads for

In socket fusion, you are heating

The following indicators will allow you

Mark the pipe where you want the outlet. Once

1 2 metric or metric-compatible peelers.

Pro tip: The black indicator on the top of

Aquatherm supports butt welding on sizes 6”

Dimension Heating Welding (Fusion) Cooling Maintenance should only be

Drag Pressure: Find the drag pressure by

The heating phase requires as

Whether on hangers or blocks, the pipe should be

The external bead should appear

For small holes in the pipe, such

install and cap an outlet or

Having the right crew and tooling

A jig-style fusion machine eliminates A bench-style fusion machine

Full-size butt fusion machines W 4400 Most four-jaw machines can

Crew: 1 primary, 1 support Unproductive time

Primary then performs the hot

Crew: 1 primary, 1-2 support This process can also be done

Process: Support sets up first jig

In areas where lateral movement is

One side of the pipe is peeled back

Flange adaptors can join the

difficult or impossible. Flange

Planning for flanged spools will

Beyond heat fusion, there are a number of

Remember that, when using an

Support intervals (ft)

Pipe diameter Pipe diameter

Pipe diameter Pipe diameter

strainers, etc.), care must be copper in the water resulting catalog.

withstand temperatures above case, do not expose any PP-R

hole pattern is built to the gaskets and bolt kids, or these

applications. Industrial brass not threading to the PP-R.

fittings are available for all other • Always apply counter

SDR 7.4 SDR 9 SDR 11 SDR 17.6

so additional pressure may be required to help it stabilize.

• Release the pressure from the system.

Step 5: Complete and submit the pressure test record.

All information can be submitted electronically on Aquatherm’s website at http://www.aquatherm.com/

Contents Segmented fittings 1.17