Zurn PEX Plumbing, PEX Tubing, PEX Fittings, QickPort Manifold, Qick/Sert® Fittings Installation Guide

Zurn PEX Plumbing Design and Application Guide
Zurn PEX Tubing and Fittings
Certified
Notice: This manual contains recommended installation instructions for Zurn PEX hot
and cold water systems. Failure to observe these installation instructions may result in
substandard performance of the system. Zurn Industries, Inc. expressly disclaims any
responsibility or liability for substandard performance resulting from failure to comply
with installation instructions.
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Zurn PEX Plumbing Design and Application Guide
ZURN PEX PLUMBING
Design and Application Guide
STANDARDS, LISTINGS, APPROVALS, OR ACCEPTANCES
PEX Plumbing Systems are covered in the following codes, standards or
approvals:
ASTM F876
ASTM F877
ASTM F1807
American Society for Testing and Materials
ANSI/NSF Standard 14
NSF International
ANSI/NSF Standard 61
NSF International
CAN/CSA B137.5
Canadian Standards Association
IPC
International Plumbing Code
IRC
International Residential Code
UPC
International Association of Plumbing and
Mechanical Officials
State and Local
City, County, and State Residential
Code Acceptance
Contact your local plumbing official
The standards and code bodies above may not list all elements comprising
the Zurn PEX System. Check your local code under “cross-linked
polyethylene” or “PEX.”
MARKING
All Zurn PEX tube is marked with nominal size, wall thickness, pressure
rating, NSF-PW, and the applicable ASTM standards. Zurn PEX tube
is for water applications only. Do not use with LP or natural gas.
See Figure 1.
ASTM
Standards
Zurn PEX
–
NSF-pw-Cl-TD
–
ASTM F876/F877
Manufacturer
Standard
Dimension Ratio
–
SDR-9
OD Size
–
100 PSI at 180°F
Pressure/Temperature
Rating
–
3/4" CTS - 7/8"
–
AA-12-21-95-18:36
Production Code
Listing Agency and
Chlorine Rating
Figure 1
It is the sole responsibility of the installer to assure that this product
meets local codes.
Page 1
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Zurn PEX Plumbing Design and Application Guide
WHAT IS ZURN PEX?
Zurn PEX:
• is a flexible pipe for hot and cold water plumbing applications.
• is listed by NSF as safe for use with drinking water, meets or exceeds
the requirements of ASTM F877.
• is installed using insert and crimp system of fittings, tools, and
Go/No-Go gauges.
• can be used in residential and light commercial hot and cold water
plumbing applications.
• can be used in hydronic radiant floor applications.
• may be bent in a radius as small as six (6) times the outside diameter
of the tube.
IMPORTANT – Zurn PEX:
• should not be stored or installed where it will be exposed to direct or
indirect ultraviolet light (i.e. sunlight).
• should not be exposed to direct flame.
• should not be used in excessive operating conditions inconsistent with
pressure ratings that appear on tubing and applicable standards.
• should not be subjected to prolonged exposure to free chlorine concentrations greater than 4 ppm.
CAUTION:
Never use any chemicals, pipe
thread compounds, putty, mineral
or linseed oil products. They could
damage your pipe and fittings.
• should not be used in contaminated soils.
• should not be exposed to materials that affect the basic properties of
cross-linked polyethylene, brass, or copper.
NOTICE!
Zurn PEX fittings are identified by the letters “Q” and “PEX” stamped
onto the body of the fitting. The PEX fittings also have two ribs on the
insert portion of the fitting.
Zurn PEX crimp rings are identified by the letters “Q” and “PEX”
stamped on the outside of the ring. Zurn PEX crimp rings are colored
black for easy identification.
WARNING: It is the installer’s responsibility to avoid mixing PB and
Zurn PEX components. Zurn Industries, Inc. does not guarantee or
in any way warrant the installation of Zurn PEX systems due to the
wide variance in installation practices.
Mixing of PB and Zurn PEX components may cause plumbing system
failure and result in severe water damage.
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Zurn PEX Plumbing Design and Application Guide
HOW THE ZURN PEX SYSTEM WORKS
This insert and crimp-ring system is designed to help a professional
plumber make permanent, tightly sealed, leakproof connections for
creation of a well-functioning Zurn PEX pipe hot and cold water
distribution system or to repair any existing system. The tools and
recommended techniques are explained in this guide.
Fittings
Made of strong brass, the fitting is
inserted into the end of the PEX pipe.
A tightly sealed connection is formed by
properly crimping a copper ring on the
pipe. This process presses the fitting ribs
into the pipe.
Crimp Tool
The tempered steel tool provides positive
interlocking jaw action for precision crimping.
Crimp Ring
Annealed and ductile with a black finish,
this precision-formed copper ring goes
on the pipe and must be located over the
ribs of the inserted fitting. When crimped,
it permanently seals the pipe and fitting
together.
Cutting Tool
Designed for smooth, even cutting, the
tool’s jaw will fit firmly over the pipe to
allow a square, burr-free cut.
Gauge
This flat steel “Go/No-Go” gauge lets you
determine if a crimped connection was
properly made.
Crimp Ring Removal Tool
This compact tool assists in removing the
crimp ring and PEX tubing without damaging the fitting. Using the ring removal tool
allows a fitting to be safely reused.
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Zurn PEX Plumbing Design and Application Guide
MAKING A CONNECTION
Measure and cut the pipe. Be sure you
have a square burr-free cut. An uneven
or jagged cut may cause an improper
connection.
Next, slip a copper crimp ring onto the
pipe. Do not use hose clamps!
Fitting
Shoulder
1/8" to 1/4"
Crimp Ring
Spacing
Now insert the fitting into the pipe up to
the fitting shoulder. Position the crimp
ring 1/8" to 1/4" from the end of the tube.
An improperly positioned ring may produce a weak connection.
Page 4
90°
Position the tool so the crimp ring is
completely covered by the tool jaws.
Keep the tool at a 90° angle to the
fitting and close it completely.
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Zurn PEX Plumbing Design and Application Guide
USING THE ZURN CHECKING GAUGE
After making crimp connections, use the appropriate opening of this flat
“Go/No-Go” Gauge to check your finished crimp. The “Go” opening
should go freely across a crimped ring anywhere on its diameter with the
possible exception the upset area on the ring surface caused by the tool
jaws closing. Do not force the gauge across the ring. The “No-Go” opening
should not go across a crimped ring anywhere. If the crimp fails either
test, cut out the fitting and replace.
Go and No-Go Openings
DO’s
Always place the gauge
opening on the crimp ring
at a 90° angle for an
accurate check.
Be certain you use the
gauge opening sized for
the diameter of your pipe.
Replace non-conforming
crimps.
Don’t try to save time by
recrimping a crimp that
does not gauge properly.
The fitting must be cut
out and replaced.
Don’t modify the gauge
opening areas for any
reason. They have been
carefully manufactured to
.002 inch tolerance.
DON’Ts
No
Yes
Don’t slide the gauge onto
the connection by sliding
it along the tube. Push it
directly onto the crimped
ring.
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Zurn PEX Plumbing Design and Application Guide
THE PERFECT CRIMP CONNECTION
The PEX tubing must be placed to the fitting shoulder. For fittings
without a shoulder, the PEX tubing must be placed far enough to cover
all the fitting barbs. The crimp ring is placed 1/8" to 1/4" from the
shoulder or end of the PEX tubing.
Fitting Shoulder
No dimples,
“ears,” or
leak path gaps.
Proper pressure
and friction
between fitting
and pipe.
Mechanical
Interlock
Tubing forced firmly
between ribs.
INCORRECT CONNECTIONS AND THE CONSEQUENCES
#1 Ring crimped over end of the tube.
Result: Does not cover enough ribs.
#1
#2 Tool was not at 90° to the tube when crimped.
Result: Insufficient rib coverage; plastic dented.
#2
#3 Ring not completely covered by crimping tool.
Result: Ring distortion, non-uniform crimp.
#3
#4 Tube not cut squarely.
Result: Insufficient rib coverage.
#4
#5 Ring too far from pipe end.
Result: Insufficient rib coverage.
#5
In every case, the final consequence is improper sealing and leak potential.
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Zurn PEX Plumbing Design and Application Guide
ADJUSTMENT (QCRT2T, QCRT3T, QCRT4T)
Zurn crimp tools are factory set to provide proper crimps. This should
be checked before use by making a test crimp connection and checking
it with the crimp gauge. As long as the finished crimp connection gauges
properly, there is no need to adjust the tool. We recommend checking
each crimp connection with the Zurn Go/No-Go gauge.
When the tool wears and the crimps no longer gauge properly, the tool
needs adjusting. Follow these simple steps.
1. Loosen the bottom locking setscrew two turns using the hex wrench
supplied with the tool.
2. Close tool until the jaws just touch and increased resistance is felt.
This is the pre-load point.
3. Turn the top Adjusting Screw until the distance between the raised
“+” marks on the handles is between 7 and 8-1/2 inches. Tighten the
bottom locking setscrew.
4. Make a test crimp connection and check it with both the “Go” and
“No-Go” openings of the gauge. If necessary, make additional adjustments. If the “No-Go” opening goes over the crimped ring, the tool
is too tight. The distance between the “+” marks should be decreased.
If the “Go” opening does not go over the crimped ring, the tool is
too loose and the distance between the “+” marks should be increased.
5. Apply a light oil to the tool pivot points each time the tool is adjusted.
Failure to lubricate the tool will shorten its life.
Adjusting Screw
Locking Screw
7" - 8 1/2"
WARNING:
Increasing the pre-load distance
beyond 9" will make the tool hard
to use and shorten tool life because
of excessive stress.
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Zurn PEX Plumbing Design and Application Guide
ADJUSTMENT (QCRT5T)
Zurn crimp tools are factory set to provide proper crimps. This should
be checked before use by making a test crimp connection and checking
it with the crimp gauge. As long as the finished crimp connection gauges
properly, there is no need to adjust the tool.
When the tool wears and the crimps no longer gauge properly, the tool
needs adjusting. Follow these simple steps.
1. Loosen the bottom locking setscrew two turns using the hex wrench
supplied with the tool.
2. Close tool until the jaws just touch and increased resistance is felt.
This is the pre-load point.
3. Turn the top Adjusting Screw until the distance between the inside
corners of the handles is 13 inches. Tighten the bottom locking setscrew.
4. Make a test crimp connection and check it with both the “Go” and
“No-Go” openings of the gauge. If necessary, make additional adjustments. If the “No-Go” opening goes over the crimped ring, the tool
is too tight. The distance between the inside corners of the handles
should be decreased. If the “Go” opening does not go over the crimped
ring, the tool is too loose and the distance between the inside corners
of the handles should be increased.
5. Apply a light oil to the tool pivot points each time the tool is adjusted.
Failure to lubricate the tool will shorten its life.
Adjusting Screw
Locking Screw
WARNING:
Increasing the pre-load distance
beyond 13" will make the tool hard
to use and shorten tool life because
of excessive stress.
Steel Handled
13"
QCRT5T only
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Zurn PEX Plumbing Design and Application Guide
INSTALLING ZURN PEX PIPE
Always strap
pipe down
before bending.
Zurn PEX straps and hangers hold pipe in
position and prevent strain on fittings
when the pipe is bent.
6'
Straps can be as far as 6 feet apart if the
pipe is continuously supported.
32"
Vertical runs need support at every floor
level.
Horizontal runs should be supported
every 32 inches.
Or, by
making
a loop.
12"
Don’t bend in a
radius of less
than 8 times
O.D. of tubing.
Since Zurn PEX expands or contracts one
inch every 100 feet of pipe with every 10°
of temperature change, you must allow
for expansion and contraction in long
runs with a 12-inch horizontal offset.
Page 9
Always cut the pipe longer than necessary
to allow some slack for any contraction
in the pipe.
Strapping support should be firm but loose
enough to allow the pipe to move back
and forth as it expands and contracts.
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Zurn PEX Plumbing Design and Application Guide
INSTALLING ZURN PEX PIPE, cont’d.
If installing under a slab, use only a continuous length through the trench.
There must be no connections under the slab.
For details on buried pipe installations, see Page 19 of this
Installation Guide.
Long exposure to sunlight can weaken
most plastics. Always store Zurn PEX
tubing under cover – never in any
location exposed to direct sunlight.
Wall
Stud
Protect pipe with a steel plate if it’s
within two inches of a stud, plate, or
joist nailing surface.
Sleeve
Zurn PEX may be connected directly to
electric water heaters for residential
plumbing applications. Zurn PEX has brass
male and female threaded adapters and
swivel adapters that can be used for this
application.
Zurn PEX must be kept at least 6" away
from the exhaust vent of a gas-fired water
heater. This is easily accomplished by
using flexible water heater connectors.
When the inlet and outlet connections are
well away from the exhaust vent, such
as most heaters with side connections,
Zurn PEX may be connected directly to
the water heater.
Use protective sleeves or bushings on
Zurn PEX tube when penetrating metal
studs. Sleeves and bushings are not
required when penetrating ordinary
wood or particle board if the holes are at
least 1/8" larger than the tube size and
tube movement is not restricted.
Be sure to protect pipe with plastic sleeves
where it enters and leaves the slab.
Best results are achieved by using
clamps, pipe insulators, and strapping
designed for plastic plumbing systems.
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT ™ MANIFOLDS
The QickPort Manifold System is designed for efficient installation by
the plumber. The purpose of this guide is to point out some of the
features of the system and how to use them.
Other sections of this Zurn PEX illustrated Installation Guide should be
referred to for general information on the use and installation of the
Zurn PEX plumbing systems.
Sizing the Manifold
The manifold system allows individual hot or cold lines to be connected
directly to each fixture inlet from the manifold. To size a cold water
manifold, count the number of cold water locations in the house. Be
sure to include outside hose bibbs. Also, include a line for the refrigerator
ice maker, particularly if the refrigerator is not on the same wall as the
kitchen sink.
To size the hot water manifold, count the number of hot water locations
in the house.
QickPort manifolds are available in increments of five (5) outlet ports.
Always purchase a manifold that has at least as many ports as the house
has hot or cold locations. Attempting to supply two locations from a
single manifold outlet may give unsatisfactory performance and may
violate the local plumbing code. For a double vanity that has a continuous
cabinet, some local codes will allow the second lavatory faucet to be
connected to the first by using a tee fitting under the vanity. This will
reduce the needed manifold ports by one on each manifold but care
must be taken that it is acceptable to the local authorities.
All unused ports should be capped, even if the valve is closed.
Locating the Manifold
In general, manifolds should be installed in an accessible location very
near the water heater.
They should be accessible because one-half of the joints in the plumbing
system are at the manifolds and an accessible location improves the
plumber’s efficiency.
The hot water manifold should be as close as possible, but not closer
than 18" from the water heater outlet. This will assure the minimum
time for hot water to arrive at a fixture.
The cold water manifold may be located in any convenient location,
but it is usually located near the hot water manifold or near the
incoming water supply.
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT MANIFOLDS, cont’d.
Cold Water
In To
Water Heater
Hot Water
Out To
Manifold
Cold Water
Out To
Fixtures
Hot Water
Out To
Fixtures
Water
Heater
Manifold System
Incoming
Water Supply
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT MANIFOLDS, cont’d.
Horizontal Manifold Installation
First, before installing the manifold, attach any shut-off valves that are
going to be connected to the manifold.
Next, position the manifold in the desired location and nail or screw the
mounting bracket to the studs. Make sure all valve handles have room
for operation.
NOTE: A vertical manifold installation
usually requires bending the Zurn PEX
tube immediately off the manifold.
Extra care must be taken to assure
that the tube is not bent in a radius
smaller than the minimum permitted
for Zurn PEX which is six (6) times
the outside diameter of the tube. Also,
make sure that bending stress is not
applied to the fitting that connects the
tube to the manifold.
Do not install two vertical manifolds
on opposite sides in the same stud
cavity. There generally isn’t room for
correct bending of the Zurn PEX tube.
Vertical Manifold Installation
QickPort manifolds may be coupled end to end and installed vertically
along a stud. Be sure to install any main shut-off valves before mounting
the manifold to the stud.
Position the manifold in the desired location and fasten it to the studs.
Selecting the Tube Size
QickPort manifolds are designed for easy connection to 3/8" or 1/2" CTS
Zurn PEX tube. When selecting the tube size, the following factors
should be considered:
1. local code requirements;
2. water demand of the fixture;
3. distance from the manifold to the fixture;
4. elevation change from manifold to the fixture; and
5. water pressure available to the manifold.
Where possible, we recommend the use of 3/8" tubing. The smaller tubing
means hot water arrives at the fixture faster and the smaller tubing can
make smaller bends. With the reduced water usage of most sink and
lavatory faucets and showers (typically 2.0 GPM), 3/8" tube is usually
adequate unless the distance to be covered is more than 80 feet. The
pressure loss information for 3/8" and 1/2" CTS tube is listed below.
QickPort manifolds have less than 1 psi pressure drop at total flow rates
up to 20 GPM. Even if several branches are operating simultaneously,
the pressure loss due to flow through the manifold is minimal.
Flow
(GPM)
1
2
3
4
5
6
Page 13
3/8"
Pressure Drop
psi/100 ft.
6.8
24.8
52.4
Velocity
Ft./Sec.
3.3
6.6
9.9
1/2"
Pressure Drop
psi/100 ft.
1.6
5.6
12.0
20.4
30.8
43.1
Velocity
Ft./Sec.
1.8
3.6
5.4
7.2
9.0
10.8
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT MANIFOLDS, cont’d.
Running the Zurn PEX Tube
After the manifolds have been installed and the tube size selected, the
next step is to install the Zurn PEX tube. When installing the tube,
there are several points that must be considered:
1. Bending
2. Expansion and Contraction
3. Abrasion
4. Heat Sources
5. Friction Damage
6. Freeze Protection
Zurn PEX’s flexibility is key to making manifold systems practical.
Like any material, it can be damaged if it is bent too tightly.
TUBE
m
imu
Min nd
Be
ius
Rad
WRONG
Radius less than minimum. Tubing strains
becomes oval. May
kink or foil.
The minimum recommended bend radius for Zurn PEX is six (6) times
the outside diameter of the tube when bending with the natural curvature
of the coil. For 3/8" tube, this is a radius of 3" and for 1/2" tube, the
minimum radius is 4". If the tube must be bent against the natural
curvature of the coil, multiply the values by 3.
Zurn PEX expands and contracts more than most piping materials. Be
sure to allow slack of approximately 1/8" per foot of length of tube to
compensate. This will make sure the tube does not apply tension to the
connections at the manifold or the fixture inlet.
Use protective sleeves or bushings
on Zurn PEX tube when penetrating metal studs. Sleeves and bushings are not required when penetrating ordinary wood or particle
board if the holes are at least 1/8"
larger than the tube size and tube
movement is not restricted.
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT MANIFOLDS, cont’d.
Multiple tube bundles should be protected by wrapping a heavy gauge
plastic sheet around the bundle at any area of potential abrasion. This
plastic sheet may be fastened by using tape or nylon wire ties. Apply the
tape to the sheet, not the Zurn PEX tube. This ensures that the tube can
slide inside the protective plastic sheet. With nylon ties, be sure they are
not so snug that they deform any of the tube.
Metal Stud
Plastic and
Strapping
Tubing
Zurn PEX tube should be supported
or strapped every 32" when hung
from floor joists or running across
rafters. When supporting tube bundles,
use a strap to support the entire
bundle. Do not use a hook on one
tube in a bundle to carry the weight
of the entire bundle. Tubing run on a
continuous support such as a floor in an attic, may be strapped at
six-foot intervals.
The potential for heat transfer between different tubes in a bundle is
very low. Zurn PEX’s heat transfer rate is substantially less than copper.
For this reason, we think mixing hot and cold lines in a bundle is not a
problem. However, some plumbing codes do not permit mixing of hot
and cold lines in the same bundle. Be sure to check the requirements of
the local code.
12" plus
When running the Zurn PEX tube, be sure to keep it away from potential
sources of heat. Maintain a minimum of 12 inches between Zurn PEX
and any recessed light fixture and a minimum of six inches between Zurn
PEX and any gas appliance vent.
Gas
Vent
When installing runs of Zurn PEX, it is sometimes necessary to pull
one tube past another. Care should be taken to make sure that the
friction of the moving tube does not burn or wear a notch in the
stationary tube. If this occurs, the notched section of tube must be
cut out and replaced.
When it is necessary to drill holes for the tube in structural components
of the building, be sure to comply with the requirements of the local
building code.
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Zurn PEX Plumbing Design and Application Guide
INSTALLING QICKPORT MANIFOLDS, cont’d.
Stub
Out
Elbow
Stub Outs Through Walls
Most Zurn PEX runs will terminate with some sort of stub-out fitting
because the depth of a standard 2 x 4 wall is not sufficient to allow the
Zurn PEX tube to be bent with a recommended bend unless a metal bend
support is used. Zurn offers a metal bend support with a face plate,
QMBS3WB, that is ideal for this purpose. Be sure the local code allows
PEX stub-outs through walls. Zurn also offers several other fittings for
stub-outs.
Copper stub-out elbows are available with either a 3/8" or 1/2" crimp
connection to the Zurn PEX tube in the wall. The portion of the elbow
that comes through the wall is 1/2" nominal copper tube (5/8" O.D.).
Zurn drop ear elbows are available with either a 3/8" or 1/2" crimp
connection to the Zurn PEX tube in the wall. These fittings have a
1/2" female pipe thread to allow the use of a threaded nipple to
come through the wall.
Connecting Zurn PEX to the Manifold
The outlets of the valves on the QickPort manifold have 1/2" straight
pipe threads. This allows several options for connecting the Zurn PEX
tube to the manifold.
When using crimp fittings, the recommended connection is the QQSFC23X
for 3/8" tube or the QQSFC33X for 1/2" tube. These brass swivel adapters
allow you to make the crimp directly to the Zurn PEX tube and then
connect the tube to the manifold. The same fittings with plastic nuts are
also available.
If a compression connection at the manifold is desired, the recommended
connection is a Zurn nut, ring, and cone set. For 3/8" tube, use the
QFNCR2QP. For 1/2" tube, the QAFA33FQP is required.
Finishing Touches
It is recommended that all tubes be labeled so they can be readily identified
in the event the water must be shut off to a particular fixture. Zurn has
preprinted label kits that allow this to be done in a professional manner.
The labels are self-adhesive and are applied directly to the Zurn PEX tube.
Doors are usually used to cover the manifolds. These may be made by a
carpenter to match the other cabinets in the house or Zurn sells a plastic
access panel that can be used. Zurn access panels come with a frame that
can be fastened to the sheetrock with adhesive or screws for easy installation.
The panels snap into place and are essentially flush with the sheetrock.
Access Panel
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Zurn PEX Plumbing Design and Application Guide
ZURN PEX PIPE DON’TS
While an all Zurn PEX system is resistant to freeze damage, we recommend
that all plumbing systems be protected
from freezing in the usual manner.
Zurn PEX cannot prevent damage to
conventional materials if frozen and
Zurn PEX itself may be damaged if
conventional materials in the system
are allowed to freeze.
Don’t use metal hangers with sharp or
abrasive edges.
Or hangers that pinch the pipe!
Don’t crush it.
Don’t scratch it.
Brass Insert Fitting
Copper
Keep Zurn PEX pipe away from extreme heat.
Page 17
NEVER apply flame directly to Zurn PEX.
If you need to braze, solder, or weld, do it
BEFORE you connect Zurn PEX to metal pipe.
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Zurn PEX Plumbing Design and Application Guide
TESTING SYSTEM
• Test pressure shall be at least equal to normal system working pressure
(main pressure), but not less than
40 psi and not greater than 225 psi.
• Test duration should not be less than 15 minutes.
Pressure Test
• Test media may be water or compressed air.
• Test should meet local code requirements.
CAUTION
Do not use leak detectors or other
liquid solutions. Chemicals in certain
soaps can cause disintegration of
plastic tubing, so it is not a good idea
to use a soap solution in any pressure
test or for leak-checking in any way.
TROUBLE SHOOTING
Problem
Check
1. Crimp Ring will not go
into “Go” gauge opening.
1. Crimp tool needs adjustment.
Increase handle space.
2. Crimp Ring goes into
“No-Go” gauge opening.
2. Crimp tool needs adjustment.
Decrease handle space.
3. Crimp tool needs frequent
adjustment.
3. Check for wear at pivot points.
If holes or bolts are worn, tool
must be replaced. Pivot points
should be oiled every time tool
is adjusted.
4. Tube is kinked.
4. Tubing was bent too tightly. Cut
out kinked section and increase
bend radius.
5. Tubing has chalky
exterior surface or
cracks when bent.
5. Tubing has been stored in sunlight
and is damaged. DO NOT USE.
6. Crimp rings have a
“silver” or “copper”
color.
6. Proper crimp rings for Zurn PEX
insert fittings are blackened copper.
Zurn PEX crimp rings have “Q”
and “PEX” stamped on them.
Use only Zurn PEX crimp rings.
7. Crimped ring is distorted.
7. Tool was not at 90° to tube when
crimp was made. Cut out and
replace fitting.
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Zurn PEX Plumbing Design and Application Guide
WATER SERVICE INSTALLATION
Substandard tube performance may result if these instructions are not
followed.
Before You Start
Applications
Check to be sure that the tube you are using has the correct pressure rating
for local requirements. Usual practice is to have the pressure rating of the
tube 1-1/2 times higher than the maximum water system pressure to allow
for pressure surges in the system due to water hammer, pumps turning
on and off, etc. Zurn PEX tube has a pressure rating of 160 psi @ 73°F.
Inspection
Inspect all pipe before installing. Cut out any damaged areas (cuts, punctures,
excessive abrasion) and areas where the pipe has been kinked or pinched.
Contaminated Soil
Zurn PEX tube is not recommended for underground use in areas of
known soil contamination or where there is a high risk of chemical spills.
Zurn PEX should not be installed in contact with soil or under slabs in
areas known to be contaminated by, for example, organic solvents or
petroleum distillates. It should not come in contact with soil near hazardous
waste disposal sites or underground chemical or petroleum storage tanks.
If you are uncertain about the possibility of soil contamination at your
installation site, contact your local authorities.
Fittings
Several types of fittings are available for use with Zurn PEX. However, Zurn
cannot be responsible for the performance or design of other manufacturer’s products.
PVC Fittings
Molded PVC fittings for use with Zurn PEX are commercially available
for water service tube. These fittings have a molded internal stiffener,
an O-ring seal, a steel gripper, and a nut to hold it all together. They are
available as couplings, male and female adapters, and spigot adapters.
See Figure 2.
Note: Zurn Qicktite fittings are not recommended for use and should
not be used in water service applications.
Figure 2
Brass Fittings
Compression fittings normally used with copper tubing can be used to
connect Zurn PEX to corporation and curb stops. When compression
fittings are used, a type with a split clamp is recommended to ensure that
the internal stiffener will not move as a result of expansion and contraction
of the pipe. Follow the fitting manufacturer’s recommendations for proper
installation and use of their fitting.
Teflon tape is the only recommended thread sealant for fittings used with
Zurn PEX. Conventional pipe thread compounds, putty, mineral or
linseed oil-based products, and unknown mixtures should never be
used as these materials may cause damage to the pipe and fittings.
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WATER SERVICE INSTALLATION, cont’d.
Cutting the Pipe
Zurn PEX should be cut with a tubing cutter that is equipped with a
thin cutting wheel designed specifically for plastics. Gould Imperial,
Reed Manufacturing Co., Ridge Tool Co., and other firms furnish this
type of cutter. To cut the tube, make a single revolution in one direction
for tracking followed by one or two revolutions in the opposite direction.
Cuts should always be square and clean. If other methods are used to cut
the pipe (such as a saw), sandpaper should be used to remove any excess
material, flashing or burrs, and to smooth the end of the pipe.
See Figure 3.
Installation
Procedures for installing Zurn PEX, incorporating information from ASTM,
AWWA, PPI, and other organizations, are described in the following
sections. Information obtained from several water departments also has
been included. These recommendations must be followed in order for
Zurn PEX to perform properly.
Figure 3
Trench Bottom Preparation
To achieve a satisfactory installation of Zurn PEX, it is essential that
the supporting soil provide a stable and permanent support for the pipe.
Where good soil conditions exist and the trench bottom can be cut
accurately, the pipe can be installed directly on the prepared bottom.
The bottom must be flat with no hollows, no lumps, no rocks, and no
other sharp objects. In case of loose, rocky soil, the trench should be
excavated at least 6" deeper than the desired pipe depth and filled with
suitable soils such as coarse sand or peagravel. If the soil consists of solid
rock, graded, tamped granular class I material should be placed over the
rock formation. The material should not be so fine that it would wash
out and cause subsequent settling of the pipe. In unstable soils such as
black gumbo, the trench should be overexcavated by at least 4" and the
trench refilled with sand or peagravel. Regardless of soil condition, the
backfill should be free of rocks, glass, or other sharp objects. See Figure 4.
Trench Cross Selections
Ground Level
Desired
Pipe Depth
(Pipe Cross
Section)
Good Soil
Bedding
6"
6"
4"
Loose - Rocky Soil
Solid Rock
Unstable
(Black Gumbo)
Figure 4
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Zurn PEX Plumbing Design and Application Guide
Water Main
Cross-Section
WATER SERVICE INSTALLATION, cont’d.
Thermal Expansion and Contraction
The linear expansion rate for Zurn PEX is approximately one inch per
100 feet of tubing per 10°F change in temperature. When installing pipe,
add 1/8" per running foot to accommodate thermal expansion or about
13 inches per 100-foot run. Snake the pipe uniformly along the length
of the trench. See Figure 5.
Pipe
Figure 5
Ground Level
Meter Box
Wrong
Meter Box
Right
Figure 6
PEX Tube
Prepared
Trench
Bottom
Figure 7
Ground
Level
12" Min.
Rigid Foundation
Protective
on
Sleeve Basement
Wall
Connecting to Curb Stop
A general rule to remember when installing Zurn PEX is: the less the effect
of surrounding soil movements on the tubing, the better. The diagram
below shows a recommended installation for a curb stop. See Figure 6.
Other approaches requiring double (or “S”) bends are not recommended
as they are more prone to undesirable settlement which may subject the
pipe to excessive stress.
Penetration of Basement or Foundation Walls
When Zurn PEX is run through a basement or foundation wall, it must
be protected by a rigid sleeve that spans the distance from within the wall
out to the undisturbed soil in the pipe trench. The purpose of this protective sleeve is to prevent shearing of the PEX tubing at the wall in the
event there is settlement in the backfill around the wall. At the point where
the sleeve terminates inside the foundation or wall, the space between the
Zurn PEX and the sleeve should be sealed to prevent leakage into the building.
Note: Petroleum based caulks or sealants should not come in direct
contact with Zurn PEX. See Figure 7.
Pressure Testing
Water service lines should be pressure tested before the trench is backfilled with soil. Before applying pressure to the pipe, make sure that all
air is bled from the system. A large pocket of air in the pipe can cause a
severe water hammer that could damage the pipe. After a service line has
been installed and filled with water, it should be tested using a pressure
approximately 50 percent greater than the expected operating pressure.
Run the test for at least one hour.
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WATER SERVICE INSTALLATION, cont’d.
Backfilling and Compaction
Before backfilling, be sure the trench is free of all foreign objects such as
scraps of wood, metal, or glass which might puncture the pipe when buried
in the trench. If the original soil removed from the trench is rocky or
otherwise unsuitable, the pipe should be covered with a compacted 6"
layer of coarse sand or peagravel before continuing the backfill with the
original soil. See Figure 8.
Trench Cross Selections
Ground Level
Desired
Pipe Depth
Backfill
Good Soil
Backfill
Backfill
Backfill
6"
6"
6"
6"
6"
4"
Loose - Rocky Soil
Solid Rock
Unstable
(Black Gumbo)
Figure 8
Clays require more compaction than granular material, with the amount
of compaction needed being dependent on the clay’s moisture content.
In cases when an unfavorable combination of black gumbo type clay and
large variations in the water table exist, the natural bedding material should
be replaced by materials that are less prone to expansion and contraction
such as sand and peagravel.
Pipe Failures Caused By Improper Installation
An unnecessarily short service life for Zurn PEX may result if the precautions
outlined previously are not followed.
Insufficient slack and excessive longitudinal stresses as a result of temperature
variations may cause pull-out failures. Shear-off failures (circumferential
cracks in the pipe wall within one inch of the fittings) can be caused by
improper positioning of the metal stiffener during installation (see fitting
manufacturer’s recommendations) or by excessive bending stresses. It is
also possible that this type of failure will be caused by temperature variations and resulting stresses, causing the metal stiffener to travel. As soon
as the stiffener is no longer flush with the end of the compression fitting,
it may start to cut off the pipe from the inside, resulting in shear-off
failure. Although a compression fitting with a split clamp will provide
greater assurance of a well-secured fitting than one without a split clamp,
it is more important to address the cause of problems by minimizing
stresses in the pipe through proper installation.
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WATER SERVICE INSTALLATION, cont’d.
Preparing the trench bottoms, gauging the tapping angles, connecting to
curb stops, backfilling the trenches, and compacting the soil are all important
factors when using Zurn PEX for buried water service. Successful installation of the pipe, however, depends on only two major points:
1. Preventing sharp objects from contacting the pipe.
2. Preventing undesirable stress on the pipe.
Electrical Grounding
Metal pipes are often used (against the pipe supplier’s recommendations)
as the grounding electrode for electrical equipment. Zurn water service
tube, being a poor conductor, cannot be used for this purpose. The National
Electric Code should be consulted for recommended grounding methods
when plastic pipe is used.
Water Line Disinfection
Some code jurisdictions require disinfection of potable water service lines.
The most commonly used standard is AWWA C-601-81, which specifies
a chlorine concentration of at least 50 milligrams/liter (50 ppm) for 3 hours.
The Southern Building Code Congress recommends 50 ppm for 6 hours.
Zurn PEX will not be adversely affected by this exposure but care should
be exercised to avoid use of high chlorine concentrations (above 300 ppm)
for more than 12 hours, as this could damage the pipe. The system should
be thoroughly flushed at the end of any disinfection period.
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Zurn PEX Plumbing Design and Application Guide
PROFESSIONAL INSTALLATION LIMITED WARRANTY
Subject to the terms and conditions of this Limited Warranty, Zurn PEX
Plumbing and Radiant Heating Systems warrants only to the owner of
the real property when installed by licensed professional contractors or
authorized distributors who purchase and properly install in a potable
plumbing system and/or radiant heating system its:
(I)
Zurn PEX Non-Barrier and Barrier cross-linked polyethylene tubing
(PEX) and Qick/Sert® insert fittings, when installed as a system with
our Zurn PEX Non-Barrier and Barrier cross-linked polyethylene
tubing (PEX), for a period of twenty-five (25) years, and
(II) QickPort Plumbing manifolds, under normal conditions of use,
for a period of ten (10) years, and
(III) Qick/Sert® insert fitting when not installed with Zurn PEX NonBarrier and Barrier cross-linked polyethylene tubing (PEX) and
installed with PEX tubing that meets the ASTM F876 requirements
for a period of five (5) years, and
(IV) the associated hardware and accessories, including manifolds,
distribution headers, valves, electrical controls, tools, and
miscellaneous fittings for a period of two (2) years from the
date of installation.
In order for this Limited Warranty to apply, the above referenced products
must be installed by a licensed professional contractor in accordance with
Zurn installation instructions as outlined in the Zurn Installation Guide,
meeting all applicable code requirements and good plumbing practices.
FAILURE TO INSTALL ZURN PEX PRODUCTS ACCORDING
TO MANUFACTURER’S INSTRUCTIONS WILL VOID ALL
APPLICABLE WARRANTIES AND MAY RESULT IN SEVERE
WATER DAMAGE. See our free Zurn PEX Installation Guide for
instructions. For your copy, call toll-free 1-800-872-7277. Under this
warranty, you only have a right to reimbursement if the failure or leak is
a direct result of a manufacturing defect in the products covered by this
warranty and occurred during the warranty period. This warranty does
not apply and you do not have a right of reimbursement if the failure or
resulting damage is caused by:
(I)
freezing during or after the installation or inadequate freeze
protection;
(II) damage due to tear, breaks, or other external damages before,
during, or after installation;
(III) components not manufactured or sold by Zurn;
(IV) exposure to temperatures and pressures beyond the specified range
for Zurn products as specified on the product or in the Zurn PEX
Installation Manual or Zurn Design Manual;
(V) exposure to harmful, unauthorized or unanticipated chemicals or
substances or corrosive water conditions;
(VI) exposure to ultraviolet light;
(VII) damage or wear from abnormal operating conditions, accident,
abuse, misuse, or unauthorized alterations or repair.
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PROFESSIONAL INSTALLATION LIMITED WARRANTY, cont’d.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES
OR OBLIGATIONS, EXPRESS OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. ZURN DOES NOT
GUARANTEE OR IN ANY WAY WARRANT THE INSTALLATION
OF ZURN PEX PRODUCTS DUE TO THE WIDE VARIANCE IN
INSTALLATION PRACTICES AND OTHER CONDITIONS
BEYOND OUR CONTROL.
If you believe that a product fails to meet the above Limited Warranty,
you should notify us in writing within 30 days following the failure and
prior to expiration of the applicable warranty period set forth above, at
the following address:
Zurn Industries, Inc.
Zurn PEX Plumbing and Radiant Heating Systems
1801 Pittsburgh Avenue
Erie, PA, 16502
Attention: Claims Department
Notification should include a description of the product, the failed part,
model number (if available), date of purchase and/or date of installation,
and how the product fails to meet the above warranty. Upon receipt of a
written claim under this Limited Warranty and evidence/identification of
the date of manufacture of product, and after inspection by an authorized
Zurn representative and determination of a manufacturing defect, Zurn
will reimburse the property owner for reasonable repair or replacement
charges, to include drywall and painting, as well as damages to real property
and the premises within which the product is installed, resulting from the
failure or leak. At our option, and in our sole discretion, we will either
repair or replace the product with a Zurn product of the same or similar
type, size, and like quantity. Except as specified above, we will not pay any
costs (labor or otherwise) associated with removing previously installed
product(s), installing replacement product(s), or transportation or return
of a product. If, as determined by Zurn, repair or replacement of the
product is not commercially practicable, or cannot be completed in a
timely manner, we may refund the ultimate purchase price paid for the
product upon verification by providing a copy of your purchase order,
invoice, receipt, or bill of sale.
ZURN WILL NOT BE LIABLE FOR ANY OTHER LOSS
OR EXPENSE(S) NOT SPECIFICALLY DESCRIBED ABOVE,
AND DISCLAIMS ANY LIABILITY FOR CONSEQUENTIAL
OR INCIDENTAL DAMAGES.
For more information, call Zurn toll free at 1-800-872-7277.
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ZURN PLUMBING PRODUCTS GROUP
PEX PLUMBING SYSTEMS
1801 PITTSBURGH AVENUE
ERIE, PA 16502
PHONE: 1-800-872-7277
FAX: 1-800-209-2148
WEBSITE: www.zurn.com
In Canada:
ZURN INDUSTRIES LIMITED
3544 NASHUA DRIVE
MISSISSAUGA, ONTARIO CANADA L4V 1L2
PHONE: 905/405-8272
FAX: 905/405-1292
Form No. ZPM03103