Rehau EVERLOC+ Compression-sleeve Fitting System Product Instructions

EVERLOC+™ COMPRESSION-SLEEVE SYSTEM

SISTEMA DE CASQUILLOS DE COMPRESIÓN EVERLOC+™

SYSTÈME DE MANCHON À COMPRESSION EVERLOC+

MC

Product Instructions / Instrucciones del producto / Instructions relatives au produit

1. Scope 3

2. System Overview 4

3. System Components 5

4. Assembly 7

4.1 EVERLOC+ Tool Safety Warnings 8

4.2 Fitting Assembly 3/8 to 1 in. 9

4.3 Fitting Assembly 1 1/4 to 2 in. 12

5. Assembly Considerations 17

6. Installation Considerations 19

7. System Testing and Maintenance 22

CONTENTS

For updates to this publication and the most current technical instructions, safety information and manufacturer’s recommendations, visit www.na.rehau.com/resourcecenter

2

1. SCOPE

Thank you for your purchase. These instructions contain information

about the assembly and use of the EVERLOC+™ compression-sleeve

system with RAUPEX

®

UV shield pipe (PEXa Pipe) intended for use in

hot- and cold-water potable systems and RAUPEX O

2

Barrier pipe for

hydronic heating and cooling systems.

For professional use only. Persons using this guide must be experi-

enced and appropriately licensed professional contractors who

understand the principles and practices associated with the proper

installation of hot- and cold-water potable and hydronic systems.

The information presented in this product instruction manual is

intended to demonstrate the proper assembly method and installation

recommendations for the EVERLOC+ compression-sleeve system.

Allow only persons who fully understand this manual to participate in

the assembly and use of the EVERLOC+ compression-sleeve system

with RAUPEX PEXa pipe.

It is the responsibility of the licensed contractor to check the prevailing

local codes and to verify that the technical information presented in

this guide is appropriate for a particular installation.

Nothing in this manual supersedes national or local code requirements

or the recommendations of other manufacturers regarding their

components. Observe all applicable national, state and local laws,

regulations, standards, codes and ordinances. If you believe REHAU

product information conﬂicts with applicable code requirements,

industry standards, or the recommendations of other manufacturers

regarding their components, contact the REHAU distributor in your

area and consult with the building authority having jurisdiction before

installing the EVERLOC+ compression-sleeve system.

Before starting the installation process, read the REHAU PEXa Limited

Warranty, available at www.na.rehau.com/warranties. It can also be

obtained from your authorized REHAU distributor or by writing to

REHAU Construction LLC, 1501 Edwards Ferry Road NE, Leesburg VA

20176 US.

Proper installation is the responsibility of the installing contractor.

Review the REHAU Technical Guidelines prior to installation of the

REHAU crosslinked polyethylene (PEXa) piping system. REHAU

Technical Guidelines are deﬁned in the REHAU PEXa Limited Warranty

as: The most current and applicable versions of all the technical

literature available on the REHAU North America website at www.

na.rehau.com/resourcecenter, including, but not limited to, technical

manuals, instruction guides, technical bulletins, submittals and

REHAU Academy training presentations. Check the REHAU Resource

Center (www.na.rehau.com/resourcecenter) for the latest updates.

Contact the EVERLOC+ distributor in your area if you do not under-

stand the information in this manual or if you have questions about

the REHAU Technical Guidelines.

This manual contains safety-related information that requires your

special attention. It is indicated with the safety alert symbol and the

signal words described below: :

DANGER

Indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not

avoided, could result in death or serious

injury.

CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate

injury.

NOTICE

Indicates a risk of property damage,

including damage to the power tool or its

individual components.

Only trained personnel should be engaged in the installation process.

Follow the instructions in this manual and other REHAU Technical

Guidelines and use common sense to reduce the risk of injury or

property damage.

WARNING

Read the instruction manual for the EVERLOC+

compression-sleeve tools before use and follow all

safety precautions - improper use can cause serious

personal injury

WARNING

EVERLOC+ compression-sleeve tools use a strong

hydraulic force to expand PEXa pipe and compress

components of the REHAU EVERLOC+ compressi-

on-sleeve system.

To reduce the risk of crush and laceration injury,

keep ﬁngers, hands and all parts of your body away

from the expander head, hydraulic slide and

compression jaws during operation. Remove the

battery before attempting to change or adjust the

expander head or compression jaws.

3

Applications

The EVERLOC+ compression-sleeve system is designed for use with

R

AUPEX PEXa pipe, speciﬁcally RAUPEX UV shield pipe for potable

plumbing system applications and RAUPEX O

2

barrier pipe for

hydronic radiant heating and cooling system applications.

The REHAU PEXa plumbing system is intended for use in hot- and

cold-water potable systems as deﬁned by the following national

codes:

- ICC International Plumbing Code (IPC)

- ICC International Residential Code (IRC)

- IAPMO Uniform Plumbing Code (UPC)

- National Plumbing Code of Canada (NPCC)

The REHAU PEXa radiant system is intended for use in hydronic

heating and cooling systems as deﬁned by the following national

codes:

- IMC International Mechanical Code (IMC)

- International Building Code (IBC)

- International Residential Code (IRC)

- Uniform Mechanical Code (UMC)

- National Building Code of Canada (NBCC)

- CSA B214 Installation Code for Hydronic Heating Systems

RAUPEX UV shield crosslinked polyethylene (PEXa) pipe

2. SYSTEM OVERVIEW

RAUPEX O

2

barrier crosslinked polyethylene (PEXa) pipe

EVERLOC+ compression-sleeve ﬁttings and sleeves

EVERLOC+ compression-sleeve tools

4

3. SYSTEM COMPONENTS

The EVERLOC+ compression-sleeve system is a cold-expansion PEXa

ﬁtting system that is available in polymer and lead-free (LF) brass and

is assembled with a specially designed PEXa compression sleeve. The

ﬁtting is designed speciﬁcally for use with RAUPEX pipe and should

only be assembled with the EVERLOC+ compression-sleeve tools.

For a detailed description of the REHAU system components, refer to

the REHAU Sustainable Building Technology Product Catalog

(855.312).

Product Range

EVERLOC+ ﬁt

tings are available in 3/8, 1/2, 5/8, 3/4, 1, 1 1/4, 1 1/2

and 2 in. sizes and are intended for use with RAUPEX SDR9 copper

tube size (CTS) pipe manufactured in accordance with ASTM F876.

Fitting Features

EVERLOC+ polymer and lead-free (LF) brass ﬁt

tings have the

following features:

1. Four sealing edges

2. Pipe stop

3. Fitting collar

4. Tool jaw body

Fitting and Sleeve Markings

All polymer ﬁt

tings include the following marks for identiﬁcation

OR

Fitting size (3/4” for example)

Batch code for production date

All LF brass ﬁttings are marked "REHAU"

All sleeves include the following

marks for identiﬁcation

- Sleeve size (1/2” for example)

- Batch code for production date

1

2

4

3

5

Polymer Fittings

EVERLOC+ polymer ﬁttings are available in couplings, tees, elbows,

multi-port tees and plugs. All polymer ﬁttings are produced from a

polyphenylsulfone (PPSU) material that meets the requirements of

NSF61 for health effects of drinking water system components and

complies with the lead-free requirements of the U.S. Safe Drinking

Water Act. See also REHAU Technical Bulletin TB265 EVERLOC+

Polymer Fitting Material - PPSU.

Lead Free (LF) Brass Fittings

EVERLOC+ LF brass ﬁt

tings are available as couplings, tees, elbows,

plugs and transition ﬁttings to NPT thread and copper solder

connections. All metal ﬁttings are produced from ECO BRASS

®

(UNS69300 or CW724R) that meets the requirements of NSF61 for

health effects of drinking water system components and complies

with the lead-free requirements of the U.S. Safe Drinking Water Act.

See also REHAU Technical Bulletin TB264 EVERLOC+ Lead-free Brass

Fitting Material.

Metal Manifolds

Manifolds are 1 in. Type L copper with EVERLOC+ LF brass ﬁttings

brazed into the header.

PEXa Compression Sleeves

EVERLOC+ compression sleeves are produced using a specially

form

ulated PEXa material and are designed speciﬁcally for use with

EVERLOC+ ﬁttings and RAUPEX pipe. EVERLOC+ compression

sleeves have the following features:

- Co-extruded platinum-colored PE coating

- Squarely cut ends that can be slid over the pipe in either direction

- Grooved and roughened inside surface for locking the sleeve into

place once slid over the pipe and ﬁtting

Packaging, Handling, Storage

EVERLOC+ ﬁt

tings and sleeves are shipped in cardboard boxes to

protect them from sunlight, rain, dirt and other hazards. Keep the

products in the original packaging until they are required for installa-

tion. Return unused products to the packaging for storage.

Fittings and sleeves must be handled with care. At a minimum, avoid

the following:

- Storing loose ﬁttings in tool boxes

- Contact with oil or petroleum-based products, adhesives, paints,

solvents, oxidizing agents or other aggressive chemicals or products

- Exposure of polymer ﬁttings and PEXa sleeves to soldering or any

open ﬂame

- Excessive or permanent exposure to sunlight of polymer ﬁttings and

PEXa sleeves

NOTICE

Exposing the EVERLOC+ compression-sleeve system to oil or

petroleum-based products, adhesives, paints, solvents, oxidizing

agents or other aggressive chemicals or products can damage the

compression-sleeve system and result in leaking and property

damage. See Installation Considerations for further information.

Certiﬁcations

The EVERLOC+ compression-sleeve system is certiﬁed to t

he

following standards:

- ASTM F877 Standard Speciﬁcation for Crosslinked Polyethylene

(PEX) Hot- and Cold-Water Distribution Systems

- NSF/ANSI 14 Plastic Piping System Components and Related

Materials

- NSF/ANSI 61 Drinking Water System Components – Health Effects

- NSF/ANSI 372 Drinking Water System Components – Lead Content

- CSA B137.5 Crosslinked polyethylene (PEX) Tubing Systems for

Pressure Applications

6

4. ASSEMBLY

Fitting Assembly

Assembling and installation of the EVERLOC+ compression-sleeve

sys

tem requires the use of the EVERLOC+ compression-sleeve tools.

These tools are battery-operated, hand-held tools. Only make

EVERLOC+ compression-sleeve joints with these tools.

Refer to the EVERLOC+ Power Tool Product Instruction Manual

(855.725), EVERLOC+ XL Power Tool Product Instruction Manual

(855.728) and the EVERLOC+ XL Expander Tool Product Instruction

Manual (855.729) for a complete understanding of operation, care

and use of the EVERLOC+ compression-sleeve tools.

WARNING

NOTICE

Use only EVERLOC+ compression-sleeve tools for assembly and

installation. Use of other tools will result in an improperly assembled

joint, which may result in leaking and property damage.

The basic process of assembling an EVERLOC+ compression-sleeve

joi

nt is as follows:

- Make a clean, square cut of the RAUPEX pipe using a REHAU pipe

cutter

- Slide the EVERLOC+ compression sleeve over the RAUPEX pipe

ensuring the sleeve is a minimum of two times the length of the

sleeve from the end of the cut pipe to allow for expansion of the pipe

only

- Expand the RAUPEX pipe twice, ensuring the expander head is

rotated 1/2 of one expander head segment between expansions,

using the EVERLOC+ compression-sleeve tools

- Insert the EVERLOC+ compression-sleeve ﬁtting into the expanded

end of the RAUPEX pipe so that the pipe is touching the pipe stop on

the ﬁtting

- Compress the EVERLOC+ compression sleeve over the RAUPEX

pipe and EVERLOC+ compression-sleeve ﬁtting using the

EVERLOC+ compression-sleeve tools

Required assembly tools include:

- REHAU RAUPEX pipe cutter

- EVERLOC+ compression-sleeve tools

- EVERLOC+ expander heads and compression jaws

EVERLOC+ Compression-sleeve Tool Assembly

The EVERLOC+ compression jaws and expander heads are color-

c

oded per each size to provide a visual conﬁrmation that the correct

jaws and expander head are assembled onto the tool. Prior to making

a compression joint, ensure the correct size of jaws and heads are

being used.

Diameter Color Tool

3/8 in. Yellow EVERLOC+ Power Tool

1/2 in. Red EVERLOC+ Power Tool

5/8 in.. Orange

EVERLOC+ Power Tool

3/4 in. White EVERLOC+ Power Tool

1 in. Green EVERLOC+ Power Tool

1 1/4 in. Magenta EVERLOC+ XL Power Tool

EVERLOC+ XL Expander Tool

1 1/2 in. Blue

EVERLOC+ XL Power Tool

EVERLOC+ XL Expander Tool

2 in. Gray EVERLOC+ XL Power Tool

EVERLOC+ XL Expander Tool

NOTICE

For use only with RAUPEX PEXa pipe and the EVERLOC+ compres-

sion-sleeve ﬁtting system. Other materials or ﬁttings may crack or

otherwise fail which could result in leaking and property damage.

Use only REHAU or REHAU-approved expander heads and compres-

sion jaws that match the dimension of the RAUPEX PEXa pipe being

installed (e.g., ½ in. expander head and compression jaws for ½ in.

pipe). Use of unauthorized attachments or REHAU attachments that

are the wrong size may result in faulty joints, which can lead to leaking

and property damage.

Read the instruction manual for the EVERLOC+

compression sleeve tools before use and follow all safety

precautions – improper use can cause serious personal

injury or property damage.

To reduce the risk of permanent eye injury, always wear

close-ﬁtting protective eyewear with side protection.

Eyewear must be impact-rated and marked as

complying with ANSI Z87.1.

1/2”

3/4”

1”

7

4.1 EVERLOC+ TOOL SAFETY WARNINGS

WARNING

To reduce the risk of electric shock, ﬁre or serious

personal injury, read the instruction manual for your

EVERLOC+ power tool, along with all warnings and

instructions for the battery and charger before operation

- Risk of electric shock. Never operate the power tool in damp or

wet conditions – never expose to rain or submerge in water or other

liquids. Never operate the power tool near wires or cables carrying

electric current.

- Always wear close-ﬁtting protective eyewear that is impact-

rated with side protection to reduce the risk of permanent eye

injury.

- Always check your power tool and its attachments for proper

condition before starting work. Using a power tool that is

modiﬁed, damaged, improperly adjusted or maintained, or not

completely and securely assembled can increase the risk of severe

personal injury or a faulty connection and property damage.

- The EVERLOC+ Power Tool and EVERLOC+ XL Expander tool

are designed for one-handed operation. Wrap your ﬁngers

tightly around the control handle as shown in this manual and

keep a secure grasp on the tool during work. Loss of control can

lead to injuries.

- The EVERLOC+ XL Power Tool is designed for two-handed

operation. Wrap your ﬁngers tightly around the control handle

and the support handle as shown in this manual. Keep a

secure grasp on both tool handles during work. Loss of control

can lead to injuries.

- Always mount the support handle on the EVERLOC+ XL Power

Tool before starting work. The support handle helps the operator

maintain control of the power tool and helps reduce the risk of crush

or cut injuries. Never operate the power tool without the support

handle securely in place.

- Use only your index ﬁnger to trigger the tool. Using other ﬁngers

to trigger the tool may cause you to lose control of the power tool or

increase the risk of personal injury, including pinch injuries.

- Moving parts can crush and cut. Keep hands and ﬁngers clear

of the compression jaws, hydraulic slide and expander head

while operating. Always keep hands and ﬁngers away from the

hydraulic slide and compression jaws to avoid trapping your ﬁngers

in moving parts. The hydraulic slide and compression jaws are

potential pinch points.

- Keep hands and other parts of your body away from the

expander head, hydraulic slide and compression jaws during

operation to reduce the risk of injury. Avoid wearing bulky gloves

that may become caught in the compression jaws or make handling

the tool awkward or difﬁcult.

- To reduce the risk of unintended activation, remove the battery

before changing or adjusting the expander head or compres-

sion jaws. Pinching ﬁngers or trapping other parts of your body in

the expander head, hydraulic slide or compression jaws can result in

serious crush and cut injuries.

- For use only with REHAU or REHAU-authorized accessories or

attachments. Although certain unauthorized accessories and

attachments may ﬁt onto the power tool, their use may, in fact, be

extremely dangerous and result in personal injury and faulty

connections, which can lead to leaking and property damage.

- For proper installation, the expander head and compression

jaws must match the dimension of the RAUPEX PEXa pipe

being installed. F

ailure to mount the proper size expander head or

compression jaws before installing a connection may be dangerous

and also result in a faulty connection, which can lead to leaking and

property damage.

- For use only with RAUPEX PEXa pipe and the EVERLOC+

compression-sleeve ﬁtting system. Other materials or ﬁttings

may crack or otherwise fail, which could result in leaking and

substantial property damage.

- If your power tool or any part is damaged or does not function

properly, have it repaired by an authorized REHAU service

center. There are no user-authorized repairs for the battery, charger

or power tool. Do not use the power tool until the problem has been

corrected.

- To reduce the risk of personal injury from accidental activation

of the power tool, always remove the battery pack before

changing attachments, inspecting, cleaning, lubricating or

performing any other type of maintenance, inspection, repair

or cleaning.

- Follow all charging instructions and do not charge the battery

pack or tool outside the temperature range speciﬁed in the

instructions. Charging improperly or at temperatures outside the

speciﬁed range may damage the battery and increase the risk of ﬁre.

- Do not expose the battery pack or tool to ﬁre or excessive

temperature. Exposure to ﬁre or temperature above 265°F (130°C)

may cause explosion.

- Do not use a battery pack or tool that is damaged or modiﬁed.

Damaged or modiﬁed batteries may exhibit unpredictable behavior,

resulting in ﬁre, explosion or risk of injury.

- Never service damaged battery packs. Service of battery packs

should only be performed by the manufacturer or authorized service

providers.

- Do not operate the power tool while under the inﬂuence of any

substance (drug, alcohol, medication, etc.) that might impair

vision, balance, dexterity or judgment.

- Working with a power tool can be strenuous. The operator must

be in good physical condition. To reduce the risk of injury from loss

of control, be alert. Do not operate the power tool when tired. Take a

break if you become tired. Always hold the tool ﬁrmly while working

as directed in the instruction manual.

- Make sure you have good balance and secure footing at all

times. Use caution when working from a ladder or other elevated

platform. Do not overreach.

8

Assembling the EVERLOC+ compression-sleeve system with

diameters of 3/8 to 1 in. require the use of the EVERLOC+ Power

Tool. Refer to the EVERLOC+ Power Tool Product Instruction Manual

(855.725) for a complete understanding of operation, care and use of

the tool.

Cold Expanding RAUPEX Pipe

The expansion process consists of the following steps:

1. Squarely cut the RAUPEX pipe.

- Using the pipe cutter, cut the pipe to the desired length. Prior to

cutting the pipe, ensure the pipe cutter is in good condition with a

sharp blade.

- The cut must be clean and square (i.e., forming a 90° angle with

side of pipe) and must be free of burrs, nicks and jagged ends.

NOTICE

Not having a clean, square cut of the pipe could cause leakage of the

ﬁnished joint.

2. Slide the EVERLOC+ compression sleeve onto RAUPEX pipe.

- Slide the properly-sized sleeve onto the pipe. The sleeve is

omnidirectional so either end of the compression sleeve can slide

on the pipe ﬁrst.

- Slide the sleeve down the pipe at least two times the length of the

sleeve so the expander head can be inserted.

- The compression sleeve must not be expanded with the tool.

WARNING

To reduce the risk of serious personal injury from accidental activation

of the power tool:

- Always remove the battery pack before mounting or changing the

expansion adapter, expander head or compression jaws, and

before performing any other type of inspection, maintenance or

cleaning.

3. Place expander head on tool expander adapter.

- Select the properly sized expander head for the pipe diameter

(e.g., 1/2 in. expander head for 1/2 in. pipe).

- Each expander head has six separate segments. Inspect each

expander head to ensure no segments are broken or chipped. Do

not use if the expander head is damaged.

NOTICE

Do not use damaged expander tools or expander heads, as these may

produce faulty joints that could leak.

4.2 FITTING ASSEMBLY 3/8 TO 1 IN.

9

WARNING

Improper handling of the power tool can increase the risk of pinch or

crush injury. The tool is designed for one-handed operation and there

are no gripping surfaces outside of the control handle. To reduce the

risk of serious personal injury:

- Wrap your ﬁngers tightly around the control handle as shown in this

manual and keep a secure grasp on the tool during work.

- Use only your index ﬁnger to trigger the tool. Using other ﬁngers to

trigger the tool may cause you to lose control of the power tool or

increase the risk of personal injury, including pinch injuries.

- Keep hands away from the expander head, hydraulic slide and

compression jaws during operation.

4. Insert expander head into end of RAUPEX pipe.

- Fully insert the expander head into the end of the pipe ensuring

the sleeve is slid past the end of the expander segments.

- Ensure the end of the pipe makes contact with the ﬁrst step of the

expander head.

- Ensure the compression sleeve is a minimum of two times the

length of the sleeve from the end of the pipe. The compression

sleeve must not be in the expansion zone.

WARNING

Moving parts can crush and cut. This power tool uses a strong

hydraulic force to expand RAUPEX PEXa pipe and compress compo-

nents of the REHAU EVERLOC+ compression-sleeve system. To

reduce the risk of serious personal injury during operation:

- Never touch the expander head, hydraulic slide or compression jaws

during operation.

- Keep hands and other parts of your body away from the expander

head, hydraulic slide and compression jaws during operation.

5. Expand RAUPEX pipe twice.

- Once the expander head is fully inserted into the pipe, press the

trigger button on the power tool.

- Ensure the expander head is rotated 1/2 of one expander head

segment between expansions.

- Remove the expander head from the pipe.

NOTICE

Do not expand the pipe and sleeve together. This could cause leakage

of the ﬁnished joint.

6. Insert EVERLOC+ compression-sleeve ﬁtting into expanded

RAUPEX pipe.

- Push the ﬁtting into the pipe so that the end of the pipe is

contacting the pipe stop of the ﬁtting.

- If the ﬁtting does not insert far enough, remove the ﬁtting and

repeat the expansion process so that the ﬁtting can be properly

inserted.

Compressing the Sleeve Onto the Fitting

The EVERLOC+ Power Tool has interchangeable compression jaws to

pull the compression sleeve over the pipe and ﬁtting to complete the

assembly. This step completes the ﬁtting installation process.

The compression process consists of the following steps:

1. Place the EVERLOC+ compression jaws onto ﬁ tting and pipe.

- The compression jaws are color coded. For each size, there is a

black jaw and a chrome-plated jaw. The black jaw is to be inserted

onto the ﬁtting collar and the chrome-plated jaw is to be inserted

onto the pipe with contact to the end of the sleeve.

2x

sleeve

length

10

2. Compress sleeve onto ﬁtting.

- Once the jaws are placed ﬁrmly against the ﬁtting and sleeve,

press the trigger on the power tool and the sleeve will slide over

the ﬁtting. Allow the power tool to completely cycle through so the

sleeve meets the front of the collar on the ﬁtting. When com-

pleted, remove the tool from the ﬁtting.

- If necessary to make installation easier, the tool head can be

rotated, the compression jaws can be mounted on the side or the

compression jaws can be swapped and ﬂipped.

WARNING

To reduce the risk of crush or cut injury, remove index ﬁnger from

trigger before rotating the tool head.

WARNING

In the event of a pinch or unintended compression, release the

hydraulic pressure with the release button.

3. Inspect completed EVERLOC+ compression-sleeve joint.

- The EVERLOC+ compression sleeve should close tightly against

the collar of the ﬁtting. A maximum gap of up to 0.030 in (0.75

mm), or about the thickness of a credit card, is acceptable. This

applies to all sizes of ﬁttings. If the gap is more than 0.030 in

(0.75 mm) and the joint has just been completed, use the power

tool to slide the sleeve further onto the ﬁtting.

Once complete, the ﬁt

ting is immediately ready for system

pressure testing.

11

4.3 FITTING ASSEMBLY 1 1/4 TO 2 IN.

Assembling the EVERLOC+ compression-sleeve system with

diameters of 1 1/4 to 2 in. requires the use of the EVERLOC+ XL

Power Tool. Refer to the EVERLOC+ XL Power Tool Product Instruction

Manual (855.728) for a complete understanding of operation, care

and use of the tool.

Cold Expanding RAUPEX Pipe

The expansion process consists of the following steps:

1. Squarely cut the RAUPEX pipe.

- Using the pipe cutter, cut the pipe to the desired length. Prior to

cutting the pipe, ensure the pipe cutter is in good condition with a

sharp blade.

- The cut must be clean and square (i.e., forming a 90° angle with

side of pipe) and must be free of burrs, nicks and jagged ends.

NOTICE

Not having a clean, square cut of the pipe could cause leakage of the

ﬁnished joint.

2. Slide the EVERLOC+ compression sleeve onto RAUPEX pipe.

- Slide the properly-sized sleeve onto the pipe. The sleeve is

omnidirectional so either end of the compression sleeve can slide

on the pipe ﬁrst.

- Slide the sleeve down the pipe at least two times the length of the

sleeve so the expander head can be inserted.

- The compression sleeve must not be expanded with the tool.

WARNING

To reduce the risk of serious personal injury from accidental activation

of the power tool:

- Always remove the battery pack before mounting or changing the

expansion adapter, expander head or compression jaws, and before

performing any other type of inspection, maintenance or cleaning.

3. Place expander head on tool expander adapter

- Select the properly sized expander head for the pipe diameter

(e.g., 1 1/2 in. expander head for 1 1/2 in. pipe).

- Each expander head has eight separate segments. Inspect each

expander head to ensure no segments are broken or chipped. Do

not use if the expander head is damaged.

NOTICE

Do not use damaged expander tools or expander heads, as these may

produce faulty joints that could leak.

12

WARNING

Improper handling of the power tool can increase the risk of pinch or

crush injury. The tool is designed for two-handed operation and there

are no gripping surfaces outside of the control handle and the support

handle. To reduce the risk of serious personal injury:

- Wrap the ﬁngers of your trigger hand tightly around the control

handle and the ﬁngers of your other hand around the support handle

as shown in this manual.

- Keep a secure grasp with both hands during work.

- Use only your index ﬁnger to trigger the tool. Using other ﬁngers to

trigger the tool may cause you to lose control of the power tool or

increase risk of personal injury, including pinch injuries.

- Keep hands away from the expander head, hydraulic slide and

compression jaws during operation.

4. Insert expander head into end of RAUPEX pipe.

- Fully insert the expander head into the end of the pipe ensuring

the sleeve is slid past the end of the expander segments.

- Ensure the end of the pipe makes contact with the ﬁrst step of the

expander head.

- Ensure the compression sleeve is a minimum of two times the

length of the sleeve from the end of the pipe. The compression

sleeve must not be in the expansion zone.

NOTICE

Do not expand the pipe and sleeve together. This could cause leakage

of the ﬁnished joint.

WARNING

Moving parts can crush and cut. This power tool uses a strong

hydraulic force to expand RAUPEX PEXa pipe and compress compo-

nents of the REHAU EVERLOC+ compression-sleeve system. To

reduce the risk of serious personal injury during operation:

- Never touch the expander head, hydraulic slide or compression jaws

during operation.

- Keep hands and other parts of your body away from the expander

head, hydraulic slide and compression jaws during operation.

5. Expand RAUPEX pipe twice.

- Once the expander head is fully inserted into the pipe, press the

trigger on the power tool.

- Ensure the expander head is rotated 1/2 of one expander head

segment between expansions.

- Remove the expander head from the pipe.

WARNING

Rotating the tool too quickly after the ﬁrst expansion can dislodge the

expander head from the expander adapter, causing it to fall off the

tool, which may result in damage to the expander head or personal

injury.

6. Insert EVERLOC+ compression-sleeve ﬁtting into expanded

RAUPEX pipe.

- Push the ﬁtting into the pipe so that the end of the pipe is

contacting the pipe stop of the ﬁtting.

- If the ﬁtting does not insert far enough, remove the ﬁtting and

repeat the expansion process so that the ﬁtting can be properly

inserted.

13

Compressing the Sleeve Onto the Fitting

The EVERLOC+ XL Power Tool has interchangeable compression jaws

to pull the compression sleeve over the pipe and ﬁtting to complete

the assembly. This step completes the ﬁtting installation process.

The compression process consists of the following steps:

1. Place the EVERLOC+ compression jaws onto ﬁ tting and pipe.

- The compression jaws are color coded. For each size, there is a

black jaw and a chrome-plated jaw. The black jaw is to be

inserted onto the ﬁtting collar and the chrome-plated jaw is to be

inserted onto the pipe with contact to the end of the sleeve.

2. Compress sleeve onto ﬁtting.

- Once the jaws are placed ﬁrmly against the ﬁtting and sleeve,

press the trigger button on the power tool and the sleeve will slide

over the ﬁtting. Allow the power tool to completely cycle through

so the sleeve meets the front of the collar on the ﬁtting. When

completed, remove the tool from the ﬁtting.

- If necessary to make installation easier, the tool head can be

rotated, the compression jaws can be mounted on the side or the

compression jaws can be swapped and ﬂipped.

WARNING

To reduce the risk of crush or cut injury, remove index ﬁnger from

trigger before rotating the tool head.

WARNING

In the event of a pinch or unintended compression, release the

hydraulic pressure with the release button.

3. Inspect completed EVERLOC+ compression-sleeve joint.

- The EVERLOC+ compression sleeve should close tightly against

the collar of the ﬁtting. A maximum gap of up to 0.030 in (0.75

mm), or about the thickness of a credit card, is acceptable. This

applies to all sizes of ﬁttings. If the gap is more than 0.030 in

(0.75 mm) and the joint has just been completed, use the power

tool to slide the sleeve further onto the ﬁ tting.

Once complete, the ﬁt

ting is immediately ready for system

pressure testing.

14

2. Slide the EVERLOC+ compression sleeve onto RAUPEX pipe.

- Slide the properly-sized sleeve onto the pipe. The sleeve is

omnidirectional so either end of the compression sleeve can slide

on the pipe ﬁrst.

- Slide the sleeve down the pipe at least two times the length of the

sleeve so the expander head can be inserted.

- The compression sleeve must not be expanded with the tool.

WARNING

To reduce the risk of serious personal injury from accidental activation

of the power tool:

- Always remove the battery pack before mounting or changing the

expander head, and before performing any other type of inspection,

maintenance or cleaning.

3. Place expander head on tool expander adapter

- Select the properly sized expander head for the pipe diameter

(e.g., 1 1/2 in. expander head for 1 1/2 in. pipe).

- Each expander head has eight separate segments. Inspect each

expander head to ensure no segments are broken or chipped. Do

not use if the expander head is damaged.

NOTICE

Do not use damaged expander tools or expander heads, as these may

produce faulty joints that could leak.

Using the EVERLOC+ Expander Tool for Expansion

In addition to the EVERLOC+ XL Power Tool, the EVERLOC+ XL

E

xpander Tool can be used for the expansion steps of the 1 1/4 to 2

in. ﬁtting assembly process.

Refer to the EVERLOC+ XL Expander Tool Product Instruction Manual

(855.729) for a complete understanding of operation, care and use of

the tool.

Cold Expanding RAUPEX Pipe

The expansion process consists of the following steps:

1. Squarely cut the RAUPEX pipe.

- Using the pipe cutter, cut the pipe to the desired length. Prior to

cutting the pipe, ensure the pipe cutter is in good condition with a

sharp blade.

- The cut must be clean and square (i.e., forming a 90° angle with

side of pipe) and must be free of burrs, nicks and jagged ends.

NOTICE

Not having a clean, square cut of the pipe could cause leakage of the

ﬁnished joint.

15

WARNING

Improper handling of the power tool can increase the risk of pinch or

crush injury. The tool is designed for one-handed operation and there

are no gripping surfaces outside of the control handle. To reduce the

risk of serious personal injury:

- Wrap your ﬁngers tightly around the control handle as shown in this

manual.

- Keep a secure grasp on the tool during work.

- Use only your index ﬁnger to trigger the tool. Using other ﬁngers to

trigger the tool may cause you to lose control of the power tool or

increase risk of personal injury, including pinch injuries.

- Keep hands away from the expander head during operation..

4. Insert expander head into end of RAUPEX pipe.

- Fully insert the expander head into the end of the pipe ensuring

the sleeve is slid past the end of the expander segments.

- Ensure the end of the pipe makes contact with the ﬁrst step of

the expander head.

- Ensure the compression sleeve is a minimum of two times the

length of the sleeve from the end of the pipe. The compression

sleeve must not be in the expansion zone.

NOTICE

Do not expand the pipe and sleeve together. This could cause leakage

of the ﬁnished joint.

WARNING

Moving parts can crush and cut. This power tool uses a strong

hydraulic force to expand RAUPEX PEXa pipe and compress

components of the REHAU EVERLOC+ compression-sleeve system.

To reduce the risk of serious personal injury during operation:

- Never touch the expander head during operation.

- Keep hands and other parts of your body away from the expander

head during operation..

5. Expand RAUPEX pipe twice.

- Once the expander head is fully inserted into the pipe, press the

trigger on the power tool.

- Ensure the expander head is rotated 1/2 of one expander head

segment between expansions.

- Remove the expander head from the pipe.

WARNING

In the event of a pinch or unintended compression, release the

hydraulic pressure with the release button.

WARNING

Rotating the tool too quickly after the ﬁrst expansion can dislodge the

expander head from the expander adapter, causing it to fall off the

tool, which may result in damage to the expander head or personal

injury.

6. Insert EVERLOC+ compression-sleeve ﬁtting into expanded

RAUPEX pipe.

- Push the ﬁtting into the pipe so that the end of the pipe is

contacting the pipe stop of the ﬁtting.

- If the ﬁtting does not insert far enough, remove the ﬁtting and

repeat the expansion process so that the ﬁtting can be properly

inserted.

Compressing the Sleeve Onto the Fitting

To pull the compression sleeve over the pipe and ﬁt

ting to complete

the assembly process, refer to Section 4.2 Fitting Assembly 1 1/4 to

2 in. under the heading Compressing the Sleeve Onto the Fitting. This

step completes the ﬁtting installation process.

16

5. ASSEMBLY CONSIDERATIONS

- Ensure the compression sleeve is a minimum of two times the

length of the sleeve from the end of the pipe. Do not expand the

sleeve and the pipe together.

- Expand the RAUPEX pipe twice, ensuring the expander head is

rotated 1/2 of one expander head segment between expansions.

This ensures that the ﬁtting can be properly inserted.

Fitting Size

Prior to assembly, verify that the ﬁt

ting and sleeve are the proper size

to be connected with the pipe. The size (i.e. 1/2 or 1 1/4 in.) is

marked on each ﬁtting and each sleeve.

Fitting and Sleeve Inspection

Carefully inspect all ﬁt

tings and sleeves for damage prior to assembly.

Do not use ﬁttings or sleeves if there is any doubt about their

integrity.

Sleeve Direction

The sleeve is omnidirectional and can be slid on the pipe in either

dire

ction.

Pipe Cutting

When cutting the pipe to length, the cut must be clean and at a right

ang

le (90º) to the pipe wall. Ensure there are no burrs or debris

inside the pipe.

Expansion of Pipe

- Verify that the RAUPEX pipe is placed completely onto the properly

sized expander head. The pipe should be fully inserted to the ﬁrst

step of the expander head.

17

Fitting Insertion

Verify that the RAUPEX pipe is inserted completely onto the ﬁtting and

is touching the pipe stop. If the end of the pipe is not touching the

pipe stop of the ﬁtting, the ﬁtting should be removed and the pipe

expanded again for proper insertion.

Finished Joint

- A properly completed EVERLOC+ joint requires the compression

sleeve to be ﬂush with the ﬁtting collar. A small gap of 0.030 in

(0.75 mm) is acceptable.

- A ﬁnished EVERLOC+ joint should appear aligned when visually

inspecting the pipe in relation to the ﬁtting and sleeve.

- To avoid putting unnecessary stress on the pipe, ﬁtting or sleeve,

ensure that the transition of the pipe into the EVERLOC+ ﬁtting is

not at an angle.

- A ﬁnished joint can be visually inspected. There are no calibration

tools or go/no-go gauges required to inspect a ﬁnished joint.

18

Some precautions and additional considerations that should be taken

when installing the system.

- EVERLOC+ LF brass ﬁttings CAN be reused, as long the rib area

wa

s not damaged during removal.

- EVERLOC+ polymer ﬁttings CANNOT be reused and should be

discarded immediately.

- EVERLOC+ compression sleeves CANNOT be reused and should be

dis

carded immediately.

Fitting Removal for Completed Joint (LF brass ONLY)

If it is required to remove the ﬁtting or disassemble the compression-

sleeve joint, use the following procedure:

If the ﬁtting has been inserted into the pipe and the sleeve has been

compressed, heat the sleeves with a heat gun. Support the pipe while

keeping hands and other body parts away from the heat. Be careful

not to damage the ﬁtting with the tool.

1. Heat the sleeve directly using a hot air gun.

2. Rotate the joint several times while heating.

3. Remove heat and use pliers to pull the sleeve off the ﬁtting, then

immediately pull the ﬁ tting out of the pipe.

6. INSTALLATION CONSIDERATIONS

WARNING

- Do not use open ﬂames to disassemble the joint. Open ﬂames can

cause injury or property damage.

- Never use a torch, open ﬂame or heat gun on a pressurized system.

- Never rework a connection that is under pressure. Depressurize the

system, cut out connection and replace.

For re-assembly of a new joint, the following should be considered:

- The end of the pipe where the previous ﬁtting had been installed

must be completely cut off prior to making a new joint. Cutting off a

minimum of 3 in (approximately 75 mm) is recommended.

Fitting Removal for Partially Completed Joint (LF brass ONLY)

If the ﬁtting has been inserted into the pipe, but the sleeve has not

been compressed, attempt to remove it without damaging the ﬁtting.

If ﬁtting cannot be easily removed, heat 1 to 1 1/2 in (25 to 38 mm) of

the pipe that covers the ﬁtting and then follow procedures 2 and 3

under Fitting Removal for Completed Joint.

19

Protecting EVERLOC+ Joints

REHAU permits EVERLOC+ compression-sleeve joints (polymer and

LF brass) to be buried or concealed. REHAU recommends that

threaded connections never be buried or concealed as they must be

accessible for periodic inspection, per building codes.

The requirement to wrap an EVERLOC+ joint can depend on many

factors including location and the presence of other materials that

contact or can come in contact with the joint. In general, REHAU

recommends the following:

Concealed in inaccessible locations (e.g. behind drywall):

When EVERLOC+ joints are concealed but are still in open air space,

it is not necessary to wrap the joint. However, the installer should

ensure that the ﬁtting does not come in contact with chemicals (e.g.

PVC glues, solvents, cements) that could damage the ﬁtting material.

Use only Linerless Rubber Tape, Black (Art. 241002) also available at

most distributors and retailers (Scotch™ 2242).

Buried directly in a concrete slab:

When burying an EVERLOC+ joint directly in a concrete slab, it is not

necessary to wrap the joint. However, there are some additives in

concrete that could potentially damage the ﬁtting material, and in this

case, wrapping is recommended. Use only Linerless Rubber Tape,

Black (Art. 241002) also available at most distributors and retailers

(Scotch™ 2242).

Buried in a sub-base or underground in soil:

In these instances, the joint must be wrapped. Use only Linerless

Rubber Tape, Black (Art. 241002) also available at most distributors

and retailers (Scotch™ 2242).

With foaming agents:

Foaming agents and solvents in closed-cell foam insulation kits can

damage the PPSU ﬁtting material. Therefore, it is necessary to wrap

polymer ﬁttings in a protective tape to protect from polyurethane

foams. Use only REHAU Protective Tape, Red (Art. 246869-001) or

Linerless Rubber Tape, Black (Art. 241002).

When wrapping an EVERLOC+ joint, the following is required:

- Wrap the joint, ensure minimum of 50% overlap of the tape.

- Avoid wrinkles or kinks in the tape and ensure the joint is completely

covered, extending on to the pipe as necessary.

- Indicate the location of each joint as required on the “as-built”

drawings.

NOTICE

Use only REHAU recommended protective tapes for wrapping

EVERLOC+ joints. Do not use other types of tapes (e.g. duct tape,

standard electrical tape) to wrap the joint, as chemicals in the

adhesive may not be compatible with the PPSU ﬁtting material or the

PEX pipe.

NOTICE

Never use heat shrink tubing (e.g. RAUCROSS) to wrap the joint, as

the extremely high temperatures produced from a heat gun will soften

the pipe and may cause it to pull away from the ﬁtting. See also

REHAU Technical Bulletin TB266: Protecting EVERLOC+ Joints.

Pressure Testing

The compression-sleeve joint is ready for immediate pressure test and

use af

ter completion of the assembly process. There is no wait time

for the system to be put into service. See also REHAU Technical

Bulletin TB211 Pressure Testing of REHAU PEXa Piping Systems.

Pressure and Temperature Ratings

The maximum temperature and pressure ratings of the EVERLOC+

co

mpression-sleeve ﬁtting system is in accordance with ASTM F877

and CSA B137.5 for SDR9 PEX, see REHAU pipe product submittals

for ratings.

Ultraviolet Resistance

The ﬁt

tings and sleeves must never be stored in direct sunlight or

stored outside of the original cardboard packaging. In addition, the

system is not intended for permanent outdoor applications or in areas

with continuous exposure to UV.

Freeze Break Resistance

The ﬂe

xibility of the RAUPEX pipe allows it to expand as water freezes

in the pipe as long as the pipe has room to expand. However, this

does not ensure the integrity of the joint. Therefore, installers must

take precautions to ensure that pipes and ﬁttings do not freeze. This

may result in leaks and operational failures.

Chlorine Resistance

EVERLOC + compression-sleeve joints have the same chlorine

resis

tance ratings as the RAUPEX pipe. Refer to REHAU Technical

Bulletin TB135 Chlorine Resistance of RAUPEX Pipe for permitted

operating conditions.

20

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