TRU-FLEX METAL HOSE CORP. is an “ISO Registered Company” Installation/Training Guide PRO-FLEX® CSST Patented System #5,845,946, #5,857,716 & #6,102,445 and other patents pending 2391 S. St. Rd. 263 PO Box 247 West Lebanon, Indiana 47991 1-800-255-6291 or 765-893-4403 • Fax: 765-893-4114 website: http://www.tru-flex.com/ e-mail: truflex@tru-flex.
PRO-FLEX® CSST Training Guide and Installation Manual TABLE OF CONTENTS 1.0 INTRODUCTION Guidelines Limitations of Manual .....................................................................................1, 2 Applicable Codes & Standards ...............................................................................................3 2.0 DESCRIPTION OF SYSTEM AND COMPONENTS System Components .......................................................................................................
4.5 CONNECTIONS Meter Hook-ups ..............................................................................................................24, 25 Fixed Appliance.....................................................................................................................26 Moveable Appliance .............................................................................................................26 Pad Mounted Appliance............................................................................
1.0 Introduction This installation/training guide is designed to assist a Pro-Flex® qualified installer in the methods and procedures for the installation of flexible gas piping (CSST). The installer must also meet all qualifications required by the state and/or local administrative authority administering the provisions of the code where the gas piping is installed.
This standard applies to natural and propane gas piping systems using corrugated stainless steel tubing (CSST), intended for installation in residential, commercial or industrial building including the following components as a minimum: a) Corrugated stainless steel tubing (CSST) b) Fittings for connection to the CSST c) Striker plates and/or protective conduit to protect the installed CSST from puncture threats Other Components of piping systems covered in this standard include gas manifolds, gas pressure
Applicable Codes & Standards ATTENTION APPLICABLE CODES & STANDARDS The installation of PRO-FLEX Corrugated Stainless Steel Tubing (CSST) must be performed by a qualified installer who has been trained in the use of the Pro-Flex system. The installer must also meet all qualifications required by the state and/or local administrative authority administering the provision of the code where gas piping is installed. Standards: • ANSI LC1-2005 and CSA 6.
2.0 Description of System and Components ® PRO-FLEX GAS PIPING SYSTEMS (Patented #5,845,946, #5,857,716 and #6,102,445 & other patents pending) ® PRO-FLEX CONSISTS OF THE FOLLOWING: ProFlex® is manufactured in 3/8˝, 1/2˝ and 3/4˝ diameters and available in 25 ft, 50 ft, 75 ft and 225 ft coils. 1˝ diameter available in 25 ft, 50 ft, 75 ft and 150 ft coils. 11/4” diameter available in 150 ft. coil.
STRIKER PLATES PFSP-0312 PFSP-0307 PFSP-0302 PFSP-0617 3 3 3 6 x x x x 12 7 2 17 PFFF-3450 PFFF-0150 PFFF-1225 PFFF-1525 3/4” fits 3/8" (10mm) 1” fits 1/2" (15mm) 1-1/4” fits 3/4” (20mm) 1-1/2”fits 1” (25mm) FLOPPY-FLEX™ PROTECTIVE ARMOR 50 50 25 25 ft. per ft. per ft. per ft.
ADDITIONAL ITEMS APPROVED AS PART OF THE PRO-FLEX® CSST FLEXIBLE GAS SYSTEM MULTIPORT GAS DISTRIBUTING MANIFOLDS Manifolds supply multiple gas appliances in parallel arrangement from main distributing point. Single Tee and Multiple Tee Manifold Assemblies. Single Tee and Multiple Tee Manifold Assembly (Standard 150 lb Malleable Iron Threaded Fittings) – OR – CAST MANIFOLDS PFMM-CCB6 3/4” x (4) 1/2” x 3/4” PFMM-BBB6 1/2” x (4) 1/2” x 1/2” REGULATORS Maxitrol 325.
3.0 System Configuration Configuration Prior to piping installation, refer to building plans or prepare a sketch showing the location of the appliances, the various appliance load demands, point of delivery (location of gas meter or second stage LP regulator), and possible piping routes. Appliance load demand data can be obtained from the manufacturers nameplate located on each appliance, or provided to the system designer by the builder/contractor.
Series and Parallel (Low Pressure) System DETERMINE TOTAL CAPACITY NEEDED FOR APPLIANCES. Data can be obtained from the manufacturers nameplate located on the gas appliance. BTU equivalents for CFH can be obtained from the local utility. In most cases, one Cubic Foot per Hour (1 CFH) is estimated to be 1,000 BTUH heating value (natural gas) and Propane has a heating value around 2,500 BTUH, making the capacity tables easy to utilize with appliance BTU input loads.
MULTIPLE MANIFOLD SYSTEM For those installations in which the energy load demand is large or the appliances are installed throughout the structure with long distances from the meter, a multiple manifold system may be used. Elevated pressure systems are a safe, efficient method of providing for larger BTU load demands while maintaining smaller pipe diameters.
ALLOWABLE PRESSURE DROP: The Pro-Flex® gas piping system is required to be “tested, listed and installed in accordance with the ANSI standard for fuel gas piping systems using corrugated stainless steel tubing, ANSI LC-1-2005. This standard, among other things, requires the manufacturer to provide installation instructions including the necessary pipe sizing tables and methods.
3.2 Sizing Methods and Examples SIZING PROCEDURES PRO-FLEX® CSST, FLEXIBLE GAS TUBING LONGEST LENGTH METHOD EXAMPLE #1 This is a low-pressure series system with four natural gas appliances. The utility company supply pressure exiting the meter is 6 inches water column, and the maximum allowable pressure drop across the longest length from the meter to the farthest appliance is 1/2 inch water column. The gas supplied has a specified gravity of .
EXAMPLE #2, MEDIUM PRESSURE PARALLEL SYSTEM This is a medium-pressure parallel system which includes a distribution tee manifold. The natural gas supply pressure is 1/2 psig and the maximum allowable pressure drop from the meter to the farthest appliance is 6" WC. Medium Pressure (1/2 psig) Natural Gas (Parallel System) Appliance Loads Lengths Oven/Range 45 CFH Furnace = 75 CFH Dryer = 25 CFH Water Heater = 24CFH A= B= C= D= E= 10 FT 20 FT 5 FT 35 FT 50 FT size 3/4" 3/8" 3/8" 3/8" 3/8" TOTAL CFH...
EXAMPLE #3 - ELEVATED DUAL PRESSURE SYSTEM This is a 2 psig supply pressure parallel arrangement. The natural gas system incorporates a pressure reducing regulator with a distribution tee manifold located closely to several large capacity appliances. The inlet pressure downstream of the meter is 2 psig, and the designated maximum pressure drop from the meter to the reducing regulator is 1.0 psig. The outlet pressure from the regulator is set at 8 inches water column.
COMBINATION STEEL/ CSST (Hybrid System) (Hybrid system) Is Corrugated Stainless Steel Tubing used in combination with Rigid Pipe or Copper Tubing. In a low and medium pressure system it is often to your advantage to use both CSST and rigid pipe to help minimize pressure drops typically encountered on systems with high loads and/or long runs. PRO-FLEX® CSST is approved for use in combinations with approved gas piping materials by using approved pipe threads at the interface.
4.0 Installation/Practices Guidelines 1. Pro-Flex® flexible gas piping (CSST) may only be installed by a Qualified/Trained Installer who has been trained in the use of Pro-Flex®. A Qualified/Trained Installer card is required to purchase and install Pro-Flex® (CSST) Flexible Gas Piping. 2. Only the components provided or specified by Tru-Flex Metal Hose Corp., (including Pro-Flex’s striker plates and Floppy Flex™ armor conduit) as part of the piping system are to be used in the installation. 3.
13. Undue stress or strain on the tubing and fittings should be avoided. Also avoid sharp bends, stretching, kinking or twisting of the CSST tubing. 14. Sizing of Pro-Flex® CSST must be performed using the capacity tables found in this Pro-Flex® Installation/Training Guide. 15. Pro-Flex® (CSST) flexible gas piping should not be connected to moveable appliances. Connections to moveable appliances such as ranges and clothes dryers should be accomplished with a “flexible gas appliance connector.” 16.
4.2 Fitting Assembly ASSEMBLY PROCEDURES FOR PRO-FLEX® CSST 1 STEP #1 Cut-to-Length Using a standard tube cutter, cut tubing to the desired length leaving approximately one inch for fitting attachment. Clean up any jagged edges burrs. 2 STEP #2 Strip Yellow Jacket Using a utility knife, strip yellow jacket back 5-6 convolutions from the tubing end. Note: Do not use tube cutter to make yellow jacket cut, use utility knife.
TROUBLE SHOOTING MECHANICAL FITTING TERMINATION OUTLET CORRECTING LEAKS... Step 1 - Gradually tighten fitting until leak stops Step 2 - If tightening does not stop after reaching maximum torque of 35 lbs or 50 lbs (refer to maximum torque for each size listed below), When connecting to a termination outlet, slide the tube with the nut thru the back side of the termination bracket. Then slide assembly to nut from the bracket ... see illustration below.
4.3 Routing • Pro-Flex® CSST can be routed beneath, through and along side floor and ceiling joists. Consideration must be given to future construction possibilities. Alternate locations could include between supply and return air ducts which also provides protection. • Pro-Flex® can be routed inside hollow wall cavities. This is the preferred for vertical sections of piping rather than horizontal sections. Avoiding horizontal runs through the walls will minimize the need for striker protection.
CLEARANCE HOLES & NOTCHING a. Bored Holes - In locations where CSST is installed through bored holes in joists, rafters, or wood members, holes shall be bored so that the edge of the hole is not less than 2 inc. (50.8 mm) from the nearest edge of the wood member. Where this distance cannot be maintained at any point, the CSST shall be protected by a listed striker plate of the appropriate length and width installed in accordance with the manufacturers installation instructions.
CONCEALED FITTINGS LOCATION The Pro-Flex® Mechanical Fittings have been tested and listed per the requirements of ANSI/AGA LC-1 for concealed use. The fitting may be used for concealed attachment to appliance valves, branch runs using tee fittings, and length splices. These guidelines address some of the most common situations where concealing the fittings is the only practical alternative.
PROTECTION DEVICES FIGURE 4-12 PROTECTION IS REQUIRED WHEN THE CSST TUBING IS CONCEALED, CONSTRAINED AND WITHIN 3 INCHES OF A POTENTIAL THREAT. PRO-FLEX® must be protected where puncture threat exist. Install protection devices, i.e. striker plates as shown, to protect the installed tubing from penetrations by drill bits, nails, screws and in those areas where the tubing is concealed and will not be free to move to avoid such puncture threats. Shielding is defined as 3" (76.2mm) x 7" (177.
Floor Pro-Flex CSST Tubing Support Floor Joists 3" or less Striker Plates Figure 4-15 Figure 4-18 CSST Tubing Going Thru Joists Within 3" of Potential Nailing Surface. Floor Short Unsupported Tubing Run (under 3 ft.) from a Termination Outlet within a Wall Partition. Shielding Required at Support Area (studs) when Point of Penetration are Less than 2 in. from any Outside Surface.
4.5 Connections/Installations Illustrated GUIDELINES FOR INSTALLATION OF PRO-FLEX® (CSST) FLEXIBLE GAS PIPING IN OUTDOOR APPLICATIONS PRO-FLEX® tubing and fittings meet all performance requirements for outdoor applications and comply with ANSI/AGA-LC1 standards. In outdoor applications, the external yellow jacketing on PRO-FLEX® should not be removed.
On independently supported meters, PRO-FLEX® CSST can, in some locations, be routed through the exterior wall and connected directly to the meter. Direct connections must provide a loop or slack in the tubing to account for building settling and meter movement. Wall penetration must be properly sealed following local code guidelines. NOTE: Building codes vary from area to area.
appliance shut-off valve drip leg sediment trap (if required by code) union (if required by code) FIGURE 4-35 Pad mounted gas appliance • Heat Pumps • Pad Heaters Fixed Appliance PRO-FLEX® CSST may be connected directly to non-moveable appliances such as water heaters, furnaces, boilers and island cook-tops without the installation of a termination outlet or flexible appliance connector. All local codes requiring drip legs and shut-off valves must be observed.
GAS FIREPLACE INSTALLATIONS 1. PRO-FLEX® CSST may be used to deliver gas directly to the valve for gas fireplaces. This is approved for decorative and heat generating fireplaces and for gas logs used in masonry and pre-fabricated fireplaces. DO NOT use PRO-FLEX® to connect gas log lighters or gas wands for use in al-fuel (wood burning) fireplaces. 2.
ELECTRICAL BONDING In accordance with the NFPA 54 Section 7.13, Tru-Flex Metal Hose Corp., requires proper bonding of the Pro-Flex® gas-piping systems in a structure to the structure’s electrical grounding system. This must be performed by a qualified person recognized by the local jurisdiction as capable of performing such work. These requirements are for all Pro-Flex® CSST installations.
Drawing 2 Note: Bonding wire must be no smaller than 6 AWG Note: Remove any paint on pipe surface beneath clamp location Drawing 3 Note: Bonding wire must be no smaller than 6 AWG Note: Remove any paint on pipe surface beneath clamp location Proper bonding and grounding may reduce the risk of damage and fire from lightning strikes. Lightning is a highly destructive force.
FIGURE 4-32 Elevated deck a fixed Pedestal mount grill or gas light - direct connection Gas Lamps: FIGURE 4-33 FIGURE 4-34 Ceiling or wall hung infrared heater car ports / patios / decks 30
TYPICAL INSTALLATION OF CSST WITH NON-METALLIC CONDUIT BURIED UNDER CONCRETE SLAB FIGURE 4-40 TYPICAL INSTALLATION OF CSST WITH NON-METALLIC CONDUIT EMBEDDED IN CONCRETE SLAB FIGURE 4-41 31
FIGURE 4-38 Appliance termination/stub-out FIGURE 4-36 Short (2 to 6 ft.) outdoor connection to root mounted equipment Roof Mounted Equipment: FIGURE 4-36 - No special mechanical protection of the CSST is required for connections to roof top equipment. Whenever possible, roof penetrations shall be located within 6 ft of the equipment to be connected as shown in Figure (4-36). Long runs of tubing shall be supported with nonmetallic blocks every 4-ft.
4.6 Manifold Stations Manifolds are installed where multiple runs are made from a common location in a parallel arrangement. The manifold may be manufactured from a one piece, malleable iron or brass casting, or a welded fabrication of steel subcomponents or an assembly of approved, malleable iron tees and short nipples. Depending on the location and available space, different mounting arrangements are permitted.
4.8 Pressure Regulators Description a) A piping system for use at gas pressures exceeding 1/2 psi (3.45kPa), but intended to serve equipment rated for 1/2” psi (3.45 kPa) maximum, shall include a gas pressure regulator to limit the downstream supply pressure to 1/2” psi (3.45 kPa), and the installation instructions for the piping system shall specify that such a regulator shall be installed. For system pressures up to 5 psi (34.
Installation a) The regulator shall be installed in an accessible location with an approved shut-off valve on the inlet side and a union on the outlet side so that it may be inspected, maintained and serviced if repair or replacement is required. b) The regulator is suitable for multi-poise mounting. When using a vent-limiting device however, the regulator must be mounted in a horizontal upright position. All regulators provided by Pro-Flex® include a vent limiting device.
Line Regulator Capacity Tables Natural Gas Maxitrol Pressure Drop Table Capacity @ Pressure Drop - 0.64 sp gr gas expressed in CFH (m3/h) Model Number 7.0" W.C. (17 mbar) 1/2 psi (34 mbar) 3/4 psi (52 mbar) 1 psi (69 mbar) 145 (4.0) 204 (5.8) 250 (7.0) 289 (8.2) 325-3 338 (9.6) 476 (13.5) 583 (16.5) 673 (19.
5.0 Inspection and Testing of Installed CSST Pressure Testing and Inspection Procedure a) The final installation must be inspected and tested for leaks in accordance with the local/state codes. In the absence of local restrictions test in accordance with NFPA 54 (1-1/2 times the maximum working pressure, but not less than 3 PSI), using the procedures specified in the latest edition of the National Fuel Gas Code, “Gas Piping Inspection, Testing and Purging” section.
g) Most jurisdictions also require an additional pressure or leakage test performed after the construction is completed and finished interior walls are in place. The leakage test procedure is generally performed by the gas utility at the time of setting their meter. This test is performed to assure no damage was done to the tubing during the closing-in construction process, and is typically required before gas service is initiated.
5.1 Repair and Placement of Damaged CSST REPAIRING DAMAGED CSST TUBING & FITTINGS Repair Classifications: FITTINGS: Leaking fittings should be repaired in accordance with the manufacturers installation instructions. In some cases, the entire fitting or parts of the fitting must be replaced totally. CSST TUBING: If the tubing is damaged, the severity of damage and if necessary, the method of repair shall be determined as follows: a.
METHODS OF REPAIR There are different methods of repair which are discussed below depending on the nature and severity of the damage. The Installer must determine the most reliable and economical method of repair using one of the following methods. Replace the entire tubing run. When the tubing run is short and easily accessible, it can be repaired faster and economically by replacing the whole run versus repairing only the damaged section.
6.0 Sizing Tables NATURAL GAS LOW PRESSURE Gas Pressure: 6 – 7 inches WC 15 95 64 5 200 68 45 10 337 163 56 37 15 474 287 141 49 32 20 423 253 126 44 29 25 386 228 115 40 26 30 334 194 100 35 23 40 299 171 89 32 20 50 273 154 81 29 18 60 252 141 75 27 17 70 236 131 70 25 16 80 222 123 66 24 15 90 211 116 63 23 14 100 172 92 51 19 12 150 149 78 44 16 10 200 133 69 40 14 9 250 121 62 36 13 8 300 (Based on a 0.
NATURAL GAS Gas Pressure: 8 – 10 inches WC 3/8” 18 15 692 222 156 5 1162 490 160 110 10 1346 925 400 132 90 15 1165 787 346 115 78 20 1041 694 310 103 70 25 950 626 283 95 64 30 822 532 245 83 55 40 735 469 219 74 50 50 671 424 200 68 45 60 621 388 185 63 42 70 581 360 173 59 39 80 547 337 163 56 37 90 519 318 155 53 35 100 423 253 126 44 29 150 366 215 109 38 25 200 327 189 98 34 22 250 299 171 89 32 20 30
NATURAL GAS Gas Pressure: 13 – 14 inches WC 3/8” 18 15 979 308 220 5 1717 692 222 156 10 1906 1366 565 183 127 15 1650 1162 490 160 110 20 1475 1025 438 144 99 25 1346 925 400 132 90 30 1165 787 346 115 78 40 1041 694 310 103 70 50 950 626 283 95 64 60 880 574 262 88 59 70 822 532 245 83 55 80 775 498 231 78 52 90 735 469 219 74 50 100 600 373 179 61 41 150 519 318 155 53 35 200 464 280 138 48 31 250 423 253 1
NATURAL GAS Gas Pressure: 5 psig Pressure Drop: 3.5 psig Locate proper sizing table based on total pressure drop allowed in piping system by local utility for each installation.
Propane PROPANE LOW PRESSURE GAS Locate proper sizing table based on total pressure drop allowed in piping system by local utility for each installation. (Based on a 1.
PROPANE LOW PRESSURE GAS Locate proper sizing table based on total pressure drop allowed in piping system by local utility for each installation. Maximum Capacity of Pro-Flex® CSST in Thousands of BTU per Hour of Undiluted Liquified Petroleum Gas (Based on a 1.
SIZING TABLES AND PRESSURE DROP CHARTS 1/4” Nominal Iron Pipe Size (in.) 0.493 0.364 Internal Diameter (in.) 175 95 43 10 120 65 29 20 97 52 24 30 82 45 20 40 151 73 40 18 50 138 66 36 16 60 125 61 33 15 70 118 57 31 14 80 110 53 29 13 90 103 50 27 12 100 93 44 24 11 125 84 40 22 10 150 77 37 20 9 175 72 35 19 8 200 IRON PIPE CAPACITY TABLES Maximum Capacity of Steel IPS Pipe in Cubic Feet Per Hour with a Gas Pressure of 0.
Reference Data SPECIFIED GRAVITY FACTOR FOR NATURAL GAS Pressure Conversion Factors 1/4 psi = 6.921 in. w.c. = 1/2 psi = 13.842 in. w.c. = 1 psi = Fuel Gas Information (approx. 7” w.c.) (approx. 14” w.c.) 27.684 in w.c. = (approx. 28” w.c.) 2 psi = 55.368 in. w.c. = (approx. 56” w.c.) 5 psi = 138.42 in. w.c. = (approx. 140” w.c.) Natural Gas Propane BTU per Cubin Foot = 1000 2516 Specific Gravity = 0.60 1.52 Note: to determine the CFH for Natural Gas, divide the BTU load by 1000.
7.0 Technical Data Sheet PRO-FLEX® C.S.S.T.
8.0 CSST Installation Checklist Description Corrugated Stainless Steel Tubing (CSST) has been design certified by CSA (formerly know as AGA, The American Gas Association Laboratory since 1990) for use as a fuel gas piping system. CSST has been tested per ANSI/CSA-LC1 as required for approval and is listed as an approved gas piping material in the National Fuel Gas Code-NFPA 54, BOCA National Mechanical Code, SBCCI Standard Gas Code, and the new International Code Series.
9.0 Terminology 1 CONVERSION FACTORS INCHES OF WATER COLUMN (in.-w.c.) - Method by which pressure is measured inches by a manometer or pressure gauge. Used in the gas industry when the pressure is less than 1 psi. 1/4 1/2 1 2 5 2 PRESSURE psi = 6.921 psi = 13.842 psi = 27.684 psi = 55.368 psi = 138.
9.2 Limited Warranty PRO-FLEX® INTERIOR GAS PIPING SYSTEM Subject to the terms and conditions contained in this Limited Warranty, Tru-Flex Metal Hose Corp. “TRU-FLEX™" warrants to the original purchaser of the PRO-FLEX® Interior Gas Piping System that such product will be free from any defect in material and workmanship for a period of one (1) year from the date of installation.
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Please fill in all blanks to verify you have read and understand all aspects of the installation/training guide and for warranty activation. I, ____________________, Qualified Installer, have read the Pro-Flex® please PRINT your name above installation/training guide and understand all aspects of installation and local plumbing and/or building codes in accordance set forth.
TO: TRU-FLEX METAL HOSE CORP.
