8
DESIGN & INSTALLATION GUIDE
DESIGN & INSTALLATION GUIDE
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
2
www.unitray.co.nz
TABLE OF CONTENTS1 PURPOSE OF DOCUMENT 21.1 General 21.2 Supporting information 2
2. GENERAL 22.1 UNITRAY Safe Tray System explained 22.2 UNITRAY Safe Tray System scope of use 32.3 Designer & Installer skill level 32.4 Health & Safety 32.5 Handling & storage 4
3. SPECIFICATION 5
4. INSTALLATION 54.1. Assembling the UNITRAY Safe Tray System 54.1.1. Inserting the elevating posts into the UNITRAY
Safe Tray System 54.1.2 Assembling the T-Connector 54.1.3 Assembling the Tundish 74.2. Locating the UNITRAY Safe Tray System &
connecting with the HWC 7
5. FINISHING 8
6. QUALITY ASSURANCE 8
7. ADDITIONAL RESOURCES 8
1. PURPOSE OF DOCUMENT1.1. GENERALThis document is intended for designers and installers to ensure that the UNITRAY Safe Tray System is specified and installed correctly.
1.2. SUPPORTING INFORMATION This document must be read in conjunction with the following documents:
• UNITRAY Safe Tray System pass™ (product assurance supplier statement)
• UNITRAY Safe Tray System Care and Maintenance
• UNITRAY Safe Tray System Warranty
• UNITRAY Installation Sheet
2. GENERAL2.1. UNITRAY SAFE TRAY SYSTEM EXPLAINEDThe UNITRAY Safe Tray System comprises• UNITRAY Safe Tray• Tundish components• T-Connector
• Elevating posts (optional)
The UNITRAY Safe Tray System is designed specifically for use with hot water cylinders (HWC) that utilise a controlled heat source. It is designed to collect and drain any accidental overflow, thereby protecting the building and/or neighbouring properties from damage or loss of amenity.
It may be installed internally or externally depending on the position of the HWC.
The UNITRAY Safe Tray System is made from light weight, high density polyethylene Qenos (HDPE 0390) complying with BS EN 1778: 2000. It is available in 3 sizes:
• 482 mm diameter (internal) Small
• 590 mm diameter (internal) Medium
• 695 mm diameter (internal) Large
The Tundish is supplied in 3 easily assembled parts plus adaptors to suit the relief drain diameter (15 mm or 20 mm). The Tundish assembly ensures the relief drain discharges with a regulated air gap.
For more information on Unitray NZ Pty Ltd please contact:
[email protected] + 64 21 365 130
www.unitray.co.nz
Uncontrolled in printed format
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
3
www.unitray.co.nz
The UNITRAY Safe Tray System may be supported on 6 x 100 mm high elevating posts (to suit the location of the drainage waste and associated plumbing). Alternatively, the UNITRAY Safe Tray System may be placed directly on a stable, flat surface.
2.2. UNITRAY SAFE TRAY SYSTEM SCOPE OF USEThe UNITRAY Safe Tray System is intended for use in all buildings where:
• The floor has been designed to support all applied loads
• The water supply system has been installed to comply with the NZ Building Code
• A drainage system has been installed to comply with the NZ Building Code
2.3. DESIGNER AND INSTALLER SKILL LEVELWhere the UNITRAY Safe Tray System is specified, the designer shall have the appropriate skills, knowledge of the product and access to all UNITRAY Safe Tray System technical information (refer www.unitray.co.nz).
The UNITRAY Safe Tray System must be installed by a registered plumber/gas fitter in accordance with this design and installation guide.
2.4. HEALTH & SAFETYWhen installing the UNITRAY Safe Tray System :• Appropriate close fit clothing should be warn
at all times• Wear eye and ear protection and appropriate
footwear where necessary• The right equipment should be selected for
working at height (where necessary)• The work area should be kept clear and
unobstructed• With an existing HWC, ensure the HWC is
drained and isolated from the power supply
Refer to-• Worksafe New Zealand Quick Guide• The Absolutely Essential Health & Safety
Toolkit
Ø inte
rnal
695m
m Larg
e
Ø inte
rnal
590m
m Med
ium
Ø inte
rnal
482m
m Small
720mm Large
619mm Medium
520mm Small
100m
m
Minimum Footprint Sizes
160mm
50mm
50mm
85mm
28mm
50mm
UNITRAY cross section
116mm
110m
m
Optional elevating post kit dimensions
(set of 6)
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
4
www.unitray.co.nz
2.5. HANDLING & STORAGEWhen unpacking, ensure all parts have been supplied. The UNITRAY Safe Tray System comes with the following parts:
Adaptors - select the tapered adaptors for standard 15mm and 20mm NZ copper relief drain diameters. NB the adaptors pre-attached to Tundish cap must only be used for smaller diameter pipe such as KemPress™ or imported copper pipe.
UNITRAY - polymer safe tray with integrated outlet and elevating ribs to allow water and airflow as per AS/NZS 3500.4 section 5.4.5 (b).
Tundish cap - aligns relief drains withregulated “air gap” (AS/NZS 3500.4section 5.12.3(h)).
Tundish - easy connect with 50 mm regulated universal drain outlet as per AS/NZS 3500.4 section 5.4.4.1(b).
T-Connector - Screw-on 50 mm BSP female T-Connector. Also suitable for fusion welding and Fernco connections.
1
2
3
4
5
Elevating post kit* - sturdy 100 mm polymer post set.
*Optional - supplied separately.6
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
5
www.unitray.co.nz
3. SPECIFICATIONSpecification of the correct UNITRAY Safe Tray System size may only be made once the HWC to be installed has been selected. Ensure:
• the full weight of the HWC does not exceed 400kg.
• that when installed there will be sufficient space between the full circumference of the HWC and the wall of the UNITRAY Safe Tray System.
4. INSTALLATION4.1. ASSEMBLING THE UNITRAY SAFE TRAY SYSTEM4.1.1. INSERTING THE ELEVATING POSTS INTO THE UNITRAY SAFE TRAYAssemble the elevating posts by pushing the male half of the post fully into the corresponding female half. Insert the elevating posts into the locating holes and slots at even spacings. Ensure the elevating posts are firmly pushed as far as they can go. Use a soft-headed mallet if necessary to ensure that the elevating posts are fitted securely.
It is crucial that the elevating posts are evenly spaced to ensure that the HWC is evenly supported.
The UNITRAY may be used as an elevating platform, such as for outdoor installations. Installation of the elevating posts is unchanged but in this instance the UNITRAY is inverted.
ALLOWABLE ELEVATING POST LOCATION PATTERNSThe UNITRAY safe tray system is designed and engineer-certified to safely support the load of a full HWC when put together in accordance with the below elevating post locations.
1
2
Correct distribution of posts Incorrect distribution of postsMEDIUM TO LARGE UNITRAY TRAY
Uneven spacing Insufficient number of posts
Correct distribution of posts Incorrect distribution of posts
Uneven spacing
SMALL UNITRAY TRAY
Insufficient number of posts
5
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
6
www.unitray.co.nz
4.1.2 ASSEMBLING THE T -CONNECTORScrew the T-Connector securely onto the threaded UNITRAY Safe Tray outlet using thread tape on all male components to ensure a water-tight connection.
Ensure that the T-Connector is orientated correctly for the drain location. There are three options for attaching the T-Connector. Select the option to suit the configuration and dimensions of the installation space.
OR OR
1Apply Teflon thread tape to all male components. Screw T-Connector to UNITRAY.
2Choose one of the above 3 T-Connector configuration options for an indoor installation. Connect T-Connector to plumbing pipework using threaded connection or alternate fusion coupling method.
If necessary the T-Connector may be modified to suit fusion coupling. Cut threaded flange from long end of T-Connector then make connection in accordance with coupling instructions.
3
4.1.3 ASSEMBLING THE TUNDISHPush the Tundish Cap firmly into the Tundish and then screw the assembled Tundish into the upper threaded outlet of the T-Connector. Use Teflon thread tape to ensure a water-tight connection. See fig. A and fig. B.
B
AC
Insert relief drain adaptors into corresponding holes in the top of the Tundish cap to accept both 15 mm or 20 mm copper relief drains. Select the tapered adaptors for standard 15 mm and 20 mm NZ copper relief drain diameters. If necessary use a soft-headed mallet to ensure that the adaptors are inserted correctly. NB the adaptors pre-attached to Tundish cap must only be used for smaller diameter pipe such as KemPress™ or imported copper pipe.
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
7
www.unitray.co.nz
4.2. LOCATING THE UNITRAY SAFE TRAY SYSTEM & CONNECTING WITH THE HWCEnsure the floor surface is level and stable, and the area is free of any loose items such as construction debris.
Place the fully assembled UNITRAY Safe Tray System in the correct location for where the HWC is to be installed. Ensure the system is stable and level before fitting the HWC.
Connect the lower outlet of the T-Connector to a drain in accordance with Building Code plumbing requirements.
Place the HWC centrally on the UNITRAY Safe Tray System to ensure even weight distribution and spacing between HWC and safe tray wall.
Insert fabricated PRV drain pipes into adaptors in the Tundish cap. See fig D for example.
4.3. CONNECTING TO DRAIN Connection to drains must be in compliance with NZ Building Code. Examples of Acceptable Solutions include G13/AS3 and G13/AS1, which require that drain materials and products shall comply with the following table:
D
5. FINISHING Install the HWC in accordance with the supplier instructions including, but not limited to, ensuring the installation of seismic restraints.
Test the HWC in accordance with the supplier requirements.Ensure that the UNITRAY Safe Tray System is balanced and any debris is cleared from the tray and surrounds.
6. QUALITY ASSURANCEUNITRAY NZ Pty Ltd recommends that installers record the installation of the HWC with the UNITRAY Safe Tray System. This may include:
• Written notes, and
• Meaningful photos
USEFUL LINKS
Information to help with the design and specification of UNITRAY Safe Tray System refer to:
• UNITRAY Design & Installation Guide
Information to help with care and maintenance of UNITRAY refer to:
• UNITRAY Care and Maintenance document
Information on the UNITRAY pass™ (product assurance supplier statement) refer to:
• UNITRAY pass™ document
Information on the warranty of UNITRAY refer to:• UNITRAY Warranty document
7
MATERIAL STANDARD
Pipes & Fittings Air admittance values Copper pipe Copper fittings PVC pipe and fittings Plastic fittings PE pipe and fittings Elastomeric rings
ASSE 1050 or ASSE 1051, EN 12380, AS/NZS 4936 NZS 3501 AS 1589 AS/NZS 1260 AS 2887 AS/NZS 4401 AS/NZS 4130 or AS 1646
Traps Plastic Copper
AS 2887 AS 1589
UNITRAY Safe Tray System I Design & Installation Guide V2 NZ I October 2017
8
www.unitray.co.nz
INSTALLATION OPTIONSVisual representation of UNITRAY Safe Tray System installation options.
[email protected] I + 64 21 365 130 I www.unitray.co.nz
Standard indoor UNITRAY installation
Indoor UNITRAY installation using optional elevating post kit
Outdoor UNITRAY installation as inverted elevating platform using
optional elevating post kit
8
