1. Is your Distribution Manifold cast as a single piece?

Plumberstar makes heating distribution manifolds in-house. We offer two different structures: one-piece forged style and modular assembled style. Our product range covers 2 circuits up to 12 circuits. These options fit many different installation layouts and system sizes. We use integrated hot forging for 2-circuit and 3-circuit manifolds. Models with 4 circuits or more use a modular design. The main base and separate branch connectors are fitted together accurately. This structure lets you add extra circuits easily. It also makes later maintenance simpler, without weakening sealing reliability.

One-piece forged manifolds are formed in a single hot forging process. The main body goes through final CNC machining. All connection sizes and sealing surfaces are precisely finished. This design has fewer joints. It greatly reduces possible leak points. Every finished manifold gets a full hydraulic leak test before storage. We hold pressure at 0.8 MPa for 30 seconds. Goods can only enter the warehouse if the main body and all joints show zero leakage.

Modular assembled manifolds use accurate threaded connections. We follow internal quality rules during production. We test the first samples, carry out regular line checks, and run batch sampling. Extra sealing tests and steady flow tests are completed. All joints seal tightly, and every assembled part matches design standards.

2. Can you manufacture distribution manifolds with non-standard center-to-center spacing? 

Plumberstar has our own CNC workshops. We can make water manifolds with custom non-standard center-to-center distances. Most regular models use a standard 90 mm center spacing. We can produce other sizes based on your technical drawings or physical samples. Once we get your custom request, our engineering team reviews feasibility. We send you official processing suggestions within 3 working days.

We adjust our existing machining tools for manifolds with special center distances. There is no requirement to build completely new molds. All CNC operating programs are locked before mass production. This keeps tight control over branch port spacing tolerances. We carry out random sampling during production. We check three manifolds out of every twenty made to confirm real center distances meet requirements. Every finished custom manifold goes through a hydraulic leak test at 0.8 MPa for 30 seconds. Any items with sizes outside the agreed tolerance range get separated for rework. This ensures even spacing on all branch outlets.

3. Can we request specific types of valves or fittings to be pre-installed on the manifolds?

You can absolutely request the pre-installation of specific types of valves or fittings on the Distribution Manifold. This can save you on-site installation time and ensure system compatibility. This is a core part of our service.

• Pre-installable valves: There are many types of valves for you to choose from. You can select safety or control valves for installation based on your needs. You can also choose their connecting fittings, such as threaded connectors and flanges.
• Customization process: After determining the type of valve, you only need to provide the specifications and installation location. Our engineers will conduct tests to verify component compatibility and optimize the assembly structure. We can provide free samples for inspection and testing before mass production.
• For standard valve/fitting models in our inventory, we do not charge additional assembly fees. However, if you wish to use third-party brand valves, we will quote the purchase and assembly costs separately.

4. Can you produce distribution manifolds that meet German standards?

Yes, we can produce Distribution Manifolds that meet German standards.

Compliance with European standards: Our quality management system meets CE, ACS, and the general requirements of the European Union. This makes our products highly suitable for the European plumbing and heating markets.

Specific German standards: We have received orders to manufacture components in accordance with these standards. Moreover, some valves of Plumberstar also use DIN EN threads, which are recognized German (DIN) and European (EN) standards.

In addition, we can provide DVGW certification for the products upon request. DVGW is Germany’s authoritative association for gas and water professionals. Its certification is widely recognized as a symbol of high safety and reliability in plumbing and heating applications in Germany.

5. Can you reverse-engineer an existing distribution manifold sample if we provide one? 

Yes! As long as you provide a sample, we can perform reverse engineering on the Distribution Manifold.

1. 2D/3D drawing design: We will create detailed engineering drawings and 3D models based on the measurement data. Adjustments can also be made according to your requirements.

2. Prototype production and verification: We will produce a new sample using the same material as the original sample. And conduct the same performance tests as your sample. You can verify the product’s functionality before mass production.

3. Mass production: After the prototype is confirmed, we will arrange for mass production. We will follow the drawing standards to ensure consistency with the original sample.

6. Are your weldings on the manifold subject to non-destructive testing? 

Yes, all welds on our Distribution Manifold are 100% Nondestructive Testing (NDT). We mainly use two non-destructive testing methods.

1. Liquid Penetration Testing (LPT): This method is commonly used for stainless steel and brass manifold welds. It can detect surface defects such as cracks, pores, and misfusions. The reuse of the developer allows inspectors to see defects. All liquid penetrant tests comply with ASTM E165.

2. Pressure Test: After NDT, each manifold is subjected to hydrostatic testing. The test pressure for the Distribution Manifold is usually 15bar. The test will last 30 minutes. You can check for any leakage inside the Distribution Manifold. 

7. What is the experience level of your quality inspectors for the Distribution Manifold?

Our quality assurance work is handled by a professional team consisting of 15 inspectors. They have more than 10 years of experience in the heating system(QC&QA) for the entire team.

The quality control department is the core part of our factory. Our inspectors not only conduct visual inspections of the Distribution Manifold but also perform a series of rigorous tests, including dimensional inspection, material analysis, mechanical testing, and crucial hydraulic and pneumatic pressure tests. All these are operated by our experienced quality inspectors. We strive to provide you with products that are free from any problems. Please trust our quality inspectors, and please trust us,-Plumberstar.