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This file contains Technical Information of the KaRo System. The data sheets are continuously updated and available by email at info@KaRo.cc or by fax using the fax order. You can get to the documents by the navigation of the Acrobat Bookmarks or direct by a click on the page number in the index. CONTENT 1. 2. 3. 4. 5. 6. Basics System descriptions Calculation and Planning Installation Charts and Forms Diagrams 7. Formulas
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Index
Technical Information
1
G01 G02 G03 G04 G05 G06
2
K01 K02 K03 K04 K05 K06 K07 K08 K09 K10 K11
Short Description
Plaster KaRo Ceiling Metal KaRo Ceiling Plasterboard KaRo Ceilings Pre-fabricated KaRo Panel KaRo Wall Pre-fabricated KaRo Wall KaRo Floor Heating KaRo Modernisation panel KaRo Acoustic Metal Panel Plug In Coupling KaRo Skin
3
B01 B02 B03 B04 B05 B06 B07 B08 B09 B10 B11 B12 B13 B14
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Index TI Technical Information
4
M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22
Installation
KaRo Mats Thermal Welding KaRo Plaster Ceilings KaRo Metal Ceilings KaRo Plasterboard Ceiling Dew-Point Sensor Pressure Test Converter Technical Data Room Temperature Control Pre-fabricated KaRo Panel Double panelled Plasterboard Ceiling KaRo Floor Heating Fixing of KaRo Mats with Butyl Tape KaRo Glue KaRo Glue Solvent KaRo Thermal Paste Fixing of KaRo Mats with Tape KaRo Mats on Gypsum Boards Tacking KaRo Mats KaRo Wall Start of Secondary Stations KaRo AquaStop
5
T01 T02 T03 T04 T05 T06 T07 T08 T09 T10
6
D01 D02 D03 D04 D05 D06 D07 D08 D09 D10 D11 D12
Diagrams
Cooling Capacity KaRo Ceilings Cooling Capacity KaRo Plaster Ceilings Heating Capacity KaRo Cooling Ceilings Heating Capacity KaRo Plaster Ceiling Permissible Heating Capacity Ceiling Permissible Heating Capacity at Window Pressure Loss of long KaRo Mat U10 Pressure Loss of short KaRo Mat U10 Pressure Loss of long KaRo Mat G10 Pressure Loss of short KaRo Mat G10 Pressure Loss of long KaRo Mat S10 Pressure Loss of short KaRo Mat S10
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Index TI Technical Information
D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30
Pressure Loss of long KaRo Mat S15 Pressure Loss of short KaRo Mat S15 Pressure Loss Connecting Hose Pressure Loss KaRo Pipe DA 20 Pressure Loss in KaRo Elbow Flow Speed in Pipes Heat Transfer Ceiling/Room Average Surface Temperatures at the Ceiling Underside Heating Capacity of KaRo Floor Heating Pressure Loss of the KaRo Panel GK12 Frequency Dew Point Outside Air Average Heat Transmission of Buildings Basic Capacity of Cooling Ceiling Heat Volume Water Volume Cooling Capacity of KaRo Wall B12 Heating Capacity of KaRo Wall B12 Heating Capacity of the KaRo Wall Pressure Loss of KaRo Mats 600 x 600
7
F01
Formulas
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TI-Order
Following you will receive a selection of our technical information. In the enclosed list of contents all available Technical Information (TI) are listed. Please ask for the requested information. You simply have to fill out and sent this fax. The requested information will be sent to you by post. Please fill in the requested numbers:
others
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Humidity is the local and timely changing contains of steam in the air, which depends upon the regional climate, if not also influenced by individual usage of the rooms (kitchen, laundries etc.) Humidity must be considered regarding comfort as well as for functioning of the system.
2.
Basics
Air and steam in the atmosphere form a mixture, which contents behave like gases. For the mixture of both the Dalton law (1820) is true Each component i of a mixture of ideal gases in a definite volume V acts as if fills the whole volume by itself. It is under partial pressure Pi which results when the isothermal expansion of its volume Vi acts by the pressure P to the total volume V. Example Humidity: with p= pL + pD p pL pD V VL VD mD mL RD RL = = = = = = = = = = (equation 1)
Total pressure Partial pressure of the air Partial pressure of the damp Total volume Volume of air Volume of damp Masses of damp Masses of air Gas resistance: damp = 461 J/kg K Gas resistance: air, = 287 J/kg K
3.
2.1 Absolute Moisture X The absolute moisture represents the denseness of water in the air volume.
Next to temperature of the room air, the surface temperature of room enclosure areas and the velocity of the room air, the humidity is another to the room relating which is of importance for the thermal (see page G01)
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If the humidity in the room rises to such an extent that the portion of transpiration in the regulating mechanism of the temperature budget can not be kept up, the state of comfort can not be reached, even if other thermal values are within their limitation.
5.
4.
Moist air condenses at cold surfaces because of the saturation pressure being a function of the dew point temperature in dependence of the air pressure. (equation 3). This indication influences the application of a cooling ceiling decisively. Is the surface temperature kept below the dew point, there is the danger that condensation occurs. The dew point temperature must be seen in relationship to climatic zones of the location. According to DIN 4710, for our longitudes a yearly average of 60 to 90 hours are assumed, where a outdoor situation with dew point temperature above 16C will occur.
Basically the supply temperature should have a minimum of 16C. Therefore the time frame, in which theoretically the humidity in the room is the same as the humidity of the outdoor air, is restricted to 4% of the yearly working hours (depending on the location). It can be assumed though, that many building materials such as gypsum, plaster, masonry, concrete, carpeting, wallpaper etc. will slow down the rise of the humidity. To exclude this rare case a temperature sensor is installed at the coolest spot in the room. According to experience this spot is in the furthest corner away from the window directly next to the supply line. In case that the dew point is reached, this sensor actuates a setting valve in the return to the closed position preventing that further water can flow into the cooling circuit. (also see B05; Regulation of KaRo heating- and cooling ceilings). This simple way of regulation is enough to safely avoid condensation in the standard condition. At higher humidity in the room because of individual situations or at other related climate situations, dried air must be let into the room by means of a base (board) air ventilation. The incoming air is conditioned according the moisture, which has to be carried away.
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3.
Life-span
In order to express the life span for KaRo capillary tubes, the tension in the capillary tube must be determined and compared with the allowable comparative-tension at the actual instance. The actual tension in the tube (tension of the tubes wall) is determined from the tube sizes and from the internal pressure according to the following equation: V = pi (da - s )/ (2 s) with pi - Internal pressure da - Outer tube diameter s - Wall thickness of the tubes
For the KaRo capillary tube a tension is calculated of only 1.04 MPa, this at a normal operating pressure of 0.4 MPa. The allowable comparative tension at 20C and 50 years although is still 9.4 MPa. This shows, that even after 50 years there is the assurance of 9 times against material failures.
95C
1000000 50 Years
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The hauling costs for air with conventional systems in some cases reach up to 50% of the energy costs. To transport the same amount of energy trough the media water, less than 10% of motive power is needed with KaRo ceilings.
1 source: journal HLH Bd.45(1994) - Wirtschaftlichkeitsvergleich des Khldeckensystems mit VVSSystem, Dr.Marten Bruck, Dr. Franc Sodec
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Basics, General Information TI-G04 Energy- and Cost Consideration to the KaRo Cooling Ceiling
Even if the KaRo ceiling is operated in combination with a baseboard ventilation for achievement of high comforts the energy consumption is still distinguishably lower since exclusively only the air for the hygienic air exchange must be moved.
4. Investment Costs
The investment costs for a cooling system is determined by the volume of the cooling load, the building conditions, the architectural desires, the technique of the cooling system and by the demands of comfort. For high cooling loads and large buildings, the KaRo cooling ceiling is the appropriate solution to provide comfortable room climates. The modest room requirements for the KaRo capillary mats and water circuit, very seldom require additional space for maintenance- or installation channels. Also for this reason KaRo cooling ceilings are outstanding for the renovation of rooms or buildings. For new construction, at the same height of eaves and because of the low construction height of the KaRo ceilings in comparison to a system, which requires an air channel network, it is sometimes possible to gain a full storey, whereby investment costs can be saved.
KaRo heating- and cooling mats can practically be installed into any type of ceiling without any problem. Without much additional expenditure it is possible to install capillary tube mats into nearly any type of ceilings. A comparison of investment costs between the KaRo cooling ceiling and a traditional air conditioning system is possible when the room and demand for comfort are accurately specified. Basically it can be said, that the combination cooling ceiling with a mechanical air ventilation, at high cooling loads, require less investment costs and lesser room than the traditional air conditioning systems.
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Basics, General Information TI-G04 Energy- and Cost Consideration to the KaRo Cooling Ceiling
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The capillary tube technique for heating and cooling for rooms has been successful in the market for more than 15 years. Meanwhile 750.000 m of capillary tube mats have been installed for cooling ceilings or for surface heating in Europe, mainly in Germany and in Switzerland. For the homeowners and user of the rooms, at first the comfortable and healthy room climate along with low operating costs in comparison to standard air conditioning systems, are the main reasons for choosing cooling- and heating ceilings with KaRo capillary tube mats. Architects praise the nearly unrestricted possibilities of design for ceilings and implementations with the use of KaRo mats. Not the least the KaRo technique is the best suited for the installer for low costing and true time installation work because of its simple and safe connection techniques.
2. Technical Principle
Advantages: Uniform cooling through radiation and convection Healthy; through barely noticeable air movements High cooling capacity, because of the capillaries laid close beneath the surface With 16C supply temperature, approx. 20C surface temperature is reached. Energy savings through utilisation of alternative energy sources. Top in comparison with other systems. Little pressure loss /m2 Little installation expense
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Basics, General Information TI-G05 Advantages of the KaRo Capillary Tube Technique
20
Source: S+G 10/93 - Comparative capacity metering on cooling ceilings of different brands Author Dr. Bernd Glck- ROM
A - two in meander shape laid metal pipes, which are connected by a k-shaped crimp on the long side of the metal panel. The panels are fixed with clamps to the water carrying pipes. B - two units with 11 venation blind slats. These slats form current channels wherein a convection current is developed. Sheet metal cassettes of which approx. 20% perforated are fixed directly beneath the units as a closed cooling ceiling. C - Capillary tube mats with a distance of 12,5 mm between the capillary tubes, glued to sheet metal panels of which 20% being perforated. D - Copper pipes (pipe diameter = 36,7 mm2), meander shaped, laid onto sheet metal panels of which 20% being perforated, then covered with plasterboard. E - meander shaped bent metal pipes (outer diameter 12 mm) with pipe distances of 85 mm, with half of their circumference laid in thermal contacting profiles. The Wilhelmi ceiling panel with Mikropor lamination, front faced fixed with clamp bars and with magnet strips on the thermal contact profile, provide the contact between the panel and the thermal contact profile. F - Aluminium plates with integrated water carrying channels. These cooling plates are laid in Willhelmi sheets type Mikropor,
down-hold
Alternative energy sources or also open cooling via outside air are sufficient for longer time periods of the year to maintain comfort. It saves energy costs and natural resources. Compared to other systems, comfort is improved, since the KaRo system reacts very fast to load changes. Continuing heat emission time through heat accumulation, as this is known from normal floor heating systems, will be very short because of the non-existing building masses above the capillary tubes. Another advantage of the KaRo capillary tube technique, compared to the meanders made of metal pipes, is the modest pressure loss/m2 of active ceiling surface. In the KaRo mats the required water volume for the cooling capacity is distributed to a great number of capillaries (depending on the mat type this could be up to 96 tubes/m width), while for the metal pipe meanders only one pipe dia- meter is available. Even for mat surfaces of 8 m2 a flow speed of only 0.2 m/s is reached in the capillary tube. In a meander made of copper tubing DN 10mm , for the same surface, already a critical flow speed of 1.15 m/s is reached. A low flow speed, even under consideration of the substantially small diameters of the KaRo capillary tubes, results into lesser pressure loss. Therefore lesser motive power is reP.2 TI-G05
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Basics, General Information TI-G05 Advantages of the KaRo Capillary Tube Technique
quired with the KaRo systems for the circulating pumps. Metal pipe systems avoid this eventual disadvantage mostly through the fact that smaller surfaces (seldom more than 1 m ) are connected directly to a connection of the supply line. But through this the expense for the installation and for the connecting parts will be comparatively higher than with the KaRo technique.
3. Liberty of Design
Advantages KaRo mats are flexible and are fit for all building designs KaRo mats must only be laid on metal cassettes Load per unit area only approx. 800 g/m2 No reinforced sub-constructions required Dry-build boards must only be covered with KaRo mats KaRo mats can be embedded simply in plaster KaRo dry-build units are available for the advanced dry-build construction Little thermal expansion because of small temperature differences KaRo mats for floor heating
brickwork or to a plasterboard surface. The mat itself is fixed by means of gluing, nailing, tacking or with dowels. After this a thin layer of plaster is applied. The capillaries are close beneath the surface, so that a high efficiency is reached. The main pipes which the capillary tube for supply- and return line lead into, are installed in wall slots or ceiling cavities and will then be connected to the water circuit. A danger of inadequate adhesion of the plaster, also at the state of heating, is not given since operating temperatures of the water are mostly only at 30C (not more than 45C) and the plaster material is not harmed and the thermal expansion of the capillaries will be taken-up by the plaster without any problem. The use of KaRo mats for floor heating or cooling is especially suitable for renovation. The KaRo mats simply are laid on top of an a layer which is able to support load (raw concrete or floor tiles) possibly insulated to the layer below, fixed and covered with a thin layer of screed . The surface can be done with tiles or floor coverings. Different to standard floor heating systems the KaRo system leads the heat from directly beneath the surface to the room. The heating system therefore reacts very fast with water temperatures seldom higher than 28C.
Through the small dimensions of the KaRo capillary tubes the mats are very flexible and can be fit without any problem to nearly any building component. Even vaults and triangle shaped surfaces can be covered with KaRo mats. KaRo capillary tube mats can be laid on top of metal cassette units, it doesnt matter of which brand they are. With a load per unit area of only approx. 800g/m2 (filled), the sub-construction of the ceiling units is not affected. The KaRo mat is therefore also suitable for renovation of suspended metal ceilings. But also dry-build construction boards from plaster or fibrous plaster can be covered simply from the top with KaRo mats. The construction boards are prepared with the capillary tube mats at the building site and installed as usual. KaRo also offers a dry-built unit (a sandwich type sheet consisting of plasterboard with hart foam insulation and an integrated KaRo mat) especially for drybuilt purpose. This unit is available in all construction boards standard sizes. It is particularly suited for installation of large surfaces, where the borders and the cutouts on the inactive ceiling units are just cut to size at the building site. The embedding of KaRo- heating and cooling mats into ceiling or wall plastering can be done without any problem no matter if plaster is being applied to pre-mixed concrete,
KaRo heating- and cooling mats are fabricated in different versions, made to order in requested dimensions. At the building site the mats are installed according to an accurate ceiling pattern and connected to the waterlines. Tailoring of the mats at the building site is not necessary. For larger ceiling installations like lamps, speaker boxes or air vents, KaRo offers specially manufactured mats. Small cutouts (for light spots or sprinklers) are done simply by moving some capillaries to the side. Depending on the version the KaRo mats are connected by means of thermal welding or with flexible hoses which are supplied with
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Basics, General Information TI-G05 Advantages of the KaRo Capillary Tube Technique
quick-action couplings and can be connected to the factory prepared supply lines with the cold- or warm water circuit. KaRo mats for plaster ceilings are supplied as per request with adhesive tapes. Before plastering the installer just peels off the protective foil from the adhesive tape and glues the mat to the raw ceiling. KaRo capillary tubes are self-venting because of their small inner diameter. Through the laminar current in the tubes, the air is being transported out of the system even if the mats are installed with a vertical downward flow. Therefore at installations a descent must not be taken into account. Automatic vents though must be included in the supply lines of the piping. The manufacturing of KaRo mats is covered by a strict factory quality standard . Each KaRo mat is pressure tested with 20 bars for a time of 10 minutes. According to regulation the responsible installer has to make an additional pressure test after completion of the installation. On principle KaRo heating- and cooling mats are operated in closed circuits. The mats circuit (secondary circuit) is connected to the circuit of the water preparation and heating unit via a stainless steel heat exchanger. Only non-corroding components (brass, stainless steel or plastic materials) are installed in the secondary circuit. Through the system separation a reliable avoidance of sludge and clogging of the capillary tubes secured During heating operation fall-out of waterdissolving minerals will not occur, since heating temperatures are never above 45C. The system separation protects the system even at failures and will prevent from emptying. Should a failure occur, even with the safety measures laid out in the system and a capillary tube is damaged, the damage is only limited. Water will only drain from the damaged capillary tube until pressure equalisation with the environment is reached. For this reason the maximum possible amount of leakage is determined by the size of the expansion tank. Normally not more than 5 litres. Repairs of damaged capillary tubes are easily done through soldering/welding with a welding plate ore a soldering iron (see Technical Information M01). The active ceiling area and therefore a lesser performance is hardly noticeable. KaRo heating- and cooling mats stand up to the tough building site conditions. Wilful damages excluded, the mats can even
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be walked on during installation processes. The mats, pipes and supply lines can be laid at temperatures down to +5C. Once filled with water the KaRo mats will not take damage even when freezing.
KaRo capillary tube mats, pipes, supply lines and fittings are made from Random Copolymer type 3 according DIN 8078. This plastic material is a highly pure material with excellent properties regarding durability and compatibility to the environment. The polypropylene used for the KaRo mats meets the VII, Polypropylene, of the Deutschen Bundesgesundheitsamtes (BGA) (German health department) and is physiological harmless. This polypropylene can therefore also be used for cold/hot drinking water lines. Polypropylene is resistant to a great number of chemicals, even against aggressive ones. An extensive list of chemical resistances can be found in the contents of annex 1(add sheet ) to DIN 8078. KaRo mats are filled with regular tap water, because polypropylene itself is non-corrosive. Manufacturer of copper pipe systems themselves state for their systems: Because of differing water qualities it might be necessary to do water treatment; especially when the contents of chloride is higher than 50 mg/litre and a risk for germs exists. Generally checks of the water quality are suggested every year, for recording number of germs and amount of oxygen 1 For copper, along with cold oxygenise water, corrosion is possible at critical conditions, which could cause pipe damages already at short operating times. Polypropylene can be operated up to temperatures of 60C without any problem. Quality measure for the duration of life for plastic materials generally, is the duration time internal pressure behaviour according DIN E 8078 (1994).
Basics, General Information TI-G05 Advantages of the KaRo Capillary Tube Technique
According to this the duration of life for the KaRo heating- and cooling mats, pipes, supply lines and fittings are extremely (according G03 more than 50 years). Polypropylene is used for floor heating systems successfully for more than 20 years. Against beginning resistances coming from the supplier of metal pipe systems, plastic materials dominantly succeeded in the marked. According to the magazine BmK 2/93, the market share for copper pipes for floor heating systems, 1993 was already estimated to be below 10%.
The environmental compatibility of plastic materials especially for polypropylene is superior to copper and steel. In an environment analysis according to the method of results oriented comparison (VENOB) of the technische Universitt Berlin 1994 the pipe systems of different materials were examined. The diagrams above show the environmental behaviour in conclusion.
Plastic min.
Plastic max.
Copper
Impact of soil
Steel
50
100
150
200
250
300
Plastic min.
Plastic max.
Copper
Steel
5000
10000
15000
20000
25000
30000
35000
40000
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Polypropylene is a highly pure hydrocarbon material. With its properties this material can be classified in the group of plastic materials minimal. The results of this study show significant advantages for the plastic materials against the standard pipe materials concerning environmental properties. Fire behaviour of polypropylene is harmless. When Polypropylene is burned it changes to water and carbon dioxide. According DIN 4102 part 1 polypropylene belongs to the material group B2 normal flammable. Neither while polypropylene is burning or at the extinguishing phase, whether neither poisonous gases nor acids will be formed, as this is would be the case with PVC. Further comments to burning behaviour, as also comments to fire rating of capillary tube mats as given by the Amtlichen Material Prfanstalt fr das Bauwesen beim Institut fr Baustoffe, Massivbau und Brandschutz an der TU Braunschweig can be found in the technical comments of B06. KaRo capillary tube mats, supply lines and pipes, normally are not a set out to UV-light during installed situation. Shipment of the goods will be done UV light protected in cartons or foil packaging.
Polypropylene can be totally recycled without energy waste. At KaRo all the PP-production waste is ground-up and used again for plastic moulded parts. Large plastic material producer such as Hoechst AG are setting-up recycling systems. In the city of Knappsack is a recycling unit where PP-material (up to 5.000 t/year !) is recycled. Should, in any case, normal assorting of PP- material and recycling not be economical, than polypropylene can still be burned in trash burning units. Even at a trash depot polypropylenes behaviour is neutral. PP does not dissolve in water and therefore does not harm underground water or soil.
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The large assortment of KaRo products offers many possibilities for installation. Technical solutions and the extent of work involved are differing. Costs, which are mentioned at this point, are true for standard installation variations and should only be used for approximate costing. Costs are further influenced by the expense of cold-water preparation and the regulating technique in dependence to the active ceiling area. Because of so many differing offers average costing can not be ascertained. Standard-installation variations of KaRo capillary tube mats. Embedding in metal cassette units Equipping standard-dry-build panels Usage of KaRo dry-build units (sandwich sheet from plasterboard and insulation panel with integrated KaRo mats) Installation of KaRo mats in plaster (fixed to the raw concrete or to the suspended plasterboard ceiling)
3.
Equipping the plasterboard panels with KaRo mats is described in Technical Remarks M05. KaRo mats are pre-fabricated according dimensions of the ceiling and supplied to the building site. The plasterboards are then equipped according to the layout scheme. For better thermal conduction the capillary tubes are painted with a thermal conduct paste. Then the boards are pre-drilled according the layout scheme. The construction for the suspended ceiling, made from CD-profiles, is fitted in 300 mm screen distances according to standard dry-build regulations. The supplyand return lines are installed in the ceiling cavity. The plasterboards equipped with the KaRo mats are positioned at the ceiling, the supply lines connected to the waterside with flexible hoses and fixed to the suspended ceiling at the pre-drilled positions with building screws. For larger installations non-equipped inactive plasterboards are used. Small cutouts in the ceiling are done in the same manner as with metal cassettes.
2.
The steps for installation are thoroughly described in Technical Remarks M04. Before installation the KaRo mats are laid into the cassettes. For a perfect heat transfer, the mats should be glued-in or should be covered with a mineral-fibre insulating mat. In the last case the acoustical insulation is already predetermined. Standard insulation thickness is mostly 40 to 60 mm. If the metal cassette is furnished in the swing down version, the insulation sheet should be secured with clamping brackets. An insulating panel increases the cooling performance in case of a totally enclosed ceiling with an additional heating source in the ceiling cavity (water carrying piping, covers for light fixtures etc.). The supply lines are laid into the ceiling cav-
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Basics, General Information TI-G06 Standard KaRo Ceiling - Constructions and approx. Costs
Cooling ceiling as equipped dry-build panel. Capacity 70 W/m standard cooling capacity Prices 150,- to 180,- /m
5.
The installation of KaRo mats in plaster is explained in Technical Remarks M03. The KaRo mat type K.S15 is fixed to the raw concrete ceiling with butyl adhesive tape or with dowels. M13. A bonding layer must be applied to the raw concrete for plastering type MP75 or similar is used. The plaster thickness should be 12mm 15mm . The main pipes for the mats are laid in wall slots. Direct welding of the main lines with the piping does the connection of the mats. Cooling ceiling embedded on the raw concrete ceiling. Capacity 80 W/m standard cooling capacity Prices 65,- to 120,- /m
4.
Instructions for installation of KaRo dry-build units are given in the Technical Remarks M11. The KaRo dry-build unit is manufactured in standard dimensions of 2000 x 600 mm. They are suitable for installation of large connected surfaces. For the border area and for build-ins the inactive boards are tailored at the building site. KaRo dry-build units are screwed to the CDprofiles of the suspended ceiling support construction. The supply lines for supply and return are laid into the ceiling cavity. For the installation of the dry-build units the water connection from the base to the supply line is done with flexible hoses. Cooling ceiling with the dry-build unit. Capacity 64 W/m standard cooling capacity Prices 150,- to 180,- /m
A second variation is to tack plasterboard directly to the KaRo mat type K.S15. In the plasterboard surfaces slots of 150 mm are left blank. Through theses slots the mains are lead to the ceiling cavities and are connected to the piping by welding a process. The slots then are closed with plasterboard strips. A bonding layer is applied to the ceiling surface. At the end a layer of plaster (MP75) approx. 10-12 mm thick is applied. Cooling ceiling plastered onto a dry-build panel. Capacity 80 W/m Standard cooling capacity Prices 130,- to 200,- /m
(Prices are depending upon the installation expense for the dry-build panels )
Ceiling in-lays can be made up to diameters of 100 mm, only by pulling the capillary tubes apart. For larger in-lays the ceiling areas are kept empty.
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Short Description
Free Cooling
With KaRo substantial energy savings can be regained with free cooling.
City
Altitude m
Athens Berlin Istanbul Lissabon London Madrid Moskau Paris Rome Valencia Cleveland Los Angeles New York San Francisco Hongkong Singapore Chungching Sydney Melbourne
2.500 2.000 1.500 1.000 500 0 Dry bulb temperature Wet bulb temperature
Figure 3: Annual hours in Berlin with outside temperature exceeding 15 C. Free Cooling with KaRo
1 KaRo Ceiling 3 Heat exchanger 4 Cooling tower
Only when the capacity of the cooling tower is not big enough the bypass is closed and the chiller is cooling the KaRo water and the cooling tower is used for the chiller.
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TI-K01
Short Description
2. System Description
The KaRo heating- and cooling mats are simply embedded into the ceiling plaster. Since the capillary tubes are positioned directly beneath the surface (the ceiling construction is thinner than 15 mm !), the surface will heatup or cool-down fast. The time reaction of the ceiling is less than 15 minutes.
Plastered ceiling with BEKA heating- and cooling mats
4. Installation
In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials used can be: plastics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to malfunction of the system.
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Short Description TI--K01 Plaster Ceiling with KaRo Heating and Cooling Mats
5. Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. The cooling ceiling requires: a room temperature regulation, a dew point guard, and a control of the supply temperature for the cold water. Supply temperatures below 16C must be avoided because of the danger that the dew point is reached! For the heating ceiling a room temperature control is required, which regulates the volume of heating water in dependence to the desired room temperature. Supply temperatures higher than 45C must be avoided because of the danger of an excessive surface temperature of the ceiling and to prevent plaster from drying-out !
offered for the different uses in widths of 1200 mm and lengths up to 6000 mm, so that tailoring at the building site is not necessary. Only at borders and at areas where ceiling in-builds are planned, inactive areas must be provided. The KaRo heating- and cooling mats can be supplied with readily attached double sided adhesive tape, for the positioning of the mats at the raw ceiling. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All mats with its dimensions and direction of installation for the supply lines must recorded. In the ceiling pattern also all areas must be marked, which will stay empty for instance for the installation of partition walls, for light fixtures and for other ceiling in-fills. Also the installation position of the dew point KaRosensor must be marked at the ceiling pattern. The connection of the Polypropylene piping is done by thermal welding. For the execution the welding directions DVS 2207-11 of the Deutscher Verband fr Schweitechnik e.V. are valid. (The surrounding temperature during working must not be below 5C. The preheating,- welding and setting time must be according to regulations.)
8. Tools, Materials
For the installation of KaRo heating- and cooling mats in plaster ceilings the recommended tools and materials for the installations of Polypropylene must be used.: Pipe clamps Dowels and screws, if necessary Plastic pipe clamps Hand held welding device with sleeve welding adapter for plastic welding Plastic fittings Smoothening spatula Plaster material Tools and materials for plastering must be chosen according the plaster manufacturers instructions.
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TI -K01
Short Description TI--K01 Plaster Ceiling with KaRo Heating and Cooling Mats
I.
Butyl adhesive tape Raw ceiling
Apply plaster spots at the spacer bars of the mats, with this the KaRo mats are held securely until plastering is done. For installation to suspended ceilings this additional fastening will not have to be done. Eventually only tacks have to be placed above the spacers of the mats, to take the tension of the mats
II.
Plaster spots
III.
Apply the plaster base adhesive primer according to manufacturers instructions, through painting, roll-on or spraying. Apply plastering in a thin layer. Mostly 10 to 12 mm is enough. Avoid thick layers the cooling capacity will be lowered!!
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TI -K01
Short Description TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats
10. Lay-out of a Plaster Cooling Ceiling with KaRo Mats Type K.S15
Project : Project consultant : Required Cooling Capacity 1 Cooling load for the room 2 Planned coverage with mats 3 Required specific cooling capacity Performance Determination 120 100 Cooling capacity [W/m 2] 80 60 40 20 0 24 23 22 21 20 19 W m2 W/m2
Date Lay-out valid for 27C room temperature and 2K cooling water spread !
from calculation of planning office max.possible arrangement derived from room dimensions = cooling load / coverage
18
17
16
15
14
13
12
valid for room temperature 27C and cooling water spread 2K and plasster type MP75 -Fa.KNAUF
12
16
20
23
27
31
35
38
42
46
50
Mass flow of cooling water [kg/(m2h)] 4 Supply temperature -> from diagram 1 5 Return temperature 6 Water volume of mat area 7 Water volume per zone Pressure loss determination 8 Length of connecting pipe 9 Resistance in the pipe -> from diagram 2 10 Pressure loss in the pipe = pipe length * resistance 11 Pressure loss of the mat -> with value of line 2 from the diagram 1 12 Addition for pressure loss of fittings (recomm.: 30% addition to pipe) 13 Addition for heat transfer station (recomm:for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss Pa Pa
20000 Pressure loss [Pa] 15000 10000 5000 0 10 15 20 25 30 Mass flow [kg/(m2h)] 35 8m
C C kg/(m2h)
Pressure loss [Pa/m] 100 90 80 70 60 50 40 30 20 10 0 40 80 120
l/h
m Pa/m Pa Pa Pa
160
280
320
360
400
25000
4m
3m 2m 1m 40
If BEKA heat transfer stations are utilised, the pressure determinaton can be omitted. Only the quantity of cooling circuits and the total cooling capacity is required for the selection.
04/2002
P.4
TI K01
Short Description TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats
11. Lay-out of Plaster Ceiling for Ceiling Heating with KaRo Mats Type K.S15
Project : Project consultant : Date Lay-out valid for 22C room temperature and 6K Heating water spread !
Required heating capacity 1 Heat requirement for the room 2 Planned coverage with mats 3 Required specific heating capacity Performance Determination W m2 W/m2 from calculations of the planning office max.possible arrangement derived from the room dimensions = Heat requirement / coverage
valid for room temperature 27C and heating water spread 6K and plaster type MP75 -Fa.KNAUF
12
14
17
19
22
25
4 Supply temperature -> from diagram 1 5 Return temperature 6 Water volume per mat area 7 Water volume per zone Pressure Loss Determination 8 Length of connecting pipe 9 Resistance in the pipe -> from diagram 2 10 Pressure loss in the pipe = pipe length * resistance 11 Pressure loss of the pipe -> with value of line 2 from diagram 1 12 Addition for pressure loss of fittings (recomm: 30% Addition to pipe ) 13 Addition for heat transfer stations (recomm:for zone valves 500-1000 Pa for heat exchanger approx. 4000 Pa 14 Total Pressure Loss for mains regulating valves 700 - 1500 Pa
C C kg/(m2h) l/h
Pressure loss [Pa/m] Pressure loss in a pipe 20x2mm 100 80 60 40 20 0
m Pa/m Pa Pa Pa
40
80
120
160
280
320
360
400
Pa
Pa
5m 4m 3m 2m 1m 25
If BEKA heat transfer stations are utilised, the determination of pressure losses can be omitted. Only the quantity of heating circuits and the total heating capacity is required for the selection.
04/2002
P.5
TI-K01
Short Description TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats
Size Length: 600-6000 mm (in increments of 10 mm) Width: 150-1200 mm (in increments of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Cooling capacity Depending upon the type 80 W/m2 with 10 mm Plaster MP 75 (DIN 4715) Heating capacity: Depending upon the type to 150 W/m2 Operation condition : Temperature stable at long term use up to 45C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Utilisation / type of installation: Cooling- and heating ceilings, plaster-version Connection by thermal welding Type of delivery: The mats are supplied rolled-up, packed in cartons.
04/2002
P.6
TI-K01
TI-K02
Short Description
piping
4. Installation
Generally the standard installation guidelines must be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials to be used can be: plastics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to malfunction of the system.
P.1
TI-K02
Short Description TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats
5. Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. The cooling ceiling requires : a room temperature regulation, a dew point guard and regulation of the supply temperature for the cold water. Supply temperatures below 16 C must be avoided because of the danger that the dew point could be reached! For the heating ceiling a room temperature control is required which regulates the volume of heating water in dependence to the desired room temperature. In rooms higher than 3,5 m supply temperatures above 40C must be avoided because of excessive surface temperatures!
duced in measurement of the metal cassettes based on the object to avoid any tailoring work at the building site. At the border areas and at areas where ceiling in-builds are planned inactive cassettes will be installed. The KaRo heating- and cooling mats are supplied with quick-action couplings for the connection of supply- and return lines with flexible hoses. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All mats with the dimensions, the direction of installation and the supply lines must be recorded. In the ceiling pattern all areas must be marked which will stay uncovered, i.e. for the installation of partition walls or light fixtures and for other ceiling in-fills. Also the installation positions for the KaRo dew point sensor must be marked at the ceiling pattern. The connection of the polypropylene piping is done by thermal welding. Here the welding directions DVS 2207-11 of the Deutschen Verband fr Schweisstechnik e.V. must be obeyed. (the ambient temperature must not be below 5 C. The pre-heating, -welding- and setting time must be according to the given regulations.)
8. Tools, Materials
For the installation of a metal cassette heating- and cooling ceiling with KaRo capillary tube mats standard tools and materials for ceiling constructions and for the installation of plastic pipes can be used such as: Metal cassettes Suspender profiles and suspenders depending at the type of construction used for the chosen ceiling. Dowels and screws Sheet metal scissors Mineral wool insulating wool (if req.) Scissors to cut plastic piping Hand-held welder with sleeve welding adaptor for plastic welding Plastic fittings For the connection of the supply lines to the cold water circuit a hand-held welder with sleeve welding adaptor and plastic fittings are recommended . Alternatively sealing ring connectors can be used.
04/2002
P.2
TI K02
Short Description TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats
The bearing structure is fastened and aligned to the raw ceiling with vernier suspension bars according to manufacturers recommendations of the chosen ceiling brand. The supply lines are laid into the ceiling cavity and connected to the main supply lines (connections done either by thermal welding or with sealing ring connectors) The flexible connecting hoses are plugged into the quick-action couplings of the supply lines.
I.
II.
The KaRo heating- and cooling mats are laid into the cassettes and if necessary fixed with KaRo adhesive V.K.1.
III.
insulation
Plug the flexible hoses into the quick-action couplings of the KaRo mats. The cassettes with the KaRo mats in it are hooked into the bearing structure and the joints are aligned. If required, place insulating mat on top of it. Pre-test with compressed air at 10 bar for one hour. Main test with water at 10 bar for 4 hours, maintain an idle pressure of 3 bar until the system is taken into operation.
04/2002
P.3
TI K02
Short Description TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats
10. Lay-out for Metal Cassette Cooling Ceiling with KaRo Capillary Tube Mats
Project: Project consultant: Required cooling capacity 1 Cooling load for the room 2 Planned coverage with mats 3 Required specific cooling capacity Determination of performance W m2 W/m2 from calculation of the planning office maximum possible arrangement derived from the room dimensions = cooling load / coverage Date : Lay-out valid for 27C - room temperature and 2 K cooling water spread!
Quick lay-out for ceiling cooling with BEKA mats in metall cassettes
Cooling capacity [W/m ]
2
120 100 80 60 40 20 0 24 23 22 21 20 19 18 17 16 15 14 13 12
12
16
20
38
42
46
50
from diagram 1
C C
1 00
kg/m h l/h
7 Water volume per zone Pressure loss determination 8 Length of the connection pipe 9 Resistance in the pipe 10 Pressure loss in pipe = pipe length * Resistance 11 Pressure loss of the mat with value of line 2 from diagram 1 12 Addition for pressure loss through fittings (recomm: 30% addition to pipe) 13 Addition for heat transfer station (recomm: for zone valves 500 -1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa) 14 Total pressure loss If BEKA heat transfer stations are utilised the determination of pressure loss can be omitted. from diagram 2
m Pa/m Pa Pa Pa Pa
8m
5m m 1 ,6
1 m ,4 4m 1 m ,2 3m 1 m ,0 2m 1 m 1 5 1 5 20 25 30 20 25 30 M a s s e n s tro m (kg/m2h) 35 35 40 40
Pa
In this case only the quantity of cooling circuits and the total cooling capacity is required for the selection.
Mass flow[kg/m h]
04/2002
P.4
TI K02
Short Description TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats
11. Lay-out for Metal Cassette Ceiling Heating with KaRo Capillary Tube Mats
Date Lay-out valid for 22C room temperature and 6K heating water spread !
Required Haeting Capacity 1 Heat requirement for the room 2 Planned coverage with mats 3 Required specific heating capacity Determination of Performance W m2 W/m
2
from calculation of planning office maximum possible arrangement derived from room dimensions = heat requirement / coverage
Quick lay-out for ceiling heating with BEKA mats in metal cassettes 180 160 140 120 100 80 60 40 20 0 27 29 31 33 35 37 39 41 43 45 Supply temperature [C]
valid for room temperature 27C and heating water spread 6K
13
15
17
4 Supply temperature -> from diagram 1 5 Return temperature 6 Water volume per mat area 7 Water volume per zone Pressure Loss Determination 8 Length of connection pipe 9 Resistance in the pipe -> from diagram 2 10 Pressure loss in the pipe = pipe length * resistance 11 Pressure loss of the mat -> with value of line 2 from diagram 1 12 Addition for pressure loss through fittings (recomm.: 30% addition to pipe) Addition for heat transfer station (recomm.:for zone valves 500 -1000 Pa 13 for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss If BEKA heat transfer stations are utilised
m Pa/m Pa Pa Pa
Pa
the determination of pressure losses can be omitted. Then only the quantity of heating circuits and the total heating capacity is requird for the selection !
25
04/2002
P.5
TI K02
Short Description TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats
KaRo Capillary tube mats Type K.U10 Type K.UM10 Type K.G10 Material Polypropylene Random-Copolymer Type 3 DIN 8078 Geometry Collector pipe Capillary tube Capillary tube spacing Exchange surface
Dimensions Length 600-6000 mm (in increments of 10 mm) Width 150-1200 mm (in increments of 10 mm) Mass 0,43 kg/m2 (empty, without collector) 0,82 kg/m2 (filled, without collector) Water contents 0,39 l/m2 Cooling capacity: Depending upon type 80 W/m2 for metal cassette (DIN 4715) Heating capacity Depending upon type up to 150 W/m2 Condition of operation: Temperature resistant for endurance run to 45C Operation pressure 3 to 4 bar Test pressure 10 bar maximum 10 hours Operational area / type of installation : Cooling- and heating ceilings for the installation on top of metal cassettes Connections via quick-action coupling system Type of delivery: The mats are supplied lying flat in cartons or in one-way transport cassettes
04/2002
P.6
TI K02
TI-K03
Short Description
2. System Description
The KaRo capillary tube mats are simply stretched between the supporting profiles and covered with mineral wool. Afterwards, the ceiling is planked as usual - (standard cooling capacity 65 W/m2)
Pipe system
3. Cold-water/Hot-water Technology
The KaRo heating and cooling mats are integrated in rooms/zones in a tubing network as a circulation loop and connected to a cold-water generator and the heat source. We recommend that the connection is made using a KaRo singlestorey distributor. A wide variety of technologies and systems may be used for cold water generation. The economic advantages of the cooling ceiling consist primarily of the fact that the ceiling is extremely efficient even at flow temperatures which are only slightly below the room temperature. This facilitates the use of "alternative energy" (heating pumps) and natural energy (e.g. free cooling, groundwater). The same advantages apply to hot water generation. Significant energy savings are achieved not only in combination with solar heating systems, but with conventional technology as well,
4. Installation
As a rule, the general installation guidelines apply. All materials used in the tubing network of the KaRo capillary tube mats must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may cause the system to silt up and thus disrupt its function.
04/2002
P.1
TI-K03
Short Description TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats
5. Control Technology
The control technology ensures the comfort you desire and provides the necessary system safety as well. The cooling ceiling requires a room temperature control unit, a dew point safeguard control unit and a control unit for the initial flow temperature of the cold water. Initial flow temperatures below 16C must be avoided due to the dew point risk! The heating ceiling requires a room temperature control. This regulates the flow of hot water depending on the desired room temperature. Initial flow temperatures more than 45C must be avoided so that the surface temperature of the ceiling does not become too high, and the gypsum plasterboards dry out !
Before beginning work, a ceiling drawing and a laying plan must be drawn up, in which all coffers with their dimensions, alignment, and the supply lines must be recorded. In the ceiling drawing, all areas must be also marked which must remain unoccupied, e.g. where partition walls, lighting and other ceiling fittings will be installed. In addition, the location where the KaRo M.TG.1 dew point sensor will be installed must also be marked in the ceiling drawing. If thermal plastic welding is being used to connect the polypropylene tubes, the welding guideline DVS 2207-11 of the Deutscher Verband fr Schweitechnik e.V. (German Association of Welding Technology) applies. (The environment temperature during processing may not be lower than 5C and the preheating, welding and holding times must be observed according to the dimensions of the tubing.)
7. Installation Preparation
The stipulations of the dry construction guidelines and the regulations of the fitters' union apply to the assembly and mounting of the KaRo heating and cooling mats on gypsum plasterboard ceilings. We recommend that the furring be carried out using torsionally rigid steel profiles. The specification of the effective spans and the execution of anchoring the hangers on the bare ceiling must be designed for a load of 30 kg/m2. Gypsum plasterboard sheets in the customary dimensions are used. The KaRo heating and cooling mats are supplied in the correct widths and lengths, so that cutting them to size on the construction site is not necessary. Inactive areas are arranged only around the edges and in places where ceiling fittings are planned.
To connect the feed lines to the cold water circulation, a handheld welding unit with a sleeve mirror is used for plastic welding and the corresponding plastic fittings are required. Cutting ring screw fittings may be used as an alternative.
04/2002
P.2
TI -K03
Short Description TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats
In accordance with the manufacturer's instructions, the supporting and basic profiles are attached to the bare ceiling using vernier suspenders and aligned. The distance between the supporting profiles must be set at 40 or 50 cm. Additional supporting profiles (including the wetting angle) in the area around the edge for the inactive custom-cut sheets are arranged according to the ceiling plan in accordance with the dry construction guidelines. The feed lines are laid in the hollow cavity of the ceiling and connected to the supply lines (connection by means of thermal plastic welding or cutting ring screw fittings).
I.
The KaRo mats are stretched between the supporting profiles and connected to the feed lines via the flexible hoses; alternatively, the mats can be connected to each other and to the tubing system using plastic welding. Adhesive tapes are fastened from supporting profile to supporting profile, so that the mats do not sag. Mineral wool mats are laid on top of the KaRo mats from above. The mineral wool must be cut to fit as a strip in the grid dimension of the supporting profiles. If the hollow ceiling cavity is used for the exhaust ventilator or if perforated gypsum board is used, the mineral wool must be packed in fibreproof PE foil wrapping.
II.
The supporting structure is planked from below with gypsum board and filled. Preliminary test with 10 bars of compressed air for 1 hour. Main test with 10 bars of water for 4 hours maintain resting pressure of 3 bars until the system is put into operation.
III.
04/2002
P.3
TI -K03
Short Description TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats
10. Lay-out for KaRo Mats on Gypsum Plasterboard in the Cooling Ceiling
Project: Project consultant: Required Cooling Capacity 1 Room cooling load 2 Planned coverage with mats 3 Required cooling capacity
D e te rmin a tio n o f P e rfo rma n c e
Date : Lay-out valid for 27C-room temperature and 2K cooling water spread !
W qty W
from calculation of the planning office Max. possible arrangement derived from the room dimensions = Cooling load / Coverage
10
13
25
28
31
34
4 Supply temperature -> from diagram 1 5 Return temperature 6 Water volume per mat area 7 Water volume per zone Pressure loss calculation 8 Length of connecting tube 9 Resistance in the tube -> from diagram 2 10 Pressure loss in the tube = tube length * Resistance 11 Pressure loss of the mat -> with value of line 2 from diagram 1 12 Add. for pressure loss through fittings (recomm: 30% addition to tube) 13 Add.for heat transfer stations (recomm:for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss If BEKA heat transfer stations are utilised the determination of pressure loss can be omitted.
C C
k g /m 2h
m Pa/m Pa Pa Pa
Pa
2m 1 m 35 40
In this case only the quantity of cooling circuits and the total cooling capacity is required for the selection !
04/2002
P. 4
TI -K03
Short Description TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats
11. Layout for the KaRo Mats on Gypsum Plasterboard in Heating Ceiling
Project : Project consultant : Required heating capacity 1 Room heat requirement 2 Planned coverage of mats 3 Required specific heat capacity Determination of Performance W from calculation of planning office max. possible arrangement derived from room dimensions = Heating requirement /Coverage Date : Lay-out valid for 22C -room temperature and 6 K hot water!
qty
W
Quick lay-out for ceiling heating with BEKA mats on gypsum plasterboard
140 Heating capacity [W/m 2] 120 100 80 60 40 20 0 27 29 31 33 35 37 39 41 43 45 Supply temperature [C]
14
17
19
from diagram 1
C C
k g /(m 2h)
6 Water volume per mat area 7 Water volume per zone Pressure loss calculation 8 Length of connecting pipe 9 Resistance in the pipe 10 Pressure loss in the pipe = Pipe length* Resistance 11 Pressure loss of the mat with value from line 2 in diagram 1 12 Add.for pressure loss through fittings (recomm: 30% addition to pipe) 13 Add.for heat transfer station (recomm: for zone valves 500 -1000 Pa) for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss from diagram 2
l/h
m Pa/m Pa Pa Pa
Pa
4,0 m
If BEKA transfer stations are used, the pressure loss calculation is omitted. Only the number of heating circuits and the total heating capacity are required for the selection .
04/2002
P. 5
TI -K03
Short Description TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats
Size Length: 600-6000 mm (in steps of 10 mm) Width: 230- 430 mm (in steps of 10 mm) Volume 0.430 kg/m2 (unfilled, without collector) 0.824 kg/m2 (filled, without collector) Water content 0.39 l/m2 Cooling capacity: 65 W/m2 with 10 mm gypsum plasterboard (heat conductivity of the thermal sheet approximately 0.40 W/mK ) Heating capacity: Up to 130 W/m2 Operating conditions: Temperature-stable in continuous use up to 45C Operating pressure 3 to 4 bars Test pressure 10 bars for a maximum of 10 hours Field of application/Laying method: Cooling and heating ceilings in dry construction Connection via flexible hoses and quick-coupling connectors or via thermal plastic welding Form of delivery: The mats are rolled and delivered in cartons.
04/2002
P. 6
TI -K03
TI-K04
Short Description
2. System Description
The KaRo pre-fabricated units are screwed to suspend ceiling construction according drybuild construction instructions just like any standard dry-build panel. The predimensioned connection lines are laid into the ceiling cavity. The pre-fabricated unit is connected with flexible hoses to the supply lines.
Piping
4. Installation
In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials used can be: plastics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to a breakdown of the system.
P.1
TI-K04
Short Description TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit
5. Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. The cooling ceiling requires : a room temperature regulation, a dew point guard and a control of the supply temperature for the cold water. Supply temperatures below 16C must be avoided because of the danger that the dew point will be reached! For the heating ceiling a room temperature control is required, which regulates the volume of heating water in dependence to the desired room temperature. Supply temperatures above 45C must be avoided because of the danger of excessive surface temperatures of the ceiling and to avoid that the plasterboard will dry !
active panels are fitted in. The KaRo prefabricated units are delivered pre-drilled for the connection to sub-construction made from standard CD-profiles. The screws may only be placed at these predetermined positions, otherwise there is the danger that the integrated capillary tube mats are damaged. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All cassettes with their measurements, the installation direction and the supply lines must marked. In the ceiling pattern also all areas must be marked which will stay empty for the installation of partition walls, light fixtures and other ceiling in-fills. Also the installation position for the KaRo dew point sensor must be marked at the ceiling pattern. The connection of the Polypropylene piping is done by thermal welding. For the execution the welding directions DVS 2207-11 of the Deutschen Verband fr Schweitechnik e.V. are valid. (The surrounding temperature during working must not be below 5C. The preheating, welding and setting time must be according to regulations.)
8. Tools, Materials
For the installation of the KaRo pre-fabricated unit standard tools and materials for the drybuild construction work is used: CD - profile Cross connector Vernier suspension bar Dowel and screws Rapid-build screws, 55 mm length Perimeter angles Blade-knife and edge planer Screw-driver Smoothening spatula Joint filler Hand grinder For the connection of supply lines to the coldwater circuit a hand held welder with sleeve adapter is recommended for the plastic welding together with plastic fittings. Alternatively sealing ring connectors can be used.
7. Installation Instructions
For the installation of the KaRo pre-fabricated unit the standards for the dry-build construction and the fabricators recommendations must be obeyed. It is recommended to use twist-free sheet metal profiles for the supporting construction of the suspended ceiling. The distances and the type of anchoring of the suspended verniers to the raw ceiling must be for a load of 30 kg/m2 . The pre-fabricated unit is offered in the same dimensions as the standard building panels, so that tailoring work at the building site is not necessary. Only at border areas and at places where ceiling build-ins are planned, in-
04/2002
P.2
TI -K04
Short Description TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit
I.
The supply lines are laid in the ceiling cavity and are connected to the main lines (connections done by thermal welding or with sealing ring connectors).
II.
The KaRo pre-fabricated unit is fixed to the sub-construction according the ceiling-pattern. The flexible connecting hoses are plugged into the quick-action couplings of the supply lines. The pre-fabricated unit aligned at the subconstruction to the pre-drilled holes. The rapid-build screws inserted through the pre-drilled holes and screwed tight until secure fixing to the sub-construction is achieved. Pre-test with air pressure of 10 bar for 1 hour Main test with water at 10 bar for 4 hours. Maintain a resting pressure of 3 bar until taken into operation.
III.
04/2002
P.3
TI -K04
Short Description TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit
10. Lay-out of the Cooling ceiling with the KaRo Pre-fabricated Unit B.GK12
Date : Lay-out valid for 27C room temperature and 2K cooling spread !
Required cooling capacity 1 Cooling load for the room 2 Planned quantity of panels 3 Required cooling capacity of unit Determintaion of capacity Quick Lay-out for ceiling cooling load with B.GK12 W Stck W from calculation of planning office derive possible arrangement from room measurements = cooling load / quantity of panels
12
16
19
23
26
30
34
37
41
45
49
300
500
700
900
1100
1300
1500
1700
1900
2100
2300
2550
2800
valid for room temperature 27C and cooling water spread 2K and connecting hose 300mm length
4 Supply temperature --> from diagram 5 Return temperature Pressure loss determination 6 Pressure loss in the pipe = pipe length * Resistance 7 Pressure loss of unit -> with value of line 3 from diagram 8 Add. for pressure loss through fittings (Recomm.: 30% extra for pipe) 9 Add. for heat transfer station (Recomm.:for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 10 Total pressure loss
C C
kg/h l/h
Pa Pa
m Pa/m
Pa
If BEKA transfer stations are used the determination for pressure losses can be omitted. Only the quantity of cooling circuits and total cooling capacity is required for the selection.
04/2002
P.4
TI -K04
Short Description TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit
11. Lay-out for Ceiling heating with the KaRo Pre-fabricated Unit B.GK12
Project : Project consultant : Required heating capacity 1 Heat requirement for the room 2 Planned quantity of panels 3 Required heat capacity / unit Determintion of capacity
Date : Lay-out valid for 22C room temperature and 6K heating water spread !
W qty W
from calculation of planning office derive the max. possible arrangement from the room measurements = heat requirement / Quantity panels
33
35
37
39
41
43
45
17
20
22
100
200
300
400
550
700
850
1000
1150
1300
only valid for room temperature 22C and heating water spread 6K and connecting hose 300mm length
4 Supply temperature -> from diagram 5 Return temperature Determination of pressure losses 6 Pressure loss in the pipe = pipe length * resistance 7 Pressure loss of unit -> with value of line 3 from diagrame 8 Add for pressure loss through fittings (recomm: 30% extra to the pipe) 9 Add for heat transfer station (Recommen.:for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 10 Total pressure loss
C C
kg/h l/h
Pa Pa Pa Pa
m Pa/m
Pa
If BEKA transfer stations are utilised the determination for pressure losses can be omitted. Then only the quantity of heating circuits and the total heating capacity must be known for the selection.
10 0 9 0 8 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 0
Pressurelossinthepipe20x2m m
20
40
60
80
100
120
140
160
180
200
04/2002
P.5
TI -K04
Short Description TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit
04/2002
P.6
TI -K04
TI-K05
Short Description
2. System Details
Mostly the KaRo mats are installed into the plastering of outer walls, directly beneath the surface. The outer wall must have a U-value below 0,35 W/(m2K). If this is not given, insulation of the internal wall can be utilised. With a wall heating system the possibility that the dew point is moved into the wall construction is being counteracted. The connections of the mats amongst themselves and the connection of the mats to the piping, all the way to the heating circuit distributor, normally are thermal welded. In most cases the mats are installed to the wall up to a height of 2 meters. This way the possibility is given to fix things (pictures etc.) to the wall above this area.
Figure 1: KaRo mats on the wall with internal insulation and insulation panels. The piping is installed according to Tichelmann
4. Installation
In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive such as plastics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to malfunction of the system.
04/2002
P.1
TI-K05
5. Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. For the heating ceiling a room temperature control is required, which regulates the volume of heating water in dependence to the desired room temperature. Supply temperatures above 45C must be avoided because of the danger that an excessive surface temperature will dry-out the plaster !
work basis before work is started. All heating mats, their measurements and the direction they are facing must be marked in the pattern. All surfaces that will not be covered as for the installation of internal walls and fixing points for hanging cabinets must also be marked. The connections of the KaRo heating mats to another and to the Polypropylene pipelines are done by thermal welding. The welding directions DVS 2207-11 of the Deutschen Verband fr Schweitechnik e.V. are valid. (The surrounding temperature during working must not be below 5C. The preheating, welding and setting time must be according to regulations.)
04/2002
P.2
TI -K05
Fix the insulation panels for a plastering base to the raw walls (with adhesive or dowels) according manufacturers instructions. Cut a slot (100 x 30 mm) into insulation approx. 100 mm above the floor Prepare insulation panel to be bonding layer for the plastering
I.
position KaRo heating mats and fix with adhesive tape possibly secure the mats with spreading dowels to the wall connect the mats to another and to the pipelines for the supply- and return lines through thermal welding. pre-test with compressed air of 10 bar for 1 hour main test with water pressure of 10 bar for 4 hours. In resting state maintain 3 bar until taken into operation.
II.
III.
apply a thin layer of plaster (10 mm) in one step according manufacturers instructions smoothen plaster, observe the predrillings
04/2002
P.3
TI -K05
Date Lay-out valid for 22C-room temperature and 6K heating water spread !
from the calculations of the planning office derive the maximum possible arrangement from the room measurements = heat requirement/ Coverage
Quick Lay-out for wall heating with BEKA mats laid in plaster
180 Heating capacity [W/m2] 160 140 120 100 80 60 40 20 0 27 29 31 33 35 37 39 41 43 45 Supply temperature [C]
only valid for room temperatures of 27C and haeting water spread of 6K and Plaster quality MP75 -Fa.KNAUF
12
14
17
19
22
25
4 Supply temperature -> from diagram 1 5 Return temperature 6 Water volume per mat area 7 Water volume per zone Determination of pressure loss 8 Length of connecting pipe 9 Resistance in the pipe -> from diagram 2 10 Pressure loss in the pipe = Pipe length * Resistance 11 Pressure loss of the mat -> with value from diagram 1 (line 2) 12 Add for pressure loss through fittings (recomm: 30% add to the pipe) 13 Add for heat transfer station Recomm: for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss If BEKA transfer stations are utilised the determination of pressure loss can be omitted, only
m Pa/m Pa Pa Pa
6000
Pa
5000
3m
Pa
2m
the quantity of the heating circuits and the total heating capacity is required for the selection.
1m 0 5 10 15 20 25
04/2002
P.4
TI -K05
KaRo Capillary tube mats Type K.S15 Material Polypropylene Random Co-polymer type 3 DIN 8078 Geometry Collector pipe Capillary tube Capillary tube distance Exchanging surface
Measurement Length: normally 600-2000 mm (in increments of 10 mm) Width: 150-1200 mm (in increments of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Heating capacity Depending upon the type up to 150 W/m2 Conditions of operation temperature persistent at continues use up to 45C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application /Type of installation: Wall heating for plaster walls Connections through thermal welding Type of delivery Mats are delivered rolled-up, packed in cartons.
04/2002
P.5
TI -K05
TI-K06 TI-
Short Description
Because of the high thermal insulation of modern buildings the offices and residential houses have comparatively low heat requirements. In many cases they must be cooled during long periods of the year to maintain comfortable room temperatures. A low cost solution to save energy is the use of a KaRo wall heating / wall cooling system. With the use of KaRo pre-fabricated units heating and cooling surfaces can be arranged simply and economically in the dry-build version. Through the combined function of the wall surface investments for the necessary building installations can be minimized.
Description
The KaRo pre-fabricated unit is fixed to the support structure, like any other standard drybuild board, according to the dry-build directions. The supply lines, pre-fabricated to the required to measurements are laid into the wall cavities. The pre-fabricated units are connected to the supply lines with flexible hoses.
Wall with BEKA pre-fabricated units
The KaRo pre-fabricated units are connected to the supply and return of the piping of the heat- or cold-water source, room for room or zone for zone. Recommended is the connection via a KaRo storey distributor unit. For the heating water generating different techniques and constructions can be utilised . The economic advantages of a cooling ceiling are influenced mostly by fact that the wall will deliver high heating/cooling capacity already with supply temperatures, which are only slightly above /below the room temperature. This allows the use of alternative energy sources such as heat pumps or solar techniques. Even with the use of standard techniques a decisive energy saving can be achieved, since already little temperature differences in the supply temperatures to the
Installation
Basically the standard installation instructions are valid for all installations. All components used in the piping for the KaRo pre-fabricated units must be made of non- corrosive materials. Utilised may be plastic materials, copper, brass and red brass. Other materials may cause sludge and could therefore be the cause of malfunction of the system
04/2002
P.1 TI-K06
Short Description TI-K06 TIWall Heating with the KaRo Pre-fabricated Unit
Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. For the wall heating a room temperature control is required, which regulates supply temperature of the desired room temperature. Supply temperatures above 45C must be avoided because of the danger that excessive surface temperatures could dry-out the plasterboards! For the wall cooling a room temperature regulation, a dew point guard and a regulation of the supply temperature of the cold water is required. Supply temperatures below 16C must be avoided so that the dew point wont be reached!
The wall heating/cooling ceiling with KaRo pre-fabricated units are dimensioned according to the following layout table. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water temperature before the heat exchanger.
length accommodations of the KaRo prefabricated units to the room height. At the border area inactive panels are fitted. The KaRo pre-fabricated units are pre-drilled for the fixing to the sub-constructions. The fixing screws may only be located at the pre-given positions, otherwise damages may be caused to the integrated capillary mats. Before starting work a wall pattern must be arranged as a work- and positioning layout. All panels, their dimensions and the positioning of the supply lines must be recorded. On the wall pattern all areas must be marked which will be left uncovered for installation purposes of inner walls, light fixtures and other wall installations. Furthermore, the installation position for the KaRo pre-fabricated units with integrated dew point sensors must be recorded. The connection of the Polypropylene- pipelines are done by thermal welding, welding specification DVS 2207-11 of the Deutschen Verband fr Schweitechnik e.V must be obeyed. The surrounding temperature (at the time of welding) must be above 5C. The preheating temperatures, welding- and setting times must be kept according to pre-given values for the responding pipe sizes
Tools , Materials
Installation Preparation
For the processing of the KaRo pre-fabricated units the standard dry-build tools and materials can be used, such as: CW profile UW - profile Sound insulation tape Dowels and screws Building screws, 55 mm length Plate-knifes for tailoring and edge planer Screw driver Spatula Joint spatula mastic Hand grinder
For the installation of the KaRo pre-fabricated units the standards for the dry-build construction and the fabricators recommendations must be obeyed. It is recommended to use twist-free sheet metal profiles for the supporting construction of the suspended ceiling. The distances of the bracing profiles to another must be 600 mm. The choice of the supporting profiles and the type of fixing must be according to dry-build specifications. The KaRo pre-fabricated unit is supplied in standard dimensions of 2600 mm x 600 mm. The active surface area is 1,2m. Capillary tubes are not located above 2100 mm of height. This area serves the tailoring for the
A hand-held welding tool with a sleeve welding device is used for welding the supply lines to the cold water circuit. Alternatively sealing ring screw connections may be used instead.
04/2002
P.2
TI K06
Short Description TI-K06 TIWall Heating with the KaRo Pre-fabricated Unit
I.
The U- and stud profiles are aligned and fixed to the raw wall in the appropriate manner according to manufacturers specifications. The distance between the stud profiles is set to 600 mm. Additional stud profiles at the border area and for the inactive (tailored) panels have to be arranged to the wall pattern according to dry-build guidelines.
II.
The KaRo pre-fabricated unit is fitted to the stud-construction according to the wall pattern The flexible connecting hoses are plugged into the quick-action couplings. The pre-fabricated unit is aligned to the stud-construction according to the pre-drilled holes The building screws inserted into the pre-drilled holes and fastened until a secure fixing to the sub-construction is achieved. Pre-test with compressed air at 10 bar for 1 hour. The main test with water follows at 10 bar for 4 hours. Idle pressure at 3 bar must be kept until start of operation. Fill gaps, smoothen and grind.
III.
04/2002
P.3
TI K06
Short Description TI-K06 TIWall Heating with the KaRo Pre-fabricated Unit
10. Lay-out for a Wall cooling with the KaRo Pre-fabricated Unit B.GK12
Project: Project consultant : Required cooling capacity 1 Cooling load 2 Planned qty of panels 3 Required cooling capacity per unit Determination of capacity W Qty. W Calculation from planning office max.possible arrangement derived from room dimensions = cooling load / qty of panels Date : Lay-out valid for room temp. of 27C and 2K heating water spread!
10
13
33
37
40
44
300
500
700
1700
1900
2300
2800
valid for 27C room temperature and 2K cooling water spread, connection hose of 300mm length
4 Supply temp. -> from diagram 5 Return temperature Determination of pressure loss 6 Pressure loss in the piping = pipe length * resistance 7 Pressure loss of the unit -> values of line 3 from diagram 8 Add for pressure loss through fittings (recom m : 30% addition to pipe) recomm: for zone valves 500-1000 Pa 9 Add for heat exchange unit
C C
kg/h ltr/h
Pa Pa
m Pa/m
for mains regulator valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 10 Total pressure loss Pa
If BEKA heat exchange units are used, pressure loss determination can be omitted. Only the number of cooling circuits and the total cooling capacity is required for the selection!
04/2002
P.4
TI K06
Short Description TI-K06 Wall Heating with the KaRo Pre-fabricated Unit
11. Lay-out for Wall Heating with KaRo Pre-fabricated Unit B.GK12
Project : Project consultant : Required heating capacity 1 Heat requirement for the room 2 Planned qty. of panels 3 Required heating capacity / unit Determination of capacity W Qty W from calculation of planning office Derive max.possible arrangement from the room measurements = Heat requirement / Qty of panels Date : Lay-out valid for 22C room temperature and 6K heating water spread !
33
35
37
39
41
43
45
17
20
22
100
200
300
400
550
700
850
1000
1150
1300
valid for room temperature of 22C and heating water spread of 6K and connecting hose 300mm
4 Supply temperature -> from diagram 5 Return temperature Determination of pressure loss 6 Pressure loss in the pipe = Pipe lenght * Resistance 7 Pressure loss of the unit -> with value from line 3 from the diagram 8 Addition for pressure loss by the fittings (Recommentation : 30% add.to the pipe) 9 Addition for heat transfer station (Recomm. For zone valves 500-1000 Pa for mains regulator valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 10 Total pressure loss
C C
kg/h l/h
Pa Pa Pa Pa
m Pa/m
Pa
When utilizing BEKA transfer stations the determination of pressure loss is not necessary. Only the quantity heating circuits and the total heating capacity is required for the selection !
04/2002
P.5
TI-K06
Short Description TI-K06 Wall Heating with the KaRo Pre-fabricated Unit
12. Details
Construction 12,5 mm plasterboard Capillary tube mat with capillary diameter 3,35x0,5 mm ( Polypropylene) 30 mm extruded foam (heat conductivity 0,035 W*K; Fire behaviour class B1) Weight 15,5 kg/m2 (empty) 16,2 kg/m2 (filled) Size Width: 600 mm Length: 2600 mm active area 1,2 m2 upper tailoring area 500 mm pre-drilled for fixing at a stud distance of 600 mm Cooling Capacity 64 W/m2 (DIN 4715) =76 W/unit Heating Capacity 130 W/m2 = 155 W/unit Conditions of Operation: Temperature stability at duration use up to 45C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of Operation / Type of Installation Cooling- and heating walls, dry-build version Connection via KaRo quick-action coupling system Installation according the dry-build guidelines Terms of delivery: Finished dry-build units are delivered, lying on pallets.
04/2002
P.6
TI-K06
TI-K07
Short Description
wood flooring
4. Installation
Basically the known installation specifications are valid. All materials used in the KaRo heating mats must be non-corrosive. The following materials may be used: Plastic, stainless steel, copper, brass and red brass. Other materials may cause sludge in the system, which may lead to breakdowns
04/2002
P.1
TI-K07
5. Regulating Technique
The regulating technique secures, first the desired comfort, second the necessary system reliance. The floor heating requires a room temperature regulation to control the supply temperature in connection to the desired room temperature. It must be observed that surface temperature above 29C is surpassed. Depending on floor covering material and floor construction the supply temperatures will normally not be above 36C. In nonoccupied areas surface temperatures up to 35 C are permissible.
Before starting to work a layout pattern should be prepared as work base. In this layout pattern all heating mats with their sizes and positions as well as the supply lines should be outlined. In this pattern also all areas must be marked which must stay uncovered, as for the positioning of internal walls. Thermal welding does the connection of the KaRo heating mats to another and with the Polypropylene piping. For the execution the welding directions DVS 2207-11 of the Deutschen Verband fr Schweitechnik e. V. are valid. (The surrounding temperature during working must not be below 5C. The preheating, welding and setting time must be according to regulations.)
04/2002
P.2
TI -K07
Take KaRo heating mats out of the packaging. Mark the lay-out pattern at the primed raw floor connect the mats to the pipe mains to another and to the pipe lines by means of thermal welding, up to the distributor unit. Pre-test with compressed air 10 bar for 1 hour Main test with water with 10 bar for 4 hours. Sustain an idle pressure of 3 bar until start of operation.
I.
Area wise cover the capillary tubing with Styrofoam sheets for safe walking (during application of the screed the sheets are removed again) levelling- or flexible filling compound is brought out according to manufacturers specification.
II.
III.
The installation steps for variation B are similar to the shown version A. For variation B though the mains and pipeline are arranged behind a dummy wall (which has to be erected)
04/2002
P.3
TI -K07
Project : Project consultant : Required Heating Capacity 1 Heat requirement for the room 2 Planned coverage with mats 3 Required heating capacity Determination of Performance 210 190 Heating Capacity [W/m ] 170 150 130 110 90 70 50 30 10 1 2 3 4 W 2 m W/m 2
Date Lay-out valid for 22C room temperature and 6K heating water spread
from the calculation of the planning office max.possible arrangement derived from room measurements = Heat requirement / coverage
Parquet R=0,15m2K/W 5 6 7 8 9 10 11 12 13 14 15 16 Surplus temp. (K) = average heating water temp. (C)- room temp. (C) 17 18 19 20
4 Room temperature 5 Supply temp. -> from diagram 6 Spread 7 Water volume per mat 8 Water volume per zone
C C K kg/h ltr/h
C C
Pressure loss in a pipe 20x2mm 100 90 80 70 60 50 40 30 20 10 0 40 80 120 160 200 240 280 Mass flow [kg/h] 320 360 400
Determination of pressure loss 9 Length of connection pipe 10 Resistance in the pipe -> diagram 2 11 Pressure loss in the pipe = pipe length * Resistance 12 Pressure loss in the mat -> value from line 2 -> diagram 1 13 Addition for pressure loss by fittings (recomm: 30% addition to pipe) 14 Addition for heat transmission unit (recomm.:for zone valves 500-1000 Pa for heat exchanger approx. 4000 Pa 15 Total Pressure Loss Pa for mains regulating valves 700 - 1500 Pa Pa Pa Pa m Pa/m Pa
Pressure loss Type S15 25000 Pressure loss [Pa] 20000 15000 10000 5000 0 5 10 15 Mass flow [kg/(m2h)] 20 8m 7m 6m
5m 4m 3m 2m 1m 25
When using BEKA Transfer units the determination for pressure losses are obsolete. Only the qty. of heating ciruits and the total heating capacity is required for the selection.
04/2002
P.4
TI-K07
KaRo Capillary tubes mats Type K.S15 Material Polypropylene Random-Copolymer Type 3 DIN 8078 Geometry Collector pipe Capillary tube Capillary pipe distance Exchanging area
Size Length: 600-6000 mm (in steps of 10 mm) Width: 150-1200 mm (in steps of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Heating capacity: Depending upon type 180 W/m2 Operation Conditions: Temperature stable at duration up to 60C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application / type of installation: Floor heating with low construction height Connection by thermal welding Type of delivery: The mats are delivered: rolled-up and packed in cartons
04/2002
P.5
TI-K07
TI-K08
Short Description
2. System Description
The KaRo inlay unit is a sandwich made of a sound improved board and a KaRo capillary tube mat packed in a sealed PE foil. KaRo inlay-units are simply laid on top of the metal cassettes. Then the capillary tubing are resting practically direct on top of the sheet metal and the surface is heated-up or cooled down very rapidly. The reaction time of the ceiling is less than 15 minutes.
Chiller
4. Installation
Basically the standard installation guidelines must be observed. All materials used for the piping and for connection of the KaRo inlay-units must be noncorrosive . It can be used: plastic materials, copper, brass and red brass. Other materials can cause sludge in the system, which could lead to malfunction of the system.
04/2002
P.1
TI-K08
Short Description TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel
5. Regulating Technique.
The regulating technique secures for once the desired comfort and offers also the required system reliance. The cooling ceiling requires a room temperature control unit, a dew point guard control and the controlling of the supply temperatures for the cold water. Supply temperatures below 16C must be omitted to avoid the danger that the dew point is reached! The heating ceiling requires a room temperature control unit, which regulates the desired room temperature in dependence with the heating water flow. In rooms with heights up to 3,5 m supply temperatures above 40C must be omitted because of excessive surface temperature of the ceiling!
The KaRo inlay-units are supplied for the connection of supply- and return lines by means of flexible hoses with a quick-action coupling system. Before start of work a ceiling pattern must be prepared as a work base and for the installation arrangement. In this pattern all cassettes, and their dimensions, the dimensions and arrangement of the supply lines must be recorded. In the pattern all areas must be marked which will be uncovered, such as areas for the erection of inner walls, for light fixtures and other ceiling in-builds. Furthermore the position for the KaRo dew point sensor must be pointed out. In case that the connections of the Polypropylene pipelines are thermal welded, then the Schweirichtlinie DVS 2207-11 from the Deutschen Verband fr Schweitechnik e.V. must be observed. (The ambient temperature during welding must not be below 5C).It is mandatory to follow the assigned preheating,- welding and setting times which are given according to different pipe dimensions!
8. Tools, Materials
For the installation of metal cassette heatingand cooling ceilings with KaRo inlay-units standard tools and materials assigned for ceiling work and installation for plastic piping can be used. These are as follows: Metal cassettes Suspension hanger profiles and hanger an accordance to the chosen ceiling brand Dowels and screws Sheet metal scissors Plastic pipe scissors Hand held thermal welder with sleeve welding device Appropriate plastic fittings or sealing ring connectors For the connection of the supply lines to the cold-water circuit we recommend to use a hand held welder with welding sleeve device. Alternatively also sealing ring connectors can be utilized.
7. Installation Preparation
For the installation of the suspended metal cassette ceiling the manufacturers instructions must be observed. The inlay-units should best be laying directly on top of the surface of the metal cassettes, that the heat is lead directly to the water (therefore it is necessary to choose correct fitting dimensions!) The KaRo inlay-unit serves also the acoustic demands of the ceiling. The KaRo inlay-units are supplied in dimensions of 600 x 600 i.e. 625 x 625 mm, so that tailoring at the building site is not required. At the border areas and at places where ceiling in-builds are intended to be done, inactive cassettes will be used.
04/2002
P.2
TI -K08
Short Description TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel
The bearing construction is fastened and aligned to the raw ceiling, normally with vernier suspension bars, according to the manufacturers instructions of the chosen cassette brand. The supply lines are laid into the ceiling cavity and connected to the main supply lines (connections with means of thermal welding or with sealing ring connectors) The flexible hoses are plugged into the quick-action couplings of the supply lines.
I.
II.
The KaRo inlay-units are laid into the cassettes .
III.
Plug-in the flexible hoses into the quick-action couplings of the KaRo inlay-units. Hang the cassettes with the inlay-units into the bearing construction and align the run of the joints. Pre-test with compressed air at 10 bar for 1 hour. Main test with water at 10 bar for 4 hours Apply an idle pressure of 3 bar and maintain until start of operation.
04/2002
P.3
TI -K08
Short Description TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel
Date : Lay-out valid for 27C room temperature and 2K cooling water spread !
from calculations of the planning office max. possible arrangement derived from room dimensions = Cooling load / Quantity of units
Determination of Performance
40 35 30 25 20 15 10 5 0 24 23 22 21 20 19 18 17 16 15
14
13
12
6 7 8 9 10 12 Mass flow of the cooling water per Unit [kg/h] C C kg/h ltr./h Pressure loss [Pa/m]
100 80 60 40 20 0 40 80 120 160 200
13
14
15
4 Supply temperature -> from diagram 5 Return temperature 6 Water volume per unit 7 Water volume per zone
8 9 10 11 12 13
14
Pressure loss determination Length of connection pipe Resistance in pipe -> from diagram Pressure loss in the pipe = Pipe length * Resistance Pressure loss of the unit -> from diagram Add for pressure loss through fittings (recomm: 30% Add. to pipe) Add for heat transfer station (recomm: zone valves 500-1000 Pa : mains regul. valves 700 - 1500 Pa : heat exchanger approx. 4000 Pa Total Pressure Loss
m Pa/m Pa Pa Pa Pa
240
280
320
360
400
6 mats
5 mats
Pa
4 mats
3 mats 2 mats 1 mat
If BEKA transfer stations are utilised the pressure losses do not have to be determined. Only the quantity of cooling circuits and the total cooling capacity is required for the selection!
04/2002
P.4
TI-K08
Short Description TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel
Date : Lay-out valid for 22C room temperature and 6K heating water spread !
from calculations of planning offices max. possible arrangement derived from room dimensions = Heat requirement / coverage
Determination of Performance
0,5
1,0
1,5
2,1
2,6 3,2 3,7 Mass flow of the heating water per unit [kg/h]
4,3
4,9
5,4
4 Supply temperature 5 Return temperature 6 Water volume per unit 7 Water volume per zone
8 9 10 11 12 13
14
Determination of Pressure Loss Length of connection pipe Resistance in pipe -> from diagram 2 Pressure loss in pipe = Pipe length * Resistance Pressure loss of unit -> from diagram Add. for press. loss through fittings (recomm: 30% Add. to pipe) Add. for heat transfer station (recomm: zone valves 500-1000 Pa :mains regulat. valves 700 - 1500 Pa : heat exchanger approx. 4000 Pa Total Pressure Loss
m Pa/m Pa Pa Pa
6 mats
Pa
If BEKA heat transfer stations are utilised, the pressure losses do not have to be determined. Only the quantity of heating circuits and the total heating capacity is required for the selection !
04/2002
P.5
TI-K08
Short Description TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel
Construction 30 mm sound reducing board Capillary tube mats with capillary diameter 3,35 x 0,5 mm (Polypropylene) Fiber dense packaging in PE-foil Weight 4,6 kg/m2 (empty) 5,3 kg/m2 (filled) Dimensions Width: 600 mm or 625 mm Length: 600 mm or 625 mm Cooling Capacity: 67 W/m2 (DIN 4715) =24 W / Unit Heating Capacity: 78 W/m2 = 28 W / Unit Operation Conditions Temperature stable at duration up to 45C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application / Type of installation: Cooling- and heating ceilings in metal cassette version Connection via KaRo quick-action coupling system Installation according to manufacturers guidelines Type of delivery Finished inlay-units are delivered packed in cartons
04/2002
P.6
TI-K08
TI-K09
Short Description
Cooling and Heating Ceiling with the KaRo Acoustic Metal Panel
1. General Information
In modern offices and business premises, the contemporary office and computer technology combined with increased thermal insulation of the exterior walls and faades, the rooms must be air-conditioned all year round. Even during periods when heating is required, these rooms have comparatively low heat consumption. This facilitates the use of a cost-effective and energy-saving KaRo cooling and heating ceiling. With the KaRo acoustic metal panel, any metal coffered ceiling can easily be designed as a cooling and heating ceiling. The arrangement is also suitable for retrofitting. The combined functionality of the ceiling minimises the investment required for necessary building technology. which are only slightly below the room temperature. This facilitates the use of "alternative energy" (heating pumps) and natural energy reduction (e.g. free cooling, groundwater). The same advantages apply to hot water generation. Significant energy savings are achieved not only in combination with solar heating systems, but with conventional technology as well, since even at low flow temperatures (below 40C), the respectable calorific output can be used for heating.
Supply tubes Connection hoses Coffered Ceiling with BEKA acoustic metal panels
2. System Description
The KaRo acoustic metal panel is a metal coffer, which comes factory-equipped with a KaRo capillary tube mat. The capillary tube mats are glued on using a hot-melt process. Like any other metal coffer, the KaRo acoustic metal panel is simply laid on top of the supporting structure. The capillary tubes lie practically directly on top of the sheet metal, so that the surface is rapidly cooled or heated. The reaction time of the ceiling is less than 15 minutes.
Chiller
3. Cold-water/Hot-water Technology
The KaRo acoustic metal panels are integrated in rooms/zones in a tubing network as a circulation loop and connected to a cold-water generator and the heat source. We recommend that the connection is made by using a KaRo storey distributor. A wide variety of technologies and systems may be used for cold-water generation. The economic advantages of the cooling ceiling consist primarily of the fact that the ceiling is highly efficient even at flow temperatures
04/2002
4. Installation
As a rule, the general installation guidelines apply. All materials used in the tubing network of the KaRo acoustic metal panels must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may cause the system to silt up and thus disrupt its function.
P.1
TI-K09
Short Description TI-K09 Cooling and Heating Ceiling with KaRo Acoustic Metal Panel
5. Control Technology
The control technology ensures the comfort you desire and provides the necessary system safety as well. The cooling ceiling requires a room temperature control unit, a dew point safeguard control unit and a control unit for the initial flow temperature of the cold water. Initial flow temperatures below 16C must be avoided due to the dew point risk! The heating ceiling requires a room temperature control. This regulates the flow of hot water depending on the desired room temperature. In rooms with heights of up to 3.5 metres, initial flow temperatures above 40C must be avoided so that the surface temperature of the ceiling does not become too high!
equipped with a plug-in coupling system for connection to flow and return tubes by means of flexible hoses. Before beginning work, a ceiling drawing and a laying plan must be drawn up, in which all coffers with their dimensions, alignment, and the supply lines must be recorded. In the ceiling drawing, all areas must be also marked which must remain unoccupied, e.g. where partition walls, lighting and other ceiling fittings will be installed. In addition, the location where the KaRo dew point sensor will be installed must also be marked in the ceiling drawing. If thermal plastic welding is being used to connect the polypropylene tubes, the welding guideline DVS 2207-11 of the Deutscher Verband fr Schweitechnik e.V. (German Association of Welding Technology) applies. (The environment temperature during processing may not be lower than 5C and the preheating, welding and holding times must be observed according to the dimensions of the tubing.)
8. Tools, Materials
The conventional tools and materials for the installation of ceilings and plastic tubing are used for the installation of a metal coffered heating/cooling ceiling with KaRo acoustic metal panels: Metal coffers Suspension profiles and suspenders depending on the design of the selected ceiling model Dowels and screws Metal shears Plastic tube shears Handheld welding unit with a welding sleeve mirror for plastic welding Appropriate plastic fittings and cutting ring screw fittings A handheld welding unit with a sleeve mirror, appropriate for plastic welding, and the corresponding plastic fittings are recommended for connecting the feed lines to the coldwater circulation. Cutting ring screw fittings may be used as an alternative.
04/2002
P.2
TI- K09
Short Description TI-K09 Cooling and Heating Ceiling with KaRo Acoustic Metal Panel
In accordance with the manufacturer's instructions for the selected coffers, the supporting structure is attached to the bare ceiling using vernier suspenders and aligned. The feed lines are laid in the hollow cavity of the ceiling and connected to the supply lines (connection by means of thermal plastic welding or cutting ring screw fittings) Insert the flexible connection hoses in the plug-in couplings of the feed lines
I.
II.
Remove the pre-assembled KaRo acoustic metal panel from its packaging
Insert the flexible hoses into the plug-in couplings of the KaRo acoustic metal panel Hang the coffers in the supporting structure and align the joints Preliminary test with 10 bars of compressed air for 1 hour Main test with water at 10 bars for 4 hours maintain resting pressure at 3 bars until the system is put into operation
III.
04/2002
P.3
TI- K09
Short Description TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel
10. Lay-out for the KaRo Acoustic Metal Panels in the Cooling Ceiling
Project: Project consultant : Required cooling capacity 1 Room cooling load 2 Planned component qty 3 Required cooling capacity Capacity calculation W m2 W/m2 from calculations of the planning office Max. possible arrangement derived from room dimensions = Cooling load / Quantity of units Date : Lay-out valid for 27Croom temperature and 2K cooling water spread!
13
15
16
4 Supply temperature -> from diagram 5 Return temperature 6 Water qty per component 7 Water qty per zone Determination of pressure loss 8 Length of the connection tube 9 Resistance in tube -> from diagram 10 Pressure loss in tube = tube length * Resistance 11 Component pressure loss from diagram 12 Add for pressure loss through fittings (recomm: 30% Add to pipe) 13 Add for heat transfer station (recomm: for zone valves 500 -1000 Pa for branch control valves 700 - 1500 Pa for heat exchanger approx.. 4000 Pa) 14 Total pressure loss
m Pa/m Pa Pa Pa
M a s s f lo w [ k g /h ]
6 mats
Pa
5 mats 4 mats 3 mats 2 mats 1 mat Mass flow per component [kg/h]
If BEKA transfer stations are utilised the pressure losses do not have to be determined. Only the quantity of cooling circuits and the total cooling capacity is required for the selection.
04/2002
P.4
TI -K09
Short Description TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel
11. Lay-out for the KaRo Acoustic Metal Panels in the Heating Ceiling
Project: Project consultant: Required heating capacity 1 Planned heat requirement for the room 2 Planned component quantity 3 Required heating capacity Capacity calculation W m2 W/m2 from calculations of planning offices max. possible arrangement derived from room dimensions = Heat requirement / Coverage Date : Lay-out valid for 22C room temperature and 6 K hot water spread !
0,5
1,1
1,7
2,3 2,9 3,5 4,1 Mass flow of hot water per component [kg/h] C C kg/(m h) l/h
2
4,7
5,3
6,0
from diagram 1
6 Water qty per component 7 Water qty per zone Determination of pressure loss 8 Length of the connection tube 9 Resistance in tube 10 Pressure loss in tube = Tube length * Resistance 11 Component pressure loss from diagram 12 Add for pressure loss through fittings (recomm: 30% Add to tube) 13 Add for heat transfer station (recomm: for zone valves 500 -1000 Pa) for branch control valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 14 Total pressure loss from diagram 2
m Pa/m Pa Pa Pa
M a s s f lo w [ k g /h ]
8 7 6 5 4 3 2 1 0 1 0 20 30
6 mats
Pa
If BEKA heat transfer stations are utilised, the pressure losses do not have to be determined. Only the quantity of cooling circuits and the total heating capacity is required for the selection.
04/2002
P.5
TI -K09
Short Description TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel
Design Metal coffer with acoustic fleece Capillary tube mat with capillary diameter of 3.35 x 0.5 mm (polypropylene) Glued on using a hot-melt process Weight 4.6 kg/m2 (unfilled) 5.3 kg/m2 (filled) Dimensions Width: 600 mm and 625 mm Length: 600 mm and 625 mm Cooling capacity: 74 W/m2 (DIN 4715) =29 W/component Heating capacity: 130 W/m2 assuming 45C hot water/21C room temperature =51 W/component Operating conditions: Temperature stability in continuous use up to 45C Operating pressure 3 to 4 bars Test pressure 10 bars up to a maximum of 10 hours Fields of application/Method of laying: Cooling and heating ceilings in metal coffer design Connection via KaRo quick-coupling system Assembly according to manufacturer's instructions Form of delivery: Prefabricated acoustic metal panels are delivered in cartons
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TI -K09
TI-K10
Short Description
2. System Description
The KaRo tubing system with quick-action coupling contains all of the required installation materials for the tubing of cooling or heating circuits, from the KaRo mat or the KaRo prefabricated component to the distribution throughout the storey. The tube dimension of DA22 mm is designed for cooling or heating circuits with a maximum size of 15 m2. All quick-action coupling parts can be used with the KaRo DA22 tubing without additional dimensioning to assemble the heating/cooling circuits internally and to construct the connection up to the distributor. The tubing length up to the distributor may be up to a maximum of 40 metres for the flow and return tubes, respectively. The tubes and the pre-formed parts are assembled simply by pushing them together. The connection between the tubing and the KaRo mats/prefabricated components is made by using flexible hoses. For those cases in which the quick-action coupling system is to be used with tubing or components from other systems, suitable connections with " exterior threads are available.
3. Installation
As a rule, the general installation guidelines apply. All materials used in the tubing system of the KaRo mats or prefabricated components must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may
For fastening to the raw ceiling : Conventional 22 mm tube clips Dowels and screws Drill/hammer drill, if necessary Tools for mounting the tube clips
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TI-K10
Short Description TI-K10 Installation with the KaRo Plug-in Type Pipe System
6. Assembly Steps
Cut the tube to the required length. Use only the plastic tube shears to cut the tube (do not use a saw or similar tools!). Be careful to make the cut straight or angled as required.
NO
Straight connector
O-ring
Retaining element
Insert the tube with the support sleeve to the limit stop into the plug-in fitting and you're finished!
Support sleeve
PP-tube
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TI-K10
Short Description TI-K10 Installation with the KaRo Plug-in Type Pipe System
7. Technical Specifications
System Components KaRo tube, 22 mm x 2,1 mm, polypropylene, PN10 Straight connector, 22 mm Angled plug connector, 22 mm T plug connector 3 x 22 mm Reduced T plug connector, 22 x 10 x 22 mm Plug-in end cap, 22 mm Screw connector, 22 mm x exterior thread (brass) Support sleeve for 22 mm tube Flexible connecting hose with stainless steel fabric casing Operating conditions: Temperature stability in continuous use up to 45C Operating pressure 3 to 4 bars Test pressure 10 bars up to a maximum of 10 hours Fields of application: Cooling and heating floors/ceilings with KaRo capillary tube mats or prefabricated components Connection via the KaRo Plug-in type pipe system Assembly according to manufacturer's guidelines Form of delivery: Tubing in rods of 5 meters in length Plug-in fittings and hoses in accordance with the quantities ordered
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TI-K10
TI-B01
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TI-B01
Calculation, Construction and Planning TI-B01 Questions before lay-out of KaRo Cooling Ceilings
3. Ceiling Design
If it is not given anyway, the design of the ceiling must be clarified with the architect/ builder. The KaRo heating- and cooling mats are suited for practically all installation variations. But next to aesthetics also the different capacities of the cooling ceiling, depending upon the ceiling type, must be considered. Basically it can be distinguished between the following types of installations: The KaRo mats will be laid on top of suspended metal cassette units The KaRo mats will be fixed to the raw ceiling from below and plastered. The KaRo mats will be laid from below to the dry plaster boards and plastered. The KaRo mats will be placed on top of plasterboards. Each of these installation details can vary depending upon the differing building materials. Nearly any variation is given. Roughly, this can also be used as basis for the expected capacities for the different type of ceilings. For a first estimation the maximum ceiling area to be covered with mats must be established. Build-ins such as lamps, sprinklers or speaker boxes must be considered to be lost for ceiling area, the same as build-in closets and cabinets. Further it must clarified how much building space is provided for the piping. This can be hollow (dead) space in ceilings and floors of the above storey. If space for the piping was not planned for it must be created in agreement with the architect. The chosen type of ceiling is influencing the construction time schedule. Plastered ceilings require additional time for drying before they can be painted. With the installation of KaRoheating- and cooling mats on top of plaster boards the rooms can be used at an earlier stage.
Basically all mats related parts, valves (secondary circulation) and raw materials must be non-corrosive, to avoid sludge. Also increasing a secure operation of the system by taking a storey distributor into account should be discussed. In all cases the position of riser channels should be provided between storeys and eventual free spaces for sub-distributors or storey distributors. For the cold-water preparation many different technologies can be utilised. The economical advantages of the cooling ceiling is, that already with supply temperatures which are only slightly below the room temperature a high performance is achieved. This enables the utilisation of alternative energies such as solar energy for heating and ground water for cooling.
5. Control Technology
The control technology secures a desired comfort and the necessary system security. Since cooling ceilings often are operated in combination with other heating-, coolingand air-conditioning systems, a general control concept is to be developed. Interactions can therefore be avoided. The cooling ceiling by itself requires controls for room temperatures, a dew point guard and a temperature control for the supply of the cold water. Basically two types of supply temperature controls can be distinguished: constant supply temperature (not below 16 to avoid the dew point) flowing supply temperature (the ceiling will not be switched-off at critical humidity and will continue with a part load.)
Which variation is to be used must be decided by the demand on comfort, and also by the combination with the air-conditioning (ventilation).
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TI-B01
TI-B02
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TI-B02
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TI-B02
TI-B03
For the layout the form T02 can be used. The containing explanations on the form lead through the way of calculation.
P.1
TI-B03
TI-B04
1 6 9
M M
3 5 8
1 - BEKA mat for a metal ceiling 2 - BEKA mat for a plaster ceiling 3 - flexible connecting hose 4 - supply line 5 flow control valve 6 - zone valve with thermal actuating drive 7- heat exchanger 8 - pump 9 - expansion tank
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TI-B04
Calculation, Construction and Planning TI-B04 Calculation for the Piping of KaRo Heating- and Cooling Ceilings
The heat exchanger and pump must be noncorrosive. The capacity of the heat exchanger is calculated from the total volume of water at the chosen spread. The pressure loss of the heat exchanger depends on the manufacturer, and will be calculated in a special way. Usually a pressure loss of 20 kPa set forth for the heat exchanger in the primary and secondary circuit. The total pressure loss of the system results from the pressure loss of the piping and the pressure loss of the heat exchanger. The heat exchanger is chosen with the pumps equalisation of capacity and under consideration of a safety additive . The delivery height must be laid out, that the total pressure loss of the system, including a safety additive, will be overcome. The delivery capacity of the pump must fulfil safety reserve for the total water volume. For choosing pumps the manufactures specified characteristic performance line is used.
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TI-B04
Calculation, Construction and Planning TI-B03 Heating with KaRo Capillary Tube Mats
The standard capacities of the capillary tube heating ceiling can be taken from the diagrams D03 and D04. It must be observed, that heating capacity of the ceiling surface is only permissible according to diagram D05. The diagram D06 permits a fast answer for the possibilities of ceiling heating.
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TI-B03
TI-B05
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TI-B05
TI-B06
DIN 4102 Part 4 Fire behaviour of building materials, components and special components Synopsis and application of classified materials, components and special components. DIN 4102 Part 11 DIN 18232 ISO 6944 DIN 18230 Pipe partitioning + utility shafts
Fire protection Smoke- and heat outlet Part 1 3 Test of pipelines Building fire protection for industrial buildings Part 1 + 2
2. Behaviour in fire of the KaRo Heating-and Cooling Mats ,Pipes Supply lines and Fittings
KaRo heating- and cooling mats , pipes , supply lines and fittings are made from polypropylene type 3, random co-polymer, without the use of additives. This plastic material is a highly pure material which burns to water and carbon dioxide (H2O und CO2 ). According DIN 4102 Part 1 polypropylene is classified in building material group: B2 normal flammable, self-extinguishing Basically, take notice, that the KaRo capillary tube mats are practically never on the surface, after they are installed, and therefore are not directly exposed to the flame. This is true especially when laid in plaster or in a composition floor. But also if laid on top of ceiling panels the mats are mostly covered with mineral wool towards the ceiling cavity. Furthermore it can be assumed, that the water filled capillary tubes will cause a distinct reduction of the surface temperature and therefore a distinct reduction of an eventual ignition. This was confirmed in an assessment for behaviour in fire concerning capillary tube mats, at the Amtlichen Materialprfanstalt fr das Bauwesen beim Institut fr Baustoffe, Massivbau und Brandschutz, at the TU Braunschweig.
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TI-B06
Calculation, Construction and Planning TI-B06 Instructions for Fire Protection and to Burning Behaviour of KaRo Mats
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TI-B06
TI-B07
2. Cooling Load
The cooling load depends strongly on room size, room utilisation, the geographic position, and the type of building. To estimate the cooling loads for room 1 of our example, we use the table T03 The procedure for the calculation is selfexplaining and follows the model calculation in appendix 2, table 1. qN [W/m2 ] = C*TUn with: TU temperature difference between room temperature and average cooling water temperature C - constant n - exponent Since the standard capacity was established at test stand situations, a real project must be matched to the actual situation, the given loads and influence of ventilation. Therefore a room constant KR is established for the correction For our example, the sample calculation for room No. 1 is included in appendix 2, table 2. The relationships of the dates in the formulation are explained in this table.
3. Rough Planning
To do the prescribed type of ceiling, the KaRo heating- and cooling mats type K.S15 is utilised. Appendix 1, Figure 2 shows a possible arrangement of mats for our example. Our target should be a maximum coverage of the ceiling. It is advisable to use a non covered border
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TI-B07
Calculation, Construction and Planning TI-B07 Example: Construction of a KaRo Cooling Ceiling
warm water carrying pipelines lead through hollow spaces, could call for additional cooling capacity. The temperature above the ceiling (line 32) and thermal transition (upward) (line 33) depend on the situation. Logical values should be determined besides this calculation. To reach the established cooling capacity the water volume for each zone/room according (line 36)must be made avail able. If zones are separated because of differing mat lengths each zone must have a separate control appointed to regulate the calculated water volume for an equal flow.
5. Piping
Fundamentally, the KaRo cooling ceiling works in a closed system. All components of the system in the secondary circuit must be from non- corrosive material. Sludge, caused through diffusion of oxygen must not be feared In the example a storey distributor (panel) is utilised. The cold water provided from a central treatment unit runs through a heat exchanger and is passed on to the water circuit of the storey. From the storey station (panel) the water is being distributed to the separate circuits of the rooms/zones. The water volume can be regulated separately for each circuit with a flow control valve in the supply line. A valve in the return line with thermal actuating drive can regulate each circuit. To signal the room temperature, the dew point sensor is hooked onto the actuating drive. Reality has shown, that it is good practice to start-up the circuits from the storey distributor panel, for mats with a surface of 10-15 m, with a volume flow of approx. 40 kg/m. It is good policy to split the ceiling surface into circuits/zones according the building grid, which lead to separate rooms. If there will be a new room partitioning, the temperature control of the new rooms is possible without any problem. For our example a separation is chosen according appendix 1, figure 3.
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Calculation, Construction and Planning TI-B07 Example: Construction of a KaRo Cooling Ceiling
the pump must be dimensioned according to the total water volume and supply height to equalise the losses and for the support of the flow. The hydraulic lay out of the piping and the calculation of the total losses of the system, is done according the commonly known state of the art. For calculation of the total pressure loss, the pressure loss of sections, fittings and the longest supply line to the storey station is determined, considering the water volumes, and is added to the pressure loss of the KaRo mat belonging to this zone. The pressure loss in the station is mostly caused by the heat exchanger and by the control valves. The pressure loss of the KaRo heating and cooling mats can be read from the diagram D07-D14. In our example for a KaRo mat type K.S15, length 4.30 m at a volume flow of 40 kg/m, a pressure loss of 17 kPa is ascertained. The pressure loss for length of a pipe is determinate by the following equation: pR [Pa] = * L / (di*10-3) * /2 * w2 with: - pressure loss coefficient L length of pipe [m] - density [kg/m3] and w [m/s] = 21,22 * m / di2
The equation for the determination of pressure losses for fittings is: pF [Pa] = * w2 * /2 with - coefficient of resistance
Coefficients of resistance for moulded parts can be found in standard tables. Pressure losses of valves or flow control valves are calculated according the following equation: pV [Pa] = (ma / kVS)2 *10-1 with ma impendent flow volume [kg/h] kVS value accord. manufacturer [m3/h].
To demonstrate the connections of single pressure losses our example shows a mains schematic, in appendix 1, figure 4, for the longest section to the KaRo mat located in room 1. The relevant single pressure losses up to the mains of the distributor station (panel) are put together in the table below:
with : m water volume (l/min) di - inner pipe diameter (mm) Pos. Component 1 2 3 4 5 6 7 8 KaRo mat Section 1 (pipe 20x2) Elbow 90 T-joint Section 2 (pipe 20x2) Elbow 90 Flow control Kvs-1,5 Control valve Kvs-1,8 Total pressure loss of the longest section Qty / Length 4300 mm 2 x 1200 mm 2 pieces 2 pieces 2 x 10000 mm 6 piece 1 piece 1 piece Flow volume [l/min] (2,90) 2,90 2,90 2,90 5,76 5,76 5,76 5,76 Pressure loss [Pa] 17000,00 174,48 28,95 86,84 586,87 423,06 5308,42 3686,40 27295,02 = 27,3 kPa
Tip:
The flow volume in the KaRo mat is shown in the diagrams D07-14 in the unit kg/m2h. The losses, in the separate pipelines for supply and return for the viewed section, are combined as sections of double lengths. water outlet of the primary- and secondary circuits and of the total water volume, the pressure loss has to be determined according
The pressure loss of the heat exchanger is product specific. In dependence of the temperature difference between water input and
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P.3
TI-B07
Calculation, Construction and Planning TI-B07 Example: Construction of a KaRo Cooling Ceiling
the manufactures specification. In our example a total water volume of 2,6 m3/h for the cooling surfaces was ascertained. For the primary side a customary spread of 6/12C is set forth for the cold water temperature. The secondary side is operated with 16/18C. The chosen heat exchanger 9 has a pressure loss of 17 kPa . In our example, the temperature of the secondary circuit is controlled with a mixing valve of the primary circuit. To choose the pump for the total pressure loss in the storey station the sum of the pressure loss of the longest section + the pressure loss of the heat exchanger results to 44,3 kPa. The pressure loss in the storey station itself is neglect able since the pipe dimensions used in the system are laid out oversized, which ensures a slow flow (= little noise and equal distribution of the temperature). The type of pump can be chosen after knowledge of the total water volume and the total pressure loss. Non- corrosive type, pressure dependent controlled and uncontrolled pumps can be utilised. In our example an uncontrolled pump with a delivery height of 6 m(Water column) and 4 m3/h delivery capacity was chosen. The over dimensioning is being relieved through an overflow valve in the bypass of the storey station.
In our example 65 m of KaRo mats Type K.S15 where installed. By a specific water volume of 0.27 l/m a proportionate volume of 17.55 litres result for the KaRo mats. For the piping, including storey station, a volume of 29.3 litres was determined. The system is therefore filled with 46.85 litres. For the lay out sizes the following equations are used: Ve = (VA x n )/100 (1)
with Ve - volume of expansion VA water volume in the system n - coefficient of expansion for water in % - for 18C = 0.15 VV = 0,005 x VA with VV - water pattern (3) (2)
pe = pSV - dpa
with pe -top pressure = overpressure at the connection socket pSV -reacting pressure of the safety valve, standard is 3 bar dpa operational pressure difference of the safety valve normal = 0.5 bar Vn min = (Ve+VV) x (pe+1) / (pe- p0) (4)
7. Expansion Tank
The expansion tank has the following functions in the system: Absorption of the water volume which is from the heating of the water in the system Storage of a water volume which can be supplied into the system again at demand, for instance, when the system cools down. Maintaining a minimum overpressure in the system (pressure control)
with: Vn - nominal volume (expansion tank) p0 - supply pressure at pressure less situation normal case = 1 bar (maximum) pa min = (VH (p0+1)) / (VH-VV) - 1 (5)
with: pa - pressure at start / filling pressure VH - total volume / commercial size In our example, for these relations a minimum nominal volume of 0,7 litre is calculated. This size is not commercially available. Therefore a small size with 6 litre is chosen. This results to a filling pressure of 1.08 bar.
For determining the size of the expansion tank the fluid volume must be calculated. Appendix 1 figure 1: figure 2: figure 3: figure 4: Appendix 2 Table 1: Table 2: Room arrangement and load situation Layout scheme for KaRo mats Connection piping for KaRo mats Line Schematic (Detail)
Layout table for the cooling ceiling Rough calculation for the sensible (dry) cooling load
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TI-B07
Calculation, Construction and Planning TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4
8m
No.1
4,5m
= 2020 W
3 m2 5m
1m
No.2
TR = 26 C inner Cooling Load = 435 W external Cooling Load= 726W 3m
No.3
T = 25 C
R
3,5m
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TI-B07a
Calculation, Construction and Planning TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4
Figure 2:
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TI-B07a
Calculation, Construction and Planning TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4
Figure 3:
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TI-B07a
Calculation, Construction and Planning TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4
Figure 4:
II
2+3
5+6
10
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TI-B07a
Calculation, Construction and Planning TI-B07b Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project - Room No. I
Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project Room No. I
Lay out Table Cooling Ceiling
Project: prepared by Date :
Musterraum Nr.1 Bauke 09.08.96 C m2 m 27,00 36,00 3,00 0,98 2020 1211 89,75 1,20 500,00 25,00 27,00 8,89 1 35,00 0,97 80,86 83,17 0,92 16,00 18,00 17,00 10,00 1,11 80,30 89,13 2,00 8 4,30 1,00 34,40 35,82 27,00 27,00 1,10 11,00 40,55
Cooling loads Internal total cooling load 6 External total cooling load 7 Total cooling load based on floor space 8 Load factor
5 9 10 11 12 13
W W W/m2
from calculation of the planning office from calculation of the planning office =(internal+external load) / floor space =Total load (internal load+external load / 2)
Ventilation Air volume intake Temperature of intaken air Exhaust temperature Cooling capacity of incomming air Ventilation factor Required cooling capacity Ceiling area covered with mats Facor for ceiling coverage Required cooling capacity for ceiling Specific cooling capacity, ceiling Factor for coverage Performance Calculation Supply temperature Return temperature Average water temperature Effective under temperature Room constant factor Standard cooling capacity Real cooling capacity per m in W: Water volume Cooling water spread Quantity of mats per room Length of room Width of room Area covered with mats Mass flow of water
m3/h C C W/m2
14 15 16 17 18
m2 W/m2 W/m2
-> compare with calculated value of line 30 =ceiling area to be covered / floor space =Total cooling load - cooling capacity of air intake =req. cool cap / ceiling area to cover ->target value =1,21 - 0,3* covering factor
19 20 21 22 23 24 25
=(Supply temp.+ return temp.) / 2 = room temp.- average water temp. =height factor*load fac*ventil facr*overage fac.. -> read from diagram =Stand capac*room const fac <- comp taget value
26 27 28 29 30 31 32
=Length * width * quantity of mats =(specific cooling capacity*3600)/(Spread*4180) water volume should be minimum 17ltr/m h Standard = room temperature of the room above =Therm. conduct. to top*(temp w/o aver water temp) =((spec cooling capacity+capacity to top)*3600)/ (Spread * 4180)
Temperature above ceiling 33 Thermal conductance factor 34 Capacity to top 35 Corrected mass flow of water
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TI-B07b
Calculation, Construction and Planning TI-B07b Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project - Room No. I
8m
Height: 3
(Outer frame dimensions)
Area: 36
Volume: 108
1. Solar Radiation, Windows: Window Cardinal points South South West South East North North West North East West East 2. Transmission energy: Windows x x x Width [m]
Height [m] x x x
Qty.
Area [m2] = = =
double glazed windows without blinds x 205 x 245 x 250 with x 175 x 205 x 205 x 50 x 145 x 140 x 215 x 210 with x 60 = x 75 = x 75 = x 20 = x 50 = x 50 = x 75 = x 75 = W W W inside blinds outside blinds
x x x x x
1.35
x x x x x
= = = = =
5,4
108 W
W W W W
area m2+ 3. Transmission energy: Walls North- and inside walls All other walls 4. Ceiling or Roof Ceiling to non - climate controlled rooms Ceiling beneath the attic, attic floor not insulated Ceiling with 50 mm thermal insulation Flat roof, not insulated Flat roof, with 50 mm thermal insulation 5. Floor above non climate controlled rooms
(omitted when basement is not heated)
2 5.4 m + 2 3 m =
8.4 m
x 20
168 W
area
m2+ m2+
2 24 m +
2 18.6 m =
13.5 m +
= = = = =
7.5 m =
45.6 m 2 21 m
2 36 m
x 8 x 10
= =
x 10 x 17 x 10 x 35 x 12
= = = = =
m2
m2 m2 m2
2 / m
x 5
/ W
6. Open passages Width x 7. No. of persons in the room physical work Qty. light average x 70 x 85 heavy x 95 = Height x Qty. = Area m2 x 100 =
/ W
10
8. Lights
(Connection value)
700 W
Qty.
connection value
12 x
9. Electrical appliances
(connection value: observe simultaneousness) Type
60
x 1
720 W
Qty
Connection value
Overhead x
10. Other heat sources
1 x
Description:
600
x 1
600 W
=
External cooling load, section 1- 6 = Internal cooling load, section 7-10 = Sensible total cooling load =
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TI-B07b
TI-B08
Components for the floor heating construction DIN 18164 Plastic foams for insulation in the building practice, part 1 +2 DIN 18165 Fibre insulation materials for the building practice DIN 18560 Cement asphalt floor for the building practice VOB Verdingungsordnung fr Bauleistungen, Teil C Allgemeine technische Vertragsbedingungen fr Bauleistungen (Order of contract procedure) DIN 18352 Tiles and tile laying work DIN 18353 Concrete asphalt work DIN 18356 Parquet work DIN 19365 Floor covering work Typical Standards and Regulations DIN 18195 Building sealing work DIN 18202 Tolerances for building constructions DIN 18336 Sealing against pressing water DIN 18337 Sealing against non-pressing water DIN 4102 Fire behaviour of building materials and components DIN 4108 Thermal insulation for building construction DIN 4109 Sound insulation for the building construction DIN 1055 Part 3, Load bearing for buildings DIN 4725 Warm water floor heating Energy conservation regulations
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P.1
TI-B08
Calculation, Construction and Planning TI-B08 Questions before lay-out of KaRo Floor Heating
3. System Specification
Floor heating with KaRo heating- and cooling mats was designed especially for fast reaction times and for low construction heights of 15 to 20 mm. The supply and return for the heating water in the KaRo heating- and cooling mats are alternate at distances of 15 mm. This results into an equal floor temperature with a high efficiency. Low supply temperatures, normally at a maximum of 30C, are enough for most of the cases, to achieve room comfort even at extremely low outside temperatures. In spite of the low construction, height there will be no restrictions to the floor bearing. KaRo heating- and cooling mats are manufactured in all lengths and can be assembled to the required widths. Through the extremely short reaction time of the heating system, KaRo heating- and cooling mats are positioned directly beneath the floor surface, only the real required energy is being consumed.
For the installation of floor heating no special building materials are required. In its basics the floor construction is in accordance with the regular design. At new construction, only the asphalt concrete is laid in two steps. For renovation, the floor heating can be installed in one step. The heating circuits may not contain any corrosive components. Suitable materials are all plastic materials, brass and stainless steel. Copper is only suitable by reservations. At a passage from copper to plastic materials, a brass bridge must be added to avoid electrochemical reactions. If it is not possible to use only non-corrosive materials for the heating circuit, a separation must be achieved by means of a heat exchanger. The collector pipes of the KaRo mats and the connection piping can be positioned in wall slots. If the floor construction for a KaRo floor heating system can be planned for a new building, channels can be integrated into the load-bearing layer, in which later on the piping is put into
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TI-B08
Calculation, Construction and Planning TI-B08 Questions before lay-out of KaRo Floor Heating
4. Floor Construction
4.1 New Construction For new construction the KaRo heating- and cooling mats are positioned layer closed to the floor surface, on top of the load-bearing layer. The insulation is done according to the regulations of: - DIN 4725 part 3 - DIN 4109 - WSchV 1/95 (German energy conservation regulation) For the concrete asphalt layer it can be basically used: Dry asphalt, synthetic resin modified cement asphalt and liquid asphalt according DIN 18560. The load bearing base layer, the insulation and the load distributor layer must be laid out according the expected traffic load.
The KaRo heating- and cooling mats are positioned on top of the distributor layer. There after a levelling compound of 10 to 15 mm is applied. The levelling compound must be suitable for floor heating systems, the application must be done according to manufactures specification. According to the applying working directives parquet, tiles and/or textile coverings can be laid onto the floor. Border insulation strips, expansion joints and building construction sealing are not influenced, and must be planned as usual.
tile elastic joint motar border strip leveling mass BEKA heating- and cooling mat load distribution layer polyethelene foil insulation board equalization screeding polyethylene foil sealing to construction
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TI-B08
Calculation, Construction and Planning TI-B08 Questions before lay-out of KaRo Floor Heating
4.2 Modernising For renovation low construction heights prove its worth for the use in floor heating systems with KaRo heating- and cooling mats. Pre-condition for the application of a floor heating system in renovation is the existing load carrying floor base. For boarded wood floors, the floorboards must have the necessary strength features and must lie firmly supported. Defective boarded floors must be repaired or exchanged. Concrete asphalt-or tile floors must be repaired if defective.
Only after that installation of floor heating system can be started with. The KaRo heating- and cooling mats are fixed to the floor base. For boarded wood floors, it is advisable to support the KaRo heating- and cooling mats with a 5 mm thick impact sound insulation layer. On top of the KaRo heating- and cooling mats, a layer of (minimum 6 mm) latex concrete plaster is applied, and on top of this a layer of ceramic tiles or natural stone tiles is laid. Border strips, expansion joints- and building construction sealing is to be done according to applying working directives for the latex concrete-plaster.
tile elastic joint mortar border strip latex cement mortar BEKA heating and cooling mat impact sound isolation wooden planks
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TI-B08
TI-B09
Under consideration of the heat resistances of the floor coverings, the heating capacity of the KaRo floor heating can be taken from the diagram 21. This diagram shows the heat capacity in dependence to the temperature differences of: floor covering, the average heating water temperature and room temperature. The average heating water temperature is calculated by: TWM [C ] = (TVL - TRL) / 2 with TVL Supply temperature [C] TRL Return temperature [C]
Based on the heat requirement, which is calculated externally, now the specific heat capacity in W/m can be calculated for the floor surface, which has to be covered with the KaRo mats (generally 80% of the room area can be covered, the rest will be covered with furniture). With this value and with the chosen floor covering the average heating water temperature can be determined with the help of diagram. By election of the spread ( sp = TVL - TRL und TVL = TWM + sp/2 ) the necessary supply temperature for the heating water can be easily calculated. The water volume, which is required for the heating capacity, follows the equation: Q = m * c * T With m - Mass flow c - specific heat capacity T- temperature difference based on the heat requirement, which is calculated externally TVL - TRL
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TI-B09
TI-B10
A wall heating system has the advantage that there are no radiators obstructing the room and that a natural cosiness is achieved. The installation of KaRo heating- and cooling mats can be done without any problems in new construction and for renovation. A further advantage is, that the wall heating system can also be used for cooling in the summertime. In this case water with a minimum temperature of 16C (avoiding the dew point) is circulating through the KaRo heating- and cooling mats. Even at the hottest days a cosiness, can be achieved with this solution, especially in critical rooms (beneath sloped roofs or in rooms facing the Southside).
04/2002
P.1
TI-B10
Calculation, Construction and Planning TI-B10 Questions before lay-out of KaRo Wall Heating
In the following diagram, the cosiness is shown in relationship to the temperatures between wall- and room temperature according to ISO 7730. The most pleasant feeling can be reached with lowered room temperatures and warm walls. The chosen room temperature is depending on the utilisation of the room. Normally, higher temperatures than 22C are not necessary.
rectly beneath the wall surface), only the real required energy would be used up. When KaRo heating- and cooling mats are embedded in the plaster of the outside walls, a layer of insulation has to be assigned to minimise energy losses. The wall heating with KaRo heating- and cooling mats often are only covering the walls up to a height of 2 m. Above the mats then there is the possibility to fasten pictures, lights and other things. KaRo heating- and cooling mats can be positioned very good at the parapet area below windows, because the mats can be made to size by the manufacturer. For wall heating no special building materials are necessary. Essentially the wall construction is like a conventional wall. For the plaster version, the connector pipes are laid in the baseboard or in a special purpose wall groove.
35 30 25 20 15 10 5
too cool cool pleasantly too warm
4. Wall Construction
15 20 25 30 35
The KaRo heating- and cooling mats are laid in the wall plaster. For the plaster, any customary type (mineral based) can be used. Coarse-grained rubbing plaster is not allowed for use, because of the danger, that the capillary tubes could be damaged. The working instructions of the plaster suppliers must be obeyed. The base surface must be solid and must have bearing strength. Plaster reinforcement fabrics are not necessary above the mats. Only above the loops of the mats and on top of the collector pipes when laid in a wall cavity reinforcing of the plaster this recommended.
10
3. System Specification
The wall heating system with KaRo heatingand cooling mats was especially designed for short reaction times and for cosy living standards. With the KaRo heating- and cooling mats embedded in plaster the supply and return of the heating water are alternating in distances of 15 mm. This results to a uniform surface temperature with a high performance release. Low supply temperatures, normally with a maximum of 35C, are sufficient for most cases, to reach a cosiness inside the rooms, even at extremely low outside temperatures. For heating the rooms normally only outside walls are used. Only in cases of exceptions, with large glazed window- or door units, also inner walls can be taken into consideration. KaRo heating- and cooling mats are produced in all lengths and can be assembled to the requested widths. Through the extremely short reaction times of the heating system (KaRo heating- and cooling mats are positioned di-
04/2002
P.2
TI-B10
Calculation, Construction and Planning TI-B10 Questions before lay-out of KaRo Wall Heating
Positioning of the collector pipes in the baseboard and in the wall cavity. If required, the insulation can be done according to the DIN or the WSVO. Also, an inside insulation can be used without any problem. Since the walls are heated, dew point displacements will not occur.
04/2002
P.3
TI-B10
The mass flow should best be converted into the specific mass flow per m of KaRo mats. With this value the pressure loss can be determined in relationship to the length and type of mat, with help of the diagrams 7 to 14. The pressure loss of the KaRo mat will then be used in the calculation for the hydraulic layout of the piping and for the selection of the pump. The dimensioning is done according to known standards. References are included in B04 pipeline calculation for KaRo heatingand cooling mats. For the layout the form, T07 Lay-out for KaRo floor heating (tables and forms) can be used. The explanation in the form will lead through the calculation.
04/2002
P.2
TI-B09
TI-B11
Under the consideration of heat resistance of the plaster, the heat capacity of the KaRo wall heating system read from the diagram 29 Heating capacity of the KaRo wall heating system. The diagram arranges the heating capacity in dependence to the plaster type and the plaster thickness to the temperature difference between the average heating water temperatures and the room temperature. The average heating water temperature is calculated from: TWM [C ] = (TVL - TRL) / 2 with TVL supply temperature [C] TRL return temperature [C]
Starting from the heat requirement for the room, which is being determined externally, the necessary specific heating capacity (W/m) can be calculated for the wall covered with KaRo mats (normally the walls are covered up to the height of 2 m the rest is kept for pictures and other things to be fastened there). With this value and the value for the chosen plaster and the plaster thickness, the average heating water temperature can be taken from the diagram 29. With the choice of the spread ( sp = TVL - TRL and TVL = TWM + sp/2 ) now very easily the necessary supply temperature for the heating can be calculated.
04/2002
P.1
TI-B11
The amount of water necessary for the heating capacity follows the relation. Q = m * c * T with m - mass flow c - specific heat capacity T- temperature difference TVL - TRL
The mass flow should be converted to the specific mass flow per m of KaRo mats. With this value the pressure loss of the KaRo mat, according the length and the mat type, can be taken from the diagrams 7 14. The pressure loss of the mat is considered for the hydraulic layout of the piping and for the choice of the pump. The dimensioning is done according the state of the art. Tips are found in B04 Calculation for the piping of KaRo heating- and cooling mats. For the layout the form T11 Layout for KaRo wall heating ( tables and forms ) can be used. The explanations contained in the form will lead through the way of calculation.
04/2002
P.2
TI-B11
TI-B12
04/2002
P.1
TI-B12
TI-B13
2. Length Tolerances
The KaRo heating- and cooling mats are supplied with minus tolerances, this ensures that they will always fit into the existing building screen.
Length/ Type to 1000 mm to 2000 mm to 4000 mm to 5000 mm Over 6000 mm K.U10 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.UM10 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.S10 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.S15 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.WS15 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.G10 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.G20 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.G30 -5 -20 -5 -20 -5 -35 -5 -40 -5 -50 K.GG10 -5 -15 -5 -15
3. Widths Tolerances
The widths of the KaRo heating- and cooling mats are supplied with minus tolerances, this ensures that they will always fit into the existing building screen. Depending on the type the KaRo heating- and cooling mat can only take up certain widths. For a Utype mats one more capillary will course a leap in widths of 20 mm. For the mat type K.G10 a fixed measurement of 10 mm must be added to the resulting capillary distances. This measurements result from the overlapping spacers.
Tolerance Basic widths (via capillaries or via connections ) K.U10 0 -10 X05; X25; X45; X65; X85 K.UM10 0 -10 X15; X35; X55; X75; X95 K.S10 0 -5 multiple of 50 plus the fixed amount of 10; starting at 150 mm 50 K.S15 K.WS15 0 -5 0 -5 multiple of multiple of 30 30 K.G10 -5 -10 multiple of von 10 plus the fixed amount of starting at starting at 10; 150 mm starting at 150 mm 150 mm 30 30 10 K.G20 -5 -10 multiple of 20 plus the fixed amount of 10; starting at 150 mm 20 K.G30 -5 -10 Multiple of 30 plus the fixed amount of 10; starting at 150 mm 30 K.GG10 -5 -10 multiple of 10 plus the fixed amount of 10; starting at 150 mm 10
Width leap
20
20
X= 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12 The realisable width can be checked with the equation n= (width fixed amount) / width leap. The value n must always be a whole number.
04/2002
P.1
TI-B13
TI-B14
3. Pressure Losses
The heat exchanger has a strong influence to the pressure loss in the distributor. The choice of the heat exchanger through KaRo is done in a way, that the resistance on the secondary side will not exceed the value of 15 kPa If special demands for the resistance of the primary side are existing, they must be mentioned at the time of ordering The choices for the pump, the heat exchanger, pipes, fittings and valves made by KaRo are such, that a pressure of approx. 40 kPa will be available for the cooling circuit
4. Pump
Recently almost every pump installed in the distributor is pressure regulated. These pumps have the advantage, that because of the pressure regulation the particular sections of the cooling zones can be excellently tuned without a change of volume flow if zones are switched-on or switched-off. Only pumps with non-corrosive components such as bronze- or stainless-steel housings can be utilised. For choosing pumps, KaRo makes the choice that the working point of the pumps is near to the middle third of the characteristic curve of the pump. Here the pump works with its highest efficiency at the lowest operating costs. A further advantage is, that the delivery height of the pump can be adjusted to the exact working point. By this measure, it is possible, that only the required energy is consumed.
2. Basic Data
The most important basic dates for the layout of the distributors are: efficiency in kW primary temperatures: . 6/12C secondary temperatures: 16/18C cooling fluid (share of Glycol included) possible dimensions number of zones and their dimensions.
The nominal sizes of the pipes, fittings and valves are designed, that flow speeds of 1,2 m/s are not exceeded.
04/2002
P.1
TI-B14
Calculation, Construction and Planning TI-B14 Technical Requirements for Basis Stations and Storey Distributors
the temperature display. Thermometers with larger display ranges or of another accuracy class will not have given an adequate result at a spread of 2K. The pressure gauge should have a display range of 0 to 6 bar or 0 to 10. Larger display ranges will not have the required readout accuracy.
8. Zones
The dimensioning of the zones is depending on the area, spread and capacity. In the normal version, a volume flow control and regulating valve (Taco setter, TA- valve or similar) for the supply and a ball faucet are intended. For the return a ball faucet and regulating valve is used. For DN15 and DN20 a low cost thermal actuating drive can be used for the initiation of the regulating valve. Larger than DN20 setting valves with motor actuating drives are utilised. At this point, the accuracy of the volume flows should be pointed out. The capacity of the heating- and cooling mats is determined according DIN 4715 part 1. The capacity determination is done with the full- and with only 50% of the volume flow. The capacity results of both volume flows will show, that already with a 50% volume flow a capacity of approx. 89% of the full volume flow is reached. These findings should be used to positively influence the operating costs. If a volume flow of 90% is planned for each zone, the pump can be dimensioned smaller, thus resulting into lower energy costs. The capacity of the heating- and cooling ceiling will only be insignificantly lower than the standard capacity.
9. Electrical Connections
Storey distributors and basis stations can be supplied with the switch panel fully connected. The measuring- and control engineering, supplied by KaRo, works on 24 volts (see: M08 Technical Data of the converter M.K.1, M09 Technical Data of the room temperature control unit M.R 2/3). All regulating valves of the storey stations should be equipped with auxiliary contacts. The electrical circuit arrangement can be carried out such, that when the last cooling circuit is switched-off, also the pump is switched-off. So the pump is treated gently and energy is saved. The thermal actuating drives used by KaRo are equipped with an auxiliary contact. They operate on 24 Volt, on a switch-on current of 250 mA and an input power at operation of 3 Watt.
6. Filter
Experience has shown, that filter units are not required for closed system. Pollution, which could have been caused by the installation, will be removed through the filling- and rinsing process. Further pollution will not occur in the closed system. If a filter is being used after all, a cleaning process must be done unconditionally after start of operation. The rinsing operation contributes exclusively for the rinse-out of air bubbles when filters are in use.
P.2
TI-B14
TI-M01
Installation
The KaRo heating- and cooling system is easy to install. KaRo supplies the mats in the exact required measurements. Accommodation work at the building site is not required. Only for the installation of the piping tailoring work is necessary. The state of the art for working with plastic material is valid. In all cases good workmanship and carefulness is required. The described guidelines must be obeyed so that good function and the safety of the KaRo system can be secured. The KaRo heating- and cooling mats function by laminar flow. The system is equipped with automatic vents. After the complete installation, the system will be rinsed; at the same time there will be self-venting. During installation, a descent for the mats is not necessary. KaRo heating- and cooling mats and the supply are normally operated at pressures between 0 and 4 bar. The minimum room temperature for installation work is 5C. The KaRo heating- and cooling mats, pipes, supply lines and fittings must be kept free of permanent direct UV-light.
according to manufacturer
At the welding process it must observed that excessive heat-up time and/or excessive welding pressure will not reduce the inner diameter of the tubing, since this will cause undefined and increased flow resistances. For introduction in thermal welding technique for plastic piping KaRo offers seminars.
04/2002
P.1
TI-M01
Installation TI-M01 Installation Instruction for KaRo Heating- and Cooling Mats
In case that leakage had to be repaired, the pressure test must be repeated. In the report, all faults must be recorded. At the end of the pressure test the system is brought to idle (operating) pressure of 2 to 3 bar kept in this state at best until the end of the construction work.
6. Pressure Test
Even that all KaRo heating- and cooling mats have been factory pressure tested a new pressure test must be done after installation at the building side. For guaranty reasons the pressure tests after installation is mandatory. In all cases, the person responsible for the installation must draw up a test report. Directly after connections of the mats to the supply lines, the mats are pre-tested with compressed air at 10 bar. With this, eventual leakages at the connections can be recognized. For the main test, the mats are filled with water zone-by-zone and tested for 10 minutes with 3 bar. Eventual leakages must be fixed at once. After this the pressure is raised to 10 bar . After another hour, eventual pressure drops caused by the elasticity of the piping should be equalized again. If the pressure in the system will sustain for 4 hours then the pressure test has been successful.
This repair is only admissible for one or two damaged capillary tube otherwise the effective heating/cooling surface will be reduced too much. Closing the cut ends of the capillary tubes with an open flame (cigarette lighter) is not admissible for a repairing. The open flame will burn the plastic material form the outside and carbon black particles will be in the weld, causing a weak weld strength. Furthermore the appropriate welding temperature of 240C can not be assured, so that a weak weld could be the result.
04/2002
P.2
TI-M01
TI-M02
Installation
warm-up
heat-up welding plate to 260 C slightly time-off-set press on/in to the welding plate (first the sleeve then the pipe) join uninterrupted with slight pressure up to the stop or the marking. in this position the parts are warmed-up for 5 seconds.
Warm-up
Heat-up welding plate to 240 C. Press both pipe ends simultaneously and rapidly with slight pressure to the welding plate until a small weld bead of 1 mm occurs. Warm-up the pipe ends, while keeping this position for 3 seconds.
Joining
After the warm-up time pull-off, the parts to be joined from the welding plate and join them together, accurately with little pressure and without twisting. The material joins molecular homogeneous after a few seconds. For better shape keeping the pipes must be held together in a stable position. The connection can be fully stressed after 30 seconds.
Joining
After the warm-up time take away both ends from the welding plate and rapidly join the parts together, accurately with slight pressure and without twisting. The material joins molecular homogeneous after a few seconds. For better shape keeping the pipes must be held together in a stable position. The connection can be fully stressed after 30 minutes.
Remark: Longer warm-up times and excessive joining pressure will lead to narrowing of the inner pipe diameter
04/2002
P.1
TI-M02
PP-
5. Tools
For thermal welding of plastic material the following is required: Pipe scissors W.S.20 Butt weld unit W.STSG.1 or sleeve weld unit WMSG1 with sleeve insert W.MSE.20 or inner sleeve insert IMSE.16 Ruler Marking pen
All pipes and fittings made from polypropylene which are supplied by KaRo can be welded to another. The PP-materials used are all classified in welding material index group 006. For testing the weld ability in principle the Richtlinie des Deutschen Verbandes fr Schweitechnik e.V. DVS 2207-11 (Entwurf August 1997) is the valid standard. Under consideration of this standard a weld index value of MFR 190/5 0,3 to 1,0 g/10 min is appropriate. The classification of the welding material index groups is always applicable.
1)
0,3
0,4
0,8
1,0
Source: DVS 2207-11/1997
04/2002
P.2
TI-M02
TI-M03
Installation
04/2002
P.1
TI-M03
Ceiling Finish
Apply layer of paint Trim the snuffing pipe of the sensor even with the ceiling surface, mark its location (dirt must be kept from the snuffing pipe openings to avoid that the sensor will not function!).
Installation of Plasterboards
Fix plasterboards with rapid-fixing-screws to the sub-construction, according manufacturers instructions push the plasterboards from both sides to the KaRo mats to form gaps of approx. ca. 10 mm.
3. Installation Steps for the Suspended Plasterboard Ceiling Prepare the Sub-construction
Arrange the connection piping for the KaRo mats at the ceiling according to the lay-out plan Fix the CD profiles firmly to the vernier suspension bars, according to manufacturers instructions. The subconstructions must be installed in such a way, that the supply- and return lines of the KaRo mats are on top of the plasterboards. Consider an additional load of nearly 15,5 kg/m2..
Ceiling Finish
Apply paint Trim snuffing pipe of the dew point sensor even with the surface of the ceiling. (Dirt must be kept from the snuffing pipe to avoid that sensor will not function !)
carrier
04/2002
TI-M03
4.
ATTENTION ! This installation is only possible when the installation work is closely coordinated between the installer and the plasterer. Instructions and special advice for plastering are to be obtained from the plaster producer.
forcement fabric) Afterwards (within 15 minutes after first application) apply a second thin layer of plaster (normally 10 mm is enough) ( the plaster thickness influences the expected cooling performance decisively!) - Set plaster to the usual consistency! Position dew point sensor above the capillary tubes in the moist plaster. Embedding of reinforcement fabric 80 x 80 mm at the mats ends and in critical spots is recommended. After settling smoothen the plaster - definitively avoiding any damage of the capillaries; damages must be repaired at once (warm-up ends of damaged tubes with welding unit or soldering iron and press ends of tubes together, if necessary replace the whole mat) Smoothen the plaster - definitely avoiding any damage to the capillary tubes.
Ceiling Finish
Apply paint Trim snuffing pipe of the dew point sensor even with the surface of the ceiling. (Dirt must be kept from the snuffing pipe to avoid that sensor will not function !)
04/2002
P.3
TI-M03
TI-M04
Installation
By laying the KaRo mats into the metal cassettes, a heating- or cooling ceiling can be made out of any suspended ceiling construction. Therefore the KaRo mat is simply laid into the cassette from the backside. That the mat will have thorough contact, simply place a mineral insulation mat on top of it. Additional coverings with plasterboards or sheet metal will assure a good contact of the mats to the metal cassettes. It is also possible to glue-in the KaRo mats. The KaRo adhesive is simply applied with a spraying gun onto the mat. After that the mat is placed into the cassette and pressed-onto it with a PU-roller. A drying time is not required for the adhesive. The glue is transparent after hardening; it has a neutral odour. Only full contact of the mat will secure maximum cooling capacity. Before beginning the work, a pattern has to be prepared as a work- and positioning base. All measurements with the positioning, the direction and the supply lines must be recorded. In the pattern, all areas which will have to stay uncovered (for internal walls, light fixtures and other ceiling in-lays) must be marked. Furthermore, the position of the dew point sensor has to be marked on the pattern.
Pressure Test (see M07 Test Instructions for KaRo heating- and cooling systems)
Pre-test with compressed air, at 10 bar for 1 hour Main test with water, at 10 bar for 10 hours Idle pressure, maintain at 3 bar until start of operation.
04/2002
P.1
TI-M04
TI-M05
Installation
KaRo mats can be laid onto the backside of dry-build boards without any problem. This way cooling ceiling units can be made out of plasterboards or from fibre plaster boards, which can be installed in the dry-build version. KaRo manufactures also special capillary tube mats just for the use with dry-build boards. Lengths and widths are accommodated to the dry-build standard boards. At areas where they are screwed to the ceiling and/or wall construction, special spacers are provided. The space between the spacers is 300 mm, they determine the space of the profiles at the wood or metal subconstruction. Illustration of the KaRo heating- and cooling mat for dry-build boards:
2. Installation Steps
A working place where the dry-build board can be fully laid-out is necessary for the installation. a) Installation of the additional spacers at the front end. On the installation table the dry-build board is laid with its equipped side facing up. The additional supplied spacers, which are supplied with the KaRo heating- and cooling mats are tacked to the front-end side.
04/2002
P.1
TI-M05
b)
Fastening of the KaRo heating- and cooling mats with tacks. The heating- and cooling mat is arranged and positioned between the spacers (described in point 1) In this position, the spacers located close to the collector pipes (marked with 2 in picture 1) are tacked to both sides of the heating- and cooling mats. Ongoing the heating- and cooling mats are pulled flush through pulling on the collector pipes. The distances of the other spacers to another is measured and corrected if required. Then the spacers are fastened with tacks. Application of thermal conductive past with a paint roller, through pouring or other suitable measures, the thermal conductive paste (approx. 800g/m2). After the paste is applied between the spacers it will be brushed in the direction of the capillary tubes towards the base with a narrow brush. At normal temperatures, the thermal conductive paste dries within 20 minutes, so that the ceiling boards can be installed. The spacers who have contact to the ceiling profile are smoothened with a spatula or with other appropriate tools, in case that paste had been applied there. Drilling of holes for the fixing screws: Before drilling, the heating- and cooling mats are put under air pressure of 8 to 10 bar. If there are any injuries to the tubes, they can be detected then. The spacers have oblong holes (every 40 mm) (see figure 1, marked with 2). These oblong holes are used for pre-drilling with a 2,5 mm for the fixing screws. The drill-grid (distances of the holes to another in diagonal direction to the heating- and cooling mats) depends upon the installation instruction of the dry-build board manufacturer. Finishing After the pressure test, the quick-action couplings are then closed again with cover caps. Installation variation If the installation is done by more than one person or if work is done in work steps it has been found best when workstep 3 is done last.
3. Tools
For the application of the dry-build board to the heating- and cooling mat G.10.X, the following tools are required: Installation table Scissors to cut plastic material Power drill Drill-bit 2,5 mm Tackler Tacks Paint roller Narrow brush Tape measure Spatula Compressed air connection
c)
Remark: With long, narrow and thin dry-build boards, the influence of moisture from the thermal conductive paste can lead to momentarily little reduction in strength of the dry-build boards. Careful handling of the boards is then necessary. Picture of an equipped dry-build board
d)
e)
f)
04/2002
P.2
TI-M05
TI-M06
Installation
04/2002
P.1
TI-M06
1
3.1 Installation The dew point sensor is installed at the coolest spot of the cooling ceiling. The dew point sensor is best positioned between the collecting pipe and the first row of the spacers diagonal to the capillary tubes (see illustration). The dew point sensor M.TP.1 is fixed to its position before plastering! The sensor is connected to the converter or to the room temperature control unit by its connecting cable. The connecting cable with its length of 10 m can be installed in the ceiling cavity, plaster or in electric tubing.
Illustration 1:Placing the plaster spot 1 Raw ceiling 2 Capillary tube 3 Plaster spot
Installation Steps
1. The dew point sensor M.TP.1 is electrically connected and placed closely near to its final position. Until its final positioning the dew point sensor is kept in its protective cover. After fixing of the KaRo mat at the raw ceiling a plaster spot or another appropriate means of fastening is placed at the installation position of the dew point sensor (see illustration) The self-sticking backside of the gold plated conductor plate of the dew point sensor for plaster ceilings is positioned diagonal to the capillary tubes. Then the ceiling is plastered After paintwork is done the sniffing hose is shortened even to the ceiling surface. Care must be taken, that the openings of the snuffing hose will not closed.
2.
Illustration 2: Positioning of the Dew point sensor : 4 Gold-plated conductor plate 5 Plastic housing 6 Snuffing hose
3.
4.
7
Illustration 3: Plastered Dew point sensor 7 Plaster
04/2002
P.2
TI-M06
The dew point sensor is positioned best between the collector pipe and the first row of the spacers diagonal to the capillary tubes. Installation Steps The dew point sensor is electrically connected and positioned closed to its final installation position. Until the final positioning the dew point sensor is kept in its protective cover The installation of the dew point sensor can be done together with the supply lines (parts : Z.EM, Z.EE, Z.DM or Z.DE ). Together with the arrangement of the plasterboard ceiling at the ceiling construction also the dew point sensor is fixed. The dew point sensor is best located between the collector pipe and the first row of the spacer, diagonal to the capillary tubes. The protective cover is taken from the conductor plate and the protective foil from the dew point sensor and is then glued to the pre-determined installation position.
4.1 Installation The dew point sensor is located at the coolest spot at the ceiling. The dew point sensor is best positioned between the collector pipe and the first row of spacers, diagonal to the capillary tubes. Depending on the type of ceiling cavities various dew point sensors are utilised. Open ceiling cavity For open ceiling cavities, these are ceiling cavities which are in connection with the room air , the dew point sensor M.TM.1 for metal ceilings is utilised..
Illustration 4: Arrangement of the dew point sensor inside the open ceiling cavity 1 Dew point sensor 2 Connector plate 3 Supply line 4 Capillary tube 5 Plaster board ceiling
04/2002
P.3
TI-M06
Closed ceiling cavity For closed ceiling cavities, these are ceiling cavities which have no air connection to the room, the dew point sensor for plasterboards M.TG.1 is utilised. The dew point sensor is best positioned between the collector pipe and the first row of spacers, diagonal to the capillary. Installation Steps The dew point sensor is electrically connected and positioned near the final installation position. Until the final positioning the dew point sensor is kept in its protection cover. .
Installation of the dew point sensor can be done with the supply lines (parts: Z.EM, Z.EE, Z.DM or Z.DE). Drilling of the hole for the snuffing hose. For the preparation of the final installation position of the dew point sensor a hole of 6 mm must be drilled for the snuffing hose. Together with the fixing of the plaster board ceiling also the dew point sensor is fixed. The dew point sensor is best positioned between the connecting pipe and the first row of spacers, diagonal to the capillary tubes. The adhesive protection tape for conductor plate is taken off and the dew point sensor is brought to its final position.
Illustration 5: Arrangement of the dew point sensor in a closed ceiling cavity 6 Snuffing hose shortened even to the ceiling surface.
04/2002
P.4
TI-M06
TI-M07
Installation
Directly after the connection of the KaRo mats to the supply lines, the mats are pressure tested with compressed air at 10 bar. The pressure is sustained for 1 hour. Eventual leakages at the connections can be detected at once. For the main test the mats have to be filled with water section by section, then be vented and pressure tested for 10 minutes with a pressure of 3 bar. Eventual leakages must be sealed at once. Thereafter the pressure is raised to 10 bar. After 1 hour the eventual pressure loss, caused by the elastic expansion of the piping, must be equalized. If the systems will hold the pressure of 10 bar steady for 4 hours the pressure test had been successful. In case leakages had to be cleared away, the pressure test must be repeated. In the report, all faults must be recorded. At the end of the pressure test the system is pressure released to a normal pressure of 2 to 3 bar and must remain until the all construction work is finished.
2. Test Procedure
A thorough test report must be prepared by the responsible person (see test report T05) and be handed to the project manager. The fully completed test report is the basic requirement for the 15 year warranty of KaRo for the material. On principle, the common rules for the pressure testing of water carrying systems are valid. These include also the following items: Proceed section by section. The sections should only be so big, that it can be kept under control when pressure tested. Never pressure test with the connection opened to the City water system, because of the danger, that the city water will
04/2002
P.1
TI-M07
TI-M08
Installation
3. Electrical Connection
2. Specifications
L x W x H (mm): Supply Voltage Switch contact load 1): Power input Allowable ambient temp.
1)
For controlling of relays, contactors etc. with co sinus <0,3 it is advisable to use a RC-limb parallel to the coil. This will lessen the contacts burn-off and will avoid high frequency interference impulses.
Clamp 1 2 3 4 5 6 7
Connection System potential 24 V AC System neutral Dew point sensor Dew point sensor Relay Work contact Relay Centre contact Relay Repose contact
04/2002
P.1
TI-M08
TI-M09
Installation
1. Description of Functions
The room temperature control unit with dew point control Type M.R2/3 is especially suitable for controlling of heating- and cooling systems where the formation of condensation (for example: at cooling ceilings) is detected prematurely and reliably, so that cooling can be shut-off (to avoid condensation). With the setting knob at the front side the desired temperature is set. The set temperature can also be changed by means of an external remote control unit. Control lamps of different colours inform of the state of operation: State of Operations of the Room Temperature Control Unit red: = "Heat" -> Fall short of pre-set temperature green: = "Cool" -> Exceeding the pre-set temperature yellow; = "Cooling off" -> due to possible condensation . Through switching of unit-internal switches it can be chosen between double- and triple conductors.
M.R3
DIP-switch closed
3. Control Range
The room temperature can be pre-set in the range 5...30C, while the adjustments can be limited mechanically to maximum temperatures of 16, 18, 20, 22 and 24C. The imitating is done through a pin, which is positioned from below into the marked holes in the setting knob. By design this works also as a lower temperature limitation: max.Temp . 16 C 18 C 20 C 22 C 24 C Minim. Temp. 5 C 7 C 9 C
At pre-set temperatures of 16C and 18C a lower limitation can not be effective because it would fall short of the range.
2. Unit Versions
Through switching of two unit-internal DIPswitches (see: figure 5) two different functions: M.R2" or "M.R3", can be chosen ( M.R2 is pre-set). Attention: Both switches must be either open or closed! M.R2 DIP-switch opened Control unit for the double conductor system, with a valvecontrol outlet which can
04/2002
P.1
TI-M09
12V
Summer:If the input is closed, the control will switch the valve to cooling when the pre-set temperature is exceeded. Winter: If the input is open, the control will switch the valve for the heating when the pre-set room temperature has fallen short.
04/2002
P.2
TI-M09
8. Name of Terminals
At the switch outputs for the heating / cooling valve, up to a maximum load of 1 amp., also a 24 volt auxiliary relays can be connected.
9. Technical Specification
Operation voltage: 24V~ 10%, 50...60 Hz Power consumption: 30mA (w/o load output) Outputs: Triac-outputs; Heating / Cooling not potential free Switch capacity 1A / 24V~ [short term (1 min) approx. .2,5A] Control range: 5...30C Switch hysterics: 1K Neutral zone: 2,5 K Temp. sensor: unit internal NTC Ambient temp.: 0...+40C Protection type IP 40 Protection class: III Measures (WxHxL): 74 x 74 x 36 mm Colour: grey/white
04/2002
P.3
TI-M09
TI-M10
Installation
04/2002
P.1
TI-M10
2. Installation Steps
1. Suspension of the CD - profiles The carrier- and basic profiles are fixed and aligned to the raw ceiling with vernier suspension bars according to manufacturers instructions. The distance of the carrier profiles is fixed to 500 mm. Additional carrier profiles (also the border angles)at the border area and for the inactive tailored boards are positioned according the ceiling pattern. The dry-build construction guidelines must be obeyed. 2. Installation of the KaRo supply lines. The supply lines are laid into the ceiling cavity and are connected to the main supply lines (see M02 Thermal welding for plastic materials) 3. Preparation of the KaRo dry-build units. Remove dust protection covers from the plug-in couplings on the unit. Plug-in the flexible connection hoses into the quick-action couplings of the KaRo dry-build unit. 4. Fasten dry-build unit to sub-construction Place dry-build unit according ceiling pattern to the sub-construction. Plug-in the flexible connection hoses to the quick-action couplings of the supply lines. Align dry-build unit to the pre-drilled holes at the sub-construction. Insert hammer-drive screws into the predrilled holes and screw until a firm hold to the sub-construction is achieved and the screw head has sunk in 1 mm deep. (Set the torque of the power tool !!) 5. Pressure test (see M07 Test instructions) Pre-test with compressed air at 10 bar for 1 hour. Main test with water at 10 bar for 10 hours . Keep-up idle pressure at 3 bar until start of operation. 6. Connection of the KaRo Dew point sensor Unroll the connecting cable of the dew point sensor and lead to the KaRo room temperature control unit M.R2/3. Connect to the room temperature control unit according the connection scheme.
7. Ceiling Finish Cut in-active boards for the border area and close ceiling area completely. Fill-in board joint gaps, smoothen and grind even. Apply ceiling paint. Trim snuffing tube with knife even with the ceiling.
3. Tools, Materials
For the application of the KaRo dry-build units standard tools and materials, commonly used for dry-build construction, can be utilised: CD profiles Cross-connectors Vernier suspension bars Dowels and screws Hammer-drive screws, length 55 mm Border angles Blade-knife for tailoring and edgeplanner Power screw unit Spatula Joint filler material Manual grinder
For connection of the supply lines to the cold water circuit a hand held welding unit with sleeve welding device is required (see M03).
04/2002
P.2
TI-M10
TI-M11
Installation
insulation board
plaster board
system spacer
04/2002
P.1
TI-M11
Installation TI-M11 Installation Instructions to KaRo Mats between double panelled Plasterboard Ceiling
2. Installation Steps
1. Suspension of the CD - Profiles The carrier- and basic profiles are connected and aligned to the raw ceiling according manufacturers specification, normally by means of vernier suspension bars. The distance between the carrier profiles according standards is set at 600 mm and 500 mm. 2. Installation of the supply lines. The supply lines for feed and return are laid into the ceiling cavity according hydraulic interpretation. The connecting points for the mats must be aligned exactly to the suspension ceiling construction 3. Hook-up of the KaRo Mats Fastening of the mains for the mats to the basic profiles with cable-binders. . Connection of the mats with the supply lines (see M02 - Thermal welding of plastic materials). 4. Pressure Test (see M07 -Test Instructions) Pre-test with compressed air at 10 for 1 hour. Main test with water at 10 bar for 10 hours. Idle Pressure at 3 bar keep-up until start of operation. 5. Installation of the first Layer of Dry-build Boards Screw-on the plasterboards according to drybuild construction specification 6. Attaching (gluing) the KaRo Mats Unroll the mat, align and glue-on with adhesive tape to the first layer of dry-build boards between the carrier profiles. If wanted, insulation sheets can be placed under the mats. Glue system spacers under the carrier profiles.
7. Installation of the Second Layer of Dry-build boards Screw-on the plasterboards according to the dry-build construction specification through the system spacer onto the carrier profile. Layout the KaRo Dew point sensor and connect: Roll-out the connecting cable of the dew point sensor and lead to the room temperature control unit M.R2/3. Connect the sensor to the room temperature control unit according to connection scheme. Insert snuffing tube of the sensor through a pre-drilled hole of the plasterboard. . 8. Finishing the Ceiling Fill joints between boards, smoothen and grind even. Apply ceiling paint. Trim snuffing tube with knife even with the ceiling.
3. Tools, Materials
For the application of the KaRo pre-fabricated units commonly standard tools and materials for the dry-build construction can be utilised. CD profile Cross-connector Vernier suspension bars Dowels and screws Hammer drive screws Corner angles Plate knife for tailoring and edge-planner Power screw unit Spatula Joint filler material Manual grinder
For the connection of the supply lines to the cold water circuit a hand-held welder with a sleeve welding device is utilised (see M03).
04/2002
P.2
TI-M11
TI-M12
Installation
Tile
Before starting to work, a layout pattern must be prepared as work basis. All mats with their measurements , the direction they are laid and the supply lines must be indicated
elastic joint motar border strip leveling mass BeKa heating- and cooling mat Load distribution layer Polyethelene foil Insulation board Equalization screeding Polyethylene foil Construction sealing
04/2002
P.1
TI-M12
If chipboards are used for the loaddistributing layer, two layers should be chosen. At places where channels have to be formed, then one layer is simply omitted. The carrying capacity of the load-distributing layer will be recovered again, when the channels are poured with levelling compound. In renovation cases, it is possible to make free-cuts in the floorboard in longitudinal direction of the beams. In these cases the carrying capacity must be restored again with an appropriate wood sub-construction. Illustr. 2: Arrangement of the collector pipes behind the cover-wall
2. Connect and pressure test KaRo mats to the waterside. Install supply lines. Connect KaRo mats to the supply lines (see M02 Instructions for thermal welding of plastic materials) Pressure test of the completely installed system. (see M07 Test instruction for KaRo heating- and cooling systems) Setting to idle pressure to 3 bar (the mats will remain under idle pressure during the total time of installation until start of operation!) 3. Fastening of mats to the raw floor Fastening of the KaRo mats on the load distributing layer with means of:
Plaster board pre-wall on wood latting BeKa heating- and cooling mat Tile elastic joint mortar border strip latex cement
The collector pipes and the connection lines can also be laid in wall slots. Before the chiselling work is started, it is necessary to check if the stability of the wall construction is sufficient. If the stability of the wall is not strong enough, slots can be created by addition of a cover (plasterboards on lathing).
3. Installation Steps
Take KaRo mats out of packaging and roll-out on a flat and clean surface, to keep them down apply some (flat) weights at the loopribbon side. The mats can stack up to 15 on top of each other. Before further work, the mats should rest for one day for stress relieving. 1. Preparation of the raw floor Smoothen unevenness Apply priming Make plan for arrangement of mats at the floor. Fix clamps for fastening of supply lines and for the collector
Butyl adhesive tape Plug-type dowel double clamps (Supplier: Hilti Type: EDD 4-12) Tack with non-corrosives staples (use only in conjunction with application on dryscreed floor base!) The staples are positioned above braces of the spacer-ribbon. The tucker application strength and length of staples chosen should be fit to hold the mats firmly in place, the spacers lengths though should not be damaged.
4. Apply covering layer and smoothen. (observe manufacturers advices!) Apply self-levelling equalisation compound watch for minimal thickness, normally 10 to 15 mm . In case capillaries are damaged, repair at once by closing tube ends with soldering iron, or if required replace damaged mat. TI.M01
04/2002
P.2
TI-M12
TI-M13
Installation
3. Installation Steps
Take KaRo mats out of the packaging place on clean and even surface, if required place some flat weights to the loop ribbon side. The mats can be stacked up to 15 layers.
04/2002
P.1
TI-M13
TI-M14
Installation
2. Characteristics
The KaRo Adhesive V.K.1 is an adhesive, which is good for spray-application with a long open time. For tension free application on to sucking materials, it is possible to work with a one-sided layer of adhesive. The adhesive forms an elastic, permanent and colourless adhesive joint.
3. Processing Guidelines
For gluing into metal ceiling sheets the KaRo adhesive V.K.1 is reduced with KaRo solvent V.L.1 in the proportion up to max. 5:1 before applying. The adhesive, dosed economically, is sprayed onto the mats. The mat is then laid immediately in the cassette and rolled-onto the surface. As guideline for the amount of usage: 80 g/m2.
4. Technical Data
Raw material base: Solid base contents: Density: Viscosity: Colour: Application of adhesive: Nozzle size: Spraying pressure: Drying-off time: Pot time: Cleaning agent: Shelf time: Storage temperature: Application temperature: SBS -caoutchouc ca. 43% ca. 0,83 g/ml ca. 200 mPas (Brookfield) natural with spraying gun 1,5 - 2,5 mm 2 - 6 bar ca. 0,5 - 3,0 minutes, in dependence of layer thickness, material and temperature for double sited application: approx. 120 minutes for one sided application: approx. 15 minutes solvent V.L.1 at +15C to 20C approx. 6 months not below +10C, effected by frost Material-, room- and adhesive temperature Not below +15C and not above +25C; best application temperature is +18C to +22C
Identification code according GefStoffV (regulation for dangerous materials) : flame symbol, F, easy to ignite Identification according VbF: AI
04/2002
P.1
TI-M14
TI-M15
Installation
2. Working Directions
For gluing into metal ceiling sheets the KaRo V.K.1 adhesive is reduced with KaRo solvent V.L.1 in proportions up to max. 5:1. The adhesive, dosed economically, is sprayed onto the mats. The mat is laid into the cassette immediately and rolled-onto the surface. A guideline for the amount of usage is: 80 g/m2. In case of the usage of reducing solvents for better viscosity it must be observed that there is still enough adhesive left which ensures a sufficient adhesive film after application, otherwise it could cause insufficient adhesion.
3. Technical Data
Storage temperature: Shelf time: Application temperature: cool storage; not effected by frost unlimited, if kept in tightly closed container Material-, room- and adhesive temperature not below +15C and not above +25C; best application temperature at +18C to +22C Flame symbol, F, easy to ignite AI
04/2002
P.1
TI-M15
TI-M16
Installation
2. Characteristics
The KaRo thermal conductive paste V.WLP.1 is a highly elastic, solvent free liquid foil with a long pot time. The thermal conductive paste is prepared ready for application. After maturing, the paste forms an elastic, resistant to aging, thermal conductive and grey joint.
3. Application Directions
The thermal conductive paste is applied with a paint roller, through pouring or by other applications (ca. 800g/m2). After the paste is applied everywhere between the spacers, it is then distributed with a narrow long brush parallel to the capillary tubes. This will form a bridge between the air space between the base of the capillary tube and the surface of the plate. At normal temperatures, the thermal conductive paste will mature within 20 minutes so that the ceiling boards can be installed. The spacers which have contact to the ceiling profile is smoothened with a spatula or with another suitable tool from the eventually applied thermal conductive paste.
4. Technical Data
Raw material base: Colour: Density: Consistence: Joint coverage: Tensile strength: Tear stretching : Application of paste: Pot time: Cleaning agent: Storage time: Storage temperature: Application temperature: plastic water based, modified grey ca. 0,83 g/ml highly viscous, non dripping up to 2,1 mm 1,5 N/mm2 ca. 400% with brush ca. 120 minutes in fresh situation, with water at +15C to 20C approx. 6 Months free of frost not below +5C
04/2002
P.1
TI-M16
TI-M17
Installation
3. Installation Steps
Take KaRo mats out of the packaging and rollout onto a flat surface, and if necessary place some (flat) weights onto the loop strip side. The mats can be stored up to 15 layers . Before work is started the mats should be left for stress relieving for the time of one day. Position and fasten the main pipes of the KaRo mats to pre-fixed clamps. Depending upon their length the mats can be loosely rolled-up again for easier handling. Make water connection to the main pipes . see working direction TI-M02 Pressure test after installation according TI-M07. Rollout the mat and fix to the ceiling with adhesive tape. Therefore, peel-off the protective foil from the adhesive tape and press the mat to the ceiling with little but equal pressure. The mats should be stretched, so that they are even with the ceiling. Pulling them into direction of the loops can tighten capillary tubes, which are sagging. If necessary fasten the mats additionally with staples. Prepare the surface of the grounding for plastering. Suitable adhesive primer is Beto Kontakt 90 from Knauf or other similar materials. Apply the plaster to the KaRo mats. Put the KaRo mats under pressure with compressed air of 3 bar and retain this pressure during the total time when the plaster is applied (eventually occurring leakages will be made evident by air bubbles, it can be repaired rapidly without drainage of the water from the mats. TI-M01).
2. Application Time The fixing of the KaRo mats with adhesive tape to the plasterboards is only laid out as an installation aid before plastering. The mats can only be held with the adhesive tape to the ceiling up to a time of 3 days. In case of a longer interruption of work the capillary tube mats must be fixed to the ceiling with additional means.
Flow pressure and consistence of the plaster should be such, that the mats are not drawn from the ceiling when the plaster is applied!
04/2002
P.1
TI-M17
TI-M18
Installation
04/2002
P.1
TI-M18
To avoid fibre dust the insulation sheets are commonly wrapped in PE protection foil. Alternative to the connection of KaRo mats by flexible hoses, the mats can also joined among themselves at the main pipes, on the top of the carrier profiles, through thermal welding. For this installation version KaRo supplies the mat type K.GK 10, which is supplied readily equipped with sleeves and extended main pipes ends.
4. Pressure test (see M07 Test instructions for KaRo heating- and cooling systems) Pre-Test with compressed air at 10 bar for 1 hour. Main-Test with water at 10 bar for 10 hours. Set an idle pressure of 3 bar and maintain until start of operation. 5. Installation boards. of dry-build construction
2. Installation Steps
1. Suspension of the CD - profiles The carrying- and basic profiles are arranged and fixed to the raw ceiling with vernier suspension bars according to manufacturers specifications. The spaces between the carrying profiles must be laid-out according to specifications. According the arrangement layout for the mats, sometimes it requires additional basic profiles for the fastening of the main lines. 2. Installation of KaRo Supply Lines. The supply lines are laid in the ceiling cavity and connected to the piping according M02 Instructions for the thermal welding of plastics . 3. Hook-up of the KaRo Mats Fastening of the main lines of the mats on to the basic profiles, for instance with tie-down straps. Possibly pull bracing wires diagonal to the carrying profiles to avoid sagging of the mats. Plug the flexible hoses into the quick-action couplings of the supply lines
04/2002
Screws fasten the plasterboard according drybuild construction specifications. Position and connect KaRo dew point sensor. Unroll the connection cable of the dew point sensor and lead to the KaRo room temperature control unit M.R2/3 (see M06 Instructions for the installation of the KaRo dew point-sensor. Connect the dew point sensor to the room temperature control unit according to the connection plan. Insert the snuffing pipe of the sensor through the pre-drilled hole of the plasterboard. Possibly, place insulation boards in sections between the carrying profiles from the top onto the KaRo mats. 6. Finishing the ceiling Fill-in joints, smoothen and grind plane. Apply ceiling paint. Trim snuffing tube with knife to the plane of the ceiling.
P.2
TI-M18
3. Tools, Materials
For processing and installation of the KaRo pre-fabricated units normal tools for dry-build constructions and materials can be utilised: CD profile Cross connector Vernier suspension bars Dowels and screws Hammer-drive screws Edge angles Blade-knife for tailoring and edgeplanner Power screwing unit Spatula Joint filler compound Hand grinder
For the jointing of the supply lines to the cold water circuit a hand held welding unit with sleeve welding device is required for the plastic welding (see M03).
04/2002
P.3
TI-M18
TI-M19
Installation
2. Installation Steps
2.1 Plaster Ceiling At the installation the collector pipes of the mats must be fixed properly. After connecting the mats to the water lines according the instructions TI-M07 Test instructions for KaRo heating- and cooling systems- pressure tests must be performed. Then the capillary tube mats will have to stand a idle pressure at 3 bar for the entire time of installation until start of operation. KaRo mats with long lengths are hang to the ceiling, already connected, rolled-up until the actual tacking is performed.
04/2002
P.1
TI-M19
2.2 Dry-build construction board The KaRo mat is positioned on the dry-build construction board (plasterboard or fibre plasterboard) by placing the spacers to their pre-determined positions. Then they are tacked to the boards. First both outer spacer busses are fastened. The spacer busses are especially shaped, so that staples can be set to determined areas. The cross-connections between the side flanges are laid lower and have direct contact to the plasterboards. The driving-force set for tacking must be such, that the flange in the spacer will only be deformed to a miner degree. The length of the staples should be not more than 12 mm. Max. 15 mm must be the length of the staples when the side flanges of the spacers are used according to the point 2.1 (Plaster ceiling). .
The flat-wire staples are suitable for all types or plasterboards. If staples come to use where the shanks are tightly together (narrow-back staples of 4 mm) then the shanks work like a wide piece. At fibre plasterboards, the use of those staples can cause damages. The rigidness in these areas is damaged because of the local load. Often the fibre material is pressed through the fibre plasterboard and rests as a hump to the opposite side. Often the fibre material is separated from the fibre plasterboard. The stapler must be adjusted to such a force, that the staples will not, or in exceptions will deform the plastic material of the spacer by not more than 1 mm (side flange and staples will form one height).
plaster board
3. Tools, Materials
Best results will be achieved with flat wire- or surface improved staples. These staples are available for all staple-guns. The lengths of the staples for stapling the side flange of the spacers should be max. 15 mm (see point 2.1. and 2.2). A max. staple length of 13 mm can be utilised, when the cross-pieces of the spacers are stapled.
04/2002
P.2
TI-M19
TI-M20
Installation
04/2002
P.1
TI-M20
Figure 1 Arrangement of the collector pipes and piping according to Tichelmann by utilisation of insulation sheets for the formation of installation grooves.
3. Installation Steps
Take KaRo mat out of the package, roll-out onto a clean flat surface and burden the loop side with a flat. The mats can be stored up to 15 layers on top of another. Before further processing the mats should be stress relived for one day. 1. Preparation of the raw wall smoothen unevenness. Apply grounding (primer) Lay down the arrangement of the mats on the wall and fix temporarily Attach clamps for reception of supply lines and collector pipes 2. Connect the KaRo mats to the water line and make pressure test. Install the supply lines. Connect the KaRo mats to the supply lines ( TI-M02 Instruction for thermal welding of plastics ). Do pressure test of the finished installed system ( TI-M07 Test instructions for KaRo- heating- and cooling systems) Set an idle pressure of 3 bar and retain this pressure during the time of installation until start of operation!
3. Fastening of the mats to the raw wall with: - Butyl adhesive tape TI-M13 - Stick-in dowels Double dowel clamps from Fa. Hilti Type: EDD 4-12 - fasten with staples made of noncorroding steel (valid for the fixing to plasterboards!) The staples a posi tioned over the strap of the spacerstrips. The staple applying force and the lengths of the staples should be chosen, that the mats are fastened securely , but the spacers will not tear. TI-M19 Align the mats Tighten the capillary tubes 4. Apply plastering and smoothen (pay attention to manufacturers instructions!) Apply plaster - minimal thickness, normally 10 to 15 mm are sufficient. If capillaries are damaged repair by soldering the tube ends. If required exchange the total TI-M01
04/2002
P.2
TI-M20
TI-M21
Installation
04/2002
P.1
TI-M21
Through the air leaving the system, the operating pressure could sink, it must be corrected to its appointed pressure by refilling. An automated refilling can be arranged by means of an adequate refilling set-up. Without such a set-up, the first control must take place in the first week after the system was taken into operation. After some monthly controls the checking can be done after every 6 months.
schematic is included in the storey distributor- or basis stations. The regulating valves of the storey distributors should be equipped with auxiliary contacts. The electrical circuit arrangement can then be laid-out for gentle treatment and energy saving reasons, that with the switch-off of the last cooling circuit also the pump is switched-off. Attention : After initiation the thermal actuating drive has an opening time of approx. 2,5 minutes. Only after this time the auxiliary contact and therewith the pump is actuated. After the shut-off of the thermal actuating drive a closing time of approx. 2,5 minutes must be accounted for .Only after this time, after the last zone is switched-off, the pump can be switched off-circuit The thermal actuating drives supplied by KaRo have an auxiliary contact, they are operated with 24 V~, they have a peak starting current of 250 mA and power intake of 3 watt at operation. The auxiliary contact has a load capacity of 2 amps and 230 volt.
5. Filter
In case that filters are utilised, they must be cleaned after start of operation. The rinsing operation with installed filters are exclusively for the rinse-out of air-bubbles.
6. General
Pump manufactures instructions for the operation of the pump are given in the operating manual. Pay attention to the sense of rotation of some pumps. Electrical work may only be performed through appropriate trade staff.
4. Electrical Connections
Storey distributors and basis stations can be supplied including electric wiring and control panel. The measuring- and controlling technique supplied by KaRo is operated by 24 V~ ( TI-M08 Technical data of the converter M.K.1;TI-M09 Technical data on the room temperature control-unit M.TR 2/3). The
04/2002
P.2
TI-M21
TI-M22
Installation
2. KaRo AquaStop
The water flow of each control zone can be turned off by ball valves in the supply and return lines. At the end of the supply line an AquaStop valve for depressing the system and adapting a pressure test set is positioned picture.
KaRo AquaStop
3.
1. 2.
Close the 2 ball valves of return and supply lines. Open shortly the KaRo AquaStop and close it again. Collect drops of water with a cloth or can. The water system is now pressure less. The CC-couplings can be opened and changed now without problem.
Mr. K. says: KaRo mats are self bleeding. Any air that may get into the water system while changing the connections will go with the water flow and can be taken out at the central petcock. After every change at the system the water pressure has to be checked at the secondary station and water has to be refilled if necessary.
3.
04/2002
TI-M22
Charts and Forms TI-T01 Lay-out Chart for KaRo Cooling Ceilings
1 Room temperature 2 Surface area of the room 3 Room height 4 Height factor
Cooling Loads
C m2 m =1,117 - 0,045 * Room height W W W/m2 (calculation from planning office) (calculation from planning office) =(internal + external load) / surface area = total load / (internal load + external load / 2) m3/h C C W/m2 = intake air volume flow * dT * 0,32 / surface area Source =1, convector=1,08; ceiling slot=1,13 m2 W/m2 W/m2 -> compare with calculated value from line 30 = coverable ceiling area / basic area = total cooling load cooling capacity of air intake = req. cooling capacity. / factor of ceiling coverage-> target value =1,21 - 0,3 * degree of ceiling coverage minimum 50m3/h per person
5 Internal total cooling load 6 External total cooling load 7 Total cooling load based on surface area 8 Load factor
Proportion of Ventilation
9 Intake air volume 10 Intake air temperature 11 Exhaust air temperature 12 Cooling capacity of intake-air 13 Ventilation factor
Required Cooling Capacity
14 With mats coverable ceiling area 15 Proportion of ceiling coverage 16 Required cooling capacity for ceiling 17 Special: cooling capacity for ceiling 18 Factor of coverage
Calculation of Capacity
19 Supply temperature 20 Return temperature 21 Average temperature 22 Effective under-temperature 23 Room constant factor 24 Standard cooling capacity 25 Real cooling capacity per m in W:
Water Volume
C C C C = (supply temperature + return temperature) / 2 =room temperature average water temperature =Height factor * load factor * ventilation factor * coverage factor -> read from diagram =Standard capacity* room constant factor <compare target value = supply temperature return temperature
W/m
W/m2
26 Cooling water spread 27 Qty. of mats per zone 28 Length of mat 29 Width of mat 30 Surface area covered with mats 31 Mass flow water 32 Temperature above ceiling 33 Thermal conductance factor to top 34 Capacity to top 35 Corrected mass flow water 36 Water volume per zone
= length * width * Qty. of mats = (special cooling capacity * 3600) / (spread * 4180) Water volume should be minimum 17 ltr. / m2 h Normally it is equal to the room temperature above = Thermal conductance to top * (Temp. top- aver. Water temp.) = (spec .cooling capacity + capacity to top) *3600 / spread * 4180 = corrected mass flow / 60 * covered surface area = corrected mass flow * covered surface area
04/2002
P.1
TI-T01
Charts and Forms TI-T02 Lay-out Chart for KaRo Heating Ceilings
Calculation of Capacity 15 Supply temperature 16 Return temperature 17 Average temperature 18 Effective temperature 19 Standard heating capacity 20 Qty. of mats per zone 21 Length of mat 22 Width of mat 23 With mats covered surface area 24 Real heating capacity of ceiling C C C C W/m2 Qty. m m m2 W =Length * width * Qty. of mats = Standard heat capacity * covered ceiling surface -> compare with req heat capacity from line 13 = (Supply temperature + return temperature) / 2 = room temperature average water temperature -> from diagram -> compare with target value from line 13
Water Volume 25 Heating water spread 26 Mass flow of water 27 Temperature above ceiling 28 Thermal conductance factor to top 29 Capacity to top 30 Corrected mass flow water 31 Water volume per zone K ltr./m2 h C W/m2 K W/m2 ltr./m2 h ltr./min ltr./h =Therm conduct fact top * (Temp.top average water temp) =((req heat capac + capac top) *3600 / spread * 4180) = corrected mass flow / 60 * covered ceiling surface = corrected mass flow * covered ceiling surface = Supply temp - return temp. =(required heat capacity * 3600) / (spread * 4180) Water volume should be minimum of 17 ltr. / m2 h Temperature in the ceiling cavity
04/2002
P.1
TI-T02
Charts and Forms TI-T03 Estimate calculation of the sensible (dry) cooling
T he calculation is based on a temperature difference between room- and outs ide temperature of 6 to 8C
Area:
Volume:
Double glazed window without with with blinds inner blinds outer blinds x 205 x 175 x 60 = x 245 x 205 x 75 = x 250 x 205 x 75 = x 60 x 50 x 20 = x 165 x 145 x 50 = x 155 x 140 x 50 = x 255 x 215 x 75 = x 250 x 210 x 75 =
(use only maximum values; disregard other values ! )
W W W W W W W W
2. Transmission-heat windows m+ 3. Transmission-heat walls Nord- and internal walls All other walls 4. Ceiling or Roof Ceiling to non temperature conditioned rooms Ceiling below roof, non-ins ulated Ceiling with 50mm thermal ins ulation F lat roof, non ins ulated F lat roof, with 50 thermal ins ulation m+ m+
m+
(minus window s urface)
m =
Area m Area m m
x 20
m+ m+
m= m=
x 8 x 10
= =
W W
= = = = = =
m m m m m m Qty Area = m
x 10 x 17 x 10 x 35 x 12 x 5
= = = = = =
W W W W W W
Height x
x 100
heavy x 95
Qty
x 1
9. Electrical Applications
(connected load; obs e rve s imilarity)
Type x
Qty
x 1
Description
=
External cooling load Field 1 to 6 = Internal cooling load Field 7 to 10 = Sensible total cooling load =
W W W W
04/2002
P.1
TI-T03
Charts and Forms TI-T04 Identification Data for Standard Capacities of KaRo Cooling Ceilings
C
6,259
n
1,105
2 3 4 5 6
6,693
1,096
7 8 9 10 11 12
5,080 5,140
1,070 1,080
04/2002
P.1
TI-T04
Charts and Forms TI-T05 Final Pressure Test Report for KaRo Heating and Cooling systems
Final Pressure Test Report for KaRo Heating and Cooling systems
Construction project: Project No.: Section* Begin End Begin End Begin End Begin End Begin End Begin End Begin End Begin End Begin End Begin End *) Room- or mains identification Additional remarks: Pressure Date Time Remarks Signature
Hereby I confirm, that a pressure test for the above mentioned sections has been successfully performed according to the KaRo installation instruction M07. The system was filled with water, air bladed and with a testing pump set to 10 bar . The pressure loss caused by elastic expansion has been compensated for. The water pressure of 10 bar was maintained for 4 hours. Thereafter the system was lowered to an idle pressure of 3 bar.
Date
Signature
04/2002
P.1
TI-T05
Combustion Heat
1. Combustion Heat of PP-Random-Copolymer
Source: Statement of the company Borealis H = 42,23 MJ/kg = 42,23 * 106 Ws/kg = 11,73 kWh/kg
Outer Diameter da
[mm]
Nominal size DN
Wall thickness s
[mm]
Combustion Heat H
[kWh/m]
16,0 20,0 25,0 32,0 40,0 50,0 63,0 75,0 90,0 110,0 125,0 140,0
12 15 20 25 32 40 50 63 75 90 100 110
1,6 1,8 2,3 3,0 3,7 4,6 5,8 6,9 8,2 10,0 11,4 12,8
0,76 1,09 1,73 2,89 4,45 6,93 11,00 15,59 22,25 33,17 42,95 54,00
04/2002
P.1
TI-T06
Charts and Forms TI-T07 Lay-out for KaRo Floor Heating System
2 2
Estimate value -> compare with calculated value of line 18 = heat requirement/ planned coverage
W/m
m K/W C W/m K C C C
2
from external calculation or estimate value -> with values from line 7 and 8 from diagram 21 -> from diagram 21 customary are values between 6 to 12 K = Room temperature + excess temperature +Spread / 2 = Supply temperature - Spread =(Supply temperature - return temperature) / 2
=Length * width * Qty of mats =Standard heat capacity * covered floor area -> compare with required heat capacity from line 5; possibly the average water temperature must be raised
Water volume 20 Heating water spread 21 Mass flow water 22 Temperature below the floor 23 Thermal conductance factor to bottom 24 Capacity to the bottom 25 Corrected mass flow of water 26 Water volume per zone K ltr./m2 h C W/m K W/m
2 2
= Supply temperature - return temperature =(required heat capacity * 3600 / spread * 4180) Temperature below the floor from external calculation = Thermal conductive fact to bottom*(aver water temp - temp bott) =(required heat capac+ capac to bottom*3600 /Spread*4180) =corrected mass flow/60*covered floor area =corrected mass flow * covered floor area
04/2002
P.1
TI-T07
Charts and Forms TI-T08 Lay-out for KaRo Wall Heating System
Room Data 1 Room temperature 2 Length of wall 3 Height of wall 4 Heat requirement of room Required Heat Capacity 5 Planned coverage of wall 6 Required specific heat capacity Performance Calculation 7 Plaster quality 8 Thermal conductive factor 9 Plaster thickness above the mat 10 Resistance characteristic value 11 Effective excess temperature: heating water 12 Standard heating capacity 13 Spread 14 Supply temperature 15 Return temperature 16 average water temperature Selection of the BEKA Mats 17 Qty of mats per zone / wall 18 Length of mat 19 Width of mat 20 With mats covered wall area 21 Real heating capacity of wall Qty m m m W =Lenth * width * Qty of mats =Standard heating capacity * covered wall area -> compare with required heat capac from line 6; possibly the average water temp must be raised Water volume 22 Heating water spread 23 Mass flow of water 24 Water volume per zone/wall K l/m h l/min l/h =Supply temperature - return temperature = required heating capac * 3600 / spread * 4180 =Mass flow / 60 * covered wall area =Massflow*covered wall area C W/m K C C C W/mK mm -> from chart/diagram 29 -> with values from line 6 and 10 from diagram 29 -> from diagram 29 customary are values between 6 to 12 K = Room temperature + excess temperature+Spread / 2 = Supply temperature -Spread =(Supply temp - return temp) / 2 m W/m Estimate value -> compare with calc value from line 18 =Heat requirement / planned coverage C m m W from calculation of the planning offices
04/2002
P.1
TI-T08
Charts and Forms TI-T09 Quick Lay-out for Wall Heating with KaRo Prefabricated Panels
10
12
15
17
20
22
100
200
300
400
550
700
850
1000
1150
1300
valid for room temperature of 22C and heating water spread of 6K and 300 mm connection hose
4 Supply temperature -> from diagram 5 Return temperature Pressure loss determination 6 Pressure loss in pipe = pipe length * resistance 7 Pressure loss of the unit -> with value of line 3 from diagram 8 Addition for pressure loss by fittings (recomm. 30% additions to pipe) 9 Additions for heat transfer station (recomm:for zone valves 500 to 1000 Pa for mains regulating valves 700 to 1500 Pa for heat exchanger appox. 4000 Pa 10 Total Pressure Los
C C
kg/h l/h
Pa Pa
m Pa/m
Pa
When using the BEKA transfer stations the pressure loss deterination can be ommitted. Only the quantity of the heating circuits and the total capacity is required for the selection.
04/2002
P.1
TI-T09
Charts and Forms TI-T10 Quick Lay-out for KaRo Cooling Ceilings with KaRo prefabricated ceiling panels
Quick Lay-out for KaRo Cooling Ceilings with KaRo prefabricated ceiling panels
Project : Project consultant : Required cooling load 1 Cooling load for the room 2 Planned quantity units 3 Required cooling capacity per unit Performance determination W Qty W from calculations of planning office max. possible arrangement derived from room dimensions = cooling load / Quantity of units Date: Lay-out valid for 27C room temperature and 2K cooling water spread !
12
16
37
41
45
49
300
500
700
900
1100
1300
1500
1700
1900
2100
2300
2550
2800
valid for room temperature 27C and cooling water spread 2K and connection hose 300mm length
4 Supply temperature -> from diagram 5 Return temperature Pressure Loss Determination 6 Pressure loss in pipe = pipe length * resistance 7 Pressure loss of the unit -> with value of line 3 from diagram 8 Addition for pressure loss through fittings (recomm: 30% addition to pipe ) 9 Additions for heat transfer stations (recomm for zone valves 500-1000 Pa for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa 10 Total Pressure Loss By using the BEKA transfer stations the pressure
C C
kg/h ltr./h
Pa Pa
m Pa/m
Pa
loss determinaion can be ommited.Only the quantity of the cooling circuits and the total cooling capacity is required for the selection !
04/2002
P.1
TI-T10
TI-D01
Diagrams
04/2002
P.1
TI-D01
TI-D02
Diagrams
plaster
Thermal conductivity for plaster in W/m K 0,45 0,45 0,45 0,45 0,35 0,35 0,35 0,35 0,87 0,87 0,87 0,87 1,50 1,50 1,50 1,50 0,12 0,12 0,12
Characteristic Line R21 R32 R41 R70 R24 R38 R52 R90 R12 R18 R23 R38 R10 R13 R15 R24 R39 R55 R72
R10
Gypsum plaster
Gypsum plaster Gypsum plaster Gypsum plaster Gypsum plaster Gypsum plaster Gypsum plaster Gypsum plaster Lime plaster Lime Plaster Lime plaster Lime plaster Concrete plaster Concrete p. Concrete p. Concrete p. Acoustic p. Acoustic p. Acoustic p.
R70
Example: Plaster ceiling with embedded capillary tube mat; Gypsum plaster 10 mm thick over capillary tube (R32); Temperature difference (room temperature average water temperature) DT=9,5 K; results to a cooling capacity of 78 W/m.
04/2002
P.1
TI-D02
TI-D03
Diagram
Metalcassette Ceiling with glued-in acoustic fabric lining and K.U10-mat Fermacell board with glued-on K.GG10-mat Plaster board with glued-on K.GG10mat Prefabricated Ceiling Panel B.GK12
Example: Fermacell board, 10 mm thick with glued-on K.GG.10-mat; Temperature difference (average water temperature - room temperature ) = 9,7 K; results to a heating capacity of 61 W/m
04/2002
P.1
TI-D03
TI-D04
Diagrams
R 10 R 30 R 50 R 70 R 90
Example: Plaster ceiling with embedded capillary tube mat; Gypsum plaster 15 mm thick over capillary tubes (R41); Temperature difference (average water temperature room temperature) DT=9,3 K; results to a heating capacity of 63 W/m.
04/2002
P.1 TI-D04
TI-D05
Diagrams
04/2002
P.1
TI-D05
TI-D06
Diagrams
length (W/m)
R o o m h e ig h t H = 3 ,0 0 m H = 2 ,7 5 m H = 2 ,5 0 m
W id t h o f t h e c o v e r e d c e i l i n g s t r i p ( m )
Example: In a 2,75 m high room with the width of the covered ceiling strips of 3,3 m the permissible heating capacity may be maximum 210 W/m
04/2002
P.1
TI-D06
TI-D07
Diagrams
Pressure Loss of the KaRo Mat K.U10 (Length from 1,0m to 8,0m)
18000 16000 14000 Pressure loss (Pa) 12000 10000 8000 6000 4000 2000 0 10 15 20 25 Mass flow (kg/mh) 30 35 2m 1 m 40 4m 8m 7m 6m 5m
3m
Example: Mass flow water = 23 kg/mh; length of mat = 5 m; results to a pressure loss of = 9500 Pa
04/2002
P.1
TI-D07
TI-D08
Diagrams
1,2 m
Example: Mass flow water = 23 kg/mh; length of mat = 1,6 m; results to a pressure loss of = 950 Pa
04/2002
P.1
TI-D08
TI-D09
Diagrams
Pressure Loss of the KaRo Mat K.G10 (Length from 1,0m to 8,0m )
4500 4000 3500 3000 2500 2000 1500 1000 500 0 10 15 20 25 Mass flow (kg/mh) 30 35 2m 1m 40 3m 4m
8m
7m
6m
5m
Example : Mass flow water = 27 kg/mh; length of mat = 5 m; results to a pressure loss of = 2900 Pa
04/2002
P.1
TI-D09
TI-D10
Diagrams
Pressure Loss of the KaRo Mat K.G10 (Length from 1,0m to 2,6m)
500 450 2,6 m 400 350 Pressure loss (Pa) 300 250 1,2 m 200 150 100 50 0 10 15 20 25 Mass flow (kg/mh) 30 35 40 1,0 m 1,4 m 2,4 m
2,2 m
2,0
1,8 m
1,6 m
Example: Mass flow water = 22 kg/mh; Length of mat = 1,4 m; results to a pressure loss of = 180 Pa
04/2002
P.1
TI-D10
TI-D11
Diagrams
Pressure Loss of the KaRo Mat K.S10 (Length from 1,0 to 8,0m)
18000 8m 16000 14000 12000 10000 8000 6000 4000 2000 0 10 15 20 25 Mass flow (kg/mh) 30 35 2m 1m 40 3m 4m 7m 6m 5m
Example: Mass flow water = 23 kg/mh; Length of mat = 5 m; results to a pressure loss of = 9500 Pa
04/2002
P.1
TI-D11
TI-D12
Diagrams
Pressure Loss of the KaRo Mat K.S10 (Length from 1,0m to 2,6m)
2000 1800 1600 Pressure loss (Pa) 1400 1200 1000 800 600 400 200 0 10 15 20 25 Mass flow (kg/mh) 30 35 40 1,4 m 1,2 m 1,0 m 2,6 m 2,4 m 2,2 m 2,0 1,8 m 1,6 m
Example: Mass flow water = 23 kg/ mh; Length of mat = 1,4 m; result to a pressure loss of = 750 Pa
04/2002
P.1
TI-D12
TI-D13
Diagrams
15000
4m
Example: Mass flow water = 23 kg/mh; Length of mat = 5 m; result to a pressure loss of = 14000 Pa
04/2002
P.1
TI-D13
TI-D14
Diagrams
Pressure Loss of the KaRo Mat K.S15 (Length from 1,0 m to 2,6 m)
3000 2,6 m 2500 1,6 m 2000 Pressure loss (Pa) 1,4 m 1500 1,2 m 1000 1,0 m 500 2,4 m 2,2 m 2,0 m 1,8 m
Example: Mass flow water = 23 kg/mh; Length of mat = 1,4 m; results to a pressure loss of = 1150 Pa
04/2002
P.1
TI-D14
TI-D15
Diagrams
Example: Mass flow water = 85 kg/h results to a pressure loss of = 615 Pa in a 800 mm long connecting hose
04/2002
P.1
TI-D15
TI-D16
Diagrams
325 300 275 250 225 200 175 150 125 100 75 50 25 0 40 80 120 160 200 240 280 320 360 400 460 520
Example: Through a pipe of 6 m length 350 kg/h should be flowing through. The pressure loss per 1 m is 250 Pa. This results to a total pressure loss in the pipe of: 6 m x 250 Pa/m = 1500 Pa
04/2002 Learning from Nature www.KaRo.cc oN P.1 TI-D16
TI-D17
Diagrams
intake + outlet
1 outle t
100
110
120
Example: Mass flow water = 83 kg/h ; in both elbows outgoing there will be a pressure loss of 230 Pa
04/2002
P.1
TI-D17
TI-D18
Diagrams
1,4 1,2 Flow speed (m/s) 1 0,8 0,6 0,4 0,2 0 8 12 16 20 24 28 32 36 40 Mass flow (l/min) DN 15 DN 20 DN 25
1,4 1,2 Flow speed (m/s) 1 0,8 0,6 0,4 0,2 0 40 50 60 70 80 90 100 110 120 130 Mass flow (l/min) DN 50 DN 32 DN 40
Example: 85 l/min are flowing through a pipe DN 40 with a flow speed of approx. 1,08 m/s
04/2002
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TI-D18
1,4 1,2 Flow Speed [m/s] 1 0,8 0,6 0,4 0,2 0 100 150 200 250 300 350 400 450 Mass flow [l/min] DN 63 DN 75 DN
04/2002
P.2
TI-D18
TI-D19
Diagrams
11
10
04/2002
P.1
TI-D19
TI-D20
Diagrams
21 20 19 18 17 16 15 14 13 12 15 16 17 18 19 20 Construction sheet Femacell Metal cassette ceiling Plaster ceiling Gypsum board ceiling
TI-D21
Diagrams
C a rpet R = 0,10 m K /W
Example: KaRo floor heating covered by tiles; temp difference (average water temp room temp) DT = 8 K; results to a heating capacity of 78 W/m
04/2002
P.1
TI-D21
TI-D22
Diagrams
2500
1500
Pressure loss(Pa)
1000
500
15
35
40
36
42
48
TI-D23
Diagrams
0 15 16 17 18 19 20 21 22 23
04/2002
P.1
TI-D23
TI-D24
Diagrams
Old buildings
Buildings up to 1976
0,8
1,0
1,2
TI-D25
Diagrams
140
120
100
80
60
40
20
0 0 1 2 3 4 5 6 7 8 9 10 11 12
Temperature difference DT= TR-TD (K) TR = room temperature TD = average ceiling temperature at the underside
04/2002 Learning from Nature www.KaRo.cc P.1 TI-D25
TI-D26
Diagrams
3 K s pread 2 K s pread 20 30 40 50
3 K s pread
2 K s pread
80
120
160
200
240
280
320
360
400
440
480
520
560
600
04/2002
P.1
TI-D26
TI-D27
Diagrams
Example: The KaRo dry-build construction unit B.GK.12, at a temp. difference (room temp. average water temp.) DT = 10 K, achieves a cooling capacity of 69 W.
04/2002 Learning from Nature www.KaRo.cc n P.1 TI-D27
TI-D28
Diagrams
04/2002
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TI-D28
TI-D29
Diagrams
Type of Plaster
120 100 80 60 40 20 0 4 6 8 10 12 14
R 10 R 50
R 30 R 70 R 90
Gypsum Gypsum Gypsum Gypsum Gypsum Gypsum Lime Lime Lime Concrete Concrete concrete
20
Thermal conductivity factor for plaster in W/m K 0,45 0,45 0,45 0,35 0,35 0,35 0,87 0,87 0,87 1,50 1,50 1,50
Plaster Characthickness teristic over mats in mm 10 15 20 10 15 20 10 15 20 10 15 20 curve R32 R41 R70 R38 R52 R90 R18 R23 R38 R13 R15 R24
16
18
Example: Wall heating with embedded capillary tube mat; gypsum plaster, 15 mm thick, over the capillaries (R41); Temperature difference (average water temp room temp) DT=9,3 K; results to a heating capacity of 63 W/m.
04/2002
P.1
TI-D29
TI-D30
Diagrams
Example: For KaRo mats K.G10.0600.0600.20 in one row, a mass flow of 35 kg/(mh) will result to a pressure loss of 6,13 Pa.
04/2002
P.1
TI-D30
TI-F
Formulas
Formulas
Building Identification Data
Height Factor KH KH = 1,117 - 0.045 H [m] with: H - room height valid for 2,5m < H < 5m Load Factor KK KK = (qiL + qeL) / (qiL + qeL/2) with: qiL - internal specific cooling load [W/m2] qeL - external specific cooling load [W/m2] KK maximum = 1,2 permissible (2) (1) DG = AD / AB with: AD - ceiling area covered with mats [m2] AB - floor area of room [m2] Factor of coverage KB KB = 1,21 - 0,3 DG valid for 0,3 < DG < 1,0 Constant factor, room KR KR = KH KK KL KB (8) (7)
Ventilation
Specific cooling load of draft qL qL [W/m2 ] = vL TL cL L with: vL - specific air intake volume flow [m3/hm2] TL- temperature difference exhaust-intake [K] cL - specific heat capacity of the air = 1004 J/kgK L - density of the air = 1,14 kg/m3 or qL [W/m2 ] = 0,32 vL T Ventilation Factor KL (5) (4) (3)
TWM [C ] = (TVL + TRL) / 2 with; TVL - supply temperature [C] TRL - return temperature [C] Effective under temperature TU TU [C ] = TR - TWM with TR room air temperature [C] Required specific capacity for cooling ceiling qERF qERF [W/m ] = qGA - qL with qGA - total cooling load in reference to floor area [W/m2] Specific Standard Cooling Capacity qN according DIN 4715 qN [W/m ] = C T
2 n U 2
(10)
(11)
Ventilation system Ventilation factor KL Basic airflow 1,00 Climate convector 1,08 Ceiling slot outlet 1,10 Ceiling momentum outlet 1,13
(12)
Ceiling Construction
Degree of coverage, ceiling DG (6)
04/2002
P.1
TI-F
Actual Specific Cooling Capacity to bottom qT qT [W/m2 ] = KR qN Specific Capacity to Top qO qO [W/m2 ] = kO ( T - TWM ) with kO Thermal conductance factor to top [W/m2K] T Temperature above the ceiling [C]
(13)
(14)
w [m/s] = V /AS with V volume flow [m3/s] AS sectional area of flow [m2] or w [m/s] = 21,22 m / di2 with m water volume [l/min] di - pipe diameter [mm] Pressure loss in the pipe pR pR [Pa] = L / (d 10-3) /2 w2 i with - pressure loss coefficient L - length of pipe [m] - density [kg/m3] or pR [Pa] = 499200 L / di w2 with W density of water = 998,4 kg/m3 Pressure loss at fittings and passages pF (24) (23) (22)
Heat Flow Density (Basis characteristic curve) qi (15) qi [W/m2] = 8,92 ( Ti - TD )1,1 with Ti - room temperature [C] TD average ceiling temp. at bottom side [C] Internal Thermal transmittance coefficient (16) [W/m2K] = qi / (tD - TWM) with TWM average cooling water temperature [C] for capillary tube mats 110 W/m2K
Mass Flow
Cooling water spread SP SP [K] = TVL - TRL Specific mass flow water mW mW [kg/m h] = 3600 qN / (cW SP ) with cW - specific heat capacity of water = 4180 J/kgK oder mW [kg/m2h] = 0,861 qN / SP Corrected Specific Mass Flow Water mKW mKW [kg/m h] = 0,861 (qN + qO ) / SP
2 2
(25)
(17)
(18)
(19)
Type of Fitting Sleeve connector Elbow, wide Elbow, narrow Expansion T-Junction, Separation T-Junction, Union T-Passage, Separation T-Passage, Union T-Counter current Pressure loss at valves pV
- Value 0,0 0,5 0,3 0,5 1,5 1,0 0,0 0,5 3,0 (26)
(20)
10-1
04/2002
P.2
TI-F
with ma queued up mass flow [kg/h] kVS value according manufacturer [m3/h] Pressure loss in the capillary tube mat pM 1 (27) pM [Pa] = V2 8 / 2 1/ ( nK dK5 / ( dK + K LM) )2 + (S B/dS + nK) wS2 /2 with V - Volume flow [m3/s] nK - Quantity of capillary tubes dK - Inner diameter of capillary tube [m] K - Friction factor of capillary tube LM - Extended length of capillary tube mat [m] S - Friction factor of mains B - Length of mains or width of mat [m] dS - Inner diameter of mains [m] - Resistance coefficient for junction = 0,04 wS Velocity of flow in the mains [m/s] Reynolds number Re Re = w di or Re = w di 103 with - kinematical Viscosity for water [10-6 m2/s] w Velocity of flow [m/s] di Inner diameter [mm] Pressure loss coefficient for Re < 2300 = 64 / Re for 2300< Re< 105 = 0,3164/ Re0,25 (29) and (30) (28)
with a - air temperature [C] mrt- average radiation temperature [C] v - air velocity [m/s] or for v< 0,1 m/s res = (a + mrt )/ 2 Average radiation temperature mrt mrt [C] = ( i Ai ) / Ai with i - surface temperature of the area Ai Valid when the emission coefficients of the particular surfaces are equal (standard case); Is not valid if in the room in question infra red reflective layers have been used ! Required air exchange2 VLW VLW [m3/h] = VCO2 / ( CCO2I - CCO2A) with VCO2 - CO2 - Emission in the room [l/h] CCO2I - CO2I Concentration in room air [l/m3] CCO2A- CO2A Concentrat. in outside air [l/m3] (34) (33) (32)
Stability
Comparative tension V V [MPa]= pi (da - s )/ (2 s) with pi - inside pressure [MPa] da - outer diameter of pipe [mm] s - wall thickness of pipe [mm] (35)
Comfortableness
Percept Temperature2 res res [C] = a a + (1- a ) mrt where a = 0,5 + 0,25 v (31)
Vogel Fachbuch: Wagner - Strmung und Druckverlust, Vogel Buchverlag Wrzburg 1992 2 Source: Praxishandbuch Haustechnik, Akademie fr technische Gebudeausrstung, Wien 1995
04/2002
(37)
P.3
TI-F
with i - inner Thermal transition coefficient [W/m2K] inner Thermal transition resistance Ri = 1 / i = 0,13 m2K/W a- outer thermal transition coefficient W/m2K] outer thermal transition resistance Ra = 1 / a = 0,04 m2K/W si - thickness of layer [m] i - thermal conductivity of the layer [W/mK] Average k-value km km [ W/m2K] = (kW AW + 0,8 kD AD + 0,5 kB AB + kF AF) / Ages with kW,D,B,F - k-value for wall; ceiling; floor; windows [ W/m2K] AW;D;B;F - area of wall; ceiling; floor; window [ W/m2K] Ages - total embracing area [m2] (38)
Heat
Approximate heat requirement QW QW [W] = (km Ao/V + 0,34 nW ) Vo T with km - average overall heat transfer coefficient W/m2K] Ao - total embracing area [m2] Vo - total building volume [m3] nW - rate of hourly air exchange=0,5 to 1,0 [h-1] T - temperature difference outside/inside [K] (39)
1 daPa = 10-4 1kp/cm2 = 0,9807 1 at = 1mmWs= 0,9807 x10-4 1 Torr = 1,33322 -3 1mmHg = x10 1 atm = 1,01325
04/2002
P.4
TI-F
MPa W/m2 W/m2 W/m2 W/m2 W/m2 W/m2 W/m2 W/m2 W/m2 W W mm m K C C C C C C C
04/2002
P.5
TI-F
Average water temperature Air velocity Volume flow Specific air intake flow Required air exchange rate Total building (or) room volume Velocity of flow Velocity of flow in the mains Outer, thermal transition coefficient Inner, thermal transition coefficient Pressure loss coefficient Thermal conductivity of a layer Pressure loss coefficient in the capillary tube Pressure loss coefficient in the mains Inner thermal transition coefficient Pressure loss at the fitting Pressure loss of the mat Pressure loss of the pipe Pressure loss at the valve Temperature difference air intake exhaust air Density of air = 1,14 kg/m3 Density of water = 998,4 kg/m3 Air temperature Surface temperature of an area Average radiation temperature of an area Percept temperature Comparative tension Resistance coefficient
04/2002
P.6
TI-F