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KE KELIT
Kunststoffwerk GesmbH.
A-4017 Linz, Ignaz-Mayer-Straße 17
Austria – Europe
Tel. +43/73 2/77 92 06-0 I N N O VAT I V E P I P E S Y S T E M S
Fax +43/73 2/77 92 06-118
e-mail: office@kekelit.com
www.kekelit.com
Handbook/07
Index Abbreviation Description Unit Contents
2
A
The following commonly d 4
used abbreviations are
di Inside diameter of pipe mm
found in this catalogue. 5 Technical standards
E Module of elasticity N/mm2
FP Fixing point 6–7 Waterflex®; Ketrix®
Ft Force of heat expansion N 8–9 Problems and solutions
IS Insulation thickness mm
l Length of piping m 10–11 Raw material data: PP-R, metals, insulation
MS Minimum length of expansion pipe mm 12–13 Pipe types KE00, KE02, KE08; operating temperatures
N Force Newton
14 ALU composite pipe KE06
P Pressure bar
PN Pressure rating bar 15–17 SENSO-LX insulated pipes; heat losses; savings
R Pressure loss caused by friction Pa/m 18–19 Methods of joining; the safest pipe connection
s Wall thickness mm
20–21 Joining the pipes with the hand welding machine
sec Time second
SF Safety factor 22–23 Welding the LX pipes; welding the saddle fittings
SP Supporting point
24–25 Table welding machine
t Temperature °C
tm Temperature of medium °C 26–27 Butt welding machine
tv Temperature at time of installation °C 28–29 Overhead welding machine
V Volume l/m
30–31 Electrofusion socket welding
V̇ Flow volume l/sec
v Flow velocity m/sec 32–33 Plumber friendly solutions
VP Packing unit pc 34 Pipe sizing; flow velocity; fitting pressure losses; circulation pipes
VR Total flow rate (DIN) l/sec
VS Peak flow rate l/sec 35–36 Pipe sizing according to DIN 1988
W Power Watt 37–39 Sizing charts for PN10, PN16 and PN20
Z Flow resistance for type of fitting Pa
40–43 Flow rate calculations according to DIN 1988
z z dimension mm
Coefficient of expansion mm/m°C 44–45 Expansion; compensation; force of expansion
l Specific linear expansion mm 46–47 Compensating expansion in practice; pipe supports
p Total pressure loss Pa
Temperature difference °C 48–49 Pressure testing
t
The blue line KE KELIT`s Technical standards National and international test institutes
test the conformity of our products to a
Quality targets range of different standards.*
Blue is KE KELIT´s company colour and
conjures up the following associations: 1. Our quality targets are not confined
to the product.
The preciousness of blue water: They include all areas covered by
Clean water is becoming ever more ÖNORM EN ISO 9001:2000.
precious. The surface of metal pipes are
being destroyed by ever more aggressive 2. Suppliers and customers are ÖNORM B 5174
ions. integrated into the quality assurance DIN 8077/8078 Dimensions, pressure ratings
system to ensure that mistakes are EN ISO 15 874 1-5 Material requirements
The durability of blue sapphire: prevented. EN ISO 15 494
Symbolic of value, durability and eternity.
3. Every employee is responsible
The reliability of blue chip: for the quality of his own work and
On the fast moving share markets a should be highly motivated to
synonym for ”safe bet”, or ”market continually assess his work.
leader” or ”recommended purchase”
or ”no risk” 4. Customer satisfaction can only
be achieved by responding to the
Lines are associated with continuity, ÖNORM B 5174 Dimensions, pressure ratings
requirements of the customer and
direction and connections. the market. EN ISO 15 494 Material requirements, resistance to impact
DIN 8078-1 Resistance to chemicals
The colours, design and marking of the 5. A responsible attitude to the ASTM F1249-90 Diffusion of water vapour
products are regulated by various national environment can only be achieved ÖNORM B 5157 O2 diffusion
standards. KE KELIT products are easily by manufacturing long-life products
identified by the ”blue line” marking by environment-friendly processes.
on the product.
General:
The advantages of the ”blue line” range: EN ISO 8795:2001
BS 6920
● A complete system from one supplier. Suitability for drinking water
● All three pipe materials use the ÖNORM B 5014-1
same joint technology, ÖNORM B 5018-1 + 2
the same machines and the same tools. EN 12 873-1 Migration
● However, each system has been DIN 2999
designed for its particular application. Metal threads
DIN 16 962
● Every new innovation is integrated
DIN 50 911 Stress corrosion cracking
into the complete product range.
ISO 6509 Dezincification resistance
The Blue line is the new direction taken DIN 17660 Brass materials
by the leading pipe system supplier KE * For information about specific national approvals please contact the headquarters in Linz or the regional offices.
KELIT. Karl Egger eh.
Managing Director
4 5
Chilled water/air Impermeability The NONOX® process
conditioning (PN10) to oxygen KE KELIT has developed a new
Pipe systems for chilled water cooling The molecular structure of the polymers patented process:
systems (down to +2°C) means that small amounts gases diffuse
Pipe systems for brine refrigeration The alternative pipe through the material at different rates. The structure of the polymer alloy makes
systems (down to –30°C) it possible to close the ”molecular pores”
system The problem is well-known: by means of a ”redox” treatment.
O2 molecules can no longer diffuse
Advantages The polymer ● Carbonated drinks should not lose
through the material.
any CO2
● Range of sizes: d20 - 160 KEtrix® is made of CRYOLEN®,
● Resistant to impact at –30°C
● Resistant to any concentration of
a PP-based polyolefine blend. ● Many foods need to be protected The result
glycol brines from the effects of O2
(fats, oils, milk cheese, meat…) KEtrix® pipes, which are made
● Oxygen barrier
completely of plastic are
(NONOX® process)
● On the other hand aromas should impermeable to oxygen when the
● Resistant to corrosion even when
not escape wall thickness is a minimum
the temperature unintentionally drops
(coffee, jam, vegetables….) of 3,7 mm.
below the dew point and at the
aggressive temperature of 0°C.
● Sheets act as water vapour barriers The material was tested to ÖNORM B5157
in buildings Pipes in water circulation according to the zinc absorption method.
systems must not allow oxygen to
Drinking water diffuse through the pipe as this will Test reports by the TGM institute in Vienna
max.temp: 30°C PN10 Compressed air attack the metal components and showed the following results:
cause the following problems:
max.temp: 40°C PN16 technology (PN16) – Corrosion (Iron, steel) Max. diffusion
– Incrustation defined by standard: 0,1 mg O2 /d . m3
Advantages Compressed air has become indispensable – Blockages Result for Ketrix: < 0,005 mg O2 /d . m3
for the manufacturing sector and is used – Malfunctioning
● Highly secure welded joint for the following tasks:
(safety factor > 3) – Expensive repairs
● Driving medium for tools
● Tools, machines, and welding times ● Pneumatic control systems
similar to KELEN® pipe system ● Driving medium for regulator fittings In general these problems are solved
● Resistant to chemicals, water particles ● Air purification at the workplace by using composite materials:
and pressure hammer, even at low
temperatures Advantages A combination of plastic material with
● Resistant to corrosion even in places ● Range of sizes: d 20 – 110 other materials which provide strength or
where unwanted condensation has ● High chemical resistance to a barrier to oxygen diffusion E.g.
formed compressor oils – EVOH to prevent O2 diffusion
● No corrosion and therefore no – Fluorine polymers to prevent
variation in the quality of the H2O vapour
compressed air – PA to prevent diffusion of oils
and fuels
A separate catalogue is available for the KEtrix® pipe system! – Metal to prevent the loss of aroma
6 7
Drinking water Operating conditions The Result
problems
The KELEN pipe system has many
advantages. Ideal for hot and
Corrosion cold water installations for both
new projects and renovation.
● The concentration of ions in drinking
water is increasing and consequently
● Pressure ratings:
the risk of using metal pipes:
PN10, PN16 and PN20
Chlorides: attack stainless steel
● Cold water: d20 – d160 mm
Sulphates: attack galvanised steel
Hot water: d20 – d110 mm
Nitrates: attack copper
● Resistant to internal and external
● Ever more problematic sources
corrosion caused by ions in the water
of water reserves have to be tapped
or chemicals on the site
for the supply of drinking water Internal corrosion - Cu ● No crystallisation points for lime
● Acid rain reduces the pH value of
deposits
surface and spring water to critical
● Secure joint technology which requires
levels below 7 (=neutral).
no additional materials.
External corrosion occurs as a result
● Conforms to hygiene regulations and
of new building and insulation
approved for transporting foodstuff
materials and new installation
● Low pressure losses as a result of
methods.
smooth bore
● Disinfectants (chlorine, ozone)
● Low noise level
attack copper in particular.
● Resistant to high temperatures and
Poisonous Cu ions are released
pressure
into the water!
● Low thermal conductivity
comparison of λ-values:
Incrustation KELEN 0,24 W/m°C
The solution Copper 320,00 W/m°C
● Hard water causes incrustation on
Cast iron/steel 42,00 W/m°C
the inside walls of metal materials. KELEN
External corrosion - Steel ● Stringent testing and monitoring of
drinking water quality to international standards
The consequences: pipe system ● Secure long-term performance
● Higher pressure losses ● Pipes are insulated at the factory and
● Reduced flow Plastics are not can be located behind the wall
● Blockages ”replacement ● Can be combined with Waterflex
● Expensive repair work materials”. flexible pipe system
● Time-consuming renovation When chosen and
● Disruptions in the water supply applied correctly they
often provide
the better solution
for a defined problem.
A secure supply of
drinking water Sometimes even ”No more
the only one!
is an essential factor for corrosion in the
a high quality of life Calcite deposits 3rd millennium”
8 9
The raw materials Metal adaptor ● Dezincification resistant brass
fittings (MS 63, CZ 132) for all parts
The long-life plastic transporting water ensures high
Special care has been taken over the resistance against aggressive water.
The raw material is a polypropylene choice and quality control of the metal ● A pore-free, chemically applied
copolymer (PP.R) with its typical quality threads. metal plating prevents stress corrosion
characteristics (DIN 8077, DIN 8078). cracking.
Every material is subject to ageing. ● Metal parts which are not in contact
PP-R is no exception to this rule of nature. with the media are generally made
● KELIT technology has made of metal-plated MS 58 brass.
The ”long-term creep curves”, which are
determined by temperature and stress,
KELEN pipes particularly ● Exceptional resistance to torsion force
resistant to impact at –5°C. and suitable for on-site conditions
are proof of the long service life
(see page 13 for operating conditions). ● Depth of the thread conforms to
● Pipes and fittings are made DIN 1692 for normal faucets
of the same raw material.
SENSO PIPE
40°: 0.038 W/m°C
δvTensile strength in MPa
Protective coating:
High quality 5-layer composite made of
polyolefines and aluminium
Time in h >
10 11
PP-R pipe system Dimensions: Application as specified by DIN: Operating pressure in relation to
Colour: Grey. 3 co-extruded green lines Cold water service life and operating
(90 apart) help the plumber to align PN10: 20 / 10 bar temperature
pipe and fitting. Safety factor: The DIN standard takes
account of raw material properties and
Standard length: 4 m, calculates a safety factor of 50% (SF=1.5)
Other lengths can be produced on request when deriving the operating conditions given
subject to minimum order quantities! on the right:
12 13
KELIT KELEN –LX SENSO
ALU Composite pipe insulated pipe system
Colour: The PP-R medium pipe is
colourless. The outside layer is azure blue.
Standard length: 4 m.
20 21
Polyfusion welding The following guidelines apply for 4. SENSO pipe detection 4.
all pre-insulated KELEN-LX pipes. SENSO properties LX
of KELEN®-LX pipes insulation allows the system to be located
with the hand up to a maximum depth of 80 mm in the
approx. 50 cm
2.3
4. Once the heating time is over the 4.
saddle fitting is pushed into the pipe wall
immediately (do not twist!) and pressed
for approx. 30 sec. The melting of both
the pipe wall and the pipe surface ensures
a strong homogenous joint. After approx.
10 minutes the joint can be subjected to
operating conditions.
22 23
See pages 20 and 21 for instructions The welding procedure:
Table welding on preparing pipes and fittings for 1.
machine welding. 1. Fix the fitting in the clamp and the
fitting holder. Ensure that the face of the
fitting is flat against the clamp.
1.1 Put the pipe in the pipe clamp.
1. Screw the required heating 4. Set the pipe diameter switch to Do not tighten the clamp.
elements to the welding plate. the required size. This switch regulates 1.2 Hold down the spacing button
The length of the heating element varies the length of the pipe that will be welded and move the sliding blocks together
according to the size of the pipe and the into the socket using the hand wheel until the pipe is
section of pipe to be welded. touching the fitting or the sliding blocks
5. Spacing button.
can no longer move
2. One side of the pipe clamps can Press the button to fix the distance
between the two sliding blocks which will 1.3 Release the spacing button. 2.
be used for small pipe sizes (d20 – d40).
enable the appropriate section of pipe Only now fix the pipe in the clamp.
For larger sizes (d50 – d90) the clamps
should be turned around. and the complete socket of the fitting to
be heated on the welding elements. 2. Move the sliding blocks apart and
pull down the welding plate.
3. The same principle applies for the Note: The machine is available in
fittings clamps. 2.1 Move the sliding blocks together
two sizes:
until they are stopped by the lock
Type 1: d 20 – 90 mm
Type 2: d 25 – 125 mm 2.2 When the heating time has elapsed
move the sliding blocks apart briskly and
quickly remove the welding plate.
Heating element
Fitting clamp 3. Push the sliding blocks together 3.
briskly until the pipe diameter switch
Welding plate catches.
Fitting holder
3.1 Never cool the welded joint abruptly.
After a while loosen the clamp and the
Lock finished joint can be removed from the
machine.
3.2 Once the cooling time has elapsed
Pipe clamp the joint can be subjected to operating
conditions.
Spacing button
24 25
Butt welding machine Welding plate
for KELEN® PN10 1. Loosen the screws and fit the required
pipes reducers in the clamps
1.1 The end of the pipes should protrude
The table below is valid for the KELIT butt from the clamps by no more than 30 mm.
welding machine WZ115.
2. Put the surface cutter between the
If you use other welding machines pipe ends. Move the pipes together and
then follow the operating instructions remove the oxide layer on the welding
for that machine. surface by cutting away 0.2mm of the
Time to build up pressure surface. Ensure that the ends of the pipes
are vertically parallel to each other
Max. change-over time
Welding pressure
Heating pressure
Joining pressure
Surface cutter
Heating time
Cooling time
maximum deviation horizontally is 0.5
SDR series
mm.
Pipe
dxs bar mm bar sec sec sec bar min 3. The welding procedure
160 x 14,6 11 27 1,0 3 277 8 13 27 24
(see table on the left for welding criteria)
IMPORTANT:
3.1 Before welding begins read off the The pipes ends cannot be touched and
manometer the pressure required to bring must be welded immediately.
Hydraulic the pipes together. This pressure must be
control unit; If this is impossible and the welding has
added to the joining pressure given in to be done later then the welding surface
Plug connection the table.
for welding plate has to be cleaned and any grease
3.2 Insert the heating element (temp: removed.
and surface
approx. 210 C). Press the pipe ends on
cutter
the heating element and apply the pressure
as defined in 3.1 until a bead forms around
the complete circumference of the pipe.
During the heating time the pressure
must be reduced to the heating m
pressure. Once the heating time is over 30m
move the sliding blocks apart rapidly and
remove the heating element.
3.3 The change-over time (time
between removing the heating element
and welding the pipes) should be as short
as possible.
3.4 The welding pressure should be built
up as smoothly as possible during the time Never cool the joint abruptly.
given in the table (minimum: 0.15 If the weld has been done correctly a
N/mm2) double bead should be visible around the
3.5 The welding pressure must be whole circumference of the pipe.
30 mm maintained during the cooling time.
Pipe clamps
26 27
Overhead welding It is recommended to use the 1. Fix the pipe clamps to a pipe that 1.
overhead welding machine for has already been installed. The machine 1.1 1.3
machine exposed piping in confined areas will hang at the end of the pipe.
(d50 – d110). 1.1 To provide extra support the pipe
should be clamped close to a pipe bracket
1.2 A pole can be placed under the centre
of gravity to support the machine if
necessary.
Adjustable
pipe clamps 1.3 The pipe should protrude far enough
(d50 – d110) are out of the pipe clamp to ensure that the
Adjustable
mounted on pipe can be fully welded into the socket 1.2
fitting clamps
sliding blocks of the fitting but also allow enough space
(d50 – d110)
for the welding plate. 2. min. 100 mm
are fixed to
the machine The space between the pipe and the
fitting when the sliding block has
been completely rolled back should
be approx. 100 to 150 mm.
Centre of gravity
is marked below the machine
28 29
Special plumbing K85 KELEN® K85H KELEN®
solutions Joining set Fixing plate for
Polyfusion welding of the KELEN® pipe The set is used for fixing the outlets at
partition walls
system is both secure and quick. A lot the wall and consists of the following
A special system is required for installations
more time is spent fixing the pipes and items:
in front of the wall and in partition walls.
joining to the faucets. The are some ● Metal plate (2.5 mm thick)
practical solutions which can make the ● Wall brackets: KE83 d 20 or By cutting the K85 H plate to the required
job easier for the plumber. d 25 x 1/2" and double peg fitting length it is possible to arrange the plate
● Sound insulation caps
so that the fittings are fixed in the required
Method of installation: ● Elastomer sound insulation pads
positions.
● Partition wall installation ● Plastic stoppers
● Pegs and screws
● Brick wall installation The fitting is fixed to the double peg fitting
● Connection to d 50 siphon trap and
● Installation in front of the wall K86 D behind the plate.
d 30 rubber nipple is optional
● Set available for single outlet or
for double outlet (80-100mm or
150 mm)
KE86 D
50 mm
50
m
m
50 mm
m
m
10 mm
50
K86 HA Faucet plate
The faucet connection fitting KE83 HA
has the following properties:
● No transmission of energy
to the plaster board
● The holes are octagonal to prevent
twisting of the fitting
● The torque force on both fittings
is balanced by the fixing plate
● The octagonal holes mean that the
K85K sound insulation cap for KE83. fitting can be fixed in every position
For special applications the metal The cap does not fix the fitting. ● Sound insulating pad is completely
plate is available separately A special solution is required for fixing covered with PE soft foam Settings: 80, 100, 150 mm
(ref: K85 A) the fitting and the cap.
32 33
Pipe sizing Guidelines for pipe 3. Use of total flow rate / peak
flow rate
Pressure losses in sizing (DIN 1988/3) The design flow rate of all draw-off points
KELEN® pipes 1. Determine the design flow rate
shall be included in the design of water
supply system, adding the flow rate of
The total pressure loss (Δp) in the and minimum flow pressure for all
the draw-off points for which continuous
KELEN® pipe system is calculated by the draw-off fittings
use is to be assumed to the peak flow rate
multiplying the friction loss (R) by the The design flow rate VR is derived from
length of the piping (l) plus the sum (∑) of the other draw-off points
the draw-off fitting flow rate. The table (continuous use being defined as use
of the friction losses for the individual
fittings (Z). below gives guideline values for the design lasting more than 15 minutes).
flow rate of common types of fittings and Assumptions regarding simultaneous
Fitting Symbol Coefficient appliances. The design flow rate VR may demand are to be based on the type of
ζ be determined as a mean value using the building or its occupation (e.g. residential
The choice of pipe size for the water following equation. building or communal facility).
supply is dependent on the following Normally it may be assumed that not all
factors: draw-off fittings are fully open at the
● The available water pressure same time.
● Geodetic difference in height The conversion curves for the different
● Pressure losses through system applications are shown on pages
components 40 and 41.
● Minimum flow pressure through
faucets 2. Determine total flow rates and
● Pressure losses in the pipes assign to pipe runs
● The individual pressure losses of the 4. Determination of pipe diameter
fittings The design flow rates for all draw-off
● Type, number and simultaneous use points shall be added, starting at the draw- Determine the pipe size, pressure loss and
of the draw-off points off point furthest from the water main flow velocity (see tables on pages
● Flow velocity and ending at the water main, and the 37 to 39).
Note: total flow rates so obtained assigned to
For the purpose of pipe sizing it is assumed the pipe runs considered, each run
that that there will be no reduction in the extending from the fitting where the total
G flow rate or pipe diameter changes until
internal diameter caused by incrustation 5. Evaluation of head loss in terms
since the surface structure of the pipe is the next fitting. of available pressure
amorphous and the surface roughness of
the pipe is minimal (0,007). The head loss shall be almost equal to
At the junction of the cold water
but not greater than the available total
Maximum flow velocity pipe feeding the water heater with
S head loss.
according to DIN 1988 the pipe that branches off, the total
flow rate comprises that of the cold
Maximum design flow
velocity for a given pipe run ≤ 15 min >15 min and hot water side.
m/s m/s
Service pipes 2 2
Supply mains:
pipe runs with low head loss
in-line valves ( ζ < 2.5) 5 2
In-line valves
with greater
loss factor 2,5 2
34 35
Guidelines for pipe Pressure losses The pressure losses are calculated
according to the Nikuradse formula:
sizing (DIN 1988/3) PN10
The method for calculating the pressure
loss of the individual fittings is described
on page 34. Surface roughness: 0,007 mm
6. Minimum flow pressure and
design flow rate for typical draw-
off points and appliances.
36
Pressure losses The pressure losses are calculated Pressure losses The pressure losses are calculated
according to the Nikuradse formula: according to the Nikuradse formula:
PN16 PN20
The method for calculating the pressure The method for calculating the pressure
loss of the individual fittings is described Surface roughness: 0,007 mm loss of the individual fittings is described Surface roughness: 0,007 mm
on page 34. on page 34.
38 39
Excerpt from Excerpt from
DIN 1988/3 DIN 1988/3
30 30 30 30
5
C B 5 5 5
4 4 4 4
3
D 3 3 3
2 2 2 2
1,5
B 1,5 1,5
K 1,5
1
A
1 1 F 1
Calculating the peak flow rate V̇S Calculating the peak flow rate V̇S
Residential buildings Special case Hotels, department stores and Other special buildings, commercial
An additional wash basin, sitz bath, WC, If the system is equipped with draw-off hospitals and industrial premises
urinal and bath tub (in addition to the fittings with a design flow rate of more If the system is equipped with draw-off Particular considerations must be given
bath tub) need not be allowed for in than V̇R ≥ 0,5 l/s then, where the total fittings with a design flow rate of more to the extent to which simultaneous
determining the total flow rate if it may flow rate is between 0,5 l/s and than V̇R ≥ 0,5 l/s then, where the total demand is to be assumed for water supply
be assumed that the level of simultaneous 1,0 l/s the peak flow rate shall be flow rate is ≤ 1,0 l/s the peak flow rate systems on commercial and trade
use will not be increased by the use of deemed to be equal to the total flow rate. shall be deemed to be equal to the total premises. The total flow rate is determined
these appliances. If the total flow rate is ≥ 1,0 l/s or more flow rate. If the total flow rate is in consultation with the operator of the
curve B shall be used. >1,0 l/s and ≤ 20 l/s curve K system.
Schools (equation: V̇S =(∑V̇R)0,366 in l/s) is used
The peak flow rate is deemed to be equal for calculating the peak flow rate.
to the design flow rate where ∑ VR does
not exceed 1,5 l/s.
40 41
Expansion behaviour Expansion arm for Heat expansion chart (unhindered linear expansion) l
Comparison of 2400 d 90
2300
materials Example:
2200
A d 50 mm pipe runs over a length of d 75
Coefficient of E-module 60°
expansion 15 m. t = 35°C 2100
= mm/m°C N/mm2 Question: How long does the expansion 2000
d 63
Galv. steel 0,012 220 000 arm have to be to compensate for the 1900
Stainless steel 0,015 200 000 expansion? 1800
d 50
Copper 0,016 130 000 1700
KELIT Alu comp.* 0,035* 3 500 1600
d 40
PVC 0,080 1 100 1500
KELEN 0,150 300 1400 d 32
PEX 0,175 540 1300 d 25
* d 63 and above = 0,050 1200 d 20
Length of piping l
1100
1000
900
d 50 mm
800
FP MS 700
600
This means that when heated 500
KELEN® will expand more than metal 400
materials if the expansion is FP 300
unhindered. 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
42 43
The E-module of PP-R (like any other Practical solutions
Force of heat plastic) is dependant on the temperature
expansion (see graph below) for compensating
> Temperature: < E-module expansion
The force of linear expansion is different < Temperature: > E-module
for each material. The specific force of As the temperature increases the E-module The following methods can be used to ● Pipe channels may be used to increase
heat expansion is calculated according to decreases. control the linear expansion and the force the stability of the pipe.
the following formula: of expansion: The expansion is reduced to the same
E-module of PP-R in relation to the value as steel pipes.
operating temperature tm ● Piping that is embedded in the
wall or the floor is prevented ● The strength of the fixed points should
from expansion by frictional be sufficient to compensate the
The force of heat expansion is force. No extra measures are expansion force.
dependant on the dimension of the required.
pipe and the change in temperature ● The specific expansion can be
but not on the length of piping. ● Compensation must be made minimised by installing the KELIT ALU
An important factor is the rigidity of the for expansion of exposed piping composite pipe (d 20 – d 90),
material (E-module) especially on long pipelines.
● Even if the rise in temperature is only This pipe reduces the expansion by
for a short time sufficient approx. 75%.
compensation must be made for this
temperature difference
Comparison of the materials: (see pages 42, 43, 46 and 47)
If unhindered KELEN® pipes will
expand more than metal materials ● Every change in temperature will exert
under the influence of heat. The a force.
force of heat expansion, however, > An expansion force will occur when
is much smaller! the temperature rises.
< A shrinking force will occur when
Force of expansion (Ft) the temperature falls.
Dimension Linear expansion
25 x 3,5 KELEN®
25 x 3,5 PEX/VPE
44 45
Installing KELEN® 3. Exposed piping
3.1 Preventing expansion by In order to achieve this stability all of the
1. Installing the pipes in the shaft mechanical restraint d 20 – d50 pipes must be supported by pipe channels
In practise the main risers can expand and contract and all of the brackets must be fastened
laterally in the shaft between two floors if a fixed point
For aesthetic reasons KELEN ALU pipes tightly to the pipe to make them fixed
is located next to the pipe that branches off from the
main pipe. The distance between two fixed points should are often preferred for exposed pipes points. In addition the channels are fixed
not exceed 3 m. Other methods can be used to below d 63. Greater stability can be to the pipe (e.g. using cable ties) except
accommodate expansion such as an expansion arm in obtained by installing the pipes in steel for the sizes d 20, d 25 and d32 as the
the pipe branching off from the riser. channels. channels for these sizes are self-locking.
This method reduces the linear expansion
2. Embedding the pipe to the same amount as steel.
Piping that is embedded in the wall, floor screed etc….
is prevented from linear expansion. The material can
absorb the pressure and tensile stress without causing
any damage. If the pipes are insulated then the
insulation material provides further room for expansion. max. 180 cm
3.2 Expansion loops d 63 – 110 The fixed points are arranged so that the
Guidelines for distance between pipe piping is divided into sections and the
All changes in the direction of the pipe
support points expansion force can be guided in the
can be used to accommodate the linear
The distances between the support points given below expansion. In some cases an expansion desired direction. See pages 42 –45 for
(in cm) prevent KELEN® pipes from sagging when loop will be necessary. the calculations of the length of the
they are filled with water and there are NO pipe expansion arm.
channels.
MS
SP SP
FP FP
46 47
Pressure testing b) Preliminary testing Drinking water – Pressure test report
for drinking water The test pressure is equal to the maximum
operating pressure of the system plus 5
systems bar (minimum: 15 bar). The test pressure Location:
must be built up over a period of 30
KE KELIT recommends pressure testing to minutes. Within the 30 minutes the Project:
DIN 1988/2 for plastic pipes as stated pressure should be re-adjusted 2 times
below. (each time 10 minutes apart). After a Length of piping: d 16 _____ m Length of piping: d 63 _____ m
As a result of the material properties of further period of 30 minutes under Length of piping: d 20 _____ m Length of piping: d 75 _____ m
plastic pipes the pipe will expand during pressure testing there should be no leaks
Length of piping: d 25 _____ m Length of piping: d 90 _____ m
the pressure testing. The pressure testing and the drop in pressure should not
exceed 0,6 bar. Length of piping: d 32 _____ m Length of piping: d 110 ____ m
is split into a preliminary test and a main
test. The preliminary test is sufficient for Length of piping: d 40 _____ m Length of piping: d 125 ____ m
small sections of the piping such as c) Main testing
Length of piping: d 50 _____ m Length of piping: d 160 ____ m
connecting pipes and distributing pipes The main testing should be carried out
in the wet rooms. immediately after the preliminary testing. Test: Yes No
The duration of the test is 2 hours. The
a) Preparation drop in pressure between the end of the Visual check:
preliminary testing and the end of the 2
1. After the pipes have been installed hour main test must not exceed 0,2 bar. Test pressure: ___ bar (minimum: 15 bar)
and before they are concealed the
piping is filled with water and any air After the pressure testing has been
Preliminary test:
removed. completed we recommend issuing a
Testing time = 60 min.
2. If possible the pump should be placed confirmed report. ___ bar (max. pressure drop: ≤ 0,6 bar)
Pressure after 1 hour:
at the lowest point in the system
3. The manometer should be capable Please note:
Main test:
of reading changes in pressure of ● Fluctuations in the temperature
Testing time = 120 min.
0,1 bar and should be placed at the may alter the test pressure ___ bar (max. pressure drop: ≤ 0,2 bar)
Pressure after 2 hours
lowest point of the section of piping ● Every pressure test is an
being tested. assessment of the current state Location of highest outlet: ___ m above the manometer
of the system and is no
guarantee against any mistakes Ambient temperature: ___ ° C
made during installation.
The piping is free of leaks:
Complaints:
Confirmation
Person in charge:
Client:
signature/stamp
48 49
Technical rules Heat insulation for
for drinking water potable water pipes
Assuming that the design and installation Drinking water pipes (cold)
has been done professionally we Cold water pipes need to be insulated
recommend that the following guidelines against warming and condensation.
are followed. It must be ensured that the water quality
is not reduced as a result of the water
Rinsing Sound control warming.
After pressure testing the drinking water DIN 4109 recommends the following DIN 1988/2 specifies the minimum
pipes must be rinsed. measures: insulation thickness for potable water
Depending on the size of the installation pipes when the medium temperature is
● Use low-sound faucets
and how the piping is run the system assumed to be 10°C.
should be rinsed in sections from the ● Avoid direct contact between pipes
bottom to the top. and other sound transmitting
Each riser is rinsed in turn and the length bodies when fixing the pipe.
of piping should not exceed 100 m. ● Avoid high pressures and high
DIN 1988/2, table 10, specifies the flow velocities
minimum number of draw-off points that ● Special measures should be taken
have to be opened. Under normal for sound sensitive areas
circumstances all draw-off points should
be opened. The rinsing time depends on ● Cover with sound reducing
the length of piping and should not be insulation
less than 15 seconds for each metre of ● KELEN LX pipes
pipe. The rinsing time at each draw-off (4 mm or 9 mm insulation)
point should be at least 2 minutes. After The bubble structure of the insulation
the pipe has been rinsed for approx. 2 provides excellent protection
minutes at the last draw-off point all the against sound transmission.
draw-off points are closed in the reverse The high strength of the insulation
order to which they were opened. cover provides a long term
barrier between the pipe and other
sound transmitters.
Drinking water pipes (hot)
We recommend that hot water pipes are
insulated in accordance with DIN 1988/2.
If there is no requirement for hot water
in circulation it is usually possible to do
without insulation for pipes up to 25 mm.
50 51
Summary of the 4. 7. 11.
instruction guidelines Any corrections to the Avoid using heat to The following
alignment of pipe and bend the pipes precautions can be
fitting up to a (it is possible to bend made to ensure that
maximum of 5 must the cold pipe to a the maximum
1. be made during the welding procedure radius of 8 x d). If the pipe has to be operating temperature is not exceeded:
The KELEN® pipe (see pages 18 – 25 for the permissible heated then only use hot air. Never heat • Monitor and regulate solar energy
system is made of time for adjustments). Any later corrections the pipe with a naked flame! storage.
plastic and needs to be will damage the joint. Maximum temperature for bending • Check the electric connections to the hot
treated carefully to the pipe: 140 C water storage before the system is
prevent shocks and impact on the pipe operated.
during transportation, storage and 8. • We recommend installing in the hot
installation. 5. Try to make the joints water piping a mixer valve which is
Do NOT screw any for standard sections regulated by the boiler.
threaded pipes or any of piping at the work
cast iron fittings into bench before they are
the female threads of installed. This saves time and increases
2. the metal moulded fittings. the security of the system. 12.
Protect the pipes, Only join to faucets and components with In order to qualify for
fittings and straight threads. The threaded joint can guarantee cover each
components from be sealed by the usual methods (hemp, 15
20
25
9. installation must use
Once the system has
lengthy exposure to paste, tape …). 10 30 KELEN® system parts
been installed it
direct UV radiation from the sun. Do not over twist the threads. bar only.
5 35 should be subjected to
0
The usual time required for storage and pressure testing.
installation will have no effect on the You can copy pages 48 and 49 of the
material as it is stabilised against UV rays catalogue to make a test report.
but the material is not resistant to long- 6. 13.
In order to install the
term UV exposure. The expansion of 10. KELEN® system
KELEN® pipes is 90 °C • A temperature of
CL2 90°C for short periods correctly a minimal
clearly defined and
O3 of time is NO problem amount of
must be accounted for
for KELEN. Higher expenditure is required for tools For your
3. in the design and installation of the system.
temperatures over own security we recommend that you use
The welding machines Please refer to pages 42-47 regarding and maintain the tried and trusted tools.
longer periods of time should be avoided.
are regulated to the methods of accommodating the The pipe system is suited for thermal
operate at 260 C. expansion of exposed piping disinfection.
Welding times • KELIT Alu composite pipe (page 14) • The gradual or continual (max. 6
are based on an ambient temperature • Pipe channels (page 47) months) disinfection of the pipe system
of 20 C. • Expansion loops (pages 42 and 43) with chlorine dioxide, chlorine or ozone 14.
is only permitted for the cold water system If you are in doubt do
If the ambient temperature changes the For longer sections of piping the fixed
and after consultation with KE KELIT. not hesitate to consult
time required to push the pipe and fitting points can be located in such a way that
• Excessive concentrations are not only our technicians.
on to the heating elements (before the the system is split into expansion zones.
threatening to health they can also cause There is not always a
heating time begins) may alter slightly.
Suppliers of pipe clamps and brackets premature ageing of pipe systems. perfect solution but we can always help.
offer a wide range of solutions. • Copper und copper ions have a
destabilising effect and their presence in
the system should be avoided.
52 53
KE02-LX4 KELEN® LX-SENSO pipe PN10 KE 10 Socket
d s di IS L Weight V di z t AD BL VP
mm mm mm mm m kg/m l/m mm mm mm mm mm Pcs
20 1,9 16,2 4 4 0,14 0,21 20 1,5 15 29 33 10
25 2,3 20,4 4 4 0,20 0,33 25 1,5 20 36 43 10
32 2,9 26,2 4 4 0,30 0,54 32 1,5 24 46 51 10
40 1,5 27 54 57 5
50 2 28 68 60 2
63 2 29 85 62 1
75 2,5 30 101 65 1
diagram for all KELEN® LX-SENSO pipes 90 3 34 121 74 1
110 5,5 37 145 85 1
125 10 40 165 90 1
KE08-LX4 KELEN® LX-SENSO pipe PN16
d s di IS L Weight V
mm mm mm mm m kg/m l/m
20 2,8 14,4 4 4 0,18 0,16 KE 20 Elbow 90
25 3,5 18,0 4 4 0,26 0,25 di z t AD VP
32 4,4 23,2 4 4 0,40 0,42 mm mm mm mm Pcs
20 11 15 29 10
25 16 20 36 10
32 20 24 46 10
KE08-LX9 KELEN® LX-SENSO pipe PN16 40 25 27 54 5
d s di IS L Weight V 50 30 28 68 2
mm mm mm mm m kg/m l/m 63 36 29 85 1
20 2,8 14,4 9 4 0,22 0,16 75 41 30 102 1
25 3,5 18,0 9 4 0,30 0,25 90 50 34 122 1
32 4,4 23,2 9 4 0,44 0,42 110 58 37 145 1
125 84 40 165 1
56 57
KE 26 Elbow 90 (male/female) KE 35 Reducer tee
d/di z t z1 t1 AD VP di di1 z t z1 t1 AD BL VP
20 11 15 33 15 29 10 25 20 16 20 16 15 36 68 10
25 16 20 42 20 36 10 32 20 20 24 26 15 46 84 5
32 20 24 42 22 43 5 32 25 20 24 22 20 46 84 5
40 20 25 27 27 15 54 94 5
z1
t1 40 25 25 27 24 20 54 94 5
40 32 25 27 26 24 54 94 5
d 50 20 30 28 32 15 68 112 2
z
50 25 30 28 28 20 68 112 2
t 50 32 30 28 30 24 68 112 2
di 50 40 30 28 29 27 68 112 2
AD 63 25 36 29 40 20 85 128 1
63 32 36 29 36 24 85 128 1
63 40 36 29 37 27 85 128 1
KE 27 Elbow 45 (male/female) 63 50 36 29 36 28 85 128 1
d/di z t z1 t1 AD VP 75 32 41 30 42 24 102 142 1
mm mm mm mm mm mm Pcs
75 40 41 30 41 27 102 142 1
20 11 16 31 16 29 10 BL
t z
75 50 41 30 40 28 102 142 1
25 18 20 33 20 36 10
75 63 41 30 39 29 102 142 1
z1
z 90 63 50 34 54 29 122 166 1
t AD di
t1 z1 90 75 50 34 50 30 122 166 1
t1 110 63 58 37 70 29 145 195 1
110 75 58 37 68 30 145 195 1
di d di1
AD 110 90 58 37 65 34 145 195 1
125 75 84 40 74 30 165 248 1
125 90 84 40 72 34 165 248 1
125 110 84 40 73 37 165 248 1
di1
58 59
KE 38 Manifold tee (male/female) KE 47 Saddle fitting
di/d di1 z t z1 t1 AD BL VP d di t AD BH VP
25 20 13 20 16 15 36 71 10 40 20 15 36 29 5
40 25 20 36 29 5
50 20 15 36 29 5
50 25 20 36 29 5
63 20 15 36 29 5
BL 63 25 20 36 29 5
z t
d
75 20 15 36 29 5
AD di 75 25 20 36 29 5
d di AD 90 20 15 36 29 5
z1
90 25 20 36 29 5
t
t1 110 20 15 36 29 5
BH
di1 110 25 20 36 29 5
KE 90 Curved pipe
d z AD BL VP
mm mm mm mm Pcs
20 215 45 430 10
25 215 48 430 10
32 215 55 430 5
11 09 04
AD
d
z
BL
AHA!
60 61
KE 83 Wall bracket 90 (female) KE81 LA LA Wall bracket 90 (male) 50 mm
di IG z z1 t AD BL VP di AG z t t1 K BL VP
mm Inch mm mm mm mm mm Pcs
20 1/2" 13 21 15 41,5 48,5 10 20 1/2" 13 15 50 43 98 10
20 3/4" 17 26 15 46 57 10
25 1/2" 17 26 20 46 57 10
25 3/4" 17 26 20 46 57 10 di
t
di
z
t
K AG
z
DO NOT join to any threaded AD IG
pipes or cast iron fittings! t1
BL
z1
BL
KE 83 HA Partition wall fitting 90 (female) 50 mm K84 Fitting for partition wall connection
di IG AG z t t1 K BL SW VP IG AG AG t BL SW VP
mm Inch mm mm mm mm mm mm mm Pcs Inch Inch mm mm mm mm Pcs
20 1/2" M28x1,5 13 15 50 43 98 30 5 1/2" 1/2" M 28x1,5 50 64 30 5
di
t
AG1
z SW IG AG
K SW AG IG
20 1/2" 18 15 45 45 - 10 20 1/2" 13 15 21 42 - 10
20 3/4" 18 15 45 45 - 10 20 3/4" 13 15 21 42 - 10
25 1/2" 16 20 45 45 - 10 25 1/2" 17 20 21 46 - 10
25 3/4" 16 20 45 45 - 10 25 3/4" 17 20 21 46 - 10
32 3/4" 25 24 60 68 - 5 32 3/4" 20 24 21 46 - 5
32 1" 22 24 60 68 39 5 32 1" 20 24 38 61 39 5
40 1" 25 27 76 70 39 2 z1
SW IG di AD 40 11/4" 26 27 76 71 48 2
50 11/2" 28 28 82 71 56 1
63 2" 38 29 97 86 70 1 DO NOT join to any threaded AD SW IG
z t z
75 21/2" 44 30 123 96 88 1 pipes or cast iron fittings!
BL t
AD SW AG
z SW AG z BL
t t
di di
AD
KE 43 Saddle fitting (female)
d IG AD BH VP
mm Inch mm mm Pcs KE 31 LA LA Tee with male thread 50 mm
40 1/2" 36 29 5 di AG z t z1 t1 AD BL VP
50 1/2" 36 29 5 mm Inch mm mm mm mm mm mm Pcs
63 1/2" 36 29 5 20 1/2"BF 13 15 85 50 29 54 10
75 1/2" 36 29 5
90 1/2" 36 29 5
110 1/2" 36 29 5
AG
z
d
t
AD IG
t1 di
DO NOT join to any threaded AD
BH pipes or cast iron fittings! BL
64 65
KE 33 Tee with female thread KE50 A Valve with stopper
di IG z t z1 AD BL SW VP di IG z t t1 AD BH VP
z1
IG
z
t
SW IG BL
z All common stems are compatible di
t with the valve. AD
DO NOT join to any threaded di
pipes or cast iron fittings! AD
KE50 P Stop valve with stopper
KE 33 HA Tee with female thread for partition walls di IG z t t1 AD BH VP
mm Inch mm mm mm mm mm Pcs
di IG AG z t t1 AD BL SW VP
mm Inch mm mm mm mm mm mm mm Pcs 20 3/4" 23 15 58 37 78 1
20 1/2"BF M28x1,5 13 15 50 29 99 30 10 25 3/4" 23 15 58 37 78 1
32 3/4" 21 18 58 43 78 1
BH
t1
S W AG IG
z
IG
t z
t1 di t
DO NOT join to any threaded AD
di
pipes or cast iron fittings! BL
AD
IG AG R
z
R
t
di
AD
66 67
K50 F Stem for KE50 A and KE50 P KE55 Union (plastic - metal)
AG BL AD SW VP d AG z t z1 BL SW SW1 VP
mm Inch mm mm mm mm mm mm Pcs
3/4" 45,5 50 17 1 20 1/2" 42 17 33 75 36 23 5
25 3/4" 49 20 40 89 46 30 5
32 1" 55 26 44 99 52 37 3
40 5/4" 85 50 52 137 66 45 2
50 6/4" 85 50 58 143 70 55 1
63 2" 85 50 65 150 86 66 1
AD AG SW 75 2 1/2" 90 50 68 158 108 80 1
BL
z1 z
90 3" 90 50 73 163 122 94 1
BL
t
SW1 AG d SW includes drainage and replaceable EPDM seals!
K50 S Extension to K50 C
IG AD BL VP
Inch mm mm Pcs
1/2" – 3/4" 26 150 1 KE56 Union (plastic - plastic)
d z t BL SW VP
mm mm mm mm mm Pcs
20 42 17 84 36 5
25 49 20 98 46 5
32 55 26 110 52 3
40 85 50 170 66 2
IG
50 85 50 170 70 1
AD 63 85 50 170 86 1
BL 75 90 50 180 108 1
BL z z 90 90 50 180 122 1
t
d d SW
KE52 Slanted seat valve with KE57 union includes drainage and replaceable EPDM seals!
union d DN AG z t BL BH SW VP
mm Inch mm mm mm mm mm Pcs
20 15 1" 84 17 168 110 36 1 KE57 Union with female thread
25 20 5/4" 95 20 190 130 46 1 d IG z t BL SW VP
32 25 6/4" 107 26 214 155 52 1 mm Inch mm mm mm mm Pcs
40 32 2" 147 50 294 180 66 1 20 1" 44 17 53 36 5
50 40 21/4" 155 50 310 190 70 1 25 5/4" 50 20 60 46 5
63 50 23/4" 165 50 330 225 86 1 32 6/4" 56 26 67 52 3
40 2" 87 50 103 66 2
BL 50 2 1/4" 87 50 103 70 1
z z
63 2 3/4" 87 50 103 86 1
t t BL
SW AG d includes drainage and replaceable EPDM seals! 75 3 1/4" 93 50 114 108 1
z
t 90 3 3/4" 93 50 115 122 1
BH
SW IG d
includes drainage and replaceable EPDM seals!
68 69
K17 E-Uni Welding socket KE 85 Joining set
di z t AD BL VP Setting Dimension VP
mm Pcs
20 1,5 26 48 55 1 Single outlet d20 x 1/2" 1
25 1,5 26 54 55 1 80 – 100 d20 x 1/2" 1
32 1,5 25 62 53 1 80 – 100 d25 x 1/2" 1
includes cleaning tissue 40 1,5 25 70 53 1 150 d20 x 1/2" 1
50 1,5 25 80 53 1 150 d25 x 1/2" 1
63 1,5 30 94 63 1
di AD 75 2 33 107 70 1
90 2 36 121 76 1
110 2,5 41 143 87 1
z t
Includes KE83 with sound insulation,
BL
stoppers, metal plate, pegs and DO NOT join to any threaded
screws. pipes or cast iron fittings!
d1 d
d
BL
AD d
BL
BL
z
d
BH
z1
d1
72 73
Accessories K85 K Sound insulation cap
K19 A Flange seal set d di D AD BL VP
mm mm mm mm mm Pcs
d Holes VP 20 41,5 53 75 52 10
mm Pcs Pcs
25 46 53 75 60 10
20 4 1
25 4 1
32 4 1
40 4 1 Sound insulation for KE83.
D di AD
50 4 1 Does NOT fix or secure the fitting.
63 4 1
75 4 1 BL
90 8 1
1 set consisting of screws, bolts, 110 8 1
washers and EPDM seal. 125 8 1 K86 L Perforated plate
160 8 1 BL BH ST VP
mm mm mm Pcs
2000 60 3 1
KE99 Repair plug
d BL VP ST
mm mm Pcs
7 – 11 120 10 Steel plate for securing fittings BH
in all positions.
BL
K85 A Rail
Setting A1 A2 AL BL BH BT ST R VP
K86 D pegs for K86L
mm mm mm mm mm mm mm mm mm Pcs VP
Einzel. - - - 228 60 45 3 - 1 Pcs
80-100 80 100 210 456 60 45 3 - 1 10
74 75
K88 Pipe channel KELIT tools
di s L VP WZ100 Welding set
20 0,6 2000 20 Pipe welding machine 230 Volt, 800 Watt
25 0,6 2000 20 Includes case, table clamp and floor rest
L
32 0,6 2000 20 Heating elements: d20 – 32 mm
40 0,6 2000 10 Pipe cutters d16 – 40 mm.
50 0,8 2000 10
63 0,8 2000 10
di s
75 0,8 2000 10
90 0,8 2000 10
Galvanised steel - d20, d25
110 0,9 2000 10
and d32 have clips to lock the
pipe into the channel.
WZ110 Pipe welding machine
Pipe welding machine 230 Volt, 1000 Watt
Includes case,
K95 Stopper heating elements d 20 – 90 or d 25 – 125,
Pipe cutters d 20 – 75, d 50 – 140,
AG BL AD IB VP special gloves and pipe rests.
Inch mm mm mm Pcs Packaged in transport crate.
1/2" sh 22 32 12 10
1/2" lg 32 58 12 5 Type 1 d 20 – 90
3/4" lg 42 58 12 5 Type 2 d 25 – 125
76 77
WZ129 Timer WZ128 Repair welding tool
For setting and checking the welding times d VP
of d20 – 110
7 1
11 1
78 79
WZ140 E-socket welding machine WZ150 Alu peeler
d
mm
For welding the E-UNI welding socket 20
K17. Hand scraper included. 25
d VP 32
mm Pcs 40
20 – 110 1 50
63
75
90
For peeling KELIT ALU composite pipes K06
before welding. Remove the screw to extend the
peeling area if the pipe is going to be welded to
an E-UNI socket K17.
Peeler can be connected to a drill.
75
d 75 – d 110
100
For shaving the surface of the pipes 120
before electrofusion welding. 150
200
240
80 81
I N N O VATI V E P IP E S Y S T E MS I N N O VATI V E P IP E S Y S T E MS
Partners worldwide ”There is hardly anything in this world that It is imprudent to pay too much but it is
somebody cannot do a little bit worse and worse to pay too little. When you pay too
sell at a lower price. People who are only little, sometimes you lose everything since
dictated by price are easy prey for such the object you have bought cannot fulfil
machinations. the task it has been set. According to the
law of the economy it is not possible to
acquire high value with little money.