Planning manual 2013 1 4 clina heiz- und kühlelemente gmb-h

All rights reserved by the manufacturer. Particularly those with reference to technical alterations. (01/2013)

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I n d e x - P l a n n i n g M a n u a l

1 Introduction

1.1 The environment and our responsibility

1.2 New approaches in the air conditioning of buildings

2 Plastic Capillary Tube Systems – Function Principles and Features

2.1 Description of function of Clina-surface cooling or heating systems

2.2 System separation

2.3 Application areas of Clina-capillary tube systems

2.4 Control concept

2.5 Plant and control schematic

2.6 Advantages in comparison with conventional systems

3 The System Components - Description and Technical Data

3.1 Polypropylene – material data and characteristics

3.2 Clina capillary tube mats made of PP

3.3 Clina adhesives for fixation of the capillary tube mats in metal ceiling plates

3.4 Clina socket connections

3.5 Clina connecting hoses

3.6 Clina supply + return lines made of PP, with welded socket connections in the works

3.7 Distributing lines made of PP

3.8 Valves for control on water side and for hydraulic balancing

3.9 Transfer station / storey distributing station with heat exchanger, pump etc

3.10 Clina dewpoint monitorin

3.11 Clina room temperature control

3.12 Tools and assembly kit


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4 Planning and Design of Clina-Capillary Tube Systems

4.1 Application: COOLING CEILING

4.1.1 Cooling ceilings with or without ventilation

4.1.2 Room temperature

4.1.3 Room air humidity

4.1.4 System temperatures for ST (supply) + RT (return)

4.1.5 Ceiling type / design and construction

4.1.6 Mat type

4.1.7 Dischargeable specific cooling capacity

4.1.8 Capacity of the cooling ceiling of a room

4.1.9 Mass flow and pressure loss of the Clina mat

4.1.10 Subdivisioning and allocation of zones

4.1.11 Piping connections and arrangement of the zone control groups

4.1.12 Determining the pressure loss and p of the plant

4.1.13 Design of the heat exchangers

4.1.14 Design of the pump


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1 Introduction

1.1 The environment and our responsibility One of the most predominantly discussed subjects at the present time is the attitude of humans to their environmental surroundings and the question as to how the environment can be given adequate and long-lasting protection. We should not forget that we as human beings increasingly determine and influence the environment with our production methods, consumer behaviour and daily lifestyle. As a result, the requirement and consumption of energy has a considerable influence on the climatisation of the areas in which we live. In the Federal Republic of Germany, for example, this amounts to approx. 40% of the primary energy consumption. A sustained securement of our living basics presupposes that we succeed in reducing energy consumption and that we use environment energy on a greater scale. The applied plant technology in the future will have key significance in our efforts towards this objective. It should be inexpensive with regard to costs and should not cause any additional contamination of the environment during manufacture, operation or waste removal. Read the facts and see for yourself how success has been achieved in making substantial progress towards this objective with the development of capillary tube technology using the material polypropylene, a plastic which can be completely recycled.

1.2 New approaches in the air conditioning of buildings The air conditioning of modern buildings at the present time is required to comply with very high demands. Classical systems such as ventilation plants or static heating systems reach their limits very quickly when an optimum state of comfort and a minimum space and energy requirement are demanded at the same time. The capillary tube technology has adopted a completely new approach in this respect. It orientates itself on the conditions of nature. Water carrying capillary tube mats made of flexible plastic are installed closely below the surface of the room enclosing surfaces. This produces a gentle temperation of ceilings, walls or floors. In this way, the energy transfer between the users and the activated surfaces takes place mainly by means of radiation, something which corresponds to the natural conditions during the regulation of the heat balance of all living species. For this reason, studies have proved that people working in rooms heated or cooled with Clina capillary tube systems feel better and are more productive.


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2 Plastic – Capillary Tube Systems Function Principles and Features

2.1 Description of function of Clina-capillary tube surface cooling or

heating systems Clina capillary tube mats are installed directly under the surface of one or several room enclosing surfaces – and these can be either the ceiling, the walls or the floor. For the cooling or heating of rooms, cold or warm tap water flows through the very thin capillary tubes having outer diameters of 3.4 or 4.3 mm. The surface areas with installed Clina mats are evenly temperated and provide for a quick withdrawal of the cooling loads or for a quick supply of the heat requirement, respectively, by about 60% through radiation and about 40% by way of convection. Due to the large exchange surfaces, considerable amounts of energy can be transferred without draughts and noise even with minor temperature differences between the active room surfaces and the room air. For COOLING purposes, Clina capillary tube mats are preferentially installed either in or on the ceiling; the surface temperature of the ceiling here is, depending on the supply temperature, approx. 19 °C at only 2 to 3 K spreading between supply (15 °C to 17 °C) and return (17 °C to 19 °C). Depending on the type of ceiling or its installed condition, up to 83.5 W/m² DIN-cooling capacity can be achieved here. Each control zone is equipped with one or several dewpoint sensors in order to safely exclude the existing danger of dewpoint sublevels and the subsequently related condensate accumulation involved with all surface cooling systems. As long as the sensor registers condensate, either the flow through the mats is stopped by a closure of the control valve or the supply temperature is gradually increased. Such a case rarely occurs in practice because cooling ceilings are frequently combined with a supporting ventilation plant in large and intensively used office buildings. This is necessary as a rule in order to provide all users with the required volume of fresh air as well as to extract the occurring material loads. The relative humidity is controlled here by way of the ventilation and maintained for the users in a comfortable and dewpoint noncritical range of approx. 50% relative humidity. The withdrawal of the cooling loads with this type of plant combination is performed by way of the cooling ceiling. For this reason, the air change rate can be reduced to the hygienically necessary minimum (approx. two to three times air change) and the ventilation plant considerably reduced in size. For HEATING purposes, warm water with a temperature between 28 °C and 30°C flows through the Clina capillary tube system. In this case, the surface temperature of the ceilings is in the region of 27°C. Even during the heating phase, the radiation energy from the human skin (temperature about 32 °C) is discharged to the ceiling. Studies have shown that, with a capacity of approx. 30-40 W/m², no losses to comfort are expected when heating with the room ceiling.


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Clina systems are, of course, thoroughly suitable for use as floor or wall heating purposes. In such applications, the heat-dispensing capillary tubes can be installed directly under the surface. Where floors are concerned, for example, the prefabricated Clina mats can be located under the tiles and above the load distributing layer. Due to their substantially larger surface, Clina capillary tube mats are much more efficient than conventional systems. This is evident from the fact that they require substantially lower supply temperatures in order to obtain the same heating capacity. Therefore, the Clina capillary tube technology is the ideal system for the utilization of regenerative energies, such as in combination with heat pumps or the utilization of solar energy. Furthermore, they allow the realization of extraordinary small build-up heights. As a result of the location and geometry of the capillary tubes, Clina floor heating is clearly more efficient than conventional systems.

2.2 System separation A main feature of the system is the oxygen diffusion through the PP capillary tubes which occurs up to a saturation of the oxygen concentration in the plant. In order to securely avoid an oxygen-related sludging, there is a system separation between the primary cycle with cold or heat generator and the secondary cycle by means of a high-quality stainless steel heat exchanger. This results in two completely separate cycles which are known as the primary cycle (generator to heat exchanger) and secondary cycle (from the heat exchanger to the mat). The heat exchanger is part of a compact transfer station in the secondary cycle which consists of the recycling pump and the expansion vessel, among other things. All components having contact with water in the secondary cycle must be made of corrosion-resistant materials such as plastic, bronze or brass. If this rule is upheld, a blockage of the capillary tubes is definitely excluded. As incoming oxygen causes no damage whatsoever, inhibitors are not required. In large buildings, several separate secondary cycles are frequently arranged which, for example, cover one storey or one structural component in each case. This mode of plant configuration has two practical advantages for the user: In the event of damage with subsequently related leakage, the water volume escaping is limited to a minimum. Only such an amount of water can leak out up to the point of depressurization in the respective secondary cycle. Moreover, capillary mats have only approx. 0.4 liters of water per square meter. Furthermore, with reconstruction or maintenance or operational disturbances, only small partial sectors of the plant have to be taken out of function and emptied if required.


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2.3 Application areas of Clina-capillary tube systems Clina-capillary tube systems are preferentially used in such areas where it is of utmost importance that the user be provided with optimum room conditions, meaning, air conditioned surroundings for personal comfort as well as from health aspects. Architectural reasons (space requirement, flexibility, concealed technical systems) as well as cost considerations frequently play a significant role. As a low energy system, the Clina capillary tube technology makes a significant contribution towards the reduction of operating costs and negative effects on the environment. Up to the present, these advantages were utilized particularly in large industrial office and bank buildings. But Clina mats have been used successfully for many years, not only in new buildings but also in the rehabilitation and modernization of buildings. Further information on the cooling ceilings is given in the reference lists (Chapter 5ff) which are arranged according to the various types. By way of the persistent and continued development of application options, we have now succeeded in being able to offer extremely attractive and interesting solutions even for small-scale objects and living accommodation, such as bio-Clina-floor heating or the convective Clina cooling columns and shafts. 2.4 Control concept In principle, Clina capillary tube systems are operated with a constant supply temperature. By means of an immersion sensor in the intake line of the plant, the system temperature is compared with the setpoint and the mass flow on the primary side is controlled accordingly. Depending on the hydraulic system of the primary cycle, this constant valve is either a 2-way or a 3-way valve. We do not recommend a control of the supply temperature by means of a sidestream mixture to the return line in the secondary cycle due to the narrow spreading. As a result of the low water content and the spreading of 2 K or 3 K, the zone control is effected as a two-point control (on/off). As a rule, a constant control of the mass flow is not considered practical as the two-point control is effective enough. Depending on the control signal of the room temperature controller, the electro-thermal actuator on the relevant zone valve either opens or closes. Zone temperature control occurs separately for each zone where the setpoint can have both central and decentral adjustment. A switchover between heating or cooling operation can also be carried out centrally. In addition, each zone is equipped with a dewpoint sensor. This has only the function of a safety device which either shuts off the zone where there is a danger of dewpoint sublevel – even if the room temperature is above the setpoint – or it gradually raises the supply temperature according to the relative humidity of the room and/or the enthalpy of the ambient air condition. With an increasing dewpoint, the sub-normal temperature of the system and also the capacity is reduced, but a continued operation of the cooling ceiling is possible. When the humidity in the room has dropped again and condensation is ruled out, the system returns to the normal control mode. The capacity of a cooling ceiling results from the mean sub-normal temperature to the room temperature, meaning, the higher this mean sub-normal temperature, the higher the capacity of the cooling ceiling. As in the case of floor heating, we can speak here of a self-control effect.


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2.5 Plant and control schematic

T

TR2/3

TR2/3

Zone 2 Clina-capillary tube mats

AG

regulating valve for hydraulic balancing

zone valve

room temperature controller heating / cooling

dew point sensor

principle sketch :plant and control schematic Clina – capillary tube system cooling

6°C

12°C 18°C

16°C

M

M

T

T

Zone 1 Clina-capillary tube mats

dew point sensor

ball valve


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2.6 Advantages in comparison with conventional systems Clina capillary tube systems made from PP offer their users in the following areas considerable advantages compared with conventional technical solutions: b e t t e r F U N C T I O N e a s i e r I N T E G R A T I O N h i g h e r O P E R A T I O N A L S A F E T Y l o w e r C O S T S r e d u c e d P O L U T I ON L E V E L S

T h e f u n c t i o n: Optimum sense of well-being Clina capillary tube systems function without draughts and are absolutely noiseless. For this reason, people speak of “systems of silent cooling“. The energy exchange by means of radiation is in full compliance with natural conditions and creates that full sense of well-being. In addition, the surfaces have a very uniform temperature profile without major fluctuations because of the small clearances between the Clina capillary tubes. This means that every user finds the exact identical conditions and that the “traditional” discussion on whether workplaces are better or worse from room-climatical aspects is now a thing of the past. No negative effects on health Conventional air conditioning units use cooled air for withdrawing the heat load. This is not the case with water-carrying Clina capillary tube systems. With the conventional systems, large volumes of air at temperatures well below normal level are blown into the rooms. This reduces personal comfort and is very often the cause of illness. In addition to the draught risk and noise disturbances, poor hygienic conditions in the air duct network are frequently a negative influential factor. Individual controlling with short reaction times Each zone can be individually controlled by means of room temperature controllers without any problems whatsoever. Setpoint adjustments bring about a perceptible change of the room conditions within a few minutes.


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I n t e g r a t i o n i n t h e b u i l d i n g: Non-visible technical elements Clina capillary tube systems have a small structural height and, for this reason, they can be fully integrated into room enclosing surfaces. Visible technical elements such as radiators or room cooling equipment can be completely dispensed with. Clina mats are permanently non-visible even in such cases where they are covered over with thin layers of plaster. Discolouring of the plaster surface, the socalled copper shadows, which frequently occur when metal tubes are plastered over, is not possible with capillary tubes made from polypropylene. Maximum flexibility Clina capillary tube mats are fabricated to size for practically all dimensions and characteristic forms. They have such a high degree of flexibility that they can be conveniently adapted to even dome-shaped surfaces or individual ceiling designs. The integration of cut-outs in the mat for attachments such as lamps, air ducts, fire extinguishers etc. is possible. Clina capillary tube mats give architects and planners practically unrestricted freedom with regard to design and layout. Minimum space requirement Not only the capillary tube mats themselves but also the entire system requires considerably less space than conventional technical systems. This fact becomes particularly evident when making comparisons with the usual ventilation type air-conditioning units. In order to transport a capacity of 10 KW, a air ventilation plant requires an air duct with the dimensions 530 x 400 mm (spreading 8 K at 5 m/s). As water is much more suitable for energy transport, Clina capillary tube systems require only a PP-line DN 50 (da = 63 mm) for the same performance. Convenient retrofitting The small overall height and the low weight of Clina capillary tube mats (with water max. 900 g/m²) do not require any special supporting structures and allow quick and trouble-free retrofitting into existing ceiling elements. Even when local conditions do not allow the installation of an intermediate ceiling, you do not have to do without a cooling or heating ceiling when using Clina capillary tube mats. In such cases, the capillary tubes are plastered into location directly underneath the concrete ceiling. As a result, the loss in height in the room is only 10 – 15 mm.


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O p e r a t i o n a l s a f e t y : Intensive quality assurance Clina capillary tube mats are manufactured from high quality special polypropylene. Each mat is subjected to quality control in our works at 20 bar air pressure and then intensively examined in a water bath for any possible leakage. This test pressure corresponds to approximately ten times the operating pressure. After assembly, the installed mats are again pressure tested locally at 10 bar. This pressure test is performed with air and water in accordance with a method specified by Clina. No blockage With Clina capillary tube systems, the water cycle through the capillary tube mats is always separated from the primary water cycle by a high-quality steel heat exchanger. In the secondary cycle, only corrosion resistant materials such as plastic, red brass, brass and high-quality steel are used. Unlike other systems available on the market, with the application of Clina capillary tube technology the formation of scale deposits in the piping resulting from oxidation products is technically impossible, even with oxygen diffusion through the polypropylene tube wall. Sludge through micro-organisms can also not occur due to lack of phosphor and nitrogen combinations. Limestone deposits at operating temperatures between 16 and 40 °C are physically ruled out. In Clina systems it is therefore ensured that water remains absolutely free of solids even after decades of operation. Self-venting Due to the narrow diameter and the surface tension of the water, the capillary tubes of the Clina mat are self-venting. Even with flows in a vertical and downward direction, the water drives the air bubbles in front of it, both during the filling operation as well as during the plant startup later. For this reason, it is not necessary to take the angle of inclination into account when installing mats in the ceiling. Easy to repair If a capillary tube mat is damaged, for example during drilling, the water would leak out until such time as the system is depressurised. This trickling water volume depends on the size of the expansion vessel and is normally only a few liters. As a rule, the damaged capillary can be easily uncovered, repaired with a soldering iron or welding mirror and then plastered over. The necessity of replacing complete surface elements, as would be the case with conventional tube systems, cannot occur with Clina capillary tube systems.


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T h e c o s t s : Economical As a rule, the investment costs are not substantially higher than those for conventional ventilation and air-conditioning plants. If the Clina capillary tube ceiling can be used also for heating purposes, for example in well-insulated office buildings, the investment costs are even more favourable. Where cooling operation is concerned, the consumption and operating costs are up to 40% lower compared with conventional air-conditioning plants. A key factor here is the transport costs for the cooling energy by means of air (high expenditure) and water (very economical). Capillary tube systems are practically maintenance-free and have only 1/5 to 1/7 of the pressure loss compared with conventional tube systems. Even compared with other cooling ceilings on the basis of copper cooling elements, Clina capillary tube systems offer considerable cost advantages where the user does not face any losses with regard to the function. Space saving The building owner gains up to 15% usable (effective) surface compared with conventional air-conditioning plants in buildings of a similar size. The reason is that the ceiling hollow spaces only have to be 10 to 15 cm high (=> possible reduction in storey height) and that machine rooms as well as shafts can be made significantly smaller. This is a considerable advantage, especially where the planning of new construction projects is involved. Long life service Long period creep tests and material tests have shown that a long period creep resistance of more than 50 years can be expected. Clina customers receive for each Clina mat, in accordance with the insurance terms and conditions, a 10 year full warranty which covers not only the replacement of the damaged product but also the installation and removal as well as the regulation of consequential damage. This warranty applies practically worldwide and is covered by a reputable insurance company. In this way, all risks are avoided both for the plant constructor as well as for the building owner.


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E n v i r o n m e n t a l p r o t e c t i o n: The temperation of surfaces with Clina capillary tube mats is much more efficient compared with conventional tube systems due to the small capillary tube clearance of 10 and 15 mm, respectively, and the large surface. This provides for an optimum energy transfer to the room. Consequently, only very small spreadings between the water temperature and the room temperature are necessary. Further energy savings result from the fact that the room temperature as perceived by the user with the use of radiation cooling and heating is about 2 to 3°C lower and higher, respectively, than the actual room air temperature. Significant energy savings when using Clina capillary tube systems are evident here also. For example, energy saving for a cooling ceiling with source ventilation can amount up to 40% compared with an “air-only-plant”. Furthermore, the production of Clina capillary tube mats is absolutely pollutant-free. No contaminated exhaust air or contaminated waste water result in the process. All production waste can be 100% recycled and used again. The manufacture of polypropylene requires considerably less amounts of primary energy compared with other materials. Copper requires 5 ½ times more, and aluminium even 8 times more primary energy. As can be seen from the following figures of comparison, the environmental pollution during the manufacture of polypropylene is significantly lower compared with metals such as copper. Pollution values during manufacture of polypropylene compared with copper

Material Air Water Ground

Cu 100 % 100 % 100 %

PP 10 % 30 % 15 %

Source: „Environmental analysis of drinking water installation systems“ by Prof. Käufer in the publication „Sanitation and Heating Technology“, special edition 1995

During the selective dismantling of buildings, Clina capillary tube mats can be conveniently removed and recycled to a high value result; subsequently, they fulfill the basic demands of the Recycling Economy Law which is applicable since 1996. No environment-relevant pollutants occur when polypropylene is burnt because polypropylene is built up on carbon and hydrogen atoms. Particularly where fires are involved, there are no toxic combustion products which could lead to permanent injurious effects for humans and animals, as well as to high costs for the decontamination of buildings.


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3 The System Components – Description and Technical Data

3.1 Polypropylene – material data and characteristics

3.1.1 Basic facts with reference to polypropylene

All Clina capillary tube mats are manufactured from polypropylene. Polypropylene results by means of polymerisation from propylene. Therefore, the polymer is exclusively built up on carbon and hydrogen atoms. Polypropylene has excellent characteristics for the construction of pipes and tubes, fittings and plastic heat exchangers. The Clina capillary tube mats made from polypropylene for use as cooling ceilings and ceiling heating have a life duration service of well over 50 years. Tubes from polypropylene are very smooth and are not porous. For this reason, unevenness of the surface is extremely low, a fact which results in low wall friction as well as reduced pressure loss. The material used for the manufacture of Clina mats is a high-molecular polypropylene-copolymer (random/copolymer) with high rigidity, hardness and tensile strength. The manufactured Clina mats are characterised by high flexibility and retain impact resistance at temperatures of 0° C. The outstanding material properties are: - resistance to corrosion, - low weight (9 times lighter than iron), - weldable with very good results, - low wall friction losses, - low level flow noise, - suitable for high pressure stress, - good thermal insulation properties ( = 0,21 W/mK), - high resistance to aggressive flow media and structural materials, - high shape stability under heat influence, - hygienically unobjectionable, - no stress crack formation, - non-conductive, - very good resistance to thermal ageing, Based on the constant examination of the guaranteed quality, Clina grants a 10 year warranty by way of a product liability insurance for all Clina mats made from polypropylene. This warranty applies worldwide, with the exception of USA and Canada.


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3.1.2 Chemical structure of polypropylene

Polypropylene results through polymerisation from propylene

The methyl group located at every second carbon atom is arranged on one side of the zig-zag shaped molecule chain, producing good properties for a technically useable material. There are no risks with the use of polypropylene from physiological and toxicological aspects. Vessels and closures for storing foodstuffs can be manufactured from polypropylene without any risks involved. In addition, polypropylene is suitable for use in the manufacture of pharmaceutical packings. For the drinking water supply plants, the „recommendations for health assessment of plastics and other nonmetallic materials for the drinking water sector” are applicable. Polypropylene complies with these recommendations and is neutral with regard to ground water.

3.1.3 Working with polypropylene

Clina mats, pipes/tubes and fittings made from polypropylene can be joined together by means of heating element welding. The welding location itself indicates a high seal-tight condition and resistance to stress and strain. In principle, only the same material types should be welded together. Socket joint welding must be performed in accordance with the DVS-Directive (German Association for Welding Technology eV). The welding temperature here is 260 °C 10° C.

C

H

H

C

H

CH3

=


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3.1.4 Properties of polypropylene 3.1.4.1 Change in length Changes in length as caused by alternating temperatures are greater for all plastic materials as compared with metals. Figure 1 shows the temperature dependence of the linear expansion coefficient of polypropylene according to DIN 53 752.

0,6 . 10-4

0,8 . 10-4

1,0 . 10-4

1,2 . 10 -4

1,4 . 10 -4

1,6 . 10 -4

1,8 . 10 -4

-20 0 20 40 60 Temperatur [°C]

Fig. 1 – Linear expansion coefficient as a factor of the temperature DIN 53 752

3.1.4.2 Water absorption The material polypropylene is water repellent. For this reason it does not swell up in water. Changes in the moisture content of the surroundings have no influence on the material properties.

Linear expansion coefficient [1/K]


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3.1.4.3 Oxygen permeability As shown in Figure 2, the oxygen permeability has no negative effect on the use of polypropylene for the heating sector. In this case, the details as specified in DIN 4726/4728 are to be given due observance.

Fig. 2 – Oxygen permeability 3.1.4.4 Low heat conductivity The heat conductivity at 0,23 W/mK is very low. This results in only weak heat losses for the media in transport. When transporting cold flow media, there is only a very minor amount of condensate accumulation on the tube surface in comparison with metal tubes. 3.1.4.5 Resistance to ageing The temperature and duration of the heat effect determine the chemical process of ageing by means of heat. Figure 3 shows the creep behaviour. The max. allowable operating pressure is calculated according to the following formula: P = v 10 2 s Si da - s Here, P = max. allowable operating pressure in bar, V = comparative stress (refer to diagram), da = mean tube diameter, s = wall thickness of tube and Si = safety factor.

oxygen permeability [cm3 /mpipe

. 24 h . bar] PP in air

surrounded by flooring

20 30 40 50 60

Temperatur [°C]

6

1

2

3

4

5


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Bild 1 – internal pressure – creep diagram

3.1.4.6 Temperature stability For applications without appreciable mechanical stresses as well as the assumption that the material has been correctly processed as required, the upper limit for the temperature of use is about 100 °C. Brief heat impacts which do not cover the entire plastic cross-section are possible up to 130 °C. PP-tubes with the nominal pressure PN 10 and water as a flow medium must have the following operating times according to DIN E 8077: Temperature Operating time at Operating time at 10 bar oper. pressure 4 bar oper. pressure 20 °C 100 years 100 years 30 °C 50 years 50 years 40 °C 7 years 50 years 50 °C 50 years 60 °C 50 years 70 °C 50 years 80 °C 10 years These specified values were maintained during life service duration tests with the material polypropylene as used by Clina.

years

100 102 103 104

Life duration service [h]

1

5

10 comparison tension

v [Mpa]

101

2

106105

1 5 1 25 50

20

20 °C

95 °C

110 °C

CEN Draft SS 25


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3.1.4.7 Light stability With the exception of the black coloured polypropylene, all other polypropylene materials are suitable only for internal use because these materials are not UV-resistant. If at all possible, they should be packaged in light-proof packing during storage and during transport to the final destination. No changes occur in the material properties as a result of a temporary effect of radiation in the range of visible light. However, prolonged and immediate influence of sun light can have a negative effect on the material properties, particularly as a result of the ultraviolet radiation portion. Black polypropylene has excellent resistance to light, UV and weather conditions, however it has low resistance to thermal ageing. 3.1.4.8 Allowable operating pressures and maximum operating years For a maximum operating period of 50 years, the allowable operating pressure for tubes made from polypropylene PN 10 with a safety factor Si of 1.5 is as follows: Temperature Allowable oper. pressure 20 °C 12,9 bar 30 °C 10,9 bar 40 °C 9,2 bar 50 °C 7,7 bar 60 °C 6,5 bar 70 °C 4,3 bar 80 °C 3,2 bar It can be seen from this chart that, for the usual operating pressures of approx. 2 bar, there is adequate safety even after 50 operating years. 3.1.4.9 Fire conditions The materials made from polypropylene fulfill the fire category B 2 according to DIN 4102 T 2. Therefore, they are normally inflammable. According to ASTM D 1929/77, the self ignition temperature is 360 °C and the external ignition temperature 345 °C. There are no environment-relevant pollutants with the burning of polypropylene. The calorific value of polypropylene is 12.8 kWh/kg. 3.1.4.10 Low wall friction losses The wall of the polypropylene tubes is very smooth and not porous. For this reason, unevenness of the surface is extremely low. This result in low wall friction and, subsequently, reduced pressure loss.


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3.1.4.11 Material properties Property Testing method Result

Density at 23° C ISO 1183, DIN 53 479/A 897 kg/m³ Elongation to fracture ISO 527/1A, 50 mm/min > 400 % Tensile elasticity module ISO 527/1A, 50 mm/min 808 MPa Bending module ISO 178,2 mm/min 874 MPa Bending strength ISO 178,2 mm/min 30,5 MPa Notch impact strength / Izod ISO 180/1A 23° C 2,75 J 22,5 kJ/m² 0° C 1,0 J 5,6 kJ/m² -20° C 1,0 J 3,4 kJ/m² Impact strength acc. to Izod ISO 180/1C 23° C 5,5 J NB 0° C 5,5 J NB -20° C 2,75 J 38,4 kJ/m² Shore D hardness/15 s ISO 868 60 Rockwell hardness ISO 2039-2 50 Vicat softening temperature ISO 306, Method A, 50 K/h 131,3 °C Melting range ISO 3146-19 142,4 °C Specif. thermal capacity at 20° C

DSC 2,0 kJ/kg K

Thermal conductivity(10-60°C) DIN 52 612 0,21 W/m K Thermal shape resistance HDT-A

ISO 75, Method A 45,2 °C

Figure 4: Material properties

3.1.5 Chemical resistance

Polypropylene has an unusually high resistance to chemicals and other media as a result of its non-polar structure. It has resistance to watery solutions of salts, non-oxidising acids and alkalis. Up to 60 °C, polypropylene is resistant to many solvents. However, it swells resulting from contacts with aromatic and halogenated hydrogens as well as with certain oils, greases and waxes. This swelling is only minor up to 30 °C. The resistance of polypropylene is between limited and non-resistant with regard to strong oxidation agents such as nitric acid, ozone, oleum (fuming sulfuric acid), hydrogen super oxide or halons. Organic acids, alcohols and ester do not normally attack polypropylene. At the very most, they cause a swelling of the material and influence the mechanical properties. If polypropylene is exposed to copper ions over a longer period and at higher temperatures, a worsening of the physical properties can occur. Brass up to 60 °C has no negative effects on polypropylene. Parts which come into contact with polypropylene should have a chrome or nickel coating. Refer to DIN 8078 for details on resistance. Refer also to ISO-TR 7471 for detailed information on chemical resistance.


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3.1.6 Physiological compatibility

From physiological and toxicological aspects, there are no risks involved with the use of polypropylene. In its recommendation 7 „Polypropylene”, the Federal Board of Health BGA regulates the use of polypropylene for the manufacture of consumer commodities in the sense of Section 5.1 No. 1 of the Foodstuffs and Consumer Commodity Law (LMGB). According to this, polypropylene complies with the regulations of the Federal Board of Health, Communication 152, Sheet 25 dated April 04, 1982 as well as the above-mentioned applicable KTW-recommendations. Plastics, vessels and closures made from polypropylene can be used without any risk for the storage of foodstuffs. In addition, polypropylene is suitable for the manufacture of pharmaceutical packings. The „recommendations for health assessment of plastics and other nonmetallic materials for the drinking water sector“ the socalled KTW-recommendations, apply for drinking water plants. Polypropylene complies with these recommendations. Polypropylene is neutral with regard to ground water and is not attacked by micro-organisms. The chemical composition of the applied polypropylene conforms with national and international rules and regulations for the use of materials which have contact with drinking water. The polypropylene used by Clina was examined by the VTT Food Research Laboratory in Finland. It was discovered that there was extensive conformity with the following directives: the list for monomers 260/92 of the Ministry for Trade and Industry, the list for monomers of the European Community, Directive 90/128/EEC and 92/93/ EEC

and 93/9/EEC, the positive list of the BGA (Federal Board of Health in Germany) for polypropylene, the positive list of the KTW (Germany) for polypropylene, which has contact with water. The polypropylene used by Clina fulfills the requirement for products, which come into contact with foodstuffs, for the following countries: Belgium, Germany, Great Britain, Italy, Holland, Spain, United States of America and the European Community.


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3.1.7 Relevant inspection standards

In Germany, the DIN standards 8077 and 8078 are stipulated as applicable standards for polypropylene. The recommendations contained in these standards have already been adopted by countries such as Poland, Austria, Italy, the Czech Republic and many more. In Europe at present, uniform standards are in the processing stage under the title: CEN/TC 155/WG 16-System Standard 25; „Plastic piping systems for hot and cold water-polypropylene (PP)“. According to confirmation by the Süddeutsche Kunststoffzentrum (SKZ), the Southern German Institute for Plastics, the polypropylene applied for Clina mats is suitable for hot and cold water systems and complies with the requirements of DIN E 8077 / E 8078. For tubes made from polypropylene, the following DIN standards apply in Germany and in other countries: DIN 1988, 4109, 16774, 16887, 4725, 4726, 4728, 8076, 8077, 8078, 16928, 16960, 16962. DVS 2203, 2207, 2208 DVGW EW 534


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3.2 Clina Capillary tube mats made from PP Basic types of Clina - mats G - Mat S - Mat U - Mat

Technical data: Material : PP – Typ 3 Main tube : 20 x 2,0 mm Capillary tube: 3,4 x 0,55 mm or 4,3 x 0,8 mm Capillary clearance: 10 - 30 mm Length: 600 - 6000 mm in 10 mm - steps Width: as from 150 - 1000 mm in ca. 20 mm - steps Connection type: both ends open, or with socket connections spec. exchange surface: 0,72 - 1,05 m² / m² capillary tube surface spec. mass: ca. 250 - 370 g / m² capillary tube surface spec. water content: 0,25 - 0,37 l / m² capillary tube surface spec. overall weight: ca. 500 - 740 g / m² capillary tube surface Index key: e.g. S 15 . 00 Symbol Designation Alternatives S Mat type G, U 15 Capillary tube clearance 15 mm 10, 20, 30 mm .00 Connection variant both sides open

ends 11 connections both sides alternate 20 both connections lefts 02 both connections right

3,4 mm Capillary tube diameter 4,3 mm

A

L

BB

L

A

A

B

L


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Connection variants

1. With socket connections and end caps

Here, the Clina mat is connected up to the supply lines with the flexible Clina connecting hoses (refer to 3.4). The angle setting of the connections is a standard 60°. Other angular settings (e.g. 45° or 0°) are also optional without extra costs, but must be explicitly specified in the order.

Detail: side branch-off with a normal location of the Omega band

Connection variants .11: each one

connection left and right

.20: two connections

left

.02: two connections

right

The capillary mats are supplied in complete ready-made units with end pieces and socket connection at the distributor main tubes. 2. Open ends for welding

The open ends of the main tubes are welded to the neighbouring mat and/or to the supply lines either by a butt weld or with a socket joint weld connection. The welding equipment required for this purpose is listed in chapter 3.11 “Tools and Assembly Kit” of the Clina catalogue.

60°


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Location of the Omega bands Depending on the application and type of the Clina mats, the order must contain

specified details as to how the Omega bands are to be secured to the mat. A difference is made beween two securement types: 1. Omega bands – normal positioning

2. Omega bands – rear positioning

Differentiation must be made in the following cases: Cns. No.

Type Location of collecting a. distributing lines

Installation of Omega bands

Detail for order

1 Metal panel In ceiling hollow space normal n 2 Plaster ceiling to concrete

ceiling In ceiling blank space rear h

3 Plaster ceiling to concrete ceiling

In wall blank space, stucco edge / dry plate covering or overhead structure of room wall

normal n

4 Plaster ceiling to gypsum plate ceiling

In ceiling hollow space Rear h

5 Plastered wall In ceiling blank space normal n 6 Plastered wall In wall blank space Rear h 7 Floor heating In wall blank space normal n 8 Floor heating In floor blank space Rear h 9 Floor heating In plaster normal n


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3.3 Clina-Adhesive for the fixation of capillary tube mats in metal ceiling plates

The Clina adhesive is used for the securement of the Clina capillary tube mats in metal ceiling elements. It is suitable for sticking together a large number of materials with each other according to the contact method. The adhesive is applied with a short gauze painter´s roller. The adhesive substance is applied to the side underneath the capillary tube mat. Then the mat is located in the panel and pressed into position as required. With this one-sided application, the parts for tension-free adhesion can be placed together under light pressure while the adhesive coating is still moist. Ensure that the panels have sufficient surface coating of adhesive. The Clina adhesive VK 1 is a contact adhesive, with long open time, and can be applied lightly and is also sprayable. With tension-free adhesions involving absorbent materials, the application of adhesive coating on one side is sufficient. The Clina adhesive forms an elastic and breathing-durable adhesive joint. The material basis is SBS-caoutchouc. Processing temperature: 15-25 °C Storage temperature: not below 10° C, sensitive to frost ! Atomising pressure: 2 – 6 bar Nozzle diameter : 1,5 – 2,5 mm Designation: N. GefStoffV : flame symbol, F, easily ignitable Designation: N. VbF : A 1


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3.4 Clina Socket connections Clina mats which are to be integrated into metal cassettes requiring inspection are equipped with Clina socket connections in the workshop. By inserting the flexible hoses (refer to 3.5), the mats are connected up easily and securely with the supply and return lines of the water-transporting piping network system. Clina socket connections are also attached in the works to these 20 mm pipes (refer to 3.6) or they are done on the jobsite by means of socket joints. Clina socket connections consist of insert sleeves and cartridges which were developed for Clina and are made from a special brass alloy. The metal claw ensures that these connections, which are under pressure, do not loosen or become leaky after years of operational service. A metal guide sleeve provides for a correct seating of the hose ferrule of the flexible hose. The ferrules of the flexible connecting hoses are made of non-rusting metal. Even after repeated insertion of the hose ferrules into the socket connections, it is ensured that the ferrule surfaces are not scratched in the process. An O-ring is used for sealing purposes and this prevents water from coming into contact with the insert sleeve. The O-ring cannot be pressed out of its position even if the hose ferrules are pressed in at a slant angle. The sealing O-ring is protected by the claw against damage resulting from turning and tilting when the flexible hose is inserted into position.

60°


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3.5 Flexible hoses The Clina connection system consists of flexible connecting hoses and the Clina socket connections as already mentioned. The flexible hoses are made from elastomer caoutschouc (EPDM). Nylon and high quality steel braiding guarantee the operation pressure (pressure rating 10 bar). It is available in the standard lengths 500 mm, 800 mm and 1.200 mm. Special sizes are available on request. Various types of connecting modes on both hose ends facilitate the assembly with various equipment and connections. However, we have developed a specially designed connecting system for the case of application which consists of a nickel-coated brass ferrule with an outer diameter of 10 mm and an integrated holding nut.

Insert ferrule: - outer = 10 mm brass, nickel-coating Inner hose : EPDM Pressure rating PN 10


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3.6 Clina supply + return lines Clina supply + return lines are used in such heating and cooling systems where Clina capillary tube mats with socket connections and connecting hoses are used, such as for metal ceiling cassettes as foldable cooling ceilings. These connecting units are prefabricated in our workshops. For this reason, they serve to reduce assembly hours and costs on the jobsite. Here, the Clina supply + return lines serve the internal tubing of the Clina capillary tube mats in the room. As a standard design, these supply + return lines are made from a tube with the sizes 20 x 2.0 mm and can be provided with single outlets and double outlets. The decisive factor for the number (quantity) of outlets is the mass flow resulting from the mats to be connected up. In this case, the limit of the max. tube friction pressure loss should be fixed at 200 Pa/m. Subject to the machine fabrication of the supply + return lines 20 x 2.0 mm, the smallest possible gauge size (B) between the snap closures is a minimum of 200 mm ! Example: Supply + return lines with single outlets

Smaller gauge sizes ( B < 200 mm ) are only available as customised products. If you want to join up larger mat surfaces to any particular supply + return line, we are in a position to manufacture larger nominal widths such as 25 x 2,3 mm or 32 x 3,0 mm. Please do not hesitate to consult us if you have any questions in this respect.

20 B

L

S

D


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3.7 Piping, tubes and fittings made from PP Polypropylene is a high-molecular and static polypropylene copolymer (random copolymer) which is characterised by a wide range of application options as well as an extraordinary long life duration service. PP can be fully recycled and corresponds subsequently to the requirements of the Recycling Economy Law. All polypropylene tube and form parts purchased from Clina correspond to the pressure rating 10. The dimensions and quality requirements comply with DIN 16 962. PP-tubes of the pressure rating 10 Nominal width Dimension (da x s) DN 15 20 x 2.0 mm DN 20 25 x 2.3 mm DN 25 32 x 3.0 mm DN 32 40 x 3.7 mm DN 40 50 x 4.6 mm DN 50 63 x 5.8 mm DN 65 75 x 6.9 mm DN 80 90 x 8.2 mm DN 100 110 x 10.0 mm Refer to chapter 3.1 for details on the material data and properties of polypropylene. The assembly of PP-tubes and fittings by means of the socket joint welding method is very uncomplicated, quick, clean and safe (no naked flames). You obtain a 100% homogenous union of the same material so that, after welding, both parts are really one piece from a molecular-homogenous viewpoint. In principle, only materials of the same type should be welded together. For assembly of PP-tubes in accordance with standard engineering practice, you require a tube shears and a socket joint welding unit with replaceable heating elements in various sizes.


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3.8 Valves for water-side control and for hydraulic balancing In principle, all commercially-available valves and armatures can be used within the capillary tube system provided they fulfill the requirement for corrosion resistance (refer to Chapter 2.2). The system requires for each zone the installation of armatures for shutoff, hydraulic balancing and a control valve. For shutoff purposes, corrosion-resistant ball valves made either of metal or plastic can be used. The hydraulic balancing is effected by means of line-type regulating armatures (Oventrop, Heimeier, Taco, TA and similar types) which allocate their setpoint mass flow to the individual zones. From thermal aspects, the zones are normally controlled by means of a 2-point-valve. This plain open/shut control mode is fully adequate due to the low level water content and the low inertia of the system, particularly in view of the fact that a constant control with a 2 K spreading would not be practical and would involve high expenditure. For smaller dimensions and plant pressures, thermo-electric actuators 24V and/or 230V are normally used. For higher plant pressures, actuators with E-motors are applied. The transitions of the valves/armatures, normally provided with threads, to PP is established by means of transition form parts metal/plastic which are welded into the plastic piping.

Clina Zone valve

For direct tie-in of a zone valve into a PP-line DN 15, Clina engineers have developed a special plastic zone valve DN 15 for socket joint welding. This valve is a PP-valve with a “Braukmann” valve assembly having a kVS – value of 2,0 m³/h. In combination with the thermo actuator TAZU of Clina, it adopts the function of a reliable 2-point-control element. The entire valve body is made of PP-R. Therefore it is very easy to weld it to the other tubing by means of socket or butt welding equipment. Illustration without valve assembly

M30x1,5

20


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Clina-Assembly protection cap for zone valve

The assembly protection cap is supplied in principle with the Clina valve. This cap protects the valve pin against damage, and also protects the external thread against fouling during transport and during assembly at the jobsite.

Clina-Thermal valve actuator

The matching actuator to the Clina zone valve for open/shut control (2-point-control) in heating and air-conditioning plants. The thermal actuator keeps the valve shut in a de-energised condition. If requested by the customer, it can be supplied selectively with an auxiliary switch for on/off-control of the circulating pump.

Technical data: Operating voltage: 24 V 10%, 50 - 60 Hz Continuous rating: 2 Watt Ambient temperature: max. 50°C Opening time: max. 5 min Lift: 3.0 mm Allowable differential pressure: 2.5 bar


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3.9 Transfer or storey distributing station with heat exchanger, pump etc.

Due to the oxygen diffusion through the capillary tubes, a system separation of the primary and secondary cycles is indispensable (refer to chapter 2.2). This separation is established with a transfer station which comprises the following basic elements: heat exchanger, circulating pump, expansion vessel with safety valves, shutoff valves and thermometers/pressure gauges. In addition, there are nozzles in the supply line of the transfer station with ½“ internal thread for an immersion sleeve. All components installed in-line in the secondary cycle as from the heat exchanger must be made of corrosion-resistant materials. In principle, a capillary tube system has two main variants: A) In many cases it is practical to have decentralised distribution and control of the water

flows of the secondary cycle. Connected up to a ring main, the control groups of the individual zones (refer to chapter 3.8) in this case are located at accessible points in the interim ceiling, directly in or at the individual zone. You only then require a central transfer station for the energy transfer and the system separation between the primary and secondary cycle.

This standard transfer station mainly consists of the following elements:

p – controlled circulating pump, corrosion-resistant (as from the station, a delivery

head of max. 6 mWc is usually sufficient) stainless steel - plate heat exchanger Two pressure gauges 0 – 4.0 bar Two thermometers 0 – 40 °C brass – membrane safety valve 2 ball valves with hose connection shutoff ball valves, with pipe nominal width of main supply and return lines membrane expansion vessel, drinking water design type socket type mud strainer DN 15 – DN 65 and/or mud strainer with sight glass or filters

(optional) Partial flow de-aeration by means of a venting (optional)

B) With this more sophisticated but user-friendly variant, each zone is connected up by

means of its own supply and return line with a storey distributing station which contains the above-mentioned components of a transfer station as well as control groups of the individual zones. Balancing and regulation of all zones can therefore be conducted from this central transfer location.

The Clina standard – storey distributor works according to the two-line principle up to an overall volume flow of approx. 7.5 m³/h. The basic arrangement is shown in the following illustration.


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This standard – storey distributor consists mainly of the following elements:

1. p – controlled bronze circulating pump 2. stainless steel – plate heat exchanger 3. two pressure gauges 0 – 4.0 bar 4. two thermometers 0 – 40 °C 5. brass – membrane safety valve 6. membrane expansion vessel (in drinking

water design type) 7. mud strainer DN 15 - DN 65 (selective) 8. one Taco - setter DN 15 - DN 50 per control

zone 9. in each case, two shutoff ball valves in pipe

nominal width per control zone 10. one autom. heavy duty venter in each main

SL/ RL 11. one control valve type FZ 1 per control

zone, incl. therm. actuator (without elec. auxiliary switch)

12. galvanised steel frame

3.10 Clina-dew point monitoring Clina-dew point sensors register any possible accumulation of condensation at the capillary tube mat or in its immediate surroundings, thereby changing their electric resistance. This resistance change in the sensor is recognised by the room temperature controller TR2/3 and causes the control valve to close. It therefore protects the cooling ceiling effectively against damage. The Clina-dew point sensor consists of a printed circuit board with an imprinted circuit-board conductor pattern. With a relative humidity of 80 – 85%, the sensor conductivity increases considerably so that the controller recognises this. If the resistance, as a result of moisture precipitation, reaches a value of approx. 8 M-Ohm, the controller switches off the cooling. It is switched on again when the resistance increases to approx. 16 M-Ohm as a result of the drying process. The sensor has two latches on the side of the casing and is secured to the capillaries by means of the attached clips. Two variants are available, and these differ exclusively with regard to their use in various types of ceilings, meaning, depending of the case of application and the type of ceiling itself. The Clina dew point sensor TF 3 P/R is designed for assembly into plastered ceilings as well as for cold-water transporting piping; the dew point sensor TF 3 M/G is used for metal or gypsum plate ceilings.


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Clina-Dew Point Sensor Technical data TF 3 P/R and TF 3 G/M: Operating voltage: 24V AC 10% 50...60 Hz Allowable ambient temp.: 0...50 °C Max. cable length: 10 m (to ca. 50 m with shrouded line) Switchpoint dew point: ca. 8 M-Ohm corresponds to ca. 80% rel. humidity and ca. 16 M-Ohm

Dew point sensor printed circuit board

Sizes: L x W x H = 34.5 x 12 x 1 mm

Dew point sensor (TF 3 P/R) for plaster ceitings or for pipe mounting

Sizes : 70 x 20 x 7 mm

Dew point sensor (TF 3 G / M) for gypsum cardboard or metal panel ceitings

Sizes : 70 x 20 x 7 mm

The dew point sensors are to be exclusively connected to the Clina room temperature controller TR … directly or for connection to a building master controlling by way of the Clina converter TK … From there, they receive their 24V supply voltage.


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The Clina-converter TK1-PF / TK2-PF evaluates the information from the allocated dew point sensor. On reaching the dew point, the integrated contact (closing or opening contact) is actuated. This information can, for example, be of service to the remote signal of a GLT on the customer´s side, or similar. Up to 5 dew point sensors (5 pieces parallel) can be hooked up to a converter. The converter is envisaged for the installation in the casings of automatic units and other installation variants. Sizes : 86 x 36 x 59 mm Supply voltage : 24 V or 230 V~ / 50 Hz Max. capacity of the outlet: 48 V~ / 60 V or 230 V~ DC Switching output : floating change-over contact


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3.11 Clina-Room temperature controller TR ...

-

+

ECO 0

Illustration TR 1 B

- +

Illustration TR 2/3

Illustration TR 2/3 M

The Clina - Room Temperature Controller TR 1 B and TR2/3 is designed for temperature control of the room as well as for the protection of the cooling ceiling against damage resulting from condensation. The controller TR1 B (finery appliance) has an exit for heading for a valve and is switchable between heating or cooling The controller TR2/3 (sub finery appliance) can as well as 1 valve (heating or cooling) heads for and is rearranged moreover internally and consequently 2 valves, heating and cooling, heads for. With the option of the external set point remote adjustment, it is applied to two-line systems (heating or cooling) and three/four line systems (heating and cooling) as a surface equipment unit. The controller TR2/3 M (sub finery appliance) for the Integration in different switch Programs can as well as 1 valve (heating or cooling) heads for and is rearranged moreover internally and consequently 2 valves, heating and cooling, heads for. With the option of the external set point remote adjustment, it is applied to two-line systems (heating or cooling) and three/four line systems (heating and cooling) as a surface equipment unit. The Clina - Room Temperature Controller is equipped with a connection for Clina dew point sensors. The actual operating status (cooling / heating / danger of dew point ) is indicated by light-emitting diodes.

The room temperature is upheld by means of a plain 2-point-control mode (Open/Shut). By way of the room temperature controller, the temperature is recorded, and by an actuating signal the zone valve with actuator is energised. As a result of this low level water content and the spreading of 2K, a constant control is not necessary. This mode of room temperature control is preferentially applied both for cooling and heating purposes with the capillary tube system.


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Technical Data

TR 1 B TR 2/3 TR 2/3 M Dimensions: 78 x 83 x 25 mm 70 x 70 x 20 mm 81 x 85 x 16 mm Operating voltage:

24 V 10%, 50 - 60 Hz 24 V 10%, 50 - 60 Hz 24 V 10%, 50 - 60 Hz

Power input at no-load run:

30 mA

Control range: 13 – 29°C 5 - 30°C 13 – 29°C Switching hysteresis:

ca. 1 K statisch 1 K < 1 K

Temperature sensor:

internal NTC internal NTC internal NTC

Switching outputs:

24 V / 32 VA (1A) TRIAC, 24 V / 1 A, temporary bis 2,5 A

24 V / 32 VA (1A)

Casing colour: equal RAL 9010 RAL 9010 Equal RAL 9010 Functions: cooling or heating

with changeover point-remote adjustment

a) cooling or heating b) cooling and heating with point-remote adjustment

a) cooling or heating b) cooling and heating with point-remote adjustment

installation: Finery appliance Sub finery appliance


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3.12 Tools and assembly kit

The following tool assortment must be readily available on all jobsites for professional installation of the Clina mats and the PP-tube connecting assignments. Further special tools can be supplied on request.

Shears

Hand shears for cutting plastic tubes 20 mm to 32 mm

Coupling disconnecting element

Coupling disconnecting element for disconnecting the flexible hose with the capillary tube mats and/or the supply lines.

Butt welding unit HSG 90 No illustration, similar to socket joint welding unit

Welding hot-tool with a 90 mm for butt welding PP-tubes according to the directives of the manufacturer as well as the hot-tool welding directives.

Thermostat control, 220 V, 600 W

Socket joint welding unit

Welding hot-tool for holding socket joint weld assemblies for various tube dimensions for socket welding of PP-tubes up to DN 50 according to the directives of the manufacturer as well as the hot-tool welding directives. Thermostat control 220 V, 800 W


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Socket joint weld assemblies

These assemblies are to be used for the socket joint welding unit MSG 40 for the welding of the individual tube diameters. By means of form and connecting parts, the tubes are joined up together with welded socket joints.

Welding tools for built-in saddle These assemblies are to be used for the socket joint welding unit MSG 63 for the welding of built-in saddles onto PP-tubes.

Drill tools for built-in saddle

Art.-No. Type Tube - WSM-I 16 socket (int.) 16 WSM 20 Socket (ext.) 20 WSM 25 Socket (ext.) 25 WSM 32 Socket (ext.) 32 WSM 40 Socket (ext.) 40 WSM 50 Socket (ext.) 50 WSM 63 Socket (ext.) 63 WSM 75 Socket (ext.) 75 WSM 90 Socket (ext.) 90 WSM 110 Socket (ext.) 110

Art.-No. Tube - Drill -

WSA 40-25 40 mm 25

WSA 50 - 25 50 mm 25

WSA 63 - … 63 mm 25 / 32

WSA 75 - … 75 mm 25 / 32

WSA 90 - … 90 mm 25 / 32

WSA 110 - … 110 mm 25 / 32

Art.-No. Drill -

WKB 25 25

WKB 32 32

NEU !


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4 Planning and Design of Clina-Capillary Tube Systems

4.1 Application: COOLING CEILING

4.1.1 Cooling ceilings with or without ventilation

In principle, cooling ceilings can be operated with or without supporting ventilation (ventilation plant). However, with systems without supporting ventilation – window ventilation – reductions in the performance or limitations in the operating mode cannot be ruled out. In most cases, however, the most frequent application is the cooling ceiling in combination with a ventilation plant. Cooling ceilings with natural window ventilation Two methods of control can be selected:

1.) Constant supply temperature with a shutdown of the cooling ceiling by way of a dew point sensor when there is a danger of a level below dew point;

2.) Variable supply temperature with an increase of this depending on air humidity. In all cases, the supply temperature must be set 1-2 K above the dew point temperature. At a constant supply temperature, this value is about 16 °C in Germany or central Europe. Judging by experience in the past, a drop below dew point (sublevel) is relatively seldom. It only occurs on those few very warm and damp days in the year. The operating mode stated as variant 1 (constant supply temp.) has the disadvantage that, on these days in particular, when operation of the cooling ceiling is really necessary, it is switched off because of a possible drop below dew point level. With variant 2 (variable supply temp.), the cooling capacity declines because of the automatic increasing of the supply temperature. Nevertheless, the cooling ceiling remains in operation. Another way of protecting the cooling ceiling against condensation is the use of window contacts which cause a shutdown of the cooling ceiling by opening the windows. With incoming damp ambient air, a drop below dew point is not possible. However, changes in humidity resulting from inner load factors must be given due consideration. For safety reasons, a dew point sensor is to be installed for all variants for the event of an emergency shutdown. Cooling ceilings with supporting ventilation Primarily as well as for practical purposes, a cooling ceiling is applied with supporting ventilation. With this method, the humidity of the room air is controlled by the ventilation and is usually regulated to a level of approx. 50% relative humidity. In addition, the hygienic


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minimum air change is realised by way of the ventilation. Subsequently, the duct cross-sections of the ventilation plant can be reduced considerably in size because there is no need for air flows for transporting the cooling load. The cooling load with this system configuration is drawn off by way of the cooling ceiling which works, from energetical aspects, much more economical and more comfortable than an air-only-system. These reason here lies in the transport medium water and the functioning mode of radiation cooling. Smaller duct cross-sections and the considerably more advantageous transport of energy by way of water piping lead to substantial space saving within the main structural body. Therefore, for the transport of energy, only 1/1000 of the volume of water with 4 times the thermal capacity is required in comparison with air. Cooling ceilings can be combined with source as well as with mixed ventilation without any reductions in personal comfort. With normal air flows from 4 to 6 m³/h per m² or 20 to 40 m³/h per person for the hygienic minimum air change, air flows and flow velocities are relatively low. The cooling ceiling is operated with a constant supply temperature of usually 16 °C. With a room air condition of 50% relative humidity and 26 °C, the dew point temperature is about 14.8 °C. Therefore, there is adequate safety against any level drop below the dew point. The installation of a dew point sensor in the room as a safety element is also indispensable with the combination of the cooling ceiling with an ventilation plant, even then when there is danger of condensation only in the event of failure, shutdown or malfunctioning of the ventilation plant. For the design and layout of a cooling ceiling, the cooling load must be determined according to VDI 2078. This is a prerequisite. With factual knowledge of the cooling load, proceed as follows with the design and layout of a cooling ceiling.

4.1.2 Room temperature

Here, the maximum effective room temperature allowable in the zone should be applied here. This temperature is equal to the temperature which has been applied for the cooling load calculation and amounts to TR = 26°C according to VDI 2078. The perceived, or also the operative temperature, is approx. 2K below the room temperature. The human being perceives the room temperature as the mean (average) of room air temperature and the temperature of the enclosing surfaces. The perceiving temperature is additionally influenced by the type of clothing worn and the degree of activities. In this way, it is quite possible to allow the room temperature to increase to 28 °C. Subsequently, the cooling capacity increases but the comfort limits are upheld due to the perceptive temperature of 26 °C. The decisive factor for the cooling capacity is, depending on the installation condition, ultimately the difference between room temperature and the mean water temperature. e.g. TRoom = 26 °C


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4.1.3 Room air humidity

According to VDI 2078, this value is fixed at 50% of the relative humidity and lies approximately in the middle of the comfort range for human sense of well-being. With this value and the room air temperature, the dew point temperature is calculated. If there is a drop below the dew point temperature, the cooling ceiling goes out of operation. On this basis, the supply temperature is specified and this must always be above the dew point. This is followed here again by the acceptance of the value of the base values for the cooling load calculation. e.g. 50 % relative humidity From the h-x-diagram, the dew point temperature of 14.8 °C can be determined for this room air condition 26 °C and 50 % relative humidity.

4.1.4 System temperatures for supply and return

The system temperatures of a cooling ceiling are determined based on the dew point. Normally, a supply temperature of 16 °C and a return temperature of 18 °C or 19 °C is selected which are the most favourable system temperatures for obtaining the best possible capacity and the dew point protection for a room air condition according to VDI 2078. The mean sublevel temperature to room temperature is decisive for the capacity. For this reason, the supply temperature should be fixed as close as possible to the dew point with the required safety factor, and the spreading with 2K and/or 3K should be selected relatively small. A greater spreading would lead to a reduction of the mass flow, but it would reduce the mean sublevel temperature at the same time, and subsequently reduce the capacity. e.g. Troom = 26 °C 50 % rel. humidity

TVL = 16 °C TRL = 18 °C

Mean arithmetic water temperature Tm

T m = TVL +[ (TRL - TVL) / 2 ] Mean sublevel temperature

TU = TR - Tm The resulting value under the usual conditions would be as follows: Tm = 17 °C TU = 26 °C – 17 °C = 9 K


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4.1.5 Ceiling type / structure

In principle, Clina capillary tube mats can be combined without problems with practically all ceiling types. For the capacity of the cooling ceiling, the heat throughput from the room air (heat source) to the capillary tube mat is decisive. This means that, from the room, only the heat volume can be drawn off which is allowed to pass through by the separating layer between the capillary tube mat and the room air per unit of time. In this way, the ceiling type and the structure of a cooling ceiling, meaning, the location of the cooling element in the ceiling and the enclosing materials, have a decisive influence on the specific capacity of a cooling ceiling per m² of active surface. Typical ceiling types are as follows: Plastered ceiling (on concrete) with integrated cooling function:

The capillary tubes of the Clina mats are installed in the layer of plaster on the concrete ceiling. All commercially available plastering from gypsum, limestone or cement as well as acoustic plastering are suitable.

The main tubes of the mat and the tubing are located in blank spaces, a covering-off or in the ceiling hollow space of an adjoining floor level. Advantages: - minimum structural height, especially suitable for low level rooms

- no room height loss when installed at a later date

This is the most cost-favourable variant of a cooling ceiling with a high DIN cooling capacity of 84 W/m² (MP 75) without reduction of the effective room height. Plastered ceiling with integrated cooling function

Below a dry structure ceiling, the capillary tubes of the Clina mat are secured and then plastered over. The main tubes of the mat and various piping as well as the installations of other house-technical units are located within the ceiling narrow space.

Advantages: - all installations in the ceiling hollow space - on the visual side, jointless plastered ceiling - cut-outs for lamps and ventilation grids can be made even during the

construction phase without any problems, by drawing the capillaries apart up to approx. 150 mm

Clina-capillary-tube mat

concrete ceiling

plaster 10 - 15 mm

Clina-capillary- tube mat

plaster 10 - 15 mm

carrying profile C-profile

concrete ceiling

dry structure plate

nonius spacer


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On the visual side, again a jointless plastered ceiling with very good capacity values of 84 W/m² (MP 75) according to DIN EN 14240. Dry structure ceiling with integrated cooling function

Above a jointless and closed dry structure ceiling, the Clina capillary tube mats are integrated and covered off with insulation. Later, the visual is smoothened over with a spatula and painted on the customer´s side. A dry structural element, prefabricated in the workshop is available here. The Clina Sandwich Plate (CSP) is a structural element with integrated capillary tube mat. The CSP-elements are

delivered on pallets to the jobsite and are mounted similar to a standard dry structure plate. With the bore holes predrilled in the workshop, the assembly is facilitated and damage to the capillary tubes is prevented. Advantages: - the capillary tube mats are located on the inside of the ceiling and can

therefore be easily connected up to the supply + return line - on the visual side, uniform appearance of a jointless dry structure ceiling - for positioning the Clina capillary tube mats and the supply + return lines,

the ceiling has only to be lowered by approx. 10 cm - uncomplicated, quick and clean assembly

With a dry structure ceiling using “Fermacell” plates, a DIN cooling capacity of 70 W/m² is obtainable. All kinds of dry structure plates can, of course, be used here so that, among other things, an acoustically effective variant with perforated dry structure plates is possible. Metal cassette ceiling with integrated cooling function

All types and shapes of metal cassette plates can be equipped with the Clina capillary tube system. In this case, the Clina capillary tube mats are adhesively located in the metal cassettes and covered off with insulation. Prefabrication in the workshop is possible depending of the ceiling make.

Flexible hoses are used to connect up to the Clina supply + return lines (refer to chapter 3.6), and these are located in the ceiling hollow space. Advantages: - the capillary tube mats are lying on the inner side of the ceiling and can

therefore be easily connected up to the supply + return line; - the ceiling area is accessible at all times and the cassettes can be opened

during operation;

dry structure plate

insulation


carrying profile C-profileconcrete ceiling

metal cassette

insulation



45

- existing lowered ceilings with metal panels can be re-equipped later without any problems;

- uncomplicated, quick and clean assembly A customary metal panel ceiling with adhesively applied capillary tube mats, complying with acoustical requirements, has a very high DIN-cooling capacity of 87,7 W/m². However, due to the small mat dimensions and the resulting complex tubing, it is more cost-intensive on the investment side compared with the already-mentioned design types.

4.1.6 Mat type

Depending on the installation condition / ceiling type, the mat types listed below can be applied. The correct mat type in each case is determined according to the ceiling type as well as the peripheral conditions because the mats differ, if particular, with regard to the type of connection, location of distributing mains and pressure losses. Installation condition of the mat Mat type Structural component type Mat, adhesively positioned in or on location

OVAMAT / ORIMAT U , S , G

Metal cassette ceiling Dry structure ceiling

Mat, embedded (plaster, etc.) OPTIMAT S , G

Plastered ceiling Plastered wall Floor

G - Mat S - Mat U - Mat

With these details, the mass flow required for the output and the resulting pressure loss can also be determined.

4.1.7 Determination of the specific cooling output (capacity)

The capacity of a cooling ceiling is indicated with test certificates depending on the ceiling type. These certificates contain exact details on the ceiling type and the structural layout.

A

L

BB

L

A

A

B

L


46

As DIN proceeds on the basis of a mean sublevel temperature of 10K (e.g. 15° / 17° to 26°C), but where such a temperature is rarely selected in practice due to the safety clearance to the dew point, the actually obtainable spec. cooling capacity is lower. In accordance with the parameters for ceiling type (installation condition) and the mean sublevel temperature, the spec. capacity at design conditions can be determined with the following diagram.

specific cooling output of various chilled ceilings

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

100,0

110,0

120,0

5 6 7 8 9 10 11 12

average undertemperature in K

coo

lin

g o

utp

ut

in W

/m²

A[W/m²]

B[W/m²]

C[W/m²]

D[W/m²]

F[W/m²]

A perforated steel plate ceiling, closed with capillary tube mat stuck into position B Plaster ceiling, 10-15 mm MP 75, with capillary tube mat plastered into position C Dry structure ceiling, non-perforated; 12.5 mm dry plate ( = 0.21 W/mK) prefabricated dry structure model with capillary tube mat stuck on D Dry structure ceiling, non-perforated, 10 mm Fermacell ( = 0.36 W/mK) capillary tube mat above the Fermacell-plates F Dry structure ceiling, perforated, 12,5 mm dry plate ( = 0.21 W/mK)

capillary tube mat above the gypsum board


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e.g. plaster ceiling MP 75 e.g. Troom = 26°C 50 % rel. humidity

TVL = 16°C TRL = 18°C

Tm = 17°C TU = 26°C - 17°C = 9 K q specif. = 75 W/m²

4.1.8 Capacity of the cooling ceiling of a room

The capacity in a given room drawn off by way of the cooling ceiling is calculated by multiplying the active surface by the specific capacity per m² active surface. If this cooling capacity is not sufficient to draw off the cooling load of the room, then the remaining portion is to be withdrawn by way of the ventilation or other systems (e.g. Clina cooling shafts or columns). Even if the determined cooling load is smaller than the cooling capacity of the entire ceiling surface, the entire ceiling surface should be covered because of a uniform temperature profile in the room. The size of the mats as well as the mat type depend on the ceiling design and the panel sizes, the grating size of the substructure, the room depth with plastered ceilings and the resulting pressure loss. The installation surface in a zone can never amount to 100% of the ceiling surface or the base surface, respectively. It depends on the execution and design of the ceiling as well as the attachments to be installed (ceiling layout). The degree of installation, as a rule, is in the region of 75%. Due to the flexibility of the Clina capillary tube mats, smaller cutouts for reflector lamps, sprinklers, loudspeakers and similar objects can be realised by drawing the capillaries apart. This is possible without any problems and usually without any reductions of the installable surface space.


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Example: Ceiling layout e.g. Plastered ceiling MP 75 Room base surface = ceiling surface 4.5 m x 4.25 m Active surface for plastered ceiling approx. 90% Installation on in the intermediate ceiling area of the floor, connection by way of welding, mats plastered at the concrete ceiling Mat type: SB 20 . 4500 . 1000 . 00 Plastered active surface in room 4 mats à 1 m wide x 4.3 m long active surface = 17,2 m² cooling capacity: Q = A * q specific

Q = 17,2 m² * 75 W/m² = 1290 W

Figure 1: Ceiling layout


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4.1.9 Mass flow and pressure loss of the Clina mat

The required mass flow is usually determined from the required specific cooling capacity or from estimated experience values for customary specific mass flows based on the execution variants. This forms the basis for determining the pressure loss which is considerably influenced by the length of the capillary tube mats. The longer the capillary tube mats and the higher the mass flow, the higher is also the pressure loss per mat which increases linearly. The influence of the width of the mats for the customary dimensions (length > width) is practically negligible. However, if there is a reverse in the size ratios, (length < width), a corresponding calculation /enquiry is necessary. The mats are connected up to the supply line in parallel so that the individual elements, which should have almost the same size within a given zone, do not require additional hydraulic balancing. e.g. Plastered ceiling MP 75 e.g. Troom = 26°C 50 % rel. humidity

TVL = 16°C TRL = 18°C

m specif. = 75 / (2 * 1,16) m specif. = 33 kg/hm² Mat type: SB 20.4500.1000.00 Length 4500 mm Width 1000 mm Mass flow per mat m = m specific * A m = 33 kg/hm² * 4,5 m² m = 149 kg/h p Mat = 13 kPa

m specif. = q specif. / (T * 1,16) [kg/h]


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SB 20.00 capillary 4,3 x 0,8 mm 1m wide without hosecooling Tsupply= 16°C Treturn= 18°C

L = 1 m

L = 2 m

L = 3 m

L = 4 m

L = 5 m

L = 6 m

0

5

10

15

20

25

30

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

massflow [kg/h]

pres

sure

loss

[kP

a]

Figure: Pressure losses of SB 20 mats


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4.1.10 Subdivisioning and installation of the zones

The zones are to be subdivisioned according to various aspects:

1. Utilisation and comfort

- Single room = control zone ; based on varying utilisation (internal loads) and comfort sensitivity

- Large room = possibly several control zones, depending on o Direction o Utilisation / installation (internal loads) o Hydraulic system and pressure losses o Dew point safety

Each zone and/or each room receives, in principle, one dew point sensor for protection

against condensation. For oversized zones with different heat and moisture sources, it is possible that the room air condition within this zone fluctuates considerably (e.g., door or entry areas). Here, it would be practical to have these areas subdivided into single zones.

2. Hydraulic system and pressure losses

Where larger rooms are concerned, it can be more advantageous to provide for several control zones within a room with regard to the piping/tubing (dimensions and pressure loss). The pressure loss varies depending on the type of mat, the mat size and the mass flow. However, it is generally considerably lower compared with other similar single-tube systems. With oversize expansions of a zone, however, the expenditure for dimensioning of supply lines and the tube system can be considerable.

Dimensioning of supply lines and room control groups

peripheral condition Troom 26 °C

relative humidity 50%16 / 18 °C zu 26 °C 16 / 19 °C zu 26 °C

A - capillary tube mats stuck into perforated metal cassettes 74,4 W/m² 69,9 W/m²B - capillary tube mats embedded in plaster (MP 75 10-15 mm) 71,4 W/m² 67,0 W/m²C - capillary tube mats integrated in bubble glass granulate elements 62,9 W/m² 59,1 W/m²

PP-pipe controlling group 2 K 3 K A B C A B CDa x s [mm] Zoll W W

20 x 2,0 1/2" 734 1101 9,87 10,28 11,67 15,75 16,43 18,63

25 x 2,3 3/4" 1392 2088 18,71 19,50 22,13 29,87 31,16 35,33

32 x 3,0 1" 2715 4073 36,49 38,03 43,16 58,27 60,79 68,92

40 x 3,7 1 1/4" 5044 7566 67,80 70,64 80,19 108,24 112,93 128,02

50 x 4,6 1 1/2" 9220 13936 123,92 129,13 146,58 199,37 208,00 235,80

63 x 5,8 2" 17368 26051 233,44 243,25 276,12 372,69 388,82 440,80

spec. cooling capacity DIN 4715

max. heat flowspreading

Dimension

m²

max. cooling surface at 16 / 18 °C max. cooling surface at 16 / 19 °C

m²


52

pressure loss calculation for pipe network calculation for cooling water linesPP - pipe PN 10, DIN 8077 / 8078, series 4

valid for : cold water with t Wm = 20 °C

density = 998,22 kg/m³ viscosity [ mm² / s ] = 1,01 0,1004 0,09871041tube roughness k = 0,0070 mm spec. heat cwater = 4,1836 kJ/kg K

DN 15 tube outer dimension 20,00 mm R = tube friction pressure gradient [ Pa/m ] p [ Pa/m ]

wall thickness 2,00 mm w = flow velocity [ m/s ] w [ m/s ]tube inner dimension 16,00 mm

connectable capacity at DN 15 20 25 32 40 50 65

t = mass flow 20,00 25,00 32,00 40,00 50,00 63,00 75,004 K 3 K 2 K 1 K 2,00 2,30 3,00 3,70 4,60 5,80 6,90

Q [kW] Q [kW] Q [kW] Q [kW] [kg/h] [l/s] 16,00 20,40 26,00 32,60 40,80 51,40 61,20259 0,07 125 38 11 3 1 - -

1,20 0,90 0,60 0,30 0,36 0,22 0,13 0,08 0,05 0,03 0,02360 0,10 222 67 20 6 2 1 -

1,67 1,25 0,83 0,41 0,49 0,30 0,18 0,11 0,07 0,04 0,03468 0,13 365 109 33 11 3 1 -

2,17 1,63 1,08 0,54 0,64 0,39 0,24 0,15 0,09 0,06 0,04540 0,15 479 143 45 14 5 2 1

2,51 1,88 1,25 0,62 0,74 0,45 0,28 0,17 0,11 0,07 0,05720 0,20 826 252 75 24 8 2 1

3,34 2,51 1,67 0,83 0,99 0,61 0,37 0,23 0,15 0,09 0,06792 0,22 989 300 91 30 9 3 1

3,68 2,76 1,84 0,92 1,09 0,67 0,41 0,26 0,16 0,10 0,07900 0,25 1.261 380 117 37 13 4 2

4,18 3,13 2,09 1,04 1,24 0,76 0,47 0,29 0,19 0,12 0,081.080 0,30 1.781 532 162 52 17 6 2

5,02 3,76 2,51 1,25 1,49 0,91 0,56 0,35 0,22 0,14 0,101.260 0,35 2.385 721 214 70 23 7 3

5,85 4,39 2,92 1,46 1,74 1,07 0,65 0,41 0,26 0,16 0,111.440 0,40 3.043 923 280 90 30 10 4

6,69 5,02 3,34 1,67 1,98 1,22 0,75 0,47 0,30 0,19 0,131.620 0,45 3.809 1.148 346 113 38 12 5

7,53 5,64 3,76 1,88 2,23 1,37 0,84 0,53 0,34 0,21 0,151.800 0,50 4.656 1.395 427 138 47 15 6

8,36 6,27 4,18 2,09 2,48 1,52 0,94 0,59 0,38 0,24 0,161.980 0,55 5.583 1.685 507 165 56 18 7

9,20 6,90 4,60 2,30 2,73 1,68 1,03 0,65 0,42 0,26 0,182.160 0,60 6.590 1.980 604 195 64 20 9

10,04 7,53 5,02 2,51 2,98 1,83 1,13 0,71 0,45 0,28 0,202.340 0,65 7.677 2.297 698 227 75 25 11

10,87 8,15 5,43 2,71 3,23 1,98 1,22 0,77 0,49 0,31 0,222.520 0,70 8.842 2.659 797 261 87 28 12

11,71 8,78 5,85 2,92 3,48 2,14 1,31 0,83 0,53 0,33 0,232.700 0,75 3.022 916 297 100 32 13

12,55 9,41 6,27 3,13 2,29 1,41 0,89 0,57 0,36 0,252.880 0,80 3.407 1.029 336 113 36 16

13,38 10,04 6,69 3,34 2,44 1,50 0,95 0,61 0,38 0,273.240 0,90 4.272 1.288 420 139 45 19

15,06 11,29 7,53 3,76 2,75 1,69 1,07 0,68 0,43 0,303.600 1,00 5.197 1.575 513 171 56 23

16,73 12,55 8,36 4,18 3,05 1,88 1,19 0,76 0,48 0,333.960 1,10 6.243 1.888 615 206 67 28

18,40 13,80 9,20 4,60 3,36 2,07 1,31 0,84 0,53 0,374.320 1,20 7.380 2.229 725 240 77 32

In Figure 1: Ceiling layout (p. 48) is shown as the variant of a supply with supply lines 25 x 2.3 mm with a max. volume flow of approx. 640 kg/h and a pressure loss of approx. 200 Pa/m. Piping connection is from a central distributor with hydraulic control valve, zone valve with thermoelectric 2-point-actuator as well as shutoff valves. The tie-in and the supply lines are located in the intermediate ceiling of the floor. Supply line: 25 x 2,3 mm ; max. ca. 640 kg/h 4 Mats á 4,5 m² and 33 kg/hm² m = 594 kg/h PP 25 x 2,3 mm p = 175 Pa/m When using a maximum dimension of the supply line of 20 x 2.0 mm, the room is to be divided up into two hydraulic zones. Thermally, the control is effected by way of a room temperature controller which activates two zone valves.


53

With adequate spacing in the intermediate ceiling, this room is to be supplied from a central distributor with the with the supply line in the corresponding dimension for 2 x 280 kg/h, therefore, 594 kg/h (25 x 2,3 mm p = 175 Pa/m). Subsequently, only one zone control group is to be installed in DN 20.

4.1.11 Piping connection and arrangement of the zone control groups

The Clina capillary tube system is normally connected up by way of a system separation in the form of a heat exchanger. As from this heat exchanger, the secondary tube network must be absolutely corrosion-resistant. In principle, a capillary tube system has two main variants: A) In many cases it is practical to have a decentralised distribution and control of the water

flows of the secondary cycle. Connected up to a ring main, the control groups of the individual zones (refer to chapters 3.8 and 3.9) in this case are at accessible locations in the intermediate ceiling, either directly in or at the zone in question. Only one or several central transfer stations are required for the energy transfer and the system separation between the primary and the secondary cycle.

B) With this more sophisticated but user-friendly variant, each zone is has its own supply

and return line and is connected up to a storey distributing station which contains the above-mentioned components of a transfer station as well as the control groups of the individual zones. Balancing and regulation of all zones can therefore be performed from this central transfer point.

The selection of one of these variants depends on local conditions and the specific requirements and wishes of the customer. Refer to the table in chapter 4.1.10 for the dimensioning of the zone and room control groups. For uniform supply of the individual capillary tube mats, the piping within the zone should be conducted in the reverse-return principle. In this case, the mats planned for the zone should have almost the same size or should have the same pressure loss. The decisive factor here is the length of the capillary tube mats in particular. Hydraulic balancing of the individual zones is necessary in all cases. This hydraulic balancing is carried out according to the values of the tube network and pressure loss calculation.


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4.1.12 Determining the pressure loss p of the plant

For calculation, begin with the longest length of pipe and the largest mat and/or the mat with the highest pressure loss. The overall pressure loss of a hydraulic system is derived from: p System = p capillary tube mat + p pipe + p internals + valves + p heat exchanger p – Capillary tube mat From the output per mat and the mass flow as a factor of the system temperatures, the pressure loss per mat is determined depending on the size of the mat itself (refer to chapter 4.1.9). e.g. Mat type SB 20 . 4500 . 1000 . 00 m specif = 33 kg/hm² m = 149 kg/h p Mat = 13 kPa p - Pipe The pressure loss of the supply network is determined from the generally known rules of a pipe dimensioning. As an approximate value, apply a pressure loss of 150-200 Pa/m pipe. Refer to the annex for values for the pipe friction pressure losses of DN 15 to DN 100 of the PP-tube PN 10. There are also the pressure losses resulting from form and connecting parts with their zeta values. p pipe = R*l + Z = R*l + ( * /2 w²) R = tube friction pressure loss in Pa/m l = tube length in m = resistance coefficient = density in kg/m³ w = water velocity in m/s


55

p – Internals and valves The pressure loss from internals (installed elements) and valves covers all valves in the secondary cycle of the partial length of line to be calculated. These include items such as ball valves, shutoffs, filters, valves, control valves. e.g. PP-zone valve with kvs = 2,0 m³/h

m = 297 kg/h p Valve = 2,2 kPa p – Heat exchanger For the heat exchanger, the pressure loss is to be applied according to the details given by the manufacturer under the existing service conditions (size of the heat exchanger, capacity, mass flows, primary/secondary etc.). p - System The overall pressure drop of the heating cycle therefore results from the sum of the pressure loss of the capillary tube mat and the tube network as well as the internals (installed elements). These data are adopted as a basis for the design of the pump.

4.1.13 Design of the heat exchanger

for the design of the heat exchanger as a factor of the required capacity (output) for the corresponding primary and secondary temperatures, a maximum pressure loss, in each case, of max. 10 kPa on both sides should not be exceeded. Standard temperatures are 16 / 18 °C on the secondary side and 6 / 12 °C respectively 10 / 15 °C on the primary side. Under all circumstances, a corrosion-resistant heat exchanger must be selected. In this case, plate type heat exchangers made from high quality steel are recommended.

4.1.14 Design of the pump

In principle, the selected pump must have absolute corrosion-resistance (housing + impeller). Observe the instructions of the various manufacturers in this respect. We recommend in all cases the use of a high quality steel or bronze pump. After determining the overall pressure loss of the plant, select a suitable pump for the required total volume flow with the required discharge head. Normally, a discharge head of approx. 6 mWc is sufficient for cooling ceilings with the capillary tube system. For systems with several zones, a pump with differential pressure control should be used for reasons involving energy saving.

Date post:	21-Mar-2017
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Planning manual 2013 1 4 clina heiz- und kühlelemente gmb-h

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