Technical manual sanitary/heating The comfort pipeTechnical Manual Mainpex Creep behavior of Pe-RT...

The comfortpipe

Technical manual sanitary/heating

Plumbing & Heating

2

Table o f ConTenTsAlong the road to master at full throttle!

Atze RohrstolzPipologist

Technical Manual Mainpex

3

Table o f ConTenTsSimple processing for more comfort ......................... 4

Pipe system and drinking water ordinance ............... 6

Quality and safety for professionals ......................... 7

Technology .......................................................................... 7

Pipe ...................................................................................... 8

Pipe structure ...................................................................... 9

system advantages ........................................................... 10

Resistance .......................................................................... 10

Processing instructions ........................................... 11

sliding sleeve ..................................................................... 11

bending .............................................................................. 12

Thermal change in length ................................................ 12

expansion compensation and attachments ................... 13

Contact with other building materials .............................13

Protection against external corrosion ............................. 14

Connection to water heater or continuous-flow water heaters ..................................... 14

Mixed installation ..............................................................14

Insulation of pipes ..............................................................14

Thermal insulation ................................................... 15

Preventive fire protection ....................................... 19

Pipe system and drinking water ordinance ............. 20

Reference values for minimum flow pressures ............... 23

Pipe friction pressure loss with Vs ................................... 24

Project planning and quick calculation of drinking water systems ................................................ 25

Pressure test according to 1988 part 2 ........................... 26

Pressure test protocol ...................................................... 27

flush protocol ................................................................... 28

Mainpex heating system installation ....................... 31

Pipe performance data .................................................... 32

Connection options .......................................................... 33

Thermal insulation ............................................................ 33

Heat demand calculation ................................................. 33

flushing heating systems ................................................. 33

Pressure testing heating systems .................................... 33

Practical aids ..................................................................... 34

Tips and notes .................................................................. 34

DIN standards ......................................................... 35

4


sIMPle PRoCessIng foR MoRe CoMfoRT

Double profileWith the first double groove, the support sleeve is protected against mechanical damages.

• high processing comfort

• easy to be bent

• inherently stable

• no spring-back forces

• less required tools

The multi-layer compound pipe MPX sets the standards

in the field of processing. It is suited ideally for fast and

safe installation, because it can be bent easily and never-

theless it is inherently stable. – advantages hitherto only

known from the field of pressed systems.

as one single pipe system is sufficient to implement nu-

merous different applications in the field of HVaCR in an

ideal manner, additional tools and fitting systems, as well

as expensive material transportation are not applicable.

fast, technically perfect, and economic solutions are the

result.

MPXT E C H N O L O G Y

fIelds of aPPlICaTIon• for drinking water system installation according to DIN 1988

• for heating system installation according to DIN EN 12831

• for panel heating systems according to DIN EN 1264 and DIN 18560

5

The pipe with comfort.The pipe with comfort.

WITHouT o RIng noTHIng WIll age

The MPX pipe system is connected by means of slid-

ing sleeves and does not require any o rings for being

impermeable. Thus, no rubber seal can become porous

and your lines will remain leak-proof on a permanent

basis.

• permanently impermeable without

O rings

• time-saving routing

• sleeve can be used on both sides

• higher flow rates

• special brass, tin-plated,

protects against corrosion

Attachment of the sleeveThe sleeve is equipped with an additional groove. Here, the material flows in and prevents that the sleeve loses its position.

Sleeve can be used on both sidesThe sleeve can be mounted in any direction, improper attachment is impos-sible.

More flowBy expanding the MPX pipe, the cross-section in the joint is substan-tially larger when com-pared to traditional joint systems.

Undercut Due to the special design of the fittings, any contact between the aluminum layer and the fitting body is prevented.

ProfileThe optimized lands of the support sleeve maintain the leak-proofness of the joint on a permanent basis - without O rings.

fIelds of aPPlICaTIon

as of January 1, 2003, drinking water lines in buildings have to comply with even more stringent requirements as be-fore. Already on November 3, 1998, the regulations were put into national legislation with the amendment of the drinking water directive 98/83/EC. In doing so, the individual components and their materials in the drinking water installation (e.g. pipes, fittings, faucets) are observed closer. The monitoring has become significantly more strin-gent and exceeds the water supplier and has been extended to cover the last faucet. Thus, for example the lim-its for nickel have become stricter from 50 to 20µg/l and for copper from 3 to 2mg/l. Copper lines should only be used when the pH value is 7.4 or higher, or when the ToC value (total organic carbon) is below 1.5mg/l for lower pH values. We recommend consulting the water supply company in case this value is not complied with. Thus, everyone assumes a higher

responsibility for the food drinking wa-ter complying with the requirements. It includes all home owners, designers, architects, and installers in the fields of sanitation, heating, and air conditioning and controls the responsibilities of the chemical and microbiological param-eters so that the same comply with the regulation.

The use of plastic pipe systems in the field of HVaCR minimizes the risk of high, in-admissible, metallic values in the drinking water. given the possibility of extreme pH values in the drinking water it is important to be able to resort to state-of-the-art plas-tic pipe systems without brass connectors.

The installation system MaInPeX com-plies with the requirements of the drinking water regulation to the full extent. by using tin as fitting coating, the direct contact of the drinking water with brass or red bronze is prevented. Many changes in direction

occurring while routing the lines during the construction phase can be implement-ed without formed parts with the help of the multi-layer compound pipe MaInPeX. The use of fittings is only required in a few installation situations. Changes in direc-tion can be implemented manually or with tools. MaInPeX compound pipes consist of Pe-RT, a material the installer has been famil-iar with for decades and suited very well for drinking water lines. The quality of the drinking water is in no way impaired by us-ing MaInPeX pipes. MaInPeX pipe sys-tems are approved and can be used in the field of drinking water installation. The re-quirements of the dIn 1988 are complied with by the MaInPeX pipe system.

PIPe sysTeM and dRInkIng WaTeR RegulaTIon


6

The pipe with comfort.

7

MaInPeX - QualITy and safeTy foR PRofessIonalsTHe TeCHnology

The MaInPeX sliding sleeve joint is a permanent, o ring-free, permanently leak-proof, and dVgW-tested joint that does not re-quire any additional seals or seal materials between pipe and fit-ting. on the basis of the expansion technology, the pressure loss and the flow rate in the formed parts are very low. furthermore, there is no need for deburring or marking the insertion depth.

The advantages of the MAINPEX pipe system at a glance

•100%oxygen-proofmulti-layercompoundpipe• inherentlystablepipe,thusnoback-springeffectsandneverthelessflexible•noneedforformedpartsbysimplybendingthepipemanually• linearexpansionsimilartometalpipe• shorterinstallationtimeduetosimpleconnectiontechnology•non-pressedjoint100%"leaky"andeasilytoberecognized,thus,sleevehasnofirmseat•alreadypressedfittingsarere-usablebyheatingthesameandlooseningthesleeve•additionalprotectionagainstcorrosionduetotin-platedfittingsurfaces•preventionofstresscorrosioncrackingduetoadditionalreannealingofthefittings

General facts on the use

The MaInPeX pipe system is characterized by a high resilience:

•maximumtemperature 95°C•maximumcontinuousoperatingtemperature 70°Cat10bar

Attention

The MaInPeX pipe system must not be connected directly to systemswithoperatingtemperaturesabove95°C,e.g.solarordistrict heating plants. It has to be ensured that the application parameters of the MaInPeX pipe system cannot be exceeded in any operating situation.In case of questions on different fields of application, please con-sult the department Technology.

Pe-RT layer

adhesion promoteraluminum layer

adhesive layer

Pe-RT layer

PIPeThe MaInPeX system pipe is a pressure-resistant multi-layer compound pipe con-sisting of Pe-RT material. on the basis of the 100% oxygen proofness, this pipe issuited ideally for being used in the heat-ing area.

When using MaInPeX system pipes as drinking water line, the raw material suited very well from the point of view of hygien-ics is significantly superior to other raw materials.

The MaInPeX multi-layer compound pipe is the first Pe-RT compound pipe system for sliding sleeves.due to the special design of the pipe, back-spring during bending is impossible. The force required for bending the pipe is substantially lower than for pipes with

a low aluminum thickness and a stronger internal Pe layer. The internal Pe layer on MaInPeX is not as thick as for all other sliding sleeve systems. bearing frames to support the pipe are not required.

8


Creep behavior of Pe-RT dowlex pipes in comparison with Pe-X pipessource: Pe-RT 2388 made of bodycote - measurement report, PeX from dIn 16892

creep behavior PE-RT vs. PEX

100

10

1

Pe-RT 110oC

Pe-RT 80oC

Pe-RT 20oC

PeX 110oC

PeX 80oC

PeX 20oC

1 10 100 1.000 10.000 100.000 1.000.000

time h


9

System data overview

Dimension mm 16 x 2.2 20 x 2.8 25 x 3.5 32 x 4.4 40 x 4 50 x 4.5External diameter

length ring m 200 100 50 / / /

length bar m 3.5 3.5 3.5 3.5 5.0 5.0

Water volume (l/m) 0.106 0.163 0.254 0.423 0.803 1.32

Pipe roughness k (mm) 0.0004 0.0004 0.0004 0.0004 0.0004 0.0004

Thermal conductivity ( W/m x k ) 0.4 0.4 0.4 0.4 0.4 0.4

Coefficient of expansionmm/m x k 0.025 0.025 0.025 0.025 0.025 0.025

bending radius manual mm 5 x d / 80 5 x d / 100 5 x d / 160 / / /

bending radius machine mm 4 x d / 64 4 x d / 80 4 x d / 100 4 x d / 128 / /

attachment intervals m

Wall 1.50 1.70 1.90 2.0 2.2 2.4

Ceiling 1.00 1.10 1.30 1.50 1.70 1.50

Pressurestages 70°C/10baror95°C/6bar(permanentoperatingpressureatTmax)

Internal pipe material Pe-RT Pe-RT Pe-RT Pe-RT Pe-RT Pe-RT

Wall thickness

Pe-RT

adhesion promoter

diffusion barrier Pe-RT

Pip

e d

imen

sio

n

PIPe sTRuCTuRe

Material properties• multi-layercompoundpipePE-RT/AL/PE-RT• 5layertechnology• pressure-resistant

• nospring-backeffect• acid-resistantandresistantagainstchemicals• verygoodflowresistance

Fitting materialbrass CW 617 n (Cu Zn 40 Pb 2)finish: tin (sn)

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ResIsTanCeMaInPeX is resistant for all drinking waters and drinking water admixtures according to dIn 1988. Rain water lines (pH value 6.2-8.7) may be routed without limitations using MaInPeX system pipes.When using heating water additives, please

consult the factory. for compressed air sys-tems installed with MaInPeX system pipes, the use of oil-containing compressed air is inadmissible. When transporting other gases or fluids as those we approved, it is indispensable that you consult MaInPeX.

Pe raw material is resistant against numer-ous substances. Please consult the factory for precise information and the written ap-proval.

sysTeM adVanTagesThe MaInPeX compound pipe system ensures low flow resistance and pressure losses due to the fitting. one of the ad-vantages of MaInPeX can be seen clearly when routing pipes with many fittings. The zeta value is substantially lower compared

to comparable pipe systems.

all fittings and sliding sleeves of the MaIn-PeX system can be used for all fields of application, heating and sanitation instal-lation, without limitations. sanitary pipes

from MaInPeX can be used for heating installations without limitations as well.

CoatingMany installers do not want to use brass anymore. one reason is the introduction of the new drinking water regulations in Janu-ary 2003. The installer is responsible for the compat-ibility of his pipe system with the drinking water to be transported.Thecoatingofourfittingswith99.9%puretin is an additional safety for designing and executing drinking water lines.The closed tin layer allows for hardly any contact with the brass material.

another advantage of the tin layer is the re-duction of the risk of corrosion.for pipe systems with multi-layer com-pound pipes made of brass or red bronze there is a huge possibility of electrochemi-cal corrosion. aluminum and copper are very far apart in the electrochemical series.Within the electrochemical series tin is sig-nificantly closer to aluminum than copper. additionally, both materials are part of the base metals, which is why aluminum cannot be dissolved in a cathodic manner.

other metals can be combined to become our fittings without "transition piece".Compliance with a certain installation ar-rangement"inflowdirection"asknownforcopper and tin-plated pipes does not have to be taken into account with MaInPeX. In order to reduce the corrosion risk as re-gards to the sliding sleeves as well, the slid-ing sleeves have been coated as well.

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PRoCessIng InsTRuCTIonsslIdIng sleeVeStep 1 Cut pipe at right angle with the MaInPeX pipe cutter

Step 2 Push sliding sleeve over pipe end. Push the pipe end onto the expansion head as far as it will go and expand the same. Push together the expansion pliers up to the next mechanic stop.

Step 3 upon expansion, push the expanded pipe end over the fitting. The pipe has to be pushed along the complete fitting profile. Push the sliding sleeve manually up to the expanded pipe end.

Step 4 Insert the pipe with the fitting into the slid-ing tool. Use the sliding pliers with the appropriate inserts!The inserts are marked with the letters f for fitting and s respectively H for sliding sleeve.

Observe a safe seat of the tool! The sliding procedure is completed when the sleeve has been pushed onto the pipe as far as it will go. The sleeve has to be pushed onto completely!

The external pipe skin being compressed slight-ly is possible, but does not lead to any impair-ments regarding the joint.

bendIng

basically, the compound pipe from MaIn-PeX can be bent when the smallest bend-ing radii are complied with. The pipes can be bent manually or with the help of tools.If the pipes are bent manually, use both hands.

The pipes must not be bent directly at the joint.for better processing, you can use a knee. This results in the bends showing small kinks. Pipes with kinks must not be installed!auxiliary tools can be bending springs or

bending devices. It is indispensable for you to observe our smallest bending radii.

Bending radii The smallest possible bending radii, as shown in the table below, have to be ob-served and must not be fallen below.

Minimum radii (mm) for pipe bending Pipe size Bending radius (manual) Bending radius (tool)

ad 16 5 x d / 80 4 x d / 64

ad 20 5 x d / 100 4 x d / 80

ad 25 5 x d / 160 4 x d / 100

ad 32 - 4 x d / 128

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THeRMal CHange In lengTHWhen routing MaInPeX pipes the chang-es in length due to heating have to be taken into consideration. The following

formula has to be used when calculating the change in length.

Linear expansion (mm) = coefficient of linear expansion (mm/m x K) x pipe length (m) x temperature difference (K)

The coefficient of linear expansion for MaInPeX compound pipe = 0.025 mm/m x k

Example:20 m of pipe have to be routed in a hall. In order to accept the expansion by means of expansion brackets at the hall ends, the max linear expansion for the clamp attachment and the attach-ment interval have to be determined.

Withintheheatinglinethewatermaycooldownto5°C.Youhavetoassumethatthemaxheatingwatertemperatureof95°Cflowsthrough the line.The following values have to be entered into the formula:20 m x 90 K x 0.025 mm/m x K = 45 mm linear expansion

100

90

80

70

60

50

40

30

20

10

0

∆t =

exp

ansi

on

mm

∆t = 70k

∆t = 60k

∆t = 50k

∆t = 40k

∆t = 30k

∆t = 20k

∆t = 10k

0 10 20 30 40 50

line length m

13


50

eXPansIon CoMPensaTIon and aTTaCHMenTs

Expansion compensation

Changes in pipe lengths for MaInPeX pipes result from heating and cooling. These changes in length of the pipes have to be considered by taking measures al-ready during installation. The following options to compen-sate the linear expansion are available: routing the lines with bending brackets. This is the easiest way to compensate linear expansions. However, bending brackets cannot be installed in all places. Regarding this installation type it is impor-

tant that the expansion bend is equipped with a sliding clamp on the one side and a fixing point clamp on the other side. The space requirements for this type of routing have to be dimensioned sufficiently. The expansion length has to be calculated us-ing the formula on page 12. using expansion bends is possible. a slid-ing clamp has to be installed on each side of the expansion bend. The space require-ments for this type of routing have to be dimensioned sufficiently. The expansion

length has to be calculated using the for-mula on page 12.bellow expansion joints can be used for the MaInPeX pipe system.The position of the sliding and fixing point clamps has to be selected properly and the installation has to be implemented in accordance with the recognized rules of technology.

Pipe attachment

The dimensions shown in the table are maximum distances. for pipes heated by morethan40°Cthedistanceshavetobereducedbyapprox.20%!When attaching MaInPeX pipes on the floor, attachment intervals of 75 cm have to

be observed. In bending areas intervals of 30 cm to the bend have to be observed. When attaching MaInPeX pipes the over-all weight of the installation has to be ob-served. The same depends on the insula-tion, the medium, and the pipe expansion.

our pipes have to be attached according to the recognized rules of technology.

ConTaCT WITH oTHeR buIldIng MaTeRIalsWall and ceiling ducts for MaInPeX pipes have to be implemented in a way that the regulations regarding fire and noise pro-tection in buildings are complied with. direct contact to wall and concrete parts

is inadmissible. The fittings have to be protected against aggressive media and substances. Contact with bitumen or oil-containing substances is prohibited. The pipes have to be protected against uV

radiation. depending on the application case, the seals for wall and ceiling ducts have to be implemented according to the regulations for noise and fire protection.

Pipe clamps and attachment materials for MaInPeX pipes must be used only if the same are suitable for the pipe material and diameter. Requirements regarding noise protection and pipe expansion have to be observed.Pipes have to be attached at sufficient dis-tances to ceilings and walls.

Attachment intervals (m) Pipe size vertical pipes horizontal pipes

16 1.50 1.00

20 1.70 1.10

25 1.90 1.30

32 2.00 1.50

40 2.00 1.50

50 2.00 1.50

basically, it is possible to connect MaIn-PeX system pipes directly to water heaters or continuous-flow water heaters without special measures. However, it has to be ensured that the devices correspond to the technical specifications (dIn 4753, dIn

Vde 0700, and dIn 1988) and do not gener-atetemperaturesabove95°C.Ifthisisnotpossible, a cool-down distance of at least 0.8 m consisting of metallic pipe should be installed after the hot water output be-tween water heater or continuous-flow wa-

ter heater and the MaInPeX system pipe. In order to prevent damages to the pipe sys-tem, further measures have to be taken in case of a possible pressure increase during operation of the hot water generator.

ConneCTIon To WaTeR HeaTeR oR ConTInuous-floW WaTeR HeaTeRs

If it is necessary to connect the MaInPeX pipe system directly onto copper, stain-less steel, or tin-plated steel pipes, this is possible. our fittings are made of coated brass. This ensures that our MaInPeX pipe system can be connected with drinking wa-

ter systems made of copper, stainless steel or tin-plated pipes without taking specific measures,e.g."insulatingpiece".

The portfolio covers special fittings for di-rect connection to press or soldering sys-tems.

MIXed InsTallaTIon

When designing the insulation of pipes according to dIn 1988, the following require-ments have to be observed:

• compliancewith statutoryobligations and furtherobligations, suchas for example state building regulations. It has to be observed that dIn 4140 part 1 and part 2 are not applicable to drinking water lines• protectionagainstmoisturepenetrationoftheinsulationlayers• Compliancewithdesignedandspecifiedoperatingtemperatures

InsulaTIon of PIPesInsulation according to DIN 1988

14


MaInPeX fittings and connectors have to be protected against external corrosion, if re-quired. The connectors have to be protected against salt-containing air or aggressive envi-

ronmental substances by means of appropri-ate coatings. Please observe that insulation and coating materials must not have corro-sive effects on connectors or formed parts.

PRoTeCTIon agaInsT eXTeRnal CoRRosIon


15

THeRMal InsulaTIon

InsulaTIon THICkness: 5 MMavailable as MPX compound pipe in the dimensions: 16 x 2.2 / 20 x 2.8 / 25 x 3.5

Fields of application:

Technical notes and fields of application of pre-insulated MAINPEX heating and sanitation pipes

HVAC

•all radiator connection lines and distribution lines between heated rooms in the same and against other accommodation units• when the heating pipes are routed on a ceiling (foundation slab) against soil and unheated rooms an additional insulation of 100 % has to be placed below the pipes (e.g. ePs 20)•other: heating pipes in unheated and against adjacent unheated rooms havetobeinsulated100%

Drinking water cold

• for lines above ground in unheated and heated rooms•onconcreteceilings• inwall slots for single connection lines and as riser• ininstallationductswithouthotlines•other notes: next to hot lines all TWK lines have to be insulated with 13 mm, without insulation regulations, TWk and TWW have to be insulated with 9 mm

Drinking water hot

• inwall slots for single connection lines in the same accommodation unit (heated similarly)• forcirculationconnectionbetween heated rooms in the same accommodation unit•other notes: where no insulation is specified, TWk with circulation has tobeinsulatedwith100%

HVAC

• radiator connection lines (controlled) between heated rooms in the same accommodation unit • when the heating pipes are routed on a ceiling (foundation slab) against soil and partially heated or unheated rooms an additional insulation (100%) has to be placed below the pipes (e.g. ePs 20)

Drinking water cold

• for lines above ground in unheated rooms•onconcreteceilings• inwallslotsforsingleconnectionlines• ininstallationductswithouthotlines•othernotes:nexttohotlinesallTWK lines have to be insulated with 13 mm, without insulation regulations, TWk and TWW have to be insulated with 9 mm

Drinking water hot

• inwall slots for single connection lines in the same accommodation unit • for circulation connection between heated rooms in the same accommodation unit•other notes: TWK with circulation hastobeinsulatedwith100%

InsulaTIon THICkness: 9 MMavailable as MPX compound pipe in the dimensions: 16 x 2.2 / 20 x 2.8 / 25 x 3.5

Fields of application:

16


EnEV 2007

annex 5 (for § 14 section 5)Requirements for the limitation of heat dissipation of heat distribution and hot water lines as well as faucets

Table 1Thermal insulation of heat distribution and hot water lines as well as faucets

Line Type of line / faucetsMinimum thickness of the insulation layer, referred to a ther-

mal conductivity of 0.035 W/(m K)

1 Internal diameter up to 22 mm 20 mm

2 Internal diameter above 22 mm up to 35 mm 30 mm

3 Internal diameter above 35 mm up to 100 mm equal to internal diameter

4 Internal diameter above 100 mm 100 mm

5lines and faucets according to lines 1 to 4 in wall and ceiling breakthroughs, in the area of crossing lines, at line joints, at

central network manifolds½ of the requirements of the lines 1 to 4

6lines of central heating systems according to lines 1 to 4

routed in parts between heated rooms of different users after this regulation came into force.

½ of the requirements of the lines 1 to 4

7 lines according to line 6 in the floor structure 6 mm

details on the requirements, fields of application, and insulation thicknesses can be found in table 1. Table 1 corresponds to table 1 of § 14, annex 5 of the eneV 2007.

Table 2: Explanations/examples heating, for § 14, annex 5, table 1, EnEV 2007

Heating systemsapartment house /

non-residential building several userssingle-family house /

non-residential building 1 user

lines in unheated rooms and cellars 100% 100%

lines in external walls, external parts, between an unheated and a heated room, in shafts and ducts

100% 100%

Manifold lines to supply several, different users 100% no requirements

underfloor lines, also heating/cooling connection lines against soil / unheated rooms1) 100% 100%

lines and faucets in wall and ceiling breakthroughs, in the area of crossing lines, at line joints, at central line manifolds

50% 50%

lines in parts, between heated rooms of different users 50% no requirements

lines routed in the floor structure, between heated rooms of different users

see eneV, table 1annex 5, line 73) no requirements

heating lines in heated rooms or in parts between heated rooms of a user and lockable

/ no requirements 2)

1) eccentric/asymmetrical pipe hoses are admissible to limit the heat dissipation. The nominal width has to point towards the cold side. details can be found in the required general technical approval of the corresponding manufacturer.2) although there are no requirements applicable at this point, insulation has to be provided due to the following reasons: corrosion protection, avoidance of impulsive and flow noises, impact-sound insulation, reduction of the thermal load.

InsulaTIon of PIPes aCCoRdIng To eneV

17


The following insulation thicknesses apply to pipes of all dimensions routed in the floor structure (independent of the position) between heated rooms of different users:

Minimum thickness referred to a thermal conductivity of

0.035 W/(mk) for concentric insulation 0.040 W/(mk) for concentric insulation0.040 W/(mk) for eccentric /

asymmetrical insulation

> _ 6 mm > _ 9 mmsee general technical

approval of the corresponding manufacturer

Cold water lines are not subject to the EnEV, but have to be insulated accord-ing to DIN 1988, part 2 as follows.

DIN 1988 part 2 for cold water lines

Installation situations Insulation layer thickness at = 0.040 W/mK*)

Pipes above ground, in unheated room (e.g. cellar) 4

Pipes above ground, in heated room 9

pipes in ducts, without hot pipes 4

pipes in ducts, next to hot pipes 13

Pipes in wall slots, riser 4

Pipes in wall recess, next to hot pipes

13

Pipes on concrete ceiling 4

*) The insulation layers have to be converted correspondingly for other values of thermal conductivity, for a diameter of d=20 mm.

y

18


Protection against heating and condensation for drinking water systems in the cold water range

The dIn 1988 provides an overview for better overview over the selection of insu-lation materials for cold water-containing drinking water lines.

The overview is designed for the operating conditions typical in the field of domestic construction. Pipe in pipe provides sufficient condensa-tion protection!

Protection of hot water and circulation lines

Regarding thermal insulation for hot water and circulation lines the minimum require-ments of the heating systems regulation to the energy Conservation act are appli-cable.

Further details can be found in the DIN 1988 part 2.

Thermal insulation

The minimum thickness of the insulation layers refer to a thermal conductivity of 0.035 W/m x k (Wlg 035) according to eneV. When using insulations with different thermal conductivities, the insulation layer thicknesses have to be converted. The pro-tective pipe of MaInPeX is not an insula-tion within the meaning of eneV 2/02.

Possible insulation materials include:

•mineralfiber•foamedplastics•softandhardfoams•furtherrecognizedinsulationmaterialsarepossible

You will find more information on thermal insulation in the specialized areas.

Noise protection

Wall and ceiling ducts for MaInPeX pipes have to be implemented in a way that the regulations regarding fire and noise protec-tion in buildings are complied with. direct contact to wall and concrete parts is inad-missible. The fittings have to be protected against aggressive media and substances. The pipes must not be subjected to uV rays for longer periods of time. depending on the application case, the seals for wall and ceiling ducts have to be implemented according to the regulations for noise and fire protection.

Pipes should be protected and insulated due to many reasons. a very comprehensive description of this can be found in the dIn 1988-2. an impor-tant reason is the protection of the pipes against impact sound transmission. even small contact points of the pipe with parts are sufficient. Regarding the aforemen-tioned, the dIn 1988 writes as follows: "The standards of the DIN 4109 are ap-plicable to the requirements regarding the noise protection. There, the values for the admissible noise levels in rooms

to be protected are determined. De-tails on design, execution, and opera-tion of the systems, as well as on the certification of noise protection can also be found in the standards of the series DIN 4109 (see also datasheet of the ZVSHK3).

When insulating the pipes please observe in particular that the pipe insulation com-pletely encloses the pipe and is not dam-aged.

Installation situation Insulation layer thickness at = 0.040 W/(mK)*) mm

Pipe above ground, in unheated room (e.g. cellar) 4

Pipe above ground, in heated room 9

Pipe in ducts, without hot pipes 4

Pipe in ducts, next to hot pipes 13

Pipe in wall slots, riser 4

Pipe in wall recess, next to hot pipes 13

Pipe on concrete ceiling 4

*) for different values of thermal conductivity theinsulation layer thicknesses,referring to a diameter of d = 20mm have to be converted correspondingly.

y

19


The preventive fire protection as one of the most important tasks when routing and in-stalling lines is specified very precisely and comprehensively in germany.The same specifies the requirements for the preventive fire protection in pipe sys-tems, in the state building regulations intro-duced by the building law, and in the pipe system guidelines of the federal states.

for the user, the fact that according to the building Code (Mbo 2002) §§ 40 and 41 there are no requirements for sealing pipe systems, installation shafts, ducts, and ventilation systems within apart-ments and units with a maximum of 400 m² in less than 2 floors is important. along with the provisions of the Mbo 2002, please also observe the corresponding state

building regulations to the Mbo 2002.MaInPeX pipe system corresponds to building material class b2 (normally flam-mable) according to dIn 4102.

PReVenTIVe fIRe PRoTeCTIon foR HVaCR In buIldIngs and Houses

fIRe PRoTeCTIonFire protection insulation is required when HVACR installation lines go through fire-resistant ceilings and walls. In these cases measures have to be tak-

en preventing fire and smoke from en-croaching. These measures are classified according to building type and material. As regards to the building material, the

differentiation is made between flam-mable and flame-proof building materi-als as follows:

• A1,e.g.concreteorrockwool• A2,e.g.foil-laminatedpipeshells made of rock wool

• B1,flame-retardantbuildingmaterials, e.g. gypsum plasterboards• B2,normallyinflammablebuilding materials, e.g. wood and PeX pipes• B3,easilyflammablebuildingmaterials must not be used in buildings in germany.

Flame-proof: Flammable:

Mainpex pipes are classified into building material class b2, continue to burn without back-up fire, and are not self-extinguishing.

Insulated Mainpex pipes (16 mm-25 mm) may be routed in common or individual ceiling and wall breakthroughs, provided that:

• minimumwallorceilingthickness= 80 mm• insulationintheareaoftheconduit has to be building material class a1 or a2• lengthof thefireprotection insulation has to correspond at least to the wall and ceiling thickness

• forcontinuedinsulationwith building material classes a1 or a2 the clear distance between the fire protection insulation is 50 mm• forcontinuedinsulationwith building material classes b1 or b2 the clear distance between the fire protection insulation is 160 mm

• theresidualaperturehastobeclosed with concrete or cement mortar• if tested systems with general technical test certificate are to be used, no minimum pipe distance is required

Furthermore, the following is applicable to Mainpex pipes larger than dimension 32mm:

• basically, systemswithgeneral technical test certificate have to be used (minimum distance pipe not applicable)

• theinsulationmateriallayersand thicknesses depend on the manufacturer's specifications

basically, free routing of Mainpex pipes in emergency exits and escape routes is pro-hibited. The same have to be routed in fire protected installation ducts, suspended

ceilings, false floors, or flush mounted. In these cases, insulation of the fire protec-tion classes b1 or b2 is sufficient.

Recommendation:

Mainpex recommends products of the company Rockwool Conlit.

In order to prevent legionella contamina-tion, avoiding errors during the design and execution phases of drinking water lines is particularly important.

The following reasons can result in a contamination:

• improperplanning• inappropriate system selection to heat the drinking water• poor observation of regulations • error during installation (design, hydraulic comparison,...)• poormaintenance• contaminationswithinthepipe

often it is sufficient just to observe the regulations during drinking water instal-lation and to select an appropriate pipe system in a reasonable manner.

The following regulations and work sheets on this topic have to be observed:

dIn 1988 TRWIdVgW work sheets W 551, W 552, and W 553.dIn 4753dIn 4708VdI 6023

On the basis of mixing waters, the devel-opment of new wells, and feeds in peak times by other suppliers fluctuations as regards to the specific properties of the drinking water occur in waterworks.

These fluctuations have to be taken into account during the planning stage, be-cause traditional metallic materials may be deluted and exceed the limits. When selecting the raw materials, please con-sider that the pipe network will be ex-posed to fluctuating water qualities for many years.

20


PIPe sysTeM and dRInkIng WaTeR RegulaTIonLegionella issues no problem for MAINPEX

legionella and the risks for human beings caused by this bacterium were unknown until approx. 1977. only after at first mys-terious diseases developed amongst the participants of a meeting of legionnaires in the usa, this type of bacteria and the diseases caused by the same were discov-ered, such as legionella pneumonia and the Pontiac fever.

Human beings mostly pick up legionella by inhaling contaminated water aerosols in their lungs. The same can cause the Pontiac fever or legionella pneumonia (le-gionnaire's disease) in human beings.

legionella can be found in natural and arti-ficial humid zones: running waters, thermal waters, drinking water lines, shower heads, hot water accumulators, air conditioning systems, and similar. sporadically, legion-ella are also found in humid soils, sludge, and compost soil.

The legionella pneumophila are rod-shaped bacteria. at temperatures from 5°C–66°CandapHvalueof5and8.5they can survive. They proliferate very strongly at approx. 37 °C and a slightlyacid or neutral pH value. legionella have the ability to proliferate within free liv-ing amoeba, microorganisms with their enzymes and nutrients form the food re-source for legionella.

The following procedures to eliminate legionella in drinking water systems are possible:

• short-termexcesschlorination• thermalwatertreatment(please observe W552)•hydrogenperoxidedisinfection•ozonetreatment•disinfectionwithchlorinedioxide•UVradiation•copper/silverionization•anodicoxidation

The raw materials are demonstrably in-significant for the settlement of legion-ella. Together with other microorganisms legionella form a biological film in pipes, in which they can also proliferate. Cavities (grooves) in the pipe system are particu-larly suited for the settlement. biological films can form in pipes made of copper, steel, or plastic. even increased water flow does not flush out the legionella.

nevertheless, you should not use any material when selecting the raw materi-als for you drinking water installation. We recommend using only pipes that have an approval. In the field of hygienics this is a passed kTW test, as well as the test of the pipe according to work sheet W 270 (micro-organic growth).

MaInPeX pipes have a kTW approval and are particularly suited for drinking water lines.

21


Regulation/organization (mg/L) Type of limit concentration Justification

eC drinking water directive 3.0 reference value after 12 h stagnation aesthetically

WHo drinking water guidelines 1.0 Reference value aesthetically 2.0 guide value regarding health

TrinkwV ( annex 7, no.1 ) 3.0 reference value after 12 h stagnation aesthetically

german Health authority observe the regulations of the german Health authority!

Please also observe the information and examinationsof the"committeeforplas-ticpipesystems"ofthe"Robert-KochIn-stitute".

We can also provide personal support during the design and execution phase of drinking water lines or in case of prob-lems.

TRaCe HeaTIngusing trace heating tapes is possible.The heating tapes to be used have to ensure that too high a pressure increase within the pipe system due to uncontrolled heat-ing can be ruled out. Too high a pressure increase is also possible when the water ex-panding in the pipes cannot be prevented

due to shut-off units or at water heaters. In this case, the aforementioned has to be prevented by appropriate safety measures (diaphragm expansion containers or safety valves).The heating tape has to be attached accord-ing to the manufacturer's specifications.

MaInPeX pipes can be classified in the cat-egory"plasticpipes".When routing the heating tapes, please ob-serve the installation guidelines and routing instructions of the manufacturer.

CIRCulaTIon lIne sysTeMThe installation of a circulation line in hot water systems does not only enhance the user comfort when drawing water, but is required in many cases.In apartment houses it is normally impor-tant to provide hot water around the clock. The need to ensure the aforementioned is determined in the work sheets W 551, W 552, W 553, and in the dIn 1988-3. It is

important to note that a maximum of 3l water may run out before hot water is pres-ent at the faucet.

using the MaInPeX pipe system any type of circulation line can be created. even "internal hot water circulation systems"can be implemented with MaInPeX in an extraordinary manner. on the basis of the

very low flow reduction within the connec-tors, the system is suited particularly well for this type of hot water circulation. How-ever, the MaInPeX system pipe must only be used as external pipe and not as inter-nal circulation pipe.

•pipes thatareas shortaspossibleand small but hydraulically sufficient pipe diameters, in order to achieve a short dwell time of the drinking water in the system.• stagnation of the drinking water in system parts without flow has to be avoided.•heating cold drinking water manifold systems has to be avoided.•unusedpipeparts have tobedrained.

The technical rules regarding the imple-mentation and operation of drinking wa-ter systems are determined in the dIn 1988 (TRWI) – technical rules of the dVgW (german Technical and scientific associa-tion for gas and Water) . The dVgW work sheets W 551 and W 552 on the avoid-ance of legionella growth are applicable as well.

When erecting and planning the instal-lation, changing drinking water proper-ties have to be considered. The installer should consult the water supplier on the quality, by means of § 21 of the drinking water regulations the supplier is obliged to do so.

dRInkIng WaTeR lInes fRoM THe PoInT of VIeW of HygIenICs

22


Determination of the pipe diameters according to DIN 1988Scheme of the calculation steps

dIMensIonIng

1 determine the calculation flows of the faucets.

2 determine the total flows and assign the same to the sections.

3 determine the peak flow from the total flow.

4 determine the available pressure differential for pipe friction and individual resistances.

5 deduct the estimated share of available pressure differential for individual resistances and determine the available pipe friction pressure loss.

6 select the pipe diameter and determine the pipe friction pressure loss and the related calculatory flow rate

simplified calculation run (V)

V 7 Calculate the sum of the pressure losses from pipe friction of all sections and compare to the pressure differential available for the same.

V 8 If applicable, check with modified pipe diameters.

differentiated calculation run (d)

d 7 determine the pressure losses from the individual resistances via the loss coefficient

d 8 Calculate the total pressure loss from pipe friction and individual resistances and compare to available pressure differential

d 9 If applicable, check with modified pipe diameters.

ResIsTanCes / loss CoeffICIenTs (fITTIngs and PIPe) No. Individual resistance Graphic symbol, Loss coefficient simplified representation

1 Changeindirectionbybend90° 0.3

2 Changeindirectionbybendangle90° 0.7

3 T piece, branch at stream separation 1.3

4 T piece, passage at stream combination 0.9

5 T piece, passage at stream separation 0.3

6 T piece, counter current at stream combination 3.0

7 T piece, counter current at stream separation 1.5

8 Changeindirectionbyangle45° 0.4

drinking water systems are planned and installed according to dIn 1988, VdI 6023, and the dVgW work sheets W 551 and W 553. Please observe that the drinking water systems correspond

to the recognized rules of technology from the points of view of hygienics and hydraulics.

23


Reference values for minimum flow pressures and calculation flows of common drinking water tapping points

Minimumflow pressure

P min fl

bar

Type of drinking water tapping point

Calculation flow when tapping

mixed water *) only cold or heated drinking water

VR cold l/s

VR hot l/s

VR l/s

discharge valves

0.5 without aerator**) dn 15 - - 0.30

0.5 dn 20 - - 0.50

0.5 dn 25 - - 1.00

1.0 with aerator dn 10 - - 0.15

1.0 dn 15 - - 0.15

1.0 shower heads for cleaning showers dn 15 0.10 0.10 0.20

1.2 Pressure flusher according to dIn 3265 part 1 dn 15 - - 0.70



1.0 Pressure flush for urinal dn 15 - - 0.30

1.0 domestic dishwasher dn 15 - - 0.15

1.0 domestic washing machine dn 15 - - 0.25

faucet for

1.0 shower tubs dn 15 0.15 0.15 -

1.0 bathtubs dn 15 0.15 0.15 -

1.0 kitchen sinks dn 15 0.07 0.07 -

1.0 Vanities dn 15 0.07 0.07 -

1.0 bidet dn 15 0.07 0.07 -

1.0 faucet dn 20 0.30 0.30 -

0.5 Toilet tank according to dIn 19 542 dn 15 - - 0.13

1.0 electronic water kettle dn 15 - - 0.10***)

*) The calculation flows for mixed water tappingarebasedon15°Cforcold drinkingwaterand60 °C forheated drinking water.

**) for discharge valves without aerator and with hose coupling, the pressure loss in the hose line (length 10 m)- and in the connected apparatus (e.g. lawn sprinkler) is considered across the board by means of the minimum flow pressure. In this case, the minimum flow pressure is increased by 1.0 bar to 1.5 bar.

***) at fully opened throttle screw. Comment: tapping points and devices of the same type not included in the table having larger fitting flows or minimum flow pressures than specified have to be considered in accordance with the information of the manufacturers when determining the pipe diameters.

PIPe fRICTIon PRessuRe loss WITH Vs

Peak DN 8 DN 12 DN 15 DN 20 flow di = 8.4 mm di = 11.6 mm di = 14.4 di = 18.0 Vs V/L=0.06L/m V/L=0.11L/m V/L=0.16L/m V/L=0.25L/m L/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s

0.01 1.2 0.2 0.3 0.1 0.1 0.1 0.0 0.04

0.02 3.7 0.4 0.8 0.2 0.3 0.1 0.1 0.08

0.03 7.4 0.5 1.6 0.3 0.6 0.2 0.2 0.12

0.04 12.1 0.7 2.6 0.4 0.9 0.2 0.3 0.16

0.05 17.8 0.9 3.9 0.5 1.4 0.3 0.5 0.20

0.06 24.5 1.1 5.3 0.6 1.9 0.4 0.7 0.24

0.07 32.1 1.3 6.9 0.7 2.5 0.4 0.9 0.28

0.08 40.6 1.4 8.7 0.8 3.1 0.5 1.1 0.31

0.09 49.9 1.6 10.7 0.9 3.8 0.6 1.3 0.35

0.10 60.1 1.8 12.8 0.9 4.6 0.6 1.6 0.4

0.15 123.8 2.7 26.1 1.4 9.3 0.9 3.2 0.6

0.20 207.9 3.6 43.5 1.9 15.4 1.2 5.3 0.8

0.25 311.6 4.5 64.8 2.4 22.8 1.5 7.8 1.0

0.30 434.8 5.4 89.9 2.8 31.6 1.8 10.8 1.2

0.35 577.0 6.3 118.8 3.3 41.6 2.1 14.2 1.4

0.40 738.2 7.2 151.3 3.8 52.9 2.5 18.0 1.6

0.45 187.4 4.3 65.4 2.8 22.2 1.8

0.50 227.2 4.7 79.1 3.1 26.8 2.0

0.55 270.5 5.2 94.0 3.4 31.8 2.2

0.60 317.3 5.7 110.1 3.7 37.2 2.4

0.65 367.7 6.2 127.3 4.0 43.0 2.6

0.70 145.8 4.3 49.2 2.8

0.75 165.3 4.6 55.7 2.9

0.80 186.1 4.9 62.6 3.1

0.85 208.0 5.2 69.9 3.3

0.90 231.0 5.5 77.5 3.5

0.95 255.2 5.8 85.5 3.7

1.00 280.5 6.1 93.9 3.9

1.05 102.7 4.1

1.10 111.8 4.3

1.15 121.3 4.5

1.20 131.1 4.7

1.25 141.3 4.9

1.30 151.8 5.1

Peak DN 25 DN 40 DN 50 flow di = 23.2 mm di = 36.2 mm di = 45.6 mm Vs V/L=0.42L/m V/L=1.03L/m V/L=1.63L/m L/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s

0.1 0.5 0.2 0.1 0.1 0.0 0.1

0.2 1.6 0.5 0.2 0.2 0.1 0.1

0.3 3.2 0.7 0.4 0.3 0.1 0.2

0.4 5.3 0.9 0.6 0.4 0.2 0.2

0.5 7.9 1.2 0.9 0.5 0.3 0.3

0.6 10.9 1.4 1.3 0.6 0.4 0.4

0.7 14.4 1.7 1.7 0.7 0.6 0.4

0.8 18.3 1.9 2.2 0.8 0.7 0.5

0.9 22.6 2.1 2.7 0.9 0.9 0.6

1.0 27.3 2.4 3.2 1.0 1.1 0.6

1.1 32.5 2.6 3.8 1.1 1.3 0.7

1.2 38.0 2.8 4.4 1.2 1.5 0.7

1.3 44.0 3.1 5.1 1.3 1.7 0.8

1.4 50.3 3.3 5.8 1.4 1.9 0.9

1.5 52.0 3.5 6.6 1.5 2.2 0.9

1.6 64.2 3.8 7.4 1.6 2.4 1.0

1.7 71.7 4.0 8.3 1.7 2.7 1.0

1.8 79.6 4.3 9.2 1.7 3.0 1.1

1.9 87.9 4.5 10.1 1.8 3.3 1.2

2.0 96.5 4.7 11.1 1.9 3.6 1.2

2.1 105.6 5.0 12.1 2.0 4.0 1.3

2.2 115.0 5.2 13.2 2.1 4.3 1.3

2.3 14.3 2.2 4.7 1.4

2.4 15.4 2.3 5.0 1.5

2.5 16.6 2.4 5.4 1.5

2.6 17.8 2.5 5.8 1.6

2.7 19.1 2.6 6.2 1.7

2.8 20.4 2.7 6.7 1.7

2.9 21.7 2.8 7.1 1.8

3.0 23.1 2.9 7.5 1.8

3.1 24.5 3.0 8.0 1.9

3.2 26.0 3.1 8.5 2.0

3.3 27.5 3.2 9.0 2.0

3.4 29.0 3.3 9.5 2.1

3.5 30.6 3.4 10.0 2.1

3.6 32.2 3.5 10.5 2.2

3.7 33.9 3.6 11.0 2.3

3.8 35.6 3.7 11.6 2.3

3.9 37.3 3.8 12.1 2.4

4.0 39.1 3.9 12.7 2.4

4.1 40.9 4.0 13.3 2.5

4.2 42.7 4.1 13.9 2.6

4.3 44.6 4.2 14.5 2.6

4.4 46.5 4.3 15.1 2.7

4.5 48.5 4.4 15.7 2.8

4.6 50.5 4.5 16.4 2.8

4.7 52.6 4.6 17.0 2.9

4.8 54.6 4.7 17.7 2.9

4.9 56.7 4.8 18.4 3.0

5.0 58.9 4.9 19.1 3.1

24


Peak DN 25 DN 40 DN 50 flow di = 23.2 mm di = 36.2 mm di = 45.6 mm Vs V/L=0.42L/m V/L=1.03L/m V/L=1.63L/m L/s R mbar/m v m/s R mbar/m v m/s R mbar/m v m/s

0.1 0.5 0.2 0.1 0.1 0.0 0.1

0.2 1.6 0.5 0.2 0.2 0.1 0.1

0.3 3.2 0.7 0.4 0.3 0.1 0.2

0.4 5.3 0.9 0.6 0.4 0.2 0.2

0.5 7.9 1.2 0.9 0.5 0.3 0.3

0.6 10.9 1.4 1.3 0.6 0.4 0.4

0.7 14.4 1.7 1.7 0.7 0.6 0.4

0.8 18.3 1.9 2.2 0.8 0.7 0.5

0.9 22.6 2.1 2.7 0.9 0.9 0.6

1.0 27.3 2.4 3.2 1.0 1.1 0.6

1.1 32.5 2.6 3.8 1.1 1.3 0.7

1.2 38.0 2.8 4.4 1.2 1.5 0.7

1.3 44.0 3.1 5.1 1.3 1.7 0.8

1.4 50.3 3.3 5.8 1.4 1.9 0.9

1.5 52.0 3.5 6.6 1.5 2.2 0.9

1.6 64.2 3.8 7.4 1.6 2.4 1.0

1.7 71.7 4.0 8.3 1.7 2.7 1.0

1.8 79.6 4.3 9.2 1.7 3.0 1.1

1.9 87.9 4.5 10.1 1.8 3.3 1.2

2.0 96.5 4.7 11.1 1.9 3.6 1.2

2.1 105.6 5.0 12.1 2.0 4.0 1.3

2.2 115.0 5.2 13.2 2.1 4.3 1.3

2.3 14.3 2.2 4.7 1.4

2.4 15.4 2.3 5.0 1.5

2.5 16.6 2.4 5.4 1.5

2.6 17.8 2.5 5.8 1.6

2.7 19.1 2.6 6.2 1.7

2.8 20.4 2.7 6.7 1.7

2.9 21.7 2.8 7.1 1.8

3.0 23.1 2.9 7.5 1.8

3.1 24.5 3.0 8.0 1.9

3.2 26.0 3.1 8.5 2.0

3.3 27.5 3.2 9.0 2.0

3.4 29.0 3.3 9.5 2.1

3.5 30.6 3.4 10.0 2.1

3.6 32.2 3.5 10.5 2.2

3.7 33.9 3.6 11.0 2.3

3.8 35.6 3.7 11.6 2.3

3.9 37.3 3.8 12.1 2.4

4.0 39.1 3.9 12.7 2.4

4.1 40.9 4.0 13.3 2.5

4.2 42.7 4.1 13.9 2.6

4.3 44.6 4.2 14.5 2.6

4.4 46.5 4.3 15.1 2.7

4.5 48.5 4.4 15.7 2.8

4.6 50.5 4.5 16.4 2.8

4.7 52.6 4.6 17.0 2.9

4.8 54.6 4.7 17.7 2.9

4.9 56.7 4.8 18.4 3.0

5.0 58.9 4.9 19.1 3.1

25


Determination of the weights by means of the Mainpex quick calculation

PRoJeCT PlannIng and QuICk CalCulaTIon of dRInkIng WaTeR sysTeMs:

for pure weight determination, we offer an online calculation program on our web-site.

The same is released by means of a pass-word and can be used by our customers at no costs. Handling is very easy and un-complicated.

Project planning and design using the calculation service

you are also invited to use our in-house calculation service. We design and plan the system individually for your building. The drinking water is designed in accor-dance with the currently applicable stan-dards and regulations.

26

Main test

The main test is implemented directly after the pre-test. The test pressure read after the pre-test must not fall by more than 0.2 bar after two hours. leakages must not be

detectable at any points of the tested sys-tem.Pressure tests with air and inert gases are possible. Please observe the ZVsHk

datasheet"implementationof apressuretest with compressed air or inert gases for drinking water installations in accordance withDIN19887TRWI".

The pressure test for the MaInPeX pipe system has to be implemented after com-pletion of the installation and in accor-dance with dIn 1988 part 2. at first, every

joint has to be subjected to a visual inspec-tion. In doing so, check that all sleeves have been pushed on properly.only devices being able to indicate a

pressure increase of 0.1 bar are admitted for pressure testing. The pressure gage has to be connected to the lowest point in the system.

PRessuRe TesT aCCoRdIng To 1988 PaRT 2

Pre-test

During pre-test, an operating pres-sure of 5 bar has to be exerted as test pressure (15 bar). This test pressure has to be reset to the initial test pressure twice

within a period of 30 minutes at intervals of 10 minutes each. afterwards, the pressure must not fall by more than 0.6 bar (0.1 bar per 5 minutes) after a time of 30 minutes

has expired and no leakages must occur.

all lines have to be closed with metal plugs, caps, shut-off plates, or blind flanges. de-vices, pressure vessels, or drinking water heaters have to be disconnected from the lines. all pipe joints have been visually in-

spected for professional execution. leak-age spray can be used for leakage search-ing purposes. external corrosion has to be avoided!

Special note when performing the pressure test with compressed air or inert gas

Special note when flushing pipes according to DIN 1988 part 2

after the pressure test, the total system has to be flushed thoroughly. flushing has to be implemented according to the spec-ifications of dIn 1988 part 2.

Protocols and certificates on the pressure tests have to be developed. (see page 21)


27


TeMPlaTe foR PRessuRe TesT

PRessuRe TesT PRoToCol aCCoRdIng To dIn 1988 PaRT 1 foR dRInkIng WaTeR lInes Pressuretestwithtestmedium"water"

development:

Construction stage:

Testing person / company:

PRe-TesT:Test duration approx. 60 minutes

Test pressure = max admissible operating pressure / 10 bar + 5 bar = 15 bar at least 1bar (referred to the lowest point of the system)

start: (date, time) Test pressure: bar

afterwards, within 30 minutes at intervals of 10 minutes, double reset of the test pressure, wait again for 30 minutes and read the test pressure (max pressure loss 0.6 bar).

end: (date, time) Test pressure: bar

MaIn TesT:test duration approx. 120 minutes



Confirmation:

both during the pre- and during the main test no leakages could be detected for the system mentioned above.

(place, date) (stamp, signature, contractor)

(place, date) (stamp, signature, customer)

28

TeMPlaTe foR PRessuRe TesT

PRessuRe TesT PRoToCol aCCoRdIng To dIn 1988 PaRT 2 foR dRInkIng WaTeR lInes Pressure test medium: oil-free compressed air nitrogen carbon dioxide

development:

Construction stage:


leakage TesT:Test pressure 110mbar. Test duration up to 100 liters output volme at least 30 minutes.The test duration has to be increased by 10 minutes for each 100 liters.

output volume: liters

The test duration starts after having waited for temperature and steady state.

start: (date, time) Test pressure: mbar

end: (date, time) Test pressure: mbar

sTRengTH TesT:with increased pressureTest pressure: ≤ 63 x 6 mm max 3 bar > 63 x 6 mm max 1 bar test duration up to 100 liters output volume at least 30 minutes. The test dura-tion has to be increased by 10 minutes for each 100 liters. The test duration starts after having waited for temperature and steady state.



Confirmation: both during the pre- and during the main test no leakages could be detected for the system mentioned above.




29


TeMPlaTe foR flusHIng PRoToCol dRInkIng WaTeR sysTeM

flusHIng PRoToCol aCCoRdIng To dIn 1988 PaRT 2 foR dRInkIng WaTeR lInes development:

Construction stage:

Testing person:

Raw material: multi-layer compound pipe Pe-RT

Connection technology: sliding sleeve system MaInPeX

largest nominal width of the manifold line 25 32 40 50 65 80 100 Minimum number of tapping points dn 15 to be opened 1 2 3 4 6 9 14

Reference value for minimum number of tapping points to be opened, referred to the largest nominal width of the manifold line.

The line length per flushed section should not exceed 100 m.

The tapping points have to be closed successively, after the last flushing point has been flushed for at least 5 minutes.

floor shut-off devices, pre-shut-off devices (maintenance fittings) were fully opened during the flushing procedure.

sensitive fittings and devices have been removed and replaced by fitting parts respectively bypassed by flexible lines. Control valves and aerators had been removed.

The drinking water used for flushing purposes is filtrated, static pressure pw = bar.

dirt screens and dirt collectors were cleansed upon completion of the water flushing procedure.The flushing procedure started at the main shut-off fitting and was implemented section-wise to the farthest tapping point.

The drinking water system was flushed properly.



30

TeMPlaTe foR PRessuRe TesT WITH MaInPeX

PRessuRe TesT PRoToCol aCCoRdIng To dIn 18380 foR HeaTIng lInes

development:

Construction stage:


system height m

Designparameters supplytemperature °C returntemperature °C

start: (date, time) Test pressure: bar (min 5 bar, max 6 bar)

end: (date, time) Pressure loss: bar (max 0.2 bar)

max admissible operating pressure (referring to the lowest point of the system) bar

MaInPeX nominal widths

The system mentioned above was heated to the design temperature on and no leakages were found. no leak-ages resulted after the system had cooled down either.

The connections were subjected to a visual inspection: yes no

frost protection agent was added to the water: yes no

Procedure explained as specified above: yes no

Certification:




31


MaInPeX HeaTIng sysTeM InsTallaTIonUsing the Mainpex pipe system near-ly all application options in the field of heating system installation are at your disposal. All fittings can be used for the installation that are also used in the drinking water installation. Furthermore, fittings designed espe-cially for heating system installation are at your disposal, e.g. the intersection T piece.

geneRal

Connections to existing pipe systems such as copper, stainless steel, or other plastic pipe systems can be implemented without using special tools.

Thus, the Mainpex pipe system is not only usable for installations in new buildings, but also for old-building renovation in an ideal manner. all plastic pipe systems used in heating system installations have to be

oxygen impermeable in accordance with dIn 4726. The limit specified by the stan-dard is 0.1g oxygen/m3 at a water temper-atureof40°C.TheMainpexpipesystemis100%oxygenimpermeable.

When using heating water additives, please consult the factory.

When designing, installing, and operating heating systems in buildings, the following regulations and standards have to be complied with:

dIn en 12831 Method for calculation of the design heat load of buildings, dIn en 12828 Heating systems in buildings, design of water-based heating systems, dIn en 1254 Copper and copper allow fittings, dIn en 14336 Heating systems in buildings, Installation and commission-

ing of the water-based heating system, dIn 18380 Heating systems and central hot water systems, dIn 4102 fire behavior of building materials and parts, dIn 4108 Thermal insulation and energy savings in buildings, dIn 4109 noise insulation in building construction, dIn V 4701-10 ener-

getic evaluation of heating and ventilation systems, dIn 4726 Pipes made of plastics, eneV energy savings ordinance, MlaR Prototype line systems - directive on fire-protection requirements for line systems.

32


PIPe PeRfoRManCe daTaPerformance data of Mainpex MPX pipes

Recommended maximum pressure losses:

small heating systems: 50 - 100 Pa/mlarge heating systems: 100 - 200 Pa/munderfloor heating systems: 200 - 250 Pa/m

Recommended maximum flow rates:

Radiator Connection lines: up to 0.5 m/sHeating manifold lines: up to 1.0 m/s

errors and technical modifications reserved.

king pin inclination 10 k 15 k 20 k 25 k m R w

Pipe dimension max heating output Q [kW] [kg/h] [Pa/m] [m/s]

16 x 2.2 1.9 2.6 3.4 4.3 146 201 0.38

20 x 2.8 3.2 4.7 6.2 7.8 261 199 0.45

25 x 3.5 5.8 8.4 11.2 14.0 481 201 0.53

32 x 4.4 11.5 16.7 22.2 27.8 955 200 0.63

Mainpex single-pipe systemReturn of the previous radiator as supply for the following radia-tor.

Mainpex double-pipe system Pipes are routed below the radiator in the marginal area of the room.

Mainpex Tichelmann system Pipe routing as return loop. The first radiator has the shortest supply and the longest return. Regarding the last radiator it is the other way around.

33


ConneCTIon oPTIonsRadiator connections with the Mainpex pipe system can be implemented seam-lessly with the usual methods. This nor-mally comprises radiator connections from the raw floor, the wall, and in front of the

wall. In doing so, please observe that con-tact to other building materials is inadmis-sible. direct contact to wall and concrete parts is inadmissible. The fittings have to be protected against external corrosion.

The regulations for fire and noise protec-tion have to be complied with. The afore-mentioned also holds true for string and manifold lines.

THeRMal InsulaTIonThe EnEV is applicable regarding the insulation of heating systems. The same determines that heat distribution lines

have to be insulated with 100 % respec-tively in the area of crossings or wall and ceiling breakthroughs with 50 %. The

percental data of the insulation thick-ness always refers to the internal pipe diameter.

lines routed in parts between rooms (heated) of different users also have to be insulated with 50 % only. When routingwithin the floor structure, it is admissible to insulate with concentric insulation.

no insulation is required for pipes routed in rooms or parts of one (!) user and when shut-off devices above the floor are used to detect the heat dissipation In these cas-es, routing pipe in pipe (TiT) is sufficient.

HeaT deMand CalCulaTIon

flusHIng HeaTIng sysTeMs

Planning and dimensioning heating sys-tems are implemented by calculating the heat load of the building according to

dIn en 12813. normally, HVaCR planning programs, templates from engineering offices, or the calculation implemented

by the specialized technician are used for calculation purposes and to determine the quantities.

In order to remove metallic residua or flux material residua from the lines, a heating installation has to be flushed thoroughly before the same is commissioned. This

is to protect metallic components of the heating system, such as radiators or heat generators. The same may be damaged by galvanic reactions. The MaInPeX sys-

tem is not sensitive as regards to these contaminations.

The pressure test is implemented alike the one for drinking water systems, but the test pressure is only 1.3-times the operat-ing pressure. Heating installation systems have to be subjected to a leakage test ac-

cording to dIn 18380. upon installation and before closing the wall slots, wall and ceiling breakthroughs, the system has to be subjected to a pressure test. before the aforementioned, you have to check the

connectors for proper processing visually. The contractor has to develop a certificate on this pressure test and has to provide the customer with the same.

PRessuRe TesTIng HeaTIng sysTeMs

The table shows the minimum insulation layer thickness at 100 % for MAINPEX pipes according to EnEV

If insulation materials having a different thermal conductivity than =0.035W/(m x k) are being used, the insulation layer thicknesses have to be converted using the calculation procedure from the rules of technology.

Dimension Internal diameter Minimum insulation layer thicknesses da x s (mm) di (mm) 0.035=ג W/(m x k)

16 x 2.2 11.6 20 mm

20 x 2.8 14.4 20 mm

25 x 3.5 18.0 20 mm

32 x 4.4 23.2 30 mm

40 x 4.0 32.0 30 mm

50 x 4.5 41.0 41 mm

y

y

34


PRaCTICal aIdsour employees are ready to support you regarding the development. Please con-tact your responsible sales representative.

furthermore, customers of the company Mainpex may use cost-free programs for roughly estimated planning by means of the customer number and a password se-lected by themselves via our website.

TIPs and noTes

our employees are ready to support you regarding the development. Please contact your responsible sales representative.

Reference values installation times

Mainpex Nominal widths Installation times for running meter Multi-layer compound (included, completely routed, including pipe in mm attachment in group minutes)

16 dn 12 4 - 8 min

20 dn 15 5 - 9 min

25 dn 20 6 - 10 min

32 dn 25 7 - 11 min

40 dn 32 13 - 15 min

50 dn 40 15 - 17min

The specified installation times are complete reference values in group minutes.Calculation installers with system experience. all other auxiliary services are excluded.

35


dInsTandaRdsDIN 1988-2 1988-12 Technical rules for drinking water installations (TRWI); design and execution;TRWI Parts, devices, materials, technical rules of the dVgW DIN 1988-2 1988-12 Technical rules for drinking water installations (TRWI); compilation ofsupplement 1 standards and other technical rules on materials, parts, and devices;TRWI Technical rule of the dVgW DIN 1988-6 2002-05 Technical rules for drinking water installations (TRWI); part 6: fire extinguishing and fire protection systems - Technical rule of the dVgW DIN 2000 2000-10 Central drinking water supply - guidelines for requirements for drinking water, design, construction, operation, and maintenance of the supply systems - Technical rule of the dVgW DIN 4703-1 1999-12 Room radiators - part 1: dimensions of sectional radiators DIN 4703-3 2000-10 Room radiators - part 3: Conversion of the standard heat output DIN 4721 2001-06 Plastic pipe systems for hot water underfloor heating and radiator connection - Polyethylene of increased temperature stability DIN 4725-200 2001-03 Hot water underfloor heating systems - systems and components - part 200: determination of the heat output (pipe coverage <higher than>0.065 m) DIN EN 806-1 2001-12 Technical rules for drinking water installations - part 1: general; german version en 806-1:2001 + a1:2001 DIN EN 806-2 2005-06 Technical rules for drinking water installations - part 2: Planning; german version en 806-2:2005 DIN EN 806-3 2006-07 Technical rules for drinking water installations - part 3: Calculation of the Internal pipe diameters - simplified procedure; german version en 806-3:2006 DIN EN 12828 2003-06 Heating systems in buildings - Planning and hot water heating systems; german version en 12828:2003 DIN EN 14336 2005-01 heating systems in buildings - Installation and commissioning of the hot water heating systems; german version en 14336:2004

www.mainpex.de

MaInPeX gesmbHbachwinkl 27a-5761 Maria alm am steinernen Meer, austriaPhone +43 (0) 6584/22800fax +43 (0) 6584/[email protected]

MaInPeX gmbH & Co. kgsilbersteinstraße 14d-97424 schweinfurt, germanyPhone +49 (0) 9721/65977-500fax +49 (0) 9721/[email protected]

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