The blue line

Transcription

The blue line

D R I N K I N G
W AT E R
P I P E
S Y S T E M
The
blue
line
Handbook 2014
Index
The following commonly
used abbreviations are
found in this catalogue.
2
Abbreviation Description Unit
A
Cross-sectional area
mm2
d
Outside diameter of pipe
mm
di
Inside diameter of pipe
mm
E
Module of elasticity
N/mm2
FP
Fixing point
Force of heat expansion
N
Ft
IS Insulation thickness
mm
l
Length of piping
m
Minimum length of expansion pipemm
MS
NForce
Newton
PPressure
bar
PN
Pressure rating
bar
R
Pressure loss caused by friction
Pa/m
s
Wall thickness
mm
secTime
second
SF
Safety factor
SP Supporting point
tTemperature
°C
Temperature of medium
°C
tm
Temperature at time of installation°C
tv
VVolume
l/m
V̇
Flow volume
l/sec
v
Flow velocity
m/sec
VP
Packing unit
pc
Total flow rate (DIN)
l/sec
VR
Peak flow rate
l/sec
VS
W
Power Watt
Z
Flow resistance for type of fitting Pa
zz-dimension
mm
α
Coefficient of expansion
mm/m°C
Specific linear expansion
mm
∆ l
Total pressure loss
Pa
∆ p
Temperature difference∆°C
∆ t
Pressure loss coefficient
ζ
Coefficient of heat conductivity W/m°C
λ
Densitykg/m3
ρ
∑Sum
Tensile stress
Mpa
δv
Contents
4
5
Quality targets; the blue line
Technical standards
6–7Ketrix®
8–9
Problems and solutions
10–11
Raw material data: PP-R, metals, insulation
12–13
Pipe types KE00, KE02, KE08; operating temperatures
14
ALU composite pipe KE06
15–17
SENSO-LX insulated pipes; heat losses; savings
18–19
Methods of joining; the safest pipe connection
20–21
Joining the pipes with the hand welding machine
22–23
Welding the LX pipes; welding the saddle fittings
24–25
Table welding machine
26–27
Butt welding machine
28–29
Overhead welding machine
30–31
Electrofusion socket welding
32–33
Plumber friendly solutions
34
Pipe sizing; flow velocity; fitting pressure losses; circulation pipes
35–36
Pipe sizing according to DIN 1988-300
37–39
Sizing charts for PN10, PN16 and PN20
40–43
Flow rate calculations according to DIN 1988-300
44–45
Expansion; compensation; force of expansion
46–47
Compensating expansion in practice; pipe supports
48–51
Pressure testing
52–53
Rinsing; noise prevention; heat insulation
54–55
General installation guidelines
56–85
Product range; dimensions
86–87
Agencies; addresses
3
The blue line
Blue is KE KELIT´s company colour and
conjures up the following associations:
The preciousness of blue water:
Clean water is becoming ever more precious.
The surface of metal pipes are being destroyed by ever more aggressive ions.
The durability of blue sapphire:
Symbolic of value, durability and eternity.
The reliability of blue chip:
On the fast moving share markets a synonym for ”safe bet”, or ”market leader” or
”recommended purchase” or ”no risk”
Lines are associated with continuity,
direction and connections.
The colours, design and marking of the
products are regulated by various national
standards. KE KELIT products are easily
identified by the ”blue line” marking on
the product.
KE KELIT’s
Quality targets
Technical standards
National and international test institutes
test the conformity of our products to a
range of different standards.*
1. Our quality targets are not confined to the product.
They include all areas covered by
ÖNORM EN ISO 9001:2000.
2. Suppliers and customers are integrated
into the quality assurance system to
ensure that mistakes are prevented.
DIN 8077/8078
EN ISO 15874 1– 5
EN ISO 15494
Dimensions, pressure ratings
Material requirements
ÖNORM B5174
EN ISO 15494
DIN 8078-1
ASTM F1249-90
Dimensions, pressure ratings
Material requirements, resistance to impact
Resistance to chemicals
Diffusion of water vapour
3. Every employee is responsible for the
quality of his own work and should be
highly motivated to continually assess
his work.
4. Customer satisfaction can only be achie-
ved by responding to the requirements
of the customer and the market.
5. A responsible attitude to the
environment can only be achieved by
manufacturing long-life products by
environment-friendly processes.
The advantages of the ”blue line” range:
l
l
l
l
General:
A complete system from one supplier.
All three pipe materials use the same
joint technology, the same machines and
the same tools.
However, each system has been designed for its particular application.
Every new innovation is integrated
into the complete product range.
The Blue line is the new direction taken by
the leading pipe system supplier KE KELIT.
Senator Karl Egger eh.
Managing Director
EN ISO 8795:2001
BS 6920
ÖNORM B5014-1
ÖNORM B5018-1 + 2
EN 12873-1
DIN 2999
DIN 16962
DIN 50911
ISO 6509
DIN 17660
Suitability for drinking water
Migration
Metal threads
Stress corrosion cracking
Dezincification resistance
Brass materials
*For information about specific national approvals please contact the headquarters in Linz or the regional offices.
4
5
Chilled water
conditioning (PN10)
KETRIX pipe system
Operating conditions as specified
by ÖNORM:
Pipe systems for chilled water cooling
systems (down to +2°C)
Pipe systems for brine refrigeration
systems (down to –30°C)
Advantages
● Range of sizes: d20 –160
● Resistant to impact at – 30°C
● Resistant to any concentration of
glycol brines
● Resistant to corrosion even when
the temperature unintentionally drops below the dew point and at the aggressive temperature of 0°C.
Drinking water
max.temp: 30°C PN10
max.temp: 40°C PN16
Advantages
● Highly secure welded joint
(safety factor > 3)
● Tools, machines, and welding times similar to KELEN® pipe system
● Resistant to chemicals, water particles and pressure hammer, even at low temperatures
● Resistant to corrosion even in places where unwanted condensation has formed
PN10: 20°C/10 bar
From –30°C to +30°C/8 bar
Safety factor: Taking into account the
properties of the raw material ÖNORM
B5174 includes a safety factor of
(SF=1.25) in the operating conditions
given on the right.
The alternative pipe
system
The polymer
KEtrix® is made of CRYOLEN®,
a PP-based polyolefine blend.
Temperature (°C) 10 20 30 Pressure Service life
13,4 10,9 8,7 50
50
50
Pressure Service life
(bar) (years)
Properties:
Density
Tensile strength:
Elongation at tear:
E-module (20°C):
Heat conductivity:
Spec. thermal expansion: Resistance to impact:
Operating pressure in relation to
service life and temperature
g/cm3
0,9
40 N/mm2
800 %
1500 N/mm2
0,23 W/m °C
0,14 mm/m °C
– 30° C
Compressed air
technology (PN16)
by ÖNORM:
PN16: 20°C/16 bar
Safety factor: Taking into account the
properties of the raw material ÖNORM
B5174 includes a safety factor of
(SF=1.25) in the operating conditions
given on the right.
Temperature (°C) (bar) 10 20 30 40 21,2 17,2 13,8 10,9 Temperature Pressure (years)
50
50
50
50
Compressed air has become indispensable
for the manufacturing sector and is used for
the following tasks:
●
●
●
●
Driving medium for tools
Pneumatic control systems
Driving medium for regulator fittings
Air purification at the workplace
Advantages
● Range of sizes: d20 – 125
● High chemical resistance to
compressor oils
● No corrosion and therefore no variation in the quality of the compressed air
by ÖNORM:
PN16: 20°C/16 bar
Safety factor: As a result of the
aluminium layer a PN 12.5 medium pipe
can withstand the same operating
conditions as a standard PN16 pipe.
(°C) 10 20 30 40 (bar) 21,2 17,2 13,8 10,9 Service life
(years)
50
50
50
50
A separate catalogue is available for the KEtrix® pipe system!
6
7
Drinking water
problems
Operating conditions
Corrosion
PN16 = 20°C/16 bar; 60°C/8 bar
● The concentration of ions in drinking
PN10 = 20°C/10 bar;
water is increasing and consequently the risk of using metal pipes:
Chlorides: attack stainless steel
Sulphates: attack galvanised steel
Nitrates: attack copper
● Ever more problematic sources
of water reserves have to be tapped for the supply of drinking water
● Acid rain reduces the pH value of surface and spring water to critical levels below 7 (=neutral).
External corrosion occurs as a result of new building and insulation materials
and new installation methods.
● Disinfectants (chlorine, ozone)
attack copper in particular. Poisonous
Cu ions are released into the water!
PN20 = 20°C/20 bar; 70°C/8 bar
PN10, PN16 and PN20
● Cold water: d20 – d160 mm
Hot water: d20 – d110 mm
● Resistant to internal and external Internal corrosion - Cu
● Hard water causes incrustation on
the inside walls of metal materials.
The solution
External corrosion - Steel
● Higher pressure losses
● Reduced flow
●Blockages
● Expensive repair work
● Disruptions in the water supply
8
KELEN
drinking water
pipe system
Plastics are not
”replacement materials”.
When chosen and applied
correctly they often
provide the better
solution for a defined
problem.
● Time-consuming renovation
A secure supply of
drinking water is an
essential factor for
a high quality of life
The KELEN pipe system has many
advantages. Ideal for hot and
cold water installations for both
new projects and renovation.
● Pressure ratings:
Incrustation
The consequences:
The Result
Calcite deposits
Sometimes even
the only one
corrosion caused by ions in the
water or chemicals on the site
● No crystallisation points for lime deposits
● Secure joint technology which
requires no additional materials.
● Conforms to hygiene regulations
and approved for transporting
foodstuff
● Low pressure losses as a result
of smooth bore
● Low noise level
● Resistant to high temperatures
and pressure
● Low thermal conductivity
comparison of λ-values:
KELEN
0,24 W/m°C
Copper
320,00 W/m°C
Cast iron/steel 42,00 W/m°C
● Stringent testing and monitoring of
quality to international standards
● Secure long-term performance
● Pipes are insulated at the factory
and can be located behind the wall
● Can be combined with KELOX-multilayer flexible pipe system
”No more
corrosion in the
3rd millennium”
9
The raw materials
Density:
0,91 g/cm3
Melting Point:
~ 140° C
Tensile strength:
40 N/mm2
Elongation at tear:
800 %
E-module (20°C):
900 N/mm2
Spec. heat
2 kJ/kg °C
Heat conductivity: 0,24 W/m °C
Spec. themal expansion: 0,15 mm/m °C
The long-life plastic
The raw material is a polypropylene
copolymer (PP.R) with its typical quality
characteristics (DIN 8077, DIN 8078).
Every material is subject to ageing.
PP-R is no exception to this rule of nature.
The ”long-term creep curves”, which are
determined by temperature and stress,
are proof of the long service life
(see page 13 for operating conditions).
●
KELIT technology has made KELEN pipes particularly resistant to impact at –5°C.
●
Pipes and fittings are made
of the same raw material.
Metal adaptor
fittings
Special care has been taken over the
choice and quality control of the metal
threads.
(MS 63, CZ 132) for all parts transporting water ensures high resistance against aggressive water.
● A pore-free, chemically applied
metal plating prevents stress corrosion cracking.
● Metal parts which are not in contact with the media are generally made of metal-plated MS 58 brass.
● Exceptional resistance to torsion force and suitable for on-site conditions
● Depth of the thread conforms to
DIN 1692 for normal faucets
The insulation (LX)
Long-term creep curve DIN 8078
Foam:
The following formula
is used to calculate the
tensile stress:
●
●
●
●
10
SENSO
δvTensile strength in MPa
●
The expected service
life can be read off the
graph.
Special quality criteria:
● Dezincification resistant brass
●
●
●
Cross-linked PE
100% closed pore
Density: 30 kg/m3
Heat conductivity (λ) at:
40°:
0.038 W/m°C
60°:
0.039 W/m°C
Water vapour permeability
µ = 10,000
(an effective vapour barrier)
Environment-friendly
(CFC- free foam)
Bubble structure to insulate against noise transmission
● Strong enough to withstand site
conditions
● Concealed pipe can be located electronically
● Insulation can be pushed back to
allow room for the welding
Protective coating:
High quality 5-layer composite made
of polyolefines and aluminium
Time in h >
10
11
PP-R pipe system
KEO2 KELEN pipe
dxs
20 x 1,9 mm
25 x 2,3 mm
32 x 2,9 mm
40 x 3,7 mm
50 x 4,6 mm
63 x 5,8 mm
75 x 6,8 mm
90 x 8,2 mm
110 x 10,0 mm
125 x 11,4 mm
160 x 14,6 mm
KEO2 KELEN pipe
dxs
20 x 2,8 mm
25 x 3,5 mm
32 x 4,4 mm
40 x 5,5 mm
50 x 6,9 mm
63 x 8,6 mm
75 x 10,3 mm
90 x 12,3 mm
110 x 15,1 mm
KEO2 KELEN pipe
12
dxs
20 x 3,4 mm
25 x 4,2 mm
32 x 5,4 mm
40 x 6,7 mm
50 x 8,3 mm
63 x 10,5 mm
75 x 12,5 mm
90 x 15,0 mm
110 x 18,3 mm
PN10
Flow rate L/m
0,21
0,33
0,54
0,83
1,31
2,07
2,96
4,25
6,36
8,20
13,52
PN16
Flow rate L/m
0,16
0,25
0,42
0,66
1,03
1,65
2,32
3,36
6,36
PN20
Flow rate L/m
0,14
0,22
0,35
0,56
0,88
1,39
1,96
2,83
4,23
Dimensions: as specified by DIN 8077
Colour: Grey. 3 co-extruded green lines
(90° apart) help the plumber to align pipe
and fitting.
Standard length: 4 m,
Other lengths can be produced on request
subject to minimum order quantities!
Application as specified:
Cold water
PN10:
20°/10 bar
Safety factor: The DIN standard takes account
of raw material properties and calculates a safety
factor of 50% (SF=1.5) when deriving the operating conditions given on the right:
Operating pressure in relation
to service life and operating
temperature
Colour: Grey. 3 co-extruded blue lines
and fitting.
Hot and cold water
PN16:20°/16 bar
60°/8 bar
Temperature Pressure Service life
Colour: Grey. 3 co-extruded red lines
and fitting.
Hot and cold water
PN20: 20°/20 bar
70°/8 bar
(*C) (bar)(years)
20 10 50
30
9 50
40
8 50
(°C) (bar)(years)
20 16 50
40 12 50
60
8 50
70
6 25
(°C)
20
40
60
70
80
(bar)(years)
20
15
10
8
6
50
50
50
50
25
13
KELIT
ALU Composite pipe
KELEN-LX SENSO
insulated pipe system
KO6 KELIT ALU Composite pipe
PN20
dxs
20 x 2,8 mm
25 x 3,5 mm
32 x 4,4 mm
40 x 5,5 mm
50 x 6,9 mm
63 x 8,6 mm
75 x 10,3 mm
90 x 12,3 mm
Flow rate L/m
0,16
0,25
0,42
0,66
1,03
1,65
2,32
3,36
Colour: The PP-R medium pipe is colourless.
The outside layer is azure blue.
Standard length: 4 m.
A perforated ALU layer is bonded to the
medium pipe by a coupling agent.
This bonding reduces the expansion
considerably.
Operating pressure in relation to
service life and temperature
Operating conditions as specified:
Cold water 20°– 20 bar
Hot water 70°– 8 bar
Safety factor: As a result of its higher
resistance to temperature and pressure
a PN16 ALU composite pipe can withstand
the same operating conditions as a standard
KELEN PN20 pipe.
14
(°C) (bar)(years)
20 2050
40 1550
60 1050
70 8 50
80 6 25
Pressure rating
Type
Insulation thickness
Size
PN10
KE02-LX4
4 mm
d 20 x 1,9 mm
d 25 x 2,3 mm
d 32 x 2,8 mm
Pressure rating
PN16
PN20
Type
KE08-LX4/LX9KE00-LX4/LX9
Insulation thickness
4 mm und 9 mm
4 mm und 9 mm
Size
d 20 x 2,8 mm
d 20 x 3,4 mm
d 25 x 3,5 mm
d 25 x 4,2 mm
d 32 x 4,4 mm
d 32 x 5,4 mm
Length of pipe:
Insulation:
4m
Pipe is covered in
PE foam on the
extruder line
Insulation thickness:standard 4 mm
and 9 mm
Protective covering: HDPE linen bound fabric and viscoplastic polymer alloy
Tracing the pipe: SENSO layer makes it possible to trace concealed pipe
Advantages
● Enormous time savings
● Cost savings
● As a result of its elasticity the insulation can be pulled back
from the welding area
● The ends of the pipes are protected from damage and dirt
● Prevents noise transmission
of concealed pipes
15
The effect
Drinking water pipes made of PP-R are
winning an ever bigger share of the world
market as the best possible alternative to
metal pipes which are subject to corrosion.
The appropriate institutions (DIN,CEN, ISO)
lay down the minimum standards.
KE KELIT does more than merely meet
the minimum standards. KE KELIT provides
solutions to specific economic and technical
problems such as the heat loss in piping
systems.
There is a much lower heat loss through
KELEN hot water pipes than through metal
pipes as a result of the vastly different heat
conductivity of the materials
(PP-R λ = 0.24 W/m°C; Copper λ= 320
W/m°C; Steel λ= 42 W/m°C ).
This fact alone is not sufficient for KE KELIT
who have gone a step further.
KELEN without LX …
60°
The difference between the heat loss
through non-insulated and insulated
KELEN pipes over the period of a year
shows that there is a remarkable potential
for savings.
Comparison of a hotel room installation
with and without LX 4 insulation:
2.7 m Riser d32 (installed in shaft)
6.0 m Distributor pipe (embedded in
concrete)
8.0 m Circulation pipe (embedded in
mortar)
Operating conditions:
Hot water temperature:
60°C
Average room temperature:
25°C
System in constant operation 365 days
per year: t2
Hot water requirement: 2 hours/day: t1
Source of energy: Electricity
Annual heat loss (W)
Type of installation Riser pipes and exposed piping
Medium temp.°C
Example
The d20, d25 and d32 pipes are pre-insulated at the factory with either 4 mm or 9 mm
of a special insulation (LEXEL=LX) against
heat loss.
The results are remarkable:
Heat loss QR (W/m)
The potential savings
70° KELEN LX4
60°
70° KELEN LX9
60°
70°
Ambient temp.°C 20°25°20°25°20°25° 20°25°20°25°20°25°
d20
17,515,321,819,7 12,410,915,514,0 9,4 8,311,810,6
d25
21,318,626,623,9 14,612,818,316,510,9 9,613,712,3
Pipes
Calculation
d/lfm
lfm · QR · t2 · t1
KELEN
Q R
KELEN LX4
QR
208,08,0 · QR · 365 · 2
43,1
251 704
15,4
30 353
Potential
256,06,0 · QR · 365 · 2
45,3
198 414
17,7
77 526
energy
322,72,7 · QR · 365 · 2
22,9
45 136
15,4
30 353
savings
Sum
495 254
197 815
297 439 W = 297 KWh/a
d32 26,1
22,932,7 29,4 17,615,422,019,812,911,316,214,5
Type of installation Embedded piping in concrete and mortar
KELEN without LX …
Medium temp.°C
60°
70° KELEN LX4
60°
70° Annual heat loss (W)
KELEN LX9
60°
70°
Ambient temp.°C 20°25°20°25°20°25° 20°25°20°25°20°25°
d2049,3
43,161,6 55,4 17,615,422,119,911,0 9,713,812,4
d25 51,7
45,364,7 58,2 20,317,725,322,812,711,115,914,3
d32 54,3
47,567,8 61,0 23,520,629,426,514,913,018,616,7
The following formula is used to calculate the heat loss:
Amortisation calculation
The heat loss calculated above must be compensated by the permanent supply of extra
energy. Depending on the source of energy
(electricity, oil, gas or geothermic energy)
the costs will increase considerably.
● The extra costs of the insulation
is re-paid within WEEKS.
● The total cost of the piping and
Example
1KWh of electricity: e 0.06 – 0.15
1KWh of oil/gas: e 0.04 – 0.08
If we assume that the average energy
cost is e 0.075/KWh then the reduction
in heat loss of 297 KWh by installing the
insulated LX4 pipe will provide savings
amounting to: e 22.28 /year.
16
By comparing the costs
you can make the following
conclusions:
the insulation is re-paid within
a few MONTHS
● This represents a rate of return
which cannot be matched by
any other form of investment
or shares.
Blue line = blue chip = secure tip
17
The six ways of
joining the pipes
A wide range of safe and secure methods
for joining the pipes is essential for a pipe
system.
KE KELIT has a comprehensive range of
fittings for each method of joining.
1. Polyfusion welding
Principle:
Fusion welding occurs when a
large area of the outside of
the pipe and the inside of the
socket are welded together
A wide range of welding
fittings is available
3.
All KELEN polyfusion fittings from
d20 to d110 are rated PN20.
They can be used for welding to
pipes of all pressure ratings.
Advantages
Threaded adaptor fittings
Sizes:
Advantages
● Wide range of fittings
Female thread is a straight thread
● Male thread is tapered and roughened
● Thread is firmly anchored
in the fitting
High resistance to twisting
strain
4. Flange connection
Advantages
● Can be detached at
any time
● Elastic EPDM seal
● Dimensions conform
to DIN 2501-PN16
d20 x 1/2”– d75 x 2 1/2”
The threads conform to
DIN 2999 and are made of
dezincification resistant brass
(MS63-CZ 132). They are metalplated to protect against stress
corrosion cracking. Male and
female threads are available as
both straight and elbow fittings.
● Pipe and fitting are made
of the same material.
No additional materials
are required.
● Welded joints are not a
weak point in the system
● Pipe can only enter the
fitting after they have
been heated on the
welding machine
(important safety feature)
● The weld does not cause
a reduction in the flow at
the joint.
Sizes: d20 – d160
The solution for flanged
fittings
Backing ring conforms to
pipe sizes
Fusion welding: d20 – d125
Butt welding: d160
Advantages
● Detachable fittings
● Elastic EPDM fittings
● KE57 fitting for
connecting to appliances
5. Detachable union fittings
Sizes: d20 x 1/2”– d90 x 3”
Sizes: d20 – d110
3 types:
2. Butt welding
Advantages
● Pipe and fitting are made
of the same material. No
additional materials are
required.
KE55-PPR-male thread
6. Electrofusion welding
● Welded joints are not a Principle:
After the end of the pipe has been cut
flat the face of the pipe and fitting are
simultaneously heated to melting
temperature. They are then pressed
together under pressure until the
material has cooled.
18
weak point in the system.
● The weld does not cause
a reduction in the flow at the joint
Sizes: d125– d160
Sizes: d20 – d160
KELIT E-welding sockets may
be considered for welding in
confined areas.
KE56-PPR-PPR
KE57-PPR-male thread
Advantages
● Repair socket for confined areas
● Welding machine available at KE KELIT
● Each fitting is packaged
individually
Instruction sheet and
cleaning tissue are
enclosed
19
KELEN® polyfusion
welding with the
hand welding machine
Welding times
1. The pipes and fittings are joined by
polyfusion welding at 260°C. The welding
machines and tools are self-regulating.
Just connect to the electricity supply (230V)
and wait:
The red light indicates that the machine is
connected to the electricity supply.
When the green light goes out the welding
temperature has been reached.
Work can begin.
Measure the length of pipe
required and cut the pipe with the appropriate pipe cutter (up to d40 with the pipe
shears;
up to d110 with the wheel pipe cutter).
1.1
1.1Before welding the KELIT ALU
composite pipe sufficient aluminium
must be removed by the peeler to allow
the pipe to be welded to the full depth of
the socket. The colourless medium pipe is
clearly distinctive from the protective
covering.
Important: There should be no aluminium
in the welding area. Make a visual check
before welding!
The pipe can then be welded to the fittings
in the same way as the standard KELEN
pipe.
2.1
The welding procedure
2. Ensure that the surface of the pipes
are clean and free of grease
2.1 Measure the depth of the socket
and mark the insertion depth on the pipe
accordingly.
20
2.2 The heating time (see table) begins
when the full insertion depth of the pipe
and the whole of the socket in the fitting
have been pushed on to the welding tools.
2.3 The heating time varies according to
the pipe size (see table).
Once the heating time has elapsed push
the pipe and fitting together smoothly and
evenly without delay. The result is a homogeneous and strong joint.
2.4Three lines on the pipe (90° apart)
act as a guide for making a straight joint.
2.5The position of the fitting can be
adjusted for a few seconds immediately
after the pipe and fitting have been joined.
A short time later (see table) the joint
is capable of withstanding operating
conditions.
3. The low weight and high flexibility
of the material makes it possible to weld
whole sections of the piping at the work
bench. Take advantage of this and save
a lot of time.
4.
4. Make sure that any joints which still
need to made in the wall are positioned so
that they are accessible with the welding
machine.
5. The distance between the draw-off
points at the wall can be set (for all common
installations) both horizontally and
vertically using a template equipped with
a spirit level.
5.
6. The pipes should be insulated according
to the relevant national standards.
21
Polyfusion welding
of KELEN®-LX pipes
with the hand
welding machine
Important!
The bubble structure and the good
grip make it easy to pull back the
insulation.
Pressing the insulation to the pipe
can prevent the insulation from
slipping back
4. SENSO pipe detection
The SENSO properties of the LX
insulation allows the system to be located
up to a maximum depth of 80 mm in the
wall.
The following guidelines apply for
all pre-insulated KELEN-LX pipes.
4.1 Follow the instructions for the detector.
Point 1. is identical to the instructions
for non-insulated pipes on pages 20 and 21
4.2 Locate where the pipe is running both
horizontally and vertically within a radius
of 50 cm from the place where the hole is
going to be drilled.
2. Exposing the ends of the pipes
Welding KELEN®
saddle fittings
2.1 For short lengths of pipes the welding
area can be exposed by simultaneously
supporting the pipe on a bench and
pushing back the insulation.
1. The surface of the pipes and saddle
fittings should be free of grease, clean
and dry.
2. A hole is drilled in the pipe using
a 24 mm saddle drill.
2.2 For longer lengths of pipes one hand
holds the pipe while the other hand pushes
back the insulation
2.3 For especially long lengths of pipe it
may be easier if the hands are crossed over.
2.4 It is NOT necessary to cut the insulation.
3. The welding procedure and welding
times are identical to point 2. of the
instructions for the standard KELEN pipe.
22
3. The pipe wall and the saddle fitting
are heated simultaneously with the specially
designed welding tools for approx. 30 sec.
4. Once the heating time is over the saddle
fitting is pushed into the pipe wall immediately (do not twist!) and pressed for approx.
30 sec. The melting of both the pipe wall
and the pipe surface ensures a strong
homogenous joint. After approx. 10 minutes the joint can be subjected to operating
conditions.
23
Table welding
machine
See pages 20 and 21 for instructions
on preparing pipes and fittings for
welding.
1. Screw the required heating
elements to the welding plate.
The length of the heating element varies
according to the size of the pipe and the
section of pipe to be welded.
4. Set the pipe diameter switch to
the required size. This switch regulates
the length of the pipe that will be welded
into the socket
2. One side of the pipe clamps can
be used for small pipe sizes (d20 – d40).
For larger sizes (d50 – d90) the clamps
should be turned around.
3. The same principle applies for the
fittings clamps.
Heating element
5. Spacing button.
Press the button to fix the distance
between the two sliding blocks which will
enable the appropriate section of pipe
and the complete socket of the fitting to
be heated on the welding elements.
Note: The machine is available in
two sizes:
Type 1: d20 – 90 mm
Type 2: d25 – 125 mm
1. Fix the fitting in the clamp and the
fitting holder. Ensure that the face of the
fitting is flat against the clamp.
1.1 Put the pipe in the pipe clamp.
Do not tighten the clamp.
1.2 Hold down the spacing button and move
the sliding blocks together using the hand
wheel until the pipe is touching the fitting or
the sliding blocks can no longer move
1.3 Release the spacing button.
Only now fix the pipe in the clamp.
2. Move the sliding blocks apart and
pull down the welding plate.
2.1 Move the sliding blocks together
until they are stopped by the lock
2.2 When the heating time has elapsed
move the sliding blocks apart briskly and
quickly remove the welding plate.
Fitting clamp
Welding plate
The welding procedure:
Fitting holder
Lock
3. Push the sliding blocks together
briskly until the pipe diameter switch
catches.
3.1 Never cool the welded joint abruptly.
After a while loosen the clamp and the
finished joint can be removed from the
machine.
Pipe clamp
3.2 Once the cooling time has elapsed
the joint can be subjected to operating
conditions.
Spacing button
Pipe diameter switch
24
Hand wheel
25
for KELEN® PN10
pipes
1. Loosen the screws and fit the required
reducers in the clamps
The table below is valid for the KELIT butt
welding machine WZ115.
2. Put the surface cutter between the
pipe ends. Move the pipes together and
remove the oxide layer on the welding
surface by cutting away 0.2 mm of the
surface. Ensure that the ends of the pipes
are vertically parallel to each other
(maximum deviation: 0.3 mm).
The maximum deviation horizontally is
0.5 mm.
1.1 The end of the pipes should protrude
from the clamps by no more than 30 mm.
Cooling time
Welding pressure
Time to build up pressure
Max. change-over Time
Heating time
Heating pressure
Height of bead
Joining pressure
SDR series
Pipe
If you use other welding machines
then follow the operating instructions
for that machine.
3. The welding procedure
(see table on the left for welding criteria)
dx s
bar mm bar sec sec sec bar min
125 x11,4 11 16 1,0 2 237 7 11 16 19
160 x14,6 11 27 1,0 3 277 8 13 27 24
3.1 Before welding begins read off the
manometer the pressure required to bring
the pipes together. This pressure must be
added to the joining pressure given in
the table.
Hydraulic
control unit;
Plug connection
for welding plate
and surface
cutter
3.2 Insert the heating element (temp:
approx. 210 °C). Press the pipe ends on
the heating element and apply the pressure
as defined in 3.1 until a bead forms around
the complete circumference of the pipe.
During the heating time the pressure
must be reduced to the heating pressure.
Once the heating time is over move the
sliding blocks apart rapidly and remove the
heating element.
IMPORTANT:
The pipes ends cannot be touched and
must be welded immediately.
If this is impossible and the welding has
to be done later then the welding surface
has to be cleaned and any grease
removed.
3.3 The change-over time (time between
removing the heating element and welding the
pipes) should be as short as possible.
3.4 The welding pressure should be built
up as smoothly as possible during the time
given in the table (minimum: 0.15 N/mm2)
3.5 The welding pressure must be
maintained during the cooling time.
Never cool the joint abruptly.
If the weld has been done correctly a
double bead should be visible around the
whole circumference of the pipe.
30 mm
26
27
Overhead welding
machine
It is recommended to use the
overhead welding machine for
exposed piping in confined areas
(d50–d110).
Adjustable
pipe clamps
(d50–d110) are
mounted on
siding blocks
Adjustable
fitting clamps
(d50–d110)
are fixed to
the machine
1. Fix the pipe clamps to a pipe that
has already been installed. The machine will
hang at the end of the pipe.
1.1 To provide extra support the pipe should
be clamped close to a pipe bracket
1.2 A pole can be placed under the centre
of gravity to support the machine if necessary.
1.3 The pipe should protrude far enough
out of the pipe clamp to ensure that the pipe
can be fully welded into the socket of the
fitting but also allow enough space for the
welding plate.
The space between the pipe and the
fitting when the sliding block has been
completely rolled back should be
approx. 100 to 150 mm.
2. Put the fitting in the clamp and support
the fitting with the fixing elbow. The fitting
must have sufficient room to move sideways
so that the whole of the socket can be welded.
3. Put the welding plate between the pipe
and fitting. Turn the hand wheel to move the
pipe and fitting on to the welding tools. Heat
the pipe and fitting.
Hand wheel
for fixing
the pipes
3.1 When the heating time is over remove
the welding plate and push the pipe and fitting
together briskly to weld the joint.
Hand wheel
for moving the
sliding block on
the pipe side
Hand wheel for
Fixing the fitting
Elbow for
supporting
the fitting
3.2 When the cooling time is over the joint
can be subjected to operating conditions.
Centre of gravity
is marked below the
machine
28
29
11. The warning codes are as follows:
KELIT® E-Uni welding socket
1.
1. Cut the KELEN® pipe at right angles.
2.
5.
5. By cutting out the buffer in the middle
of the socket the e-socket can be pushed completely over the pipe.
5.1
2. Scrape the surface of the KELEN® pipe with
a suitable tool, e.g. a blade (DO NOT use sandpaper). A thin layer must be removed from the
pipe. At the same time the diameter should not
be reduced below its nominal value.
3.
3. Alu peelers are available for removing the
aluminium layer from the Alu pipes (please
note that more aluminium has to be removed for an electrofusion socket than for a standard socket).
4.
5.1 In order to guarantee the central position
of the weld, mark the welding depth of the
socket on the pipe. For pipes which are being
installed horizontally try to ensure that the
tracers point upwards.
Check the electricity supply before using
the electrofusion welding machine for
the first time.
Turn on the main switch to position “1”
Press the arrow key to choose the language
and press “OK”. Use the arrow and OK keys
to set the time and date and confirm by
pressing “OK”. This information only needs to
be entered when the machine is being used
for the first time
Start-OK
4. Remove any grease from the end of the
pipes and the electrofusion sockets where the
weld is going to be made. This should be done
with the cleaning tissue (soaked in isopropyl
alcohol) which is enclosed with the E-socket.
No oil-based solvents (e.g. paint thinner)
should be used to clean the socket.
30
Display
Stop
Menu
Welding cable
Main switch
Electricity supply
6.1 Check that the electricity supply is 230V
+/- 10% and 50/60 Hz. Switch the main
switch to position “1”
6.2 Take the orange adapter cable for d20110mm sockets and connect the socket to
the welding cable, adapter cable and welding
machine
6.3 Using the arrow key confirm the correct
socket type “KE KELIT” by pressing “OK”
6.4 Using the arrow key select the required diameter size and confirm by pressing “OK”
The display will show that the correct
size has been selected
6.5 Press “OK” to start the welding procedure. The welding machine automatically calculates the welding time. The voltage, welding
time and ambient temperature will appear on
the display.
6.6 There is a sound to indicate when the welding time is over. Then press “STOP” to end
the welding. Check whether the tracers are protruding from the socket.
7. Ensure that the electrofusion socket is axial to the pipe and is not subjected to stress or
strain during welding.
7.1 If necessary use the E-UNI socket holder
(WZ146)
8. Ensure that no moisture is present inside or
outside of the weld zone during welding
The ambient temperature should be between
–10°C and +45°C
9. Ensure that the weld is not subject to stress,
impact, moisture or any other strain during the
cooling period (allow at least 10 minutes for
cooling)
10. Wait for at least one hour before pressure
testing or subjecting to operating conditions.
05: Electricity supply not OK
10: Frequency (50/60 Hz) not OK
20:Ambient temperature outside the permitted range (–10 to +45°C)
30: Welding voltage outside the
permitted range
35: Machine overheated
45:Maximum welding voltage exceeded new electrofusion socket required
50: Minimum welding current not attained new electrofusion socket is required
55: Welding cycle interrupted by operator new electrofusion socket required
60:Short circuit – new electrofusion socket required
65: Interruption of electricity supply new electrofusion socket required.
70–75: Hardware defect
Should one of these codes appear during
welding follow the instructions in the manual.
symbol appears it is recommended
If the
to get the machine checked by the manufacturer or an authorised service centre.
Press “STOP” if you temporarily wish to
symbol will reapremove the symbol. The
pear the next time the machine is switched on.
31
Special plumbing
solutions
K85 KELEN®
Joining set
Polyfusion welding of the KELEN®pipe
system is both secure and quick. A lot more
time is spent fixing the pipes and joining
to the faucets. The are some practical
solutions which can make the job easier for
the plumber.
The set is used for fixing the outlets at
the wall and consists of the following
items:
Method of installation:
●Partition wall installation
●Brick wall installation
●Installation in front of the wall
● Metal plate (2.5 mm thick)
● Wall brackets: KE83 d20 or
d25 x 1/2” and double peg fitting
● Sound insulation caps
● Elastomer sound insulation pads
● Plastic stoppers
● Pegs and screws
● Connection to d50 siphon trap and
d30 rubber nipple is optional
● Set available for single outlet or
for double outlet (80–100 mm
or 150 mm)
K85H KELEN®
Fixing plate for
partition walls
A special system is required for installations
in front of the wall and in partition walls.
By cutting the K85H plate to the required
length it is possible to arrange the plate so
that the fittings are fixed in the required
positions.
The fitting is fixed to the double peg fitting
K86D behind the plate.
K86 HA Faucet plate
The faucet connection fitting KE83HA
has the following properties:
● No transmission of energy
to the plaster board
● The holes are octagonal to prevent twisting of the fitting
● The torque force on both fittings
is balanced by the fixing plate
For special applications the metal
plate is available separately
(ref: K85A)
32
K85K sound insulation cap for KE83.
The cap does not fix the fitting.
A special solution is required for fixing
the fitting and the cap.
● The octagonal holes mean that the fitting can be fixed in every position
● Sound insulating pad is completely covered with PE soft foam
33
Pipe sizing
Pressure losses in
KELEN®pipes
Calculation of the pressure loss (Z)
for the standard fittings
The total pressure loss (∆p) in the KELEN®pipe
system is calculated by multiplying the friction
loss (R) by the length of the piping (l) plus the
sum (∑) of the friction losses for the individual
fittings (Z).
∆p = (I · R + ∑Z) in Pa
The choice of pipe size for the water
supply is dependent on the following
factors:
●
●
●
●
●
●
●
●
The available water pressure
Geodetic difference in height
Pressure losses through system
components
Minimum flow pressure through faucets
Pressure losses in the pipes
The individual pressure losses of the fittings
Type, number and simultaneous use of the draw-off points
Flow velocity
Note:
For the purpose of pipe sizing it is assumed
that that there will be no reduction in the
internal diameter caused by incrustation
since the surface structure of the pipe is
amorphous and the surface roughness of
the pipe is minimal (0,007).
Maximum flow velocity
according to DIN 1988-300
Maximum design flow
velocity for a given pipe run ≤ 15 min >15 min
m/sm/s
Service pipes
Supply mains:
pipe runs with low head loss
in-line valves
(ζ < 2.5)
In-line valves
with greater
loss factor
34
2
2
5
2
2,5
2
Z = ζ•
v2 ρ
2
Fitting Symbol
Elbow 90°
Coefficient ζ
1,3
Elbow 45° 0,4
Tee-straight flow
0,3
Tee-flow separation
0,3
Tee-reverse flow
1,5
Reducer
Stop valve
d20
d25
G
0,4
10,0
8,5
Slanted seat valve
d20 3,5
d25
2,5
S
d32–63
2,0
Guidelines for circulating pipe systems
(DIN 1988–300)
For hygienic reasons the circulating system
should be designed so that the temperature
at any point in the system is no lower than
5K below the operating temperature.
The power of the pump and the regulation of the temperature are designed so that
the temperature does not fall below 55°C at
any point in the system. For economic reasons the flow velocity in circulating systems
should be approx.. 0.2– 0.5 m/s and in
exceptional circumstances up to a maximum
of 1.0 l/s.
Guidelines for pipe
sizing (DIN 1988-300)
1. Determining the calculated flow rate
and minimum flow pressures of the
outlet fittings
The calculated flow rate V̇R is an adopted outlet fitting flow value in the calculation rate. The
guidance values of the calculated flow rates of
common fixtures are included in the table.
The calculated flow rate V̇R (as an average
value) is obtained from the following equation:
V̇R = V̇min + V̇max
2
2. Determining total flows and
allocating them to the sections
The calculated flow rates are to be added contrary to the flow direction – always at the farthest sampling point and ending at the supply
line – the total flow rates achieved in this way
are then to be allocated to the corresponding
sections. The part route in question begins with
the mold piece on which the cumulative flow or
the diameter changes.
The total flow rates (cold and hot
water) are to be added to the cold
water line branch point which heads
to the drinking water heater.
3. Application of the conversion curve
from the total flow to the peak flow
During calculation of the line systems, it is absolutely necessary that all sampling points be
applied with their calculated flow rates.
An exception to this is when a second sink, a
bathtub with a shower unit, a bidet, a urinal or
nozzles in toilet facilities vestibules are included in a usage unit (NE). These are not taken
into account in the total flow.
4. Simultaneity depending on
building type
The calculation of the peak flow depends on the
total flow; the simultaneity of the water outlet
depends on how the building is used (e.g. flats,
hotels etc.).
Generally it is not expected that all connected
outlets will ever be fully open at once.
On Pages 40 and 41 you will find the conversion curves for the various building types.
5. Select pipe diameter
Pipe diameters and pipe friction pressure gradients and all corresponding calculated flow rates
must be determined. (Pressure loss diagrams:
Page 37 to 39).
6. Pressure loss compared with
available pressure
The total pressure loss for the determined pipe
diameter should reach the existing pressure
difference, but not exceed it.
35
Guidelines for pipe
sizing (DIN 1988-300)
Pressure losses
PN10
The pressure losses are calculated according
to the Nikuradse formula:
7. Minimum flow pressures and calculated flow rates (VR: l/s)
of common drinking water extraction points
The method for calculating the pressure
loss of the individual fittings is described
on page 34.
Surface roughness: 0,007 mm
Min. flow-
pressure
Drinking water extraction type
bar
Dimension
V̇R: l/s
Outlet valves
0,5
Without aerator a
0,5
0,5
1,0
With aerator
1,0
Mixing valves b,c for
1,0
Shower tubs
1,0
Bathtubs
1,0
Kitchen sinks
1,0
Washbasins
1,0
Bidets
DN 15
DN 20
DN 25
DN 10
DN 15
0,30
0,50
1,00
0,15
0,15
DN 15
DN 15
DN 15
DN 15
DN 15
0,15
0,15
0,07
0,07
0,07
0,5
0,5
Household machines
Dishwasher
Washing machine
DN 15
DN 15
0,07
0,15
1,0
1,2
0,5
WC basins and urinals
Urinal flush valve
manual or automatic
Flush valve for WC Cistern according to EN 14124
DN 15
0,30
DN 20
DN 15
1,00
0,13
a) Without connected appliances (e.g. sprinklers)
b) The indicated calculation flow is to be included in the cold and warm water calculations
c) Angle valves for e.g. basin taps and shower hose connections are to be regarded as
individual resistors or recognised with the outlet fitting minimum flow pressure.
36
Important note:
Notes:
The valves manufacturers must specify the minimum flow
pressure and the fittings flow rates calculations (VR). The
manufacturer’s information absolutely must be considered when measuring the pipe diameter – if it lies above the values listed in the table, then the drinking water
installation must be sized according to the manufacturer’s
instructions.
Equal-type outlets and devices not
included in the table with flow rates
or minimum flow pressures that are
greater than those listed must also
be taken into account according to
the manufacturer’s instructions.
37
38
Pressure losses
PN16
on page 34.
Pressure losses
PN20
on page 34.
39
Excerpt from DIN 1988-300
For the building types indicated in the table,
the peak flow (V̇S) is calculated with the
following scope:
Peak flow constants (a, b, c) for each building type
Depending on the building type, the peak flow
(V̇S) is calculated with the constants included in
the table on Page 33 as follows:
Building typeConstants
V̇S in l/s
Graphical solution for the calculation of the peak flow V̇S depending
on the total flow V̇R for the range 0–50 l/s Zusammenstellung
5
5
Hotel
4
School, adminis
tration building
2
2
Care home
1
1
0
20
Pflegeheim
30
Wohngebäude Seniorenheim
Krankenhaus
40
Hotel
Schule/Verwaltung
V̇R in l/s
50
V̇S in l/s
Graphical solution for the calculation of the peak flow V̇S depending
on the total flow V̇R for the range 0–600 l/s
Zusammenstellung
15
15
Hotel
14
13
12
Hospital
11
11
10
10
9
9
8
8
7
School, administration build
6
5
ing
Residential building, nursing home
4
Care home
3
6
5
4
3
2
1
1
0
50
100
Pflegeheim
40
7
2
0
150
200
250
300
350
Krankenhaus
400
Hotel
450
500
Schule/Verwaltung
1,48 0,19 0,94
Assisted living facility, nursing home
1,48 0,19 0,94
Bed house in hospital 0,75 0,44 0,18
Hotel 0,70 0,48 0,13
School and administration building
0,91 0,31 0,38
Care home
1,40 0,14 0,92
550
V̇R in l/s
0
600 0
Usage units (NE)
Permanent consumers
A room with outlets in residential buildings
(e.g. bath, kitchen, utility room) or in non-residential buildings (in the event that the recognised use is similar to that of a flat).
The flow of permanent consumers is added to
the peak flow of the other outlets. Permanent
consumers are defined as water outlets which
last longer than 15 min e.g. garden blast valve.
Therefore, the peak flow in each leg of a NE is,
at maximum, equal to the total flow of the two
biggest outlets installed in the leg (also applies
in cases within an NE where the calculation indicates a smaller flow).
If a second NE is attached to a leg (e.g. in the
riser), then the values of the peak rates of the
two NEs shall be added (if the resulting peak
flow is smaller than the value calculated according to the calculation).
Otherwise, the peak flow must be determined
according to the respective equation.
14
13
12
Residential building Experience has shown that the flows of the flow
direction up to the end of the strand cable
and in the floor distribution of NE‘s are too
high; this is because, normally, no more than
two outlets are open at the same
time e.g. in
Zusammenstellung
a bath.
0
10
c
Exceptions with calculation of the
peak flow V̇S
3
ng home
Residential building, nursi
0
b
4
Hospital
3
50
a
V̇S: a (Σ V̇R)b – c
Σ V̇R: 0,2 bis ≤ 500 l/s
50
100
Pflegeheim
150
200
250
300
350
Krankenhaus
Series equipment
The total flow is the basis for the calculation.
The simultaneity of the water outlet is to be
defined with the operator. The multiple peak
flow rates of the series system must to be
added up if they could both occur at once.
Special buildings, commercial and
industrial facilities
With special buildings (other than those indicated above), including industry buildings, agriculture buildings, gardening buildings, slaughterhouses, dairies, shops, laundries, large kitchens,
public baths etc. the peak flow must be determined from the total flow in co-operation with
the facilities operator. The peak flows of the
sub-zones of the drinking water installation
must be added up if they coincide.
400
Hotel
450
500
550
600
Schule/Verwaltung
41
Under heat conditions all materials
increase in volume and/or length
according to the following formula:
Calculation of the linear expansion:
∆l = I · ∆t· α
The linear expansion is determined
by the length of the pipe, the increase
in temperature and the coefficient
of expansion.
It is not determined by the diameter
of the pipe
Comparison of
materials
Coefficient of
expansion α = mm/m°C
Galv. steel
Stainless steel
Copper
KELIT Alu comp.*
PVC
KELEN
PEX
E-module 60°
N/mm2
0,012
220000
0,015
200000
0,016130000
0,035*
3500
0,0801100
0,150300
0,175540
* α d63 and above = 0,050
Compensation must be made for the
expansion of KELEN pipes under heat
conditions.
Even if the rise in temperature is only for
a short time sufficient compensation must
be made for this temperature difference
Compensation is always made between
two fixed points or between a fixed point
and a change in direction of the piping
(expansion arm).
Calculation of the expansion arm:
Difference in temperature ∆t
Linear heat expansion
Heat expansion chart (unhindered linear expansion) ∆l
Expansion arm for
exposed piping
MS = 20 · d · ∆ l
20 = Coefficient for KELEN
MS = Minmum length of the
expansion arm (mm)
Length of pipe which branches off
at 90° from the main pipe to the
next fixed point
Example:
d50 mm pipe runs over a length of 15 m
∆t = 35°C
Question: How long does the expansion
arm have to be to compensate for the
expansion?
∆I = 15 · 35 · 0.15
∆I = 79 mm expansion
MS = 20 · 50 · 79
MS = 1256 mm expansion arm
Minimum length of expansion arm (mm)
Expansion behaviour
of KELEN® pipes
This means that when heated
KELEN® will expand more than metal
materials if the expansion is
unhindered.
42
43
Force of heat
expansion
The force of linear expansion is different
for each material. The specific force of heat
expansion is calculated according to the
following formula:
Ft = E · A · α · Δt
1000
Comparison of the materials:
If unhindered KELEN® pipes will
expand more than metal materials
under the influence of heat. The
force of heat expansion, however,
is much smaller!
Dimension
Linear expansion
The following methods can be used to
control the linear expansion and the force
of expansion:
E-module of PP-R in relation to the
operating temperature tm
l
1000
The force of heat expansion is
dependant on the dimension of the
pipe and the change in temperature
but not on the length of piping.
900
800
700
600
E-module (E) in N/mm2
An important factor is the rigidity of the
material (E-module)
Practical solutions
for compensating
expansion
The E-module of PP-R (like any other
plastic) is dependant on the temperature
(see graph below)
> Temperature: < E-module
< Temperature: > E-module
As the temperature increases the E-module
decreases.
l
500
400
300
l
200
180
0
10
20
30
40
50
60
70
80
Temperature tm in °C >
l
Example:
Length of piping:
l =50 m
Temperature during installation: tv =20°C
Medium temperature: tm = 60°C
Difference in temperature: dl=40°C
Force of expansion(Ft)
27,3 x 3,2 Galvanised steel
25 585 N
26,9 x 2,0 Stainless steel
18 774 N
28 x 1,2 Copper
8 406 N
25 x 3,5 KELIT Alu Composite
1 248 N
25 x 2,9 PVC
771 N
25 x 3,5 KELEN®
426 N
25 x 3,5 PEX/VPE
894 N
Piping that is embedded in the
wall or the floor is prevented from
expansion by frictional force.
No extra measures are required.
Compensation must be made
for expansion of exposed piping
Even if the rise in temperature is only for
a short time sufficient compensation must
be made for this temperature difference
(see pages 42, 43, 44, 46 and 47)
l
l
l
Pipe channels may be used to increase
the stability of the pipe.
The expansion is reduced to the same
value as steel pipes.
The strength of the fixed points should
be sufficient to compensate the expansion
force.
The specific expansion can be minimised by
installing the KELIT ALU composite pipe
(d20 – d90), especially on long pipelines.
This pipe reduces the expansion by
approx. 75%.
Every change in temperature will exert
a force.
> An expansion force will occur when
the temperature rises.
< A shrinking force will occur when
the temperature falls.
The force of expansion can be calculated
for every installation. However, in general the force is just a fraction of the
force which occurs with metal materials.
Suppliers of pipe clamps and brackets know
the properties of the materials and offer a
range of solutions.
0 100200300
400 mm
44
45
Installing KELEN®
3. Exposed piping
1. Installing the pipes in the shaft
In practise the main risers can expand and contract laterally
in the shaft between two floors if a fixed point is located next
to the pipe that branches off from the main pipe. The distance
between two fixed points should not exceed 3 m. Other methods
can be used to accommodate expansion such as an expansion
arm in the pipe branching off from the riser.
3.1 Preventing expansion by
mechanical restraint d20–d50
For aesthetic reasons KELEN ALU pipes
are often preferred for exposed pipes
below d63. Greater stability can be
obtained by installing the pipes in steel
channels.
2. Embedding the pipe
In order to achieve this stability all of the
pipes must be supported by pipe channels
and all of the brackets must be fastened
tightly to the pipe to make them fixed
points. In addition the channels are fixed
to the pipe (e.g. using cable ties) except
for the sizes d20, d25 and d32 as the
channels for these sizes are self-locking.
This method reduces the linear expansion
to the same amount as steel.
Piping that is embedded in the wall, floor screed etc. …
is prevented from linear expansion. The material can absorb
the pressure and tensile stress without causing any damage.
If the pipes are insulated then the insulation material provides
further room for expansion.
3.2 Expansion loops d 63–110
Guidelines for distance between pipe
support points
The distances between the support points given below (in cm)
prevent KELEN® pipes from sagging when they are filled with
water and there are NO pipe channels.
d
PN 1O
PN 16
mm20°C20°C60°C
20707560
25758070
32909580
40 100 105 90
50115120100
63130135110
75150160130
90185195150
110195205160
125 205
–
–
160 220
–
–
46
PN 20
ALU PN 20
20°C 60°C 20°C 60°C
80 65 120100
85 75 130110
10085 150130
110 95
170 150
125 105 180 160
140 120 195 180
170 150 205 190
205 170 215 200
215 180 – –
–
–
–
–
–
–
–
–
All changes in the direction of the pipe
can be used to accommodate the linear
expansion. In some cases an expansion
loop will be necessary.
The fixed points are arranged so that the
piping is divided into sections and the
expansion force can be guided in the
desired direction. See pages 42 –45 for
the calculations of the length of the
expansion arm.
MS
minimum (mm)
2 · Δ l + 150 mm
47
The accuracy of the pressure gauge (positioned
at the lowest possible point wherever possible)
is to the nearest 0.02 MPa (0.2 bar).
Depending on the pipe materials and
dimensions, 3 different procedures can
be applied in the leakage and load test.
Test procedure A– test time 10 minutes
For all metal and multi-layer composite systems
For all plastics (e.g. PP, PE, PEX, PB etc.
≤ DN 50/OD 63
For all combined systems (metal systems/multi-layer
composite systems with plastics)
≤ DN 50/OD 63
MDP
Client: .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1,1
1,0
0
0
10 20
30 40 50
60 min
Test procedure C – test time 180 minutes
1
For all plastics
(e.g. PP, PE, PEX, PB etc.)
1,1
1
> DN
50/OD 63
1,0
1,1
1,0
≤ 0,06 MPa
≤ 0,02 MPa
composite
systems with plastics)
0,5
0,5
> DN 50/OD 63
The00test pressure
(1)10mustmin
be achieved with
pumping
0
0 10 20 30
60
120
180 min
and maintained for 30 minutes by subsequent pumping, then the test pressure must be checked, and
1 30 minutes the pressure must be cheafter another
1,1 again. If after this period the pressure has dropcked
1,0
ped
to less than 0.06 MPa (0.6 bar) then the test
pressure must be continued with no further pumping.
0,5 The test period is an additional 120 minutes,
during which the last recorded test pressure may not
drop by more than 0.02 MPa (0.2 bar). In addition,0it is necessary
a visual
inspection of
0 10 to
20 perform
30 40 50
60 min
the connections.
≤ 0,02 MPa
48
0
0,5
0
10
min
0
Pipe materials and dimensions:. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient temperature:.. . . . . . . . . . . . . . . . . . . . . . . . . . . . System vents:
Temperature compensation:
Visual inspection:
Maximum system operating pressure MDP: . . . . . . . . . . . Pipes: Pipes: Pipes: Pipes: d 16 . . . . . . . . . . . . .
d 20 . . . . . . . . . . . . .
d 25. . . . . . . . . . . . . .
d 32. . . . . . . . . . . . . .
m
m
m
m
Pipes:
Pipes:
Pipes:
Pipes:
Test pressure 1.1 x MDP:.. . . . . . . . . . .
d 40. . . . . . . . . . . . . m
d 50 .. . . . . . . . . . . . m
d 63. . . . . . . . . . . . . m
d 75. . . . . . . . . . . . . m
Metal and composite pipe systems – all sizes
Plastic systems and combined systems with plastics ≤ DN 50/OD 63
Choice of test method B or C
Test procedure B – test time 60 minutes
Plastic systems and combined systems with plastics > DN 50/OD 63
Test procedure C – test time 180 minutes
Plastic systems and combined systems with plastics > DN 50/OD 63
Notes:
• Temperature fluctuations can affect the test pressure!
• Each pressure test is a snapshot survey of the actual condition and it cannot guarantee
no installation faults.
• Following a successful pressure test, we would recommend the creation of a confirmed test protocol.
Confirmation:
Date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time: from:
≤ 0,06 MPa
0,5
Subject:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test section:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clerk:.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1,1
1,0
1,1
1,0
Contractor:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test procedure A – test time 10 minutes
0,5
MDP
MDP
The test pressure (1) must be achieved with pumping
and maintained for up to 10 minutes; during this
time the test pressure must remain constant, and
there must be no drop in pressure.
composite systems with plastics)
> DN 50/OD 63
The test pressure (1) must be achieved with pumping
and maintained for 30 minutes by subsequent pumping, then
the pressure must be reduced to 50% of
1
the1,1test pressure by draining it; then the drain valve
1,0
must
be closed. During the time of the additional
30 minutes the 50% test pressure must remain con0,5
stant and there must be no drop in pressure.
In addition,
it is necessary to perform a visual inspec0
0
10
min
tion of the connections.
MDP
As the test pressure must be 1.1 x the
maximum system operating pressure (in
accordance with ÖNORM EN 806-4), the
pressure test must be performed with at
least 1100 kPa (11 bar) (recommended
by KE KELIT 15 bar).
Pressure testing protocol according to
ÖNORM EN 806-4 for KELEN-Drinking water systems
test medium: drinking water
MDP MDP
The pressure test with drinking water is a
combined leakage / load test and it must be
performed for all lines in accordance with
the specifications of ÖNORM EN 806-4. Pipes
and other piping components are designed
for maximum operating pressure (MDP)
in accordance with the ÖNORM EN 805 or
ÖNORM EN 806 series.
However, they must be designed to withstand
at least a system operating pressure (MDP) /
nominal pressure (PN) of 1000 kPa (10 bar).
Choice of test method B or C
Test procedure B – test time 60 minutes
For all plastics (e.g. PP, PE, PEX, PB etc.)
> DN 50/OD 63
MDP
Pressure test –
drinking water systems with
drinking water according to
ÖNORM EN 806-4
.................
to:.. . . . . . . . . . . . . . . . . .
Client:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................................................................................
0 10 20 30
60
120
180
min
49
Pressure test –
drinking water systems with air or inert gases
according to ÖNORM B 2531
Pressure testing protocol according to
ÖNORM B 2531 for KELEN-Drinking water systems
test medium: air or inert gases
A pressure test with air or inert gases takes
place using a two-step procedure consisting of
the leak test and the load test. For ≤ DN 50/
OD 63 pipes the leak test can be carried out in
2 ways.
Two-step pressure test for all pipes
≤ DN 50/OD 63
Client: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Consisting of leak test
(variant 1 or 2) and load test
Subject:.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test section:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The pressure test with light or inert
gases can be carried out bit by bit, and
may not replace the final pressure test
with drinking water!
Leak test – variant 1
Pressure test 15 kPa (150 mbar) – test time
60 minutes. Display accuracy of the pressure
gauge or standpipe to the nearest
0.1 kPa (1 mbar)
The pressure test must be performed with light
or inert gases that is / are largely free of oil
and dust, and it is suitable for all pipe materials.
In buildings with higher hygiene demands (e.g.
medical establishments) inert gas must be used
for the pressure test.
Leak test – variant 2
Test pressure 100 kPa (1 bar) – test time
gauge to the nearest 5 kPa (50 mbar); in
addition, all connection points in the system
must be checked for leakage with appropriate
bubbling test equipment.
Due to the compressibility of the medium, during a pressure test with light or
inert gases no pressure test greater than Load test
300 kPa (3 bar) may be applied, for
safety reasons.
gauge to the nearest 10 kPa (100 mbar)
Higher test pressures comprise a large safety
risk and they do include the test accuracy. The
safety of people and goods must be considered Two-level pressure test for all pipes
> DN 50/OD 63
during the test.
Consisting of leakage test and load test
During a pressure test, division into small line
sections ensures a higher test accuracy and the- Leakage test
refore a higher level of safety. A gradual increTest pressure 15 kPa (150 mbar) – test time
ase in pressure is useful as an additional secu90 minutes. Display accuracy of the measuring
rity measure.
gauge or standpipe to the nearest 0.1 kPa
(1 mbar); in addition, all connection points in
All pipe openings must be well sealed against
the test pressure (with sufficient strength) with the system must be checked for leakage with
appropriate bubbling test equipment.
plugs or blind flanges.
During a pressure test with light or inert gases,
the connection parts of the pipe elements must
be accessible and visible. Bleed valves are provided for the safe discharge of the test pressure.
If any leakage is detected, or a drop in pressure is noticed, then all connections must be tested
for leaks using appropriate bubbling test equipment, and the pressure test must be repeated
after the leaks have been eliminated.
Load test
gauge to the nearest 10 kPa (100 mbar).
Contractor:.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe materials and dimensions:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient temperature:.. . . . . . . . . . . . . . . . . . . . . . . . Temperature compensation:
Maximum system operating pressure MDP:. . . . . . Visual inspection:
Two-stage pressure test for all pipes ≤ DN 50/OD 63:
consisting of leak test (variant 1 or 2)
and load test
Leakage test – variant 1
Test pressure 15 kPa (150 mbar) – test time 60 minutes
Leakage test – variant 2
Test pressure 100 kPa (1 bar) – test time 60 minutes
In addition, all component points in the system must be checked for leakage using appropriate bubbling test
equipment.
Load test
Two-stage pressure test for all pipes > DN 50/OD 63:
consisting of Leak test and load test
Leak test
Test pressure 15 kPa (150 mbar) – test time 90 minutes
In addition, all component points in the system must be checked for leakage using appropriate bubbling test
equipment.
Load test
Notes
• Following a successful pressure test, we would recommend the creation of a
confirmed test protocol.
• In accordance with ÖNORM EN 806-4, a pressure test with light or inert gases cannot replace
a pressure test; it must be performed immediately prior to the activation of the system.
Confirmation
Clerk:.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time: from:
........................
to:. . . . . . . . . . . . . . .
Client. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
........................................................................................
50
51
Technical rules
for drinking water
Heat insulation for
potable water pipes
Assuming that the design and installation
has been done professionally we
recommend that the following guidelines
are followed.
Drinking water pipes (cold)
Cold water pipes need to be insulated
against warming and condensation.
It must be ensured that the water quality
is not reduced as a result of the water
warming.
Rinsing
Sound control
After pressure testing the drinking water
pipes must be rinsed.
Depending on the size of the installation
and how the piping is run the system
should be rinsed in sections from the
bottom to the top.
Each riser is rinsed in turn and the length
of piping should not exceed 100 m.
DIN 1988/2, table 10, specifies the
minimum number of draw-off points that
have to be opened. Under normal
circumstances all draw-off points should
be opened. The rinsing time depends on
the length of piping and should not be
less than 15 seconds for each metre of
pipe. The rinsing time at each draw-off
point should be at least 2 minutes. After
the pipe has been rinsed for approx. 2
minutes at the last draw-off point all the
draw-off points are closed in the reverse
order to which they were opened.
DIN 4109 recommends the following
measures:
l Use low-sound faucets
l Avoid direct contact between pipes
and other sound transmitting
bodies when fixing the pipe.
l
l
l
l
Avoid high pressures and high
flow velocities
Special measures should be taken
for sound sensitive areas
KELEN LX pipes
(4 mm or 9 mm insulation)
The bubble structure of the insulation
provides excellent protection against
sound transmission.
The high strength of the insulation
cover provides a long term
barrier between the pipe and other
sound transmitters.
Pipework underground with no adjacent hot water pipes
DN 25 324050 6580100
DN15
1 234 6914
Minimum flow and minimum number of draw-off points to be openedfor rinsing at
a minimum velocity of 0,5 m/so
52
Exposed pipework in an unheated room (e.g. cellar)
Exposed pipework in an heated room Minimum flow through the
completely full distributing pipe I/min
15 253859100151
236
Minimum number of draw-off
points to be opened
Type of Installation
Cover with sound reducing insulation
DIN1988/2
Largest nominal diameter
of the distributing pipe
DIN 1988/2 specifies the minimum
insulation thickness for potable water
pipes when the medium temperature is
assumed to be 10°C.
Pipework underground next to hot water pipes
Thickness of insulation
mm
4 KELEN LX-4
13 KELEN + Insulation
4 KELEN LX-4
13 KELEN + Insulation
Pipework in wall, riser
4 KELEN LX-4
Pipework on concrete ceiling
4 KELEN LX-4
Drinking water pipes (hot)
We recommend that hot water pipes are
insulated in accordance with DIN 1988/2.
If there is no requirement for hot water
in circulation it is usually possible to do
without insulation for pipes up to 25 mm.
Even thin insulation reduces the
heat loss considerably!
See pages 16 and 17.
53
Summary of the
instruction guidelines
1.
The KELEN® pipe
system is made of
plastic and needs to be
treated carefully to
prevent shocks and impact on the pipe
during transportation, storage and
installation.
2.
Protect the pipes,
fittings and
components from
lengthy exposure to
direct UV radiation from the sun.
The usual time required for storage and
installation will have no effect on the
material as it is stabilised against UV rays
but the material is not resistant to long term
UV exposure.
3.
The welding machines
are regulated to
operate at 260° C.
Welding times
are based on an ambient temperature
of 20°C.
If the ambient temperature changes the
time required to push the pipe and fitting
on to the heating elements (before the
heating time begins) may alter slightly.
54
4.
Any corrections to the
alignment of pipe and
fitting up to a
maximum of 5 must
be made during the welding procedure
(see pages 18 – 25 for the permissible
time for adjustments). Any later corrections
will damage the joint.
5.
Do NOT screw any
threaded pipes or any
cast iron fittings into
the female threads of
the metal moulded fittings.
Only join to faucets and components with
straight threads. The threaded joint can
be sealed by the usual methods (hemp,
paste, tape …).
Do not over twist the threads.
6.
The expansion of
KELEN® pipes is
clearly defined and
must be accounted for
in the design and installation of the system.
Please refer to pages 42– 47 regarding
the methods of accommodating the
expansion of exposed piping
• KELIT Alu composite pipe (page 14)
• Pipe channels (page 47)
• Expansion loops (pages 42 and 43)
For longer sections of piping the fixed
points can be located in such a way that
the system is split into expansion zones.
Suppliers of pipe clamps and brackets
offer a wide range of solutions.
7.
Avoid using heat to
bend the pipes
(it is possible to bend
the cold pipe to a
radius of 8 x d). If the pipe has to be heated
then only use hot air. Never heat
the pipe with a naked flame!
Maximum temperature for bending
the pipe: 140°C
8.
Try to make the joints
for standard sections
of piping at the work
bench before they are
installed. This saves time
and increases the security of the system.
9.
Once the system has
been installed it
should be subjected to
pressure testing.
You can copy pages 48 and 49 of the
catalogue to make a test report.
10.
• A temperature of
90°C for short periods
of time is NO problem
for KELEN®. Higher
temperatures over longer periods of time should be avoided. The
pipe system is suited for thermal disinfection.
• The gradual or continual (max. 6 months)
disinfection of the pipe system with chlorine
dioxide, chlorine or ozone is only permitted
for the cold water system and after consultation with KE KELIT.
• Excessive concentrations are not only
threatening to health they can also cause
premature ageing of pipe systems.
• Copper und copper ions have a destabilising effect and their presence in the system
should be avoided.
11.
The following
precautions can be
made to ensure that
the maximum
operating temperature is not exceeded:
• Monitor and regulate solar energy
storage.
• Check the electric connections to the hot
water storage before the system is
operated.
• We recommend installing in the hot
water piping a mixer valve which is
regulated by the boiler.
12.
In order to qualify for
guarantee cover each
installation must use
KELEN® system parts
only.
13.
In order to install the
KELEN® system
correctly a minimal
amount of
expenditure is required for tools For your
own security we recommend that you use
and maintain the tried and trusted tools.
14.
If you are in doubt do
not hesitate to consult
our technicians.
There is not always a
perfect solution but we can always help.
55
Product range
KE08KELEN® pipe The KELEN®pipe system is constantly
being extended and updated to meet the
requirements of the industry.
Please refer to the current KELEN®price
list for the complete product range.
The abbreviated references, e.g
KE00 (= PN20 pipe) or
KE30 (= tee), simplify the administration.
Please refer to the KE numbers when you
place your order.
d s di LWeight
mmmm mm m kg/m
202,814,4 4 0,15
253,518,0 4 0,23
324,423,2 4 0,37
405,529,0 4 0,58
506,936,2 4 0,90
638,645,8 4 1,41
7510,354,4 4 2,01
9012,365,4 4 2,87
11015,1 79,8 4 4,30
On request and subject to minimum
quantities and capacities we can
manufacture special types of fittings
(e.g. 30° elbow).
KE02KELEN® pipe PN10
KE00KELEN® pipe d s di LWeight
mmmm mm m kg/m
203,413,2 4 0,17
254,216,6 4 0,27
325,421,2 4 0,43
406,726,6 4 0,67
508,333,4 4 1,04
6310,542,0 4 1,65
7512,550,0 4 2,34
9015,060,0 4 3,36
11018,3 73,4 4 5,01
d s di LWeight
V
mmmm mm m kg/m
l/m
201,916,2 4 0,11
0,21
252,320,4 4 0,17
0,33
322,926,2 4 0,27
0,54
403,732,6 4 0,42
0,83
504,640,8 4 0,66
1,31
635,851,4 4 1,04
2,07
756,861,4 4 1,41
2,96
908,273,6 4 2,11
4,25
11010,0 90,0 4 3,01
6,36
12511,4 102,2 4 3,92
8,20
16014,6 130,8 4 6,35
13,52
K06
KELIT-ALU composite pipe d s di LWeight
mmmm mm m kg/m
202,814,4 4 0,21
253,518,0 4 0,32
324,423,2 4 0,47
405,529,0 4 0,70
506,936,2 4 1,03
638,645,8 4 1,60
7510,354,4 4 2,22
9012,365,4 4 3,15
56
PN16
V
l/m
0,16
0,25
0,42
0,66
1,03
1,65
2,32
3,36
5,00
PN20
V
l/m
0,14
0,22
0,35
0,56
0,88
1,39
1,96
2,83
4,23
PN20
V
l/m
0,16
0,25
0,42
0,66
1,03
1,65
2,32
3,36
57
KE02-LX4KELEN® LX-SENSO pipe
PN10
KE10Socket
d s di IS LWeightV
mmmm mm mm m kg/m l/m
201,916,2440,140,21
252,320,4440,200,33
322,926,2440,300,54
di z tADBL
mmmmmmmm
201,5 15 29 33
251,5 20 36 43
321,5 22 46 51
402,5 25 54 57
502,5 26 68 60
632,5 29 85 62
752,5 30 101 65
90 3 34121 74
1105,5 37 145 85
Diagram for all KELEN LX-SENSO pipes
PN16
d s di IS LWeightV
202,814,4440,180,16
253,518,0440,260,25
324,423,2440,40
0,42
KE20
PN16
PN20
d s di IS LWeightV
203,413,2940,250,14
254,216,6940,340,22
325,421,2940,500,35
58
t
AD
mmmm
15 29
20 36
22 46
25 54
26 68
29 85
30102
34122
37 145
VP
Pcs
10
10
10
5
2
1
1
1
1
PN20
d s di IS LWeightV
203,413,2440,210,14
254,216,6440,300,22
325,421,2440,460,35
Elbow 90°
di
z
mm mm
2011
2516
3220
4027
5032
6336
7541
9050
11058
d s di IS LWeightV
202,814,4940,220,16
253,518,0940,300,25
324,423,2940,440,42
VP
Pcs
10
10
10
5
2
1
1
1
1
KE70
Elbow 45°
diztAD
mmmm mmmm
2012 15 29
2513 20 36
3215 22 46
4021 25 53
5025 26 68
6332 29 85
7537 30 101
9048 34 122
VP
Pcs
10
10
10
5
2
1
1
1
59
KE26
Elbow 90° (male/female)
d/di z mm mm 20 11 25 16 32 20 KE27
t1 mm 15 20 22 AD mm 29 36 43 VP
Pcs
10
10
5
AD mm 29 36 VP
Pcs
10
10
t
mm 16 20 z1 mm 31 33 t1 mm 16 20 z
mm 11 16 20 27 32 36 41 50 58 t
mm 15 20 22 25 26 29 30 34 37 AD
mm 29 36 46 54 68 85 102 122 145 BL
mm 52 68 84 94 112 128 142 166 195 VP
Pcs
10
10
5
5
2
1
1
1
1
Reducer tee
di di1 z t z1 t1 AD BL VP
mm mm mm mm mm mm mm mm Pcs
25 20 16 20 16 15 36 68 10
32 20 20 22 26 15 46 84 5
32 25 20 22 22 20 46 84 5
40 20 27 25 27 15 54 94 5
40 25 27 25 24 20 54 94 5
40 322725 2622 54 945
50 203226 3215 68 1122
50 253226 2820 68 1122
50 323226 3022 68 1122
50 403226 2927 68 1122
63 253629 4020 85 1281
63323629 3624 85 1281
63 403629 3727 85 1281
63503629 3628 85 1281
75 324130 4222 1021421
75 404130 4127 1021421
75 504130 4028 1021421
75 634130 3929 1021421
90 635034 5429 1221661
90 755034 5030 1221661
110 635837 7029 1451951
110 755837 6830 1451951
110 905837 6534 1451951
Equal tee
di mm 20 25 32 40 50 63 75 90 110 60
z1 mm 33 42 42 Elbow 45° (male/female)
d/di z mm mm 20 11 25 18 KE30
t
mm 15 20 22 KE35
KE36
Reducer tee
didi1di2z t z1t1z2 t2ADBLVP
mmmmmmmmmmmmmmmm mm mmmm Pcs
2025201615 16201615 36 6810
2520201620 18151815 36 6810
2525201620 16201815 46 8410
32 20252022 26152220 46 84 5
3225202022 22202615 46 84 5
3225252022 22202220 46 84 5
3232202022 20222615 46 84 5
3232252022 20222220 46 84 5
61
KE38
Manifold tee (male/female)
KE47
d di
mm mm
40–63
20
75–12520
40–63
25
75–125 25
di/d di1 z t z1 t1 AD BL VP
mm mm mm mm mm mm mm mm Pcs
25 20 13 20 16 15 36 71 10
KE60
KE41Reducer (male/female)
d di z t BL ADVP
mmmmmmmm mm mmPcs
25
202315382910
32202715422910
32252720473610
40
2029154429 5
40
2528204836 5
40
3236226045 5
50
3265208545 2
50
4056248053 2
63
4061248553 1
63
5061248568 1
755068269468 1
756365299484 1
90
6366299584 1
90756629951011
110 6361248785 1
110756129901011
110906132931191
Saddle Fitting
t ADBH VP
mmmm mm Pcs
1536 29 5
2036 29 5
2036 29 5
2036 29 5
End cap
di z tADBL VP
mmmmmmmm mm Pcs
208 162924 10
259 213630 10
3211224636 10
4013255338 5
5017266743 5
6319308449 5
75213110052 1
90263612062 1
110
413714578 1
KE61
Manifold cap
d t ADBL VP
mmmmmmmm Pcs
25 18
36
48
10
KE90
Curved pipe
d z ADBL VP
mmmmmmmm Pcs
20 215 45
430
10
25 215 48
430
10
32 215 55
430
5
62
63
KE83
Wall bracket 90° (female)
KE81LA
di IG zi z1 t ADBLVP
mmInchmmmmmmmmmmPcs
20 1/2" 13 21 15 41,5 48,5 10
20 3/4"
1726154657 10
25 1/2"
1726204657 10
25 3/4"
1726204657 10
LA Wall bracket 90° (male) 50 mm
di AG z t t1 K BLVP
mmInchmmmmmmmmmmPcs
20 1/2"
1315504398 10
DO NOT join to any
threaded pipes or cast
iron fittings!
K84
KE83HA
IG AG AG t BL SWVP
InchInchmmmmmmmmPcs
1/2" 1/2"
M28x1,5
5064305
Partition wall fiitting 90°(female) 50 mm
di IG AG z t t1 K BL SWVP
mmInch mm mm mm mmmmmm mmPcs
20 1/2"
M28 x1,513 15504398305
DO NOT join to any
iron fittings!
KE83SP
KE11
Flush box fitting 90°(female) 15 mm
di IG AG z t t1 K BL SWVP
mmInch mm mm mm mmmmmm mmPcs
20 1/2"
M28 x1,513 15154363305
DO NOT join to any
iron fittings!
64
Fitting for partition wall connection
Male adapter
di AG z t AD BLSWVP
mmInchmmmmmmmmmmPcs
20 1/2"
44154560-10
20 3/4"
44154560-10
25 1/2"
40204560-10
25 3/4"
40204560-10
32 3/4"
48226072- 5
32 1"59226083395
40 1"62257687392
40 5/4"
65257690462
506/4"
68268292521
63 2"802997107641
75 2 1/2"
9030123
120801
65
KE13
DO NOT join to any threaded
pipes or cast iron fittings!
KE21
Female adapter
KE23
di IG z t AD BLSWVP
mmInchmmmmmmmmmmPcs
20 1/2"
18 1545 45- 10
20 3/4"
18 1545 45- 10
25 1/2"
16 2045 45- 10
25 3/4"
16 2045 45- 10
32 3/4"
25 2260 68- 5
32 1" 22 2260 6839 5
40 1" 27 2576 7039 2
40 5/4"
28 2576 7148 2
50 6/4"
30 2682 7156 1
63 2" 38 2997 8670 1
75 2 1/2"
44 301239688 1
di IG z t zi ADSWVP
mmInchmmmmmmmmmmPcs
20 1/2"
13 1521 42- 10
20 3/4"
13 1521 42- 10
25 1/2"
17 2021 46- 10
25 3/4"
17 2021 46- 10
32 3/4"
20 2421 46- 5
32 1" 20 2438 6139 5
KE31
Elbow adapter 90° (male)
Tee with male thread
di AG z t zi AD BL SWVP
mmInchmmmmmmmmmmmmPcs
20 1/2"
1315492954- 10
20 1/2"BF
1315492954- 10
25 3/4"
1720603666- 10
32 1" 2024784686395
di AG z t z1 ADSWVP
mmInchmmmmmmmmmmPcs
20 1/2"
13 1549 42- 10
25 3/4"
17 2052 46- 10
32 1" 20 2261 6139 5
KE43
Elbow adapter 90° (female)
Saddle fitting (female)
d IG AD
mm Inch mm
40–63 1/2"36
75–110 1/2"36
BHVP
mmPcs
29 5
29 5
KE31LA
LA Tee with male thread 50 mm
di AG z t zi t1 ADBLVP
20 1/2"BF 13158550295410
66
67
KE33
Tee with female thread
KE50A
di IG z t zi AD BL SWVP
20 1/2"1315233056- 10
20 1/2"BF
1315233056- 10
25 1/2"1720323766- 10
25 3/4"1720323766- 10
32 1" 2022424684395
Valve with stopper
di IG z t t1 AD BHVP
mmInchmmmmmmmmmmPcs
20 1/2"21 1580 30127 5
20 1/2"BF
21 1580 30127 5
25 3/4"23 2080 37132 5
KE33HA
Tee with female thread for partition walls
KE50P
di IG
AG z t t1 AD BL SWVP
mm Inch mm mm mmmmmmmmmmPcs
201/2"BFM28 x1,513 15 5029 993010
Stop valve with stopper
mmInchmmmmmmmmmmPcs
20 3/4"
231580 371321
25 3/4"
231580 371321
32 3/4"
212080 431321
KE50
Valve with stem
di IG z t zi ADBH RVP
mmInchmm mmmmmmmmmmPcs
20 1/2"
21 15 8030127701
25 3/4"
23 20 8037132701
68
KE50PF
Valve with stem
mmInchmmmmmmmmmmPcs
20 3/4"23 1546 3793 1
25 3/4"23 1546 3793 1
32 3/4"21 2046 4393 1
69
K50C
Stem for KE 50A
KE52
AGBL R
Inchmm mm
1/2" 80
70
3/4" 80
70
VP
Pcs
1
1
Slanted seat valve with KE57 union
d DN AG z t BL BH SWVP
mm Inch mmmmmm mmmmPcs
2015 1" 84 17 168110361
2520 5/4" 95 20 190130461
3225 6/4" 10726 214155521
4032 2" 14750 294180661
50402 1/4"15550 310190701
63502 3/4"16550 330225861
includes drainage and replaceable EPDM seals!
K50F
Stem for KE50A and KE50P
AGBL ADSW
Inchmmmmmm
3/4"
465017
K50S
VP
Pcs
1
KE55
d AG z
t z1 BL SW SW1VP
mmInchInch mmmmmm mmmmPcs
20 1/2"
4217337536235
25 3/4"
4920408946305
32 1" 5526449952373
40 5/4"
85505213766452
50 6/4"
85505814370551
63 2" 85 50 65 15086 661
75 2 1/2"90 50 68 158 108801
90 3" 90 50 73 163122941
Extension to K50C
IG
AD
Inch
mm
1/2"–3/4“ 26
BL
mm
150
VP
Pcs
1
Union (plastic – metal)
KE56
Union (plastic – plastic)
d z t BLSW
mmmmmmmm mm
2042 17 84 36
2549 20 98 46
3255 26 11052
4085 50 17066
5085 50 17070
6385 50 17086
7590 50 180108
9090 50 180122
VP
Pcs
5
5
3
2
1
1
1
1
70
71
KE57
Union with female thread
KE19
d IG z t BL SWVP
mm inch mm mm mm mmPcs
20 1" 441753 365
25 5/4"502060 465
32 6/4"562667 523
40 2" 8750103662
50 2 1/4"
8750103701
63 2 3/4"
8750103861
75 3 1/4"
93501141081
90 3 3/4"
93501151221
KE17
E-UNI Welding socket
di z t ADBL
mmmmmmmm mm
201,5 26 48 55
251,5 26 54 55
321,5 25 62 53
401,5 25 70 53
501,5 25 80 53
631,5 30 94 63
752 33 10770
902 36 12176
1102,5 41 143 87
1253 82 164 165
1603 89 200 177
KE18
Backing ring PP-R
di DN
mm
2015
2520
3225
4032
5040
63 50
75 65
90 80
110100
72
VP
Pcs
1
1
1
1
1
1
1
1
1
1
1
z t BL
mm mm mm
5 1621
5 1823
5 1924
4 2226
6 2430
5 28 33
6 32 38
5 37 42
5 42 47
d DN di LK d1Holes BL AD VP
mm
InchmmmmmmmmmmmmPcs
20152865144 12951
25203475144 121051
32254285144 161151
4032 5110018 4 161401
5040 6211018 4 181501
6350 7812518 4 181651
7565 9214518 4 181851
908010816018 8 182001
110
10013518018 8 182201
Sizing according to
DIN 2501 PN16
KE85
Joining set
Dimension d20 x 1/2" d20 x 1/2" d25 x 1/2" d20 x 1/2" d25 x 1/2" Setting
mm
Single outlet
80 – 100
80 – 100
150
150
VP
Pcs
1
1
1
1
1
Setting
mm
80 – 100
150
VP
Pcs
1
1
Includes KE83 with sound insulation,
stoppers, metal plate, pegs and
screws.
KE85SB
ADVP
mmPcs
451
581
681
781
881
1021
1221
1381
158 1
PP flange with steel insert
Joining set
Dimension d20 x 1/2"
d25 x 1/2" DO NOT join to any threaded
Includes KE83 with sound insulation, stoppers,
metal plate, pegs and screws, siphon trap and d30
rubber nipple.
73
Butt welding fittings
KE20ST
KE35ST
Elbow 90°
VP
Pcs
1
1
KE41STReducer
d d1BL
mmmmmm
125
90190
125
110200
160
125225
KE70ST
Elbow 45°
Equal tee
d
z z1
mm mm mm
125 175
175
160
220
220
PN10
VP
Pcs
1
1
1
PN10
d z
mmmm
125133
160172
KE30ST
PN10
d d1zz1 z1 BL BH VP
mmmmmmmmmm mmPcs
125 63 170 170340 240 1
12590 170 170170 240 1
125110170 170340 240 1
16090 220 180424 260 1
160110220 200424 280 1
PN10
d zBL
mmmmmm
125
164229
160220 300
Reducer tee
VP
Pcs
1
1
KE18ST
Welding neck
PN10
d ADBL
mmmmmm
125
158
173 160125 202
VP
Pcs
1
1
KE19STFlange
PN10
PN10
BL BHVP
mm mmPcs
355
240
1
440
300
1
d DN di LK d1 Holes BL AD VP
mmInchmm mm mmmmmmmmPcs
125 110 135 180 18 8 18 220 1
160 150 178 240 22 8 24 285 1
Sizing according to
DIN 2501 PN16
74
75
Accessoires
KE19A
1 set consisting of screws, bolts,
washers and EPDM seal.
KE19K
1 set consisting of screws, bolts,
washers and EPDM seal.
KE99
K85H
Flange seal set plastic - metal
d
Holes
mm
Pcs
204
254
324
404
504
634
754
908
1108
1258
1608
VP
Pcs
1
1
1
1
1
1
1
1
1
1
1
d
Holes
mm
Pcs
204
254
324
404
504
634
754
908
1108
1258
1608
VP
Pcs
1
1
1
1
1
1
1
1
1
1
1
d
BL
mm
mm
7–11120
VP
Pcs
10
K85ARail
SettingA1 A2 AL BL BH BT ST R VP
mm InchmmmmmmmmmmmmmmPcs
Single---228
60
453-1
80-10080 100210 456 60 45 3 - 1
150 130150260 506 60 45 3 30 1i
76
BLBHBT ST
mmmmmmmm
350 60
45
3
K84K
VP
Pcs
1
Sound insulation cap
d
mm
20
25
Flange seal set plastic - plastic
Repair plug
Rail for partition walls
di D
mm mm
41,5 53
46 53
ADBLVP
mm mmPcs
75 5210
75 6010
Sound insulation for KE83.
Does NOT fix or secure the fitting.
K86L
Perforated plate
BL BHST
mmmmmm
200060 3
VP
Pcs
1
Steel plate for securing fittings
in all positions.
K86D
Pegs for K86L
VP
Pcs
10
Includes sound insulating discs and screws.
77
KELIT tools
K86HA
WZ100
Fixing plate
Welding set
Pipe welding machine 230 Volt, 800 Watt
Includes case, table clamp and floor rest
Pipe cutters d16 – 40 mm.
Heating elements: d20 – 32 mm
A1A2A3BLBHR VP
mmmmmmmmmm mmPcs
150100 80 20080 65 1
Heating elements: d20 – 40 mm
Octagonal holes to prevent twisting
of KE83HA and K84 and elastomer
covering for dry wall installations.
K88
Galvanised steel – d20, d25
and d32 have clips to lock the
pipe into the channel.
WZ110
Pipe welding machine 230 Volt, 1000 Watt
Includes case,
heating elements d20 – 90 or d25 – 125,
Pipe cutters d20 – 75, d50 – 140,
special gloves and pipe rests.
Packaged in transport crate.
Pipe channel
di
sL
mmmmmm
20 0,62000
25 0,62000
32 0,62000
40 0,62000
50 0,82000
63 0,82000
75 0,82000
90 0,82000
1100,92000
VP
Pcs
20
20
20
10
10
10
10
10
10
Type 1 Type 2 WZ120
d20 – 90
d25 – 125
Overhead welding machine
For making polyfusion joints in areas that cannot
be accessed with the table welding machine.
Can be used for the pipe types KE00, KE02,
KE06 and KE08. Includes hand welding
machine (1200 Watt), d50 – 110 welding
tools, d16–75 and d50–140 pipe cutters,
timer and special gloves. Packaged in
transport crate.
K95Stopper
AGBL DIB
inch mmmmmm
1/2"
803612
3/4"
804212
Pipe welding machine
VP
Pcs
10
10
Weight of machine: approx. 12 kilos
WZ115
hydraulic butt welding machine 230 Volt,
1000 Watt
Includes plane cutter, welding plate,
d40 –160 welding tools.
Packaged in transport crate.
78
79
WZ129Timer
WZ128
Repair welding tool
d
VP
mm
Pcs
71
111
For setting and checking the welding times
of d20 – 110 pipes.
Heating elements for welding
the repair plugs
WZ122
Heating elements
WZ124
Size of drilled holes
For d7 = 6 mm hole
For d11 = 10 mm hole
Polyfusion welding tool
d
VP
mm
Pcs
201
321
401
501
631
751
901
1101
WZ130
Pipe cutter
d
VP
mm
Pcs
16–401
Replacement blade
1
Saddle welding tool
d
VP
mm
Pcs
40 – 63 x 20/251
75 –125 x 20/251
WZ130
Wheel pipe cutter
d
VP
mm
Pcs
16 –751
50 –1401
Replacement whee: small
1
Replacement whee: large
1
For welding the saddle
fittings
WZ125
Saddle drill
d
VP
mm
Pcs
241
For drilling the pipes before welding
the saddle fitting.
80
81
WZ140
E-socket welding machine
WZ150
d
mm
20
25
32
40
50
63
75
90
For welding the E-UNI welding socket
KE17 Hand scraper included.
d
VP
mm
Pcs
20 – 1101
WZ141
Alu peeler
E-socket welding machine
For welding the E-UNI welding socket
KE17 Hand scraper included.
For peeling KELIT ALU composite pipes K06
before welding. Remove the screw to extend the
peeling area if the pipe is going to be welded to
an E-UNI socket KE17.
Peeler can be connected to a drill.
d
VP
mm
Pcs
20 – 4501
WZ138
Bending tool for K86 L
for bending the perforated plate K86L
WZ145
Pipe scraper
For scraping the surface of the pipe before electrofusion
welding
Hand scraper
Pipe shaver d63– d160
WZ155
Setting gauge
For setting the outlets adjustable depth
WZ146
E-socket aligner
For fixing the electrofusion socket
d
VP
mm
Pcs
20 – 631
63 – 1601
82
Settings
mm
75
100
120
150
200
240
83
84
85
Please note that for technical printing
reasons the numbers are written according
to the common practice in the German
speaking countries (i.e. the number and
the decimals are separated by a comma).
Full technical back-up and support for
the KELEN-pipe system is provided by
KE KELIT-Austria/Europe.
The network of sales partners, subsidiaries
and agents is constantly being expanded.
Please ask at the Austrian headquarters
for the current status.
86
KE KELIT
Kunststoffwerk GesmbH.
Ignaz-Mayer-Straße 17
A-4020 Linz
Austria – Europe
Tel. +43 (0)5 07791
Fax +43 (0)5 0779 118
[email protected]
www.kekelit.com
The technical contents in this brochure are for your information and consultation. We are not liable for the
contents. The application and installation of the products should be adapted to the individual requirements of
each project. KE KELIT is constantly improving its products a nd retains the right to make technical changes
in the course of these improvements. We are not liable for printing and spelling errors.
© by KE KELIT, KELEN Handbook 10/2014 engl.
87
Certified Quality Assurance System
by ÖQS
ÖNORM EN ISO 9001:2000
Reg.Nr.366/0
Member of the
Austrian Working Group
PLASTIC PIPE
RECYCLING
ARA-Lizenz Nr.9087
KE KELIT
Kunststoffwerk GesmbH.
Ignaz-Mayer-Straße 17
A-4020 Linz
Austria – Europe
Tel. +43 (0)5 0779
Fax +43 (0)5 0779 118
[email protected]
www.kekelit.com

The blue line

Transcription

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