TI A00

Technical Information

04/2002 Learning from Nature – www.KaRo.cc TI-A 00

This file contains Technical Information of the KaRo System. The data sheets are continuously updated and available by email at info@KaRo.cc or by fax using the fax order. You can get to the documents by the navigation of the Ac-robat Bookmarks or direct by a click on the page number in the index. CONTENT

1. Basics 2. System descriptions 3. Calculation and Planning 4. Installation 5. Charts and Forms 6. Diagrams 7. Formulas

TI Index

Technical Information

04/2002 Learning from Nature – www.KaRo.cc P.1 TI

1 Basics, General Information G

G01 Thermal Comfort G02 Humidity and Dew Point G03 Lifetime Behaviour of Polypropylene G04 Energy- and Cost with KaRo G05 KaRo Technique G06 Cost of KaRo Ceiling 2 Short Description K

K01 Plaster KaRo Ceiling K02 Metal KaRo Ceiling K03 Plasterboard KaRo Ceilings K04 Pre-fabricated KaRo Panel K05 KaRo Wall K06 Pre-fabricated KaRo Wall K07 KaRo Floor Heating K08 KaRo Modernisation panel K09 KaRo Acoustic Metal Panel K10 Plug In CouplingK11 KaRo Skin 3 Calculation and Planning B

B01 Before lay-out of KaRo Ceilings B02 Lay-out of KaRo Ceilings B03 Heating with KaRo B04 Calculation of KaRo Ceilings B05 Control of KaRo Ceilings B06 Fire Protection B07 Example of KaRo Ceiling B08 Before lay-out of KaRo Floor B09 Lay-out of KaRo Floor B10 Before lay-out of KaRo Wall B11 Lay-out of KaRo Wall Heating B12 Water Quality for KaRo B13 Tolerances of KaRo Mats B14 Secondary Stations

Weiter1

Index · TI Technical Information

04/2002 Learning from Nature – www

4 Installation M

M01 KaRo Mats M02 Thermal Welding M03 KaRo Plaster Ceilings M04 KaRo Metal Ceilings M05 KaRo Plasterboard Ceiling M06 Dew-Point Sensor M07 Pressure Test M08 Converter Technical Data M09 Room Temperature Control M10 Pre-fabricated KaRo Panel M11 Double panelled Plasterboard Ceiling M12 KaRo Floor Heating M13 Fixing of KaRo Mats with Butyl Tape M14 KaRo Glue M15 KaRo Glue Solvent M16 KaRo Thermal Paste M17 Fixing of KaRo Mats with Tape M18 KaRo Mats on Gypsum Boards M19 Tacking KaRo Mats M20 KaRo Wall M21 Start of Secondary Stations

M22 KaRo AquaStop 5 Charts and Forms T

T01 Chart KaRo Cooling Ceilings T02 Chart KaRo Heating Ceilings T03 Calculation of Cooling Load T04 Cooling Capacity of KaRo Ceilings T05 Protocol Pressure Test T06 Combustion Heat of Polyprop T07 Chart KaRo Floor Heating T08 Chart KaRo Wall Heating T09 Quick Lay-out for KaRo Wall Heating BK12 T10 Quick Lay-out for KaRo Cooling Ceilings BK12 6 Diagrams

D01 Cooling Capacity KaRo Ceilings D02 Cooling Capacity KaRo Plaster Ceilings D03 Heating Capacity KaRo Cooling Ceilings D04 Heating Capacity KaRo Plaster Ceiling D05 Permissible Heating Capacity Ceiling D06 Permissible Heating Capacity at Window D07 Pressure Loss of long KaRo Mat U10 D08 Pressure Loss of short KaRo Mat U10 D09 Pressure Loss of long KaRo Mat G10 D10 Pressure Loss of short KaRo Mat G10 D11 Pressure Loss of long KaRo Mat S10 D12 Pressure Loss of short KaRo Mat S10

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D

Index · TI Technical Information

04/2002 Learning from Nature – www.KaRo.cc P.3 TI

D13 Pressure Loss of long KaRo Mat S15 D14 Pressure Loss of short KaRo Mat S15 D15 Pressure Loss Connecting Hose D16 Pressure Loss KaRo Pipe DA 20 D17 Pressure Loss in KaRo Elbow D18 Flow Speed in Pipes D19 Heat Transfer Ceiling/Room D20 Average Surface Temperatures at the Ceiling Underside D21 Heating Capacity of KaRo Floor Heating D22 Pressure Loss of the KaRo Panel GK12 D23 Frequency Dew Point Outside Air D24 Average Heat Transmission of Buildings D25 Basic Capacity of Cooling Ceiling D26 Heat Volume – Water Volume D27 Cooling Capacity of KaRo Wall B12 D28 Heating Capacity of KaRo Wall B12 D29 Heating Capacity of the KaRo Wall D30 Pressure Loss of KaRo Mats 600 x 600

7 Formulas F

F01

Zurück 3

TI-Fax TI-Order

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TI-G01 Basics, General Information

Introduction into "Thermal Comfort"

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G01

1. General

Thermal comfort is a decisive criterion for good health, because the human body has permanent thermal exchange with the sur-roundings through radiation, convec-tion/conduction and transpiration. If through metabolism more heat is produced than nec-essary, surplus heat must be passed on to the surroundings. If there is a thermal deficit, the thermal looses must be reduced and the heat production must be raised. The thought that human beings prefer differ-ent thermal surroundings, because of their age, sex or their regional origin, and therefore well-being would only be a subjective matter, is from a scientifically point of view not the whole truth. On the contrary, comfort is de-pending upon factors, which influence one another. An optimal coordination of theses factors to another cause that 95% of all hu-man beings will feel comfort in the same way. These influences can be classified if the are depending upon the human being or the room they are in. 2. Influences of Thermal Comfort

according ISO 7730

According ISO 7730 the thermal comfort is calculated by means of an extensive equation. In this equation (according investigations of Prof. Fanger 1) the following values are con-sidered. Room air temperature in °C Average radiation temperature of surround-ing surfaces in °C Relative air velocity of the room air in m/s Partial humidity pressure of the room air in Pa Thermal transmittance resistance of clothing in m² K/W Metabolic rate in W/ m² for the surface of the human body

The 7thparameter: the external work (in W/m2) can be neglected, because for most of the activities it is close to zero. For the mentioned factors a PMV-index (pre-dicted mean vote) is calculated. PPD-index (predicated percentage of dissatisfied) is be-longing to it. The PPD-index shows the value in percentage of the probable dissatisfied people. Even at best situations there will be always 5% dissatisfied people.

0%

5%

10%

15%

20%

25%

Standard climateconditioning

system

baseboard vairsupply withoutcooling ceiling

Cooling ceiling incombination with

baseboard airsupply

Diagram 1: Statistical percentage of possible dissatisfied people according Prof. Fanger 1) Prof. Ole Franger , Kopenhagen

TI-G02 Basics, General Information

Humidity and Dew Point

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G02

1. General

Humidity is the local and timely changing contains of steam in the air, which depends upon the regional climate, if not also influ-enced by individual usage of the rooms (kitchen, laundries etc.) Humidity must be considered regarding com-fort as well as for functioning of the system. 2. Basics

Air and steam in the atmosphere form a mix-ture, which contents behave like gases. For the mixture of both the Dalton law (1820) is true „Each component i of a mixture of ideal gases in a definite volume V acts as if fills the whole volume by itself. It is under partial pressure Pi which results when the isothermal expansion of its volume Vi acts by the pres-sure P to the total volume V.“ Example Humidity: (equation 1)

p VD = pD V= mD RD T und p VL = pL V=mL RL T

with p= pL + pD und V= VL + VD

p = Total pressure pL = Partial pressure of the air pD = Partial pressure of the damp V = Total volume VL = Volume of air VD = Volume of damp mD = Masses of damp mL = Masses of air RD = Gas resistance: damp = 461 J/kg· K RL = Gas resistance: air, = 287 J/kg· K

2.1 Absolute Moisture X

The absolute moisture represents the dense-ness of water in the air volume.

Absolute Moisture X (equation 2)

X = mD / mL

From equation 1 and ρ = m/V follows: X= 0,622 · pD / ( p - pD ) The total mass of 1 kg of moist air is 1+X ! For dry air X = 0, for pure damp X is infinite. 2.2 Saturation Moisture X’

Air can only take up moisture until its partial pressure pD is equal to the temperature de-pending saturation pS. At pD > pS moisture will turn into water (fog)

X’= 0,622 · pS / ( p - pS ) (equation 3) 2.3 Dew Point

When air is cooled down, the damp pressure pS and therefore the saturation moisture re-duces. The dew point is reached, when the saturation pressure pS is equal to the damp pressure pD . Therefore: pS = pD or X’ = X (equation 4) 2.4 Relative Moisture ϕ=X/X’

The relative moisture prescribes how far the humidity is away from saturation or in other words, the relative moisture is the ratio be-tween damp pressure to the saturation pres-sure. The value is expressed in percent % . ϕ= pD / pS (equation 5) 3. Influence of Humidity to Comfort

Next to temperature of the room air, the sur-face temperature of room enclosure areas and the velocity of the room air, the humidity is another to the room relating which is of importance for the thermal (see → page G01)

Basics, General Information · TI-G02 Humidity and Dew Point

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-G02

If the humidity in the room rises to such an extent that the portion of transpiration in the regulating mechanism of the temperature budget can not be kept up, the state of com-fort can not be reached, even if other thermal values are within their limitation. 4. Influence of Humidity

to the System Safety

Moist air condenses at cold surfaces because of the saturation pressure being a function of the dew point temperature in dependence of the air pressure. →(equation 3). This indication influences the application of a cooling ceiling decisively. Is the surface tem-perature kept below the dew point, there is the danger that condensation occurs. The dew point temperature must be seen in relationship to climatic zones of the location. According to DIN 4710, for our longitudes a yearly average of 60 to 90 hours are assumed, where a outdoor situation with dew point temperature above 16°C will occur.

5. Technical Solutions for

Controlling the Dew Point

Basically the supply temperature should have a minimum of 16°C. Therefore the time frame, in which theoretically the humidity in the room is the same as the humidity of the outdoor air, is restricted to 4% of the yearly working hours (depending on the location). It can be assumed though, that many build-ing materials such as gypsum, plaster, ma-sonry, concrete, carpeting, wallpaper etc. will slow down the rise of the humidity. To exclude this rare case a temperature sensor is installed at the coolest spot in the room. According to experience this spot is in the fur-thest corner away from the window directly next to the supply line. In case that the dew point is reached, this sensor actuates a setting valve in the return to the closed position pre-venting that further water can flow into the cooling circuit. (also see → B05; Regulation of KaRo heating- and cooling ceilings). This simple way of regulation is enough to safely avoid condensation in the standard condition. At higher humidity in the room be-cause of individual situations or at other re-lated climate situations, dried air must be let into the room by means of a base (board) air ventilation. The incoming air is conditioned according the moisture, which has to be car-ried away.

TI-G03 Basics, General Information

Duration Time Behaviour Polypropylene

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G03

1. Polypropylene

KaRo heating- and cooling mats are made from PP-Random-Copolymer. This material is especially suitable for water carrying pipes the surfaces do not swell. PP has an extraordinary resistance against many different aggressive chemicals (-> DIN 8078 - appendix). PP can take up high temperature loads and can take, without any problem, du-ration temperatures up to 60°C. For this rea-son it is used successfully for floor heating systems and for drinking water supplying. Since KaRo heating- and cooling systems are operated with substantially modest tempera-tures in comparison to conventional floor heating systems (standard this would be up to 45°C for heating and 16°C for cooling), the actual strain on material of the KaRo pipes is clearly lower. 2. Duration Time for Internal

Pressure Behaviour

Quality measure for the life span of plastic pipes is expressed in the “Duration time for internal pressure behaviour” according DIN E 8078 (1994). In this a multitude probes of plastic materials are tested at different temperatures and different pressures to the point of burst. The statistics of the resulting measurements is

evaluated in the “Duration time for internal pressure behaviour”. The diagram below shows the duration time behaviour for the material used in the KaRo heating- and cooling mats, supply lines and pipes. The particular functions, in relation to temperatures, show the progress for the al-lowable comparative-tension in time duration until material failure. 3. Life-span

In order to express the life span for KaRo cap-illary tubes, the tension in the capillary tube must be determined and compared with the allowable comparative-tension at the actual instance. The actual tension in the tube (tension of the tube‘s wall) is determined from the tube sizes and from the internal pressure according to the following equation: σV = pi · (da - s )/ (2· s) with pi - Internal pressure da - Outer tube diameter s - Wall thickness of the tubes For the KaRo capillary tube a tension is calcu-lated of only 1.04 MPa, this at a normal oper-ating pressure of 0.4 MPa. The allowable comparative tension at 20°C and 50 years al-though is still 9.4 MPa. This shows, that even

after 50 years there is the assurance of 9 times against material failures.

Allowable comparative tension PP

0

2

4

6

8

10

12

14

16

1 10 100 1000 10000 100000 1000000

time (h) 1 10 25 50 Years

20°C

110°C

Root at 0,4 MPa

95°C

Capillary tube at 0,4 MPa

comparative tension (MPa)

TI-G04 Basics, General Information

Energy- and Cost Consideration to the KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G04

1. General

Modern office- and business premises must be cooled nearly all year because of the their ex-tremely good thermal insulation and the internal loads from the office- and computer techniques. Considering the limitations for the permissible air velocity and the turbulences in the room, conven-tional air conditioning in many cases cannot suf-ficiently cope with the high cooling loads or only with high technical expenditure. These systems are comparatively uneconomical and have disad-vantages such as draft- and noise annoyances. The KaRo cooling ceiling however creates well-being all-around while being an economical solu-tion.. 2. Cooling capacity of the KaRo

Cooling Ceiling

KaRo radiation cooling ceilings provide 60% of the cooling through radiation and 40% through convection into the room. In this case the cooling ceiling takes exclusively the sensible (dry) cooling load out of the air. The necessary hygienic air exchange to vent the latent (moist) cooling load can be done in the simplest way through the open window or with a more comfortable solution through a base (board) ven-tilation. Depending upon the ceiling construction, pre-given intake temperature of the cooling water (for KaRo ceiling normally 16°C) and difference to the room temperature (27°C) the KaRo cooling ceiling by itself reaches a cooling capacity higher than 83 W/m2. This capacity normally covers all demands on a cooling system for normally used office facilities. In the combination cooling ceiling with a temperature controlled base (board)- or mixed ventilation decisively higher cooling ca-pacities can be achieved and at the same time comfort is assured through the fresh air supply.

3. Energy Consumption + Energy sources with KaRo Cooling Ceilings

The energy consumption costs with cooling ceil-ings are without a doubt lower than “air only sys-tems”1. The energy consumption of a KaRo cool-ing ceiling depends mainly on the type of technique, which is used for the cold-water preparation. In addition only little energy is con-sumed for the regulating technique. The neces-sary cooling capacity is given by the location, the type of building and utilisation of room/building, and can be determined by a cooling load calcula-tion. For the cooling water generation different en-ergy sources can be utilised. The particular tech-nique is not only distinguished by the invest-ment costs, but mostly by the operation costs. A frequently used method are cooling towers, which operate by open cooling, in combination with cooling units powered by electric energy. This combination secures low costs for the cold water preparation during a long period of the year and the cooling unit only goes into opera-tion if open cooling is not possible, on very hot summer days. KaRo cooling ceilings can be utilised evidently de-pendable with low energy consuming techniques, alternative energy sources like quell water, cooling through open waters (lakes etc.) or through earth coolness. Since the KaRo cooling ceiling operates with “mild” temperatures (6°/12°C in the primary circuit of the cold water circuit), these natural en-ergy sources can be used by a relatively low tech-nical effort. The cost advantage of these systems can be clearly seen. In comparison to “air only sys-tems” the cooling ceiling offers another substan-tial cost 1. The hauling costs for air with conventional sys-tems in some cases reach up to 50% of the en-ergy costs. To transport the same amount of en-ergy trough the media water, less than 10% of motive power is needed with KaRo ceilings.

1 source: journal HLH Bd.45(1994) -„ Wirtschaftlich-keitsvergleich des Kühldeckensystems mit VVS-System“, Dr.Marten Bruck, Dr. Franc Sodec

Basics, General Information · TI-G04 Energy- and Cost Consideration to the KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-G04

Even if the KaRo ceiling is operated in combi-nation with a baseboard ventilation for achievement of high comforts the energy con-sumption is still distinguishably lower since ex-clusively only the air for the hygienic air ex-change must be moved. 4. Investment Costs

The investment costs for a cooling system is determined by the volume of the cooling load, the building conditions, the architectural de-sires, the technique of the cooling system and by the demands of comfort. For high cooling loads and large buildings, the KaRo cooling ceiling is the appropriate solu-tion to provide comfortable room climates. The modest room requirements for the KaRo capillary mats and water circuit, very seldom require additional space for maintenance- or installation channels. Also for this reason KaRo cooling ceilings are outstanding for the reno-vation of rooms or buildings. For new con-struction, at the same height of eaves and be-cause of the low construction height of the KaRo ceilings in comparison to a system, which requires an air channel network, it is sometimes possible to gain a full storey, whereby investment costs can be saved.

KaRo heating- and cooling mats can practically be installed into any type of ceiling without any problem. Without much additional expen-diture it is possible to install capillary tube mats into nearly any type of ceilings. A com-parison of investment costs between the KaRo cooling ceiling and a traditional air condition-ing system is possible when the room and de-mand for comfort are accurately specified. Ba-sically it can be said, that the combination cooling ceiling with a mechanical air ventila-tion, at high cooling loads, require less in-vestment costs and lesser room than the tradi-tional air conditioning systems.

Comparism of Energy Costs

0

5

10

15

20

25

30

35

20 30 40 50 60 70 80 90

spezific cooling load W/m 2

En

erg

y co

sts/

(m2 *

a) w ith open cooling

w ithout open cooling

cooling ceiling

air conditioning w ith variable volume f low rateVVS

V=8m3/(hm2) for cooling

Basics, General Information · TI-G04 Energy- and Cost Consideration to the KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-G04

Comparison of Investment Costs

0

200

400

600

800

1000

1200

1400

1600

20 30 40 50 60 70 80 90

Specific Cooling Load W/m2

Inve

stm

ent

Co

sts

DM

/m2

Costs and volume of

cooling load

installation costs

cooling ceiling

variable volume flow rate

TI-G05 Basics, General Information

Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G05

1. General

Advantages:

• Successful since more than 15 years • More than 750.000 m2 of mats installed • Healthy room climate • Low operating costs • Free in choice of ceiling design • Simple and safe installation The capillary tube technique for heating and cooling for rooms has been successful in the market for more than 15 years. Meanwhile 750.000 m² of capillary tube mats have been installed for cooling ceilings or for surface heating in Europe, mainly in Germany and in Switzerland. For the homeowners and user of the rooms, at first the comfortable and healthy room climate along with low operat-ing costs in comparison to standard air condi-tioning systems, are the main reasons for choosing cooling- and heating ceilings with KaRo capillary tube mats. Architects praise the nearly unrestricted possibilities of design for ceilings and implementations with the use of KaRo mats. Not the least the KaRo tech-nique is the best suited for the installer for low costing and true time installation work because of its simple and safe connection techniques. 2. Technical Principle

Advantages:

• Uniform cooling through radiation and convection

• Healthy; through barely noticeable air movements

• High cooling capacity, because of the capillaries laid close beneath the surface

• With 16°C supply temperature, approx. 20°C surface temperature is reached.

• Energy savings through utilisation of al-ternative energy sources.

• Top in comparison with other systems. • Little pressure loss /m2 • Little installation expense

Similar to what blood vessels in the human body do, the water carrying KaRo capillary tubes are distributed through the room sur-faces. Thereby the water cools or heats the surfaces, which again emit the coolness or heat to the room by radiation or convection. The resulting room climate is comfortable and healthy. There will be no noticeable air move-ments and therefore dust will not be whirled up. The capacity of a cooling ceiling is deter-mined by the difference between operating room temperature and average ceiling surface temperature “as bigger the difference, the higher the cooling capacity”. KaRo heating and cooling mats can be laid directly beneath the surface because of its little outer diame-ter of only 3.35 mm. This is the decisive advantage of the capillary tube technique in comparison to other pipe systems, because the supply temperature of the cooling water on all systems can not low-ered to any desired temperature (in order to avoid condensation the supply temperature normally is limited to 16°C!). Because of the narrow distance of one capillary tube to an-other (10 mm or 15 mm) a very uniform sur-face temperature is achieved. The KaRo sys-tem reaches an average ceiling surface temperature of approx. 20°C already with an average water temperature of 17°C. The same is true for the wall and floor heating. For cooling as well as for heating, the KaRo system can therefore be operated with water temperatures, which are close to the desired room temperature. The diagram „Capacity comparison for cool-ing ceiling systems”, a comparison of a capac-ity metering by an independent tester, shows clear advantages of the capillary tube system.

Basics, General Information · TI-G05 Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-G05

Capacity Comparision of Cooling Ceiling Systems

0

20

40

60

80

100

120

5 6 7 8 9 10 11 12

Temperature difference room average water temperature [K]

spec

ific

cap

acit

y [W

/m²]

A

D

B

E

F

C

Source: S+G 10/93 - „Comparative capacity metering on cooling ceilings of different brands“ Author Dr. Bernd Glück- ROM A - two in meander shape laid metal pipes,

which are connected by a k-shaped crimp on the long side of the metal panel. The panels are fixed with clamps to the water carrying pipes.

B - two units with 11 venation blind slats. These slats form current channels wherein a convection current is developed. Sheet metal cassettes of which approx. 20% perforated are fixed directly beneath the units as a closed cooling ceiling.

C - Capillary tube mats with a distance of 12,5 mm between the capillary tubes, glued to sheet metal panels of which 20% being perforated.

D - Copper pipes (pipe diameter = 36,7 mm2), meander shaped, laid onto sheet metal panels of which 20% being perforated, then covered with plasterboard.

E - meander shaped bent metal pipes (outer diameter 12 mm) with pipe distances of 85 mm, with half of their circumference laid in thermal contacting profiles. The Wilhelmi ceiling panel with Mikropor – lamination, front faced fixed with clamp bars and with magnet strips on the ther-mal contact profile, provide the contact

between the panel and the thermal con- tact profile. F - Aluminium plates with integrated water

carrying channels. These cooling plates are laid in Willhelmi sheets type Mikropor,

fixed to the sheets with down-hold

brackets and magnet strips. Alternative energy sources or also open cool-ing via outside air are sufficient for longer time periods of the year to maintain comfort. It saves energy costs and natural resources. Compared to other systems, comfort is im-proved, since the KaRo system reacts very fast to load changes. Continuing heat emission time through heat accumulation, as this is known from normal floor heating systems, will be very short because of the non-existing building masses above the capillary tubes. Another advantage of the KaRo capillary tube technique, compared to the meanders made of metal pipes, is the modest pressure loss/m2 of active ceiling surface. In the KaRo mats the required water volume for the cooling capac-ity is distributed to a great number of capillar-ies (depending on the mat type this could be up to 96 tubes/m width), while for the metal pipe meanders only one pipe dia- meter is available. Even for mat surfaces of 8 m2 a flow speed of only 0.2 m/s is reached in the capillary tube. In a meander made of copper tubing DN 10mm , for the same surface, already a critical flow speed of 1.15 m/s is reached. A low flow speed, even under consideration of the substantially small diameters of the KaRo capillary tubes, results into lesser pres-sure loss. Therefore lesser motive power is re-

Basics, General Information · TI-G05 Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-G05

quired with the KaRo systems for the circulat-ing pumps. Metal pipe systems avoid this eventual disadvantage mostly through the fact that smaller surfaces (seldom more than 1 m² ) are connected directly to a connection of the supply line. But through this the ex-pense for the installation and for the connect-ing parts will be comparatively higher than with the KaRo technique. 3. Liberty of Design

Advantages

• KaRo mats are flexible and are fit for all building designs

• KaRo mats must only be laid on metal cassettes

• Load per unit area only approx. 800 g/m2 • No reinforced sub-constructions required • Dry-build boards must only be covered

with KaRo mats • KaRo mats can be embedded simply in

plaster • KaRo dry-build units are available for the

advanced dry-build construction • Little thermal expansion because of small

temperature differences • KaRo mats for floor heating

Through the small dimensions of the KaRo capillary tubes the mats are very flexible and can be fit without any problem to nearly any building component. Even vaults and triangle shaped surfaces can be covered with KaRo mats. KaRo capillary tube mats can be laid on top of metal cassette units, it doesn’t matter of which brand they are. With a load per unit area of only approx. 800g/m2 (filled), the sub-construction of the ceiling units is not af-fected. The KaRo mat is therefore also suit-able for renovation of suspended metal ceil-ings. But also dry-build construction boards from plaster or fibrous plaster can be covered sim-ply from the top with KaRo mats. The con-struction boards are prepared with the capil-lary tube mats at the building site and installed as usual. KaRo also offers a dry-built unit (a sandwich type sheet consisting of plasterboard with hart foam insulation and an integrated KaRo mat) especially for dry-built purpose. This unit is available in all con-struction boards standard sizes. It is particu-larly suited for installation of large surfaces, where the borders and the cutouts on the in-active ceiling units are just cut to size at the building site. The embedding of KaRo- heating and cooling mats into ceiling or wall plastering can be done without any problem no matter if plas-ter is being applied to pre-mixed concrete,

brickwork or to a plasterboard surface. The mat itself is fixed by means of gluing, nailing, tacking or with dowels. After this a thin layer of plaster is applied. The capillaries are close beneath the surface, so that a high efficiency is reached. The main pipes which the capillary tube for supply- and return line lead into, are installed in wall slots or ceiling cavities and will then be connected to the wa-ter circuit. A danger of inadequate adhesion of the plaster, also at the state of heating, is not given since operating temperatures of the water are mostly only at 30°C (not more than 45°C) and the plaster material is not harmed and the thermal expansion of the capillaries will be taken-up by the plaster without any problem. The use of KaRo mats for floor heating or cooling is especially suitable for renovation. The KaRo mats simply are laid on top of an a layer which is able to support load (raw con-crete or floor tiles) possibly insulated to the layer below, fixed and covered with a thin layer of screed . The surface can be done with tiles or floor coverings. Different to standard floor heating systems the KaRo system leads the heat from directly beneath the surface to the room. The heating system therefore re-acts very fast with water temperatures sel-dom higher than 28°C. 4. Easy Installation and Safety

Advantages:

• Sizes made to order • Special mats for larger ceiling installation • Simple installation through quick-action

couplings or thermal welding • KaRo mats supplied with adhesive tapes • Capillary tubes self-venting • Safety since pressure tested • No corrosion through separated system • Repairs of damages without any problem • KaRo mats can freeze without any dam-

ages

KaRo heating- and cooling mats are fabri-cated in different versions, made to order in requested dimensions. At the building site the mats are installed according to an accurate ceiling pattern and connected to the water-lines. Tailoring of the mats at the building site is not necessary. For larger ceiling installations like lamps, speaker boxes or air vents, KaRo offers specially manufactured mats. Small cut-outs (for light spots or sprinklers) are done simply by moving some capillaries to the side. Depending on the version the KaRo mats are connected by means of thermal welding or with flexible hoses which are supplied with

Basics, General Information · TI-G05 Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-G05

quick-action couplings and can be connected to the factory prepared supply lines with the cold- or warm water circuit. KaRo mats for plaster ceilings are supplied as per request with adhesive tapes. Before plastering the in-staller just peels off the protective foil from the adhesive tape and glues the mat to the raw ceiling. KaRo capillary tubes are self-venting because of their small inner diameter. Through the laminar current in the tubes, the air is being transported out of the system even if the mats are installed with a vertical downward flow. Therefore at installations a descent must not be taken into account. Automatic vents though must be included in the supply lines of the piping. The manufacturing of KaRo mats is covered by a strict factory quality standard . Each KaRo mat is pressure tested with 20 bars for a time of 10 minutes. According to regulation the responsible installer has to make an addi-tional pressure test after completion of the installation. On principle KaRo heating- and cooling mats are operated in closed circuits. The mats’ cir-cuit (secondary circuit) is connected to the cir-cuit of the water preparation and heating unit via a stainless steel heat exchanger. Only non-corroding components (brass, stainless steel or plastic materials) are in-stalled in the secondary circuit. Through the system separation a reliable avoidance of sludge and clogging of the capillary tubes se-cured During heating operation fall-out of water-dissolving minerals will not occur, since heat-ing temperatures are never above 45°C. The system separation protects the system even at failures and will prevent from emptying. Should a failure occur, even with the safety measures laid out in the system and a capil-lary tube is damaged, the damage is only lim-ited. Water will only drain from the damaged capillary tube until pressure equalisation with the environment is reached. For this reason the maximum possible amount of leakage is determined by the size of the expansion tank. Normally not more than 5 litres. Repairs of damaged capillary tubes are easily done through soldering/welding with a welding plate ore a soldering iron (see “Technical In-formation” M01). The active ceiling area and therefore a lesser performance is hardly no-ticeable. KaRo heating- and cooling mats stand up to the tough building site conditions. Wilful damages excluded, the mats can even

be walked on during installation processes. The mats, pipes and supply lines can be laid at temperatures down to +5°C. Once filled with water the KaRo mats will not take dam-age even when freezing. 5. Polypropylene contra Copper and

Steel

Advantages:

• Physiologically harmless • Resistant against aggressive chemicals • No special demands for the water quality • Durability even at 60°C • Duration of life more than 50 years • Non-polluting • No poisonous gases in case of fire • Recycling is not a problem

KaRo capillary tube mats, pipes, supply lines and fittings are made from Random Copoly-mer type 3 according DIN 8078. This plastic material is a highly pure material with excel-lent properties regarding durability and com-patibility to the environment. The polypropyl-ene used for the KaRo mats meets the VII, Polypropylene, of the Deutschen Bundesge-sundheitsamtes (BGA) (German health de-partment) and is physiological harmless. This polypropylene can therefore also be used for cold/hot drinking water lines. Polypropylene is resistant to a great number of chemicals, even against aggressive ones. An extensive list of chemical resistances can be found in the contents of annex 1(add sheet ) to DIN 8078. KaRo mats are filled with regular tap water, because polypropylene it-self is non-corrosive. Manufacturer of copper pipe systems themselves state for their sys-tems: „Because of differing water qualities it might be necessary to do water treatment; especially when the contents of chloride is higher than 50 mg/litre and a risk for germs exists. Generally checks of the water quality are suggested every year, for recording num-ber of germs and amount of oxygen 1 „For copper, along with cold oxygenise water, cor-rosion is possible at critical conditions, which could cause pipe damages already at short operating times“.² Polypropylene can be operated up to tem-peratures of 60°C without any problem. Qual-ity measure for the duration of life for plastic materials generally, is the duration time inter-nal pressure behaviour according DIN E 8078 (1994). ² Brochure Carrier Cooling Ceiling, Carrier Comfort Ceiling 56AA, 1996

Basics, General Information · TI-G05 Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.5 TI-G05

According to this the duration of life for the KaRo heating- and cooling mats, pipes, sup-ply lines and fittings are extremely (according G03 more than 50 years). Polypropylene is used for floor heating systems successfully for more than 20 years. Against beginning resistances coming from the supplier of metal pipe systems, plastic materials dominantly succeeded in the marked. According to the magazine BmK 2/93, “the market share for copper pipes for floor heating systems, 1993 was already es-timated to be below 10%”.

The environmental compatibility of plastic materials especially for polypropylene is supe-rior to copper and steel. In an environment analysis according to the method of results oriented comparison (VENOB) of the tech-nische Universität Berlin 1994 the pipe sys-tems of different materials were examined. The diagrams above show the environmental behaviour in conclusion.

Standardized dimensionless Environmental Characteristics

0 50 100 150 200 250 300

Steel

Copper

Plastic max.

Plastic min.

exposure to air

exposure to w ater

Impact of soil

Expenditur of energy for production

0 5000 10000 15000 20000 25000 30000 35000 40000

Steel

Copper

Plastic max.

Plastic min.

Expenditur of energy [MJ]

Basics, General Information · TI-G05 Advantages of the KaRo Capillary Tube Technique

04/2002 Learning from Nature – www.KaRo.cc P.6 TI-G05

Polypropylene is a highly pure hydrocarbon material. With its properties this material can be classified in the group of plastic materials “minimal”. The results of this study show sig-nificant advantages for the plastic materials against the standard pipe materials concern-ing environmental properties. Fire behaviour of polypropylene is harmless. When Polypropylene is burned it changes to water and carbon dioxide. According DIN 4102 part 1 polypropylene belongs to the material group B2 – “normal flammable”. Nei-ther while polypropylene is burning or at the extinguishing phase, whether neither poison-ous gases nor acids will be formed, as this is would be the case with PVC. Further com-ments to burning behaviour, as also com-ments to fire rating of capillary tube mats as given by the “Amtlichen Material Prüfanstalt für das Bauwesen beim Institut für Baustoffe, Massivbau und Brandschutz an der TU Braun-schweig” can be found in the technical com-ments of B06.

KaRo capillary tube mats, supply lines and pipes, normally are not a set out to UV-light during installed situation. Shipment of the goods will be done UV light protected in cartons or foil packaging.

Polypropylene can be totally recycled without energy waste. At KaRo all the PP-production waste is ground-up and used again for plastic moulded parts. Large plastic material pro-ducer such as Hoechst AG are setting-up recy-cling systems. In the city of Knappsack is a recycling unit where PP-material (up to 5.000 t/year !) is recycled. Should, in any case, normal assorting of PP- material and recycling not be economical, than polypropylene can still be burned in trash burning units. Even at a trash depot polypropylene’s behaviour is neutral. PP does not dissolve in water and therefore does not harm underground water or soil.

TI-G06 Basics, General Information

Standard KaRo Ceiling - Constructions and approx. Costs

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-G06

1. General Remarks

The large assortment of KaRo products offers many possibilities for installation. Technical solutions and the extent of work involved are differing. Costs, which are mentioned at this point, are true for standard installation varia-tions and should only be used for approxi-mate costing. Costs are further influenced by the expense of cold-water preparation and the regulating technique in dependence to the active ceiling area. Because of so many differing offers average costing can not be ascertained. Standard-installation variations of KaRo capil-lary tube mats. • Embedding in metal cassette units • Equipping standard-dry-build panels • Usage of KaRo dry-build units (sandwich

sheet from plasterboard and insulation panel with integrated KaRo mats)

• Installation of KaRo mats in plaster (fixed to the raw concrete or to the suspended plasterboard ceiling)

2. Installation of KaRo Mats on top

of Metal Cassettes

The steps for installation are thoroughly de-scribed in “Technical Remarks” M04. Before installation the KaRo mats are laid into the cassettes. For a perfect heat transfer, the mats should be glued-in or should be covered with a mineral-fibre insulating mat. In the last case the acoustical insulation is already pre-determined. Standard insulation thickness is mostly 40 to 60 mm. If the metal cassette is furnished in the swing down version, the in-sulation sheet should be secured with clamp-ing brackets. An insulating panel increases the cooling performance in case of a totally enclosed ceiling with an additional heating source in the ceiling cavity (water carrying piping, covers for light fixtures etc.). The supply lines are laid into the ceiling cav-

ity. During hook-up of the metal cassettes the connections between supply lines and mats are made with flexible hoses. Openings in the metal cassettes of up to 50 mm are possible by just bending the capil-lary tubes around the openings. For larger openings KaRo offers special pre-fabricated mats with cutouts. Cooling ceilings, as a metal cassette ceiling

Capacity: 83 W/m² Standard cooling capacity

Prices: 180,- to 450,- ª /m² (prices depend upon type and brand of the metal cassettes) 3. Equipping Standard Dry-build

Panels

Equipping the plasterboard panels with KaRo mats is described in “Technical Remarks” M05. KaRo mats are pre-fabricated according di-mensions of the ceiling and supplied to the building site. The plasterboards are then equipped according to the layout scheme. For better thermal conduction the capillary tubes are painted with a thermal conduct paste. Then the boards are pre-drilled according the layout scheme. The construction for the sus-pended ceiling, made from CD-profiles, is fit-ted in 300 mm screen distances according to standard dry-build regulations. The supply- and return lines are installed in the ceiling cavity. The plasterboards equipped with the KaRo mats are positioned at the ceiling, the supply lines connected to the waterside with flexible hoses and fixed to the suspended ceil-ing at the pre-drilled positions with building screws. For larger installations non-equipped inactive plasterboards are used. Small cutouts in the ceiling are done in the same manner as with metal cassettes.

Basics, General Information · TI-G06 Standard KaRo Ceiling - Constructions and approx. Costs

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-G06

Cooling ceiling as equipped dry-build panel.

Capacity 70 W/m² standard cooling capacity Prices 150,- to 180,- ª /m² (prices depend upon type and expense of the dry-build ceiling) 4. Utilisation of the KaRo Dry-build

units.

Instructions for installation of KaRo dry-build units are given in the “Technical Remarks” M11. The KaRo dry-build unit is manufactured in standard dimensions of 2000 x 600 mm. They are suitable for installation of large con-nected surfaces. For the border area and for build-ins the inactive boards are tailored at the building site. KaRo dry-build units are screwed to the CD-profiles of the suspended ceiling support con-struction. The supply lines for supply and re-turn are laid into the ceiling cavity. For the in-stallation of the dry-build units the water connection from the base to the supply line is done with flexible hoses. Cooling ceiling with the dry-build unit.

Capacity 64 W/m² standard cooling capacity Prices 150,- to 180,- ª /m² (Prices are depending upon the installation expense for the dry-build panels )

5. Installing KaRo Mats in Plaster

The installation of KaRo mats in plaster is ex-plained in “Technical Remarks” M03. The KaRo mat type K.S15 is fixed to the raw concrete ceiling with butyl adhesive tape or with dowels. → M13. A bonding layer must be applied to the raw concrete for plastering type MP75 or similar is used. The plaster thickness should be 12mm– 15mm . The main pipes for the mats are laid in wall slots. Direct welding of the main lines with the piping does the connection of the mats. Cooling ceiling embedded on the raw con-crete ceiling.

Capacity 80 W/m² standard cooling capacity

Prices 65,- to 120,- ª /m² A second variation is to tack plasterboard di-rectly to the KaRo mat type K.S15. In the plas-terboard surfaces slots of 150 mm are left blank. Through theses slots the mains are lead to the ceiling cavities and are connected to the piping by welding a process. The slots then are closed with plasterboard strips. A bonding layer is applied to the ceiling surface. At the end a layer of plaster (MP75) approx. 10-12 mm thick is applied. Cooling ceiling plastered onto a dry-build panel.

Capacity 80 W/m² Standard cooling capacity Prices 130,- to 200,- ª /m² Ceiling in-lays can be made up to diameters of 100 mm, only by pulling the capillary tubes apart. For larger in-lays the ceiling areas are kept empty.

TI-G07 Short Description

Free Cooling

04/2002 Learning from Nature – www.KaRo.cc TI-G07

With KaRo substantial energy savings can be re-gained with free cooling. 1. Free Cooling by ventilation

With conventional air condition systems the free cooling can be done with the ventilation of fresh air. As long as the dry bulb tempera-ture of the outside air is substantial lower than the temperature inside the building the cooling can be done just by ventilation with-out the cooling machine. 2. Free Cooling with KaRo

With KaRo the free cooling is done by using the cooling tower to cool the KaRo water. As long as the dew point temperature of the outside air is substantial lower than the room temperature inside the building the cooling can be done just by running the KaRo Ceiling direct by the cooling tower without the cool-ing machine.

Cooling with a chiller 1 KaRo Ceiling 2 Chiller 4 Cooling tower 3. How does it work?

A plate heat exchanger is installed in a bypass to the cooling machine. As long as possible the KaRo water is cooled directly from the cooling tower via this heat exchanger. The chiller is not running.

Free Cooling with KaRo 1 KaRo Ceiling 3 Heat exchanger 4 Cooling tower Only when the capacity of the cooling tower is not big enough the bypass is closed and the chiller is cooling the KaRo water and the cool-ing tower is used for the chiller.

4. Energy saving with free cooling

The dew point of the outside air is for many hours of the year substantial lower than the interior temperature→ Figure 3. During these hours no energy for the chiller is needed. This situation can be for more than 50% of the cooling period. City Altitude Out side air temperature

Dry bulb Dew point Difference

m C C KAthens 110 37 22 15Berlin 40 32 21 11Istanbul 70 27 19 8Lissabon 100 34 22 12London 40 34 22 12Madrid 650 36 22 14Moskau 140 31 21 10Paris 50 32 21 11Rome 50 36 23 13Valencia 25 33 24 9

Cleveland 205 35 24 11Los Angeles 165 32 21 11New York 130 35 24 11San Francisco 50 29 18 11

Hongkong 15 36 30 6Singapore 10 36 28 8Chungching 230 36 27 9

Sydney 40 35 23 12Melbourne 30 35 23 12 Max. Temperatures from some cities for design-ing in summer

Dry bulb temperature

Wet bulb temperature

0

500

1.000

1.500

2.000

2.500

h/a

Figure 3: Annual hours in Berlin with outside temperature exceeding 15 °C.

TI-K01 Short Description

Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K01

1. General

Modern office- and business premises must be climate controlled nearly all year long be-cause of their high thermal insulation and their internal loads from computers and of-fice appliances. At the heating period they have comparatively low heat consumption. The energetic cost saving solution is a KaRo heating- and cooling ceiling. The KaRo heating- and cooling mats can be directly fixed to the raw ceiling and then be plastered. Even already suspended plaster-board ceilings can be made very easily into economical heating- and cooling ceilings. This arrangement can also be used for renovation of historical protected rooms. Through the combined function of the ceiling the invest-ment costs for heating system installations can be minimised. 2. System Description

The KaRo heating- and cooling mats are sim-ply embedded into the ceiling plaster. Since the capillary tubes are positioned directly be-neath the surface (the ceiling construction is thinner than 15 mm !), the surface will heat-up or cool-down fast. The time reaction of the ceiling is less than 15 minutes. 3. Cold Water-/ Heating Water

Technique

The KaRo heating- and cooling mats are tied up in zones to the piping as a circuit and con-nected to the heat- or cooling supplier. The connection via a storey-distributor is recom-mended. For the cold water preparation different tech-niques and systems can be utilised. The eco-nomical advantages of the cooling ceiling ex-ist because the ceiling will provide already sufficient performance even with supply tem-peratures which are only slightly below the room temperature. This makes the utilisation of “alternative energy sources” like heat pumps or open cooling and ground water

possible. For the generation of heating water the same advantages are true. In connection with solar collector systems, and even with standard techniques a significant energy saving is al-ready reached, because respectable heating performances are achieved with considerable low supply temperatures (below 40°C).

4. Installation

In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials used can be: plas-tics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to malfunction of the system.

Plastered ceiling with BEKA heating- and cooling mats

Connection cooling or heating unit

Short Description · TI--K01 Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K01

5. Regulating Technique

The regulating technique secures, first the de-sired comfort, second the necessary system reliance. The cooling ceiling requires: a room tempera-ture regulation, a dew point guard, and a control of the supply temperature for the cold water. Supply temperatures below 16°C must be avoided because of the danger that the dew point is reached! For the heating ceiling a room temperature control is required, which regulates the vol-ume of heating water in dependence to the desired room temperature. Supply tempera-tures higher than 45°C must be avoided be-cause of the danger of an excessive surface temperature of the ceiling and to prevent plaster from drying-out ! 6. Dimensioning of the System

The KaRo heating- and cooling mats are di-mensioned according to the following lay-out table. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water temperature before the heat exchanger. 7. Preparation for Installation

For the connection of the KaRo heating- and cooling mats the manufacturers instructions must be obeyed. For the plastering instruc-tions of the plaster material supplier must be followed. The raw ceiling must have a solid base, which is able to carry surface loads of at least ≥ 20 kg/m2 . If the plaster ceiling must be applied onto a suspended ceiling, the supporting dis-tances and design of the suspender from the raw ceiling must bear a load of at least ≥ 30 kg/m2 . The KaRo heating- and cooling mats are

offered for the different uses in widths of 1200 mm and lengths up to 6000 mm, so that tailoring at the building site is not neces-sary. Only at borders and at areas where ceil-ing in-builds are planned, inactive areas must be provided. The KaRo heating- and cooling mats can be supplied with readily attached double sided adhesive tape, for the position-ing of the mats at the raw ceiling. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All mats with its dimensions and direction of in-stallation for the supply lines must recorded. In the ceiling pattern also all areas must be marked, which will stay empty for instance for the installation of partition walls, for light fixtures and for other ceiling in-fills. Also the installation position of the dew point KaRo-sensor must be marked at the ceiling pattern. The connection of the Polypropylene piping is done by thermal welding. For the execution the welding directions DVS 2207-11 of the Deutscher Verband für Schweißtechnik e.V. are valid. (The surrounding temperature dur-ing working must not be below 5°C. The pre-heating,- welding and setting time must be according to regulations.) 8. Tools, Materials

For the installation of KaRo heating- and cool-ing mats in plaster ceilings the recommended tools and materials for the installations of Polypropylene must be used.: • Pipe clamps • Dowels and screws, if necessary • Plastic pipe clamps • Hand held welding device with sleeve

welding adapter for plastic welding • Plastic fittings • Smoothening spatula • Plaster material Tools and materials for plastering must be chosen according the plaster manufacturer’s instructions.

Short Description · TI--K01 Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K01

9. Installation Steps at for the Ceiling

• Fasten main pipes of the mats with hose

clamps to the raw ceiling or in the cavity of suspended ceilings. Later on the main pipes are located behind partition walls towards the corridor or behind cavities in the wall or mouldings.

• Connect mats to another and to the wa-ter circuit by means of thermal welding.

• Unroll the KaRo mats and position them to the raw ceiling or to the suspended ceiling by means of adhesive tape.

• Pre-test with air pressure of 10 bar for 1 hour.

• Main-test with water with 10 bar for 4 hours. Resting pressure of 3 bar must be kept-up until system is taken into opera-tion.

• Apply plaster spots at the spacer bars of

the mats, with this the KaRo mats are held securely until plastering is done. For installation to suspended ceilings this additional fastening will not have to be done. Eventually only tacks have to be placed above the spacers of the mats, to take the tension of the mats

• Apply the plaster base adhesive

primer according to manufacturers in-structions, through painting, roll-on or spraying.

• Apply plastering in a thin layer. Mostly 10 to 12 mm is enough. Avoid thick layers – the cooling capacity will be lowered!!

I.I.

II.II.

IIII.II.

Raw ceiling

Butyl adhesive tape

BEKA heating- and cooling mats

room corridor

Plaster spots

Partition wall fixed to metal runner

Short Description TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.4 TI K01

10. Lay-out of a Plaster Cooling Ceiling with KaRo Mats Type K.S15

Project : Date

Project consultant : Lay-out valid for 27°C room temperature and 2K cooling water spread !

Required Cooling Capacity

1 Cooling load for the room W from calculation of planning office

2 Planned coverage with mats m2 max.possible arrangement derived from room dimensions

3 Required specific cooling capacity W/m2 = cooling load / coverage

Performance Determination

4 Supply temperature -> from diagram 1 °C

5 Return temperature °C

6 Water volume of mat area kg/(m2h)

7 Water volume per zone l/h

Pressure loss determination

8 Length of connecting pipe m

9 Resistance in the pipe -> from diagram 2 Pa/m

10 Pressure loss in the pipe Pa

= pipe length * resistance

11 Pressure loss of the mat Pa

-> with value of line 2 from the diagram 1

12 Addition for pressure loss of fittings Pa

(recomm.: 30% addition to pipe)

13 Addition for heat transfer station Pa

(recomm:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA heat transfer stations are utilised, the pressure

determinaton can be omitted. Only the quantity of cooling

circuits and the total cooling capacity is

required for the selection.

Quick lay-out for ceiling cooling with BEKA mats in plaster

0

20

40

60

80

100

120

24 23 22 21 20 19 18 17 16 15 14 13 12

Supply temperature [°C]

Co

olin

g c

ap

aci

ty [W

/m2 ]

6 9 12 16 20 23 27 31 35 38 42 46 50

Mass flow of cooling water [kg/(m2h)]

valid for room temperature 27°C and cooling water spread 2K and plasster type MP75 -Fa.KNAUF

Pressure loss in a pipe 20x2mm

0102030405060708090

100

40 80 120 160 200 240 280 320 360 400Mass flow [kg/h]

Pres

sure

loss

[Pa/

m]

Pressure loss Type S15

0

5000

10000

15000

20000

25000

10 15 20 25 30 35 40Mass flow [kg/(m2h)]

Pre

ssure

loss

[P

a]

8m7m 6m 5m

4m

3m

2m

1m

Short Description · TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.5 TI-K01

11. Lay-out of Plaster Ceiling for Ceiling Heating with KaRo Mats Type K.S15

Project : Date

Project consultant : Lay-out valid for 22°C room temperature and 6K Heating water spread !

Required heating capacity

1 Heat requirement for the room W from calculations of the planning office

2 Planned coverage with mats m2 max.possible arrangement derived from the room dimensions

3 Required specific heating capacity W/m2 = Heat requirement / coverage

Performance Determination

4 Supply temperature -> from diagram 1 °C

5 Return temperature °C

6 Water volume per mat area kg/(m2h)

7 Water volume per zone l/h

Pressure Loss Determination

8 Length of connecting pipe m

9 Resistance in the pipe -> from diagram 2 Pa/m

10 Pressure loss in the pipe Pa

= pipe length * resistance

11 Pressure loss of the pipe Pa

-> with value of line 2 from diagram 1

12 Addition for pressure loss of fittings Pa

(recomm: 30% Addition to pipe )

13 Addition for heat transfer stations Pa

(recomm:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total Pressure Loss Pa

If BEKA heat transfer stations are utilised, the determination

of pressure losses can be omitted. Only the quantity

of heating circuits and the total heating capacity

is required for the selection.

Quick lay-out for ceiling heating with BEKA mats in plaster

020406080

100120140160180

27 29 31 33 35 37 39 41 43 45

Supply temperature ( °C )

Hea

ting

capa

city

[W/m

2 ]

2 4 7 9 12 14 17 19 22 25

Mass flow of the heating water [kg/(m2h)]

valid for room temperature 27°C and heating water spread 6K and plaster type MP75 -Fa.KNAUF

Pressure loss in a pipe 20x2mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400Mass flow ( kg/h)

Pre

ssure

loss

[P

a/m

]

Pressure loss Type S15

0

5000

10000

15000

20000

25000

5 10 15 20 25

Mass flow [kg/(m2h)]

Pre

ssu

re lo

ss [

Pa

]

8m 7m6m

5m

4m

3m2m

1m

Short Description · TI-K01 Plaster Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.6 TI-K01

12. Technical Details

KaRo capillary tube mats Type K.S15 Material Polypropylene Random-Copolymer Type 3 DIN 8078 Geometry Collector pipe 20 x 2 mm Capillary tube 3,35 x 0,5 mm Capillary tube distance 15 mm Exchange surface 0,71 m2 Size Length: 600-6000 mm (in increments of 10 mm) Width: 150-1200 mm (in increments of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Cooling capacity Depending upon the type 80 W/m2 with 10 mm Plaster MP 75 (DIN 4715) Heating capacity: Depending upon the type to 150 W/m2 Operation condition : Temperature stable at long term use up to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Utilisation / type of installation: Cooling- and heating ceilings, plaster-version Connection by thermal welding Type of delivery: The mats are supplied rolled-up, packed in cartons.

TI-K02 Short Description

Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K02

1. General

Modern office- and business facilities must be cooled mostly throughout the whole year be-cause of the internal loads coming from of-fice- and computer appliances and because of the high thermal insulation of walls and fa-cades. During the heating period itself the rooms need comparatively little heating. Be-cause of this the utilisation of the energeti-cally low cost KaRo heating- and cooling ceil-ing is possible. The KaRo heating- and cooling mats are sim-ply laid on top of the panels of the suspended metal cassette ceiling. This way each metal cassette ceiling can be utilised very easily and economically as a heating- and cooling ceil-ing. This set-up can also be used for renova-tion. Because of the combined function of the ceiling the investment cost for the building installations can be minimised. 2. Description of the System

The KaRo heating- and cooling mats are sim-ply laid on top of the metal cassettes. The capillary tubes are positioned directly on the sheet metal or on a thin acoustic fibre. The surface is rapidly cooled-down or heated-up. The reaction time of the ceiling is less than 15 minutes. 3. Cold Water Heating Water

Technique

The KaRo heating- and cooling mats are tied-up in zones to the piping as a circuit and con-nected to the heating- or cooling supplier. The connection to a storey distributor is rec-ommended. For the cold-water preparation different tech-niques and systems can be utilised. The eco-nomical advantages of the cooling ceiling ex-ists because the ceiling will provide already high performances with supply temperatures which are only slightly below the room tem-perature. This makes the utilisation of “alter-native energy sources” such as heat pumps or

open cooling and ground water possible. For the generating of heating water the same ad-vantages are true. In connection with solar collector systems and even with standard techniques significant energy savings are achieved, because already with low supply temperatures (below 40°C) it can be heated with respectable heating performances.

4. Installation

Generally the standard installation guidelines must be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials to be used can be: plastics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to malfunction of the system.

Cassette ceiling with BEKA heating- and cooling mats

Connection to Cooling unit or heating source

Supply lines Connecting hoses

piping

Further ceiling areas

Short Description · TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI K02

5. Regulating Technique

The regulating technique secures, first the desired comfort, second the necessary system reliance. The cooling ceiling requires : a room tempera-ture regulation, a dew point guard and regu-lation of the supply temperature for the cold water. Supply temperatures below 16 °C must be avoided because of the danger that the dew point could be reached! For the heating ceiling a room temperature control is required which regulates the vol-ume of heating water in dependence to the desired room temperature. In rooms higher than 3,5 m supply temperatures above 40°C must be avoided because of excessive surface temperatures! 6. Dimensioning of the Installation

The KaRo heating- and cooling mats are di-mensioned according the dimensions of the metal cassettes. The necessary quantity of mats and the temperature of the cooling wa-ter or heating water are determined accord-ing to the following layout tables. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water tem-perature before the heat exchanger. 7. Preparation for Installation

For the installation of the suspended metal cassette ceiling, the manufacturer’s instruc-tions must be followed. The capillary tubes of the KaRo heating- and cooling mats should have good contact to the surface of the metal cassettes, so that the heat transfer is directly lead to the water. If there are additional heat sources in the ceil-ing cavity (heat radiation from light fixtures and from warm water pipes, etc.) a mineral wool mat can be laid on top of the capillary tubes for energy saving purpose. Sometimes such an installation could be required for the sound insulation of the ceiling. If this re-quirement is not set forth we recommend to glue the capillary tubes to the surfaces. The KaRo heating- and cooling mats are pro-

duced in measurement of the metal cassettes based on the object to avoid any tailoring work at the building site. At the border areas and at areas where ceiling in-builds are planned inactive cassettes will be installed. The KaRo heating- and cooling mats are sup-plied with quick-action couplings for the con-nection of supply- and return lines with flexi-ble hoses. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All mats with the dimensions, the direction of in-stallation and the supply lines must be re-corded. In the ceiling pattern all areas must be marked which will stay uncovered, i.e. for the installation of partition walls or light fixtures and for other ceiling in-fills. Also the installa-tion positions for the KaRo dew point sensor must be marked at the ceiling pattern. The connection of the polypropylene piping is done by thermal welding. Here the welding directions DVS 2207-11 of the Deutschen Verband für Schweisstechnik e.V. must be obeyed. (the ambient tempera-ture must not be below 5 °C. The pre-heating, -welding- and setting time must be according to the given regulations.) 8. Tools, Materials

For the installation of a metal cassette heat-ing- and cooling ceiling with KaRo capillary tube mats standard tools and materials for ceiling constructions and for the installation of plastic pipes can be used such as:

• Metal cassettes • Suspender profiles and suspenders

depending at the type of construc-tion used for the chosen ceiling.

• Dowels and screws • Sheet metal scissors • Mineral wool insulating wool (if req.) • Scissors to cut plastic piping • Hand-held welder with sleeve weld-

ing adaptor for plastic welding • Plastic fittings

For the connection of the supply lines to the cold water circuit a hand-held welder with sleeve welding adaptor and plastic fittings are recommended . Alternatively sealing ring connectors can be used.

Short Description · TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.3 TI K02

9. Installation Steps at the Ceiling

• The bearing structure is fastened and

aligned to the raw ceiling with vernier suspension bars according to manufac-turer’s recommendations of the chosen ceiling brand.

• The supply lines are laid into the ceiling cavity and connected to the main supply lines (connections done either by thermal welding or with sealing ring connectors)

• The flexible connecting hoses are plugged into the quick-action couplings of the supply lines.

• The KaRo heating- and cooling mats are

laid into the cassettes and if necessary fixed with KaRo adhesive V.K.1.

• Plug the flexible hoses into the

quick-action couplings of the KaRo mats. • The cassettes with the KaRo mats in it are

hooked into the bearing structure and the joints are aligned.

• If required, place insulating mat on top of it.

• Pre-test with compressed air at 10 bar for one hour.

• Main test with water at 10 bar for 4 hours, maintain an idle pressure of 3 bar until the system is taken into operation.

I.I.

II.II.

III.III.

insulation

Short Description · TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.4 TI K02

10. Lay-out for Metal Cassette Cooling Ceiling with KaRo Capillary Tube Mats

Project: Date :

Project consultant: Lay-out valid for 27°C - room temperature and 2 K cooling water spread!

Required cooling capacity

1 Cooling load for the room W from calculation of the planning office

2 Planned coverage with mats m2 maximum possible arrangement derived from the room dimensions

3 Required specific cooling capacity W/m2 = cooling load / coverage

Determination of performance

4 Supply temperature � from diagram 1 °C

5 Return temperature °C

6 Water volume per mat kg/m2h

7 Water volume per zone l/h

Pressure loss determination

8 Length of the connection pipe m

9 Resistance in the pipe � from diagram 2 Pa/m

10 Pressure loss in pipe Pa

= pipe length * Resistance

11 Pressure loss of the mat Pa� with value of line 2 from diagram 1

12 Addition for pressure loss through fittings Pa

(recomm: 30% addition to pipe)

13 Addition for heat transfer station Pa

(recomm: for zone valves 500 -1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa)

14 Total pressure loss Pa

If BEKA heat transfer stations are utilised the

determination of pressure loss can be omitted.

In this case only the quantity of cooling circuits and the

total cooling capacity is required for the selection.

Quick lay-out for ceiling cooling with BEKA mats in metall cassettes

0

20

40

60

80

100

120

24 23 22 21 20 19 18 17 16 15 14 13 12

Supply temperature [°C]

Cool

ing

capa

city

[W

/m2 ]

6 9 12 16 20 23 27 31 35 38 42 46 50Mass flow of cooling water [kg/(m2h)]

va lid fo r ro o m temperature 27°C

and co o ling water spread 2K

Pressure loss in the pipe 20x2mm

0

10

20

30

40

50

60

70

80

90

100

40 80 120 160 200 240 280 320 360 400

Mass flow [kg/h]

Pres

sure

loss

[Pa/

m]

D ruckverlust Typ S15

0

5000

10000

15000

20000

25000

10 15 20 25 30 35 40

M assenstro m (kg/m2h)

8m 7m 6m 5m

4m

3m

2m

1m

Pressure loss type U 10

0

200

400

600

800

1000

1200

1400

1600

1800

2000

10 15 20 25 30 35 40

Mass flow[kg/m2h]

Pres

sure

loss

[Pa]

2,0 m1,8 m 1,6 m

1,4 m

1,2 m

1,0 m

Short Description · TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.5 TI K02

11. Lay-out for Metal Cassette Ceiling Heating with KaRo Capillary Tube Mats

Project : Date

Projekt consultant: Lay-out valid for 22°C room temperature and 6K heating water spread !

Required Haeting Capacity

1 Heat requirement for the room W from calculation of planning office

2 Planned coverage with mats m2 maximum possible arrangement derived from room dimensions

3 Required specific heating capacity W/m2 = heat requirement / coverage

Determination of Performance

4 Supply temperature -> from diagram 1 °C

5 Return temperature °C

6 Water volume per mat area kg/(m2h)

7 Water volume per zone l/h

Pressure Loss Determination

8 Length of connection pipe m

9 Resistance in the pipe -> from diagram 2 Pa/m

10 Pressure loss in the pipe Pa

= pipe length * resistance

11 Pressure loss of the mat Pa

-> with value of line 2 from diagram 1

12 Addition for pressure loss through fittings Pa

(recomm.: 30% addition to pipe)

Addition for heat transfer station Pa

(recomm.:for zone valves 500 -1000 Pa

13 for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA heat transfer stations are utilised

the determination of pressure losses can be omitted.

Then only the quantity of heating circuits and the total

heating capacity is requird for the selection !

Quick lay-out for ceiling heating with BEKA mats in metal cassettes

020406080

100120140160180

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

he

atin

g c

ap

aci

ty [

W/m

2]

1 3 5 6 8 10 11 13 15 17Mass flow of the heating water [kg/(m2h)]

valid for room temperature 27°C and heating water spread 6K

Pressure loss in a pipe 20x2mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400Mass flow [kg/h]

Pre

ssure

loss

[P

a/m

]

Pressure loss type U10

0200400600800

10001200140016001800

5 10 15 20 25

Mass flow (kg/(m2h)]

Pre

ssu

re lo

ss

(Pa

)

2,0m

1,6m

1,2m

Short Description · TI-K02 Metal Cassette Ceiling with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.6 TI K02

12. Technical Data

KaRo Capillary tube mats Type K.U10 Type K.UM10 Type K.G10 Material Polypropylene Random-Copolymer Type 3 DIN 8078 Geometry Collector pipe 20 x 2 mm Capillary tube 3,35 x 0,5 mm Capillary tube spacing 10 mm Exchange surface 1,067 m2 Dimensions Length 600-6000 mm (in increments of 10 mm) Width 150-1200 mm (in increments of 10 mm) Mass 0,43 kg/m2 (empty, without collector) 0,82 kg/m2 (filled, without collector) Water contents 0,39 l/m2 Cooling capacity: Depending upon type 80 W/m2 for metal cassette (DIN 4715) Heating capacity Depending upon type up to 150 W/m2 Condition of operation: Temperature resistant for endurance run to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar maximum 10 hours Operational area / type of installation : Cooling- and heating ceilings for the installation on top of metal cassettes Connections via quick-action coupling system Type of delivery: The mats are supplied lying flat in cartons or in one-way transport cassettes

TI-K03 Short Description

Gypsum Plasterboard Ceilings with KaRo Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K03

1. General Information

Suspended gypsum plasterboard ceilings can very easily and economically be designed as heating and cooling ceilings with KaRo heating and cooling mats. Contemporary office and computer technology combined with a high de-gree of thermal insulation make it necessary to air-condition offices and business premises nearly all year round. Even during periods when heating is required, these rooms have a com-paratively low heat consumption. The most cost-effective solution with regard to energy is the in-stallation of a KaRo cooling and heating ceiling. The combined functionality of the ceiling mini-mises the investment required for the necessary building technology. 2. System Description

The KaRo capillary tube mats are simply stretched between the supporting profiles and covered with mineral wool. Afterwards, the ceil-ing is planked as usual - (standard cooling ca-pacity 65 W/m2) 3. Cold-water/Hot-water Technology

The KaRo heating and cooling mats are inte-grated in rooms/zones in a tubing network as a circulation loop and connected to a cold-water generator and the heat source. We recommend that the connection is made using a KaRo single-storey distributor. A wide variety of technologies and systems may be used for cold water generation. The eco-nomic advantages of the cooling ceiling consist primarily of the fact that the ceiling is extremely efficient even at flow temperatures which are only slightly below the room temperature. This facilitates the use of "alternative energy" (heating pumps) and natural energy (e.g. free cooling, groundwater). The same advantages apply to hot water gen-eration. Significant energy savings are achieved not only in combination with solar heating sys-tems, but with conventional technology as well,

since even at low flow temperatures (below 40° C), the respectable calorific output can be used for heating. 4. Installation

As a rule, the general installation guidelines ap-ply. All materials used in the tubing network of the KaRo capillary tube mats must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may cause the system to silt up and thus disrupt its function.

Pipe system

Further Ceiling surfaces

Connection to Cooling unit or heating source

Feed lines to connection hoses

Short Description · TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K03

5. Control Technology

The control technology ensures the comfort you desire and provides the necessary system safety as well. The cooling ceiling requires a room temperature control unit, a dew point safeguard control unit and a control unit for the initial flow tempera-ture of the cold water. Initial flow temperatures below 16°C must be avoided due to the dew point risk! The heating ceiling requires a room temperature control. This regulates the flow of hot water de-pending on the desired room temperature. Ini-tial flow temperatures more than 45°C must be avoided so that the surface temperature of the ceiling does not become too high, and the gyp-sum plasterboards dry out ! 6. Dimensioning of the System

The KaRo heating and cooling mats are sized ac-cording to the following design tables. The ini-tial flow temperature in the water circulation of the KaRo mats is set by adjusting the water temperature in front of the heat exchanger on the cold generator or heat generator side. 7. Installation Preparation

The stipulations of the dry construction guide-lines and the regulations of the fitters' union ap-ply to the assembly and mounting of the KaRo heating and cooling mats on gypsum plaster-board ceilings. We recommend that the furring be carried out using torsionally rigid steel profiles. The specifi-cation of the effective spans and the execution of anchoring the hangers on the bare ceiling must be designed for a load of ≤ 30 kg/m2. Gypsum plasterboard sheets in the customary dimensions are used. The KaRo heating and cooling mats are supplied in the correct widths and lengths, so that cutting them to size on the construction site is not necessary. Inactive areas are arranged only around the edges and in places where ceiling fittings are planned.

Before beginning work, a ceiling drawing and a laying plan must be drawn up, in which all cof-fers with their dimensions, alignment, and the supply lines must be recorded. In the ceiling drawing, all areas must be also marked which must remain unoccupied, e.g. where partition walls, lighting and other ceiling fittings will be installed. In addition, the location where the KaRo M.TG.1 dew point sensor will be installed must also be marked in the ceiling drawing. If thermal plastic welding is being used to con-nect the polypropylene tubes, the welding guideline DVS 2207-11 of the Deutscher Ver-band für Schweißtechnik e.V. (German Associa-tion of Welding Technology) applies. (The envi-ronment temperature during processing may not be lower than 5°C and the preheating, weld-ing and holding times must be observed accord-ing to the dimensions of the tubing.) 8. Tools, Materials

The conventional tools and materials used in dry construction are used for the installation of the gypsum plasterboard ceiling covered with KaRo mats: • CD profiles • Cross connectors • Vernier hangers • Dowels and screws • Dry wall screws, 25mm long • (Only variation B) dry wall screws, 40 mm

long • Wetting angle • Possibly a blade knife for cutting to size and

an edge-trimming plane • Screwdriver • Spatula • Joint filler • Hand grinder To connect the feed lines to the cold water cir-culation, a handheld welding unit with a sleeve mirror is used for plastic welding and the corre-sponding plastic fittings are required. Cutting ring screw fittings may be used as an alternative.

Short Description · TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K03

9. Steps in Assembling the Ceiling

• In accordance with the manufacturer's in-structions, the supporting and basic profiles are attached to the bare ceiling using vernier suspenders and aligned. The distance be-tween the supporting profiles must be set at 40 or 50 cm. Additional supporting profiles (including the wetting angle) in the area around the edge for the inactive custom-cut sheets are arranged according to the ceiling plan in accordance with the dry construction guidelines.

• The feed lines are laid in the hollow cavity of the ceiling and connected to the supply lines (connection by means of thermal plastic welding or cutting ring screw fittings).

• The KaRo mats are stretched between the

supporting profiles and connected to the feed lines via the flexible hoses; alternatively, the mats can be connected to each other and to the tubing system using plastic weld-ing.

• Adhesive tapes are fastened from supporting profile to supporting profile, so that the mats do not sag.

• Mineral wool mats are laid on top of the KaRo mats from above. The mineral wool must be cut to fit as a strip in the grid di-mension of the supporting profiles. If the hollow ceiling cavity is used for the exhaust ventilator or if perforated gypsum board is used, the mineral wool must be packed in fibreproof PE foil wrapping.

• The supporting structure is planked from be-

low with gypsum board and filled. • Preliminary test with 10 bars of compressed

air for 1 hour. • Main test with 10 bars of water for 4 hours

– maintain resting pressure of 3 bars until the system is put into operation.

I.I.

II.II.

III.III.

Short Description · TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P. 4 TI -K03

10. Lay-out for KaRo Mats on Gypsum Plasterboard in the Cooling Ceiling

Project: Date :

Project consultant: Lay-out valid for 27°C-room temperature and 2K cooling water spread !

Required Cooling Capacity1 Room cooling load W from calculation of the planning office

2 Planned coverage with mats qty Max. possible arrangement derived from the room dimensions

3 Required cooling capacity W = Cooling load / Coverage

D e te rmin a tio n o f P e rfo rma n c e

4 Supply temperature -> from diagram 1 °C

5 Return temperature °C

6 Water volume per mat area kg/m2h

7 Water volume per zone l/h

Pressure loss calculation

8 Length of connecting tube m

9 Resistance in the tube -> from diagram 2 Pa/m

10 Pressure loss in the tube Pa

= tube length * Resistance

11 Pressure loss of the mat Pa

-> with value of line 2 from diagram 1

12 Add. for pressure loss through fittings Pa

(recomm: 30% addition to tube)

13 Add.for heat transfer stations Pa

(recomm:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA heat transfer stations are utilised the

determination of pressure loss can be omitted.

In this case only the quantity of cooling circuits and the

total cooling capacity is required for the selection !

Pressure loss in the pipe 20x2mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400

Mass flow [kg/h]

Pre

ssu

re lo

ss

[Pa/

m]

Pressure loss type G10

0

1000

2000

3000

4000

5000

10 15 20 25 30 35 40

Mass flow [kg/(m 2h)]

Pre

ssu

re lo

ss [

Pa]

6m

1m

4m

2m

Quick lay-out of ceiling cooling with BEKA mats on gypsum plasterboard

0

10

20

30

40

50

60

70

80

90

100

24 23 22 21 20 19 18 17 16 15 14 13 12

Supply temperature [°C]

Co

olin

g c

apac

ity

[W/m

2]

5 7 10 13 16 19 22 25 28 31 34Mass flow cooling water [kg/m 2]

Va lid fo r ro o m temperature 27°C

and co o ling water spread 2K

Short Description · TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P. 5 TI -K03

11. Layout for the KaRo Mats on Gypsum Plasterboard in Heating Ceiling

Project : Date :

Project consultant : Lay-out valid for 22°C -room temperature and 6 K hot water!

Required heating capacityRequired heating capacity

1 Room heat requirement W from calculation of planning office

2 Planned coverage of mats qty max. possible arrangement derived from room dimensions

3 Required specific heat capacity W = Heating requirement /Coverage

Determination of PerformanceDetermination of Performance

4 Supply temperature � from diagram 1 °C

5 Return temperature °C

6 Water volume per mat area kg/(m2h)

7 Water volume per zone l/h

Pressure loss calculation

8 Length of connecting pipe m

9 Resistance in the pipe � from diagram 2 Pa/m

10 Pressure loss in the pipe Pa

= Pipe length* Resistance

11 Pressure loss of the mat Pa� with value from line 2 in diagram 1

12 Add.for pressure loss through fittings Pa

(recomm: 30% addition to pipe)

13 Add.for heat transfer station Pa

(recomm: for zone valves 500 -1000 Pa)

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA transfer stations are used, the pressure loss

calculation is omitted. Only the number of heating

circuits and the total heating capacity are required

for the selection .

Pressure loss in the pipe 20 x 2 mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400

Mass flow [kg/h]

Pre

ssu

re lo

ss [P

a/m

]

Quick lay-out for ceiling heating with BEKA mats on gypsum plasterboard

0

20

40

60

80

100

120

140

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Hea

tin

g c

apac

ity

[W

/m2 ]

1 3 5 7 8 10 12 14 17 19Mass flow of hot water [kg/m 2]

Va lid fo r ro o m temperature 22°C

and co o ling water spread o f 6K

Pressure loss type K.G10

0

500

1000

1500

2000

2500

3000

5 10 15 20 25

Mass flow [kg/(m2h)]

Pre

ssu

re lo

ss [P

a]

6,0 m

1,0 m2,0 m

4,0 m

Short Description · TI-K03 Gypsum Plasterboard Ceilings with BEKA Heating and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P. 6 TI -K03

12. Technical Specifications

KaRo capillary tube mats Type K.G10/K.GK10 Material Polypropylene random copolymerisate Type 3 DIN 8078 Geometry Collection tube 20 x 2 mm Capillary tube 3.35 x 0.5 mm Capillary tube interval 10 mm Exchange surface 1.067 m2 Size Length: 600-6000 mm (in steps of 10 mm) Width: 230- 430 mm (in steps of 10 mm) Volume 0.430 kg/m2 (unfilled, without collector) 0.824 kg/m2 (filled, without collector) Water content 0.39 l/m2 Cooling capacity: 65 W/m2 with 10 mm gypsum plasterboard (heat conductivity of the thermal sheet approximately 0.40 W/mK ) Heating capacity: Up to 130 W/m2 Operating conditions: Temperature-stable in continuous use up to 45°C Operating pressure 3 to 4 bars Test pressure 10 bars for a maximum of 10 hours Field of application/Laying method: Cooling and heating ceilings in dry construction Connection via flexible hoses and quick-coupling connectors or via thermal plastic welding Form of delivery: The mats are rolled and delivered in cartons.

TI-K04 Short Description

Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K04

1. General

Modern office- and business premises must be climate controlled nearly all year long be-cause of their high thermal insulation and their internal loads coming from computers and other office appliances. At the heating period they have comparatively low heat con-sumption. The energetic cost saving solution is a KaRo heating- and cooling ceiling. With the KaRo pre-fabricated unit heating- and cooling mats can easily and economically be utilised for the dry-built construction. Through the combined function of the ceiling investment costs for heating system installa-tions can be minimised. 2. System Description

The KaRo pre-fabricated units are screwed to suspend ceiling construction according dry-build construction instructions just like any standard dry-build panel. The pre-dimensioned connection lines are laid into the ceiling cavity. The pre-fabricated unit is con-nected with flexible hoses to the supply lines. 3. Cold Water- /Hot Water

Technique

The KaRo heating- and cooling mats are tied up in zones to the piping as a circuit and con-nected to the heat- or cooling supplier. The connection via a storey-distributor is recom-mended. For the cold-water preparation different tech-niques and systems can be utilised. The eco-nomical advantages of cooling ceiling exist because the ceiling will provide already suffi-cient performance even with supply tempera-tures which are only slightly below the room temperature. This makes the utilisation of “al-ternative energy sources” such as heat pumps or open cooling and ground water possible. For generating of heating water the same ad-vantages are true. In connection with solar

collector systems and even with standard techniques a significant energy saving is al-ready reached, because respectable heating performances are achieved with considerable low supply temperatures (below 40°C).

4. Installation

In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive. Materials used can be: plas-tics, stainless steel, copper, brass and red brass. Other materials in use could cause sludge and could lead to a breakdown of the system.

Ceiling with BEKA pre-fabricated units

Piping

for other ceiling areas

Connection to Cooling unit or to heat supply

Supply lines Connecting hoses

Short Description · TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K04

5. Regulating Technique

The regulating technique secures, first the de-sired comfort, second the necessary system reliance. The cooling ceiling requires : a room tempera-ture regulation, a dew point guard and a con-trol of the supply temperature for the cold water. Supply temperatures below 16°C must be avoided because of the danger that the dew point will be reached! For the heating ceiling a room temperature control is required, which regulates the vol-ume of heating water in dependence to the desired room temperature. Supply tempera-tures above 45°C must be avoided because of the danger of excessive surface temperatures of the ceiling and to avoid that the plaster-board will dry ! 6. Dimensioning of the System

The cooling ceiling from KaRo pre-fabricated units is dimensioned according to the follow-ing layout table. The supply temperature de-termined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water temperature before the heat exchanger. 7. Installation Instructions

For the installation of the KaRo pre-fabricated unit the standards for the dry-build construc-tion and the fabricator’s recommendations must be obeyed. It is recommended to use twist-free sheet metal profiles for the supporting construction of the suspended ceiling. The distances and the type of anchoring of the suspended verniers to the raw ceiling must be for a load of ≤ 30 kg/m2 . The pre-fabricated unit is offered in the same dimensions as the standard building panels, so that tailoring work at the building site is not necessary. Only at border areas and at places where ceiling build-ins are planned, in-

active panels are fitted in. The KaRo pre-fabricated units are delivered pre-drilled for the connection to sub-construction made from standard CD-profiles. The screws may only be placed at these pre-determined positions, otherwise there is the danger that the integrated capillary tube mats are damaged. Before starting work a ceiling pattern and an installation pattern must be drawn-up. All cassettes with their measurements, the instal-lation direction and the supply lines must marked. In the ceiling pattern also all areas must be marked which will stay empty for the installation of partition walls, light fixtures and other ceiling in-fills. Also the installation position for the KaRo dew point sensor must be marked at the ceiling pattern. The connection of the Polypropylene piping is done by thermal welding. For the execution the welding directions DVS 2207-11 of the Deutschen Verband für Schweißtechnik e.V. are valid. (The surrounding temperature dur-ing working must not be below 5°C. The pre-heating, welding and setting time must be according to regulations.) 8. Tools, Materials

For the installation of the KaRo pre-fabricated unit standard tools and materials for the dry-build construction work is used: • CD - profile • Cross connector • Vernier suspension bar • Dowel and screws • Rapid-build screws, 55 mm length • Perimeter angles • Blade-knife and edge planer • Screw-driver • Smoothening spatula • Joint filler • Hand grinder For the connection of supply lines to the cold-water circuit a hand held welder with sleeve adapter is recommended for the plastic weld-ing together with plastic fittings. Alternatively sealing ring connectors can be used.

Short Description · TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K04

9. Installation Steps at the Ceiling

• The bearing structure is aligned and fixed at

the raw ceiling with vernier suspension bars. • The distances for the bearing profiles should

be 500 mm. Additional bearing profiles ( also the perimeter angle ) at the border ar-eas for the inactive tailored panels are posi-tioned according to dry-build directions.

• The supply lines are laid in the ceiling cavity

and are connected to the main lines (con-nections done by thermal welding or with sealing ring connectors).

• The KaRo pre-fabricated unit is

fixed to the sub-construction according the ceiling-pattern.

• The flexible connecting hoses are plugged into the quick-action couplings of the supply lines.

• The pre-fabricated unit aligned at the sub-construction to the pre-drilled holes.

• The rapid-build screws inserted through the pre-drilled holes and screwed tight un-til secure fixing to the sub-construction is achieved.

• Pre-test with air pressure of 10 bar for 1 hour

• Main test with water at 10 bar for 4 hours. • Maintain a resting pressure of 3 bar until taken into operation.

I.I.

II.II.

III.III.

Short Description · TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.4 TI -K04

10. Lay-out of the Cooling ceiling with the KaRo Pre-fabricated Unit B.GK12

Project : Date :

Projekt consultant : Lay-out valid for 27°C room temperature and 2K cooling spread !

Required cooling capacity

1 Cooling load for the room W from calculation of planning office

2 Planned quantity of panels Stück derive possible arrangement from room measurements

3 Required cooling capacity of unit W = cooling load / quantity of panels

Determintaion of capacity

4 Supply temperature --> from diagram °C Water volume per unit kg/h -> from diagram

5 Return temperature °C Water volume per zone l/h

Pressure loss determination

6 Pressure loss in the pipe Pa Length of connecting pipe m only one lead

= pipe length * Resistance Resistance in pipe -> from diagram Pa/m Value --> from diagram

7 Pressure loss of unit Pa

-> with value of line 3 from diagram

8 Add. for pressure loss through fittings Pa

(Recomm.: 30% extra for pipe)

9 Add. for heat transfer station Pa

(Recomm.:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

10 Total pressure loss Pa

If BEKA transfer stations are used the determination

for pressure losses can be omitted. Only the quantity of

cooling circuits and total cooling capacity is required

for the selection.

Quick Lay-out for ceiling cooling load with B.GK12

0102030405060708090

100110120

24 23 22 21 20 19 18 17 16 15 14 13 12Supply temperature [°C]

Cooling load [Watt/unit]

6 9 12 16 19 23 26 30 34 37 41 45 49

Mass flow of cooling water per unit [kg/h]

300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2550 2800

Pressure loss of unit [Pa] valid for room temperature 27°C andcooling water spread 2K andconnecting hose 300mm length

Pressure loss in the pipe 20x2mm

0

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Mass flow [kg/h]

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ss [P

a/m

]

Short Description · TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.5 TI -K04

11. Lay-out for Ceiling heating with the KaRo Pre-fabricated Unit B.GK12

Project : Date :Project consultant : Lay-out valid for 22°C room temperature and 6K heating water spread !

Required heating capacity1 Heat requirement for the room W from calculation of planning office2 Planned quantity of panels qty derive the max. possible arrangement from the room measurements3 Required heat capacity / unit W = heat requirement / Quantity panels

Determintion of capacity

4 Supply temperature -> from diagram °C Water volume / unit kg/h -> from diagram5 Return temperature °C Water volume / zone l/h

Determination of pressure losses6 Pressure loss in the pipe Pa Length of connecting pipe m only one lead

= pipe length * resistance Resistance in pipe -> from diagram Pa/m Value -> from diagram7 Pressure loss of unit Pa

-> with value of line 3 from diagrame8 Add for pressure loss through fittings Pa

(recomm: 30% extra to the pipe)9 Add for heat transfer station Pa

(Recommen.:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa for heat exchanger approx. 4000 Pa

10 Total pressure loss Pa

If BEKA transfer stations are utilised the determination for pressure losses can be omitted. Then only the quantity of heating circuits and the total heating capacity must be knownfor the selection.

Quick Lay-out for Ceiling Heating with B.GK12

0

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100

120

140

160

180

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Heating capacity [W/Unit]

100 200 300 400 550 700 850 1000 1150 1300

Pressure loss of Unit [Pa] only valid for room temperature 22°C and heating water spread 6K and connecting hose 300mm length

2 4 6 8 10 12 15 17 20 22Mass flow of heating water / unit [kg/h]

Pressure loss in the pipe 20x2mm

0102030405060708090100

20 40 60 80 100 120 140 160 180 200Mass flow [kg/h]

Pre

ssure

loss

[Pa/m

]

Short Description · TI-K04 Ceiling Cooling and Ceiling Heating with KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.6 TI -K04

12. Technical Data

Construction 12,5 mm Plasterboard Capillary tube mat with capillary diameter 3,35x0,5 mm (Polypropylene) 30 mm Extruded foam (thermal conductivity 0,035 W/mK; Fire rating: B1) Weight 11,8 kg/m2 (empty) 12,5 kg/m2 (filled) Size Width: 600 mm Length: 2000 mm Pre-drilled to be screwed in 500 mm grid Cooling capacity : 64 W/m2 (DIN 4715) =76 W/Unit Heating capacity: 130 W/m2 = 155 W/Unit Conditions for operation: Temperature persistent at continues use up to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application /Type of installation: Cooling- and heating ceilings for Dry-built construction Connections with KaRo quick-action-coupling system Installation according to Dry-built instructions Type of delivery: Finished dry-built units are delivered laid on pallets.

TI-K05 Short Description

Wall Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K05

1. General

Wall heating with KaRo heating mats releases the heat to the room and directly to the room occupant in a natural way through radiation. The small diameter of the capillary tubes al-lows the construction of wall heating with a low construction height. For this reason KaRo mats are distinguished for the renovation where wall heating is installed to a later stage. Differing to standard wall heating sys-tems the heat is directly beneath the wall sur-face. The KaRo wall heating reacts very fast and can be operated with low supply tem-peratures. 2. System Details

Mostly the KaRo mats are installed into the plastering of outer walls, directly beneath the surface. The outer wall must have a U-value below 0,35 W/(m2K). If this is not given, insu-lation of the internal wall can be utilised. With a wall heating system the possibility that the dew point is moved into the wall con-struction is being counteracted. The connec-tions of the mats amongst themselves and the connection of the mats to the piping, all the way to the heating circuit distributor, normally are thermal welded. In most cases the mats are installed to the wall up to a height of 2 meters. This way the possibility is given to fix things (pictures etc.) to the wall above this area. 3. Heating Water Technique

The KaRo heating mats are connected in a cir-cuit to the heat source via pipelines to the supply- and return lines, room for room or zone for zone. It is recommended to connect to KaRo storey distributor stations. The economical advantages of KaRo wall heating systems are based on the fact, that already at supply temperatures that are barely above room temperatures, the wall releases a high efficiency. This makes it possible to util-ise alternative energies (heat pumps, solar collector systems etc). But also with the stan-

dard heating a significant energy saving will be achieved, since heating with supply tem-peratures below 40°C is possible.

Figure 1: KaRo mats on the wall with internal insulation and insulation panels. The piping is installed according to Tichelmann 4. Installation

In general the standard Installation guidelines have to be obeyed. All materials used in the KaRo heating- and cooling mat system must be non-corrosive such as plastics, stainless steel, copper, brass and red brass. Other ma-terials in use could cause sludge and could lead to malfunction of the system.

Connection through a distributor to the heat source

Short Description · TI-K05 Wall Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K05

5. Regulating Technique

The regulating technique secures, first the de-sired comfort, second the necessary system reliance. For the heating ceiling a room temperature control is required, which regulates the vol-ume of heating water in dependence to the desired room temperature. Supply tempera-tures above 45°C must be avoided because of the danger that an excessive surface tempera-ture will dry-out the plaster ! 6. Dimensioning of the System

The wall heating with KaRo heating mats are dimensioned according to the following lay-out table. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water temperature before the heat exchanger. 7. Preparation for Installation

For the installation of wall heating with KaRo heating mats the installation instructions of the plaster supply and the KaRo instructions must be obeyed. The walls to be heated must have a load-bearing surface. The KaRo heating mats are pre-fabricated to the required dimensions for each object, so that tailoring at the building site is not neces-sary. It is recommended to have the mats supplied already prepared with adhesive tape for the positioning of the mats to the raw ceiling. A layout pattern should be prepared as a

work basis before work is started. All heating mats, their measurements and the direction they are facing must be marked in the pat-tern. All surfaces that will not be covered as for the installation of internal walls and fixing points for hanging cabinets must also be marked. The connections of the KaRo heating mats to another and to the Polypropylene pipelines are done by thermal welding. The welding directions DVS 2207-11 of the Deutschen Verband für Schweißtechnik e.V. are valid. (The surrounding temperature dur-ing working must not be below 5°C. The pre-heating, welding and setting time must be according to regulations.) 8. Tools and Materials

For the installation of KaRo heating mats for wall heating, the usual tools and materials for plastering and for installation of plastic pipes can be used, such as: • Plastering material (suitable for wall heat-

ing systems) • Mixer • Smoothening spatula • Bonding layer • Roller or brush • Border strip • Possibly spreading dowels and a hand

drill for additional securing of the mats to the raw ceiling

• Pair of scissors for cutting plastic piping • Pencil For the connection of the piping to the water circuit a hand held thermal welder suitable to weld sleeves of plastic fittings is required. Al-ternatively sealing ring connections can be used.

Short Description · TI-K05 Wall Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K05

9. Installation Steps at the Wall (with Inside Insulation)

• Fix the insulation panels for a plastering base to the raw walls (with adhesive or dowels) according manufacturers instructions.

• Cut a slot (100 x 30 mm) into insula-tion approx. 100 mm above the floor

• Prepare insulation panel to be bond-ing layer for the plastering

• position KaRo heating mats and fix with adhesive tape

• possibly secure the mats with spreading dowels to the wall

• connect the mats to another and to the pipelines for the supply- and return lines through thermal welding.

• pre-test with compressed air of 10 bar for 1 hour

• main test with water pressure of 10 bar for 4 hours. In resting state maintain 3 bar until taken into op-eration.

• apply a thin layer of plaster (10 mm)

in one step according manufacturers instructions

• smoothen plaster, observe the pre-drillings

I.I.

II.II.

III.III.

Short Description · TI-K05 Wall Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.4 TI -K05

10. Lay-out of Wall Heating with KaRo Heating Mats

Project : Date

Project consultant : Lay-out valid for 22°C-room temperature and 6K heating water spread !

Required heating capacity

1 Heat requirement for the room W from the calculations of the planning office

2 Planned coverage with mats m2 derive the maximum possible arrangement from the room measurements

3 Required specific heating capacity W/m2 = heat requirement/ Coverage

Determination of capacity

4 Supply temperature -> from diagram 1 °C

5 Return temperature °C

6 Water volume per mat area kg/(m2h)

7 Water volume per zone l/h

Determination of pressure loss

8 Length of connecting pipe m

9 Resistance in the pipe -> from diagram 2 Pa/m

10 Pressure loss in the pipe Pa

= Pipe length * Resistance

11 Pressure loss of the mat Pa

-> with value from diagram 1 (line 2)

12 Add for pressure loss through fittings Pa

(recomm: 30% add to the pipe)

13 Add for heat transfer station Pa

Recomm: for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA transfer stations are utilised the

determination of pressure loss can be omitted, only

the quantity of the heating circuits and the total heating

capacity is required for the selection.

Quick Lay-out for wall heating with BEKA mats laid in plaster

0

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60

80

100

120

140

160

180

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Hea

ting

capa

city

[W/m

2 ]

2 4 7 9 12 14 17 19 22 25

Mass flow of the heating water [kg/(m2h)]

only valid for room temperatures of 27°C and haeting water spread of 6K andPlaster quality MP75 -Fa.KNAUF

pressure loss in a pipe 20x2mm

0

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5 10 15 20 25

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Short Description · TI-K05 Wall Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.5 TI -K05

11. Technical Data

KaRo Capillary tube mats Type K.S15 Material Polypropylene Random Co-polymer type 3 DIN 8078 Geometry Collector pipe 20 x 2 mm Capillary tube 3,35 x 0,5 mm Capillary tube distance 15 mm Exchanging surface 0,71 m2 Measurement Length: normally 600-2000 mm (in increments of 10 mm) Width: 150-1200 mm (in increments of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Heating capacity Depending upon the type up to 150 W/m2 Conditions of operation temperature persistent at continues use up to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application /Type of installation: Wall heating for plaster walls Connections through thermal welding Type of delivery Mats are delivered rolled-up, packed in cartons.

TITI--K06K06 Short Description

Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K06

1 General

Because of the high thermal insulation of modern buildings the offices and residential houses have comparatively low heat require-ments. In many cases they must be cooled during long periods of the year to maintain comfortable room temperatures. A low cost solution to save energy is the use of a KaRo wall heating / wall cooling system. With the use of KaRo pre-fabricated units heating and cooling surfaces can be arranged simply and economically in the dry-build version. Through the combined function of the wall surface investments for the necessary building installations can be minimized. 2 Description

The KaRo pre-fabricated unit is fixed to the support structure, like any other standard dry-build board, according to the dry-build direc-tions. The supply lines, pre-fabricated to the required to measurements are laid into the wall cavities. The pre-fabricated units are con-nected to the supply lines with flexible hoses. 3 Cold Water- / Heating Water

Technique

The KaRo pre-fabricated units are connected to the supply and return of the piping of the heat- or cold-water source, room for room or zone for zone. Recommended is the connec-tion via a KaRo storey distributor unit. For the heating water generating different techniques and constructions can be utilised . The economic advantages of a cooling ceiling are influenced mostly by fact that the wall will deliver high heating/cooling capacity al-ready with supply temperatures, which are only slightly above /below the room tempera-ture. This allows the use of alternative energy sources such as heat pumps or solar tech-niques. Even with the use of standard tech-niques a decisive energy saving can be achieved, since already little temperature dif-ferences in the supply temperatures to the

room temperatures (for heating: supply temp. below 40°C) will achieve respectable heating capacities of 110 W/m2. For cold water cooling similar advantages are achieved. The supply temperatures must be restricted to minimum of 16°C, to surely avoid any condensation. At a room temperature of 27°C cooling capacities of approx. 65 W/m² can be achieved.

4 Installation

Basically the standard installation instructions are valid for all installations. All components used in the piping for the KaRo pre-fabricated units must be made of non- corrosive materi-als. Utilised may be plastic materials, copper, brass and red brass. Other materials may cause sludge and could therefore be the cause of malfunction of the system

Wall with BEKA pre-fabricated units

Other wall surfaces

Connection for Cooling unit or heat supply

Supply lines hose connections

Short Description · TITI--K06K06 Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.2 TI K06

5 Regulating Technique

The regulating technique secures, first the de-sired comfort, second the necessary system reliance. For the wall heating a room temperature con-trol is required, which regulates supply tem-perature of the desired room temperature. Supply temperatures above 45°C must be avoided because of the danger that excessive surface temperatures could dry-out the plas-terboards! For the wall cooling a room temperature regulation, a dew point guard and a regula-tion of the supply temperature of the cold water is required. Supply temperatures below 16°C must be avoided so that the dew point won’t be reached! 6 Dimensioning of the System

The wall heating/cooling ceiling with KaRo pre-fabricated units are dimensioned accord-ing to the following layout table. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water tem-perature before the heat exchanger. 7 Installation Preparation

For the installation of the KaRo pre-fabricated units the standards for the dry-build construc-tion and the fabricator’s recommendations must be obeyed. It is recommended to use twist-free sheet metal profiles for the supporting construction of the suspended ceiling. The distances of the bracing profiles to another must be 600 mm. The choice of the supporting profiles and the type of fixing must be according to dry-build specifications. The KaRo pre-fabricated unit is supplied in standard dimensions of 2600 mm x 600 mm. The active surface area is 1,2m². Capillary tubes are not located above 2100 mm of height. This area serves the tailoring for the

length accommodations of the KaRo pre-fabricated units to the room height. At the border area inactive panels are fitted. The KaRo pre-fabricated units are pre-drilled for the fixing to the sub-constructions. The fixing screws may only be located at the pre-given positions, otherwise damages may be caused to the integrated capillary mats. Before starting work a wall pattern must be arranged as a work- and positioning layout. All panels, their dimensions and the position-ing of the supply lines must be recorded. On the wall pattern all areas must be marked which will be left uncovered for installation purposes of inner walls, light fixtures and other wall installations. Furthermore, the in-stallation position for the KaRo pre-fabricated units with integrated dew point sensors must be recorded. The connection of the Polypropylene- pipe-lines are done by thermal welding, welding specification DVS 2207-11 of the Deutschen Verband für Schweißtechnik e.V must be obeyed. The surrounding temperature (at the time of welding) must be above 5°C. The pre-heating temperatures, welding- and setting times must be kept according to pre-given values for the responding pipe sizes 8 Tools , Materials

For the processing of the KaRo pre-fabricated units the standard dry-build tools and materi-als can be used, such as: • CW profile • UW - profile • Sound insulation tape • Dowels and screws • Building screws, 55 mm length • Plate-knifes for tailoring and edge planer • Screw driver • Spatula • Joint spatula mastic • Hand grinder A hand-held welding tool with a sleeve weld-ing device is used for welding the supply lines to the cold water circuit. Alternatively sealing ring screw connections may be used instead.

Short Description · TITI--K06K06 Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.3 TI K06

9 Installation Steps at the wall

• The connection lines are installed at

the raw wall at a height of approx. 2100 mm and fixed with pipe clamps according to installation instructions. The supply lines are connected by means of thermal welding or sealing ring connections.

� The U- and stud profiles are aligned

and fixed to the raw wall in the ap-propriate manner according to manufacturer’s specifications. The distance between the stud profiles is set to 600 mm. Additional stud pro-files at the border area and for the inactive (tailored) panels have to be arranged to the wall pattern accord-ing to dry-build guidelines.

• The KaRo pre-fabricated unit is fit-

ted to the stud-construction ac-cording to the wall pattern

• The flexible connecting hoses are plugged into the quick-action cou-plings.

• The pre-fabricated unit is aligned to the stud-construction according to the pre-drilled holes

• The building screws inserted into the pre-drilled holes and fastened until a secure fixing to the sub-construction is achieved.

• Pre-test with compressed air at 10 bar for 1 hour.

� The main test with water follows at 10 bar for 4 hours. Idle pressure at 3 bar must be kept until start of opera-tion.

� Fill gaps, smoothen and grind.

I.I.

II.II.

III.III.

Short Description· TITI--K06K06 Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.4 TI K06

10. Lay-out for a Wall cooling with the KaRo Pre-fabricated Unit B.GK12

Project: Date :

Project consultant : Lay-out valid for room temp. of 27°C and 2K heating water spread!

Required cooling capacity

1 Cooling load W Calculation from planning office

2 Planned qty of panels Qty. max.possible arrangement derived from room dimensions

3 Required cooling capacity per unit W = cooling load / qty of panels

Determination of capacity

4 Supply temp. -> from diagram °C Water volume per unit kg/h -> from diagram

5 Return temperature °C Water volume per zone or wall ltr/h

Determination of pressure loss

6 Pressure loss in the piping Pa Length of connecting pipe m only 1 pipeline

= pipe length * resistance Resistance in pipe -> from diagram Pa/m value -> diagram

7 Pressure loss of the unit Pa

-> values of line 3 from diagram

8 Add for pressure loss through fittings Pa

(recomm: 30% addition to pipe)

9 Add for heat exchange unit Pa

recomm: for zone valves 500-1000 Pa

for mains regulator valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

10 Total pressure loss Pa

If BEKA heat exchange units are used, pressure

loss determination can be omitted. Only the

number of cooling circuits and the total cooling

capacity is required for the selection!

Quick Lay-out for W all cooling with B.GK12

0102030405060708090

100110120

24 23 22 21 20 19 18 17 16 15 14 13 12Supply temperature [°C]

Co

olin

g c

ap

aci

ty [W

/Un

it]

300 500 700 1100 1300 1500 1700 1900 2300 2800Pressure loss of the unit [Pa]

valid for 27°C room temperature and2K cooling water spread, connection hose of 300mm length

pressure loss in pipe 20x2mm

0102030405060708090

100

40 80 120 160 200 240 280 320 360 400

mass flow [kg/h]

pre

ssu

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ss [P

a/m

]

5 7 10 13 16 20 23 26 30 33 37 40 44Mass flow of cooling water per unit [kg/h]

Short Description · TI-K06 Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.5 TI-K06

11. Lay-out for Wall Heating with KaRo Pre-fabricated Unit B.GK12

Project : Date :

Project consultant : Lay-out valid for 22°C room temperature and 6K heating water spread !

Required heating capacity

1 Heat requirement for the room W from calculation of planning office

2 Planned qty. of panels Qty Derive max.possible arrangement from the room measurements

3 Required heating capacity / unit W = Heat requirement / Qty of panels

Determination of capacity

4 Supply temperature -> from diagram °C Water volume per unit kg/h -> from Diagram

5 Return temperature °C Water volume per zone or wall l/h

Determination of pressure loss

6 Pressure loss in the pipe Pa Length of connecting pipe m only one lead

= Pipe lenght * Resistance Resistance in the pipe -> from diagram Pa/m Value -> from diagram

7 Pressure loss of the unit -> with value Pa

from line 3 from the diagram

8 Addition for pressure loss by the fittings Pa

(Recommentation : 30% add.to the pipe)

9 Addition for heat transfer station Pa

(Recomm. For zone valves 500-1000 Pa

for mains regulator valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

10 Total pressure loss Pa

When utilizing BEKA transfer stations the determination

of pressure loss is not necessary. Only the quantity

heating circuits and the total heating capacity is required

for the selection !

Quick Lay-out Wall Heating with B.GK12

0

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40

60

80

100

120

140

160

180

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Heat capaacity [W/Unit]

2 4 6 8 10 12 15 17 20 22Mass flow of the heating water per unit [kg/h]

100 200 300 400 550 700 850 1000 1150 1300

Pressure loss of the unit [Pa] valid for room temperature of 22°C and heatingwater spread of 6K and connecting hose 300mm

Pressure loss in the pipe 20x2mm

0

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Short Description · TI-K06 Wall Heating with the KaRo Pre-fabricated Unit

04/2002 Learning from Nature – www.KaRo.cc P.6 TI-K06

12. Details

Construction 12,5 mm plasterboard Capillary tube mat with capillary diameter 3,35x0,5 mm ( Polypropylene) 30 mm extruded foam (heat conductivity 0,035 W*K; Fire behaviour class B1) Weight 15,5 kg/m2 (empty) 16,2 kg/m2 (filled) Size Width: 600 mm Length: 2600 mm active area 1,2 m2 upper tailoring area 500 mm pre-drilled for fixing at a stud distance of 600 mm Cooling Capacity 64 W/m2 (DIN 4715) =76 W/unit Heating Capacity 130 W/m2 = 155 W/unit Conditions of Operation: Temperature stability at duration use up to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of Operation / Type of Installation Cooling- and heating walls, dry-build version Connection via KaRo quick-action coupling system Installation according the dry-build guidelines Terms of delivery: Finished dry-build units are delivered, lying on pallets.

TI-K07 Short Description

Floor Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K07

1. General

The small diameter of the capillary tubes of the KaRo mats allow a low construction height of the floor heating. For this reason the KaRo mats are especially useful for mod-ernising when floor heating is installed at a later stage. Different to the standard floor heating systems the heat is brought closely beneath the floor surface. For this reason the KaRo floor heating reacts very fast and can be operated already with low supply tempera-tures. 2. Description of the System

The KaRo mats are laid on top of a load carry-ing base, directly below the surface of a float-ing screed . The capillaries tubes do not weaken the load carrying ability of this thin layer of screed. The mats between another, to the pipelines and up to the heating circuit distributor normally are connected by means of thermal plastic welding. 3. Heating Water Technique

Die KaRo heating mats are connected room-/zone-wise with the pipelines for the supply- and return in one circuit to the heat source. The connection via a KaRo storey distributor unit is recommended. The economic advan-tages of the KaRo floor heating are based mostly on the fact, that already low supply temperatures, which are only slightly above the room temperature, will transmit high per-formances. This makes the utilisation of alter-native energy (heat pumps and solar collec-tors) possible. But even with conventional techniques a defi-nite energy saving will be achieved, since it can be operated with temperatures below 40°C .

BEKA heat-and cooling matelastic joint mortar

tile

load disribution layer

Variation A: Arrangement for new floor construction

tile

latex cement

BEKA heat-and cooling mat

palster board pre-wall on wood latting

wood flooring

Variation B: Arrangement for modernizing 4. Installation

Basically the known installation specifications are valid. All materials used in the KaRo heat-ing mats must be non-corrosive. The following materials may be used: Plastic, stainless steel, copper, brass and red brass. Other materials may cause sludge in the sys-tem, which may lead to breakdowns

Short Description · TI-K07 Floor Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K07

5. Regulating Technique

The regulating technique secures, first the de-sired comfort, second the necessary system reliance. The floor heating requires a room tempera-ture regulation to control the supply tem-perature in connection to the desired room temperature. It must be observed that surface temperature above 29°C is surpassed. Depending on floor covering material and floor construction the supply temperatures will normally not be above 36°C. In non-occupied areas surface temperatures up to 35 °C are permissible. 6. Dimensioning of the System

The floor heating with KaRo floor mats are dimensioned according to the following lay-out table. The supply temperature determined in the water circuit, taken at the side of the cooling unit or heat generator, is regulated with the water temperature before the heat exchanger. 7. Preparation for Installation

For the installation of the floor heating with KaRo heating mats, working and installation instructions of the floor concrete manufac-turers must be obeyed. The floor to be heated must have load carrying, possibly thermal in-sulated layer. KaRo mats are pre-manufactured to object measurements, so that there must be no tai-loring at the building site. It is recommended to have the mats supplied already prepared with adhesive tapes for bet-ter positioning at the floor. The laid-out KaRo Heating mats can be walked-on when the floor screed is brought in, they should be protected area wise with Styrofoam sheets to avoid damages of the capillary tubes.

Before starting to work a layout pattern should be prepared as work base. In this lay-out pattern all heating mats with their sizes and positions as well as the supply lines should be outlined. In this pattern also all ar-eas must be marked which must stay uncov-ered, as for the positioning of internal walls. Thermal welding does the connection of the KaRo heating mats to another and with the Polypropylene piping. For the execution the welding directions DVS 2207-11 of the Deutschen Verband für Schweißtechnik e. V. are valid. (The surrounding temperature dur-ing working must not be below 5°C. The pre-heating, welding and setting time must be according to regulations.) 8. Tools and Materials

For installation of KaRo heating mats for floor heating all tools and materials normally used for floor concreting (screed , for installations of plastic tubing can be utilised, as: • Levelling compound (suitable for floor

heating) • Mixer • Smoothening trowel • Adhesive layer • Roller or paint brush • Border strips • Eventually butterfly dowels and hand drill

und for additional fixing of the mats to the raw floor.

• Styrofoam sheets for protection of the capillary tubing when walking on them

• Scissors to cut plastic piping. • Marker For the connection of the supply lines to the heating circuit a hand-held welding unit with a sleeve welding device is needed for the welding of the plastic fittings. Alternatively sealing ring connectors can also be used.

Short Description · TI-K07 Floor Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K07

9. Installation Steps for the Floor Variation A

• Take KaRo heating mats out of the packaging. Mark the lay-out pattern at the primed raw floor

• connect the mats to the pipe mains to another and to the pipe lines by means of thermal welding, up to the distributor unit.

• Pre-test with compressed air 10 bar for 1 hour

• Main test with water with 10 bar for • 4 hours. Sustain an idle pressure of 3

bar until start of operation.

• Area wise cover the capillary tubing

with Styrofoam sheets for safe walk-ing (during application of the screed the sheets are removed again)

• levelling- or flexible filling compound

is brought out according to manu-facturers specification.

• Finishing of the floor covering,

(tiles etc.)

The installation steps for variation B are similar to the shown version A. For variation B though the mains and pipeline are arranged behind a dummy wall (which has to be erected)

I.I.

II.II.

III.III.

Short Description · TI-K07 Floor Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-K07

10. Lay-out of the Floor Heating with KaRo Heating Mats

Project : Date

Project consultant : Lay-out valid for 22°C room temperature and 6K heating water spread

Required Heating Capacity

1 Heat requirement for the room W from the calculation of the planning office

2 Planned coverage with mats m2 max.possible arrangement derived from room measurements

3 Required heating capacity W/m2 = Heat requirement / coverage

Determination of Performance

4 Room temperature °C average heating water temp. °C -> from diagram

5 Supply temp. -> from diagram °C return temperature °C

6 Spread K

7 Water volume per mat kg/h = (Heating capacity x 3600) / (Spread x 4180)

8 Water volume per zone ltr/h

Determination of pressure loss

9 Length of connection pipe m

10 Resistance in the pipe -> diagram 2 Pa/m

11 Pressure loss in the pipe Pa

= pipe length * Resistance

12 Pressure loss in the mat Pa

-> value from line 2 -> diagram 1

13 Addition for pressure loss by fittings Pa

(recomm: 30% addition to pipe)

14 Addition for heat transmission unit Pa

(recomm.:for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

15 Total Pressure Loss Pa

When using BEKA Transfer units the determination

for pressure losses are obsolete. Only the qty.

of heating ciruits and the total heating capacity

is required for the selection.

Pressure loss in a pipe 20x2mm

0102030405060708090

100

40 80 120 160 200 240 280 320 360 400Mass flow [kg/h]

Pre

ssure

loss

[Pa/m

]

Pressure loss Type S15

0

5000

10000

15000

20000

25000

5 10 15 20 25

Mass flow [kg/(m2h)]

Pre

ssu

re lo

ss [P

a]

8m 7m6m

5m

4m

3m

2m1m

10

30

50

70

90

110

130

150

170

190

210

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Surplus temp. (K) = average heating water temp. (°C)- room temp. (°C)

He

atin

g C

ap

aci

ty [W

/m2 ]

Tiles

R=0,02m2K/W

Carpet

R=0,10m2K/W

Parquet

R=0,15m2K/W

Short Description · TI-K07 Floor Heating with KaRo Heating Mats

04/2002 Learning from Nature – www.KaRo.cc P.5 TI-K07

11. Technical Data

KaRo Capillary tubes mats Type K.S15 Material Polypropylene Random-Copolymer Type 3 DIN 8078 Geometry Collector pipe 20 x 2 mm Capillary tube 3,35 x 0,5 mm Capillary pipe distance 15 mm Exchanging area 0,71 m2 Size Length: 600-6000 mm (in steps of 10 mm) Width: 150-1200 mm (in steps of 30 mm) Masses 0,44 kg/m2 (empty, without collector) 0,71 kg/m2 (filled, without collector) Water contents 0,27 l/m2 Heating capacity: Depending upon type 180 W/m2 Operation Conditions: Temperature stable at duration up to 60°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application / type of installation: Floor heating with low construction height Connection by thermal welding Type of delivery: The mats are delivered: rolled-up and packed in cartons

TI-K08 Short Description

Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K08

1. General

In modern office- and business premises must be temperature conditioned nearly all year long because of their high thermal insulation of the outer walls and facades. In the heating period the room shave a comparatively low heat requirement. Therefore the utilization of an energetic low cost KaRo cooling- and heat-ing ceiling is possible With KaRo inlay-units it is very simple and very economical to change any metal cassette ceiling into a cooling- and heating ceiling. The arrangement is also qualified for renovation. Through the combined function of the ceiling the investment costs for heating equipment can be minimized. 2. System Description

The KaRo inlay unit is a sandwich made of a sound improved board and a KaRo capillary tube mat packed in a sealed PE foil. KaRo inlay-units are simply laid on top of the metal cassettes. Then the capillary tubing are resting practically direct on top of the sheet metal and the surface is heated-up or cooled down very rapidly. The reaction time of the ceiling is less than 15 minutes. 3. Cold Water / Hot Water

Technique

The KaRo inlay-units are bound room/zone wise to the piping as a circuit and connected to cold water or hot water source. Recom-mended is the connection to KaRo storey dis-tributor unit. For the cold water preparation different tech-niques and systems can be utilized. The eco-nomic advantages of a cooling ceiling exist mostly because the supply temperatures are only slightly below the room temperature and the ceiling will already provide high perform-ances. This make the utilization of “alternative energy sources” (heat pumps) and natural en-ergy bottom swages ( open cooling, ground water) possible. For natural heat sources the same advantages are effective. In connection

with solar systems, and even with conven-tional technique already significant energy savings are achieved, because with compara-tively low supply temperatures (below 40°C) respectable heat performances are reached.

4. Installation

Basically the standard installation guidelines must be observed. All materials used for the piping and for con-nection of the KaRo inlay-units must be non-corrosive . It can be used: plastic materials, copper, brass and red brass. Other materials can cause sludge in the system, which could lead to malfunction of the system.

Chiller

Cassette ceiling with BEKA heating- and cooling mats

Other ceiling areas

Supply lines and con-nection hoses

Dew point sensor

Short Description · TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.2 TI -K08

5. Regulating Technique.

The regulating technique secures for once the desired comfort and offers also the required system reliance. The cooling ceiling requires a room tempera-ture control unit, a dew point guard control and the controlling of the supply tempera-tures for the cold water. Supply temperatures below 16°C must be omitted to avoid the danger that the dew point is reached! The heating ceiling requires a room tempera-ture control unit, which regulates the desired room temperature in dependence with the heating water flow. In rooms with heights up to 3,5 m supply temperatures above 40°C must be omitted because of excessive surface temperature of the ceiling! 6. Dimensioning of the System

The KaRo inlay-units are supplied in ceiling cassette’s standard dimensions of 600 x 600 mm respectively 625 x 625 mm. The necessary quantity of inlay-units and temperatures of the cooling- and heating water are deter-mined accordingly with the following lay-out tables. The supply temperature determined from the water circuit of the KaRo inlay-units is controlled through regulation of the water temperature before it enters the heat ex-changer at the side of the cooling machine i.e. the heat source. 7. Installation Preparation

For the installation of the suspended metal cassette ceiling the manufacturer’s instruc-tions must be observed. The inlay-units should best be laying directly on top of the surface of the metal cassettes, that the heat is lead directly to the water (therefore it is necessary to choose correct fit-ting dimensions!) The KaRo inlay-unit serves also the acoustic demands of the ceiling. The KaRo inlay-units are supplied in dimen-sions of 600 x 600 i.e. 625 x 625 mm, so that tailoring at the building site is not required. At the border areas and at places where

The KaRo inlay-units are supplied for the con-nection of supply- and return lines by means of flexible hoses with a quick-action coupling system. Before start of work a ceiling pattern must be prepared as a work base and for the installa-tion arrangement. In this pattern all cassettes, and their dimensions, the dimensions and ar-rangement of the supply lines must be re-corded. In the pattern all areas must be marked which will be uncovered, such as ar-eas for the erection of inner walls, for light fixtures and other ceiling in-builds. Further-more the position for the KaRo dew point sensor must be pointed out. In case that the connections of the Polypro-pylene pipelines are thermal welded, then the Schweißrichtlinie DVS 2207-11 from the Deutschen Verband für Schweißtechnik e.V. must be observed. (The ambient temperature during welding must not be below 5°C).It is mandatory to follow the assigned pre-heating,- welding and setting times which are given according to different pipe dimensions! 8. Tools, Materials

For the installation of metal cassette heating- and cooling ceilings with KaRo inlay-units standard tools and materials assigned for ceil-ing work and installation for plastic piping can be used. These are as follows: • Metal cassettes • Suspension hanger profiles and hanger

an accordance to the chosen ceiling brand

• Dowels and screws • Sheet metal scissors • Plastic pipe scissors • Hand held thermal welder with sleeve

welding device • Appropriate plastic fittings or sealing ring

connectors For the connection of the supply lines to the cold-water circuit we recommend to use a hand held welder with welding sleeve device. Alternatively also sealing ring connectors can be utilized.

ceiling in-builds are intended to be done, inactive cassettes will be used.

Short Description · TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.3 TI -K08

9. Installation Steps at the Ceiling

• The bearing construction is fastened and

aligned to the raw ceiling, normally with vernier suspension bars, according to the manufacturer’s instructions of the chosen cassette brand.

• The supply lines are laid into the ceiling cavity and connected to the main supply lines (connections with means of thermal welding or with sealing ring

connectors) • The flexible hoses are plugged into the

quick-action couplings of the supply lines.

• The KaRo inlay-units are laid into the cassettes .

• Plug-in the flexible hoses into the quick-action couplings of the KaRo inlay-units. • Hang the cassettes with the inlay-units into the bearing construction and align the run of the joints. • Pre-test with compressed air at 10 bar for 1 hour. • Main test with water at 10 bar for 4 hours • Apply an idle pressure of 3 bar and maintain until start of operation.

I.I.

II.II.

III.III.

Short Description · TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-K08

10. Lay-out for a Cooling Ceiling with KaRo Inlay-Units

Project : Date :Project consultant : Lay-out valid for 27°C room temperature and 2K cooling water spread !

Required cooling capacity1 Cooling load for the room W from calculations of the planning office2 Planned area for mats m2 max. possible arrangement derived from room dimensions3 Required cooling capacity per unit W/m2 = Cooling load / Quantity of units

Determination of Performance

4 Supply temperature -> from diagram °C

5 Return temperature °C

6 Water volume per unit kg/h

7 Water volume per zone ltr./h

Pressure loss determination8 Length of connection pipe m

9 Resistance in pipe -> from diagram Pa/m

10 Pressure loss in the pipe Pa

= Pipe length * Resistance11 Pressure loss of the unit Pa

-> from diagram12 Add for pressure loss through fittings Pa

(recomm: 30% Add. to pipe)

13 Add for heat transfer station Pa

(recomm: zone valves 500-1000 Pa: mains regul. valves 700 - 1500 Pa : heat exchanger approx. 4000 Pa

14 Total Pressure Loss Pa

If BEKA transfer stations are utilised the pressurelosses do not have to be determined. Only the quantity of cooling circuits and the total coolingcapacity is required for the selection!

Quick lay-out for ceiling cooling with BEKA Inlay-units

05

10152025303540

24 23 22 21 20 19 18 17 16 15 14 13 12

Supply temperature [°C]

Co

olin

g c

ap

aci

ty

[W/U

nit]

2 3 4 5 6 7 8 9 10 12 13 14 15Mass flow of the cooling water per Unit [kg/h]

Valid for room temperature 27°C and cooling water spread 2K

Pressure loss of the row

0123456789

2 5 10 15

Mass flow per unit [kg/h]

Pre

ssu

re lo

ss [

kPa

]

BEKA Complete System

600x600 /625x625

1 mat

2 mats

3 mats

4 mats

5 mats

6 mats

Pressure loss in a pipe 20x2mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400Mass flow [kg/h]

Pre

ssu

re lo

ss [

Pa

/m]

Short Description · TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.5 TI-K08

11. Lay-out for Ceiling Heating with KaRo Inlay-Unit

Project : Date :

Project consultant : Lay-out valid for 22°C room temperature and 6K heating water spread !

Required heating capacity1 Heat requirement for the room W from calculations of planning offices2 Planned qauntiy of units m2 max. possible arrangement derived from room dimensions3 Required heating capacity W/m2 = Heat requirement / coverage

Determination of Performance

4 Supply temperature °C

5 Return temperature °C

6 Water volume per unit kg/(m2h)

7 Water volume per zone ltr./h

Determination of Pressure Loss8 Length of connection pipe m

9 Resistance in pipe -> from diagram 2 Pa/m

10 Pressure loss in pipe Pa

= Pipe length * Resistance11 Pressure loss of unit Pa

-> from diagram12 Add. for press. loss through fittings Pa

(recomm: 30% Add. to pipe)13 Add. for heat transfer station Pa

(recomm: zone valves 500-1000 Pa:mains regulat. valves 700 - 1500 Pa: heat exchanger approx. 4000 Pa

14 Total Pressure Loss Pa

If BEKA heat transfer stations are utilised, the pressure losses do not have to be determined. Only the quantity of heating circuits and the total heating capacity is required for the selection !

Quick lay-out Ceiling heating with BEKA Inlay-units

0

5

10

15

20

25

30

35

40

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

He

atin

g c

ap

aci

ty [

W/u

nit]

0,5 1,0 1,5 2,1 2,6 3,2 3,7 4,3 4,9 5,4Mass flow of the heating water per unit [kg/h]

valid for room temperature 27°C and heating water spread 6K

Pressure loss in a pipe 20x2mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400

Mass flow [kg/h]

Pre

ssure

loss

[P

a/m

]

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2

1 6 11 16

Mass flow per unit [kg/h]

Pre

ssure

loss

[kP

a]

BEKA System 600x600/625x625

Pressure loss of the row 1

3 mats

2 mats

4 mats

5 mats

6 mats

1 mat

Short Description · TI-K08 Cooling Ceiling with KaRo Lay-in Ceiling Panel

04/2002 Learning from Nature – www.KaRo.cc P.6 TI-K08

12. Technical Data

Construction 30 mm sound reducing board Capillary tube mats with capillary diameter 3,35 x 0,5 mm (Polypropylene) Fiber dense packaging in PE-foil Weight 4,6 kg/m2 (empty) 5,3 kg/m2 (filled) Dimensions Width: 600 mm or 625 mm Length: 600 mm or 625 mm Cooling Capacity: 67 W/m2 (DIN 4715) =24 W / Unit Heating Capacity: 78 W/m2 = 28 W / Unit Operation Conditions Temperature stable at duration up to 45°C Operation pressure 3 to 4 bar Test pressure 10 bar max. 10 hours Place of application / Type of installation: Cooling- and heating ceilings in metal cassette version Connection via KaRo quick-action coupling system Installation according to manufacturer’s guidelines Type of delivery Finished inlay-units are delivered packed in cartons

TI-K09 Short Description

Cooling and Heating Ceiling with the KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K09

1. General Information

In modern offices and business premises, the contemporary office and computer technol-ogy combined with increased thermal insula-tion of the exterior walls and façades, the rooms must be air-conditioned all year round. Even during periods when heating is required, these rooms have comparatively low heat consumption. This facilitates the use of a cost-effective and energy-saving KaRo cooling and heating ceiling. With the KaRo acoustic metal panel, any metal coffered ceiling can easily be designed as a cooling and heating ceiling. The ar-rangement is also suitable for retrofitting. The combined functionality of the ceiling mini-mises the investment required for necessary building technology. 2. System Description

The KaRo acoustic metal panel is a metal cof-fer, which comes factory-equipped with a KaRo capillary tube mat. The capillary tube mats are glued on using a hot-melt process. Like any other metal coffer, the KaRo acoustic metal panel is simply laid on top of the sup-porting structure. The capillary tubes lie prac-tically directly on top of the sheet metal, so that the surface is rapidly cooled or heated. The reaction time of the ceiling is less than 15 minutes. 3. Cold-water/Hot-water Technology

The KaRo acoustic metal panels are integrated in rooms/zones in a tubing network as a circu-lation loop and connected to a cold-water generator and the heat source. We recom-mend that the connection is made by using a KaRo storey distributor. A wide variety of technologies and systems may be used for cold-water generation. The economic advantages of the cooling ceiling consist primarily of the fact that the ceiling is highly efficient even at flow temperatures

which are only slightly below the room tem-perature. This facilitates the use of "alternative energy" (heating pumps) and natural energy reduction (e.g. free cooling, groundwater). The same advantages apply to hot water gen-eration. Significant energy savings are achieved not only in combination with solar heating systems, but with conventional tech-nology as well, since even at low flow tem-peratures (below 40°C), the respectable calo-rific output can be used for heating.

4. Installation

As a rule, the general installation guidelines apply. All materials used in the tubing net-work of the KaRo acoustic metal panels must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may cause the system to silt up and thus disrupt its function.

Chiller

Coffered Ceiling with BEKA acoustic metal panels

Further ceiling areas

Supply tubes Connection hoses

Dew Point Sensor

Short Description · TI-K09 Cooling and Heating Ceiling with KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.2 TI- K09

5. Control Technology

The control technology ensures the comfort you desire and provides the necessary system safety as well. The cooling ceiling requires a room tempera-ture control unit, a dew point safeguard con-trol unit and a control unit for the initial flow temperature of the cold water. Initial flow temperatures below 16°C must be avoided due to the dew point risk! The heating ceiling requires a room tempera-ture control. This regulates the flow of hot water depending on the desired room tem-perature. In rooms with heights of up to 3.5 metres, initial flow temperatures above 40°C must be avoided so that the surface tempera-ture of the ceiling does not become too high! 6. Dimensions of the System

The KaRo acoustic metal panels are available in the standard ceiling coffer sizes of 600 x 600 mm and 625 x 625 mm. The required quantity of panels and the temperature of the cooling or heating water are determined ac-cording to the design tables shown below. The initial flow temperature in the water cir-culation of the KaRo acoustic metal panels is set by adjusting the water temperature in front of the heat exchanger on the cold gen-erator or heat generator side. 7. Preparation for Assembly

The manufacturer's instructions for the se-lected ceiling model apply to the assembly of the suspended metal coffered ceiling. The KaRo acoustic metal panels must be laid on a 24 mm T-profile structure. The KaRo acoustic metal panel simultaneously fulfils the acoustic requirements for the ceiling. The KaRo acoustic metal panels are manufac-tured in the dimensions 600 x 600 mm and 625 x 625 mm, so that custom cutting is not required at the construction site. Inactive cof-fers are installed around the edges and in places where ceiling fittings are planned. The KaRo acoustic metal panels are factory-

equipped with a plug-in coupling system for connection to flow and return tubes by means of flexible hoses. Before beginning work, a ceiling drawing and a laying plan must be drawn up, in which all coffers with their dimensions, alignment, and the supply lines must be recorded. In the ceil-ing drawing, all areas must be also marked which must remain unoccupied, e.g. where partition walls, lighting and other ceiling fit-tings will be installed. In addition, the loca-tion where the KaRo dew point sensor will be installed must also be marked in the ceiling drawing. If thermal plastic welding is being used to connect the polypropylene tubes, the welding guideline DVS 2207-11 of the Deutscher Ver-band für Schweißtechnik e.V. (German Asso-ciation of Welding Technology) applies. (The environment temperature during processing may not be lower than 5°C and the preheat-ing, welding and holding times must be ob-served according to the dimensions of the tubing.) 8. Tools, Materials

The conventional tools and materials for the installation of ceilings and plastic tubing are used for the installation of a metal coffered heating/cooling ceiling with KaRo acoustic metal panels: • Metal coffers • Suspension profiles and suspenders de-

pending on the design of the selected ceiling model

• Dowels and screws • Metal shears • Plastic tube shears • Handheld welding unit with a welding

sleeve mirror for plastic welding • Appropriate plastic fittings and cutting

ring screw fittings A handheld welding unit with a sleeve mirror, appropriate for plastic welding, and the cor-responding plastic fittings are recommended for connecting the feed lines to the cold-water circulation. Cutting ring screw fittings may be used as an alternative.

Short Description · TI-K09 Cooling and Heating Ceiling with KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.3 TI- K09

9. Steps in Assembling the Ceiling

• In accordance with the manufac-turer's instructions for the se-lected coffers, the supporting structure is attached to the bare ceiling using vernier suspenders and aligned.

• The feed lines are laid in the hol-low cavity of the ceiling and con-nected to the supply lines (con-nection by means of thermal plastic welding or cutting ring screw fittings)

• Insert the flexible connection hoses in the plug-in couplings of the feed lines

• Remove the pre-assembled KaRo

acoustic metal panel from its packaging

• Insert the flexible hoses into the

plug-in couplings of the KaRo acoustic metal panel

• Hang the coffers in the support-ing structure and align the joints

• Preliminary test with 10 bars of compressed air for 1 hour

• Main test with water at 10 bars for 4 hours – maintain resting pressure at 3 bars until the sys-tem is put into operation

I.I.

II.II.

III.III.

Short Description · TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.4 TI -K09

10. Lay-out for the KaRo Acoustic Metal Panels in the Cooling Ceiling

Project: Date :

Project consultant : Lay-out valid for 27°Croom temperature and 2K cooling water spread!

Required cooling capacity

1 Room cooling load W from calculations of the planning office

2 Planned component qty m2 Max. possible arrangement derived from room dimensions

3 Required cooling capacity W/m2 = Cooling load / Quantity of units

Capacity calculation

4 Supply temperature -> from diagram °C

5 Return temperature °C

6 Water qty per component kg/h

7 Water qty per zone l/h

Determination of pressure loss

8 Length of the connection tube m

9 Resistance in tube -> from diagram Pa/m

10 Pressure loss in tube Pa

= tube length * Resistance

11 Component pressure loss Pa� from diagram

12 Add for pressure loss through fittings Pa

(recomm: 30% Add to pipe)

13 Add for heat transfer station Pa

(recomm: for zone valves 500 -1000 Pa

for branch control valves 700 - 1500 Pa

for heat exchanger approx.. 4000 Pa)

14 Total pressure loss Pa

If BEKA transfer stations are utilised the pressure

losses do not have to be determined. Only the

quantity of cooling circuits and the total cooling

capacity is required for the selection.

Quick Lay-out ceiling cooling with BEKA panel

05

10152025303540

24 23 22 21 20 19 18 17 16 15 14 13 12

Supply temperature [°C]

Co

olin

g c

apac

ity

[W/c

om

po

nen

t]

2 3 4 5 6 7 9 10 11 12 13 15 16Mass flow cooling water per component [kg/h]

Va lid fo r ro o m temperature 27°C

and co o l water spread 2K

P res su re lo s s in the tube 20 x 2 mmPres su re lo s s in the tube 20 x 2 mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400

M a s s f lo w [ k g /h ]

Pressure loss of the row

0

1

2

3

4

5

6

7

8

9

10 20 30 40

Mass flow per component [kg/h]

Pre

ssu

re lo

ss [k

Pa]

B E K A complete sys tem

600 x 600 / 625 x 625

1 mat2 mats3 mats

4 mats

5 mats

6 mats

Short Description · TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.5 TI -K09

11. Lay-out for the KaRo Acoustic Metal Panels in the Heating Ceiling

Project: Date :

Project consultant: Lay-out valid for 22°C room temperature and 6 K hot water spread !

Required heating capacity

1 Planned heat requirement for the room W from calculations of planning offices

2 Planned component quantity m2 max. possible arrangement derived from room dimensions

3 Required heating capacity W/m2 = Heat requirement / Coverage

Capacity calculation

4 Supply temperature � from diagram 1 °C

5 Return temperature °C

6 Water qty per component kg/(m2h)

7 Water qty per zone l/h

Determination of pressure loss

8 Length of the connection tube m

9 Resistance in tube � from diagram 2 Pa/m

10 Pressure loss in tube Pa

= Tube length * Resistance

11 Component pressure loss Pa� from diagram

12 Add for pressure loss through fittings Pa

(recomm: 30% Add to tube)

13 Add for heat transfer station Pa

(recomm: for zone valves 500 -1000 Pa)

for branch control valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

14 Total pressure loss Pa

If BEKA heat transfer stations are utilised, the pressure

losses do not have to be determined. Only the

quantity of cooling circuits and the total heating

capacity is required for the selection.

Quick Lay-out Ceiling Heating with BEKA Acoustic Metal Panel

05

101520

25303540

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Hea

tin

g c

apac

ity

[W

/co

mp

on

ent]

0,5 1,1 1,7 2,3 2,9 3,5 4,1 4,7 5,3 6,0Mass flow of hot water per component [kg/h]

va lid fo r ro o m temperature of 27°C

and heating water spread 6K

Pressure loss in tube 20 x 2 mmPressure loss in tube 20 x 2 mm

0

20

40

60

80

100

40 80 120 160 200 240 280 320 360 400

M a s s f lo w [ k g /h ]

Pressure loss of the row

0

1

2

3

45

6

7

8

9

10 20 30 40

Mass flow per component [kg/h]

Pre

ssu

re lo

ss [

kPa]

B E K A complete system

600 x 600 / 625 x 625

1 mat 2 mats

3 mats

4 mats

5 mats

6 mats

Short Description · TI-K09 Cooling and Heating Ceilings with the KaRo Acoustic Metal Panel

04/2002 Learning from Nature – www.KaRo.cc P.6 TI -K09

12. Technical Specifications

Design Metal coffer with acoustic fleece Capillary tube mat with capillary diameter of 3.35 x 0.5 mm (polypropylene) Glued on using a hot-melt process Weight 4.6 kg/m2 (unfilled) 5.3 kg/m2 (filled) Dimensions Width: 600 mm and 625 mm Length: 600 mm and 625 mm Cooling capacity: 74 W/m2 (DIN 4715) =29 W/component Heating capacity: 130 W/m2 assuming 45°C hot water/21°C room temperature =51 W/component Operating conditions: Temperature stability in continuous use up to 45°C Operating pressure 3 to 4 bars Test pressure 10 bars up to a maximum of 10 hours Fields of application/Method of laying: Cooling and heating ceilings in metal coffer design Connection via KaRo quick-coupling system Assembly according to manufacturer's instructions Form of delivery: Prefabricated acoustic metal panels are delivered in cartons

TI-K10 Short Description

Installation with the KaRo Plug-in Type Pipe System

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-K10

1. General Information

Up to now, the installation of a tubing system for the connection of heating or cooling pan-els with KaRo mats/prefabricated components usually required specialised expertise in work-ing with plastic tubing, as well as special tools. The KaRo quick-coupling tubing system is a cost-saving alternative. You can construct a complete tubing system using only a pair of plastic tube shears. 2. System Description

The KaRo tubing system with quick-action coupling contains all of the required installa-tion materials for the tubing of cooling or heating circuits, from the KaRo mat or the KaRo prefabricated component to the distribu-tion throughout the storey. The tube dimen-sion of DA22 mm is designed for cooling or heating circuits with a maximum size of 15 m2. All quick-action coupling parts can be used with the KaRo DA22 tubing without additional dimensioning to assemble the heating/cooling circuits internally and to construct the connec-tion up to the distributor. The tubing length up to the distributor may be up to a maximum of 40 metres for the flow and return tubes, re-spectively. The tubes and the pre-formed parts are assembled simply by pushing them to-gether. The connection between the tubing and the KaRo mats/prefabricated components is made by using flexible hoses. For those cases in which the quick-action coupling system is to be used with tubing or components from other systems, suitable connections with ¾" exterior threads are available. 3. Installation

As a rule, the general installation guidelines ap-ply. All materials used in the tubing system of the KaRo mats or prefabricated components must be made of non-corrosive materials. Plastics, stainless steel, copper, brass and red bronze may be used. Other materials may

cause the system to silt up and thus disrupt its function. 4. Preparation for Assembly

Before beginning work, a floor/ceiling drawing and a laying plan must be drawn up, in which all KaRo prefabricated components (metal acoustic mat, inlaid component, prefabricated ceiling or wall) with their dimensions, align-ments, and the supply lines must be recorded. In the specification of the tubing layout within a heating/cooling circuit, the general rules must be applied so that an even flow is guaranteed throughout the area. In the floor/ceiling draw-ing, all areas must be marked which must re-main untubed, e.g. where partition walls, light-ing and other ceiling fittings will be installed. In addition, the location where the KaRo dew point sensor will be installed must also be marked in the floor/ceiling drawing. All KaRo prefabricated components are factory-equipped with a quick-coupling system for con-nection to flow and return tubes by means of flexible hoses. The individual lengths of the tubing sections are determined from the floor/ceiling drawing. The tubes are fastened with conventional tube clips in accordance with the generally applicable in-stallation guidelines for the KaRo DA22 mm tube at intervals of up to 800 mm maximum to the bare floor or ceiling. 5. Tools and Materials

To process the quick-coupling system, the fol-lowing tools and materials are required:

• Plastic tube shears • Marker • Meter rule

For fastening to the raw ceiling :

• Conventional 22 mm tube clips • Dowels and screws • Drill/hammer drill, if necessary • Tools for mounting the tube clips

Short Description · TI-K10 Installation with the KaRo Plug-in Type Pipe System

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-K10

6. Assembly Steps

• Cut the tube to the required length. Use

only the plastic tube shears to cut the tube (do not use a saw or similar tools!). Be careful to make the cut straight or an-gled as required.

• Insert the support sleeve in the end of

the tube. • Insert the tube with the support sleeve to

the limit stop into the plug-in fitting – and you're finished!

Straight connector O-ring Retaining element

Support sleeve Stainless steel claw PP-tube

N O

Short Description · TI-K10 Installation with the KaRo Plug-in Type Pipe System

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-K10

7. Technical Specifications

System Components KaRo tube, 22 mm x 2,1 mm, polypropylene, PN10 Straight connector, 22 mm Angled plug connector, 22 mm T plug connector 3 x 22 mm Reduced T plug connector, 22 x 10 x 22 mm Plug-in end cap, 22 mm Screw connector, 22 mm x ¾“ exterior thread (brass) Support sleeve for 22 mm tube Flexible connecting hose with stainless steel fabric casing Operating conditions: Temperature stability in continuous use up to 45°C Operating pressure 3 to 4 bars Test pressure 10 bars up to a maximum of 10 hours Fields of application: Cooling and heating floors/ceilings with KaRo capillary tube mats or prefabricated compo-nents Connection via the KaRo Plug-in type pipe system Assembly according to manufacturer's guide-lines Form of delivery: Tubing in rods of 5 meters in length Plug-in fittings and hoses in accordance with the quantities ordered

TI-B01 Calculation, Construction and Planning

Questions before lay-out of KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B01

1. Cooling Load / Heat Requirement

The specific cooling load must be obtained, subdivided, from the planning- or architect’s office. If concrete figures cannot be traced, then the cooling loads or heat requirement for each room must be calculated by yourself, at least roughly, for the pre-planning. The calculation for the cooling load follows the VDI 2878, for the heat requirement according DIN 4701. The result for the cooling load al-though must go into the construction of the ceiling interpreted, since the calculation pro-cedure according to VDI 2078 will not ac-count for the operative temperature and in-fluence of the cooling ceiling’s storage behaviour. By establishing room identification figures, the radiation ratio and change in the share of convection, caused by the type of ventilation, can be considered for the ex-pected capacity of the ceiling. For the calculation of the cooling load the fol-lowing details are required:

• Building- and room measurements • Location of building, direction of rooms

they are facing to • Type of walls, windows- and door posi-

tions → U-values of the building compo-nents

• Climate conditions: high- and low tem-peratures of the year, outside humidity through the year

• Internal room temperature trend → room temperature

• Demands to air quality → pollutants, hu-midity

• Usage of the room, number of persons present, type of activities

• Electric appliances → quantity and con-necting loads

• lighting → electric connection values • other loads → heat caused by transports

through the room • room temperatures of adjacent rooms

A form for the (rough)calculation of the cool-ing load is included in the à collection of ta-bles. In critical areas although an accurate calcula-tion of the cooling load is absolutely neces-sary. 2. Building / Room Situation

While item 1 eventually can be fully prepared by the planner, from now on begins the ex-pert planning for the cooling ceiling. The room measurements can be taken from the construction drawing and/or can be ascer-tained by inspection of the site. It must be laid down with the planning per-son if separate ventilation is planned and/or if the windows will remain open able. The vol-ume of air supply, the condition of the air (air supply, exhaust air temperature and humid-ity) and the type of exhaust outlets must be inquired from the planning office and/or will be laid down by considering the usage of the rooms, obeying the state of the art and stan-dards for the required air exchange rates. Statements about air supply will be consid-ered for the construction of the cooling ceil-ing and will influence the cooling load of the ceiling. It is also important to clarify what energy can be used for the cooling water preparation. The technique of cooling water preparation is not part of the construction for the cooling ceiling and therefore will not be mentioned further. At least the cooling water temperatures and water volumes for the cooling circulation (secondary circle) must be co-ordinated with the planning specialist. From the necessary capacity of the ceiling and with the given split between water temperatures in supply and return of the secondary circuit the necessary volume of water can be calculated. The dif-ference in temperature between the supply and return determines the capacity of the ceiling in dependence of the chosen type of ceiling.

Calculation, Construction and Planning · TI-B01 Questions before lay-out of KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B01

3. Ceiling Design

If it is not given anyway, the design of the ceiling must be clarified with the architect/ builder. The KaRo heating- and cooling mats are suited for practically all installation variations. But next to aesthetics also the different ca-pacities of the cooling ceiling, depending upon the ceiling type, must be considered. Basically it can be distinguished between the following types of installations:

The KaRo mats will be laid on top of sus-pended metal cassette units

The KaRo mats will be fixed to the raw ceiling from below and plastered.

The KaRo mats will be laid from below to the dry plaster boards and plastered.

The KaRo mats will be placed on top of plas-terboards.

Each of these installation details can vary de-pending upon the differing building materi-als. Nearly any variation is given. Roughly, this can also be used as basis for the expected ca-pacities for the different type of ceilings. For a first estimation the maximum ceiling area to be covered with mats must be estab-lished. Build-ins such as lamps, sprinklers or speaker boxes must be considered to be lost for ceiling area, the same as build-in closets and cabinets. Further it must clarified how much building space is provided for the pip-ing. This can be hollow (dead) space in ceil-ings and floors of the above storey. If space for the piping was not planned for it must be created in agreement with the architect. The chosen type of ceiling is influencing the construction time schedule. Plastered ceilings require additional time for drying before they can be painted. With the installation of KaRo-heating- and cooling mats on top of plaster boards the rooms can be used at an earlier stage. 4. Cold Water Technique

The cooling water of the KaRo mats can sup-plied centrally from one point of each room, or from the point of cold-water preparation to the storey distributor. Variations for the cold-water distribution are possible. Which basic type or which mixed form is going to be used will depend on size and building lay-out, the approved installation material, the instal-lation requirements, the state of control accu-racy and the serviceability .

Basically all mats related parts, valves (secon-dary circulation) and raw materials must be non-corrosive, to avoid sludge. Also increas-ing a secure operation of the system by tak-ing a storey distributor into account should be discussed. In all cases the position of riser channels should be provided between storeys and eventual free spaces for sub-distributors or storey distributors. For the cold-water preparation many different technologies can be utilised. The economical advantages of the cooling ceiling is, that al-ready with supply temperatures which are only slightly below the room temperature a high performance is achieved. This enables the utilisation of “alternative energies” such as “solar energy for heating and ground wa-ter for cooling. 5. Control Technology

The control technology secures a desired comfort and the necessary system security. Since cooling ceilings often are operated in combination with other heating-, cooling- and air-conditioning systems, a general con-trol concept is to be developed. Interactions can therefore be avoided. The cooling ceiling by itself requires controls for room temperatures, a dew point guard and a temperature control for the supply of the cold water. Basically two types of supply temperature controls can be distinguished:

- constant supply temperature (not below 16° to avoid the dew point)

- flowing supply temperature (the ceiling will not be switched-off at critical humid-ity and will continue with a part load.)

Which variation is to be used must be decided by the demand on comfort, and also by the combination with the air-conditioning (venti-lation).

TI-B02 Calculation, Construction and Planning

Lay-out KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B02

1. General

To obtain a room climate in a range of com-fort, it is necessary to cool-down modern of-fices because of their inner heat loads caused by office- and computer technologies and through the high thermal insulation of the buildings. The most cost effective solution is the utilisa-tion of KaRo cooling ceilings. High cooling loads to cool down exclusively with air-conditioning are not only un-economical but also the limits of the admissible speed of the room air ventilation and rate of turbulence is often exceeded. KaRo radiation cooling ceilings achieve 60% of the cooling by radiation and 40% by con-vection. This is equivalent to how the human body regulates its temperature at moderate activity. 2. Capacity of the KaRo Cooling

Ceiling

The cooling ceiling absorbs only the sensible (dry) cooling load of the room. The required air change can be achieved by simply opening the windows or in a more comfortable way through base (board) ventilation. The reason for the temperature transport from the room to the ceiling is the tempera-ture difference of the room and the average surface temperature of the ceiling. Where the temperature of the ceiling is given by the in-ternal head transition from the lower side of the ceiling to the cooling water. The capacity of the KaRo cooling ceiling is appointed according to DIN 4715, where a standard load is a function of an under tem-perature and is represented by the following equation:

With: qN [W/m2 ] = C· TU

n Abbreviations: TU – temperature difference between room temperature and average cooling water temperature C - constant Cn - exponent

Specific figures for “C” and “n” can be determined for each installation variation of the KaRo mats. The diagram D01 and D02 (à index: Dia-grams) show the capacity-curves of standard installation situations. The table T04 “Standard capacity identifica-tion data” (index: Tables and Forms) shows further data about special ceiling construc-tions. The following equation applies for the carry-off heat volume:

Q = m · c · ∆T Abbreviations:

m - flow of the mass c - specific heat capacity ∆T- temperature difference

The above equation is used to determine the necessary amount of water with a given tem-perature difference (split) between supply and return of the cooling water. The heat volume taken from the low temperature of the ceiling must be equal to the heat volume, which is taken away by the cooling water. Since the standard capacity was established at test situations, a real project must be matched to the actual situation, to given loads and to the influence of ventilation. Therefore a room constant KR is established for the correction.

Calculation, Construction and Planning TI-B02 Lay-out KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B02

3. Construction of the KaRo Cooling Ceiling

The necessary cooling load for the ceiling is determined on the dry cooling load of the room. It must be observed that air carries-off cooling load through the fact of ventilation, even if this is only a minor factor. In principle, the KaRo cooling ceiling should only be operated with a supply temperature above 16°C, to safely avoid any condensation. At room temperatures of 27°C, depending upon the situation of installation, cooling loads above 80 W/m² will result. It must be observed, that not the room air temperature, but the operative temperature will be used for calculation. The operative temperature represents an average from air temperature and average radiation tempera-ture of the surrounding room surfaces includ-ing the cooling ceiling. For this reason it is possible to have the comfortable room air temperature below cooling ceilings 2K higher than with conventional systems. For the layout the “form” T01 “lay out table cooling ceiling” (à tables and forms) can be used. The explanations in the form will lead through the calculation. Standard cooling ca-pacities of the KaRo cooling ceiling can be taken out of the diagrams D01 and D02, or they can be calculated using the data for “C” and “n” from table T04. The extra cooling capacity for heat from hol-low ceilings or for warm water carrying pipe-lines, which the ceiling will have to produce additionally, will be equalised through the water volume.

TI-B03 Calculation, Construction and Planning

Heating with KaRo Capillary Tube Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B03

1. General

Next to aesthetics advantages (no visible ra-diators) and savings on investment costs (be-side the cooling ceiling there is no other heat-ing system necessary), the cooling ceiling also has hygienic advantages. Air movements are not noticeable, so that transport of dust particles and other pollution is stopped. The heating surfaces themselves do not develop air movements. The permissible temperature limits of the ceil-ing under side has to be observed when using KaRo mats, otherwise the radiation heat from the ceiling which hits the human body is too high, and the head will not be able to be cooled enough. The comfort disrupted (see: A. Kollmar: Heat physical calculations for heating ceilings, steel sheets and infra red radiation; Ges.-Ing 1960 p65/84). The temperature limit depends upon the geometry of the room. As lower the room, as lower is the permissible average ceil-ing temperature. For a room height of 3 m this will be 35°C. At the same time a cold air penetration at the window front must be considered for the planning of the ceiling heating, otherwise there is the danger of air draft. The heat requirement in good insulated rooms is not high anymore for most of the wintertime considering the mostly high inter-nal heat loads. The heat requirement for typi-cal office rooms is between 20 and 40 W/m². According to à diagram D05, the permissible heat capacity of the ceiling is most of the time sufficient for the complete heating. 2. Permissible Heating Capacities

The à diagram D05 shows the permissible heating capacity in relation to the room depth and room height, whereby the permis-sible temperature limits will just be reached with 75% of the maximum heat load. It is suggestive to run a higher temperate border strip on the ceiling alongside the win-dows. Here the supply temperature should not be controlled with a room temperature

control, but should be controlled, flowingly, by the outside temperature. For the border strip also the permissible heating capacity is valid, so that the comfort is not disturbed. The diagram D06 shows the relationship to the room height. 3. Lay-out of a KaRo-Heating Ceiling

The lay- out for the KaRo heating ceiling is done analogue to the cooling ceiling. Beginning with the calculation of the trans-mission heat requirement and the heat re-quirement for joints, the necessary heating capacity for the ceiling is determined. It must be observed, that the calculation for the transmission of radiator heaters besides the transmission of walls also the heat for the hy-gienic necessary air exchange is taken into ac-count. The influence of it is omitted for a heating ceiling, if the heat requirement for ventilation is covered by the heat recovery of the ventilation equipment. Internal heat pro-ducers such as lamps, technical appliances etc. also reduce the actual heat requirement. Influences for the lay- out. • Heat requirement < 100 W/m - facade →

Heating can take place through the ceil-ing without restriction.

• W/m < Heat requirement < 250 W/m of facade → Heating takes place by a border strip on the ceiling alongside the win-dows; the radiation heat will be concen-trated to the windows, air drafts are avoided.

• Heat requirement < 250 W/m facade → In dependence of the activities in the room it must be checked if the ceiling by itself is enough for heating; otherwise an additional heat source is required along-side the window.

For the layout the form à T02 can be used. The containing explanations on the form lead through the way of calculation.

TI-B04 Calculation, Construction and Planning

Calculation for the Piping of KaRo Heating- and Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B04

1. General

The KaRo heating and cooling ceiling works in a close system. The cooling-and heating water preparation in the primary circuit is parted by a heat exchanger from the ceiling system with KaRo mats in the secondary circuit. All components of the secondary circuit are from non- corrosive materials and can be de-livered from KaRo . Diffusion of oxygen through the plastic material, in this case, has no significance. Sludge therefore must not be suspected. With the KaRo systems because of the typical shallow operation temperatures for cooling and heating deterioration will not take place. Professionally installed, including a pressure check after installation, will ex-clude any water damages.

If after all safety precaution, a capillary tube should leak, the damage is limited. The mat is only filled with 0,46 litre/m² of wa-ter and the system only drains itself up to the pressure equalisation of the system’s own pressure with the atmospheric pressure. The volume in the expansion tank will be the maximum possible amount of leakage, which in normal cases is never more than 5 litres. 2. Components of the System

The schematic (below) shows the basic ar-rangement of each component. The units 5 to 9 can be united into one storey station, which is also manufactured by KaRo.

M M

1

1

2

3

4

9

8

7

5

6

1 - BEKA mat for a metal ceiling 2 - BEKA mat for a plaster ceiling 3 - flexible connecting hose 4 - supply line 5 – flow control valve 6 - zone valve with thermal actuating drive 7- heat exchanger 8 - pump 9 - expansion tank

Calculation, Construction and Planning · TI-B04 Calculation for the Piping of KaRo Heating- and Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B04

3. Lay- out of the tubing for the KaRo Cooling Ceiling

The lay-out of the piping system is done at the state of the art and therefore is only out-lined. If the cold water supply is by central distribu-tor or via storey distributors depends upon many facts, such as: size of the total cooling area, the building situation, the hydraulic few, ease for service, system safety etc. the distribution by storey stations is suggested. Herewith a high grade of service ability is reached. Regulation of the system is possible from one central point. In case of a failure, the shut-off of each separate zone is possible. Basically, only non-corrosive materials for pipes, fittings and controls are used in the secondary circuit. Plastic materials can be used without any problems. When using copper piping together with plastic material, a brass part must be placed in between them. The dimensions for the pipes are calculated under consideration of the volumes and the allowable flow speeds. . In the building technology a maximum flow speed of 1,5 m/sec. is adapted to avoid circuit flow sounds. It must be obeyed that speed changes at intersections, especially at passes with a flow uniting of more than 0,3 m/sec. are avoided. This could lead into circuit cut-offs. The total pressure loss is calculated after the sizes of mats, pipes, armatures and other components of the system are known. The pressure losses for KaRo heating and cooling mats can be taken from the diagrams àD07 to D14, in relationship with the mats’ sizes, the mat type and specific water volume.

The heat exchanger and pump must be non-corrosive. The capacity of the heat exchanger is calculated from the total volume of water at the chosen spread. The pressure loss of the heat exchanger depends on the manufac-turer, and will be calculated in a special way. Usually a pressure loss of 20 kPa set forth for the heat exchanger in the primary and secon-dary circuit. The total pressure loss of the system results from the pressure loss of the piping and the pressure loss of the heat exchanger. The heat exchanger is chosen with the pump’s equali-sation of capacity and under consideration of a safety additive . The delivery height must be laid out, that the total pressure loss of the system, including a safety additive, will be overcome. The delivery capacity of the pump must fulfil safety re-serve for the total water volume. For choosing pumps the manufactures specified character-istic performance line is used.

Calculation, Construction and Planning · TI-B03 Heating with KaRo Capillary Tube Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B03

The standard capacities of the capillary tube heating ceiling can be taken from the à dia-grams D03 and D04. It must be observed, that heating capacity of the ceiling surface is only permissible according to à diagram D05. The à diagram D06 permits a fast answer for the possibilities of ceiling heating.

TI-B05 Calculation, Construction and Planning

Control of KaRo Heating- and Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B05

1. General

The controls for the KaRo cooling ceilings must apply to the two function-appointed factors: room temperature and humidity in the room. Basically the expenditure of control technique can be kept relatively low, since a solid laid out cooling ceiling will not give many occa-sions for the control to get active for securing the safety of the system. KaRo heating- and cooling ceilings incorpo-rate already a called “self controlling effect”. This means, only after the heat source was let in the room, the heat flow will start from the heat source towards the ceiling, and the heat load is carried out of the room. The capacity of the ceiling will increase as greater the loads are, and will reach its peak, at pre-set water volume flow, when the pre-set difference between water supply- and re-turn temperature is reached. 2. Room Temperature Control

Normally the room temperature is recorded with the room temperature control unit. This directly actuates a zone valve with a thermal actuating drive when the actual temperature has fallen below the pre-set temperature, so that the cold-water circuit is interrupted. The temperature control unit is installed at a spot where no direct sunlight can reach, in height of approx. 1.5 m. 3. Dew Point Control

To avoid condensation on or in building com-ponents the supply temperature should be set above the dew point of the room (normally 16°C is sufficient). Only with this, we have al-ready a high degree of safety against conden-sation of outside air, at our latitude. For addi-tionally safety, a humidity sensor should be installed at the coolest spot of the room (from experience this is furthest corner from away from the window, directly at the supply

flow). This sensor will give a signal to the converter or room temperature control unit, when the dew point is reached, which then actuates an actuating drive on a return line at the corre-sponding circuit. For a seldom to be expected case the system will be shut-off for a short period. Because of the storage effect of the cooled building surfaces, the temperature will be kept up for some time, so that the room inhabitant does not notice the shut-off. In normal cases, this simple way of control-ling is sufficient for secure resistance against condensation. Should there be other climate situations, with a higher humidity than expected, dry air can be let into the room. The amount of incoming air is metered according the humidity, which has to be carried off. Thereby the tempera-ture of the incoming air and the air speed must be taken into consideration. A gliding control system is another way to run the cooling system with an optimal sup-ply temperature with regard to the dew point controlling. Herein a constant supply volume flow of the cooling water is set forth and a governor computes the dew point tempera-ture from the measured humidity of the room and the pre-set room temperature at the con-trol unit. Thereafter the control unit compares the value with the supply temperature and sets the measure of the possibly necessary raising or lowering of the supply temperature. In or-der not to limit the comfort in this case a temperature balancing should be designated for the room through a basic (baseboard) ventilation.

TI-B06 Calculation, Construction and Planning

Instructions for Fire Protection and to Burning Behaviour of KaRo Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B06

1. General

Under the construction law in Germany, fire prevention requisitions are set forth within the building codes of the federal states, which must be obeyed. Because of federal state laws, there could be dif-ferent requisitions. Above these, there are also separate requisitions and standards for special build-ings (high rise buildings, hospitals and meeting halls), which must be obeyed. Besides the demands for fire prevention, there are additional injunctions by the underwriters, which are relevant. For numerous requisitions, regulations are de-fined in a general manner and based on standards. DIN 4102 “Behaviour of building materials and components in fire” regulates nearly every case for fire prevention. The following standards and guidelines apply for the KaRo heating, cooling mats, and the installation material. DIN 4102 – Part 1 Building materials (classification) DIN 4102 – Part 2 Building components (fire resistance classes) DIN 4102 – Part 3 Firewalls (non load bearing external walls) DIN 4102 – Part 4 Fire behaviour of building materials, components and special components Synopsis and application of classified materials, components and special components. DIN 4102 – Part 11 Pipe partitioning + utility shafts DIN 18232 Fire protection – Smoke- and heat outlet Part 1 – 3 ISO 6944 Test of pipelines DIN 18230 Building fire protection for industrial buildings Part 1 + 2 2. Behaviour in fire of the KaRo Heating-and Cooling Mats ,Pipes Supply lines and

Fittings

KaRo heating- and cooling mats , pipes , supply lines and fittings are made from polypropylene type 3, random co-polymer, without the use of additives. This plastic material is a highly pure material which burns to water and carbon dioxide (H2O und CO2 ). According DIN 4102 Part 1 polypropylene is classified in building material group: B2 normal flam-mable, self-extinguishing Basically, take notice, that the KaRo capillary tube mats are practically never on the surface, after they are installed, and therefore are not directly exposed to the flame. This is true especially when laid in plaster or in a composition floor. But also if laid on top of ceiling panels the mats are mostly covered with mineral wool towards the ceiling cavity. Furthermore it can be assumed, that the water filled capillary tubes will cause a distinct reduction of the surface temperature and therefore a distinct reduction of an eventual ignition. This was con-firmed in an assessment for behaviour in fire concerning capillary tube mats, at the “ Amtlichen Ma-terialprüfanstalt für das Bauwesen beim Institut für Baustoffe, Massivbau und Brandschutz”, at the TU Braunschweig.

Calculation, Construction and Planning · TI-B06 Instructions for Fire Protection and to Burning Behaviour of KaRo Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B06

3. Provisions for Fire Prevention

If KaRo pipes or supply lines lead through fire section walls, partitioning (blocking) could be neces-sary. Openings for pipes tube bundles through fire walls above 50 mm diameter must be blocked. Thereby the firewalls and –ceilings must be improved by using qualified fire resistance measures, so that the called for fire resistance class is reached. Standard fire blocks for openings in fire section walls are fire prevention packing rings. Only fire blocks with approval and test certificate may be used. The manufacturer of these products must se-cure by self-auditing that the delivered merchandise is covered by the approval. Installation must be done according to manufacture’s guidelines. Certification for this must be given to the builder (owner) to be passed on to the building authority. Each fire block must be permanently marked. In the real case the exact implementation of the fire block should be advised by the building supervi-sion or should be set forth by an authorised person, since fire protection requisitions are covered by building state law where possibly differing regulations must be obeyed.

TI-B07 Calculation, Construction and Planning

Example: Construction of a KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B07

1. Situation

Figure 1, appendix 1 is an example for a room cooling ceiling, in combination with base-board ventilation. Room utilisation Room 1 – meeting room Room 2 - office Room 3 - office Rooms are at the ground level of a multi-storey building. Outer walls are thermal insu-lated, windows double glazed with outside blinds. With suspended ceilings, smoothened plaster. The ceiling height of the suspended ceiling in all rooms is 3 m. The maximum room temperatures allowable are: Meeting room: 27°C Offices: 25°C to 26°C The volume of air supply must satisfy hygiene demands. 2. Cooling Load

The cooling load depends strongly on room size, room utilisation, the geographic posi-tion, and the type of building. To estimate the cooling loads for room 1 of our example, we use the table “T03” The procedure for the calculation is self-explaining and follows the model calculation in appendix 2, table 1. 3. Rough Planning

To do the prescribed type of ceiling, the KaRo heating- and cooling mats type K.S15 is util-ised. Appendix 1, Figure 2 shows a possible ar-rangement of mats for our example. Our tar-get should be a maximum coverage of the ceiling. It is advisable to use a non covered border

area for compensation of size variations and for the installation of connecting pipes. In case that the builder has provided empty spaces for light fixtures, air vents, speakers, etc., the empty spaces are not being used (this also is not the case in our example). Small openings in the ceiling (for example: sprinklers) are not taken into account. In these cases, the capillary tubes of the KaRo mats can be laid around the openings. 4. Calculating the Cooling Capacity.

The necessary cooling capacity for the KaRo cooling ceiling can be calculated by using the calculation table “T01” For standard installations of the KaRo cooling ceiling there are norms for “standard cooling capacities” according to DIN 4715. Corresponding capacities can be taken from the diagrams “D01 – D02”, or by using table “T04” for the “standard capacity identifica-tion data” and can be calculated suiting the following equation: qN [W/m2 ] = C*TU

n with: TU – temperature difference between room temperature and average cooling water temperature C - constant n - exponent Since the standard capacity was established at test stand situations, a real project must be matched to the actual situation, the given loads and influence of ventilation. Therefore a room constant KR is established for the cor-rection For our example, the sample calculation for room No. 1 is included in appendix 2, table 2. The relationships of the dates in the formula-tion are explained in this table.

Calculation, Construction and Planning · TI-B07 Example: Construction of a KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B07

Explanation of the Calculation Procedure: • The height factor KH (line 4) takes the

change of the radiation figure into de-pendence to the room height.

• The load factor KK (line 8) takes the in-fluence of the warm outer facade to the cooling ceiling

• The air supply flow (line 9) is laid out in regard to a hygiene air exchange volume, if not otherwise advised. The air supply achieves its contribution to the cooling capacity (line 12). This reduces the re-quired cooling capacity of the cooling ceiling (line 16)

• The ventilation factor KL (line 13) covers the influence of the ventilation system to the thermal transition of convection at the cooling ceiling.

• The coverage factor KB (line 18) takes the changes of the radiation portion into account in relation to the percentage of ceiling coverage in ratio to the floor area.

• From KH, KK, KL und KB the room con-stant KR (line 23) is calculated. This serves the accommodation of the Stan-dard cooling capacity (line 24 - of D02)to the actual room situation (line 25) (see above).

• The supply (feed) temperature (line 19) is normally chosen at a minimum of 16°C, trough it condensation is being avoided.

• The average water temperature (line 21)in its difference to the room tempera-ture determines substantially the ex-pected cooling capacity (see diagram D01-02)

• A cooling water spread (line 26) of 2K is customary. With this, a minimal average water temperature is achieved at an ac-ceptable measure of control and at con-trollable water volumes.

• In the example, only mats of the same size are used in the room (line 27). Dif-ferent sized mats are arranged so that mats of the same length are split into zones. The calculation of the water flow volume is done for each separate zone.

• According to DIN 4715 the cooling ca-pacity must be checked at a water flow volume of 50%. The cooling capacity of the KaRo cooling ceilings is metered at approx. 40 kg/m². At a water volume (line 31) of less than 17 kg/m² there will be a difference to the standard cooling capacity into consideration which had been the base for the calculation.

• The upward directed heat draft is cor-rected by the water volume (line 35). Heat above the ceiling, in rooms, which are not climate controlled, or where

warm water carrying pipelines lead through hollow spaces, could call for ad-ditional cooling capacity.

• The temperature above the ceiling (line 32) and thermal transition (upward) (line 33) depend on the situation. Logical val-ues should be determined besides this calculation.

• To reach the established cooling capacity the water volume for each zone/room according (line 36)must be made avail able. If zones are separated because of differing mat lengths each zone must have a separate control appointed to regulate the calculated water volume for an equal flow. 5. Piping

Fundamentally, the KaRo cooling ceiling works in a closed system. All components of the system in the secondary circuit must be from non- corrosive material. Sludge, caused through diffusion of oxygen must not be feared In the example a storey distributor (panel) is utilised. The cold water provided from a cen-tral treatment unit runs through a heat ex-changer and is passed on to the water circuit of the storey. From the storey station (panel) the water is being distributed to the separate circuits of the rooms/zones. The water volume can be regulated separately for each circuit with a flow control valve in the supply line. A valve in the return line with thermal actuating drive can regulate each circuit. To signal the room temperature, the dew point sensor is hooked onto the actuating drive. Reality has shown, that it is good practice to start-up the circuits from the storey distributor panel, for mats with a surface of 10-15 m², with a vol-ume flow of approx. 40 kg/m². It is good pol-icy to split the ceiling surface into cir-cuits/zones according the building grid, which lead to separate rooms. If there will be a new room partitioning, the temperature control of the new rooms is possible without any prob-lem. For our example a separation is chosen according appendix 1, figure 3. 6. Pressure Loss and Choice of Pump

Decisive for comfort and the guaranty for the cooling efficiency of the KaRo cooling ceiling is, that appropriate amount of water is lead to each room or zone. Therefore it is required to dimension the pipe diameters under con-sideration of the water volume which has to be distributed and the flow speed, as well as the flow losses of the piping, valves, heat ex-changer and the KaRo mats. The capacity of

Calculation, Construction and Planning · TI-B07 Example: Construction of a KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-B07

the pump must be dimensioned according to the total water volume and supply height to equalise the losses and for the support of the flow. The hydraulic lay out of the piping and the calculation of the total losses of the system, is done according the commonly known state of the art. For calculation of the total pressure loss, the pressure loss of sections, fittings and the longest supply line to the storey station is determined, considering the water volumes, and is added to the pressure loss of the KaRo mat belonging to this zone. The pressure loss in the station is mostly caused by the heat ex-changer and by the control valves. The pressure loss of the KaRo heating and cooling mats can be read from the diagram D07-D14. In our example for a KaRo mat type K.S15, length 4.30 m at a volume flow of 40 kg/m², a pressure loss of 17 kPa is ascertained. The pressure loss for length of a pipe is de-terminate by the following equation: ∆pR [Pa] = λ * L / (di*10-3) * ρ/2 * w2

with: λ - pressure loss coefficient L – length of pipe [m] ρ - density [kg/m3] and w [m/s] = 21,22 * m / di

2 with : m – water volume (l/min) di - inner pipe diameter (mm)

The equation for the determination of pres-sure losses for fittings is: ∆pF [Pa] = ξ * w2 * ρ/2 with ξ - coefficient of resistance Coefficients of resistance for moulded parts can be found in standard tables. Pressure losses of valves or flow control valves are calculated according the following equa-tion: ∆pV [Pa] = (ma / kVS)

2 *10-1

with ma – impendent flow volume [kg/h] kVS – value accord. manufacturer [m3/h]. To demonstrate the connections of single pressure losses our example shows a mains schematic, in appendix 1, figure 4, for the longest section to the KaRo mat located in room 1. The relevant single pressure losses up to the mains of the distributor station (panel) are put together in the table below:

Pos. Component Qty / Length Flow volume Pressure loss

[l/min] [Pa] 1 KaRo mat 4300 mm (2,90) 17000,00 2 Section 1 (pipe 20x2) 2 x 1200 mm 2,90 174,48 3 Elbow 90° 2 pieces 2,90 28,95 4 T-joint 2 pieces 2,90 86,84 5 Section 2 (pipe 20x2) 2 x 10000 mm 5,76 586,87 6 Elbow 90° 6 piece 5,76 423,06 7 Flow control Kvs-1,5 1 piece 5,76 5308,42

8 Control valve Kvs-1,8 1 piece 5,76 3686,40

Total pressure loss of the longest section

27295,02 = 27,3 kPa

Tip: The flow volume in the KaRo mat is shown in the diagrams D07-14 in the unit kg/m2h.

The losses, in the separate pipelines for supply and return for the viewed section, are combined as sections of double lengths.

The pressure loss of the heat exchanger is product specific. In dependence of the tem-perature difference between water input and

water outlet of the primary- and secondary circuits and of the total water volume, the pressure loss has to be determined according

Calculation, Construction and Planning · TI-B07 Example: Construction of a KaRo Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-B07

the manufactures’ specification. In our exam-ple a total water volume of 2,6 m3/h for the cooling surfaces was ascertained. For the primary side a customary spread of 6°/12°C is set forth for the cold water temperature. The secondary side is operated with 16°/18°C. The chosen heat exchanger 9 has a pressure loss of 17 kPa . In our example, the temperature of the sec-ondary circuit is controlled with a mixing valve of the primary circuit. To choose the pump for the total pressure loss in the storey station the sum of the pressure loss of the longest section + the pressure loss of the heat exchanger results to 44,3 kPa. The pressure loss in the storey station itself is neglect able since the pipe dimensions used in the system are laid out oversized, which ensures a slow flow (= little noise and equal distribution of the temperature). The type of pump can be chosen after knowledge of the total water volume and the total pressure loss. Non- corrosive type, pressure dependent controlled and uncontrolled pumps can be utilised. In our example an uncontrolled pump with a delivery height of 6 m(Water column) and 4 m3/h delivery capacity was chosen. The over dimensioning is being re-lieved through an overflow valve in the by-pass of the storey station.

7. Expansion Tank

The expansion tank has the following func-tions in the system: • Absorption of the water volume which is

from the heating of the water in the sys-tem

• Storage of a water volume which can be supplied into the system again at de-mand, for instance, when the system cools down.

• Maintaining a minimum overpressure in the system (pressure control)

For determining the size of the expansion tank the fluid volume must be calculated.

In our example 65 m² of KaRo mats Type K.S15 where installed. By a specific water vol-ume of 0.27 l/m² a proportionate volume of 17.55 litres result for the KaRo mats. For the piping, including storey station, a volume of 29.3 litres was determined. The system is therefore filled with 46.85 litres. For the lay out sizes the following equations are used: Ve = (VA x n )/100 (1) with Ve - volume of expansion VA - water volume in the system n - coefficient of expansion for water in % - for 18°C = 0.15 VV = 0,005 x VA (2) with VV - water pattern pe = pSV - dpa (3) with pe -top pressure = overpressure at the connection socket pSV -reacting pressure of the safety valve, standard is 3 bar dpa – operational pressure difference of the safety valve normal = 0.5 bar Vn min = (Ve+VV) x (pe+1) / (pe- p0) (4) with: Vn - nominal volume (expansion tank) p0 - supply pressure at pressure less situation normal case = 1 bar (maximum) pa min = (VH (p0+1)) / (VH-VV) - 1 (5) with: pa - pressure at start / filling pressure VH - total volume / commercial size In our example, for these relations a mini-mum nominal volume of 0,7 litre is calcu-lated. This size is not commercially available. Therefore a small size with 6 litre is chosen. This results to a filling pressure of 1.08 bar.

Appendix 1 figure 1: Room arrangement and load situation figure 2: Layout scheme for KaRo mats figure 3: Connection piping for KaRo mats figure 4: Line Schematic (Detail) Appendix 2 Table 1: Layout table for the cooling ceiling Table 2: Rough calculation for the sensible (dry) cooling load

Calculation, Construction and Planning · TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4

Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B07a

Figure 1 : Floor Lay Out and Load Situation

No.1

No.2

No.3

8m

5m

4,5m

3m

3,5m

T R = 27 °C inner Cooling Load = 2020 W

external Cooling Load = 1343 W

TR = 26 °C inner Cooling Load = 435 W

external Cooling Load= 726W

T R = 25 °C

inner Cooling Load = 640W

external Cooling Load= 663W

N

1,35m 2

3 m 2

1m

Calculation, Construction and Planning · TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B07a

Figure 2: Lay Out Schematic for BEKA Mats

Calculation, Construction and Planning · TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-B07a

Figure 3: Connection Piping for BEKA Mats

Storey Station (panel)

Central Supply - /

Return

Calculation, Construction and Planning · TI-B07a Example: Construction for a KaRo Cooling Ceiling, Attachment 1, Figure 1-4

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-B07a

Figure 4: Line Schematic (Detail)

M

I II

2+3 5+6

7 8

1

4

MMM M

9

10

Calculation, Construction and Planning · TI-B07b Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project - Room No. I

Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project - Room No. I

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B07b

Lay out Table Cooling Ceiling

Project: Musterraum Nr.1prepared by BaukeDate : 09.08.96

Data1 Room temperature °C 27,002 Room surfaces m2 36,003 Room height m 3,004 Height factor 0,98 =1,117-0,045* room height

Cooling loads5 Internal total cooling load W 2020 from calculation of the planning office

6 External total cooling load W 1211 from calculation of the planning office

7 Total cooling load based on floor space W/m2 89,75 =(internal+external load) / floor space

8 Load factor 1,20 =Total load (internal load+external load / 2)

Ventilation9 Air volume intake m3/h 500,00 allow minimum of 50m³/h person

10 Temperature of intaken air °C 25,0011 Exhaust temperature °C 27,0012 Cooling capacity of incomming air W/m2 8,89 =air supply volume * dT * 0,32 / floor space

13 Ventilation factor 1 base ventilation=1,convector=1,08;ceiling slot=1,13

Required cooling capacity14 Ceiling area covered with mats m2 35,00 -> compare with calculated value of line 30

15 Facor for ceiling coverage 0,97 =ceiling area to be covered / floor space

16 Required cooling capacity for ceiling W/m2 80,86 =Total cooling load - cooling capacity of air intake

17 Specific cooling capacity, ceiling W/m2 83,17 =req. cool cap / ceiling area to cover ->target value

18 Factor for coverage 0,92 =1,21 - 0,3* covering factor

Performance Calculation 19 Supply temperature °C 16,0020 Return temperature °C 18,0021 Average water temperature °C 17,00 =(Supply temp.+ return temp.) / 2

22 Effective under temperature °C 10,00 = room temp.- average water temp.

23 Room constant factor 1,11 =height factor*load fac*ventil facr*overage fac..

24 Standard cooling capacity W/m2 80,30 -> read from diagram

25 Real cooling capacity per m² in W: W/m2 89,13 =Stand capac*room const fac <- comp taget value

Water volume26 Cooling water spread K 2,00 =Supply temperature -return temperature

27 Quantity of mats per room Stck 828 Length of room m 4,3029 Width of room m 1,0030 Area covered with mats m2 34,40 =Length * width * quantity of mats

31 Mass flow of water l/m2 h 35,82 =(specific cooling capacity*3600)/(Spread*4180)

27,00 water volume should be minimum 17ltr/m² h

32 Temperature above ceiling °C 27,00 Standard = room temperature of the room above

33 Thermal conductance factor W/m2 K 1,1034 Capacity to top W/m2 11,00 =Therm. conduct. to top*(temp w/o aver water temp)

35 Corrected mass flow of water l/m2 h 40,55 =((spec cooling capacity+capacity to top)*3600)/

(Spread * 4180)

Calculation, Construction and Planning · TI-B07b Example: Construction of a KaRo Cooling Ceiling, Attachment 2, Table 1-2 Project - Room No. I

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B07b

Rough Calculation for the sensible (dry) Cooling load

Important notice: For this calculation a temperature difference between inside and outside temperature

of 6°C to 8°C is assumed.

Room location: Sample room No.1Prepared by: Bauke

Room dimensions:

Length: 8 m Width: 4.5 m Height: 3 m Area: 36 m² Volume: 108 m³

1. Solar Radiation, Windows: (Outer frame dimensions)

Window Width Height Qty. Area double glazed windows

[m] [m] [m2] without with with

Cardinal points blinds inside blinds outside blinds

South x x = x 205 x 175 x 60 = W

South West x x = x 245 x 205 x 75 = W

South East x x = x 250 x 205 x 75 = W

North 1 x 1.35 x 4 = 5,4 x 60 x 50 x 20 = 108 W

North West x x = x 165 x 145 x 50 = W

North East x x = x 155 x 140 x 50 = W

West x x = x 255 x 215 x 75 = W

East x x = x 250 x 210 x 75 = W

(use only maximum values - delete other values! )

2. Transmission energy: Windows (All windows and outside doors)

area

m2+ 5.4 m2+ 3 m2 = 8.4 m2 x 20 = 168 W

3. Transmission energy: Walls (without windows surfaces)

area

North- and inside walls 3 m2+ 24 m2+ 18.6 m2 = 45.6 m2 x 8 = 364.8 W

All other walls m2+ 13.5 m2+ 7.5 m2 = 21 m2 x 10 = 210 W

4. Ceiling or Roof

Ceiling to non - climate controlled rooms = 36 m2 x 10 = 360 W

Ceiling beneath the attic, attic floor not insulated = m2x 17 = W

Ceiling with 50 mm thermal insulation = m2x 10 = W

Flat roof, not insulated = m2x 35 = W

Flat roof, with 50 mm thermal insulation = m2x 12 = W

5. Floor above non climate controlled rooms

(omitted when basement is not heated) = / m2 x 5 = / W

6. Open passages

Width Height Qty. Area

x x = m2 x 100 = / W7. No. of persons in the room

physical work

Qty. light average heavy

10 x 70 x 85 x 95 = 700 W

8. Lights

(Connection value) Qty. connection value

12 x 60 W x 1 = 720 W

9. Electrical appliances

(connection value: observe simultaneousness) Type Qty Connection value

Overhead x 1 x 600 W x 1 = 600 W

10. Other heat sources

Description:

= / W

External cooling load, section 1- 6 = 1211 W

Internal cooling load, section 7-10 = 2020 W

Sensible total cooling load = 3231 W

TI-B08 Calculation, Construction and Planning

Questions before lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B08

1. Place of Application

KaRo heating and cooling mats are also used for floor heating in dwelling houses and commercial buildings. Then it is utilised as low temperature heating system with an ut-most equal floor temperature. Installation is done on top of the floor con-struction. In new builds, this is done above the load-distributing layer, in renovation on top of the existing floor surface. The energy supply can take place through any warm water heating system. Because of the only low heating water temperatures, which are required, heat pumps and solar collector heating systems can be used for the energy supply.

Floor heating utilised with KaRo heating and cooling mats fascinates because of its low construction height. Especially for renovation purpose construction heights of only 15 – 20 mm are required. The universal utilisation is widened additionally by the extremely short reaction times. 2. Standards and Building

Regulations for Floor Construction

The following assignments and regulations must be obeyed for any type of floor heating construction. Regional additional issues are not taken into account:

Components for the floor heating construction DIN 18164 Plastic foams for insulation in the building practice, part 1 +2 DIN 18165 Fibre insulation materials for the building practice DIN 18560 Cement asphalt floor for the building practice VOB Verdingungsordnung für Bauleistungen, Teil C Allgemeine technische Vertragsbedingungen für Bauleistungen (Order of contract procedure) DIN 18352 Tiles and tile laying work DIN 18353 Concrete asphalt work DIN 18356 Parquet work DIN 19365 Floor covering work Typical Standards and Regulations DIN 18195 Building sealing work DIN 18202 Tolerances for building constructions DIN 18336 Sealing against pressing water DIN 18337 Sealing against non-pressing water DIN 4102 Fire behaviour of building materials and components DIN 4108 Thermal insulation for building construction DIN 4109 Sound insulation for the building construction DIN 1055 Part 3, Load bearing for buildings DIN 4725 Warm water – floor heating Energy conservation regulations

Calculation, Construction and Planning · TI-B08 Questions before lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B08

3. System Specification

Floor heating with KaRo heating- and cooling mats was designed especially for fast reaction times and for low construction heights of 15 to 20 mm. The supply and return for the heating water in the KaRo heating- and cool-ing mats are alternate at distances of 15 mm. This results into an equal floor temperature with a high efficiency. Low supply tempera-tures, normally at a maximum of 30°C, are enough for most of the cases, to achieve room comfort even at extremely low outside temperatures. In spite of the low construc-tion, height there will be no restrictions to the floor bearing. KaRo heating- and cooling mats are manufactured in all lengths and can be assembled to the required widths. Through the extremely short reaction time of the heating system, KaRo heating- and cool-ing mats are positioned directly beneath the floor surface, only the real required energy is being consumed.

For the installation of floor heating no special building materials are required. In it’s basics the floor construction is in accordance with the regular design. At new construction, only the asphalt concrete is laid in two steps. For renovation, the floor heating can be installed in one step. The heating circuits may not contain any cor-rosive components. Suitable materials are all plastic materials, brass and stainless steel. Copper is only suitable by reservations. At a passage from copper to plastic materials, a brass bridge must be added to avoid electro-chemical reactions. If it is not possible to use only non-corrosive materials for the heating circuit, a separation must be achieved by means of a heat ex-changer. The collector pipes of the KaRo mats and the connection piping can be positioned in wall slots. If the floor construction for a KaRo floor heating system can be planned for a new building, channels can be integrated into the load-bearing layer, in which later on the pip-ing is put into

Calculation, Construction and Planning · TI-B08 Questions before lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-B08

4. Floor Construction

4.1 New Construction

For new construction the KaRo heating- and cooling mats are positioned layer closed to the floor surface, on top of the load-bearing layer. The insulation is done according to the regulations of: - DIN 4725 part 3 - DIN 4109 - WSchV 1/95 (German energy conservation regulation) For the concrete asphalt layer it can be basi-cally used: Dry asphalt, synthetic resin modi-fied cement asphalt and liquid asphalt ac-cording DIN 18560. The load bearing base layer, the insulation and the load distributor layer must be laid out according the expected traffic load.

The KaRo heating- and cooling mats are posi-tioned on top of the distributor layer. There after a levelling compound of 10 to 15 mm is applied. The levelling compound must be suitable for floor heating systems, the appli-cation must be done according to manufac-tures specification. According to the applying working directives parquet, tiles and/or textile coverings can be laid onto the floor. Border insulation strips, expansion joints and building construction sealing are not influ-enced, and must be planned as usual.

equalization screeding

tile

elastic joint motar

border strip

BEKA heating- and cooling matload distribution layerpolyethelene foil

leveling mass

insulation board

polyethylene foilsealing to construction

Calculation, Construction and Planning · TI-B08 Questions before lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-B08

4.2 Modernising

For renovation low construction heights prove its worth for the use in floor heating systems with KaRo heating- and cooling mats. Pre-condition for the application of a floor heating system in renovation is the existing load carrying floor base. For boarded wood floors, the floorboards must have the necessary strength features and must lie firmly supported. Defective boarded floors must be repaired or ex-changed. Concrete asphalt-or tile floors must be re-paired if defective.

Only after that installation of floor heating system can be started with. The KaRo heating- and cooling mats are fixed to the floor base. For boarded wood floors, it is advisable to support the KaRo heating- and cooling mats with a 5 mm thick impact sound insulation layer. On top of the KaRo heating- and cooling mats, a layer of (minimum 6 mm) latex con-crete plaster is applied, and on top of this a layer of ceramic tiles or natural stone tiles is laid. Border strips, expansion joints- and building construction sealing is to be done according to applying working directives for the latex concrete-plaster.

tile

elastic joint mortar

border strip

latex cement mortar

BEKA heating and cooling mat

impact sound isolation

wooden planks

TI-B09 Calculation, Construction and Planning

Lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B09

1. General

Because of the small diameter of the KaRo capillary tubes, it is possible to keep the con-struction heights at a minimum thickness. They are perfectly suitable also for renovation for later installation of floor heating. The KaRo mats are laid on top of a load-carrying base, directly below the surface of a floating screed. The load carrying ability of this thin layer of screed is not weakened by the capil-laries tubes. Differing to other floor heating systems, the heat is brought directly beneath the floor surface. For that reason the KaRo floor heating reacts very quick and can be operated already with low supply tempera-tures. 2. Lay-out for KaRo Mats as Floor

Heating System

For floor heating the KaRo mat type K.S15 is specifically suitable. Through the close dis-tance of the capillary tubes of only 15 mm (conventional floor heating systems work with pipe distances of minimum 120 mm) the supply- and return temperatures are close to-gether. On the surface of the floor, therefore a very uniform temperature is achieved and independent from the size of the sections there will be the same surface temperature at every spot. For this reason it is possible with KaRo floor heating to achieve the maximum possible heating capacities which are actually possible, at observance of the maximum al-lowable surface temperatures (max. 29°C at the commonly used areas, 35°C at perimeters and up to 32 °C in bathrooms) in reference to DIN 4725/26. The uniform surface tempera-ture will be achieved even if there is spread of 8 K and more between the supply- and return temperature. Therefore, little specific water quantities are needed. The achievable heat capacity for a floor heat-ing system can be taken from the standard characteristic curve, according DIN 4725.

The characteristic curve follows the function:

qN [W/m2 ] = 8,92*TÜ1,1

with TÜ – Temperature difference between floor temperature and room temperature

Under consideration of the heat resistances of the floor coverings, the heating capacity of the KaRo floor heating can be taken from the diagram 21. This diagram shows the heat capacity in de-pendence to the temperature differences of: floor covering, the average heating water temperature and room temperature. The average heating water temperature is cal-culated by:

TWM [°C ] = (TVL - TRL) / 2 with TVL – Supply temperature [°C] TRL – Return temperature [°C]

Based on the heat requirement, which is cal-culated externally, now the specific heat ca-pacity in W/m² can be calculated for the floor surface, which has to be covered with the KaRo mats (generally 80% of the room area can be covered, the rest will be covered with furniture). With this value and with the cho-sen floor covering the average heating water temperature can be determined with the help of diagram. By election of the spread ( sp = TVL - TRL und TVL = TWM + sp/2 ) the necessary supply temperature for the heating water can be easily calculated. The water volume, which is required for the heating capacity, follows the equation:

Q = m * c * ∆T

With m - Mass flow c - specific heat capacity ∆T- temperature difference based on the heat requirement, which is calculated ex-ternally TVL - TRL

TI-B10 Calculation, Construction and Planning

Questions before lay-out of KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B10

1. Utilisation Range

KaRo heating- and cooling mats are also util-ised for wall heating. It is a low temperature heating system with an extremely uniform surface temperature, used for dwellings and commercial buildings. Installation is done mainly in outside walls. According to the WSVO 1995 (energy conser-vation regulation) the wall must have U-value of maximum 0,35 W/(m2K). For wall heating the KaRo heating- and cool-ing mats are mainly laid into the plastering. The energy supply can be maintained by the warm water heating system. Because of the low supply temperatures, which are required, heat pumps, solar collector systems and calo-rific value burners can be used for the energy supply. The heating circuit may not have any corrosive components. If this cannot be as-sured the system must be separated with the installation of a heat exchanger, otherwise there is the danger that capillary tubes will clog up. A wall heating system with KaRo heating- and cooling mats fascinate by its uniform surface temperatures, the very good adaptation to building conditions and by the non-polluting energies used. The universal applications are complemented by the extremely short reac-tion times of the system. 2. Features of Wall Heating

The advantages of the wall heating in general will additional be influenced through the utilisation of the KaRo heating- and cooling mats. Characteristics: of KaRo Wall Heating: • High well-being through the gentle heat

radiation • Dry building with warm walls • Qualified for the use of solar collecting

systems, calorific value burners as well the use of heat pumps

• Great comfort when lowering the room

temperature (in comparison to other heating systems). ⇒ One degree of room temperature lowering results into 6% en-ergy savings!

• Healthy room climate because of little air disturbances

• Short reaction times, since KaRo mats are laid close beneath the wall surface.

• Nearly every surface can be used for the installation of KaRo mats, since the KaRo heating- and cooling mats are very flexi-ble and can be adapted to the building construction condition.

• Total usage of the wall surfaces. Height and width of the KaRo heating- and cool-ing mats are manufactured according project requirements

• Low construction height • Low flow resistance because of the paral-

lel arrangement of the capillary tubes • Uniform surface temperatures, since sup-

ply and return have only a distance of max. 15 mm to another.

A wall heating system has the advantage that there are no radiators obstructing the room and that a natural cosiness is achieved. The installation of KaRo heating- and cooling mats can be done without any problems in new construction and for renovation. A further advantage is, that the wall heating system can also be used for cooling in the summertime. In this case water with a mini-mum temperature of 16°C (avoiding the dew point) is circulating through the KaRo heat-ing- and cooling mats. Even at the hottest days a cosiness, can be achieved with this so-lution, especially “in critical rooms” (beneath sloped roofs or in rooms facing the South-side).

Calculation, Construction and Planning · TI-B10 Questions before lay-out of KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B10

In the following diagram, the cosiness is shown in relationship to the temperatures be-tween wall- and room temperature according to ISO 7730. The most pleasant feeling can be reached with lowered room temperatures and warm walls. The chosen room temperature is de-pending on the utilisation of the room. Nor-mally, higher temperatures than 22°C are not necessary.

From the diagram it can be seen, that with a room temperature of 22°C a wall temperature of approx. 28°C can still be felt as pleasant.

3. System Specification

The wall heating system with KaRo heating- and cooling mats was especially designed for short reaction times and for cosy living stan-dards. With the KaRo heating- and cooling mats embedded in plaster the supply and re-turn of the heating water are alternating in distances of 15 mm. This results to a uniform surface temperature with a high performance release. Low supply temperatures, normally with a maximum of 35°C, are sufficient for most cases, to reach a cosiness inside the rooms, even at extremely low outside tem-peratures. For heating the rooms normally only outside walls are used. Only in cases of exceptions, with large glazed window- or door units, also inner walls can be taken into consideration. KaRo heating- and cooling mats are produced in all lengths and can be assembled to the re-quested widths. Through the extremely short reaction times of the heating system (KaRo heating- and cooling mats are positioned di-

rectly beneath the wall surface), only the real required energy would be used up. When KaRo heating- and cooling mats are embedded in the plaster of the outside walls, a layer of insulation has to be assigned to minimise energy losses. The wall heating with KaRo heating- and cooling mats often are only covering the walls up to a height of 2 m. Above the mats then there is the possibility to fasten pictures, lights and other things. KaRo heating- and cooling mats can be positioned very good at the parapet area below windows, because the mats can be made to size by the manufac-turer. For wall heating no special building materials are necessary. Essentially the wall construction is like a conventional wall. For the plaster version, the connector pipes are laid in the baseboard or in a special purpose wall groove. 4. Wall Construction

The KaRo heating- and cooling mats are laid in the wall plaster. For the plaster, any cus-tomary type (mineral based) can be used. Coarse-grained rubbing plaster is not allowed for use, because of the danger, that the capil-lary tubes could be damaged. The working in-structions of the plaster suppliers must be obeyed. The base surface must be solid and must have bearing strength. Plaster rein-forcement fabrics are not necessary above the mats. Only above the loops of the mats and on top of the collector pipes when laid in a wall cavity reinforcing of the plaster this rec-ommended.

0 5 10 15 20 25 30 35

5

10

15

20

25

30

35

mean room temperature (C°)

mea

n w

all s

urfa

ce te

mpe

ratu

re (

C°)

cool

pleasantly

too cool

too warm

Calculation, Construction and Planning · TI-B10 Questions before lay-out of KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-B10

Positioning of the collector pipes in the baseboard and in the wall cavity. If required, the insulation can be done according to the DIN or the WSVO. Also, an inside insulation can be used without any problem. Since the walls are heated, dew point displacements will not occur.

Calculation, Construction and Planning · TI-B09 Lay-out of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B09

The mass flow should best be converted into the specific mass flow per m² of KaRo mats. With this value the pressure loss can be de-termined in relationship to the length and type of mat, with help of the diagrams 7 to 14. The pressure loss of the KaRo mat will then be used in the calculation for the hydraulic lay-out of the piping and for the selection of the pump. The dimensioning is done according to known standards. References are included in B04 – pipeline calculation for KaRo heating- and cooling mats. For the layout the form, T07 “Lay-out for KaRo floor heating” (tables and forms) can be used. The explanation in the form will lead through the calculation.

TI-B11 Calculation, Construction and Planning

Layout of KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B11

1. General

The small diameter of the capillary tubes of the KaRo mats and the close distance be-tween the capillaries (only 15 mm) allow the realisation of wall heating systems with little construction heights and uniform surface temperatures. Also very short reaction times of the heating system are achieved. Already with very low supply temperatures the rooms can be heated. Therefore, the KaRo mats are perfectly suitable in connection with low temperature heating. The KaRo mats are laid onto a sound base surface into layer of plas-ter, closely beneath the surface. The plaster is not weakened. Open shelves, interior furnishing and furni-ture equipped with feet and those, which are not positioned directly to the walls, do not lower the heating capacity. Walk-in closets, which are not equipped with air vents on top and bottom towards the heating wall, or fur-niture, which have room height and are di-rectly on the wall will reduce the heating ca-pacity up to 20 % and should therefore not be planned for heating surface. 2. Construction of the KaRo Mats

for Wall Heating

For the wall heating the KaRo mat type K.S15 is especially suitable. Through the close dis-tance of the capillary tubes of only 15 mm the supply- and return temperatures are close together. For this reason a very uniform sur-face temperature is achieved on the surface of the wall. Independent from the panel size the same surface temperature will be main-tained on each spot. For this reason it is pos-sible to achieve a high efficiency while main-taining comfortable surface temperatures (max. 29°C in living areas, 35 °C at fringes or max. 32 °C in bathrooms). A uniform surface temperature is achieved even at a spread of 8 K and more between the supply- and return lines. Therefore, only a small specific amount of water is required.

The heat capacity, which can be achieved with a KaRo wall heating system, is taken from the characteristic curve in reference to DIN 4703/03. This characteristic curve follows the function:

qN [W/m2 ] = C*Tü n with Tü – temperature difference between the average heating water temp. and the room temperature

Under the consideration of heat resistance of the plaster, the heat capacity of the KaRo wall heating system read from the diagram 29 “Heating capacity of the KaRo wall heating system”. The diagram arranges the heating capacity in dependence to the plaster type and the plas-ter thickness to the temperature difference between the average heating water tempera-tures and the room temperature. The average heating water temperature is cal-culated from:

TWM [°C ] = (TVL - TRL) / 2 with TVL – supply temperature [°C] TRL – return temperature [°C]

Starting from the heat requirement for the room, which is being determined externally, the necessary specific heating capacity (W/m²) can be calculated for the wall covered with KaRo mats (normally the walls are covered up to the height of 2 m the rest is kept for pic-tures and other things to be fastened there). With this value and the value for the chosen plaster and the plaster thickness, the average heating water temperature can be taken from the diagram 29. With the choice of the spread ( sp = TVL - TRL and TVL = TWM + sp/2 ) now very easily the necessary supply tempera-ture for the heating can be calculated.

Calculation, Construction and Planning · TI-B11 Layout of KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B11

The amount of water necessary for the heat-ing capacity follows the relation.

Q = m * c * ∆T

with m - mass flow c - specific heat capacity ∆T- temperature difference TVL - TRL The mass flow should be converted to the specific mass flow per m² of KaRo mats. With this value the pressure loss of the KaRo mat, according the length and the mat type, can be taken from the diagrams 7 – 14. The pres-sure loss of the mat is considered for the hy-draulic layout of the piping and for the choice of the pump. The dimensioning is done ac-cording the state of the art. Tips are found in B04 “Calculation for the piping of KaRo heat-ing- and cooling mats”. For the layout the form T11 „Layout for KaRo wall heating“ (→ tables and forms ) can be used. The explanations contained in the form will lead through the way of calculation.

TI-B12 Calculation, Construction and Planning

Requirements for the Water Quality

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B12

1. General Notes

KaRo systems filled with simple drinking wa-ter with the quality according to the drinking water regulations of 5.12.1990. The water does not have to be treated. Enrichment with inhibitors is not required. On the contrary, only additives, which are explicitly permitted for polypropylene and other materials, are used in the system (DIN 8078 “Chemical resis-tance of pipes and piping components from polypropylene). Suggestive is only the filter-ing of the filling water ( filters 20 to µm) dur-ing filling of the system. 2. System Separation – System

Components

Between the refrigeration- or heat generation and the KaRo mats normally a heat exchanger is used for separation of the systems. All components of the KaRo Systems are made from non-corrosive materials (plastic, stainless steel brass). For the manufacturing of KaRo capillary tube mats, pipes, fittings and connecting lines, only Polypropylene is used. 3. No Danger through clogging,

sediments or through rust sludge.

Clogging through lime sediments is not pos-sible in the KaRo system, since the KaRo sys-tem is operated as a closed system (a circuit which is similar to the radiator of a car mo-tor). Different to the drinking water networks no new lime is brought in once the system is filled. Furthermore, the temperatures of the cooling water are so low (16°C to 19°C), that those in the water-released materials are not yet dissolved.

Conventional water systems can clog through the rust sludge when the oxygen (dissolved in the water) gets in touch with the corrosive materials. In the KaRo system, formation of rust-sludge is excluded since all components of the network are made from plastic, stainless steel or brass. The water in the KaRo system will stay oxygen enriched and clear, also after years.

TI-B13 Calculation, Construction and Planning

Tolerances of KaRo Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B13

1. General Notes

Given lengths and widths of the KaRo heating- and cooling mats are nominal sizes and relate to the outer dimensions of the mats. The identity of the dimensioning is given in the product sheet of the mat type in question. Depending on the mat type and manufacturing method the actual dimensions deviate from the nominal dimension. The different deviations are accommodated to the usual appli-cation of the particular mat type. 2. Length Tolerances

The KaRo heating- and cooling mats are supplied with minus tolerances, this ensures that they will always fit into the existing building screen. Length/ Type K.U10 K.UM10 K.S10 K.S15 K.WS15 K.G10 K.G20 K.G30 K.GG10 to 1000 mm -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -15 to 2000 mm -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -20 -5 -15 to 4000 mm -5 -35 -5 -35 -5 -35 -5 -35 -5 -35 -5 -35 -5 -35 -5 -35 to 5000 mm -5 -40 -5 -40 -5 -40 -5 -40 -5 -40 -5 -40 -5 -40 -5 -40 Over 6000 mm -5 -50 -5 -50 -5 -50 -5 -50 -5 -50 -5 -50 -5 -50 -5 -50

3. Widths Tolerances

The widths of the KaRo heating- and cooling mats are supplied with minus tolerances, this ensures that they will always fit into the existing building screen. Depending on the type the KaRo heating- and cooling mat can only take up certain widths. For a U- type mats one more capillary will course a leap in widths of 20 mm. For the mat type K.G10 a fixed measurement of 10 mm must be added to the resulting capillary distances. This measurements result from the overlapping spacers. K.U10 K.UM10 K.S10 K.S15 K.WS15 K.G10 K.G20 K.G30 K.GG10 Tolerance 0 -10 0 -10 0 -5 0 -5 0 -5 -5 -10 -5 -10 -5 -10 -5 -10 Basic widths (via capillaries or via connec-tions )

X05; X25; X45; X65; X85

X15; X35; X55; X75; X95

multiple of 50 plus the fixed amount of 10; starting at 150 mm

multiple of 30 starting at 150 mm

multiple of 30 starting at 150 mm

multiple of von 10 plus the fixed amount of 10; starting at 150 mm

multiple of 20 plus the fixed amount of 10; starting at 150 mm

Multiple of 30 plus the fixed amount of 10; starting at 150 mm

multiple of 10 plus the fixed amount of 10; starting at 150 mm

Width leap 20 20 50 30 30 10 20 30 10 X= 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12 The realisable width can be checked with the equation n= (width – fixed amount) / width leap. The value n must always be a whole number.

TI-B14 Calculation, Construction and Planning

Technical Requirements for Basis Stations and Storey Distributors

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-B14

1. Basics

Basis stations and storey distributors are laid out and dimensioned by KaRo according to the building project. The principle construc-tion is shown in the product sheets of the ba-sis stations and storey stations. On principle, only non-corrosive materials may be used for basis stations and storey sta-tions.

All used components must have a pressure resistance of PN10 . The distributors are mounted on a galvanised frame and pressure checked at 10 bar. Through the use of only non-corrosive mate-rials (stainless steel, brass, nickel plated brass, plastic etc.) in the secondary cooling circuit, no oxygen is used-up through the anti oxi-dant process. No potential descent of the oxygen will result between the closed cooling circuit and surrounding air. Therefore, it is in-significant if the PP material used for the KaRo mats system is not diffusion-tight. Through the non-existing descent of oxygen saturation a constant oxygen saturation of the cooling fluid is taking place. An exchange of oxygen between the surrounding air and the closed circuit is not taking. 2. Basic Data

The most important basic dates for the layout of the distributors are: • efficiency in kW • primary temperatures: . 6°/12°C • secondary temperatures: 16°/18°C • cooling fluid (share of Glycol included) • possible dimensions • number of zones and their dimensions. The nominal sizes of the pipes, fittings and valves are designed, that flow speeds of 1,2 m/s are not exceeded.

Therefore, current sounds are not expected. 3. Pressure Losses

The heat exchanger has a strong influence to the pressure loss in the distributor. The choice of the heat exchanger through KaRo is done in a way, that the resistance on the secondary side will not exceed the value of 15 kPa If special demands for the resistance of the primary side are existing, they must be men-tioned at the time of ordering The choices for the pump, the heat ex-changer, pipes, fittings and valves made by KaRo are such, that a pressure of approx. 40 kPa will be available for the cooling circuit 4. Pump

Recently almost every pump installed in the distributor is pressure regulated. These pumps have the advantage, that because of the pressure regulation the particular sections of the cooling zones can be excellently tuned without a change of volume flow if zones are switched-on or switched-off. Only pumps with non-corrosive components such as bronze- or stainless-steel housings can be util-ised. For choosing pumps, KaRo makes the choice that the working point of the pumps is near to the middle third of the characteristic curve of the pump. Here the pump works with its highest efficiency at the lowest operating costs. A further advantage is, that the delivery height of the pump can be adjusted to the exact working point. By this measure, it is possible, that only the required energy is con-sumed.

Calculation, Construction and Planning · TI-B14 Technical Requirements for Basis Stations and Storey Distributors

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-B14

5. Filling, Washing, Venting,

Degassing 5.1 Basis Station

Faucets are assigned for filling and washing of the basis station and for the heating- or cooling system. The basis station is equipped only with one KFE-faucet. Here, within the system, more KFE-faucets must be assigned. With this version, measures must be taken to vent and degas the piping system. 5.2 Storey Station

At the storey station a minimum of 3 KFE-faucets are used. Through focused opening and closing of the ball cock faucets at each zone, the particular zones can be filled with water and can be rinsed afterwards. The rinsing process should be done with the maximum possible water vol-ume. With this process possible air enclosures and installation dirt can be rinsed out. To reach a short time for the start of operation and to fill and rinse each zone individually, there is a possibility to assign a KFE- faucet for each zone in the supply and return line. At later op-eration small air bubbles will leave the water system through the automatic vent. Water is degassed, when the flow speed will reach very small values. A specific measure for this is the installation of an air joint in the return (extra costs). Through a distinctive larger dimen-sion a flow speed is reached at which the de-gassing is taking place. The air bubbles are leav-ing the water system through an automatic vent. Degassing is also achieved without the in-stallation of an air joint, if only one zone is in operation and the flow volume will be so small, that degassing begins. 6. Filter

Experience has shown, that filter units are not required for closed system. Pollution, which could have been caused by the installation, will be removed through the filling- and rinsing process. Further pollution will not occur in the closed system. If a filter is being used after all, a cleaning process must be done unconditionally after start of operation. The rinsing operation contributes exclusively for the rinse-out of air bubbles when filters are in use. 7. Temperature- and Pressure

Display

A thermometer class 1, with a display range from 0 to 60°C or 0 to 40°C should be used for

the temperature display. Thermometers with larger display ranges or of another accuracy class will not have given an adequate result at a spread of 2°K. The pressure gauge should have a display range of 0 to 6 bar or 0 to 10. Larger display ranges will not have the required read-out accuracy. 8. Zones

The dimensioning of the zones is depending on the area, spread and capacity. In the normal version, a volume flow control– and regulating valve (Taco setter, TA- valve or similar) for the supply and a ball faucet are in-tended. For the return a ball faucet and regulat-ing valve is used. For DN15 and DN20 a low cost thermal actuating drive can be used for the ini-tiation of the regulating valve. Larger than DN20 setting valves with motor actuating drives are utilised. At this point, the accuracy of the volume flows should be pointed out. The capacity of the heat-ing- and cooling mats is determined according DIN 4715 part 1. The capacity determination is done with the full- and with only 50% of the volume flow. The capacity results of both vol-ume flows will show, that already with a 50% volume flow a capacity of approx. 89% of the full volume flow is reached. These findings should be used to positively influence the oper-ating costs. If a volume flow of 90% is planned for each zone, the pump can be dimensioned smaller, thus resulting into lower energy costs. The capacity of the heating- and cooling ceiling will only be insignificantly lower than the stan-dard capacity. 9. Electrical Connections

Storey distributors and basis stations can be supplied with the switch panel fully connected. The measuring- and control engineering, sup-plied by KaRo, works on 24 volts (see: → M08 “Technical Data of the converter M.K.1, M09 “Technical Data of the room temperature control unit M.R 2/3). All regulating valves of the storey stations should be equipped with auxiliary contacts. The electrical circuit arrangement can be carried out such, that when the last cooling circuit is switched-off, also the pump is switched-off. So the pump is treated gently and energy is saved. The thermal actuating drives used by KaRo are equipped with an auxiliary contact. They operate on 24 Volt, on a switch-on current of 250 mA and an input power at operation of 3 Watt.

TI-M01 Installation

Installation Instruction for KaRo Heating- and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M01

1.

2. General

The KaRo heating- and cooling system is easy to install. KaRo supplies the mats in the exact required measurements. Accommodation work at the building site is not required. Only for the installation of the piping tailoring work is necessary. The state of the art for working with plastic material is valid. In all cases good workmanship and careful-ness is required. The described guidelines must be obeyed so that good function and the safety of the KaRo system can be secured. The KaRo heating- and cooling mats function by laminar flow. The system is equipped with automatic vents. After the complete installa-tion, the system will be rinsed; at the same time there will be self-venting. During instal-lation, a descent for the mats is not neces-sary. KaRo heating- and cooling mats and the sup-ply are normally operated at pressures be-tween 0 and 4 bar. The minimum room temperature for installa-tion work is 5°C. The KaRo heating- and cool-ing mats, pipes, supply lines and fittings must be kept free of permanent direct UV-light. 3. Connection of KaRo Heating- and

Cooling Mats and for Piping

KaRo heating- and cooling mats, pipes and fittings are made from Polypropylene (PP) type 3. All components can be joined to an-other by means of thermal welding or with sealing ring connectors. At a change-over from PP-Rohr to another material, sealing ring connectors are used. All materials used for the secondary circuit must be non-corrosive. The KaRo heating- and cooling mats, depend-ing of which type, are connected either di-rectly by thermal welding to the water pipe-lines or with flexible hoses, which are plugged into the quick-action couplings of the mats and supply lines

The thermal welding of plastic material re-quires some training. For thermal welding of plastic material, there are different versions: Sleeve welding → Welding temp. 260°C

Butt-welding → Welding temp. 240°C

Electro sleeve welding → welding current

according to manufacturer

At the welding process it must observed that excessive heat-up time and/or excessive weld-ing pressure will not reduce the inner diame-ter of the tubing, since this will cause unde-fined and increased flow resistances. For introduction in thermal welding tech-nique for plastic piping KaRo offers seminars. 4. Placing the KaRo Mats into Metal

Cassette Sheets

By placing KaRo mats into metal cassette units, each suspended metal ceiling can be made into a heating- or cooling ceiling. The KaRo mats are simply laid from the rear side into the metal cassettes. For the mats to have full contact, they can be covered with mineral insulation mats. Additional coverings with plasterboards or sheet metal will secure full contact to the metal cassettes. Another possibility is to glue the mats to the cassettes. For this the glue is applied to the mat with a spraying gun, then the mat is placed directly into the metal cassette and pressed down with a (PUR-foam) roller. After the spraying of the glue, no extra time for the adhesive to vent-off is required. The adhesive is transpar-ent after hardening; it has a neutral odour.

Installation · TI-M01 Installation Instruction for KaRo Heating- and Cooling Mats

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M01

5. KaRo Heating- and Cooling Mats in Plaster

Onto any raw- or suspended plasterboard ceiling KaRo mats can be fixed from below and can be plastered with nearly any type of mineral plaster. Rubbing plastering though is not permissible because of the danger that the capillaries could be damaged. Plaster base preparation must be according to the state of the art. For fastening the mats to the raw ceiling plas-ter, double sided butyl adhesive tape, butter-fly- or plate dowels can be utilized. The fas-tening of KaRo mats to plaster boards or building boards is done with tacks (quality of tacks should be cleared with the plaster sup-plier). The tacks are positioned at the spacer ribbon of the mats. A suitable driving force must be adjusted at the tackler gun in order not to injure the capillary tubes During plastering work the capillary tube mats are filled with water and kept at normal water circuit pressure. Damages to the tubes can therefore soon be detected and be re-paired. After fastening mats, the plaster is applied and smoothened. Plaster qualities to be used are standard types- and machine plaster MP 75 or also acoustic plaster. If the water connection to the mats is laid into the plastering then all connections from the mats to the pipelines must be done with thermal welding. If flexible hoses are used for the mats connections then the hoses must be laid into the ceiling cavity. In no case may the flexible hoses be laid in the plastering 6. Pressure Test

Even that all KaRo heating- and cooling mats have been factory pressure tested a new pres-sure test must be done after installation at the building side. For guaranty reasons the pressure tests after installation is mandatory. In all cases, the person responsible for the in-stallation must draw up a test report. Directly after connections of the mats to the supply lines, the mats are pre-tested with compressed air at 10 bar. With this, eventual leakages at the connections can be recog-nized. For the main test, the mats are filled with water zone-by-zone and tested for 10 minutes with 3 bar. Eventual leakages must be fixed at once. After this the pressure is raised to 10 bar . After another hour, eventual pressure drops caused by the elasticity of the piping should be equalized again. If the pressure in the system will sustain for 4 hours then the pressure test has been successful.

In case that leakage had to be repaired, the pressure test must be repeated. In the report, all faults must be recorded. At the end of the pressure test the system is brought to idle (operating) pressure of 2 to 3 bar kept in this state at best until the end of the construction work. 7. Repair of damaged KaRo Mats

The KaRo heating- and cooling mats are manufactured with great care and under strict quality measures. The mats are ex-tremely stress bearing and robust and if nor-mally handled they can be installed at the building side without any problems. If nevertheless, in spite of all precautions, a damage of some single capillary tube occurs, the mat must not have to be exchanged in any case. Mats can be “repaired”. The following steps must then be followed:

Separate the mat from the water

Separate the leaking tube with a pair of scis-sors

Close both end s of the capillary tube with the welder or a soldering iron, warm-up and press the cut surfaces together.

Repeat the pressure test

This repair is only admissible for one or two damaged capillary tube otherwise the effec-tive heating/cooling surface will be reduced too much. Closing the cut ends of the capillary tubes with an open flame (cigarette lighter) is not admissible for a repairing. The open flame will burn the plastic material form the outside and carbon black particles will be in the weld, causing a weak weld strength. Furthermore the appropriate welding temperature of 240°C can not be assured, so that a weak weld could be the result.

TI-M02 Installation

Instructions for Thermal Welding of Plastics

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M02

1. General

KaRo pipes and supply lines can be con-nected, to another or to the KaRo heating-and cooling mats by thermal welding. There are different types of welding:

- Butt welding - Sleeve welding Under observance of the following working direction the thermal welding is a fast, un-complicated and safe connecting technique.

2. Butt Welding

Cutting • With a pair of pipe scissors the pipe is cut

to the necessary length (allow approx. 3 mm for weld burn-off!)

• Pipes, fittings and welding plate must be free of dirt or grease.

Warm-up • Heat-up welding plate to 240 °C. • Press both pipe ends simultaneously and

rapidly with slight pressure to the weld-ing plate until a small weld bead of 1 mm occurs.

• Warm-up the pipe ends, while keeping this position for 3 seconds.

Joining • After the warm-up time take away both

ends from the welding plate and rapidly join the parts together, accurately with slight pressure and without twisting.

• The material joins molecular homogene-ous after a few seconds. For better shape keeping the pipes must be held together in a stable position. The connection can be fully stressed after 30 minutes.

Remark! Longer warm-up times and excessive joining pressure will lead to narrowing of the inner pipe dimensions! Excessive joining pressure will press the weld bead from the welding area and cannot take any loads there after.

3. Sleeve Welding

Cutting • With a pipe scissors the pipe is cut to

length (add 12 mm length for penetra-tion of the pipe into the sleeve, for

20 mm pipe diameter) • mark the weld penetration depth on the

pipe. • pipe, fitting and welding plate must be

free of dirt and grease. warm-up • heat-up welding plate to 260 °C • slightly time-off-set press on/in to the

welding plate (first the sleeve then the pipe) join uninterrupted with slight pres-sure up to the stop or the marking.

• in this position the parts are warmed-up for 5 seconds.

Joining • After the warm-up time pull-off, the

parts to be joined from the welding plate and join them together, accurately with little pressure and without twisting.

• The material joins molecular homogene-ous after a few seconds. For better shape keeping the pipes must be held together in a stable position. The connection can be fully stressed after 30 seconds.

Remark: Longer warm-up times and excessive joining pressure will lead to narrowing of the inner pipe diameter

Installation · TI-M02 Instructions for Thermal Welding of Plastics

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M02

4. Weld ability of various PP-Materials

All pipes and fittings made from polypropyl-ene which are supplied by KaRo can be welded to another. The PP-materials used are all classified in welding material index group 006. For testing the weld ability in principle the “Richtlinie des Deutschen Verbandes für Schweißtechnik e.V. DVS 2207-11 (Entwurf August 1997) is the valid standard. Under consideration of this standard a weld index value of MFR 190/5 0,3 to 1,0 g/10 min is ap-propriate. The classification of the welding material index groups is always applicable.

5. Tools

For thermal welding of plastic material the following is required: • Pipe scissors W.S.20 • Butt weld unit W.STSG.1 or sleeve weld

unit WMSG1 with sleeve insert W.MSE.20 or inner sleeve insert IMSE.16

• Ruler • Marking pen

Figure: Welding material index groups for PP according DIN 16774

Welding material index group 006

0,3 0,4 0,8 1,0

Allowable weld index range Source: DVS 2207-11/1997

MFR1) 190/5 (g/10min)

1)Old standard MFI = Melt Flow Index

TI-M03 Installation

Installation Instruction to KaRo Mats in Plaster Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M03

1. General

KaRo mats can be fixed to the underside of any raw ceiling or suspended plasterboard ceiling und can be plastered with nearly any mineral plaster material. Rubbing plastering though is not allowed because of the danger that the capillaries could be damaged. Stan-dard type plaster to be used are machine type MP 75 or ip 22 and also acoustic plaster. The small diameter of KaRo capillary tubes al-low thin layers of plaster (approx. 10 mm), through which high cooling capacities are reached. The supply lines and the mains of the mats are normally arranged in the hall way in wall slots or under cover (this could be baseboards or stepped plaster endings). At beginning of the work a ceiling pattern with the lay-out for the mats positions and supply lines must be prepared. In this pattern all areas which will stay uncovered must be marked ( positions of inner walls, light fix-tures and other ceiling in-lays). The position of the dew point sensor must be outlined at the ceiling pattern. 2. Installation Steps at the Raw

Ceiling

Preparation of the Raw Ceiling • The raw ceiling must be dry and free of

separating substances (observe cleaning directions).

• Close holes, smoothen the uneven parts • Define the position of mats. • Fix pipe clamps for the supply lines and

collector pipes. • Pre-drill dowel holes into the ceiling for

the fastening of the mats. • Install cable for smoke detector or lamps

and fix the fasteners by means of rag bolds (protect thread with tapes).

Connect KaRo Mats to Water Lines, and perform a Pressure Test • Install the supply lines • Connect the KaRo Mats to the supply

lines (see → M02 – Instructions for ther-mal welding of plastics )

• Pressure test of the installed system. see → M07 – Test instructions for KaRo

• heating- and cooling systems) § Set idle pressure to 3 bar (mats stay at

3 bar pressure for entire time of installa-tion). -Compressed air is recommended

Fixing of Mats to the Raw Ceiling • Fix KaRo Mats to raw ceiling by means of:

- Disc-dowels or plug -dowels - Butyl adhesive-tape and application

of gypsum pads (see instruction M13)

• Align the mats and stretch the capillary tubes

• Fix and make electric connection for the KaRo dew point sensor for the plaster (see → M06 Instructions to the installa-tion of KaRo dew point sensors)

Apply plaster and smoothen (obey Manufacturer’s Instructions!) • Apply primer for the plaster • Apply plaster – assure that only a mini-

mal plaster thickness is applied; normally 10 mm (the plaster thickness influences the expected cooling capacity deci-sively!)

• Smoothen plaster – definitely avoid any damage to the capillaries.

• Damages must be repaired at once (warm-up ends of damaged tubes with welding unit or soldering iron and press the end of the tubes together, if neces-sary replace the whole mat).

Installation · TI-M03 Installation Instruction to KaRo Mats in Plaster Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M03

Principle of a BEKA mat positioned below a plasterboard ceiling imbedded in plaster

Vernier susp. BEKA Mats

Raw ceil’g

MP75 Plasterboard Adhesive tape Plaster reinforcem

ca.10mm

Base profile carrier

Ceiling Finish • Apply layer of paint • Trim the snuffing pipe of the sensor even

with the ceiling surface, mark its location (dirt must be kept from the snuffing pipe openings to avoid that the sensor will not function!).

3. Installation Steps for the

Suspended Plasterboard Ceiling

Prepare the Sub-construction • Arrange the connection piping for the

KaRo mats at the ceiling according to the lay-out plan

• Fix the CD – profiles firmly to the vernier suspension bars, according to manufac-turer’s instructions. The sub-constructions must be installed in such a way, that the supply- and return lines of the KaRo mats are on top of the plaster-boards. Consider an additional load of nearly 15,5 kg/m2..

Connect KaRo mats to water lines and do pressure test • Hang KaRo mats with the mains accord-

ing to the lay-out plan into the sub-construction – the mats are then hanging down into the room. If the mats are too long, they are rolled-up loosely and held together with wires.

• Connect the KaRo mats to the supply lines inside the ceiling cavity (see → M02 - Instructions for thermal welding of plas-tics)

• Pressure test of the installed system (see → M07 – Test instructions for KaRo heat-ing- and cooling systems)

• Set idle pressure to 3 bar (this pressure stays applied to the mats for the entire time of installation until start of opera-tion!) . It is advisable to use compressed air.

Installation of Plasterboards • Fix plasterboards with rapid-fixing-screws

to the sub-construction, according manu-facturer’s instructions – push the plaster-boards from both sides to the KaRo mats to form gaps of approx. ca. 10 mm.

Fixing of Mats to the Sub-ceiling • Align the KaRo mats at the sub-ceiling, fix with double sided adhesive tape – stretch the capillary tube mats.

Alternative: Fix with staples; check-up the compliance of the staples quality with the plaster manufacturer (see → M19 In-stallation instructions to KaRo mats with staples)

• Installation and electrical connection of the KaRo dew point sensor (see → M06 Instruction for the installation of the KaRo dew point sensor)

Apply plaster and smoothen (obey manufacturer’s instructions!) • Close installation slots with joint filling

material by adding fibre cloth strength-eners into the plaster.

• Apply primer for the plaster • Apply plaster – assure only a minimal

plaster thickness: normally 10 mm ( the plaster thickness influences the expected cooling performance decisively!)

• Smoothen the plaster - definitively avoid any damage of the capillaries; Damages must be repaired at once . If necessary replace the whole mat .

Ceiling Finish • Apply paint • Trim snuffing pipe of the dew point sen-

sor even with the surface of the ceiling. (Dirt must be kept from the snuffing pipe to avoid that sensor will not function !)

Installation · TI-M03 Installation Instruction to KaRo Mats in Plaster Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-M03

4. Alternative Installation of KaRo

Mats through embedding directly into Plaster*

ATTENTION ! This installation is only possible when the installation work is closely coordi-nated between the installer and the plasterer. Instructions and special advice for plastering are to be obtained from the plaster producer. Preparation of the Raw Ceiling • The raw ceiling must be dry and free of

separating substances (observe cleaning directions)

• Close holes, smoothen the uneven parts • Apply plaster base • Define the position of mats • Fix pipe clamps for the supply lines and

collector pipes. • Pre-drill dowel holes into the ceiling for

the fastening of the mats. • Install cable for smoke detector or lamps

and fix the fasteners by means of rag bolds (protect thread with tape)

Connect KaRo mats to waterlines and execute pressure test • Install the supply lines • Connect KaRo mats to the supply lines in-

side the ceiling cavity (see à M02 - In-structions for thermal welding of plastics) – the mats should hang loosely rolled up, even better though, straight down from the ceiling

• Pressure test of the installed system (see → M07 – Test instructions)

• Drain the System • Set idle pressure to 3 bar (this pressure

stays applied to the mats for the entire time of installation until start of opera-tion!)

• Place cable of dew point sensor loosely into pre-determined position

Apply Plaster and smoothen (follow manufacturers instructions*) • Apply plaster in a thin caterpillar in the

width of the mats, in the total length – DO NOT SMOOTHEN YET ! - apply in sec-tions! Set plaster to a sturdy consistency!

• Unroll the KaRo mats below the ceiling and stretch the capillary tubs in installa-tion direction.

• Do not push the capillary tubes into the moist plaster - DO NOT PLANE THE PLASTER ! DO NOT USE SHARP-EDGED TOOLS ! (similar to embedding rein-

forcement fabric) • Afterwards (within 15 minutes after first

application) apply a second thin layer of plaster (normally 10 mm is enough) ( the plaster thickness influences the expected cooling performance decisively!) - Set plaster to the usual consistency!

• Position dew point sensor above the cap-illary tubes in the moist plaster.

• Embedding of reinforcement fabric 80 x 80 mm at the mats ends and in critical spots is recommended.

• After settling smoothen the plaster - de-finitively avoiding any damage of the capillaries; damages must be repaired at once (warm-up ends of damaged tubes with welding unit or soldering iron and press ends of tubes together, if necessary replace the whole mat)

• Smoothen the plaster - definitely avoid-ing any damage to the capillary tubes.

Ceiling Finish • Apply paint • Trim snuffing pipe of the dew point sen-

sor even with the surface of the ceiling. (Dirt must be kept from the snuffing pipe to avoid that sensor will not function !)

*The installation steps have been established coordination with the Firm : Maxit Baustoff-und Kalkwerk Mathis GmbH

TI-M04 Installation

Installation Instruction to KaRo Mats in Metal Cassette Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M04

1. General

By laying the KaRo mats into the metal cas-settes, a heating- or cooling ceiling can be made out of any suspended ceiling construc-tion. Therefore the KaRo mat is simply laid into the cassette from the backside. That the mat will have thorough contact, simply place a min-eral insulation mat on top of it. Additional coverings with plasterboards or sheet metal will assure a good contact of the mats to the metal cassettes. It is also possible to glue-in the KaRo mats. The KaRo adhesive is simply applied with a spraying gun onto the mat. Af-ter that the mat is placed into the cassette and pressed-onto it with a PU-roller. A drying time is not required for the adhesive. The glue is transparent after hardening; it has a neutral odour. Only full contact of the mat will secure maximum cooling capacity. Before beginning the work, a pattern has to be prepared as a work- and positioning base. All measurements with the positioning, the direction and the supply lines must be re-corded. In the pattern, all areas which will have to stay uncovered (for internal walls, light fixtures and other ceiling in-lays) must be marked. Furthermore, the position of the dew point sensor has to be marked on the pattern. 2. Installation Steps

Hanging the Suspension Ceiling • The carrier- and basic profiles are aligned

and fixed to the raw ceiling with vernier suspension bars according to manufac-turer’s specification.

Installation of the KaRo Supply Lines • The supply lines are installed inside the

ceiling cavity and are connected to the mains (see → M02 – Instructions for thermal welding of plastics )

Laying the KaRo Mats into the Metal Cassettes • Full surface contact of the KaRo mats in

the ceiling cassettes is achieved by: - Covering with mineral fibre mats additional bracing of the mineral

fibre mats with the sheet metal cov-ering, sheet metal brace plasterboard or similar

- bonding of the mats with KaRo adhesive

• Connect the flexible hoses to the quick-action couplings on the KaRo mats.

Laying the Ceiling Boards • The ceiling boards together with the

mats are laid into the row type grid structure.

• During installation of the ceiling mats the flexible connecting hoses are plugged into the quick-action couplings of the supply lines

• Installation of the KaRo dew point sensor for metal ceilings (see → M06 – Instruc-tions for the installation of KaRo dew point sensor )

Pressure Test (see → M07 – Test Instructions for KaRo heating- and cooling systems) • Pre-test with compressed air, at 10 bar

for 1 hour • Main test with water, at 10 bar for 10

hours • Idle pressure, maintain at 3 bar until start

of operation.

TI-M05 Installation

Installation Instruction to KaRo Mats on top of Dry-build Boards

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M05

1. General

KaRo mats can be laid onto the backside of dry-build boards without any problem. This way cooling ceiling units can be made out of plasterboards or from fibre plaster boards, which can be installed in the dry-build ver-sion. KaRo manufactures also special capillary tube mats just for the use with dry-build boards. Lengths and widths are accommo-dated to the dry-build standard boards. At areas where they are screwed to the ceiling and/or wall construction, special spacers are provided. The space between the spacers is 300 mm, they determine the space of the profiles at the wood or metal sub-construction. Illustration of the KaRo heating- and cooling mat for dry-build boards:

Illustration of KaRo capillary tube mats for heat-ing and cooling 1 Oblong hole for fixing screws 2 Spacer for the initial fixing 3 Spacer for the ceiling profile 2. Installation Steps

A working place where the dry-build board can be fully laid-out is necessary for the in-stallation.

a) Installation of the additional spacers at the front end. On the installation table the dry-build board is laid with its equipped side facing up. The additional supplied spacers, which are supplied with the KaRo heating- and cooling mats are tacked to the front-end side.

Installation · TI-M05 Installation Instruction to KaRo Mats on top of Dry-build Boards

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M05

b) Fastening of the KaRo heating- and cool-

ing mats with tacks. The heating- and cooling mat is arranged and positioned between the spacers (de-scribed in point 1) In this position, the spacers located close to the collector pipes (marked with 2 in picture 1) are tacked to both sides of the heating- and cooling mats. Ongoing the heating- and cooling mats are pulled flush through pulling on the collector pipes. The distances of the other spacers to another is measured and corrected if required. Then the spacers are fastened with tacks.

c) Application of thermal conductive past

with a paint roller, through pouring or other suitable measures, the thermal con-ductive paste (approx. 800g/m2). After the paste is applied between the spacers it will be brushed in the direction of the cap-illary tubes towards the base with a nar-row brush. At normal temperatures, the thermal conductive paste dries within 20 minutes, so that the ceiling boards can be installed. The spacers who have contact to the ceiling profile are smoothened with a spatula or with other appropriate tools, in case that paste had been applied there.

d) Drilling of holes for the fixing screws:

Before drilling, the heating- and cooling mats are put under air pressure of 8 to 10 bar. If there are any injuries to the tubes, they can be detected then. The spacers have oblong holes (every 40 mm) (see fig-ure 1, marked with 2). These oblong holes are used for pre-drilling with a ∅ 2,5 mm for the fixing screws. The drill-grid (dis-tances of the holes to another in diagonal direction to the heating- and cooling mats) depends upon the installation in-struction of the dry-build board manufac-turer.

e) Finishing After the pressure test, the quick-action couplings are then closed again with cover caps.

f) Installation variation

If the installation is done by more than one person or if work is done in work steps it has been found best when work-step 3 is done last.

3. Tools

For the application of the dry-build board to the heating- and cooling mat G.10.X, the fol-lowing tools are required: • Installation table • Scissors to cut plastic material • Power drill • Drill-bit ∅ 2,5 mm • Tackler • Tacks • Paint roller • Narrow brush • Tape measure • Spatula • Compressed air connection Remark: With long, narrow and thin dry-build boards, the influence of moisture from the thermal conductive paste can lead to momentarily lit-tle reduction in strength of the dry-build boards. Careful handling of the boards is then necessary. Picture of an equipped dry-build board

TI-M06 Installation

Instruction to the Installation of KaRo Dew-Point Sensor

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M06

1. General

The dew point sensor is build into the cooling ceiling to avoid condensation. It works by the principle of changing resistances of an electri-cal conductor, which is printed onto it in a thin layer. At the danger of condensation, the resistance sinks rapidly. The change in resis-tance is computed by the converter M.TK.1 or by the room temperature control M.R2/3 and is transmitted as switch signal. The switch sig-nal can be used to switch-off the cooling ceil-ing or for starting of an alarm signal set-off. Up to 20 dew point sensors can be connected to the converter M.TK.1. To the room temperature control unit 5 dew point sensors can be connected. 3 variations of dew point sensors are available 1. Dew point sensor for metal ceiling boards

-> M.TM.1 2. Dew point sensor for plaster ceilings

-> M.TP.1 3. Dew point sensor for plasterboards

-> M.TG.1 The connecting cable for the dew point sen-sor may be extended to 100 m without prob-lems (minimum sectional area of 2x0.14 mm2) The connection of the extension must be good conductive (soldering connection or se-curely clamped together) 2. KaRo Dew Point Sensor for Metal

Ceilings

The dew point sensor M.TM.1 has a gold plated conductor plate at one side and is equipped with an adhesive surface on the other side. The soldered connection cable has a length of 10 m.

2.1 Installation

The dew point sensor is positioned at the coolest spot on the ceiling. The position of the dew point sensor must be near to the in-

feed for the capillary tube mats. The dew point sensor can best be positioned directly below the collector pipe or between the col-lector pipe and the first row of the spacers diagonal to the capillary tubes (see illustra-tion). The dew point sensor is connected with its connecting cable to the converter M.K.1 or to the room temperature control unit M.R2/3. The connecting cable can be installed in the ceiling cavity, in plaster or in electrical tubing Installation Steps The dew point sensor M.TM.1 is electrically connected and placed closely to the final in-stallation position. Until the final positioning the dew point sensors is kept in its protective cover. The installation of the dew point sensor can be done together with the installation of the supply lines (Z.EM, Z.EE, Z.DM or Z.DE). Together with the arrangement of the ceiling boards with the applied KaRo heating- and cooling mats to the hanger of the row-type grid profile also the dew point sensors are fixed. The dew point sensors are best posi-tioned directly below the collector pipe or be-tween the collector pipe and the first row of the spacers diagonal to the capillary tubes. The protecting cover is taken from the con-ductor plate, the protective foil for the adhe-sive is removed and the dew point sensor is glued to its pre-determined installation posi-tion. Illustration: Arrangement of the dew point sensor for metal ceilings below the KaRo heating- and cooling mat

Installation · TI-M06 Instruction to the Installation of KaRo Dew-Point Sensor

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M06

3. KaRo Dew point Sensor for Plaster Ceilings

The dew point sensor for plaster ceilings M.TP.1 consists of a gold plated conductor plate, and is glued to a plastic housing. A snuffing hose is connected to the plastic housing. A connecting cable (length 10 m) is soldered to the conductor plate.

3.1 Installation

The dew point sensor is installed at the cool-est spot of the cooling ceiling. The dew point sensor is best positioned between the collect-ing pipe and the first row of the spacers diagonal to the capillary tubes (see illustra-tion). The dew point sensor M.TP.1 is fixed to its position before plastering! The sensor is con-nected to the converter or to the room tem-perature control unit by its connecting cable. The connecting cable with its length of 10 m can be installed in the ceiling cavity, plaster or in electric tubing. Installation Steps 1. The dew point sensor M.TP.1 is electri-

cally connected and placed closely near to its final position. Until its final posi-tioning the dew point sensor is kept in its protective cover.

2. After fixing of the KaRo mat at the raw

ceiling a plaster spot or another appro-priate means of fastening is placed at the installation position of the dew point sensor (see illustration)

3. The self-sticking backside of the gold

plated conductor plate of the dew point sensor for plaster ceilings is positioned diagonal to the capillary tubes. Then the ceiling is plastered

4. After paintwork is done the sniffing hose

is shortened even to the ceiling surface. Care must be taken, that the openings of the snuffing hose will not closed.

1 2 3 Illustration 1:Placing the plaster spot 1 Raw ceiling 2 Capillary tube 3 Plaster spot

45 6 Illustration 2: Positioning of the Dew point sensor : 4 Gold-plated conductor plate 5 Plastic housing 6 Snuffing hose

7 Illustration 3: Plastered Dew point sensor 7 Plaster

Installation · TI-M06 Instruction to the Installation of KaRo Dew-Point Sensor

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-M06

4. KaRo Dew Point Sensor for

Plaster Ceilings

The dew point sensor for the plaster ceilings M.TG.1 consists of a gold plated conductor plate, which is glued to a plastic housing. A snuffing hose is connected with the conduc-tor plate. A cable of 10 m length is soldered to the conductor plate.

4.1 Installation

The dew point sensor is located at the coolest spot at the ceiling. The dew point sensor is best positioned between the collector pipe and the first row of spacers, diagonal to the capillary tubes. Depending on the type of ceil-ing cavities various dew point sensors are utilised. Open ceiling cavity For open ceiling cavities, these are ceiling cavities which are in connection with the room air , the dew point sensor M.TM.1 for metal ceilings is utilised..

The dew point sensor is positioned best be-tween the collector pipe and the first row of the spacers diagonal to the capillary tubes. Installation Steps The dew point sensor is electrically connected and positioned closed to its final installation position. Until the final positioning the dew point sensor is kept in its protective cover The installation of the dew point sensor can be done together with the supply lines (parts : Z.EM, Z.EE, Z.DM or Z.DE ). Together with the arrangement of the plas-terboard ceiling at the ceiling construction also the dew point sensor is fixed. The dew point sensor is best located between the col-lector pipe and the first row of the spacer, di-agonal to the capillary tubes. The protective cover is taken from the conductor plate and the protective foil from the dew point sensor and is then glued to the pre-determined in-stallation position.

Illustration 4: Arrangement of the dew point sensor inside the open ceiling cavity 1 Dew point sensor 2 Connector plate 3 Supply line 4 Capillary tube 5 Plaster board ceiling

12 34 5

Installation · TI-M06 Instruction to the Installation of KaRo Dew-Point Sensor

04/2002 Learning from Nature – www.KaRo.cc P.4 TI-M06

Closed ceiling cavity For closed ceiling cavities, these are ceiling cavities which have no air connection to the room, the dew point sensor for plasterboards M.TG.1 is utilised. The dew point sensor is best positioned between the collector pipe and the first row of spacers, diagonal to the capillary. Installation Steps The dew point sensor is electrically connected and positioned near the final installation posi-tion. Until the final positioning the dew point sensor is kept in its protection cover. .

Installation of the dew point sensor can be done with the supply lines (parts: Z.EM, Z.EE, Z.DM or Z.DE). Drilling of the hole for the snuffing hose. For the preparation of the final installation posi-tion of the dew point sensor a hole of 6 mm must be drilled for the snuffing hose. Together with the fixing of the plaster board ceiling also the dew point sensor is fixed. The dew point sensor is best positioned between the connecting pipe and the first row of spacers, diagonal to the capillary tubes. The adhesive protection tape for conductor plate is taken off and the dew point sensor is brought to its final position.

Illustration 5: Arrangement of the dew point sensor in a closed ceiling cavity 6 Snuffing hose shortened even to the ceiling surface.

TI-M07 Installation

Test Instructions for KaRo Heating- and Cooling Systems

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M07

1. General Statements and Remarks

KaRo heating- and cooling ceilings as well as the supply lines are normally operated be-tween 0 and 4 bar. A pre-test, with compressed air of 10 bar, is recommended to assure the tightness of the heating- and cooling mats and the supply lines, which where installed at the building site. Before start of operation and after venting the water system must be tested for water tightness with 10 bar pressure. Care must be taken that gages, the allowable nominal pressure of which stays below the maximal test pressure are not installed during the time of pressure testing. All KaRo fittings und armatures of ∅ 10 and ∅ 20 mm can be short time tested with 16 bar and during 24 hours be pressure loaded with 10 bar. Until finishing all work at the construction site up to the start of operation, the system should be kept under an idle pressure of 2 to 3 bar. Damages, which are caused by other work groups after installation is finished, can be recognised soon and be repaired rapidly. 2. Test Procedure

A thorough test report must be prepared by the responsible person (see → test report T05) and be handed to the project manager. The fully completed test report is the basic requirement for the 15 year warranty of KaRo for the material. On principle, the common rules for the pres-sure testing of water carrying systems are valid. These include also the following items: • Proceed section by section. The sections

should only be so big, that it can be kept under control when pressure tested.

• Never pressure test with the connection opened to the City water system, because of the danger, that the city water will

keep on running without being recog-nized.

• Use pressure test pumps only. • All lines, which later are not accessible,

must be pressure tested successfully with 10 bar, before the final closing.

Directly after the connection of the KaRo mats to the supply lines, the mats are pres-sure tested with compressed air at 10 bar. The pressure is sustained for 1 hour. Eventual leakages at the connections can be detected at once. For the main test the mats have to be filled with water section by section, then be vented and pressure tested for 10 minutes with a pressure of 3 bar. Eventual leakages must be sealed at once. Thereafter the pressure is raised to 10 bar. Af-ter 1 hour the eventual pressure loss, caused by the elastic expansion of the piping, must be equalized. If the systems will hold the pressure of 10 bar steady for 4 hours the pressure test had been successful. In case leakages had to be cleared away, the pressure test must be repeated. In the report, all faults must be recorded. At the end of the pressure test the system is pressure released to a normal pressure of 2 to 3 bar and must remain until the all construc-tion work is finished.

TI-M08 Installation

Technical Data to the Converter

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M08

1. Product Description

The converter evaluates the existing resistance of the dew point sensor. A relay is switched in the dew point sensor if the resistance lowers by leaps and bounds. A potential clear switch-contact is available. The circuit card of the converter is inside a housing with a kombi-foot prepared for bus connection in a switchboard. The situations of operation: “operating” or “danger of dew point” is signalled by control lamps 2. Specifications

L x W x H (mm): 75 x 45 x 47 Supply Voltage 24 V AC Switch contact load 1): 230 V, 8 A Power input max. 1 VA Allowable ambient temp. 5....40 °C 1) For controlling of relays, contactors etc. with co sinus ϕ <0,3 it is advisable to use a RC-limb parallel to the coil. This will lessen the contacts burn-off and will avoid high fre-quency interference impulses.

3. Electrical Connection

Clamp Connection 1 System potential 24 V AC 2 System neutral 3 Dew point sensor 4 Dew point sensor 5 Relay Work contact 6 Relay Centre contact 7 Relay Repose contact

TI-M09 Installation

Technical Data to the Room Temperature Control

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M09

Room temperature control unit M.R2/3 for cooling ceilings with dew point control and heat release. 1. Description of Functions

The room temperature control unit with dew point control Type M.R2/3 is especially suit-able for controlling of heating- and cooling systems where the formation of condensation (for example: at cooling ceilings) is detected prematurely and reliably, so that cooling can be shut-off (to avoid condensation).

With the setting knob at the front side the desired temperature is set. The set tempera-ture can also be changed by means of an ex-ternal remote control unit. Control lamps of different colours inform of the state of opera-tion: State of Operations of the Room Temperature Control Unit red: = "Heat" -> Fall short of pre-set temperature green: = "Cool" -> Exceeding the pre-set temperature yellow; = "Cooling off" -> due to possible condensation .

Through switching of unit-internal switches it can be chosen between double- and triple conductors. 2. Unit Versions

Through switching of two unit-internal DIP-switches (see: figure 5) two different func-tions: M.R2" or "M.R3", can be chosen ( M.R2 is pre-set). Attention: Both switches must be either open or closed! M.R2 DIP-switch

opened Control unit for the double conductor sys-tem, with a valve-control outlet which can

be switched through remote control to heat-ing or cooling (win-ter/summer- operation).

M.R3 DIP-switch closed

Control unit for triple conductor system with two valve-switch outlets for heating and cooling .

3. Control Range

The room temperature can be pre-set in the range 5°...30°C, while the adjustments can be limited mechanically to maximum tempera-tures of 16°, 18°, 20°, 22° and 24°C. The imi-tating is done through a pin, which is posi-tioned from below into the marked holes in the setting knob. By design this works also as a lower temperature limitation: max.-Temp.

Mi-nim. Temp.

16 °C 18 °C 20 °C 22 °C 24 °C

- - 5 °C 7 °C 9 °C

At pre-set temperatures of 16°C and 18°C a lower limita-tion can not be effective be-cause it would fall short of the range.

4. Dew Point Identification

When condensation occurs at the sensor cool-ing will be interrupted. This situation is sig-nalled by the yellow control lamp. 5. Set point by Remote-Controlling

With a DC-voltage of 2...10V at the control input “Remote Control” a linear shifting of the pre-set value of max. ± 5K is possible (see figure 1). For example: with a DC-voltage of 8V the pre-set room temperature will be raised by approx. 2,5K. If there is no signal at the control input there would be no change of the set point.

Installation · TI-M09 Technical Data to the Room Temperature Control

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M09

Figure 1: Characteristic-curve for Set-point Remote-Controlling 6. Summer- / Winter Operation

The switch-over summer- / winter operation is only required with the double conductor sys-tem M.R2. The switch at the input "Heat / Cool" (clamp 7 and 9) will initiate a functional reverse:

Summer:If the input is closed, the control will

switch the valve to cooling when the pre-set temperature is exceeded.

Winter: If the input is open, the control will

switch the valve for the heating when the pre-set room temperature has fallen short.

7. Switch Behaviour, Hysteretic

When falling short of the pre-set room tem-perature the heating system will be activated (with M.R2 only in winter operation), which will be signalled by the red control lamp . If the room temperature is exceeded, the cool-ing system will be activated (with M.R2 only in summer operation), which will be signalled by the green control lamp.

Figure 2: Switch Behaviour, Hysteretic

0 2V 4V 6V 8V 12V 10V

5 4 3 2 1 0

-1 -2 -3 -4 -5

Control Voltage at Input "Remote Control"

Set point Change / K

Installation · TI-M09 Technical Data to the Room Temperature Control

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-M09

8. Name of Terminals

At the switch outputs for the heating / cool-ing valve, up to a maximum load of 1 amp., also a 24 volt auxiliary relays can be con-nected. 9. Technical Specification

Operation voltage: 24V~ ±10%, 50...60 Hz Power consumption: 30mA (w/o load output) Outputs: Triac-outputs; Heating / Cooling not potential free Switch capacity 1A / 24V~ [short term (1 min) approx. .2,5A] Control range: 5...30°C Switch hysterics: 1 K Neutral zone: 2,5 K Temp. sensor: unit internal NTC Ambient temp.: 0...+40°C Protection type IP 40 Protection class: III Measures (WxHxL): 74 x 74 x 36 mm Colour: grey/white

M.R2 (Double conductor system) M.R3 (Triple conductor system) Terminal Name Terminal Name 3 operating-voltage, neutral potential 3 operating-volt, Neutral potential 4 operating voltage , 24V~ 4 operating voltage, 24V~ 5 24V~ for valve outputs 5 24V~ for valve outputs 6 switch output Heat-/Cool valve 6 switch output Heat valve 7 switch-over input Heating / Cooling 7 switch output cool valve 8 input remote-control 8 input remote-control 9 neutral potential for terminal 7, 8, 10 9 neutral potential for terminal 8, 10 input dew point sensor 10 input dew point sensor

TI-M10 Installation

Installation Instructions to KaRo Dry-build Unit

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M10

1. General

The KaRo dry-build unit is a sandwich board made out of a building board (plasterboard, Ferma cell or similar) and a rigid foam insula-tion (Styrofoam) with integrated capillary tube mat, suitable for the installation in dry-build construction, similar to commonly known dry-build boards. This way heating-or cooling ceiling is developed for the dry-build construction. The dry-build units are supplied in standard sizes for building boards, so that tailoring at the building site is not required. Only at border area and at places where ceiling in-builds are planned inactive boards are fitted. The dry-build unit is supplied, pre-drilled for hammer drive screws, for the installation to a sub-construction made from standard CD-sheet Metal profiles.

The hammer-drive screws may only be posi-tioned at these places otherwise there is the danger that the integrated capillary tube mats are damaged. Before beginning of work, a layout pattern must be prepared as a work base. All mats with its measurements and laying direction also the supply lines are to mark in it. In the ceiling pattern also all areas must be identi-fied which will not be covered, for instance: the erection of internal walls, positioning of light fixtures and other ceiling in-builds. Fur-thermore, the installation position of the KaRo dry-build unit with the integrated dew point sensor must be identified in the ceiling pattern. Figure: Presentation of the arrangement of a suspended ceiling with KaRo dry-build units.

Installation · TI-M10 Installation Instructions to KaRo Dry-build Unit

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M10

2. Installation Steps

1. Suspension of the CD - profiles

The carrier- and basic profiles are fixed and aligned to the raw ceiling with vernier suspension bars according to manufactur-ers instructions. The distance of the carrier profiles is fixed to 500 mm. Additional carrier profiles (also the border angles)at the border area and for the inactive tai-lored boards are positioned according the ceiling pattern. The dry-build construction guidelines must be obeyed.

2. Installation of the KaRo supply lines.

The supply lines are laid into the ceiling cavity and are connected to the main sup-ply lines (see M02 – Thermal welding for plastic materials)

3. Preparation of the KaRo dry-build units.

Remove dust protection covers from the plug-in couplings on the unit.

Plug-in the flexible connection hoses into the quick-action couplings of the KaRo dry-build unit.

4. Fasten dry-build unit to sub-construction

Place dry-build unit according ceiling pat-tern to the sub-construction.

Plug-in the flexible connection hoses to the quick-action couplings of the supply lines.

Align dry-build unit to the pre-drilled holes at the sub-construction.

Insert hammer-drive screws into the pre-drilled holes and screw until a firm hold to the sub-construction is achieved and the screw head has sunk in 1 mm deep. (Set the torque of the power tool !!)

5. Pressure test (see M07 – Test instructions)

Pre-test with compressed air at 10 bar for 1 hour.

Main test with water at 10 bar for 10 hours .

Keep-up idle pressure at 3 bar until start of operation.

6. Connection of the KaRo Dew point sensor

Unroll the connecting cable of the dew point sensor and lead to the KaRo room temperature control unit M.R2/3. Connect to the room temperature control unit ac-cording the connection scheme.

7. Ceiling Finish

Cut in-active boards for the border area and close ceiling area completely.

Fill-in board joint gaps, smoothen and grind even.

Apply ceiling paint.

Trim snuffing tube with knife even with the ceiling.

3. Tools, Materials

For the application of the KaRo dry-build units standard tools and materials, commonly used for dry-build construction, can be util-ised: • CD profiles • Cross-connectors • Vernier suspension bars • Dowels and screws • Hammer-drive screws, length 55 mm • Border angles • Blade-knife for tailoring and edge-

planner • Power screw unit • Spatula • Joint filler material • Manual grinder For connection of the supply lines to the cold water circuit a hand held welding unit with sleeve welding device is required (see M03).

TI-M11 Installation

Installation Instructions to KaRo Mats between double panelled Plasterboard Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M11

1. General

The installation type of the KaRo mats accord-ing to the system Wedel is the arrangement of capillary tubes between two dry-build boards. KaRo cooling ceilings are manufac-tured in a pure dry-build construction man-ner. The applied procedure is protected by a “registered design”. The advantage of this so-lution is, that the whole ceiling can be done in the real dry-build construction stile by us-ing standard dry-build boards (mostly plas-terboards) and the work can be easily timed in co-ordinance with other construction works. For the Wedel system special KaRo mats, Type K.WS15 can be supplied. The mains of the mats are placed in the suspended ceiling made from CD-profiles and are piped in the cavity of the ceiling. After connecting the mats to the water side by means of thermal welding, the pressure test according regulation M07 - Test instruc-tion -

must be performed. Thereafter the first layer of plasterboards is screwed to the suspended ceiling. To enable that the mats can be taken from the ceiling cavity a gap must be kept free. Thereafter the mats are fixed with dou-ble- sided adhesive tape to the, of course not visible but by the position of the screws no-ticeable carrier profiles, under the ceiling. KaRo manufactures mats in widths equal to the spacing between the carrier profiles. The room dimensions determine the mat’s length. The system-spacers are glued under the “in-visible” carrier profiles. In the last step, the second layer of plasterboard is fixed (screwed through the system spacer on to the carrier profiles). The following gap filling, smoothen-ing and grinding is done according to the standards of the dry-build construction tech-nique. To achieve respectable cooling performances for this ceiling construction Styrofoam insula-tion boards should be laid in sections under the capillary tube mats. Illustration: Arrangement of KaRo mats according to the Wedel system.

insulation board

plaster board system spacer

Installation · TI-M11 Installation Instructions to KaRo Mats between double panelled Plasterboard Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M11

2. Installation Steps

1. Suspension of the CD - Profiles

The carrier- and basic profiles are connected and aligned to the raw ceiling according manufacturer’s specification, normally by means of vernier suspension bars. The dis-tance between the carrier profiles according standards is set at 600 mm and 500 mm. 2. Installation of the supply lines.

The supply lines for feed and return are laid into the ceiling’ cavity according hydraulic in-terpretation. The connecting points for the mats must be aligned exactly to the suspen-sion ceiling construction 3. Hook-up of the KaRo Mats

Fastening of the mains for the mats to the basic profiles with cable-binders. .

Connection of the mats with the supply lines (see M02 - Thermal welding of plastic materi-als). 4. Pressure Test (see M07 -Test Instructions)

Pre-test with compressed air at 10 for 1 hour.

Main test with water at 10 bar for 10 hours.

Idle Pressure at 3 bar keep-up until start of operation. 5. Installation of the first Layer of Dry-build

Boards

Screw-on the plasterboards according to dry-build construction specification 6. Attaching (gluing) the KaRo Mats

Unroll the mat, align and glue-on with adhe-sive tape to the first layer of dry-build boards between the carrier profiles. If wanted, insu-lation sheets can be placed under the mats. Glue system spacers under the carrier profiles.

7. Installation of the Second Layer of Dry-build boards

Screw-on the plasterboards according to the dry-build construction specification through the system spacer onto the carrier profile.

Layout the KaRo Dew point sensor and con-nect: Roll-out the connecting cable of the dew point sensor and lead to the room tem-perature control unit M.R2/3. Connect the sensor to the room temperature control unit according to connection scheme. Insert snuff-ing tube of the sensor through a pre-drilled hole of the plasterboard. . 8. Finishing the Ceiling

Fill joints between boards, smoothen and grind even.

Apply ceiling paint.

Trim snuffing tube with knife even with the ceiling.

3. Tools, Materials

For the application of the KaRo pre-fabricated units commonly standard tools and materials for the dry-build construction can be utilised. • CD profile • Cross-connector • Vernier suspension bars • Dowels and screws • Hammer drive screws • Corner angles • Plate knife for tailoring and

edge-planner • Power screw unit • Spatula • Joint filler material • Manual grinder For the connection of the supply lines to the cold water circuit a hand-held welder with a sleeve welding device is utilised (see M03).

TI-M12 Installation

Installation Instructions to KaRo Mats as Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M12

1. General Remarks

The KaRo floor heating system can be in-stalled onto nearly any carrying surface. The floor must be constructed according to the valid standards for impact sound- and heat insulation and must be able to carry the required traffic loads.

-> Remarks to the Building Specifications are found in B08 „Questions before construc-tion of KaRo-floor heating„

In contrary to other floor heating systems the KaRo floor heating is not embedded into the load carrying concrete. The capillaries are laid on top of an already load carrying base and is only covered with a thin covering-layer and with the desired floor coverings. The appro-priate floor covering must be chosen accord-ing to the existing floor base. The application should be done according to the manufac-turer’s working directions. Basically, the thickness of the layer should only be as thick as necessary. The thickness is influencing the reaction-time of the KaRo floor heating (little thickness of layer = quick reaction !).

The supply lines and the collector pipes of the mats are commonly laid in wall slots or hid-den channels in the floor. Before starting to work, a layout pat-tern must be pre-pared as work ba-sis. All mats with their measure-ments , the direc-tion they are laid and the supply lines must be indi-cated

In the layout pattern also all areas must be indicated which must be kept free of tube mats, for instance where internal walls will be put up. Areas for closets and permanently fixed furniture should not be covered with tube mats, because heating is not required at these areas. For the application of the KaRo mats for floor heating the mats must be fixed to the raw floor temporarily until the load dis-tributing layer has been brought in. For this the KaRo heating- and cooling mats can be supplied with butyl adhesive-strip. After re-moval of the protective tape from the butyl strips, the mats can simply be positioned on the raw floor. On a dry screed floor base, the mats can also be tacked-on. 2. Arrangement of the Connecting

Lines and Collector Pipes.

For a new construction of the floor, the col-lector and the supply pipes can be laid in hid-den channels. These channels are simply inte-grated into load distributing layer (temporarily wooden (roof)batten are laid-out). After the concrete is solid, they can be removed and channels had been created. Illustration 1: Cross-section of floor with the layout of collecting pipes in the floor channels

Equalization screeding

Tile

elastic joint motar

border strip

BeKa heating- and cooling matLoad distribution layerPolyethelene foil

leveling mass

Insulation board

Polyethylene foilConstruction sealing

Installation · TI-M12 Installation Instructions to KaRo Mats as Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M12

If chipboards are used for the load-distributing layer, two layers should be cho-sen. At places where channels have to be formed, then one layer is simply omitted. The carrying capacity of the load-distributing layer will be recovered again, when the chan-nels are poured with levelling compound. In renovation cases, it is possible to make free-cuts in the floorboard in longitudinal di-rection of the beams. In these cases the carry-ing capacity must be restored again with an appropriate wood sub-construction. Illustr. 2: Arrangement of the collector pipes behind the cover-wall

The collector pipes and the connection lines can also be laid in wall slots. Before the chis-elling work is started, it is necessary to check if the stability of the wall construction is suf-ficient. If the stability of the wall is not strong enough, slots can be created by addition of a cover (plasterboards on lathing). 3. Installation Steps

Take KaRo mats out of packaging and roll-out on a flat and clean surface, to keep them down apply some (flat) weights at the loop-ribbon side. The mats can stack up to 15 on top of each other. Before further work, the mats should rest for one day for stress reliev-ing. 1. Preparation of the raw floor • Smoothen unevenness • Apply priming • Make plan for arrangement of mats at the

floor. • Fix clamps for fastening of supply lines

and for the collector

2. Connect and pressure test KaRo mats to the waterside.

• Install supply lines. • Connect KaRo mats to the supply lines

(see → M02 – Instructions for thermal welding of plastic materials)

• Pressure test of the completely installed system. (see → M07 – Test instruction for KaRo heating- and cooling systems)

• Setting to idle pressure to 3 bar (the mats will remain under idle pressure during the total time of installation until start of op-eration!)

3. Fastening of mats to the raw floor • Fastening of the KaRo mats on the load

distributing layer with means of:

Butyl adhesive tape Plug-type dowel double clamps (Supplier: Hilti – Type: EDD 4-12) Tack with non-corrosives staples (use only in conjunction with application on dry-screed floor base!) The staples are positioned above braces of the spacer-ribbon. The tucker application strength and length of staples chosen should be fit to hold the mats firmly in place, the spacers length’s though should not be damaged.

• Alignment of the mats, and stretching of

the capillary tubes. 4. Apply covering layer and smoothen. (ob-

serve manufacturer’s advices!) • Apply self-levelling equalisation com-

pound – watch for minimal thickness, normally 10 to 15 mm .

• In case capillaries are damaged, repair at once by closing tube ends with soldering iron, or if required replace damaged mat. →TI.M01

Tile

elastic joint mortar

border strip

latex cement

BeKa heating- and cooling mat

Impact sound isolation

wood flooring

Plaster board pre-wallon wood latting

TI-M13 Installation

Fixing of KaRo Mats with Butyl Tape

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M13

1. General Remarks

For installation of KaRo mats in plaster ceil-ings the mats must be fixed to the raw ceiling temporarily until the actual plastering is done. Therefore, the mats can be supplied, option-ally, with butyl adhesive tapes applied to them. After removal of protective foil the mats are fixed with these adhesive tapes 2. Condition of Application for the

Gluing with Butyl Adhesive Tape

2.1 Condition of Base Surface Ground

A suitable base surface ground is formwork concrete, which is laid plane. The base surface ground must be dry, load carrying and free of dirt (grease- oil and dust free). Sucking or sanding base surface grounds must be pre-pared by the same way as for plastering. Suitable are bonding primers as “Beto Kon-takt” from “Knauf” or similar.

Processing- and Storing Temperatures :

+5°C to +28°C

2.2 Processing Time

Fixing KaRo mats by means of Butyl adhesive tape to the raw ceiling is laid out for installa-tion support. With the butyl tape, the mats can only be held to the raw ceiling up to 2 days. If there is a longer interruption in the work sequence an additional means of fixing must be found to hold the capillary mats to the raw ceiling. 3. Installation Steps

• Take KaRo mats out of the packaging place on clean and even surface, if re-quired place some flat weights to the loop ribbon side. The mats can be stacked up to 15 layers.

Before processing the mats should rest for 1 day to release tensions.

• Hook-up the main pipes of the KaRo mats to the already dowelled-on pipe-clamps at the ceiling.

• For this reason the mats may be rolled-up again.

• Make water connection for the mains pipe. → Processing guidelines TI-M02.

• Make pressure test for the installation ac-cording TI-M07.

• Rollout mats and fix to ceiling by means of butyl adhesive tape. Remove protec-tive foil from adhesive tape and press mat at the gluing areas with a slight but flat pressure to the ceiling. Stretch the mats so that they are leaning evenly on the ceiling.

• If required, use additional means of fix-ing for the mats (double-dowel plug-type clamps, “Type Hilti - EDD 4-12; disc dow-els for plug-in) or use plaster spots for holding.

• Plaster the KaRo mats at the ceiling. Ap-ply air pressure of 3 bar to the mats and keep this pressure during the time for the plastering work. If leakage occurs (bub-bles appear) it can be repaired quickly without draining the water from the mats →TI-M01.

Flow-pressure and consistency of the plaster compound must be adjusted to such a de-gree, that the mats will not lift-off the ceiling.

TI-M14 Installation

Technical Information on KaRo Glue V.K.1

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M14

1. Application Range

For gluing the capillary tube mats to acoustic fibre mats, in metal ceiling sheets and to dry-build boards.

2. Characteristics

The KaRo Adhesive V.K.1 is an adhesive, which is good for spray-application with a long open time. For tension free application on to sucking materials, it is possible to work with a one-sided layer of adhesive. The adhesive forms an elastic, permanent and colourless adhesive joint.

3. Processing Guidelines

For gluing into metal ceiling sheets the KaRo adhesive V.K.1 is reduced with KaRo solvent V.L.1 in the proportion up to max. 5:1 before applying. The adhesive, dosed economically, is sprayed onto the mats. The mat is then laid immediately in the cassette and rolled-onto the surface. As guideline for the amount of usage: 80 g/m2.

4. Technical Data

Raw material base: SBS -caoutchouc

Solid base contents: ca. 43%

Density: ca. 0,83 g/ml

Viscosity: ca. 200 mPas (Brookfield)

Colour: natural

Application of adhesive: with spraying gun

Nozzle size: 1,5 - 2,5 mm

Spraying pressure: 2 - 6 bar

Drying-off time: ca. 0,5 - 3,0 minutes, in dependence of layer thickness, material and temperature

Pot time: for double sited application: approx. 120 minutes for one sided application: approx. 15 minutes

Cleaning agent: solvent V.L.1

Shelf time: at +15°C to 20°C approx. 6 months

Storage temperature: not below +10°C, effected by frost

Application temperature: Material-, room- and adhesive temperature Not below +15°C and not above +25°C; best application temperature is +18°C to +22°C

Identification code according GefStoffV (regulation for dangerous materials) : flame symbol, F, easy to ignite

Identification according VbF: A I

TI-M15 Installation

Technical Information on KaRo Solvent V.L.1

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M15

1. Application Range

Universal solvent and cleaner for KaRo adhesive V.K.1 2. Working Directions

For gluing into metal ceiling sheets the KaRo V.K.1 adhesive is reduced with KaRo solvent V.L.1 in proportions up to max. 5:1. The adhesive, dosed economically, is sprayed onto the mats. The mat is laid into the cassette immediately and rolled-onto the surface. A guideline for the amount of usage is: 80 g/m2. In case of the usage of reducing solvents for better viscosity it must be observed that there is still enough adhesive left which ensures a sufficient adhesive film after application, otherwise it could cause insufficient adhesion. 3. Technical Data

Storage temperature: cool storage; not effected by frost Shelf time: unlimited, if kept in tightly closed container Application temperature: Material-, room- and adhesive temperature

not below +15°C and not above +25°C; best application temperature at +18°C to +22°C

Identification code according GefStoffV: Flame symbol, F, easy to ignite Identification code accord. VbF: A I

TI-M16 Installation

Technical Information on KaRo Thermal Conductive Paste V.WLP.1

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M16

1. Application Range

For thermally effective embedding of capillary tube mats onto dry-build construction sheets, such as plaster boards or gypsum wallboards.

2. Characteristics

The KaRo thermal conductive paste V.WLP.1 is a highly elastic, solvent free liquid foil with a long pot time. The thermal conductive paste is prepared ready for application. After maturing, the paste forms an elastic, resistant to aging, thermal conductive and grey joint.

3. Application Directions

The thermal conductive paste is applied with a paint roller, through pouring or by other applications (ca. 800g/m2). After the paste is applied everywhere between the spacers, it is then distributed with a narrow long brush parallel to the capillary tubes. This will form a bridge between the air space be-tween the base of the capillary tube and the surface of the plate. At normal temperatures, the ther-mal conductive paste will mature within 20 minutes so that the ceiling boards can be installed. The spacers which have contact to the ceiling profile is smoothened with a spatula or with another suit-able tool from the eventually applied thermal conductive paste.

4. Technical Data

Raw material base: plastic water based, modified

Colour: grey

Density: ca. 0,83 g/ml

Consistence: highly viscous, non dripping

Joint coverage: up to 2,1 mm

Tensile strength: 1,5 N/mm2

Tear stretching : ca. 400%

Application of paste: with brush

Pot time: ca. 120 minutes

Cleaning agent: in fresh situation, with water

Storage time: at +15°C to 20°C approx. 6 Months

Storage temperature: free of frost

Application temperature: not below +5°C

TI-M17 Installation

Fixing of KaRo Mats with Adhesive Tape

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M17

1. General Remarks

KaRo mats can be installed below suspended ceilings, laid in plaster. For this the mats must be temporarily fixed in a suitable way to the underside of the plaster board ceiling until the final plastering. The KaRo heating- and cooling mats can be supplied equipped with adhesive tape. After the protective tape is peeled from the adhesive tape the mats a simply fixed to the underside of the ceiling.

2. Application Conditions for Gluing with Adhesive Tape

2.1 Conditions of the grounding

The best grounding is a plane plasterboard. Joints between boards and head of screws must be filled and smoothened. The ground-ing must be load bearing, dry, free of dirt, free of grease , oil and dust. The adhesive primer must not be applied at this time ! Application- and storage temperatures

+5°C to +28°C 2. Application Time

The fixing of the KaRo mats with adhesive tape to the plasterboards is only laid out as an installation aid before plastering. The mats can only be held with the adhesive tape to the ceiling up to a time of 3 days. In case of a longer interruption of work the capillary tube mats must be fixed to the ceiling with addi-tional means.

3. Installation Steps

• Take KaRo mats out of the packaging and rollout onto a flat surface, and if neces-sary place some (flat) weights onto the loop strip side. The mats can be stored up to 15 layers . Before work is started the mats should be left for stress reliev-ing for the time of one day. Position and fasten the main pipes of the KaRo mats to pre-fixed clamps. Depending upon their length the mats can be loosely rolled-up again for easier handling. Make water connection to the main pipes . → see working direction TI-M02

• Pressure test after installation according TI-M07.

• Rollout the mat and fix to the ceiling with adhesive tape. Therefore, peel-off the protective foil from the adhesive tape and press the mat to the ceiling with lit-tle but equal pressure. The mats should be stretched, so that they are even with the ceiling. Pulling them into direction of the loops can tighten capillary tubes, which are sagging.

• If necessary fasten the mats additionally with staples.

• Prepare the surface of the grounding for plastering. Suitable adhesive primer is Beto Kontakt 90 from Knauf or other similar materials.

• Apply the plaster to the KaRo mats. Put the KaRo mats under pressure with com-pressed air of 3 bar and retain this pres-sure during the total time when the plas-ter is applied (eventually occurring leakages will be made evident by air bubbles, it can be repaired rapidly with-out drainage of the water from the mats.

• →TI-M01). Flow pressure and consistence of the plaster should be such, that the mats are not drawn from the ceiling when the plaster is applied!

TI-M18 Installation

Installation Instruction forKaRo Mats to Dry-build boards

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M18

1. General Remarks

Just by laying the KaRo mats from above to the suspended plasterboard ceilings, very simply cooling ceilings can be installed in the dry-build construction way. For this the mats are stretched between the carrying profiles of the suspended ceiling construction (CD-profiles) before they are screwed to the plas-terboards. KaRo supplies the mats in widths in accordance with the spaces between the carrying profiles. The room dimensions de-termine the lengths of the mats. To ensure always constant flow, the maximum mat length though should not exceed 8 m. The main lines of the mats are connected in a suitable way (with tie-down straps) to the base profiles. The piping for the supply lines had been laid before into the future ceiling cavity. The mats are only stretched so much, that they sag slightly. For very long mats it is advisable to divert the capillaries with bracing

wires, from carrying profile to carrying pro-file, otherwise the mats would sag too much. After water connection of the mats with flexible hoses, a pressure test must be per-formed according to regulation M07 – Test instructions. The installation of plasterboards and the following smoothening and grinding must be done according to the regulations of the dry-build construction techniques. In or-der to achieve respectable cooling perform-ances with such a ceiling construction, insula-tion boards from mineral wool (or fibre) should be laid in sections between the carry-ing profiles from the top onto the capillary tube mats. Illustration: Construction and arrangement of the KaRo mats onto the dry-build constructed ceiling, without coverage with insulation boards, connection to water supply by flexible connection hoses.

Installation · TI-M18 Installation Instruction to KaRo Mats to Dry-build boards

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M18

To avoid fibre dust the insulation sheets are commonly wrapped in PE – protection foil. Alternative to the connection of KaRo mats by flexible hoses, the mats can also joined among themselves at the main pipes, on the top of the carrier profiles, through thermal welding. For this installation version KaRo supplies the mat type K.GK 10, which is sup-plied readily equipped with sleeves and ex-tended main pipes ends. 2. Installation Steps

1. Suspension of the CD - profiles

The carrying- and basic profiles are arranged and fixed to the raw ceiling with vernier sus-pension bars according to manufacturer’s specifications. The spaces between the carry-ing profiles must be laid-out according to specifications. According the arrangement layout for the mats, sometimes it requires additional basic profiles for the fastening of the main lines. 2. Installation of KaRo Supply Lines.

The supply lines are laid in the ceiling cavity and connected to the piping according à M02 – Instructions for the thermal welding of plastics . 3. Hook-up of the KaRo Mats

Fastening of the main lines of the mats on to the basic profiles, for instance with tie-down straps. Possibly pull bracing wires diagonal to the carrying profiles to avoid sagging of the mats. Plug the flexible hoses into the quick-action couplings of the supply lines

4. Pressure test (see M07 – Test instructions

for KaRo heating- and cooling systems)

Pre-Test with compressed air at 10 bar for 1 hour. Main-Test with water at 10 bar for 10 hours. Set an idle pressure of 3 bar and maintain un-til start of operation. 5. Installation of dry-build construction

boards.

Screws fasten the plasterboard according dry-build construction specifications. Position and connect KaRo dew point sensor. Unroll the connection cable of the dew point sensor and lead to the KaRo room tempera-ture control unit M.R2/3 (see M06 – Instruc-tions for the installation of the KaRo dew point-sensor. Connect the dew point sensor to the room temperature control unit accord-ing to the connection plan. Insert the snuffing pipe of the sensor through the pre-drilled hole of the plasterboard. Possibly, place insulation boards in sections between the carrying profiles from the top onto the KaRo mats. . 6. Finishing the ceiling

Fill-in joints, smoothen and grind plane. Ap-ply ceiling paint. Trim snuffing tube with knife to the plane of the ceiling.

Illustration 2: Alternative connection of mats via thermal welding according to Tichelmann

Installation · TI-M18 Installation Instruction to KaRo Mats to Dry-build boards

04/2002 Learning from Nature – www.KaRo.cc P.3 TI-M18

3. Tools, Materials

For processing and installation of the KaRo pre-fabricated units normal tools for dry-build constructions and materials can be utilised: • CD profile • Cross connector • Vernier suspension bars • Dowels and screws • Hammer-drive screws • Edge angles • Blade-knife for tailoring and edge-

planner • Power screwing unit • Spatula • Joint filler compound • Hand grinder

For the jointing of the supply lines to the cold water circuit a hand held welding unit with sleeve welding device is required for the plastic welding (see M03).

TI-M19 Installation

Installation Instructions to KaRo Mats with Tacks

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M19

1. General Remarks

When KaRo mats are fixed to suspended plas-terboard ceilings from above or from below, very often the fastening technique of tacking is used. Because of the possibility that capil-laries can get damaged, staples should only be used if gluing with adhesive tape (→TI-M17) or butyl tape (→TI-M13) cannot be util-ised. The installation follows according to the type of ceiling construction. For plaster ceilings (→TI-M03) the piping for the supply lines has been laid into the future cavity of the ceiling. For dry-build construction boards (→TI-M05) the connection to the supply lines is done with flexible hoses during the time of installa-tion. Attention! It must be looked after, that

before tacking, all capillar-ies, which might have slipped out of the spacers, will be clipped back work-manlike into the spacer buss.

2. Installation Steps

2.1 Plaster Ceiling

At the installation the collector pipes of the mats must be fixed properly. After connecting the mats to the water lines according the in-structions TI-M07 – Test instructions for KaRo heating- and cooling systems- pressure tests must be performed. Then the capillary tube mats will have to stand a idle pressure at 3 bar for the entire time of installation until start of operation. KaRo mats with long lengths are hang to the ceiling, already connected, rolled-up until the actual tacking is performed.

The covering of the ceiling with plasterboards and the following joint filling, smoothening and grinding is done according to the dry-build construction specifications. The KaRo mats are tacked to the plaster board ceiling. Whereby the staples will be positioned alter-nately to both sides to the flanges. The staples are placed first at the side of the collector pipes. The KaRo mat is rolled-off during the work progress. The staples are placed in such positions, that the side flanges of the spacers are bridged over. The driving-force for tucker must be set to such a degree, that the side flanges of the spacers will not deform or in exceptions will not deform more than 1 mm. (Side flanges and staples should be one height). The length of the sta-ples should be max. 15 mm.

Installation · TI-M19 Installation Instructions to KaRo Mats with Tacks

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M19

2.2 Dry-build construction board

The KaRo mat is positioned on the dry-build construction board (plasterboard or fibre plasterboard) by placing the spacers to their pre-determined positions. Then they are tacked to the boards. First both outer spacer busses are fastened. The spacer busses are especially shaped, so that staples can be set to determined areas. The cross-connections between the side flanges are laid lower and have direct contact to the plasterboards. The driving-force set for tacking must be such, that the flange in the spacer will only be deformed to a miner de-gree. The length of the staples should be not more than 12 mm. Max. 15 mm must be the length of the sta-ples when the side flanges of the spacers are used according to the point 2.1 (Plaster ceil-ing). . 3. Tools, Materials

Best results will be achieved with flat wire- or surface improved staples. These staples are available for all staple-guns. The lengths of the staples for stapling the side flange of the spacers should be max. 15 mm (see point 2.1. and 2.2). A max. staple length of 13 mm can be utilised, when the cross-pieces of the spacers are stapled.

The flat-wire staples are suitable for all types or plasterboards. If staples come to use where the shanks are tightly together (narrow-back staples of 4 mm) then the shanks work like a wide piece. At fibre plasterboards, the use of those staples can cause damages. The rigid- ness in these areas is damaged because of the local load. Often the fibre material is pressed through the fibre plasterboard and rests as a hump to the opposite side. Often the fibre material is separated from the fibre plaster-board. The stapler must be adjusted to such a force, that the staples will not, or in exceptions will deform the plastic material of the spacer by not more than 1 mm (side flange and staples will form one height).

plaster board

TI-M20 Installation

Installation Instructions to KaRo Mats as Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M20

1. General Remarks

The KaRo wall heating can be installed to nearly any load bearing wall surface. If the in-stallation is at an outer wall, then the u-value of the wall must be better than 0,35 W / (m2K). Occasionally a additional layer of insu-lation might be necessary. General remarks can be read in à TI-B10 – Questions before lay-out of KaRo wall heating. For wall heating the KaRo- heating- and cooling mats are mostly embedded directly into the plastering.

For the installation of wall heating special building materials are not required. Funda-mentally the wall construction can be any standard type wall. After fastening the KaRo heating- and cooling mats to the raw wall the mats can be plastered with all types of min-eral plaster. Coarse grained rubbing plaster is not permissible because of the danger that the capillaries could get damaged. Common plaster types and qualities would be: machine plaster type: MP75 GF. Basically the thickness of the plaster should be chosen only as thick as necessary. Normally a thickness of 12 to 15 mm is sufficient. The thickness of this layer has an effect to the reaction time of the KaRo wall heating (thin layer thickness = fast reac-tion time!). The pre-treatment of the ground-ing is done according to manufacturer’s guidelines.

Before starting the work a (layout) pattern for the arrangement of the mats must be pre-pared for a work base. In it all mats with their measurements, the direction of arrangement and the supply lines must be lined out. In the pattern all areas which will be kept empty, as for inner walls or for closets and permanently fixed furniture should not be covered, since there is no heating required at those areas. For the utilisation of KaRo mats for wall heat-ing the mats must be positioned and fixed to the raw wall in appropriate manner until plas-tering. Therefore the mats supplied with butyl adhe-sive tape already attached to it. After the pro-tective foil is peeled-off the mats are simply fixed to the raw ceiling by means of the ad-

hesive tapes. The mats can also be staple- fixed if dry-build construction boards are used as a wall base. 2. Arrangement of the Connecting

Lines and of the Collecting Pipes

The collecting pipes and the supply lines for the KaRo wall heating, plastering version, are placed into the base board or in a special wall groove. Remarks for this version are given in the technical information TI-B10.

It could be that building regulations are against the positioning of collector pipes in wall grooves, because of possibly changes in the building static. Normally groove depths of 15 to 20 mm are sufficient. The possible weakening of the wall must be clarified prior to the changes.

For renovation purposes the old layer of plas-ter, if still load bearing, can remain. In this case it is sufficient to mill grooves into the plaster for later accommodation of the collec-tor pipes.

If inner wall insulation is required or desired, then the insulation panels can get cut-outs for the reception of the collector pipes. The insulation panels are to be fixed to the raw wall according to manufacturer’s installation guidelines. For the accommodation of the main pipes the panels are simply fixed in spaces one to another.

Installation · TI-M20 Installation Instructions to KaRo Mats as Wall Heating

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M20

Figure 1 Arrangement of the collector pipes and piping according to “Tichelmann” by utilisation of insulation sheets for the formation of installation grooves. 3. Installation Steps

Take KaRo mat out of the package, roll-out onto a clean flat surface and burden the loop side with a flat. The mats can be stored up to 15 layers on top of another. Before further processing the mats should be stress relived for one day.

1. Preparation of the raw wall

smoothen unevenness.

Apply grounding (primer)

Lay down the arrangement of the mats on the wall and fix temporarily

Attach clamps for reception of supply lines and collector pipes

2. Connect the KaRo mats to the water line

and make pressure test.

Install the supply lines.

Connect the KaRo mats to the supply lines (→ TI-M02 – Instruction for thermal weld-ing of plastics ).

Do pressure test of the finished installed system (→ TI-M07 – Test instructions for KaRo- heating- and cooling systems)

Set an idle pressure of 3 bar and retain this pressure during the time of installa-tion until start of operation!

3. Fastening of the mats to the raw wall with:

- Butyl adhesive tape → TI-M13 - Stick-in dowels –Double dowel clamps from Fa. Hilti – Type: EDD 4-12 - fasten with staples made of non- corroding steel (valid for the fixing to plasterboards!) The staples a posi tioned over the strap of the spacer- strips. The staple applying force and the lengths of the staples should be chosen, that the mats are fastened se- curely , but the spacers will not tear. → TI-M19

Align the mats Tighten the capillary tubes 4. Apply plastering and smoothen (pay at-

tention to manufacturer’s instructions!)

Apply plaster - minimal thickness, nor-mally 10 to 15 mm are sufficient.

If capillaries are damaged repair by solder-ing the tube ends. If required exchange the total → TI-M01

TI-M21 Installation

Start of Operation of Basic Stations and Storey Distributers

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-M21

1. Delivery and Transport

The story distributors and basis stations are supplied lying on palettes. To prevent them from dirt, the goods are wrapped in shrinking foil. When the goods are received from the car-rier–company a check for possible transport damages must be made. If damages are obvious, they must be re-corded at the delivery papers and reported to the carrier company.

The storey distributors and the basis stations are always installed on a zinc coated frame. Questions to the dimensioning and arrange-ment are answered in TI-B14 (Technical re-quirements for basis stations and storey dis-tributors). During transport, all forces may only have an effect on the zinc-coated frame. For handling (loading and unloading) the pumps, pipes vents and valves may not be touched! After erecting and fastening of the storey dis-tributors and basis stations at their appointed position the connections are made to the primary and secondary circuits. The connec-tion of the electric lines can also be made. Each storey distributor and each basis station had been tested with a pressure of 10 bar and checked for leakage before the delivery. A further pressure test of 10 bar at the build-ing site is not permissible since the pressure control valve will respond to a lower pressure, this could cause the damage to the pressure gauge if possibly the pressure control valve is by-passed because of its early respond. For pressure testing with 10 bar the max- pressure valve must be closed at the drainage, the pressure gauge de-installed and the threaded connection must be closed, also the cap valve towards the equalisation tank must be closed.

After the pressure test the state of supply must be re-established. 2. Filling, Rinsing and Pressure relief

For filling and rinsing the KFE faucets of the storey distributor and the basis station are provided. Filling and rinsing of basis stations may only be done together with the connect-ing lines. For the storey distributor the work sequence should be in such a way, that at best each cooling circuit is filled and rinsed separately. Thereby one KFE-faucet is used for filling and at the other KFE-faucet a hose is connected which is leading to a sink. The filling is done with only low water pres-sure up until water is coming out of the sec-ond KFE-faucet. Then the rinsing process starts with maximum water pressure, so to rinse-out possible air and installation dirt which was trapped in the circuit. After some time the water is draining calmly without any air encapsulated. The filling and rinsing process is finished. After rinsing with cold water condensation can occur at the supply lines and at the capillary tube mats. Condensation can be avoided when luke-warm, clean water is used for rinsing or when a portable rinsing apparatus is being used. With the KFE faucet the system is brought to the appointed operating pressure. Please assure that the cap valve to the pres-sure expansion tank is open and the correct gas pre-tension has been set. Any air bubbles left will be let out of the sys-tem through the automatic bleeder valve. If there is not enough water pressure for the elimination of air bubbles, the rinsing can also be done by using the pump, which is in-stalled in the system. For this the pump must be set to its maximum capacity. After filling and the first rinsing with the ex-isting water pressure each separate cooling zone will be flowed through with water by di-rected opening of the zone valves. Any air bubbles left will be let out of the system through the automatic bleeder valve.

Installation · TI-M21 Start of Operation of Basic Stations and Storey Distributers

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-M21

Through the air leaving the system, the oper-ating pressure could sink, it must be cor-rected to it’s appointed pressure by refilling. An automated refilling can be arranged by means of an adequate refilling set-up. With-out such a set-up, the first control must take place in the first week after the system was taken into operation. After some monthly controls the checking can be done after every 6 months. 3. Setting the Volume Flows for

each Zone

For the setting of the volume flows at the sto-rey distributor for the separate zones, it should be started with the zone with the highest flow resistance. Here the volume flow-control and regulating valve is set to its maximum opening. Through lowering of the pressure at the overflow-valve or reduction of the revolution at the pressure-controlled pump, the aimed volume flow can be ad-justed. Thereafter the single zones can be set to the volume flow. This is done with the volume flow-control and regulating valve. Through the steady pressure of the overflow-valve or through matching the revolution of the pressure regulated pump, the adjustment of each single zone can be done without that one zone will interfere with another zone. TA-valves cannot be adjusted according to the described method with the control- and set-ting computer. For this the pump must be set to constant volume flow that the computer can read the adequate values of the valves. At this point, the necessary accuracy of the volume flows must be pointed out. The required volume flows for each zone are pre-given by the planning- or engineers of-fice. Measuring according DIN 4715 part 1 have shown, that with 50% of the volume flow 89% of the nominal capacity is achieved (→ TI-B14 Technical Requirements for Basis Stations and Storey Distributors). From this it can derived, that at a slightly lower volume flow there will be no remark-able capacity reductions with KaRo- heating and cooling ceilings 4. Electrical Connections

Storey distributors and basis stations can be supplied including electric wiring and control panel. The measuring- and controlling technique supplied by KaRo is operated by 24 V~ ( → TI-M08 Technical data of the converter M.K.1;TI-M09 Technical data on the room temperature control-unit M.TR 2/3). The

schematic is included in the storey distribu-tor- or basis stations. The regulating valves of the storey distribu-tors should be equipped with auxiliary con-tacts. The electrical circuit arrangement can then be laid-out for gentle treatment and en-ergy saving reasons, that with the switch-off of the last cooling circuit also the pump is switched-off.

Attention : After initiation the thermal actuating drive has an opening time of approx. 2,5 minutes. Only after this time the auxiliary contact and therewith the pump is actuated. After the shut-off of the thermal actuating drive a closing time of approx. 2,5 minutes must be accounted for .Only after this time, after the last zone is switched-off, the pump can be switched off-circuit

The thermal actuating drives supplied by KaRo have an auxiliary contact, they are op-erated with 24 V~, they have a peak starting current of 250 mA and power intake of 3 watt at operation. The auxiliary contact has a load capacity of 2 amps and 230 volt. 5. Filter

In case that filters are utilised, they must be cleaned after start of operation. The rinsing operation with installed filters are exclusively for the rinse-out of air-bubbles. 6. General

Pump manufacture’s instructions for the operation of the pump are given in the oper-ating manual. Pay attention to the sense of rotation of some pumps. Electrical work may only be performed through appropriate trade staff.

TI-M22 Installation

AquaStop Easy Alteration of the Installation

04/2002 Learning from Nature – www.KaRo.cc TI-M22

1. Flexibility

With CC-Couplings alterations in the watersystem of Cooling Ceilings can be done easy and quick without using a tool for adapting the ceiling to changes of the office partitioning. Like with all quick coupling systems the piping has to be made pressureless, to open the couplings without damages. This can be done zone by zone without interrupting the running of the Cooling Ceiling in other parts of the building using the AquaStop valve. 2. KaRo AquaStop

The water flow of each control zone can be turned off by ball valves in the supply and re-turn lines. At the end of the supply line an AquaStop valve for depressing the system and adapting a pressure test set is positioned →picture.

Metal Acoustic Ceiling 1 Flexible 2 Supply line 3 KaRo AquaStop 3. Installation Process: Rebuilding

1. Close the 2 ball valves of return and supply lines.

2. Open shortly the KaRo AquaStop and

close it again. Collect drops of water with a cloth or can. The water sys-tem is now pressure less.

3. The CC-couplings can be opened and

changed now without problem.

Tip: Keep open only one CC-coupling at a time. Close couplings or flexi-bles after opening a con-nection with a stopper and with a CC-sleeve respectively to avoid air drawn into the sys-tem.

KaRo AquaStop

4. Installation Process: Pressure Test

After every work at the water system all changed parts have to be pressure tested.

1. Close the two ball valves in the sup-

ply and return line.

2. Connect the test set W.M01 at the KaRo AquaStop and do the pressure test according to prescription → TI M07.

3. Close KaRo AquaStop after success-

ful pressure test and open the two ball valves again. The system is now ready to work again.

Mr. K. says: “KaRo mats are self bleeding.” Any air that may get into the wa-ter system while changing the connections will go with the wa-

ter flow and can be taken out at the central petcock. After every change at the system the water pressure has to be checked at the secondary station and water has to be refilled if neces-sary.

Charts and Forms · TI-T01 Lay-out Chart for KaRo Cooling Ceilings

Lay-out Chart for KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T01

Project :

Project consultant :

Date :

Room data 1 Room temperature °C 2 Surface area of the room m2 3 Room height m 4 Height factor =1,117 - 0,045 * Room height Cooling Loads

5 Internal total cooling load W (calculation from planning office)

6 External total cooling load W (calculation from planning office)

7 Total cooling load based on surface area W/m2 =(internal + external load) / surface area

8 Load factor = total load / (internal load + external load / 2)

Proportion of Ventilation 9 Intake air volume m3/h minimum 50m3/h per person

10 Intake air temperature °C 11 Exhaust air temperature °C 12 Cooling capacity of intake-air W/m2 = intake air volume flow * dT * 0,32 / surface area

13 Ventilation factor Source =1, convector=1,08; ceiling slot=1,13

Required Cooling Capacity 14 With mats coverable ceiling area m2 -> compare with calculated value from line 30

15 Proportion of ceiling coverage = coverable ceiling area / basic area

16 Required cooling capacity for ceiling W/m2 = total cooling load – cooling capacity of air intake

17 Special: cooling capacity for ceiling W/m2 = req. cooling capacity. / factor of ceiling coverage-> target value

18 Factor of coverage =1,21 - 0,3 * degree of ceiling coverage

Calculation of Capacity 19 Supply temperature °C 20 Return temperature °C 21 Average temperature °C = (supply temperature + return temperature) / 2

22 Effective under-temperature °C =room temperature – average water temperature

23 Room constant factor =Height factor * load factor * ventilation factor * coverage factor

24 Standard cooling capacity W/m2 -> read from diagram 25 Real cooling capacity per m² in W: W/m2 =Standard capacity* room constant factor <-

compare target value Water Volume

26 Cooling water spread K = supply temperature – return temperature

27 Qty. of mats per zone Qty. 28 Length of mat M 29 Width of mat M 30 Surface area covered with mats m2 = length * width * Qty. of mats

31 Mass flow water ltr./m2 h = (special cooling capacity * 3600) / (spread * 4180)

Water volume should be minimum 17 ltr. / m2 h

32 Temperature above ceiling °C Normally it is equal to the room temperature above

33 Thermal conductance factor to top W/m2 K 34 Capacity to top W/m2 = Thermal conductance to top * (Temp. top- aver. Water

temp.) 35 Corrected mass flow water ltr./m2 h = (spec .cooling capacity + capacity to top) *3600 / spread *

4180 36 Water volume per zone ltr/min = corrected mass flow / 60 * covered surface area

ltr/h = corrected mass flow * covered surface area

Charts and Forms · TI-T02 Lay-out Chart for KaRo Heating Ceilings

Lay-out Chart for KaRo Heating Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T02

Project :

Project consultant :

Date :

Room Data

1 Room temperature °C

2 Surface area of the room m2

3 Room height m

Heat Requirement

4 Transmission heat requirement W (calculation from planning office)

5 Effective joint-ventilation heat requirement W (calculation from planning office (open ventilation)

6 Total Heat Requirement W = Transmission + joint-ventilation heat requirement

Proportion of Ventilation

7 Intake air volume m3/h Account for a minimum of 50m3/h per person

8 Intake air temperature °C

9 Exhaust air temperature °C

10 Heat/cool capacity of air intake W = intake air volume flow · dT · 0,32

Required Heating Capacity

11 Required heat capacity for ceiling W = total heat requirement. – heat capacity of air intake + cooling capacity of air intake

12 With mats coverable ceiling surface area m2 ->compare with calculated value of line 24

13 Estimated value: required heating capac. :ceiling W/m2 =req heat capac/possible ceiling coverage-> target value

14 Permissible heating capacity W/m2 -> from diagram. Must be greater than value from line 13

Calculation of Capacity

15 Supply temperature °C

16 Return temperature °C

17 Average temperature °C = (Supply temperature + return temperature) / 2

18 Effective temperature °C = room temperature – average water temperature

19 Standard heating capacity W/m2 -> from diagram -> compare with target value from line 13

20 Qty. of mats per zone Qty.

21 Length of mat m

22 Width of mat m

23 With mats covered surface area m2 =Length * width * Qty. of mats

24 Real heating capacity of ceiling W = Standard heat capacity * covered ceiling surface

-> compare with req heat capacity from line 13

Water Volume

25 Heating water spread K = Supply temp - return temp.

26 Mass flow of water ltr./m2 h =(required heat capacity * 3600) / (spread * 4180)

Water volume should be minimum of 17 ltr. / m2 h

27 Temperature above ceiling °C Temperature in the ceiling cavity

28 Thermal conductance factor to top W/m2 K

29 Capacity to top W/m2 =Therm conduct fact top * (Temp.top – average water temp)

30 Corrected mass flow water ltr./m2 h =((req heat capac + capac top) *3600 / spread * 4180)

31 Water volume per zone ltr./min = corrected mass flow / 60 * covered ceiling surface

ltr./h = corrected mass flow * covered ceiling surface

Charts and Forms · TI-T03 Estimate calculation of the sensible (dry) cooling

Estimate calculation of the sensible (dry) cooling load

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T03

Important Remark: The calculation is based on a temperature difference betweenroom- and outs ide temperature of 6 to 8°C

Room:Person responsible:

Room measurementsLength: Width: Height: Area: Volume:

1. Solar radiation windows (windows measurements include frame)

Windows Width Height Qty Area Double glazed window[m] [m] [m²] without with with

Direction blinds inner blinds outer blindsS outh x x = x 205 x 175 x 60 = WS outh-West x x = x 245 x 205 x 75 = WS outh-E ast x x = x 250 x 205 x 75 = WNorth x x = x 60 x 50 x 20 = WNorth-West x x = x 165 x 145 x 50 = WNorth-E ast x x = x 155 x 140 x 50 = WWest x x = x 255 x 215 x 75 = WE ast x x = x 250 x 210 x 75 = W

(use only maximum values; disregard other values ! )

2. Transmission-heat windows (All windows and outer doors )

Aream²+ m²+ m² = m² x 20 = W

3. Transmission-heat walls (minus window surface)

AreaNord- and internal walls m²+ m²+ m²= m² x 8 = WAll other walls m²+ m²+ m²= m² x 10 = W

4. Ceiling or Roof

Ceiling to non temperature conditioned rooms = m² x 10 = WCeiling below roof, non-insulated = m² x 17 = WCeiling with 50mm thermal insulation = m² x 10 = WF lat roof, non insulated = m² x 35 = WF lat roof, with 50 thermal insulation = m² x 12 = W

5. Floor above non-temperature conditioned(not applicated if un-heated cellar) = m² x 5 = W

6. Open walkthroughWidth Height Qty Area

x x = m² x 100 = W7. Qty of persons in room

P hys ical workQty light average heavy

x 70 x 85 x 95 = W

8. Light(connected load) Qty connected load

x W x 1 = W

9. Electrical Applications(connected load; observe s imilarity) Type Qty connected load

x x W x 1 = W

10. Other heat source(material put-though) Description

= W

External cooling load Field 1 to 6 = WInternal cooling load Field 7 to 10 = W

Sensible total cooling load = WW

Charts and Forms · TI-T04 Identification Data for Standard Capacities of KaRo Cooling Ceilings

Identification Data for Standard Capacities of KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T04

Type Installation Variation C n 1 Metal ceiling sheet with acoustic fleece,

Sheet metal 0,6 mm thick, mat type K.U15 glued; With mineral wool 35 mm thick and 12,5 mm plasterboard covered

6,259 1,105

2 Metal ceiling sheet, sheet metal 0,6 mm thick, Mat type K.U10 glued-in, with acoustic fleece and mineral wool 35 mm thick and covered with 12,5 mm plaster board

6,693 1,096

3 Construction sheet “Fermacell” 10 mm thick, mat type K.G10 glued-on with thermal conductive paste V.WLP.1

6,194 1,096

4 Plaster board 12,5 mm thick, mat type K.G10 glued-on with thermal conductive paste V.WLP.1

5,850 1,095

5 Plastered ceiling, mat type K.S15 plaster embedded, Plaster thickness = ca. 9 mm, machine type plaster MP7

6,210 1,112

6 Perforated plaster board 9,5 mm thick, perforated ∅ 8mm Mat type K.U10 glued-on with V.K.1, With mineral wool 20 mm thick covered, acoustic fleece and water based paint apply from the bottom side

4,329 1,117

7 Double panelled plaster board ceiling, Mat type K.S15 laid between the panelling

5,080 1,070

8 Double panelled plaster board ceiling, Mat type K.S15 laid between the panelling and covered with reflective thermal insulation

5,140 1,080

9 STO acoustic plaster 12 mm thick, mat type K.S15 plaster embedded, covered with approx. 6 mm thick acoustic plaster

3,390 1,150

10 KaRo Dry-build construction unit type B.GK12 5,210 1,100

11 Metal ceiling sheet with acoustic fleece, Sheet metal 0,6 mm thick, mat type KU10 glued-in

5,350 1,160

12 Suspended metal ceiling sail, mat type K.U10 glued-on without insulation

6,520 1,147

Charts and Forms · TI-T05 Final Pressure Test Report for KaRo Heating and Cooling systems

Final Pressure Test Report for KaRo Heating and Cooling systems

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T05

Construction project: Project No.:

Section* Pressure Date Time Remarks Signature

Begin End

Begin End

Begin End

Begin End

Begin End

Begin End

Begin End

Begin End

Begin End

Begin End

*) Room- or mains identification

Additional remarks:

Hereby I confirm, that a pressure test for the above mentioned sections has been successfully performed ac-cording to the KaRo installation instruction M07. The system was filled with water, air bladed and with a testing pump set to 10 bar . The pressure loss caused by elastic expansion has been compensated for. The water pressure of 10 bar was maintained for 4 hours. Thereafter the system was lowered to an idle pressure of 3 bar.

Name of person testing Date Signature

Charts and Forms · TI-T06 Combustion Heat

Combustion Heat

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T06

1. Combustion Heat of PP-Random-Copolymer

Source: Statement of the company Borealis H = 42,23 MJ/kg = 42,23 * 106 Ws/kg = 11,73 kWh/kg 2. Combustion Heat of PP – Pipe PN10

Outer Diameter Nominal

size Wall thickness Combustion Heat

da DN s H

[mm] [mm] [kWh/m]

16,0 12 1,6 0,76

20,0 15 1,8 1,09

25,0 20 2,3 1,73

32,0 25 3,0 2,89

40,0 32 3,7 4,45

50,0 40 4,6 6,93

63,0 50 5,8 11,00

75,0 63 6,9 15,59

90,0 75 8,2 22,25

110,0 90 10,0 33,17

125,0 100 11,4 42,95

140,0 110 12,8 54,00

3. Combustion Heat of BeKa Heating- and Cooling Mats

(without mains)

KaRo mat type

Combustion Heat H

[kWh/m2]

K.S15

3,21

K.S10 · K.U10 · K.G10

4,99

Charts and Forms · TI-T07 Lay-out for KaRo Floor Heating System

Lay-out for KaRo Floor Heating System

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T07

Project :

Project consultant :

Date :

Room data

1 Room temperature °C

2 Width of room m

3 Length of room m

4 Surface area of room m2

5 Heat requirement for room W from calulation of planning office

Required heat capacity

6 Planed coverage m2Estimate value -> compare with calculated value of line 18

7 Required specific heat capacity W/m2= heat requirement/ planned coverage

Perfomance calculation

8 Heat resistance of the floor covering m2K/W from external calculation or estimate value

9 Effective excess temp. heating water °C -> with values from line 7 and 8 from diagram 21

10 Standard-heating capacity W/m2-> from diagram 21

11 Spread K customary are values between 6 to 12 K

12 Supply temperature °C = Room temperature + excess temperature +Spread / 2

13 Return temperature °C = Supply temperature - Spread

14 Average water temperature °C =(Supply temperature - return temperature) / 2

Selection of BEKA mats

15 Quantity of mats per zone Qty

16 Length of mat m

17 Width of mat m

18 With mats covered area m2=Length * width * Qty of mats

19 Real heating capacity of the floor W =Standard heat capacity * covered floor area

-> compare with required heat capacity from line 5;

possibly the average water temperature must be raised

Water volume

20 Heating water spread K = Supply temperature - return temperature

21 Mass flow water ltr./m2 h =(required heat capacity * 3600 / spread * 4180)

22 Temperature below the floor °C Temperature below the floor

23 Thermal conductance factor to bottom W/m2 K from external calculation

24 Capacity to the bottom W/m2= Thermal conductive fact to bottom*(aver water temp - temp bott)

25 Corrected mass flow of water ltr./m2 h =(required heat capac+ capac to bottom*3600 /Spread*4180)

26 Water volume per zone ltr./min =corrected mass flow/60*covered floor area

ltr./h =corrected mass flow * covered floor area

Charts and Forms · TI-T08 Lay-out for KaRo Wall Heating System

Lay-out for KaRo Wall Heating System

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T08

Project :

Project consultant :

Date :

Room Data

1 Room temperature °C

2 Length of wall m

3 Height of wall m

4 Heat requirement of room W from calculation of the planning offices

Required Heat Capacity

5 Planned coverage of wall m² Estimate value -> compare with calc value from line 18

6 Required specific heat capacity W/m² =Heat requirement / planned coverage

Performance Calculation

7 Plaster quality

8 Thermal conductive factor W/mK

9 Plaster thickness above the mat mm

10 Resistance characteristic value -> from chart/diagram 29

11 Effective excess temperature: heating water °C -> with values from line 6 and 10 from diagram 29

12 Standard heating capacity W/m² -> from diagram 29

13 Spread K customary are values between 6 to 12 K

14 Supply temperature °C = Room temperature + excess temperature+Spread / 2

15 Return temperature °C = Supply temperature -Spread

16 average water temperature °C =(Supply temp - return temp) / 2

Selection of the BEKA Mats

17 Qty of mats per zone / wall Qty

18 Length of mat m

19 Width of mat m

20 With mats covered wall area m² =Lenth * width * Qty of mats

21 Real heating capacity of wall W =Standard heating capacity * covered wall area

-> compare with required heat capac from line 6;

possibly the average water temp must be raised

Water volume

22 Heating water spread K =Supply temperature - return temperature

23 Mass flow of water l/m² h = required heating capac * 3600 / spread * 4180

24 Water volume per zone/wall l/min =Mass flow / 60 * covered wall area

l/h =Massflow*covered wall area

Charts and Forms · TI-T09 Quick Lay-out for Wall Heating with KaRo Prefabricated Panels

Quick Lay-out for Wall Heating with KaRo Prefabricated Panels

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T09

Project: Date :

Project consultant : Lay-out valid for 22°C room temperature and 6K heating water spread !

Required Heating Capacity

1 Heat requirement for room W from calculation of planning offices

2 Planned qty of units Qty max.possible arrangement derived from room measurements

3 Required heating capacity per unit W = heat requirement / qty of units

Capacity Determination

4 Supply temperature -> from diagram °C Water volume per unit kg/h -> from diagram

5 Return temperature °C Water volume per zone or wall l/h

Pressure loss determination

6 Pressure loss in pipe Pa length of connection pipe m only one line path

= pipe length * resistance resistance in the pipe - from diagram Pa/m value - from diagram

7 Pressure loss of the unit Pa

-> with value of line 3 from diagram

8 Addition for pressure loss by fittings Pa

(recomm. 30% additions to pipe)

9 Additions for heat transfer station Pa

(recomm:for zone valves 500 to 1000 Pa

for mains regulating valves 700 to 1500 Pa for heat exchanger appox. 4000 Pa

10 Total Pressure Los Pa

When using the BEKA transfer stations the pressure

loss deterination can be ommitted. Only the quantity

of the heating circuits and the total capacity

is required for the selection.

Quick lay-out for wall heating with B.GK12

0

20

40

60

80

100

120

140

160

180

27 29 31 33 35 37 39 41 43 45

Supply temperature [°C]

Hea

tin

g c

apac

ity

[W/u

nit

]

2 4 6 8 10 12 15 17 20 22

Mass flow of the heating water per unit [kg/h]

100 200 300 400 550 700 850 1000 1150 1300

Pressure loss of the unit [Pa] valid for room temperature of 22°C and heating water spread of 6K and 300 mm connection hose

Pressure Loss in a pipe 20x2mm

0

10

20

30

40

50

60

70

80

90

100

20 40 60 80 100 120 140 160 180 200

Mass flow [kg/h]

pres

sure

loss

[Pa/

m]

Charts and Forms · TI-T10 Quick Lay-out for KaRo Cooling Ceilings with KaRo prefabricated ceiling panels

Quick Lay-out for KaRo Cooling Ceilings with KaRo prefabricated ceiling panels

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-T10

Project : Date:

Project consultant : Lay-out valid for 27°C room temperature and 2K cooling water spread !

Required cooling load Required cooling load

1 Cooling load for the room W from calculations of planning office

2 Planned quantity units Qty max. possible arrangement derived from room dimensions

3 Required cooling capacity per unit W = cooling load / Quantity of units

Performance determinationPerformance determination

4 Supply temperature -> from diagram °C Water volume per unit kg/h -> from diagram

5 Return temperature °C Water volume per zone or wall ltr./h

Pressure Loss DeterminationPressure Loss Determination

6 Pressure loss in pipe Pa Length of connection pipe m only one line path

= pipe length * resistance resistance in the pipe -> from diagram Pa/m value -> from diagram

7 Pressure loss of the unit Pa

-> with value of line 3 from diagram

8 Addition for pressure loss through fittings Pa

(recomm: 30% addition to pipe )

9 Additions for heat transfer stations Pa

(recomm for zone valves 500-1000 Pa

for mains regulating valves 700 - 1500 Pa

for heat exchanger approx. 4000 Pa

10 Total Pressure Loss Pa

By using the BEKA transfer stations the pressure

loss determinaion can be ommited.Only the quantity

of the cooling circuits and the total cooling capacity

is required for the selection !

Quick Lay-out for Ceiling Cooling with B.GK12

0

10

20

30

40

50

60

70

80

90

100

110

120

24 23 22 21 20 19 18 17 16 15 14 13 12Supply temperature [°C]

Co

olin

g c

apac

ity

[W/u

nit

]

6 9 12 16 19 23 26 30 34 37 41 45 49Mass flow of the cooling water per unit [kg/h]

300 500 700 900 1100 1300 1500 1700 1900 2100 2300 2550 2800

Pressure loss of unit (Pa] valid for room temperature 27°C and cooling water spread 2K andconnection hose 300mm length

Pressure loss in the pipe 20x2mm

0

10

20

30

40

50

60

70

80

90

100

40 80 120 160 200 240 280 320 360 400

Mass flow [kg/h]

Pre

ssu

re lo

ss [

Pa/

m]

TI-D01 Diagrams

Cooling Capacity for various Types of KaRo Cooling Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D01

Example: Metalcassette Ceilingwith glued-in acoustic fabric lining andK.U10-mat, covered with a 20mm thickacoustic insert out of mineral wool.Temperature dirfference (roomtemp. -average watertemp.) DT=9,5; -> Coolingcapacity = 78 W/m²

0

20

40

60

80

100

120

140

4 5 6 7 8 9 10 11 12 13 14

Temperature difference DT = TR-Twm [K]

Coo

ling

Cap

acit

y (W

/m²)

Metalcassette Ceiling with glued-in acousticfabriclining and K.U10-matFermacellboard with glued-on K.GG10-mat

P lasterboard with glued-on K.GG10-mat

Prefabricated ceiling panel B.GK12

TI-D02 Diagrams

Cooling Capacity of KaRo Plaster Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D02

Type of plaster

Thermal conductivity for plaster

Plaster thick-ness above

mats

Characteris-tic

Line in W/m K in mm Gypsum plaster 0,45 5 R21

Gypsum plaster 0,45 10 R32

Gypsum plaster 0,45 15 R41

Gypsum plaster 0,45 20 R70

Gypsum plaster 0,35 5 R24

Gypsum plaster 0,35 10 R38

Gypsum plaster 0,35 15 R52

Gypsum plaster 0,35 20 R90

Lime plaster 0,87 5 R12

Lime Plaster 0,87 10 R18

Lime plaster 0,87 15 R23

Lime plaster 0,87 20 R38

Concrete plaster 1,50 5 R10

Concrete p. 1,50 10 R13

Concrete p. 1,50 15 R15

Concrete p. 1,50 20 R24

Acoustic p. 0,12 2 R39

Acoustic p. 0,12 4 R55 Acoustic p. 0,12 6 R72

Example: Plaster ceiling with embedded capillary tube mat; Gypsum plaster 10 mm thick over capillary tube (R32); Temperature difference (room temperature – aver-age water temperature) DT=9,5 K; results to a cooling capacity of 78 W/m².

0

20

40

60

80

100

120

140

160

4 5 6 7 8 9 10 11 12 13 14

Temperature difference DT=TR-Twm (K)

Coo

ling

capa

city

(W

/m²)

R10

R30

R50R70

R90

TI-D03 Diagram

Heating Capacity for various Types of KaRo Ceilings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D03

0

20

40

60

80

100

120

4 5 6 7 8 9 10 11 12 13 14

Temperature difference DT=Twm-TR (K)

Hea

ting

Cap

acit

y (W

/m²)

Metalcassette Ceiling with glued-inacoustic fabric lining and K.U10-mat

Fermacell board with glued-onK.GG10-mat

Plaster board with glued-on K.GG10-mat

Prefabricated Ceiling Panel B.GK12

Example: Fermacell board, 10 mm thickwith glued-on K.GG.10-mat; Temperature difference (average water temperature - room temperature ) = 9,7 K; results to a heating capacity of 61 W/m²

TI-D04 Diagrams

Heating Capacity of KaRo Plaster Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D04

Type of plaster Thermal conduc-tivity factor

Plaster ceil-ing

Character-istic

for plaster above mat curve in W/m K in mm Gypsum 0,45 5 R21 Gypsum 0,45 10 R32 Gypsum 0,45 15 R41 Gypsum 0,45 20 R70 Gypsum 0,35 5 R24 Gypsum 0,35 10 R38 Gypsum 0,35 15 R52 Gypsum 0,35 20 R90 Lime 0,87 5 R12 Lime 0,87 10 R18 Lime 0,87 15 R23 Lime 0,87 20 R38 Lime 1,50 5 R10 Concrete 1,50 10 R13 Concrete 1,50 15 R15 Concrete 1,50 20 R24 Acoustic 0,12 2 R39 Acoustic 0,12 4 R55 Acoustic 0,12 6 R72

Example: Plaster ceiling with embedded capillary tube mat; Gypsum plaster 15 mm thick over capillary tubes (R41); Temperature difference (average water -temperature – room temperature) DT=9,3 K; results to a heating capacity of 63 W/m².

0

20

40

60

80

100

120

4 5 6 7 8 9 10 11 12 13 14

Temperature difference DT=Twm-TR (K)

Hea

ting

Cap

acit

y (

W/m

²)

R 10

R 30 R 50

R 70 R 90

TI-D05 Diagrams

Permissible Heating Capacity

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D05

Example: In a 3,0 m high and 5,5 m wide room the permissible heating capacity is maximum 57 W/m²

0

20

40

60

80

100

120

140

160

2 3 4 5 6 7 8 9 10

Room width (m)

Max

imum

per

mis

sibl

e he

atin

g ca

paci

ty (

W/m

²)

H = 3,00 m

H = 2,75 m

H = 2,50 m

Room height

According A.Kollmar: Heat physiological calcuations of heating ceilings, radiation sheets and infra red rays . Ges.-Ing. 1960, S.65 bis 84

TI-D06 Diagrams

Permissible Heating Capacity in Dependence of the covered Ceiling sector

04/2002 Learning from Nature – www.KaRo.cc n P.1 TI-D06

Example: In a 2,75 m high room with the width of the covered ceiling strips of 3,3 m the permissible heating capacity may be maximum 210 W/m²

5 0

1 0 0

1 5 0

2 0 0

2 5 0

3 0 0

3 5 0

1 ,0 0 1 ,2 0 1 ,4 0 1 ,6 0 1 ,8 0 2 ,0 0 2 ,2 0 2 ,4 0 2 ,6 0 2 ,8 0 3 ,0 0 3 ,2 0 3 ,4 0 3 ,6 0 3 ,8 0 4 ,0 0

W id t h o f t h e c o v e r e d c e i l in g s t r i p (m )

Max

. per

mis

sibl

e he

atin

g ca

paci

ty p

er m

fac

ade

leng

th (

W/m

)

H = 3 ,0 0 m

H = 2 ,7 5 m

H = 2 ,5 0 m

R o o m h e ig h t

TI-D07 Diagrams

Pressure Loss of the KaRo Mat K.U10 (Length from 1,0m to 8,0m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D07

Example: Mass flow water = 23 kg/m²h; length of mat = 5 m; results to a pressure loss of = 9500 Pa

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa)

8 m 7 m 6 m 5 m

4 m

3 m

2 m

1 m

TI-D08 Diagrams

Pressure Loss of KaRo Mat K.U10 (Length from 1,0 to 2,6m)

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D08

Example: Mass flow water = 23 kg/m²h; length of mat = 1,6 m; results to a pressure loss of = 950 Pa

0

200

400

600

800

1000

1200

1400

1600

1800

2000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

2,6 m 2,4 m 2,2 m 2,0 m 1,8 m1,6 m

1,4 m

1,2 m

1,0 m

TI-D09 Diagrams

Pressure Loss of the KaRo Mat K.G10 (Length from 1,0m to 8,0m )

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D09

Example : Mass flow water = 27 kg/m²h; length of mat = 5 m; results to a pressure loss of = 2900 Pa

0

500

1000

1500

2000

2500

3000

3500

4000

4500

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

8 m 7 m 6 m 5 m

4 m

3 m

2 m

1 m

TI-D10 Diagrams

Pressure Loss of the KaRo Mat K.G10 (Length from 1,0m to 2,6m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D10

Example: Mass flow water = 22 kg/m²h; Length of mat = 1,4 m; results to a pressure loss of = 180 Pa

0

50

100

150

200

250

300

350

400

450

500

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

1,0 m

1,2 m

1,4 m

1,6 m1,8 m2,0 2,2 m2,4 m2,6 m

TI-D11 Diagrams

Pressure Loss of the KaRo Mat K.S10 (Length from 1,0 to 8,0m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D11

Example: Mass flow water = 23 kg/m²h; Length of mat = 5 m; results to a pressure loss of = 9500 Pa

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

7 m

4 m

3 m

2 m

1 m

6 m5 m

8 m

TI-D12 Diagrams

Pressure Loss of the KaRo Mat K.S10 (Length from 1,0m to 2,6m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D12

Example: Mass flow water = 23 kg/ m²h; Length of mat = 1,4 m; result to a pressure loss of = 750 Pa

0

200

400

600

800

1000

1200

1400

1600

1800

2000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

2,6 m 2,4 m 2,2 m 2,0 1,8 m

1,6 m

1,4 m

1,2 m

1,0 m

TI-D13 Diagrams

Pressure Loss of KaRo Mat K.S15 (Length from 1,0 m to 8,0 m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D13

Example: Mass flow water = 23 kg/m²h; Length of mat = 5 m; result to a pressure loss of = 14000 Pa

0

5000

10000

15000

20000

25000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

8 m 7 m 6 m 5 m

4 m

3 m

2 m

1 m

TI-D14 Diagrams

Pressure Loss of the KaRo Mat K.S15 (Length from 1,0 m to 2,6 m)

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D14

Example: Mass flow water = 23 kg/m²h; Length of mat = 1,4 m; results to a pressure loss of = 1150 Pa

0

500

1000

1500

2000

2500

3000

10 15 20 25 30 35 40

Mass flow (kg/m²h)

Pres

sure

loss

(Pa

)

2,6 m 2,4 m 2,2 m 2,0 m 1,8 m

1,6 m

1,4 m

1,2 m

1,0 m

TI-D15 Diagrams

Pressure Loss in the Connecting Hose

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D15

Example: Mass flow water = 85 kg/h results to a pressure loss of = 615 Pa in a 800 mm long connecting hose

0

150

300

450

600

750

900

1050

1200

1350

1500

1650

10 20 30 40 50 60 70 80 90 100 110 120

Mass flow (kg/h)

Pres

sure

loss

(Pa)

A.S .1200.10

A.S .800.10

A.S .500.10

A.S .300.10

TI-D16 Diagrams

Pressure Loss in the Pipe (20x2mm)

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D16

Example: Through a pipe of 6 m length 350 kg/h should be flowing through. The pressure loss per 1 m is 250 Pa. This results to a total pressure loss in the pipe of: 6 m x 250 Pa/m = 1500 Pa

0

25

5075

100125

150

175200

225250

275

300325

350375400

425450

475

500

40 80 120 160 200 240 280 320 360 400 460 520

Total mass flow (kg/h)

Pres

sure

loss

(Pa

/m)

TI-D17 Diagrams

Pressure Loss in the Elbow Outgoing

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D17

Example: Mass flow water = 83 kg/h ; in both elbows outgoing there will be a pressure loss of 230 Pa

0

50

100

150

200

250

300

350

400

450

500

10 20 30 40 50 60 70 80 90 100 110 120

Mass flow (kg/h)

Pres

sure

loss

(Pa

)

1 outle t

intake + outlet

TI-D18 Diagrams

Flow Speed in Pipes

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D18

Example: 85 l/min are flowing through a pipe DN 40 with a flow speed of approx. 1,08 m/s

0

0,2

0,4

0,6

0,8

1

1,2

1,4

8 12 16 20 24 28 32 36 40

Mass flow (l/min)

Flow

spe

ed (

m/s

)

DN 15

DN 20

DN 25

0

0,2

0,4

0,6

0,8

1

1,2

1,4

40 50 60 70 80 90 100 110 120 130

Mass flow (l/min)

Flow

spe

ed (

m/s

)

DN 32 DN 40

DN 50

Diagrams · TI-D18 Flow Speed in Pipes

04/2002 Learning from Nature – www.KaRo.cc P.2 TI-D18

0

0,2

0,4

0,6

0,8

1

1,2

1,4

100 150 200 250 300 350 400 450

Mass flow [l/min]

Flow

Spe

ed [

m/s

]

DN 63 DN 75 DN

TI-D19 Diagrams

Heat Transfer Ceiling / Room

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D19

Source: Praxis hand book Haustechnik ATGA, Wien, 1995

7

8

9

10

11

12

20 30 40 50 60 70 80 90 100

Cooling Capacity (W/m²)

Ther

mal

tra

nsm

issi

on c

oeff

icie

nt (

W/m

²K)

TI-D20 Diagrams

Average Surface Temperature at the Ceiling Underside

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D20

12

13

14

15

16

17

18

19

20

21

22

23

15 16 17 18 19 20

Average water temperature (°C)

Ave

rage

cei

ling

tem

pera

ture

(°C

)

Plaster ceiling

Gypsum board ceiling

Construction sheetFemacell

Metal cassette ceiling

Average ceiling temperature at the bottom surface in °C at a basis- room temperature of 26°C

TI-D21 Diagrams

Heating Capacity of KaRo Floor Heating

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D21

Example: KaRo floor heating covered by tiles; temp difference (average water temp – room temp) DT = 8 K; results to a heating capacity of 78 W/m²

10

30

50

70

90

110

130

150

170

190

210

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Temperature difference DT=Twm-TR (K)

Hea

ting

cap

acit

y (W

/m²)

T iles R = 0,02 m² K /W

Carpet R = 0,10 m² K /W

P arquetR = 0,15 m² K /W

TI-D22 Diagrams

Pressure Loss of the KaRo Dry-built Unit B.GK12

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D22

Example: Mass flow water = 24 l / unit height; results to a pressure loss of = 1300 Pa

0

500

1000

1500

2000

2500

3000

12 18 24 30 36 42 48

Mass flow (ltr./ unit height)

Pres

sure

loss

(Pa

)

Pressure loss in the connecting hose

020406080

100120140160180

10 15 20 25 30 35 40Mass flow (l/h)

Pres

sure

loss

(Pa)

.1200.10

A.S.1200.10 A.S.800.10 A.S.500.10 A.S.300.10

TI-D23 Diagrams

Frequency of the Dew Point

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D23

Above the permissible Value with 12 Operating hours

Example : Outside temperature for Berlin 16° C , Frequency of Dew Point = 2,1%

0

1

2

3

4

5

6

7

15 16 17 18 19 20 21 22 23

Dew point of the outside air (°C)

Sum

fre

quen

cy (

%) F rankfurt am Main

S tuttgart

Berlin

TI-D24 Diagrams

Average Heat Transfer Coefficient of Buildings

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D24

A = total enclosed area in m² V = total building volume in m³

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

1,8

2,0

0,2 0,4 0,6 0,8 1,0 1,2Ratio A/V

Ther

mal

tra

nsm

itta

nce

co-e

ffic

ient

(W

/m²K

)

Old buildings

Buildings up to 1976Enhanced thermal insulation

very high thermal insulation

TI-D25 Diagrams

Basic Characteristic Curve: Cooling Capacity of an ideal Radiation Cooling Ceiling

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D25

TR = room temperature TD = average ceiling temperature at the underside

0

20

40

60

80

100

120

140

160

0 1 2 3 4 5 6 7 8 9 10 11 12

Temperature difference DT= TR-TD (K)

Coo

ling

capa

city

(W

/m2)

TI-D26 Diagrams

Heat Volume - Water Volume

04/2002 Learning from Nature – www.KaRo.cc oN P.1 TI-D26

Example: For a required heat volume of 305 Watt there are 130 kg/h water necessary with a spread of 2 K .

0100200300400500600700800900

1000110012001300140015001600170018001900200021002200

40 80 120 160 200 240 280 320 360 400 440 480 520 560 600

Water volume [kg/h]

Hea

t vo

lum

e [W

] 3 K s pread

2 K s pread

04080

120160200

10 20 30 40 50

Water volume [kg/h]

Hea

t vo

lum

e [W

]

3 K spread

2 K spread

TI-D27 Diagrams

Cooling Capacity for Wall Cooling with KaRo Dry-build Units

04/2002 Learning from Nature – www.KaRo.cc n P.1 TI-D27

Example: The KaRo dry-build construction unit B.GK.12, at a temp. difference (room temp. – average water temp.) DT = 10 K, achieves a cooling capacity of 69 W.

0

20

40

60

80

100

120

4 5 6 7 8 9 10 11 12 13 14

Temperature difference DT = TR - Twm (K)

Coo

ling

capa

city

(W

/ El

emen

t)

TI-D28 Diagrams

Heating Capacity of Wall Heating with KaRo Dry-build Units

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D28

Example: The dry-build unit B.GK.12, at a temperature difference (average water temp.- room temp.) DT = 9 K, will reach a heating capacity of 62 W.

0

15

30

45

60

75

90

105

120

135

150

165

2 4 6 8 10 12 14 16 18 20

Temperature differnce DT= TR - Twm (K)

Hea

ting

cap

acit

y (W

/ U

nit)

TI-D29 Diagrams

Heating Capacity of the KaRo Wall Heating

04/2002 Learning from Nature – www.KaRo.cc iOn P.1 TI-D29

Type of Plaster

Thermal con-ductivity

factor

Plaster thickness

Charac-teristic

for plaster over mats curve in W/m K in mm Gypsum 0,45 10 R32 Gypsum 0,45 15 R41 Gypsum 0,45 20 R70 Gypsum 0,35 10 R38 Gypsum 0,35 15 R52 Gypsum 0,35 20 R90 Lime 0,87 10 R18 Lime 0,87 15 R23 Lime 0,87 20 R38 Concrete 1,50 10 R13 Concrete 1,50 15 R15 concrete 1,50 20 R24

Example: Wall heating with embedded capillary tube mat; gypsum plaster, 15 mm thick, over the capillaries (R41); Temperature difference (average water temp – room temp) DT=9,3 K; results to a heating capacity of 63 W/m².

0

20

40

60

80

100

120

140

160

180

4 6 8 10 12 14 16 18 20

Temperature difference DT=Twm-TR (K)

Hea

ting

cap

acit

y (

W/m

²)

R 10R 30

R 50 R 70 R 90

TI-D30 Diagrams

Pressure Loss of Series Connections at KaRo-Mats 600x600mm

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-D30

Example: For KaRo mats K.G10.0600.0600.20 in one row, a mass flow of 35 kg/(m²h) will result to a pressure loss of 6,13 Pa.

0

1

2

3

4

5

6

7

8

9

10 20 30 40Mass flow (kg/(m²h))

Pres

sure

loss

(kP

a)

1 Mat

2 Mats

3 Mats

4 Mats

5 Mats

6 Mats

TI-F Formulas

Formulas

04/2002 Learning from Nature – www.KaRo.cc P.1 TI-F

Building Identification Data

Height Factor KH (1)

KH = 1,117 - 0.045 · H [m] with: H - room height valid for 2,5m < H < 5m Load Factor KK (2)

KK = (qiL + qeL) / (qiL + qeL/2) with: qiL - internal specific cooling load [W/m2] qeL - external specific cooling load [W/m2] KK maximum = 1,2 permissible Ventilation

Specific cooling load of draft qL (3) qL [W/m2 ] = vL· ∆TL· cL· ρL with: vL - specific air intake volume flow [m3/hm2] ∆TL- temperature difference exhaust-intake [K] cL - specific heat capacity of the air = 1004 J/kgK ρL - density of the air = 1,14 kg/m3 or (4) qL [W/m2 ] = 0,32 · vL· ∆T Ventilation Factor KL (5) Ventilation system Ventilation factor K L Basic airflow 1,00 Climate convector 1,08 Ceiling slot outlet 1,10 Ceiling momentum outlet 1,13 Ceiling Construction

Degree of coverage, ceiling DG (6)

DG = AD / AB with: AD - ceiling area covered with mats [m2] AB - floor area of room [m2] Factor of coverage KB (7)

KB = 1,21 - 0,3 · DG valid for 0,3 < DG < 1,0 Constant factor, room KR (8)

KR = KH · KK · KL · KB Cooling Ceiling Capacity

Average water temperature TWM (9) TWM [°C ] = (TVL + TRL) / 2 with; TVL - supply temperature [°C] TRL - return temperature [°C] Effective under temperature TU (10)

TU [°C ] = TR - TWM with TR – room air temperature [°C] Required specific capacity for cooling ceiling qERF (11)

qERF [W/m2 ] = qGA - qL with qGA - total cooling load in reference to floor area [W/m2] Specific Standard Cooling Capacity qN

according DIN 4715 (12)

qN [W/m2 ] = C· TUn

with C – constant factor n - exponential function → see enclosure

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Actual Specific Cooling Capacity to bottom qT (13)

qT [W/m2 ] = KR · qN Specific Capacity to Top qO (14)

qO [W/m2 ] = kO · ( TÜ - TWM ) with kO –Thermal conductance factor to top [W/m2K] TÜ – Temperature above the ceiling [°C] Heat Flow Density (Basis characteristic curve) qi (15)

qi [W/m2] = 8,92 · ( Ti - TD )1,1

with Ti - room temperature [°C] TD – average ceiling temp. at bottom side [°C] Internal Thermal transmittance coefficient κ (16) κ [W/m2K] = qi / (tD - TWM) with TWM – average cooling water temperature [°C] for capillary tube mats κ ≈ 110 W/m2K Mass Flow

Cooling water spread SP (17)

SP [K] = TVL - TRL Specific mass flow water mW (18)

mW [kg/m2h] = 3600 · qN / (cW · SP ) with cW - specific heat capacity of water

= 4180 J/kgK oder (19) mW [kg/m2h] = 0,861· qN / SP Corrected Specific Mass Flow Water mKW

(20)

mKW [kg/m2h] = 0,861· (qN + qO ) / SP

Flow / Pressure Loss

Velocity of flow w (21) w [m/s] = V /AS with V – volume flow [m3/s] AS – sectional area of flow [m2] or (22) w [m/s] = 21,22 · m / di

2 with m – water volume [l/min] di - pipe diameter [mm] Pressure loss in the pipe ∆pR (23)

∆pR [Pa] = λ · L / (di· 10-3) · ρ/2 · w2 with λ - pressure loss coefficient L - length of pipe [m] ρ - density [kg/m3] or (24) ∆pR [Pa] = 499200· λ · L / di· w2 with ρW – density of water = 998,4 kg/m3 Pressure loss at fittings and passages ∆pF (25) ∆pF [Pa] = ξ · w2 · ρ/2 with ξ - Resistance coefficient according chart Type of Fitting ξ - Value Sleeve connector 0,0 Elbow, wide 0,5 Elbow, narrow 0,3 Expansion 0,5 T-Junction, Separation 1,5 T-Junction, Union 1,0 T-Passage, Separation 0,0 T-Passage, Union 0,5 T-Counter current 3,0 Pressure loss at valves ∆pV (26)

∆pV [Pa] = (ma / kVS)

2 · 10-1

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with ma – queued up mass flow [kg/h] kVS – value according manufacturer [m3/h] Pressure loss in the capillary tube mat ∆pM

1

(27) ∆pM [Pa] = V2 · 8· ρ / π2 · 1/ ( nK · √ dK

5 / (ζ · dK + λK· LM) )2

+ (λS· B/dS + ξ · nK) wS2 · ρ/2

with V - Volume flow [m3/s] nK - Quantity of capillary tubes dK - Inner diameter of capillary tube [m] λK - Friction factor of capillary tube LM - Extended length of capillary tube mat [m] λS - Friction factor of mains B - Length of mains or width of mat [m] dS - Inner diameter of mains [m] ξ - Resistance coefficient for junction = 0,04 wS – Velocity of flow in the mains [m/s] Reynolds number Re (28) Re = w · di · ν or Re = w · di · 103

with ν - kinematical Viscosity for water [10-6 m2/s] w – Velocity of flow [m/s] di – Inner diameter [mm] Pressure loss coefficient λ (29) and (30) for Re < 2300 λ = 64 / Re for 2300< Re< 105 λ = 0,3164/ Re0,25 Comfortableness

Percept Temperature2 ϑres (31)

ϑres [°C] = a · ϑa + (1- a )· ϑmrt where a = 0,5 + 0,25 · v

1 Vogel Fachbuch: Wagner - Strömung und Druckverlust, Vogel Buchverlag Würzburg 1992 2 Source: Praxishandbuch Haustechnik, Akade-mie für technische Gebäudeausrüstung, Wien 1995

with ϑa - air temperature [°C] ϑmrt- average radiation temperature [°C] v - air velocity [m/s] or for v< 0,1 m/s (32) ϑres = (ϑa + ϑmrt )/ 2 Average radiation temperature² ϑmrt (33) ϑmrt [°C] = (Σ ϑi · Ai ) / Σ Ai with ϑi - surface temperature of the area Ai Valid when the emission coefficients of the particular surfaces are equal (standard case); Is not valid if in the room in question infra red reflective layers have been used ! Required air exchange2 VLW (34) VLW [m3/h] = VCO2 / ( CCO2I - CCO2A) with VCO2 - CO2 - Emission in the room [l/h] CCO2I - CO2I – Concentration in room air [l/m3] CCO2A- CO2A – Concentrat. in outside air [l/m3] Stability

Comparative tension σV (35) σV [MPa]= pi · (da - s )/ (2· s) with pi - inside pressure [MPa] da - outer diameter of pipe [mm] s - wall thickness of pipe [mm] Heat Flow / Heat Transition

Heat flow through a surface / wall Q (36) Q [W] = k · A · ∆T with k - overall heat transfer coefficient [ W/m2K] A - area of component [m2] ∆T- temperature difference outside/inside [K] k-Value k (37) k [ W/m2K] = 1 / ( 1/αi + 1/αa + Σ si / λi )

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with αi - inner Thermal transition coefficient [W/m2K] inner Thermal transition resistance Ri = 1 / αi = 0,13 m2K/W αa- outer thermal transition coefficient W/m2K] outer thermal transition resistance Ra = 1 / αa = 0,04 m2K/W si - thickness of layer [m] λi - thermal conductivity of the layer [W/mK] Average k-value km (38)

km [ W/m2K] = (kW· AW + 0,8· kD· AD + 0,5· kB· AB + kF· AF) / Ages with kW,D,B,F - k-value for wall; ceiling; floor;

Heat

Approximate heat requirement QW (39) QW [W] = (km · Ao/V + 0,34· nW ) · Vo · ∆T with km - average overall heat transfer coefficient W/m2K] Ao - total embracing area [m2] Vo - total building volume [m3] nW - rate of hourly air exchange=0,5 to 1,0 [h-1] ∆T - temperature difference outside/inside [K]

windows [ W/m2K] AW;D;B;F - area of wall; ceiling; floor; window [ W/m2K] Ages - total embracing area [m2] Enclosure: collection of formulas

Conversion-table for Pressure Units

units bar mbar Pa kPa daPa kp/cm2

atü mmWs kp/m2

mmHg Torr

atm psi lb/in2

1 bar = 1 1000 100 000 100 10 000 1,01972 10197 750,062 0,986923 14,5038

1 mbar = 0,001 1 100 0,1 10 1,01972 x10-3

10,197 0,750062 0,986923 x10-3

0,014504

1 Pa = 1 N/m2 =

10-5 0,01 1 0,001 0,1 1,01972 x10-5

0,10197 0,007501 9,86923 x10-6

1,45038

1 kPa = 0,01 10 1000 1 100 0,010197 101,97 7,501 9,86923 x10-3

0,145038

1 daPa = 10-4 0,1 10 0,01 1 1,0197 x10-4

1,0197 0,075 0,987 x10-4

0,00145

1kp/cm2 =1 atü =

0,9807 980,7 98066,5 98,0665 9806,6 1 10 000 735,56 0,9678 14,2233

1mmWs= 0,9807 x10-4

0,0981 9,80665 98,0665 x10-4

0,981 0,0001 1 0,0736 0,9678 x10-4

0,001242

1 Torr = 1mmHg =

1,33322 x10-3

1,33322 133,322 0,133322 13,3322 1,35951 x10-3

13,5951 1 1,31579 x10-3

0,019337

1 atm = 1,01325 1013,25 101325 101,325 10132,5 1,03323 10332,3 760 1 14,6959

1 psi = 1 lb/in2 =

0,06895 68,9576 6894,76 6,89476 689,746 0,070307 703,07 51,7149 0,068046 1

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Units and abbreviations used in formulas

Abbreviations Contents Units A Area, generally m2 AB Floor area of a room m2 AD Ceiling area covered with mats m2 Ao Total embraced area of a room m2 AS Square area of flow m2 B Width of mat e.g. length of mains m C Coefficient for DIN-standard capacity cL Specific heat capacity of air = 1004 J/kgK J/kgK cW Specific heat capacity of water =4180 J/kgK J/kgK da Outer diameter of a pipe mm DG Degree of ceiling coverage – correction factor cooling load di Pipe inner diameter mm dK Inner diameter of capillary tube m H Room height m k Overall heat transfer coefficient - k-value W/m2K KB Degree of coverage – correction value: cooling load KH Height factor – correction value: cooling load KK Load factor – correction value: cooling load KL Ventilation factor – correction value: cooling load km Average k-value W/m2K kO k- value to top (above) W/m2K KR Room constant factor – correction value cooling load kVS Specific flow rate – according to manufacturer m3/h L Length, generally m LM Length of mat m m Volume of water l/min ma Queued-up mass flow kg/h mKW Corrected specific water mass flow kg/m2h mW Specific mass flow water kg/m2h n Exponential function for DIN-standard capacity nK Quantity of capillary tubes at the mains of a mat pi Internal pressure of a pipe MPa qeL Specific external cooling load W/m2 qERF Required specific capacity of a cooling ceiling W/m2 qGA Specific total cooling load W/m2 qi Heat flow density W/m2 qiL Specific internal cooling load W/m2 qL Specific cooling load for air intake W/m2 qN Standard cooling capacity according DIN 4715 W/m2 qO Specific cooling capacity to top (above) W/m2 qT Actual specific cooling capacity W/m2 Q Heat flow, generally W QW Estimated heat requirement W Re Reynolds number s Wall thickness of a pipe mm si Layer thickness m SP Cooling water spread K TD Average ceiling temperature at the bottom (side) °C Ti Room temperature °C TR Room air temperature °C TRL Return temperature of the cooling water °C TU Effective under temperature °C TÜ Temperature above the ceiling °C TVL Supply temperature of the cooling water °C

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TWM Average water temperature K v Air velocity m/s V Volume flow m3/s vL Specific air intake flow m3/hm2 VLW Required air exchange rate m3/h Vo Total building (or) room volume m3 w Velocity of flow m/s wS Velocity of flow in the mains m/s αa Outer, thermal transition coefficient W/m2K αi Inner, thermal transition coefficient W/m2K λ Pressure loss coefficient λi Thermal conductivity of a layer W/mK λK Pressure loss coefficient in the capillary tube λS Pressure loss coefficient in the mains κ Inner thermal transition coefficient W/m2K ∆pF Pressure loss at the fitting Pa ∆pM Pressure loss of the mat Pa ∆pR Pressure loss of the pipe Pa ∆pV Pressure loss at the valve Pa ∆TL Temperature difference air intake – exhaust air K ρL Density of air = 1,14 kg/m3 kg/m3 ρW Density of water = 998,4 kg/m3 kg/m3 ϑa Air temperature °C ϑi Surface temperature of an area °C ϑmrt Average radiation temperature of an area °C ϑres Percept temperature °C σV Comparative tension MPa ξ Resistance coefficient