FLOOR HEATING VALSIR.pdf

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floor heating design manual

Transcript of FLOOR HEATING VALSIR.pdf

  • QUALITY FOR PLUMBING

    www.valsir.it

    Technical manualL02-242/1

    Floor heating and cooling system

    Energy saving

    Elevated thermal well-being

    Low operating temperature

    Uniform temperature distribution

    Characteristics, planning, dimensioning, laying and testing

  • 1 CharaCteristiCs of floor heating systems 6

    1.1 Hygienic conditions 6

    1.2 Aesthetical advantages 6

    1.3 Well-being 61.3.1 What is comfort or thermo-hygrometric well-being? 6

    1.3.2 Measurement of comfort 6

    1.3.3 Causes of discomfort 8

    1.4 Energy saving 91.4.1 Why does floor heating reduce energy consumption? 9

    1.4.2 Floor insulation 9

    1.4.3 Operating temperature 10

    1.4.4 Reduced stratification of the air temperature 11

    1.4.5 System water at low temperature 11

    2 ComPonents CatalogUe 12

    3 teChniCal CharaCteristiCs of the ComPonents 31

    3.1 PEXAL and MIXAL pipe 313.1.1 General characteristics 31

    3.1.2 Characteristics of crosslinked polyethylene PE-Xb 33

    3.1.3 Characteristics of aluminium 33

    3.1.4 Mechanical behaviour 33

    3.1.5 Expansion 34

    3.1.6 Resistance to abrasion, encrustation and corrosion 34

    3.1.7 Barrier to oxygen and UV rays 34

    3.1.8 Lightweight 35

    3.1.9 Sound absorption 35

    3.1.10 Long lasting 36

    3.1.11 Heat conductivity 36

    3.1.12 Comparison of heat outputs of different pipes 36

    3.1.13 Pressure losses 39

    3.1.14 Quality control 43

    3.1.15 Pipe approvals 46

    3.2 V-ESSE, V-ELLE, V-ZETA, V-ERRE and V-ENNE insulation panels 483.2.1 V-ESSE panel 48

    3.2.2 V-ELLE panel 50

    3.2.3. V-ZETA panel 52

    3.2.4. V-ERRE panel 54

    3.2.5. V-ENNE panel 56

    3.2.6 Instructions for laying the V-ENNE eco-compatible system 58

    3.3 V-ACUSTIC soundproof mat 603.3.1 Introduction 60

    3.3.2 Technical characteristics 60

    3.3.3 Soundproof insulation of foot-traffic noise with V-ACUSTIC 62

    3.3.4 Rules for the installation of V-ACUSTIC 66

    3.4 Distribution manifold 683.4.1 Manifold components 68

    3.4.2 Practical method for adjusting and balancing of the manifold 70

    3.4.3 Composition of the manifold (without mixing kit) 71

  • 3.5 Valsir mixing kit 733.5.1 V-MIX02 fixed point mixing kit 73

    3.5.2 V-MIX01 fixed point and variable point mixing kit 75

    3.5.3 Theory: adjustment of the mixing kit 77

    3.5.4 Practice: adjustment of the mixing kit 78

    3.5.5 The assembled mixing kit 79

    3.6 V-BOX modules 82

    3.7 Mixing and distribution groups for heating plants 853.7.1 The distribution and mixing modules 86

    3.7.2 Differential valve 94

    3.7.3 Distribution manifolds 95

    3.7.4 Hydraulic separator 97

    3.7.5 Dimensioning of the mixing groups 107

    3.8 V-DRYAIR isotherm dehumidifiers for cooling systems 1123.8.1 Condensation and the dehumidification of air 112

    3.8.2 V-DRYAIR 250V and V-DRYAIR 250H isotherm dehumidifiers 113

    3.8.3 V-DRYAIR 450H isotherm dehumidifers 115

    3.8.4 V-DRYAIR 900H isotherm dehumidifiers 116

    3.9 Control systems 1183.9.1 V-CLIMA system 118

    3.9.2 Control units of the heating circuits 127

    3.9.3 Some control schemes 138

    3.10 Concrete fluidizer 1443.10.1 Calculation of the quantity of fluidizer 144

    4 Valsir floor heating and Cooling systems 146

    4.1 System and system components 146

    4.2 Guidelines for choosing the system and its components 156

    5 dimensioning of floor heating systems in ComPlianCe with Uni en 1264 162

    5.1 Introduction 162

    5.2 Dimensioning: theory 1625.2.1 Layer composition of the floor 162

    5.2.2 Required thermal flow 165

    5.2.3 Characteristic curves 166

    5.2.4 Thermal flow limit and maximum floor temperature 166

    5.2.5 Limit curve 167

    5.2.6 Supply temperature 167

    5.2.7 Average floor temperature 168

    5.2.8 Downward heat dispersion 168

    5.2.9 Length of heating loops 169

    5.2.10 Flow and temperature of heating fluid 169

    5.2.11 Design limits in the choice of pipe spacing 170

    5.2.12 Balancing of heating circuits 170

    5.3 Dimensioning: practice 1715.3.1 Floor layer composition 173

    5.3.2 Required thermal flow 174

    5.3.3 Thermal flow limit and maximum floor temperature 175

    5.3.4 The characteristics curves and the limit curve 176

  • 5.3.5 Supply temperature 177

    5.3.6 Circuit dimensioning 178

    5.3.7 Balancing of heating circuits 180

    6 dimensioning of anti-snow and anti-iCe systems (snow-melt) 187

    6.1 Introduction 187

    6.2 System types 188

    6.3 System design 189

    6.4 Dimensioning: theory 1906.4.1 The required thermal output 190

    6.4.2 Layer composition of the radiant panel 192

    6.4.3 Calculation of temperatures 193

    6.4.4 Downward specific heat output 193

    6.4.5 Calculation of the number of loops 193

    6.4.6 Calculation of the flow rates and the temperatures of the heating fluid 194

    6.4.7 Typical snowmelt systems 195

    6.5 Dimensioning: practice 1966.5.1 Required heat output 196

    6.5.2 Layer composition of the radiant panel 196

    6.5.4 Downward specific thermal output 196

    6.5.5 Calculation of circuit loops 197

    6.5.6 Calculation of the flow and the temperature of the heating fluid 197

    7 installation 204

    7.1 Preliminary procedures and verifications 204

    7.2 Installation of the manifold and mixing kit 204

    7.3 Laying of the edging strip 205

    7.4 Laying of insulation panels 205

    7.5 Laying the pipe 207

    7.6 Creation of expansion joints 208

    7.7 Creation of the settlement joints 209

    7.8 System filling 210

    7.9 System testing 210

    7.10 Laying of the screed 210

    7.11 System commissioning 210

    8 aPPendix 211

    A Heat transfer 211A.1 Heat transfer modes 211

    A.1.1 Conduction 211

    A.1.2 Convection 211

    A.1.3 Radiation 212

    A.2 Combined heat transfer processes 212

    A.3 Heat transfer in heating systems 214

    A.3.1 Radiator systems 214

    A.3.2 Fan heater systems 214

    A.3.3 Floor heating systems 214

  • B Climatic data for Italian regions and towns 215

    C Thermal conductivity and resistance of materials 218

    D Wood as a floor covering 220

    E dimensioning of metal reinforcement in the floors 221E.1 Dimensioning example of a metal reinforcement 222

    F Antifreeze liquid in heating systems 223

    G Calculation of quantity of concrete 224

    H Insulation panels in floor heating 227H.1 The influence of insulation panels on system performance 227

    H.1.1 Mechanical function 227

    H.1.2 Reduction of thermal mass 227

    H.2 Numerical analysis of insulation 228

    H.2.1 Calculation basis 228

    H.2.2 Results 229

    H.3 Conclusion 231

    I Noise in the buildings 232I.1 Introduction 232

    I.2 Sound 232

    I.3 Noise and its measurement 234

    I.4 Noise in buildings and Italian legislation 236

    I.5 Foot traffic noise 238

    L Heat outputs 239

    M Measurement units 240

    N Standard and legislative references 243

    O Technical specifications 244

  • 1 CHARACTERISTICS OF FLOOR HEATING SYSTEMS

    The first evidence of floor heating dates back to Roman times. The working principles were straightforward but ingenious; an underground fire was made and the hot fumes were conveyed through ducts under the floor of the building. It was only after the war that the first floor heating systems were installed with the use hot water that ran through pipes that were embedded in the floor; unfortunately the poor insulation of the buildings, the high temperatures and the lack of adequate control systems caused this type of system to lose popularity for quite some time. The energy crisis of the seventies, however, and the issuing of European laws on thermal insulation resulted in the return of this type of heating. Floor heating is, today, certainly the most technically valid solution offered by the heating market for the residential, commercial and industrial sector. The various solutions available allow maximum flexibility and adaptability to all types of building and construction requirements. Furthermore, the use of a heat transfer fluid at low temperatures and the particular stratification of the heat in the room results in significant energy saving.In the following paragraphs we will analyse some of the characteristics that differentiate floor heating systems: hygienic conditions, aesthetical advantages, well-being and energy conservation.

    1.1 Hygienic conditions Floor heating naturally rules out the formation of damp areas on the floor, conditions favouring dust mites and bacteria are therefore not generated and there will also be no formation of mildew. Unlike traditional systems, there is no combustion of motes, which provoke a dry and irritated throat and there are no convective currents, which favour the transport of dust in the room.

    1.2 Aesthetical advantagesThere are no limits of an architectural nature linked to the presence of heating units; therefore, there is total freedom in interior decorating. By eliminating the problem of condensation and mildew, there will be no deterioration of wooden floors or windows and frames.Traditional heating systems limit the space available for the distribution of furniture whereas floor heating systems allow all available space to be utilised; it is also advantageous in buildings of an architectural and artistic importance where it is essential that the surroundings be left unaltered.

    1.3 Well-being

    1.3.1 What is comfort or thermo-hygrometric well-being?The objective definition defines thermo-hygrometric comfort as the state of thermal neutrality of the human body in which its thermal accumulation is zero and in which the organism maintains its mechanisms of thermoregulation (absence of perspiration in hot rooms or shivers in cold rooms) and vasomotor thermoregulation (absence of blood vessel dilation and contraction) almost inactive. The subjective definition defines thermo-hygrometric comfort as the physical and psychological state of satisfaction that an individual feels because of the conditions in which he finds himself (temperature, humidity, air velocity, etc.).The human body produces thermal energy based on the activity being carried out. A person when sedentary produces 100 W whereas under strain can produce 1000 W and this thermal energy must be dispersed to maintain the temperature under control and to avoid situations of thermal stress (discomfort). The human body is therefore a thermo-dynamic machine that exchanges energy (heat and work) with the atmosphere and in which the energy balance must be maintained, where the latent component of heat connected to evaporation and breathing and the dormant component of heat exchanged by convection and radiation, intercede.

    1.3.2 Measurement of comfortThermo-hygrometric well-being depends on several parameters:

    the energetic metabolism M that depends on the activity carried out and is measured in W/m 2 (body surface) or in met (1 met = 58,2 W/m2),the thermal resistance of clothing I cl expressed in m

    2K/W or in clo (1 clo = 0,155 m2K/W),he air temperature T a measured around the person,the average radiant temperature T mr caused by the room where the person is found,relative air velocity v a,relative air humidity UR.

    One method of identifying the conditions of well-being is to express it by means of the PMV (Predicted Mean Vote) that is based on the balance of thermal energy in the human body. Man is equilibrated when the thermal energy generated inside the body is equal to the thermal energy dispersed into the room. The PMV is therefore a function of the six parameters described and expresses the average vote of a sample of people in various climatic conditions.

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  • Table 1.1 Values of PMV.

    Sensation Very hot Hot Slightly hot Neutral Slightly cold Cold Very cold

    PMV +3 +2 +1 0 -1 -2 -3

    The PMV therefore predicts the average vote of thermal sensation expressed by a considerable number of people. The PPD (Predicted Percentage of Dissatisfied) is, on the other hand, an indicator that predicts the number of people that will be dissatisfied from a thermal point of view for a certain PMV value.

    Figure 1.1 Relationship between PMV and PPD.

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    According to this theory, climatic conditions are considered pleasant when they correspond to a percentage of satisfied people greater than 90% and therefore a percentage of dissatisfied people below 10%. Such conditions are summarized in the following table.

    Table 1.2 Conditions considered pleasant.

    Metabolism M 0,84 met

    Clothing Icl 02 clo

    Air temperature Ta 1030C

    Mean radiant temperature Tmr 1040C

    Relative air velocity va 01 m/s

    Relative air humidity UR 3070%

    As an alternative to the PMV index it is possible to use other indicators such as, for example, the operating temperature. This represents the uniform temperature of a room in which the subject exchanges the same energy by convection and radiation that effectively exchanges in the real room in which the temperature is not distributed uniformly. The operating temperature is the weighed average if the air temperature and the average radiant temperature, the weights of which are convective conductance (clothes-air) and radiative conductance (clothes-surfaces of the room).

    hc Ta + hr Tmrhc + hr

    Top =

    This temperature is in reality also a function of the air velocity in that the coefficient of convective conductance is strongly linked to this parameter. The Standard UNI EN ISO 7730 suggests a simplified formula for calculating the operating temperature:

    Top = A Ta + (1-A) Tmr

    where A is a function of the relative air velocity va.

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  • Table 1.3 Coefficient A as a function of air velocity.

    va [m/s] Ta T = 13C

    Summer conditions Radiant panels Tmr < Ta T = 12C

    Winter conditions Radiators, fan-coils, ducts Tmr < Ta T = 36C

    Summer conditions Radiators, fan-coils, ducts Tmr > Ta T = 46C

    We immediately notice that with radiant panel technologies the difference between the temperature of the air and the temperature of the surfaces is lower than the difference in temperature with traditional heating/cooling technologies. Furthermore, with an analysis of winter conditions only, it can be noted that with radiant panel systems, the temperature of the air can be lower than the temperature of the surfaces and this translates into interesting consequences for energy saving. By intersecting the field of acceptability of the PMV with the values of operating temperature, in the case of sedentary activity M1.2 met, we find that the values that ensure comfort, are the following:20C < Top < 24C in winter conditions (clothing 1 clo);23C < Top < 26C in summer conditions (clothing 0.5 clo).

    1.3.3 Causes of discomfortThe causes that can generate local discomfort are several and depend also on the type of heating/cooling system.

    Figure 1.2 Causes of local discomfort.

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    T av m

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    Vertical temperature differences are too high. A higher temperature at the height of the head compared to the temperature at the height of the ankles generates a greater local discomfort that will increase with an increase in the temperature difference; the Standard UNI EN ISO 7730 establishes a maximum temperature difference of 3C.Floor too hot or too cold. The Standard UNI EN 1264 that regulates floor heating systems has in fact established the surface temperature limits (see chapter on floor system dimensioning).Mean radiant temperature distributed in an asymmetrical manner. There will be greater sensations of discomfort when the irregularity is caused by a heated ceiling or by cold walls (windows).Air drafts. The sensation of discomfort caused by the air velocity is linked to its temperature. An air draft in the presence of low temperatures can generate sensations of discomfort while in the presence of elevated temperatures it is beneficial on a comfort level.

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  • 1.4 Energy saving

    1.4.1 Why does floor heating reduce energy consumption?Systems with radiant panels, as compared with traditional heating systems, allow an average energy saving of more than 20% at equal environmental temperatures. The reasons for this marked saving are due to the fact that the large exchange surface formed by the floor allows the room to be heated with a heat transfer fluid that runs at low temperatures. For this reason, it is convenient to use heat sources whose performance increases when run at low temperatures (heat pumps, condensation boilers, solar panels, heat recovery systems, district heating systems).The thermal gradient that is generated with a floor heating system is such that the heat losses are less as compared with a traditional heating system. This is because, unlike traditional systems, it is possible to recover the heat that is usually wasted due to the effect of air stratification that reaches higher temperatures at the ceiling; this heat recovery increases with the increase in the height of the room. With a floor heating system the condition of well-being is reached with an average room temperature that is generally 1C lower as compared with traditional heating systems and therefore, at equal comfort it is possible to reduce energy consumption. The employment of insulation panels that are required to support the pipe but at the same time significantly reduce heat losses help increase the output of the system; traditional heating systems do not require panels and therefore such panels are never employed.

    1.4.2 Floor insulation Floor heating systems are characterised by the presence (required by the European Standard UNI EN 1264) of a layer of insulation to 1) support the loops. Pocketed or smooth panels can used to create the insulation layer that has a minimum thickness of approximately 20 mm. The function of the insulation, besides acting as a mechanical support for the pipe is also to act as a thermal insulation for the rooms 2) below and to reduce the thermal inertia of the system. The presence of insulation panels in floor heating systems halves downward heat loss as compared with systems without insulation 3) panels.

    If we consider a room that lies directly over the ground, the dispersion in a system with insulation panels is about 19%, while in a system that has no insulation panels, dispersion can be as high as 36%!

    Figure 1.3 Insulation with V-ESSE pocketed panels.

    CHARACTERISTICS OF FLOOR HEATING SYSTEMS

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  • 1.4.3 Operating temperatureThe air temperature Ta and the mean radiant temperature Tmr of the structures determine the operating temperature Top. The latter indicates the conditions of well-being of an individual.In a floor heating system, the mean radiant temperature of the structures is greater than the temperature of the structures where a traditional heating system has been installed and this allows a reduction in the temperature of the air. The thermal exchange with the outside is directly proportionate to the difference in temperature between the room air temperature and the outside temperature.In a traditional system (see Figure 1.4) the mean temperature of the air is higher with a consequently higher thermal outward flow compared to a system with radiant panels where the mean temperature of the air is lower. In fact, in a system with panels the temperature in proximity with, for example, the glassed surfaces is lower and this allows a reduction in the thermal flow lost to the outside environment (see Figure 1.5). With a floor heating system it is possible to maintain an average air temperature of 19C compared to a traditional system where the average temperature is 20C, just one degree centigrade less can generate a saving in energy of approximately 7%.

    Top = A Ta + (1-A) Tmr

    Figure 1.4 Traditional system. Figure 1.5 Floor heating.

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    DISPERSION DISPERSION

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    The considerations made for floor heating systems, also apply to floor cooling systems. The temperature of cooling air can take on higher values with important consequences on an energy conservation level without altering the conditions of well-being.

    Top = A Ta + (1-A) Tmr

    Figure 1.6 Traditional air-conditioning system. Figure 1.7 Floor cooling.

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  • 1.4.4 Reduced stratification of the air temperatureAnother of the advantages of a system with radiant panels is the reduced stratification of the air temperature. In traditional systems, the heating element significantly increases the temperature of the air (35C-40C) thus favouring the distribution of hot air in proximity to the ceiling. The effect of this stratification of the air is amplified in rooms with very high ceilings where the differences in temperature between the floor and ceiling can even reach 10C (see Figure 1.8 and Figure 1.9).In floor heating systems temperature distribution is different, there is a temperature of about 22C near the floor and a temperature of 18C near the ceiling (in a residential building). This temperature distribution means that thermal energy is consumed where it is needed and that is, at the height of the room occupant. This significant difference in the distribution of temperatures introduces further advantages in energy saving.

    Figure 1.8 Ideal distribution. Figure 1.9 Real distribution.

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    1.4.5 System water at low temperatureThe elevated exchange surface formed by the radiant floor means that ample volumes can be heated with the heat transfer fluid in the system running at low temperatures. For this reason it is convenient to use heat sources whose output increases when the required temperature decreases such as heat pumps, condensation boilers and solar panels. The supply temperature to the circuits range on average from 30C to 40C depending on the climatic conditions present; in a traditional system the supply temperature is on average 70C, this significant difference consents further saving in energy since it allows an increase in the distribution performance of the system. The lower the temperatures of the heat transfer fluid the lower the energy losses in the distribution tract that runs from the boiler to the manifolds.

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  • 2 COMPONENTS CATALOGUE

    MIXAL pipe

    Di

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    Item De (mm) S (mm) Di (mm) COD. (m) (m)

    MIXAL 14x2 14 2.0 10 VS0100135 100 6400MIXAL 16x2 16 2.0 12 VS0100137 100 5600 MIXAL 16x2 16 2.0 12 VS0113005 120 6720MIXAL 16x2 16 2.0 12 VS0113007 240 5760MIXAL 16x2 16 2.0 12 VS0100141 500 3000MIXAL 20x2 20 2.0 16 VS0100139 100 3200MIXAL 20x2 20 2.0 16 VS0113009 120 3840MIXAL 20x2 20 2.0 16 VS0113011 240 1440MIXAL 26x3 26 3.0 20 VS0100143 50 1440

    Multilayer pipe in crosslinked polyethylene with intermediate layer in aluminium.

    Until stocks have fi nished quantity per pallet may be 4800 m.

    V-ESSE insulating panel

    sLs1

    PH

    Item S (mm) S1 (mm) LxH (mm) P (cm) Class (kPa) Area (m2) COD. (m2)V-ESSE20 50 20 1350x750 7.5 150 1.0125 VS0109000 12.15V-ESSE30 60 30 1350x750 7.5 150 1.0125 VS0109001 10.12

    Pocketed panel in expanded polystyrene with blue EPS film.

    V-ZETA insulating panel

    sLs1

    PH

    Item S (mm) S1 (mm) LxH (mm) P (cm) Class (kPa) Area (m2) COD. (m2)V-ZETA20 50 20 1200x750 7.5 200 0.9 VS0109016 10.8

    Pocketed panel in expanded polystyrene.

    V-ERRE insulating panel

    sLs1

    PH

    Item S (mm) S1 (mm) LxH (mm) P (cm) Class (kPa) Area (m2) COD. (m2)V-ERRE10 32 10 1000x500 5 200 0.5 VS0109017 10.0

    Pocketed panel in expanded polystyrene coupled to black, compact, impact-resistant, rigid PS film equipped with bosses for securing the pipe.

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  • V-ELLE insulating panel

    H

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    Item S (mm) H (mm) P (cm) Class (kPa) Area (m2) COD. (m2)V-ELLE20/200 20 1000 5 200 12 VS0109018 12.0V-ELLE30/250 30 1000 5 250 10 VS0109019 10.0

    Smooth panel in coils in expanded (V-ELLE 20/200) or extruded (V-ELLE 30/250) polystyrene with grey polyester aluminized film with blue square for facilitating installation, class 200 kPa (V-ELLE 20/200) and class 250 kPa (V-ELLE 30/250).

    V-ENNE biocompatible insulation panel

    sH1

    H

    L1L

    Item L (mm) H (mm) L1 (mm) H1 (mm) S (mm) Specific weight (kg/m3) COD. (pcs) (m2)V-ELLE 1250 600 1265 615 30 240 VS0109020 5 3.75

    Insulation panel made of conifer wood fibres and latex to make it impermeable to the absorption of water. It is equipped with an L-shaped rebate for connecting the panels.

    V-BAND edging stripH

    s

    Item HxS (mm) COD. (m)V-BAND 200x7 VS0109200 125

    Insulating strip in white expanded polyethylene with adhesive on one side across the entire surface with protection film divided in two.The strip is coupled with a transparent film in polyethylene with a thickness of 40 m to prevent cement seepage.

    V-BAND/N biocompatible edging stripH

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    Item L (mm) H (mm) S (mm) COD. (pcs) (m)V-BAND/N 20 150 8 VS0109202 6 120

    Biocompatible insulating strip in compact linen fibre felt. No other additional products are used in the production of the edging strip.

    V-JOINT band for expansion jointsH

    s

    Item HxS (mm) COD. (m)V-JOINT 200x7 VS0109201 125

    Insulating strip in white expanded polyethylene with 20 mm of adhesive on one end to be used with V-JOINT/T support to be stuck to the mushrooms on the V-ESSE panel.

    Eco-friendly

    Eco-friendly

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  • V-JOINT/T profile for expansion joints

    Item L (m) COD. (m)V-JOINT/T 1.2 VS0109203 12

    T-shaped profile with adhesive for securing the strip, for the V-JOINT expansion joints. Pack of 10 pieces.

    V-CLIP anchor clips

    Item De Pipe (mm) COD. (pcs)V-CLIP01 14, 16, 20 VS0109400 100

    Anchor clips for pipe diameters 14, 16, 20 mm to be used with V-ELLE panel.

    V-CLIP anchor clips

    Item De Pipe (mm) Grid wire (mm) COD. (pcs)V-CLIP02 16, 20 35 VS0109403 25V-CLIP03 26 35 VS0109405 25

    Anchor clips for securing pipes to metal grid for use on insulating screed.

    V-CLIP anchor clips

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    H

    Item L (mm) H (mm) COD. (pcs)V-CLIP04 88 28 VS0109406 100

    Clips for securing anti-shrinkage metal grids to insulation panels.

    V-RAIL fixing bars

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    Item De Pipe (mm) LxHxI (mm) P (cm) COD. (pcs) (m)

    V-RAIL01 16 2000x25x38 5 VS0109410 32 64V-RAIL02 20 2000x25x50 5 VS0109411 32 64

    Fixing rails for pipe diameters 16 and 20 mm with adhesive strip for securing to smooth insulating panels.

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  • Fixing screws for V-RAIL bar

    L1

    L

    Item L (mm) L1 (mm) COD. (pcs)Fixing screws for V-RAIL 29 14 VS0109409 100

    Fixing screws for bars to secure V-RAIL01 and V-RAIL02 pipes to smooth panel.

    V-FOIL anti-humidity film

    H

    L

    Item H (m) L (m) COD. (m2)V-FOIL 1.2 120 VS0109600 120

    Anti-vapour polyethylene film, 0.2 mm thick, with 25 mm of adhesive on the end.

    V-ACUSTIC soundproof mat

    H

    L

    Item H (m) L (m) COD. (m2)V-ACUSTIC 1 10 VS0109601 10

    V-ACUSTIC allows foot-traffic noise to be reduced by 28 dB (in compliance with EN 12354-2) thanks to a dynamic rigidity of 21 MN/m3.It is a multilayer mat that also acts as a barrier to humidity with a thickness of 8 mm that, after been laid, falls to 6 mm. The bottom layer is made of white felt, which, thanks to the Velcro effect, prevents movement during installation. The mat must be laid with the use of the special waterproof strip.

    V-ACUSTIC/N biocompatible soundproof mat

    H

    L

    Item H (m) L (m) COD. (m2)V-ACUSTIC/N 1 30 VS0109602 30

    V-ACUSTIC/N allows a reduction in foot-traffic noise of approximately 14-17 dB with a dynamic rigidity of about 55 MN/m3. This mat is made of compact linen fibre felt with a thickness of 5 mm. No other products are employed in the production of this mat. The linen fibre creates a Velcro effect with the underlying rough floor that prevents it moving during installation.

    Adhesive tape for V-ACUSTIC soundproof mat

    H (mm) L (mm) COD. (pcs)50 50 VS0109900 1

    Water proof gaffer tape for installation of V-ACUSTIC soundproof mat.

    LW = 28 dB(A)

    Eco-friendly

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  • V-FLUID concrete fluidizer

    Item COD. (kg)V-FLUID VS0109800 10

    This additive permits improved concrete flow with less water. Optimises the covering of loops during installation.

    Distribution manifold

    d

    D

    D

    L

    I

    Outlets D (inch) d (inchxmm) I (mm) L (mm) COD. (pcs)

    2 G11/4 G3/4x18 214 190 VS0110102 13 G11/4 G3/4x18 214 240 VS0110103 14 G11/4 G3/4x18 214 290 VS0110104 15 G11/4 G3/4x18 214 340 VS0110105 16 G11/4 G3/4x18 214 390 VS0110106 17 G11/4 G3/4x18 214 440 VS0110107 18 G11/4 G3/4x18 214 490 VS0110108 19 G11/4 G3/4x18 214 540 VS0110109 110 G11/4 G3/4x18 214 590 VS0110110 111 G11/4 G3/4x18 214 640 VS0110111 112 G11/4 G3/4x18 214 690 VS0110112 1

    Pre-assembled manifold for radiant panel systems complete with lockshield valves, valves with motor option (by means of thermoelectric heads supplied separately), flow meters (0.5-3.0 l/min), 11/4 tailpieces, compact terminal sets with thermometer, adjustment hexagonal key and fixing brackets for encased cabinet.

    Kit for increasing manifold outlets

    D D

    D D

    LL

    d

    Outlets D (inch) d (inchxmm) L (mm) COD. (pcs)2 G11/4 G3/4x18 168 VS0110022 1

    The package contains a supply manifold and a return manifold.

    Pre-assembled kit for adding two extra outlets to a manifold for radiant panel systems. The kit includes two 2-outlet manifolds with lockshield valves on the supply, valves with motor option (by means of thermoelectric heads supplied separately) on the return, flow meters (0.5-3.0 l/min), 11/4 tailpieces, and 11/4 nipples for connection to the existing manifold, adjustment hexagonal key and two 11/4 flat seals.

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  • Distribution manifold for high temperature circuits

    D

    LD

    L

    H

    d

    Outlets D (inch) d (inchxmm) H (mm) L (mm) kg COD. (pcs)2 G3/4 G3/4x18 87 155 1.95 VS0110020 13 G3/4 G3/4x18 87 205 2.59 VS0110021 1

    The package contains a supply manifold and a return manifold.

    Distribution manifold for high-temperature circuits. Used for supplying bathroom radiators or additional radiators in a floor heating system. (To be used with mixing kit).

    Pair of compact terminal sets for distribution manifold

    L

    D

    M

    e

    d

    D (inch) L (mm) M (mm) e (mm) d (mm) COD. (pcs)

    G11/4 64.2 61 7 14.5 VS0110026 1 pair

    The package contains two compact terminal sets complete with drainage valves, manual air vent and thermometers.

    Pair of straight interception valves for distribution manifold

    L

    H

    D2D1

    A

    D1 (inch) D2 (inch) A (mm) L (mm) H (mm) COD. (pcs)

    G11/4 G11/4 71 65 55.7 VS0110034 1 pair

    The package contains two straight valves: a red one for the supply and a blue one for the return.

    Pair of elbow interception valves for distribution manifold

    D2

    D1 L

    HA

    D1 (inch) D2 (inch) A (mm) L (mm) H (mm) COD. (pcs)

    G11/4 G11/4 36 65 55.7 VS0110033 1 pair

    The package contains two elbow valves: a red one for supply and a blue one for return.

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  • Nut-ring-insert for distribution manifold

    D (inchxmm) Pipe (mmxmm) COD. (pcs)G3/4x18 14x2 VS0110035 10G3/4x18 16x2 VS0110036 10G3/4x18 20x2 VS0110037 10

    Fitting for connection of MIXAL pipes to distribution manifolds.

    Plug for distribution manifold

    D (inchxmm) COD. (pcs)G3/4x18 VS0110040 10

    Plug for distribution manifold outlets.

    Pair of tailpieces for distribution manifold

    L

    D2D1

    D1 (inch) D2 (inch) L (mm) COD. (pcs)G11/4 G11/4 47 VS0110041 1 pair

    The package contains two tailpieces complete with flat seal for coupling with compact valves code VS0110033 and VS0110034 and the distribution manifold.

    Pair of adaptors for distribution manifoldD1 D2

    L

    D1 (inch) D2 (inch) L (mm) COD. (pcs)G11/4 G11/4 39 VS0110042 1 pair

    The package contains two adaptors complete with o-ring for coupling of two distribution manifold.

    Flow meter for distribution manifold

    D (inch x mm) Flow rate (l/m) COD. (pcs)G3/4x18 0.53.0 VS0110049 10

    Flow meter to be connected to distribution manifold (return side).

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  • Mixing kit V-MIX01/PF and V-MIX01/PV

    Model Adjustment D1 (inch) D2 (inch) L (mm) H (mm) I (mm) COD. (pcs)V-MIX01/PF Fixed point G1 11/4 345 335 214 VS0110301 1V-MIX01/PV Variable point G1 11/4 335 350 214 VS0110302 1

    V-MIX01/PF: fixed point mixing kit with three-speed pump (head of 4 m, 5 m, 6 m), three-way valve, by-pass with adjustable differential valve, supply and return thermometer, safety thermostat and thermostatic head with liquid sensor.

    V-MIX01/PV: variable point mixing kit with three-speed pump (head of 4 m, 5 m, 6 m), three-way valve, by-pass with adjustable differential valve, supply and return thermometer, safety thermostat and thermostatic head with liquid sensor.

    V-MIX02 fixed point mixing kit

    D1 (inch) D2 (inch) L (mm) H (mm) I (mm) COD. (pcs)G3/4 11/4 280 344 214 VS0110303 1

    Fixed point mixing kit complete with thermostatic head equipped with three-speed pump (head of 4 m, 5 m, 6 m), thermometer on supply and return, lockshield valve on outlet of primary circuit, pre-adjusted safety by-pass and no-return valve.

    In-wall V-BOX distribution and mixing modules for constant temperatur

    D1 (inch) D2 (inch) HxLxP (mmxmmxmm) Exit 1 Exit 2 Exit 3 Adjustment COD. (pcs)G3/4 G3/4 690x595x190 High temperature Low temperature - Fixed point VS0110311 1G3/4 G3/4 690x595x190 High temperature Low temperature Low temperature Fixed point VS0110331 1G3/4 G3/4 690x595x190 Low temperature Low temperature Low temperature Fixed point VS0110352 1

    Compact distribution module, encased version, for high and low temperature circuits with fixed point mixing valve. Available for supplying two or three zones one of which is high temperature for supplying radiators. They are supplied complete with a painted steel cabinet, expanded polypropylene insulation, manifold with hydraulic compensator incorporated, three-speed circulators with 5 m head, compact interception valves, adjustment thermostatic heads and safety thermostat. The module has three different possibilities of connection to the boiler.

    Article not in stock, must be ordered specially.

    D 2

    D1D1

    L

    I

    D 2

    H

    D 2

    L

    D1

    IH

    D 2

    D1

    H

    LD1

    D2

    PF PV

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  • In-wall V-BOX distribution and mixing modules for variable temperature

    D1 (inch) D2 (inch) HxLxP (mmxmmxmm) Exit 1 Exit 2 Exit 3 Adjustment COD. (pcs)G3/4 G3/4 690x595x190 High temperature Low temperature - Variable point VS0110321 1G3/4 G3/4 595x690x190 High temperature Low temperature Low temperature Variable point VS0110341 1G3/4 G3/4 690x595x190 Low temperature Low temperature Low temperature Variable point VS0110353 1

    Compact distribution module, encased version, for high and low temperature circuits, with variable point valve with motor option . Available for supplying two or three zones one of which is high temperature for supplying radiators. Supplied complete with painted steel cabinet, expanded polypropylene insulation, manifold with hydraulic compensator incorporated, three-speed circulators with 5 m head, compact interception valves, adjustment thermostatic heads and safety thermostat. The module has three different possibilities of connection to the boiler.

    The motor to be applied to the mixing valve (not included) is code VS0110701.

    Article not in stock, must be ordered specially.

    Wall-hanging V-BOX distribution and mixing modules for constant temperature

    D1 (inch) D2 (inch) HxLxP (mmxmmxmm) Exit 1 Exit 2 Exit 3 Adjustment COD. (pcs)G3/4 G3/4 590x490x190 High temperature Low temperature - Fixed point VS0110312 1G3/4 G3/4 590x490x190 High temperature Low temperature Low temperature Fixed point VS0110332 1G3/4 G3/4 590x490x190 Low temperature Low temperature Low temperature Fixed point VS0110355 1

    Compact distribution module, wall-hung version, for high and low temperature circuits with fixed point mixing valve. Available for supplying two or three zones one of which is high temperature for supplying radiators. Supplied complete with painted steel cabinet, expanded polypropylene insulation , manifold with hydraulic compensator incorporated, three-speed circulators with head of up to 5 m, compact interception valves, adjustment thermostatic heads and safety thermostat. Complete with protective cover in painted steel.

    Article not in stock, must be ordered specially.

    Wall-hanging V-BOX distribution and mixing modules for variable temperature

    D1 (inch) D2 (inch) HxLxP (mmxmmxmm) Exit 1 Exit 2 Exit 3 Adjustment COD. (pcs)G3/4 G3/4 590x490x190 High temperature Low temperature - Variable point VS0110322 1G3/4 G3/4 590x490x190 High temperature Low temperature Low temperature Variable point VS0110342 1

    Compact distribution module, encased version for high and low temperature circuits with variable point valve with motor option. Available for supplying two or three zones one of which is high temperature for supplying radiators. Supplied complete with painted steel cabinet, expanded polypropylene insulation, manifold with hydraulic compensator incorporated, three-speed circulators with 5 m head, compact interception valves, adjustment thermostatic heads and safety thermostat. The module has three different possibilities of connection to the boiler.

    The motor to be applied to the mixing valve (not included) is code VS0110701.

    H

    LD1

    D2

    H

    LD1

    D2

    H

    LD1

    D2

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  • Mixing sets for fixed point central heating systems

    DN D1 (inch) D2 (inch) HxLxP (mmxmmxmm) COD. (pcs)25 11/2 1 394x250x188 VS0110802 1

    Set with fixed point mixing valve with thermostatic option* with by-pass on secondary and primary circuit. The set is complete with three-speed circulator with maximum head of 6 m, insulation in expanded polypropylene, interception valves with integrated thermometer on supply and return and thermostatic head with liquid sensor (code VS0110405). Possibility of changing supply from right to left with possibility of installation of a differential pressure group.

    Thermal power plants mixing groups with variable temperature

    DN D1 (inch) D2 (inch) HxLxP (mmxmmxmm) COD. (pcs)25 G1 G11/2 394x250x188 VS0110803 132 G11/4 G2 483x265x120 VS0110809 140 G11/2 DN 40 615x320x200 VS0110815 1

    Flange DN 40 PN 6 with 4 holes.

    Group with variable point mixing valve with motor capacity with a by-pass on the secondary and primary. The group is complete with three speed circulator with maximum predominance 6 m, insulation in expanded polypropylene, interception valves with thermometer integrated on the supply and return. Possibility of changing supply from right to left with possibility of installing a differential pressure group.

    The motor to apply to the mixing valve (not included) is code number VS0110701.

    High temperature groups for thermal power plants

    DN D1 (inch) D2 (inch) HxLxP (mmxmmxmm) COD. (pcs)

    25 G1 G11/2 394x250x188 VS0110801 132 G11/4 G2 483x265x120 VS0110807 140 G11/2 DN 40 615x320x200 VS0110813 1

    Flange DN 40 PN 6 with 4 holes.

    Group for high temperature circuits complete with three speed circulator with maximum predominance 6 m, insulation in expanded polypropylene, interception valves wit thermometer integrated on the supply and return.

    PLD2

    D1

    H

    H

    pLD2

    D1

    H

    pLD2

    D1

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  • Distribution manifold for thermal power plants

    DN D1 (inch) D2 (inch) Exits HxLxP (mmxmmxmm) COD. (pcs)25 G11/2 G11/2 2 120x505x120 VS0110821 125 G11/2 G11/2 3 120x755x120 VS0110823 125 G11/2 G11/2 4 120x1005x120 VS0110824 125 G11/2 G11/2 5 120x1255x120 VS0110825 132 G11/2 G2 2 150x530x150 VS0110831 132 G11/2 G2 3 150x795x150 VS0110833 132 G11/2 G2 4 150x1060x150 VS0110834 132 G11/2 G2 5 150x1325x150 VS0110835 140 DN 65 DN 65 3 220x1020x220 VS0110843 140 DN 65 DN 65 4 220x1340x220 VS0110845 1

    Flange DN 40 PN 6 with 4 holes.

    Flange DN 65 PN 16 with 4 holes.

    Without compact interception valves (code VS0110869).

    Distribution manifolds for heat centres complete with insulation in expanded polypropylene with compact interception valves on the supply and return connections to the mixing and distribution group.

    Compact interception valves kit with nut DN 32

    DN D1 (inch) D2 (inch) COD. (pcs)32 G11/2 G2 VS0110869 1

    Hydraulic separator for distribution manifold

    DN D (inch) D1 (inch) D2 (inch) HxLxP (mmxmmxmm) COD. (pcs)

    25 G11/2 G1/2 G3/4 520x120x120 VS0110851 132 G11/2 G1/2 G11/4 970x150x150 VS0110853 140 DN 65 G1/2 G11/4 970x220x220 VS0110855 1

    Flange DN 65 PN 16 with 4 holes.

    Hydraulic separator complete with insulation in expanded polypropylene with threaded attachments for air vent groups and for system drainage.

    D2

    D1

    H

    L

    D1

    D

    D

    D

    D1

    D2

    H

    L

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  • Manifold/hydraulic separator connection kit

    DN Manifold exits COD. (pcs)25 2 VS0110871 125 3 VS0110873 125 4 VS0110874 125 5 VS0110875 132 2 VS0110881 132 3 VS0110883 132 4 VS0110884 132 5 VS0110885 140 34 VS0110891 1

    Supply/return pipes insulated for connection of the distribution manifold to the vertical hydraulic separator.

    Support kit for manifold

    DN COD. (pcs)25-32 VS0112021 140 VS0112023 1

    The kit contains a pair of supports for fixing the manifold to the wall. The kit DN 40 is composed of small support feet, adjustable in height.

    Differential pressure group

    DN COD. (pz)25 VS0110861 132 VS0110863 1

    Differential group composed of 3/4 valve with measurement field of 2 to 6.5 m.w.c. (maximum operating pressure 8 bar), fittings and seals.

    Servo motors for mixing valve

    Nominal voltage Power consumption Torque Running time COD. (pz)230 Vac 2.5 W 5 Nm 140 s VS0110701 124 Vdc 1.5 W 5 Nm 140 s VS0110703 1

    Servo motors with 3 point regulation system and 220V supply. It is complete with graded scale for the identification of the position and selector for changing the automatic/manual function. It is mounted by means of a blocking screw and a anti-rotation reference rod.

    Servo motors 010 V complete with graded scale for the identification of the position and selector for changing the automatic/manual function. It is mounted by means of a blocking screw and a anti-rotation reference rod.

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  • V-DRYAIR 250V isotherm dehumidifier for wall installation

    Item Nominal flow Water flow Voltage HxLxP (mmxmmxmm) COD. (pcs)V-DRYAIR 250V 250 m3/h 170 l/h 230 729x705x212 VS0110901 1

    Isotherm in-wall recessed dehumidifier. V-DRYAIR 250V is used for the dehumidification in the summer of rooms that are cooled wit the use of radiant panels. The load-bearing structure is in galvanized sheet metal and the ventilation part is made up of a centrifugal ventilator and a motor with the choice of three speeds that guarantees efficiency and a silent operation. Air treatment is ensured by a refrigeration circuit composed of pre-treatment and post-treatment batteries in copper pipes and aluminium fins, an alternative compressor mounted on anti-vibration supports or springs, expansion capillary and dehydrator filter.

    For in-wall installation it must be combined with the housing cabinet and wooden panel cod. VSO110911.

    V-DRYAIR 250H isotherm dehumidifier for ceiling installation with possibility of ducting

    Item Nominal flow Water flow Voltage HxLxP (mmxmmxmm) COD. (pcs)V-DRYAIR 250H 250 m3/h 170 l/h 230 250x593x800 VS0110903 1

    Isotherm dehumidifier for ceiling installation with possibility of ducting for air delivery and return. V-DRYAIR 250H is used for the dehumidification in the summer of rooms that are cooled wit the use of radiant panels. The load-bearing structure is in galvanized sheet metal and the ventilation part is made up of a centrifugal ventilator and a motor with the choice of three speeds that guarantees efficiency and a silent operation. Air treatment is ensured by a refrigeration circuit composed of pre-treatment and post-treatment batteries in copper pipes and aluminium fins, an alternative compressor mounted on anti-vibration supports or springs, expansion capillary and dehydrator filter.

    V-DRYAIR 450H isotherm dehumidifiers for ceiling installation with possibility of ducting

    Item Nominal flow Water flow Voltage HxLxP (mmxmmxmm) COD. (pcs)V-DRYAIR 450H 450 m3/h 350 l/h 230 405x875x655 VS0110905 1

    Isotherm dehumidifier for ceiling installation with possibility of ducting for air delivery and return. V-DRYAIR 250H is used for the dehumidification in the summer of rooms that are cooled wit the use of radiant panels. The load-bearing structure is in galvanized sheet metal and the ventilation part is made up of a centrifugal ventilator and a motor with the choice of three speeds that guarantees efficiency and a silent operation. Air treatment is ensured by a refrigeration circuit composed of pre-treatment and post-treatment batteries in copper pipes and aluminium fins, an alternative compressor mounted on anti-vibration supports or springs, expansion capillary and dehydrator filter.

    Can be combined with renewal and recovery unit cod. VS0110913 and plenum chamber cod. VS01109015.

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  • V-DRYAIR 900H isotherm dehumidifiers for ceiling installation with possibility of ducting

    Item Nominal flow Water flow Voltage HxLxP (mmxmmxmm) COD. (pcs)V-DRYAIR 900H 900 m3/h 600 l/h 230 405x875x805 VS0110907 1

    Isotherm dehumidifier for ceiling installation with possibility of ducting for air delivery and return. V-DRYAIR 900H is used for the dehumidification in the summer of rooms that are cooled wit the use of radiant panels. The load-bearing structure is in galvanized sheet metal and the ventilation part is made up of a centrifugal ventilator and a motor with the choice of three speeds that guarantees efficiency and a silent operation. Air treatment is ensured by a refrigeration circuit composed of pre-treatment and post-treatment batteries in copper pipes and aluminium fins, an alternative compressor mounted on anti-vibration supports or springs, expansion capillary and dehydrator filter.

    Can be connected to the renewal and recovery unit cod. VS0110917 and plenum chamber cod. VS01109019.

    CHousing cabinet and wooden covering panel for V-DRYAIR 250V

    HxLxP (mmxmmxmm) COD. (pcs)740x750x230 VS0110911 1

    The housing cabinet is installed in the wall recess and houses the V-DRYAIR 250 V dehumidifier (cod. VS0110901); the base of the cabinet is perforated to allow passage of supply and return pipes, of pipes for the discharge of condensation and the electrical wires. The covering panel is made of white lacquered wood with air delivery and inhalation grid.

    Renewal and recovery unit for V-DRYAIR 450H isotherm dehumidifiers

    Maximum input current Maximum input power Voltage HxLxP (mmxmmxmm) COD. (pcs)0.7 A 60 W 230 Vca 405x750x655 VS0110913 1

    The renewal and recovery unit guarantees a fresh air exchange inside the building by recovering the heat being discharged which is then exchanged with fresh air from the outside; this process is created by intersecting the air flows, so that the process air is preheated/pre-cooled, thus increasing the efficiency of the unit and reducing energy consumption.

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  • Plenum chamber for V-DRYAIR 450H isotherm dehumidifier

    HxLxP (mmxmmxmm) COD. (pcs)405x220x655 VS0110915 1

    The plenum chamber is hooked up to the main recovery duct of the V-DRYAIR 450H isotherm dehumidifier and allows an increase in the ducts of up to maximum number of three, contemporarily. It has been designed so that all the panels can be dismantled in order to create the most suitable configuration for the system.

    Renewal and recovery modules for V-DRYAIR 900H isotherm dehumidifier

    Maximum input current Maximum input power Voltage HxLxP (mmxmmxmm) COD. (pcs)1.5 A 150 W 230 Vca 405x1050x805 VS0110917 1

    The renewal and recovery unit guarantees a fresh air exchange inside the building by recovering the heat being discharged which is then exchanged with fresh air from the outside; this process is created by intersecting the air flows, so that the process air is preheated/pre-cooled, thus increasing the efficiency of the unit and reducing energy consumption.

    Plenum chamber for V-DRYAIR 450H isotherm dehumidifier

    HxLxP (mmxmmxmm) COD. (pcs)405x220x655 VS0110919 1

    The plenum chamber is hooked up to the main recovery duct of the V-DRYAIR 900H isotherm dehumidifier and allows an increase in the ducts of up to a maximum number of three, contemporarily. It has been designed so that all the panels can be dismantled in order to create the most suitable configuration for the system.

    Thermo-electric head

    D (mmxmm) Measuring fields A (mm) B (mm) L (mm) d (mm) COD. (pcs)M28x1.5 3050 C 52 81.5 160 11 VS0110405 1

    Thermostatic head with immersion sensor for mixing kit.

    A

    B

    L

    d

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  • Thermo-electric head

    Working frequency no. connections COD. (pcs)24 V 2 wires VS0110430 1220 V 4 wires VS0110432 1

    On/off thermoelectric heads with adaptor for distribution manifold. They regulate the flow in floor heating circuits. They are applied to the distribution manifolds (return side).

    Can be used only with the control unit code VS0110600 and VS0110605.

    Can be used with a direct connection to the zone thermostats (on/off signal) and to the electric line 220 V.

    Circuit control unit

    Zones Max circuits Working frequency COD. (pcs)1 4 24 V VS0110600 16 14 24 V VS0110605 1

    Control unit of heating circuits. It is the command box of the thermo-electric heads, which operates depending on the temperature picked up by the thermostats.

    Mixing kit pump control module

    Zones Working frequency COD. (pcs)2 24 V VS0110610 1

    Module for increasing the number of zones controlled per control unit cod. VS0110600 and cod. VS0110605.

    Mixing kit pump control module

    Working frequency COD. (pcs)24 V VS0110620 1

    Module turns off the circulator pump when all the circuits are closed, to avoid activating the safety by-pass of the mixing kit.

    Regulators for mixing groups for central heating systems

    Working frequency No. of inlets No. of relay outlets COD. (pcs)24-220 V 2 2 VS0111101 1

    Electronic control that can be mounted with a DIN guide capable of managing 1 three-way valve. Regulates the opening of the valve in order to supply water to the system based on the programmed set point. 2 inlets for NTC probes for detecting the temperature (code VS0110057) are available, as well as 2 relay outlets for controlling the servomotor 220 V (code VS0110701).

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  • V-CLIMA master adjustment kit

    Function Working frequency Working conditions Dimensions of master control unit COD. (pz)

    Heating and cooling 20/60 Vdc and 24 Vac(5060 Hz) -10C60C/U.R. < 90% 140x60x110 VS0111001 1

    Heating only 20/60 Vdc and 24 Vac(5060 Hz) -10C60C/U.R. < 90% 140x60x110 VS0111011 1

    The V-CLIMA master adjustment kit is capable of adjusting the supply temperature of a floor heating system for one zone in relation to the variations in the external temperature. With the kit code VS0111001 the adjustment is made both in the winter mode (heating) and the summer mode (cooling), with the kit code VS0111011 the adjustment occurs in the winter mode. Possibility of management of up to 6 adjustment zones by means of the addition of expansion kit. The V-CLIMA master adjustment kit is complete with master unit with built-in terminal, connection kit, timer, supply probe, room temperature/humidity probe (or just temperature probe) and external temperature probe.

    V-CLIMA expansion

    Function Working frequency Working conditions Dimensions of expansion (mm) COD. (pz)

    Heating and cooling 20/60 Vdc and 24 Vac(5060 Hz) -10C60C/U.R. < 90% 70x60x110 VS0111003 1

    Heating only 20/60 Vdc and 24 Vac(5060 Hz) -10C60C/U.R. < 90% 70x60x110 VS0111013 1

    Expansion module capable of adjusting the supply temperature of a floor heating system for one zone in relation to the variations in the external temperature. With the kit code VS0111003 adjustment is made both in the winter mode (heating) and the summer mode (cooling), with the kit code VS0111013 adjustment occurs in the winter mode only. The V-CLIMA expansion kit is composed of an expansion unit to be connected to the master module, a connection kit, supply probe and temperature/humidity room probe (or just temperature probe).

    V-CLIMA winter/summer converter

    Working frequency Working conditions Dimensions of converter (mm) COD. (pcs)24 Vac (5-60 Hz) 0-50 C / U.R. < 90% 87x36x60 VS0111065 1

    Transforming module that when connected to the V-CLIMA system is capable of activating the flow deviation valves on the supply of the floor heating system, opening the boiler circuit or the chilling circuit.

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  • V-CLIMA remote adjustment terminal

    Working frequency Working conditions Dimensions of terminal (mm) COD. (pcs)Supply through master unit or else by means of an external supplier 18/30 Vdc -20C60C/U.R. < 90% 156x82x30 VS0111051 1

    The remote terminal with LCD display allows the user to carry out all of the system adjustments and the maintenance technician to verify, test and set the operation parameters of the system.It is equipped with the function time bands, the passage from day mode to night mode of the heating system.

    Supply probe for the V-CLIMA system

    Function Working range Bulb dimensions (mm) COD. (pcs)Temperature probe -50C105C 60x40 VS0111057 1

    Supply probe (NTC type) to interface with V-CLIMA system for the measurement of the supply temperature to the system.

    Room probe for V-CLIMA system

    Function Working range Supply voltage COD. (pcs)Temperature/humidity probe 0C50C/U.R. 0100% 9/30 Vdc and 12/24 Vac VS0111058 1Temperature probe 0C50C 9/30 Vdc and 12/24 Vac VS0111060 1

    Temperature detection probe (NTC type) and room humidity probe (0-1 V type convertible 4-20 mA).

    External probe for V-CLIMA system

    Function Working range Supply voltage COD. (pcs)Temperature probe -30C50C/U.R. 0100% 9/30 Vdc and 12/24 Vac VS0111059 1

    External temperature detection probe (NTC type).

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  • Fixer for clips

    COD. (pcs)VS0112000 1

    Fixer for clips cod. VS0109400 for anchoring MIXAL pipe to V-ELLE panel.

    Pipe unwinder

    COD. (pcs)VS0112002 1

    Antishrinkage net

    LxHxm (mmxmmxmm) Wire (mm) COD. (m2)2000x1000x50 2 VS0109700 400

    Anti-shrinkage grid in sheets, in galvanised steel for impact-resistant reinforced structures.

    Polypropylene anti-shrinkage grid

    LxHxm (mxmmxmm) COD. (m2)50x1000x50 VS0109701 2

    Anti-shrinkage grid in rolls, in high-resistant polypropylene for impact-resistant reinforced structures.

    In-wall metal cabinet for distribution manifold

    L (mm) H (mm) S (mm) COD. (pcs)400 700820 80130 VS0112007 1600 700820 80130 VS0112008 1800 700820 80130 VS0112009 11000 700820 80130 VS0112010 11200 700820 80130 VS0112011 1

    In-wall cabinet for mixing kit and distribution manifold, adjustable in height and depth. In powder coated steel and complete with support feet.

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  • 3 TECHNICAL CHARACTERISTICS OF THE COMPONENTS

    3.1 PEXAL and MIXAL pipe

    3.1.1 General characteristicsValsir has chosen to use the PEXAL and MIXAL pipes for floor heating systems due to their excellent thermo-mechanical properties. The PEXAL and MIXAL pipes are characterised by a particular multilayer structure which distinguishes itself from other pipes used in floor heating systems in that it possesses an inner layer in aluminium which is completely wrapped around the pipe and makes it perfectly oxygen proof. The multilayer pipe offers all the typical advantages of a metal pipe as well as those of a plastic pipe and at the same time, the qualities of one material compensate for the inadequacies of the other. The negative aspects of metal, such as corrosion, toxicity, encrustations, rigidity, weight and elevated pressure loss, are neutralised by the crosslinked polyethylene, which is in contact with the fluid transported in the pipe. The negative aspects of plastic, such as the passage of gas, the sensitivity to UV rays, and the elevated thermal expansion are all overcome thanks to the layer in aluminium.

    The MIXAL pipe is the most suitable solution for the creation of floor heating systems both in civil and industrial applications. Its structure is composed of: an outer layer in high-density polyethylene HDPE, white in colour, RAL 9003, an intermediate layer of aluminium alloy, butt-welded in an axial direction, two binding layers of adhesive, which unite the intermediate metal layers to the outer and inner layers of plastic, an inner layer of crosslinked polyethylene PE-Xb.

    Figure 3.1.1 Multilayer structure of MIXAL pipe.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

    3

  • The PEXAL pipe is mainly employed in water supply applications and for the creation of heating plants thanks to its structure composition: an outer layer of crosslinked polyethylene PE-Xb, white in colour, RAL 9003, an intermediate layer of aluminium alloy, butt-welded in an axial direction, two binding layers of adhesive unite the intermediate metal layer to the outer and inner layers of plastic, an inner layer of crosslinked polyethylene PE-Xb.

    Figure 3.1.2 Multilayer structure of PEXAL pipe.

    The dimensional characteristics are indicated in the following table.

    Table 3.1.1 Characteristics of the MIXAL pipe for floor heating systems.

    Characteristic MIXAL

    External diameter mm 14 16 20 26

    Total thickness mm 2.0 2.0 2.0 3.0

    Thickness of aluminium layer mm 0.2 0.2 0.25 0.3

    Weight g/m 100 105 140 50

    Water capacity l/m 0.077 0.113 0.201 0.314

    Operating temperature C 080 080 080 080

    Maximum operating temperature C 95 95 95 95

    Maximum operating pressure at 95C bar 10 10 10 10

    Thermal expansion coefficient mm/mK 0.026 0.026 0.026 0.026

    Internal heat conductivity W/mK 0.42 0.43 0.43 0.42

    Internal roughness mm 0.007 0.007 0.007 0.007

    Oxygen diffusion mg/l 0 0 0 0

    Bending radius without pipe bender mm 70 80 100 140

    Bending radius with pipe bender mm 35 50 80 100

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  • 3.1.2 Characteristics of crosslinked polyethylene PE-XbCrosslinked polyethylene PE-Xb has excellent mechanical characteristics in comparison with normal high-density polyethylene. The elevated stability of its mechanical properties, even at high temperatures, make it an absolutely ideal material for use in heating applications where the fluid conveyed can reach elevated temperatures. These characteristics are generated by the crosslinking process during which the material undergoes a structural modification, which improves its mechanical resistance, its resistance to abrasion and its resistance to chemical agents.

    Table 3.1.2 Some characteristics of crosslinked polyethylene PE-Xb.

    Characteristic Measurement unit Value

    Density kg/m3 950

    Minimum degree of crosslinking % 65

    Softening temperature C 135

    Tensile strength at 23C MPa 23

    Tensile strength at 100C MPa 9

    Thermal conductivity coefficient W/mK 0.38

    Specific heat at 23C kJ/kgK 1.92

    Coefficient of linear expansion mm/mK 0.2

    3.1.3 Characteristics of aluminium The aluminium used in the production of the PEXAL and MIXAL multilayer pipes is composed of sheets of aluminium alloy. The sheet is formed around the layer of PE-X and the two extremities, which run along the length of the pipe, are butt welded with a TIG welding process (Tungsten Inert Gas).This technology enables the production of multilayer pipes with an aluminium thickness of 0.2 mm to 2.5 mm and, therefore, also large diameter pipes with an elevated aluminium thickness. The principal characteristics of the aluminium alloy utilised in the production of the multilayer pipe are good welding, elevated yield point, storage in dry areas to guarantee the perfect conservation of the aluminium.

    Figure 3.1.3 Aluminium layer in PEXAL and MIXAL pipes.

    3.1.4 Mechanical behaviourThe mechanical characteristics of the multilayer pipe make it ideal for use in floor heating systems. There is no spring-back, that is, once the pipe has been bent it maintains the circular section in proximity to the bend and remains in the desired position like a metal pipe; in this way, the applications of fixing clips that are normally used with all-plastic pipes, is considerably reduced.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

    3

  • 3.1.5 ExpansionThe heat expansion of PEXAL and MIXAL multilayer pipes is 0.026 mm/mK; this value is comparable to the heat expansion of metal pipes. The table below shows how all-plastic pipes have much higher expansion coefficients and, in particular, PE-X has an expansion coefficient of 0.20 mm/mK.

    Table 3.1.3 Comparison of heat expansion with other materials.

    Type of material Heat expansion mm/mK

    PEXAL/MIXAL 0.026

    Galvanised steel 0.012

    Stainless steel 0.016

    Copper 0.016

    Plastic material (PE-X, PE-HD, PB, PPR, PE-RT) 0.1200.200

    3.1.6 Resistance to abrasion, encrustation and corrosionPE-X does not corrode and its smooth surface does not favour the formation of encrustation. As it is not subject to corrosion, there is no build-up of rust particles resulting from galvanic corrosion. Furthermore, PE-X is particularly resistant to abrasion; this is an extremely important characteristic in the proximity of bends where the abrasive effect of fluids and the particles contained in the fluid, tends to be greater.

    3.1.7 Barrier to oxygen and UV rays The inner layer of aluminium makes for a perfect barrier to the passage of gaseous molecules, thus avoiding every danger of corrosion caused by the infiltration of oxygen and damages caused by exposure to UV rays. In the following table, a comparison is made between the coefficients of oxygen transmission (Oxygen Transmission Rate) of aluminium, of the material used for the oxygen barrier (EVOH) in PE-X pipes with EVOH, and of crosslinked polyethylene.

    Figure 3.1.4 Impermeability to oxygen of the multilayer pipe and permeability of all-plastic pipes.

    O2

    O2

    O2O2

    O2

    O2

    O2

    O2O2

    O2O2

    O2

    O2O2 O2

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    Table 3.1.4 Coefficient of oxygen transmission OTR.

    Pipe OTR a 25C and 0% UR [cm3/20mmm2giornobar]

    Aluminium 0

    Barrier EVOH 0,21

    PE-X 12000

    The oxygen diffusion value in PEXAL and MIXAL pipes is zero thanks to the presence of the internal layer of aluminium across the entire range of diameters and regardless of room temperature and humidity.

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  • In PE-X pipes with barriers, the oxygen transmission coefficient OTR increases as the temperature and relative humidity rises (Figure 3.1.5 and Figure 3.1.6). Even at a temperature of 45C and with a relative humidity of 65%, the EVOH barrier has an oxygen transmission coefficient of almost 3.0 cm3/20mm2daybar.Many of the PEX pipes distributed today on the market, possess an oxygen barrier that is generally positioned on the outside on the pipe. Such a layer is, therefore, significantly exposed not only to the danger of being scraped and cut but is also exposed to the negative effect of humidity which drastically reduces the barrier.

    Figure 3.1.5 Coefficient of oxygen transmission of EVOH in relation to temperature.OT

    R to

    65%

    UR

    4.0

    Temperature [C]

    2.5

    2.0

    1.5

    1.0

    0.5

    20 25 30 35 40 45 50

    3.5

    3.0

    2008 Valsir S.p.A.

    Figure 3.1.6 Coefficient of oxygen transmission of EVOH in relation to relative humidity.

    80100

    60

    40

    20

    1086

    4

    0.1

    OTR

    to 2

    0C

    Relative humidity UR [%]

    0 20 40 60 80 100

    2

    10.80.6

    0.4

    0.2

    2008 Valsir S.p.A.

    3.1.8 LightweightThe specific weights of the materials that make up the pipe are low. A coil of 100 metres of MIXAL 16x2 weighs approximately 10.5 kg.

    3.1.9 Sound absorption The soundproof properties of the pipe are very good. The internal and external layers in polyethylene reduce noises, which are normally not absorbed by metal pipes.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • 3.1.10 Long lasting The PEXAL and MIXAL pipes are designed to resist a pressure of up to 10 bar with working temperatures of 95C. The crosslinked polyethylene possesses, in fact, a very high ageing resistance. Artificial ageing tests carried out in laboratories guarantee the pipe a life of over 50 years. At operating temperatures below 95C, the pipe can support pressures of over 10 bar without any damage being caused; at 20C it can be used at a pressure as high as 25 bar. The technical characteristics of the PEXAL and MIXAL multilayer pipes are therefore of an elevated level, especially if they are compared with the real operating conditions of floor heating systems which, on average, operate at temperatures of 45C and pressures which do not exceed 2-2.5 bar.

    The safety margin of floor heating applications with PEXAL and MIXAL multilayer pipes is very high. With a temperature of 95C and a safety margin of 1.5, the pipe can be used at a pressure of 10 bar. At the same temperature, therefore, if used at a pressure of 2.5 bar, the safety coefficient increases to 6 and, obviously, increases even more if the temperature is reduced to 45C.

    3.1.11 Heat conductivity The heat conductivity of the MIXAL pipe depends on the multilayer structure of the pipe, and in particular, on the thickness and the position of the aluminium layer. Whereas the value for PE-X pipes is 0.38 W/mK, the conductivity of the MIXAL pipes ranges from 0.42 W/mK to 0.43 W/mK (see Table 3.1.1). This difference clearly favours the use of PEXAL and MIXAL pipes for floor heating systems in that it is possible to create systems with an optimum heat output.

    3.1.12 Comparison of heat outputs of different pipes As seen in the previous paragraph, the presence of the aluminium layer, its thickness and its particular position allow the achievement of excellent heat conductivity properties. With the MIXAL pipe, it is possible to create floor heating systems with higher heat outputs, in fact, the higher conductivity generates higher temperatures on the surface of the pipe than PEX pipes (see Figure 3.1.7) and this advantage is reflected, for example, in the possibility of using relatively lower supply temperatures (see Figure 3.1.8).

    Figure 3.1.7 External surface temperature of the pipe (example).

    Tm = 40C Tm = 40C

    Tde = 36.4C Tde = 35.7C

    MIXAL Plastic pipe

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    Figure 3.1.8 Supply temperature (example).

    Tf = 27.3C

    Ta = 20C

    Tm = 39.3C

    MIXAL Plastic pipe

    concrete

    Tm = 40C

    Tf = 27.3C

    2008 Valsir S.p.A.

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  • The greater performance of the MIXAL pipe as compared with PEX pipes is evident in Figure 3.1.9 where, with equal system conditions, greater thermal output is achieved. In the case examined, there is a increase of 2.2% in the thermal output, both with a pipe spacing of15 cm and a pipe spacing of 22.5 cm

    Figure 3.1.9 Comparison of outputs of MIXAL 16x2 pipe and PEX 16x2 pipe.

    MIXAL 16x2

    Thermal output 12 W/m+2.56%

    MIXAL 16x2

    Thermal output 18 W/m+2.22%

    Spacing 15 cm

    Spacing 22.5 cm

    PEX 16x2

    PEX 16x2

    Thermal output 11.7 W/m

    Thermal output 17.6 W/m

    Tm = 46C

    v=0.11 m/s

    T = 19C

    Tm = 46C

    v=0.11 m/s

    T = 19C

    Tm = 46C

    v=0.15 m/s

    T = 14.4C

    Tm = 46C

    v=0.15 m/s

    T = 14.4C

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    The considerations examined above allow us to reach a conclusion of significant importance, and that is, the possibility of using smaller diameters than those used with all-plastic pipes. To simplify the concept, let us imagine that we need to install a floor heating circuit for a10 m2 room that requires a specific heat output of 80 W/m2. The floor is composed of a Valsir V-ESSE20 insulation panel, the layer of concrete above the pipes is 40 mm thick and for simplicity sake, we will not take any type of floor covering into account. In the following two tables, a comparison is made between the values of two circuits installed with a 17x2 diameter PEX pipe and a 16x2 MIXAL pipe with two different pipe spacing values and a supply temperature of 45C.

    It is evident that the flow and speed of the circuits are more or less the same and therefore, that the 16x2 diameter MIXAL pipe can be used instead of the 17x2 diameter PEX pipe.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • Table 3.1.5 Comparison between PEX and MIXAL with pipe spacing of 15 cm.

    Characteristics PEX 17x2 MIXAL 16x2

    Pipe spacing [cm] 15 15

    Supply temperature [C] 45 45

    Loop lengths [m] 66.7 66.7

    Temperature difference T [C] 18.6 18.8

    Flow [l/h] 46.6 46.1

    Velocity [m/s] 0.10 0.11

    Table 3.1.6 Comparison between PEX and MIXAL pipes with a pipe spacing of 22.5 cm.

    Characteristics PEX 17x2 MIXAL 16x2

    Pipe spacing [cm] 22.5 22.5

    Supply temperature [C] 45 45

    Loop lengths [m] 44.4 44.4

    Temperature difference T [C] 14.5 14.1

    Flow [l/h] 61.4 60.0

    Velocity [m/s] 0.13 0.15

    Figure 3.1.10 Thermal output PEX 17x2 and MIXAL 16x2.

    MIXAL 16x2

    MIXAL 16x2

    Same thermal output 12 W/mSpacing 15 cm

    Same thermal output 18 W/mSpacing 22.5 cm

    PEX 16x2

    PEX 16x2

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    Tm = 45C

    v=0.11 m/s

    T = 18.8C

    Tm = 45C

    v=0.10 m/s

    T = 18.6C

    Tm = 45C

    v=0.15 m/s

    T = 14.5C

    Tm = 45C

    v=0.13 m/s

    T = 14.1C

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  • 3.1.13 Pressure losses The internal layer of the pipe has an extremely smooth surface with a roughness of 0.007 mm. This surface does not favour the formation of incrustations or rust, which means that pressure loss is very low and does not alter over time. With the use of the diagrams in Figure 3.1.14, Figure 3.1.15 and Figure 3.1.16 it is possible to determine the pressure loss and flow speed in the PEXAL and MIXAL multilayer pipes in relation to the flow rate and the temperature of the water at 10C, 30C and 50C respectively.

    When dimensioning a floor heating circuit, localised pressure losses due to the continuous changes in direction of the radiant loops must also be accounted for.

    The linear pressure losses (calculated in the diagrams shown) must be increased by a percentage point, indicated in Table 3.1.7, which depends on the type of pipe layout adopted in the system.

    Table 3.1.7 Percentage increase in pressure losses in relation to the type of piping layout pattern.

    Type of layout pattern Percentage increase Typical application

    Simple single serpentine 17% Industrial systems, snowmelt systems(Figura 3.1.11)

    Simple double serpentine 17% Industrial systems, heating systems for rooms with elevated surface areas, gymnasiums, warehouses, etc. (Figura 3.1.12)

    Counterflow spiral 13% Residential systems (Figura 3.1.13)

    Figure 3.1.11 Simple single serpentine. Figure 3.1.12 Simple double serpentine.

    2008 Valsir S.p.A. 2008 Valsir S.p.A.

    Figure 3.1.13 Counter-flow spiral.

    2008 Valsir S.p.A.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • Figure 3.1.14 Pressure losses with water at 10C.

    Water tem

    perature: 10C

    Water flow

    rate [l/s]

    Pressure losses [mbar/m]

    0.1

    0.08

    0.06

    0.04

    0.8

    0.6

    0.4

    0.2

    0.1

    0.08

    0.06

    0.04

    0.02

    0.01

    0.008

    0.006

    0.004

    0.2

    0.4

    0.6

    0.8 1 2 4 6 8

    10 20 40 60 80

    100

    200

    2

    1

    14x216x2

    18x220x2

    26x34.5

    4.0

    3.5

    3.0

    2.5

    2.0

    1.8

    1.6

    1.4

    1.2

    1.0

    0.9

    0.8

    0.7

    0.6

    0.5

    0.4

    0.35

    0.3

    0.25

    0.20.18

    0.160.14

    0.120.10

    0.090.08

    0.070.06

    0.05

    Water velocity [m/s]

    2008 Valsir S.p.A.

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  • Figure 3.1.15 Pressure losses with water at 30C.

    Water tem

    perature: 30C

    Water flow

    rate [l/s]

    Pressure losses [mbar/m]

    0.1

    0.08

    0.06

    0.04

    0.8

    0.6

    0.4

    0.2

    0.1

    0.08

    0.06

    0.04

    0.02

    0.01

    0.008

    0.006

    0.004

    0.2

    0.4

    0.6

    0.8 1 2 4 6 8

    10 20 40 60 80

    100

    200

    2

    1

    14x216x2

    18x220x2

    26x34.5

    4.0

    3.5

    3.0

    2.5

    2.0

    1.8

    1.6

    1.4

    1.2

    1.0

    0.9

    0.8

    0.7

    0.6

    0.5

    0.4

    0.35

    0.3

    0.25

    0.20,18

    0.160.14

    0.120.10

    0.090.08

    0.070.06

    0.05

    Water velocity [m/s]

    2008 Valsir S.p.A.

    41

    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • Figure 3.1.16 Pressure losses with water at 50C.

    Water flow

    rate [l/s]

    Pressure losses [mbar/m]

    2

    0.1

    0.08

    0.06

    0.04

    1

    0.8

    0.6

    0.4

    0.2

    0.1

    0.08

    0.06

    0.04

    0.02

    0.01

    0.008

    0.006

    0.004

    0.2

    0.4

    0.6

    0.8 1 2 4 6 8 10 20 40 60 80

    100

    200

    Water tem

    perature: 50C

    14x216x2

    18x220x2

    26x34.5

    4.0

    3.5

    3.0

    2.5

    2.0

    1.8

    1.6

    1.4

    1.2

    1.0

    0.9

    0.8

    0.7

    0.6

    0.5

    0.4

    0.35

    0.3

    0.25

    0.20.18

    0.160.14

    0.120.10

    0.090.08

    0.070.06

    0.05

    Water velocity [m/s]

    2008 Valsir S.p.A.

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  • 3.1.14 Quality controlIn the Valsir factories, the entire production process of the multilayer pipe undergoes continuous and strict quality controls. As well as the numerous tests requested by the protocols published by the most important international certification institutes, Valsir also carries out important tests of a high qualitative value on its products. The following paragraphs illustrate some of the tests carried out on the PEXAL and MIXAL multilayer pipes.

    1. Dimensional aspectThe principle test performed on the multilayer pipe by the Valsir quality control team is to measure the diameters and the thickness of the individual layers; this test is performed in the laboratory with the help of the most technologically advanced optical measurement equipment, complete with software capable of automatically carrying out the dimensional tests (the dimensions of the pipe are tested in the process using laser detectors). The sophisticated optical projector also enables the weld cross-section to be checked and therefore to verify that the weld has been correctly performed.

    2. Separation testOf equal importance is the separation test; this is performed using a computerised dynamometer capable of assessing the force required to separate the aluminium layer from the internal pipe (glued together). As a result, the test provides a graph describing the value of the force (at every point on the pipes circumference) to be applied to separate the layers. The adhesion between the PEX and the aluminium is fundamental for the seal of a multilayer pipe under pressure: the greater the adhesive strength, the greater the pressure the product can undergo.

    3. Bending testThe 90 bending test is one of the mechanical tests performed on the PEXAL pipe. This test is performed using a dynamometer that records the force required for bending. The test is passed if no squeezing or wrinkling of the external layer occurs on the test specimen.

    4. Estimation of the degree of crosslinkingThe finished PEXAL and MIXAL multilayer pipe (which has already completed the crosslinking process) is subjected to a test that measures the degree of cross-linking achieved by the polymeric materials. The testing procedures are defined by international standards and are strictly followed by the operators assigned to perform the test; the degree of crosslinking of the polymers is used to assess the aggregation of the materials molecules and it is therefore important for assessing the increase in the mechanical and chemical resistance of the polyethylene.

    5. Pressure testSamples of the pipe are taken (at pre-established intervals) during the daily production of the PEXAL product. The samples are used to perform hydraulic tests at different pressures and at different temperatures. The tests are designed to determine whether the product is suitable for sale and to assess the products hydraulic, mechanical and structural characteristics. The tests are performed in suitable tanks or ovens at an electronically controlled temperature. The pressure values set at the entry of each individual test specimen and the test conditions are controlled and recorded at every moment by a computerised system and have been established during the certification phase of the product.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • 6. Long duration testsThe long duration tests are carried out to confirm the reliability of the product over time. In fact, they are carried out for 1000 hours both at 95C in special tanks, and at 110C in special ovens.

    7. Cone testSamples of PEXAL and MIXAL pipe taken during the production phase at regular intervals undergo the cone test; this test is performed in compliance with international standards, and is carried out on-line by the production operators and in the laboratory by the Quality operators (in this case the test is performed using a computerised dynamometer); this test is designed to assess the seal of the weld and the sealing strength of the glue applied between the various layers, after having expanded the pipe by more than 13% of its nominal diameter.

    8. Dimensional test during productionThe diameters of the pipe are constantly monitored by laser instruments during the production of the PEXAL and MIXAL pipes, supported by a computerised system in the successive phases of the manufacturing process. In this way the production operators are able to observe the trend graphs of the individual diameters on the line monitors at every moment. Appropriate alarms are activated when the values are outside the pre-established range.

    9. Tensile testThe fundamental raw material for the production of the PEXAL and MIXAL pipes is aluminium; in order to avoid defects in the supply of this material (even with top quality suppliers) Valsir carries out tests on each consignment by measuring the dimensions and mechanical characteristics; the mechanical properties are verified by carrying out tensile tests (established by international standards) on samples of material randomly selected from the batch that has been delivered; the tests are carried out with the use of sophisticated computerised dynamometrical instruments.

    10. Analysis of melt flow indexAll of the polymerical raw materials utilised in the manufacture of the multilayer pipe are controlled on arrival in order to verify their principal characterisitcs; this allows Valsir to produce with the certainty of employing materials suitable for manufacturing. The instruments utilised for the controls are the most technogically advanced: for example, the melt flow index measurement is taken with the use of the most up-to-date automatic appliances.

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  • 11. Heat resistance testThe controls carried out by the Valsir quality control laboratories on the polymerical materials employed in the production of the PEXAL and MIXAL pipes, do not end with the controls carried out on in-coming materials, but continue after the production phase. The shrinkage and sliding test are carried out on the finished product on the various layers of polyethylene; pieces of pipe undergo artificial ageing tests and thermal stress tests in thermostatic cells.

    12. Suitability of internal diameter (marble test)Along the production line every coil of PEXAL and MIXAL multilayer product is tested by inserting a steel marble into the pipe that is then pushed into the same with the use of compressed air. This operation ensures that there are no collapses or obstacles within the pipe.

    13. Pipe hammerAt each production start-up of the PEXAL and MIXAL multilayer pipes and the plastic fittings in PPSU (Polyphenyl Sulfone) a pressure cycle test is performed at 23C. This consists of creating sudden pressure changes (frequency = 30 cycles per minute) inside the test specimen ranging from the lowest value (0.5 bar) to the highest value (25 bar) for 10,000 times with the aim of verifying the mechanical stability of the product and consequently the complete absence of leaks.

    14. Vibration testAt each production start-up of the multilayer pipe a vibration test is performed: this consists of subjecting a 2 m long specimen, obtained by combining two 1 m long pipes each with an intermediate fitting, to a combination of static pressure (15 bar) and vertical mechanical stress of misalignment ( 10 mm) with the aim of verifying the pipe-fitting compatibility or more precisely the absence of withdrawing. Each pipe-fitting combination is subjected to a total of 330 cycles each lasting 80 seconds that are made up of 20 seconds of vibrations with a pause of 60 seconds. The test is considered positive if there are no leaks or ruptures.

    15. Thermal cycle testIn order to guarantee the reliability of the PEXAL multilayer system and its relative fittings, in brass and in PPSU, over time, fatigue tests are carried out in Valsir. There are several fatigue tests that can be carried out, however, the most requested one is the Thermal Cycling Test commonly abbreviated to TCT. The test consists of first of all assembling a circuit by uniting the pipes and fittings in accordance with a pattern established by the European Standard UNI EN 12293. The circuit then undergoes a 5000 cycle thermal test with hot and cold water. This test is undertaken to verify the suitability and the compatibility of the multilayer pipe and its fittings.

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    TECHNICAL CHARACTERISTICS OF THE COMPONENTS

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  • 3.1.15 Pipe approvals

    IIP-UNI: certificate of conformity of the PEXAL multilayer pipe systems to convey hot and cold water in domestic water an space heating systems.

    RINA: approval, which guarantees the use of the PEXAL multilayer system on board ships for domestic water, heating and air-conditioning systems.

    IIS: Qualification certificate of the aluminium welding procedure adopted in the production of the PEXAL multilayer pipe, in accordance with specifications EN 288-8: 1997 Annexes No. 12.

    AS 4176 SPEC. 438 LN IP083: certificate of conformity of the PEXAL system to convey hot and cold drinking water under pressure.

    AS/NZS 4020 (PEXAL):

    Certificate of suitability of the PEXAL multilayer pipe to convey cold and hot water (up to 85C) in domestic water systems. ANALYSIS REPORT: MAT/ASN 018D.

    AS/NZS 4020 (PPSU):

    Certificate of suitability of the PPSU fittings to convey cold and hot water (up to 85C) in domestic water systems. ANALYSIS REPORT: MAT/ASN 019D.

    MC - GOST: certificate of conformity of the PEXAL system to be used to transport hot and cold drinking water in domestic water and heating systems.

    Polish certificate of suitability for the installation of PEXAL piping for heating, the supply of hot and cold water for domestic use.

    Polish certificate of suitability of the PEXAL system for the supply of drinking water.

    Approval that guarantees the suitability of the PEXAL multilayer pipe for use in conveying hot water to heating systems.

    OVGW: system certification inherent to the PEXAL product to be used in water supply systems in