Thegreen

pipe

Contents

Index 4

Quality targets, Technical standards 5

Problems and solutions 6–7

Raw material data: PP-R, metals 8–9

Pipe types MK00, MK02, MK08; operating temperatures 10–11

Methods of joining; the safest pipe connection 12–13

Joining the pipes with the hand welding machine 14–15

Table welding machine 16–17

Overhead welding machine 18–19

Pipe sizing; flow velocity; fitting pressure losses; circulation pipes 20

Pipe sizing according to DIN 1988-300 21–22

Sizing charts for PN10, PN16 and PN20 23–25

Flow rate calculations according to DIN 1988-300 26–27

Expansion; compensation; force of expansion 28–29

Compensating expansion in practice; pipe supports 30–31

Pipe installing 32–33

Pressure test with drinking water 34–35

Pressure test with air or inert gases 36–37

Rinsing; noise prevention; cold water insulation 38–39

General installation guidelines 40–41

Product range; dimensions 42–53

Agencies; addresses 54–55

Please read the information contained in this handbook before you use K2 PPR for the first time, especially the information about how to make the joints.

3

KE KELIT’s Quality targets

1. Our quality targets are not confined to the product. They include all areas covered by ÖNORM EN ISO 9001:2000.

2. Suppliers and customers are integrated into the quality assurance system to ensure that mistakes are prevented.

3. Every employee is responsible for the quality of his own work and should be highly motivated to continually assess his work.

4. Customer satisfaction can only be achie-ved by responding to the requirements of the customer and the market.

5. A responsible attitude to the environment can only be achieved by manufacturing long-life products by environment-friendly processes.

Technical standards

National and international test institutes test the conformity of our products to a range of different standards.*

EN ISO 15874 – Serie Plasticpiping systems for hot and cold water installations

Dimensions, pressure ratings Material requirements

General:

BS 6920 Suitability for drinking water

ON EN 10226-1 Metal threads

*For information about specific national approvals please contact the headquarters in Linz or the regional offices.Senator Karl Egger eh.

Managing Director

Abbreviation Description Unit

A Cross-sectional area mm2

d Outside diameter of pipe mm di Inside diameter of pipe mm E Module of elasticity N/mm2

FP Fixing point Ft Force of heat expansion N IS Insulation thickness mm l Length of piping m MS Minimum length of expansion pipe mm N Force Newton P Pressure bar PN Pressure rating bar R Pressure loss caused by friction Pa/m s Wall thickness mm sec Time second SF Safety factor SP Supporting point SDR Standard Dimension Ratio t Temperature °C tm Temperature of medium °C tv Temperature at time of installation °C V Volume l/m V̇ Flow volume l/sec v Flow velocity m/sec VP Packing unit pc V̇R Total flow rate (DIN) l/sec V̇S Peak flow rate l/sec W Power Watt Z Flow resistance for type of fitting Pa z z-dimension mm α Coefficient of expansion mm/m°C ∆ l Specific linear expansion mm ∆p Total pressure loss Pa ∆ t Temperature difference∆ °C ζ Pressure loss coefficient λ Coefficient of heat conductivity W/m°C ρ Density kg/m3

∑ Sum δv Tensile stress Mpa

IndexThe following commonlyused abbreviations arefound in this catalogue.

54

Drinking water problems

Corrosion● The concentration of ions in drinking

water is increasing and consequently the risk of using metal pipes:

Chlorides: attack stainless steel Sulphates: attack galvanised steel Nitrates: attack copper● Ever more problematic sources of water reserves have to be tapped

for the supply of drinking water● Acid rain reduces the pH value of

surface and spring water to critical levels below 7 (=neutral).

External corrosion occurs as a result of new building and insulation materials and new installation methods.

● Disinfectants (chlorine, ozone) attack copper in particular. Poisonous

Cu ions are released into the water!

Incrustation● Hard water causes incrustation on the inside walls of metal materials.

The consequences:

● Higher pressure losses● Reduced flow● Blockages● Expensive repair work● Time-consuming renovation● Disruptions in the water supply

A secure supply of drinking water is an essential factor for a high quality of life

Internal corrosion - Cu

External corrosion - Steel

Calcite deposits

Operating conditions

PN20 = 20°C/20 bar; 70°C/8 bar

PN16 = 20°C/16 bar; 60°C/8 bar

PN10 = 20°C/10 bar;

The solution

K2 PPR drinking water pipe system

Plastics are not ”replacement materials”. When chosen and applied correctly they often provide the better solution for a defined problem.

Sometimes even the only one

The Result

The K2 PPR pipe system has many advantages. Ideal for hot andcold water installations for both new projects and renovation.

● Pressure ratings: PN10, PN16 and PN20

● Cold water: d20 – d160 mm Hot water: d20 – d110 mm

● Resistant to internal and external corrosion caused by ions in the water or chemicals on the site

● No crystallisation points for lime deposits

● Secure joint technology which requires no additional materials.

● Conforms to hygiene regulations and approved for transporting foodstuff

● Low pressure losses as a result of smooth bore

● Low noise level● Resistant to high temperatures

and pressure● Low thermal conductivity comparison of λ-values: K2 PPR 0,24 W/m°C Copper 320,00 W/m°C Cast iron/steel 42,00 W/m°C● Stringent testing and monitoring of quality to international standards● Secure long-term performance● Pipes are insulated at the factory

and can be located behind the wall● Can be combined with KELOX-multi-

layer flexible pipe system

”No more corrosion in the 3rd millennium”

76

The raw materials

The long-life plasticThe raw material is a polypropylene copolymer (PP-R) with its typical quality characteristics EN ISO 15874.

Every material is subject to ageing. PP-R is no exception to this rule of nature. The ”long-term creep curves”, which are determined by temperature and stress, are proof of the long service life (see page 11 for operating conditions).

Density: 0,91 g/cm3

Melting Point: ~ 140° CTensile strength: 40 N/mm2

Elongation at tear: 800 %E-module (20°C): 900 N/mm2

Spec. heat 2 kJ/kg °CHeat conductivity: 0,24 W/m °CSpec. themal expansion: 0,15 mm/m °C

● Pipes and fittings are made of the same raw material.

The expected servicelife can be read off thegraph.

The following formulais used to calculate thetensile stress:

δvT

ensi

le s

tren

gth

in M

Pa

Time in h >

Long-term creep curve DIN 8078

10

Metal adaptor fittings

Special care has been taken over the choice and quality control of the metal threads.

Special quality criteria● Brass (MS 58, CW 617N) for all parts

transporting water ensures high resistance against aggressive water.

● A pore-free, chemically applied metal plating prevents stress corrosion cracking.

● Metal parts which are not in contact with the media are generally made of metal-plated MS 58 brass.

● Exceptional resistance to torsion force and suitable for on-site conditions

● Depth of the thread conforms to ON EN 10226-1 for normal faucets

98

PP-R pipe system

MK02 K2 PPR pipe PN10/SDR11 d x s Flow rate L/m 20 x 1,9 mm 0,21 25 x 2,3 mm 0,33 32 x 2,9 mm 0,54 40 x 3,7 mm 0,83 50 x 4,6 mm 1,31 63 x 5,8 mm 2,07 75 x 6,8 mm 2,96 90 x 8,2 mm 4,25 110 x 10,0 mm 6,36 160 x 14,6 mm 13,44

MKO8 K2 PPR pipe PN16/SDR7,4 d x s Flow rate L/m 20 x 2,8 mm 0,16 25 x 3,5 mm 0,25 32 x 4,4 mm 0,42 40 x 5,5 mm 0,66 50 x 6,9 mm 1,03 63 x 8,6 mm 1,65 75 x 10,3 mm 2,32 90 x 12,3 mm 3,36 110 x 15,1 mm 5,00 160 x 21,9 mm 10,60

MK00 K2 PPR pipe PN20/SDR6 d x s Flow rate L/m 20 x 3,4 mm 0,14 25 x 4,2 mm 0,22 32 x 5,4 mm 0,35 40 x 6,7 mm 0,56 50 x 8,3 mm 0,88 63 x 10,5 mm 1,39 75 x 12,5 mm 1,96 90 x 15,0 mm 2,83 110 x 18,3 mm 4,23

Dimensions: as specified by EN ISO 15874 Colour: Green, 3 co-extruded green lines (90° apart) help the plumber to align pipe and fitting. Standard length: 4 m, Other lengths can be produced on request subject to minimum order quantities!

Dimensions: as specified by EN ISO 15874 Colour: Green, 3 co-extruded blue lines (90° apart) help the plumber to align pipe and fitting. Standard length: 4 m, Other lengths can be produced on request subject to minimum order quantities!

Dimensions: as specified by EN ISO 15874 Colour: Green, 3 co-extruded red lines (90° apart) help the plumber to align pipe and fitting. Standard length: 4 m, Other lengths can be produced on request subject to minimum order quantities!

Application as specified: Cold water PN10/SDR11: 20°C/10 barSafety factor: The DIN standard takes account of raw material properties and calculates a safety factor of 50% (SF=1.5) when deriving the opera-ting conditions given on the right:

Application as specified: Hot and cold water PN16/SDR7,4: 20°C/16 bar 60°C/8 barSafety factor: The DIN standard takes account of raw material properties and calculates a safety factor of 50% (SF=1.5) when deriving the opera-ting conditions given on the right:

Application as specified: Hot and cold water PN20/SDR6: 20°C/20 bar 70°C/8 barSafety factor: The DIN standard takes account of raw material properties and calculates a safety factor of 25% (SF=1.5) when deriving the opera-ting conditions given on the right:

Operating pressure in relation to service life and operating temperature

Temperature Pressure Service life (*C) (bar) (years) 20 10 50 30 9 50

Temperature Pressure Service life (° C) (bar) (years) 20 16 50 40 12 50 60 8 50

Temperature Pressure Service life (° C) (bar) (years) 20 20 50 40 15 50 60 10 50 70 8 50

1110

The four ways of joining the pipes

A wide range of safe and secure methods for joining the pipes is essential for a pipe system.

KE KELIT has a comprehensive range of fittings for each method of joining.

All K2 PPR polyfusion fittings from d20 to d110 are rated PN10/16/20. Fittings d160 are rated PN10/16.

Please check the price list to see which sizes and pressure ratings are currently available.

1. Polyfusion welding

Principle: Fusion welding occurs when a large area of the outside of the pipe and the inside of the socket are welded together

A wide range of welding fittings is available

Sizes:

Fittings d20 – d110 PN10/16/20Fittings d160 PN10/16

Advantages

● Pipe and fitting are made of the same material. No additional materials are required.

● Welded joints are not a weak point in the system

● Pipe can only enter the fitting after they have been heated on the welding machine (important safety feature)

● The weld does not cause a reduction in the flow at the joint.

2. Threaded adaptor fittings

Sizes: d20 x 1/2”– d90 x 3”

The threads conform to ON EN 10226-1 and are made of dezincification resistant brass (MS58 CW 617). They are metalplated to protect against stress corrosion cracking. Male and female threads are available as both straight and elbow fittings.

3. Flange connection

Sizes: d40–d160PN10/16 The solution for flanged fittings Backing ring conforms to pipe sizes Fusion welding: d40 – d160

4. Detachable union fittings

Sizes: d20 x 1/2”– d90 x 3”

3 types:

MK55-PPR-male thread MK56-PPR-PPR MK57-PPR-male thread

Advantages● Wide range of fittings

Female thread is a straight thread

● Male thread is tapered and roughened

● Thread is firmly anchored in the fitting

High resistance to twisting

Advantages● Can be detached at any time● Elastic EPDM seal● Dimensions conform to DIN 2501-PN16

Advantages● Detachable fittings● Elastic EPDM fittings● MK57 fitting for

connecting to appliances

1312

K2 PPR polyfusion welding with the hand welding machine

1. The pipes and fittings are joined by polyfusion welding at 260°C. The welding machines and tools are self-regulating. Just connect to the electricity supply (230V) and wait: The red light indicates that the machine is connected to the electricity supply. When the green light goes out the welding temperature has been reached. Work can begin.

Measure the length of pipe required and cut the pipe with the appro-priate pipe cutter (up to d40 with the pipe shears; up to d110 with the wheel pipe cutter).

The welding procedure

2. Ensure that the surface of the pipes are clean and free of grease

2.1 Measure the depth of the socket and mark the insertion depth on the pipe accordingly.

Welding times2.2 The heating time (see table) begins when the full insertion depth of the pipe and the whole of the socket in the fitting have been pushed on to the welding tools.

2.3 The heating time varies according to the pipe size (see table). Once the heating time has elapsed push the pipe and fitting together smoothly and evenly without delay. The result is a homo-geneous and strong joint.

2.1

2.4 Three lines on the pipe (90° apart) act as a guide for making a straight joint.

2.5 The position of the fitting can be adjusted for a few seconds immediately after the pipe and fitting have been joined. A short time later (see table) the joint is capable of withstanding operating conditions.

3. The low weight and high flexibility of the material makes it possible to weld whole sections of the piping at the work bench. Take advantage of this and save a lot of time.

4. Make sure that any joints which still need to made in the wall are positioned so that they are accessible with the welding machine.

5. The distance between the draw-off points at the wall can be set (for all common installations) both horizontally and vertically using a template equipped with a spirit level.

6. The pipes should be insulated according to the relevant national standards.

4.

5.

d mm Heating time Adjusting time Cooling time Pipe-OD sec sec min 20 5

4 2

25 7 32 8 40 12 6 4 50 18 63 24 75 30 8 6 90 40 110 50

10 8 125 60 160 70

1514

The welding procedure:

1. Fix the fitting in the clamp and the fitting holder. Ensure that the face of the fitting is flat against the clamp.

1.1 Put the pipe in the pipe clamp. Do not tighten the clamp.

1.2 Hold down the spacing button and move the sliding blocks together using the hand wheel until the pipe is touching the fitting or the sliding blocks can no longer move

1.3 Release the spacing button. Only now fix the pipe in the clamp.

2. Move the sliding blocks apart and pull down the welding plate.

2.1 Move the sliding blocks together until they are stopped by the lock

2.2 When the heating time has elapsed move the sliding blocks apart briskly and quickly remove the welding plate.

3. Push the sliding blocks together briskly until the pipe diameter switch catches.

3.1 Never cool the welded joint abruptly. After a while loosen the clamp and the finished joint can be removed from the machine.

3.2 Once the cooling time has elapsed the joint can be subjected to operating conditions.

Table welding machine

1. Screw the required heatingelements to the welding plate.The length of the heating element variesaccording to the size of the pipe and thesection of pipe to be welded.

2. One side of the pipe clamps canbe used for small pipe sizes (d20 – d40).For larger sizes (d50 – d90) the clampsshould be turned around.

3. The same principle applies for thefittings clamps.

See pages 14 and 15 for instructionson preparing pipes and fittings forwelding.

4. Set the pipe diameter switch to the required size. This switch regulatesthe length of the pipe that will be weldedinto the socket

5. Spacing button.Press the button to fix the distancebetween the two sliding blocks which willenable the appropriate section of pipeand the complete socket of the fitting tobe heated on the welding elements.

Note: The machine is available intwo sizes:Type 1: d20–90 mmType 2: d25–125 mmType 3: d160 mm

Heating elementFitting clamp

Fitting holderWelding plate

Lock

Pipe clamp

Pipe diameter switch Hand wheel

Spacing button

d mm Heating time Adjusting time Cooling time Pipe-OD sec sec min 20 5

4 2

25 7 32 8 40 12 6 4 50 18 63 24 75 30 8 6 90 40 110 50

10 8 125 60 160 70

1716

1. Fix the pipe clamps to a pipe that has already been installed. The machine will hang at the end of the pipe.

1.1 To provide extra support the pipe should be clamped close to a pipe bracket

1.2 A pole can be placed under the centre of gravity to support the machine if necessary.

1.3 The pipe should protrude far enough out of the pipe clamp to ensure that the pipe can be fully welded into the socket of the fitting but also allow enough space for the welding plate.

The space between the pipe and the fitting when the sliding block has been completely rolled back should be approx. 100 to 150 mm.

2. Put the fitting in the clamp and support the fitting with the fixing elbow. The fitting must have sufficient room to move sideways so that the whole of the socket can be welded.

3. Put the welding plate between the pipe and fitting. Turn the hand wheel to move the pipe and fitting on to the welding tools. Heat the pipe and fitting.

3.1 When the heating time is over remove the welding plate and push the pipe and fitting together briskly to weld the joint.

3.2 When the cooling time is over the joint can be subjected to operating conditions.

Overhead welding machine

It is recommended to use theoverhead welding machine forexposed piping in confined areas(d50–d110).

Adjustablepipe clamps

(d50–d110) aremounted onsiding blocks

Hand wheelfor fixingthe pipes

Hand wheelfor moving the

sliding block on the pipe side

Centre of gravityis marked below the

machine

Hand wheel forFixing the fitting

Elbow forsupportingthe fitting

Adjustablefitting clamps(d50–d110) are fixed tothe machine

1918

Maximum flow velocity according to DIN 1988-300Maximum design flow velocity for a given pipe run ≤ 15 min >15 min m/s m/s

Service pipes 2 2Supply mains:pipe runs with low head lossin-line valves (ζ < 2.5) 5 2In-line valves with greater loss factor 2,5 2

Pipe sizing Pressure losses in K2 PPR pipesThe total pressure loss (∆p) in the K2 PPR pipe system is calculated by multiplying the friction loss (R) by the length of the piping (l) plus the sum (∑) of the friction losses for the individual fittings (Z).

∆p = (I · R + ∑Z) in Pa

The choice of pipe size for the water supply is dependent on the following factors:● The available water pressure● Geodetic difference in height● Pressure losses through system

components● Minimum flow pressure through faucets● Pressure losses in the pipes● The individual pressure losses of the

fittings ● Type, number and simultaneous use

of the draw-off points● Flow velocity

Note:For the purpose of pipe sizing it is assumed that that there will be no reduction in the internal diameter caused by incrustation since the surface structure of the pipe is amorphous and the surface roughness of the pipe is minimal (0,007).

Guidelines for circulating pipe systems (DIN 1988-300)For hygienic reasons the circulating system should be designed so that the temperature at any point in the system is no lower than 5K below the operating temperature. The power of the pump and the regulati-on of the temperature are designed so that the temperature does not fall below 55°C at any point in the system. For economic rea-sons the flow velocity in circulating systems should be approx.. 0.2– 0.5 m/s and in exceptional circumstances up to a maximum of 1.0 l/s.

Guidelines for pipe sizing (DIN 1988-300)

1. Determining the calculated flow rate and minimum flow pressures of the outlet fittings

The calculated flow rate V̇R is an adopted out-let fitting flow value in the calculation rate. The guidance values of the calculated flow rates of common fixtures are included in the table. The calculated flow rate V̇R (as an average value) is obtained from the following equation:

V̇R = V̇min + V̇max 2

2. Determining total flows and allocating them to the sections

The calculated flow rates are to be added con-trary to the flow direction – always at the far-thest sampling point and ending at the supply line – the total flow rates achieved in this way are then to be allocated to the corresponding sections. The part route in question begins with the mold piece on which the cumulative flow or the diameter changes.

The total flow rates (cold and hot water) are to be added to the cold water line branch point which heads to the drinking water heater.

3. Application of the conversion curve from the total flow to the peak flowDuring calculation of the line systems, it is ab-solutely necessary that all sampling points be applied with their calculated flow rates.

An exception to this is when a second sink, a bathtub with a shower unit, a bidet, a urinal or nozzles in toilet facilities vestibules are inclu-ded in a usage unit (NE). These are not taken into account in the total flow.

4. Simultaneity depending on building type The calculation of the peak flow depends on the total flow; the simultaneity of the water outlet depends on how the building is used (e.g. flats, hotels etc.).

Generally it is not expected that all connected outlets will ever be fully open at once.

On Pages 26 and 27 you will find the conversi-on curves for the various building types.

5. Select pipe diameter Pipe diameters and pipe friction pressure gradi-ents and all corresponding calculated flow rates must be determined. (Pressure loss diagrams: Page 23 to 25).

6. Pressure loss compared with available pressure The total pressure loss for the determined pipe diameter should reach the existing pressure difference, but not exceed it.

Calculation of the pressure loss (Z)for the standard fittings

Z = ζ• v2 ρ

2

Fitting Symbol Coefficient ζ

Elbow 90° 1,3

Elbow 45° 0,4

Tee-straight flow 0,3

Tee-flow separation 0,3

Tee-reverse flow 1,5

Reducer 0,4

Stop valved20 10,0d25 8,5

Slanted seat valved20 3,5d25 2,5d32–63 2,0

S

G

2120

Pressure losses PN10/SDR 11

The method for calculating the pressure loss of the individual fittings is described on page 20.

The pressure losses are calculated according to the Nikuradse formula:

Surface roughness: 0,007 mm

Guidelines for pipe sizing (DIN 1988-300)

7. Minimum flow pressures and calculated flow rates (VR: l/s) of common drinking water extraction points

Important note:The valves manufacturers must specify the minimum flow pressure and the fittings flow rates calculations (VR). The manufacturer’s information absolutely must be consi-dered when measuring the pipe diameter – if it lies abo-ve the values listed in the table, then the drinking water installation must be sized according to the manufacturer’s instructions.

Notes:Equal-type outlets and devices not included in the table with flow rates or minimum flow pressures that are greater than those listed must also be taken into account according to the manufacturer’s instructions.

Min. flow- Drinking water pressure extraction type

bar Dimension V̇R: l/s

Outlet valves 0,5 Without aerator a DN 15 0,30 0,5 DN 20 0,50 0,5 DN 25 1,00 1,0 With aerator DN 10 0,15 1,0 DN 15 0,15 Mixing valves b,c for 1,0 Shower tubs DN 15 0,15 1,0 Bathtubs DN 15 0,15 1,0 Kitchen sinks DN 15 0,07 1,0 Washbasins DN 15 0,07 1,0 Bidets DN 15 0,07

Household machines 0,5 Dishwasher DN 15 0,07 0,5 Washing machine DN 15 0,15

WC basins and urinals 1,0 Urinal flush valve DN 15 0,30 manual or automatic 1,2 Flush valve for WC DN 20 1,00 0,5 Cistern according to EN 14124 DN 15 0,13 a) Without connected appliances (e.g. sprinklers) b) The indicated calculation flow is to be included in the cold and warm water calculationsc) Angle valves for e.g. basin taps and shower hose connections are to be regarded as individual resistors or recognised with the outlet fitting minimum flow pressure.

K2 PPR pipe

2322

Pressure losses PN16/SDR 7,4

The method for calculating the pressure loss of the individual fittings is described on page 20.

The pressure losses are calculated according to the Nikuradse formula:

Surface roughness: 0,007 mm

Pressure losses PN20/SDR 6

The method for calculating the pressure loss of the individual fittings is described on page 20.

The pressure losses are calculated according to the Nikuradse formula:

Surface roughness: 0,007 mm

K2 PPR pipe K2 PPR pipe

2524

d125x17,1d160x21,9

0

1

2

3

4

5

0 10 20 30 40 50

Zusammenstellung

Pflegeheim Wohngebäude Seniorenheim Krankenhaus Hotel Schule/Verwaltung

Depending on the building type, the peak flow (V̇S) is calculated with the constants included in the table on Page 27 as follows:

V̇S: a (Σ V̇R)b – c

For the building types indicated in the table, the peak flow (V̇S) is calculated with the following scope:

Σ V̇R: 0,2 bis ≤ 500 l/s

Graphical solution for the calculation of the peak flow V̇S depending on the total flow V̇R for the range 0–600 l/s

Peak flow constants (a, b, c) for each building type

Graphical solution for the calculation of the peak flow V̇S depending on the total flow V̇R for the range 0–50 l/s

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

0 50 100 150 200 250 300 350 400 450 500 550 600

Zusammenstellung

Pflegeheim Wohngebäude Seniorenheim Krankenhaus Hotel Schule/Verwaltung

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

0 50 100 150 200 250 300 350 400 450 500 550 600

Zusammenstellung

Pflegeheim Wohngebäude Seniorenheim Krankenhaus Hotel Schule/Verwaltung

Hotel

Hospital

School, administration building

Residential building, nursing home

Care home

V̇R in l/s

V̇R in l/s

V̇ S in

l/s

V̇ S in

l/s

Exceptions with calculation of the peak flow V̇S

Usage units (NE)A room with outlets in residential buildings (e.g. bath, kitchen, utility room) or in non-resi-dential buildings (in the event that the recogni-sed use is similar to that of a flat).

Experience has shown that the flows of the flow direction up to the end of the strand cable and in the floor distribution of NE‘s are too high; this is because, normally, no more than two outlets are open at the same time e.g. in a bath.

Therefore, the peak flow in each leg of a NE is, at maximum, equal to the total flow of the two biggest outlets installed in the leg (also applies in cases within an NE where the calculation in-dicates a smaller flow). If a second NE is attached to a leg (e.g. in the riser), then the values of the peak rates of the two NEs shall be added (if the resulting peak flow is smaller than the value calculated accor-ding to the calculation). Otherwise, the peak flow must be determined according to the respective equation.

Permanent consumersThe flow of permanent consumers is added to the peak flow of the other outlets. Permanent consumers are defined as water outlets which last longer than 15 min e.g. garden blast valve.

Series equipmentThe total flow is the basis for the calculation. The simultaneity of the water outlet is to be defined with the operator. The multiple peak flow rates of the series system must to be added up if they could both occur at once.

Special buildings, commercial and industrial facilitiesWith special buildings (other than those indica-ted above), including industry buildings, agricu-lture buildings, gardening buildings, slaughter-houses, dairies, shops, laundries, large kitchens, public baths etc. the peak flow must be deter-mined from the total flow in co-operation with the facilities operator. The peak flows of the sub-zones of the drinking water installation must be added up if they coincide.

Excerpt from DIN 1988-300

0

1

2

3

4

5

0 10 20 30 40 50

Zusammenstellung

Pflegeheim Wohngebäude Seniorenheim Krankenhaus Hotel Schule/Verwaltung

Hotel

Hospital

School, administration building

Residential building, nursing home

Care home

Building type Constants a b c Residential building 1,48 0,19 0,94Assisted living facility, nursing home 1,48 0,19 0,94Bed house in hospital 0,75 0,44 0,18

Hotel 0,70 0,48 0,13

School and administration building 0,91 0,31 0,38

Care home 1,40 0,14 0,92

2726

Expansion behaviour of K2 PPR pipes

Linear heat expansion

Under heat conditions all materials increase in volume and/or length according to the following formula:

Calculation of the linear expansion:

∆ l = I · ∆ t · α

The linear expansion is determined by the length of the pipe, the increase in temperature and the coefficient of expansion. It is not determined by the diameter of the pipe

Comparison of materials

Coefficient of E-module 60° expansion α = mm/m°C N/mm2

Galv. steel 0,012 220000Stainless steel 0,015 200000Copper 0,016 130000KELIT Alu comp.* 0,035* 3500PVC 0,080 1100K2 PPR 0,150 300PEX 0,175 540

* αd63and above =0,050

This means that when heated K2 PPR will expand more than metal materials if the expansion is unhindered.

Expansion arm for exposed pipingCompensation must be made for the expansion of K2 PPR pipes under heat conditions.Even if the rise in temperature is only for a short time sufficient compensation must be made for this temperature differenceCompensation is always made between two fixed points or between a fixed point and a change in direction of the piping (expansion arm). Calculation of the expansion arm:

MS = 20 · d · ∆ l

20 = Coefficient for K2 PPR MS = Minmum length of the expansion arm (mm) Length of pipe which branches off at 90° from the main pipe to the next fixed pointExample: d50 mm pipe runs over a length of 15 m ∆t = 35°C Question: How long does the expansion arm have to be to compensate for the expansion?

∆I = 15 · 35 · 0.15 ∆I = 79 mm expansionMS = 20 · 50 · 79 MS = 1256 mm expansion arm

Heat expansion chart (unhindered linear expansion) ∆l

Diffe

renc

e in

tem

pera

ture

∆t

Min

imum

leng

th o

f exp

ansio

n ar

m (m

m)

2928

Practical solutions for compensating expansion

The following methods can be used tocontrol the linear expansion and the forceof expansion:

● Piping that is embedded in the wall or the floor is prevented from expansion by frictional force. No extra measures are required.

● Compensation must be made for expansion of exposed piping

● Even if the rise in temperature is only for a short time sufficient compensation must be made for this temperature difference (see pages 28 to 33)

● Every change in temperature will exert a force. > An expansion force will occur when the temperature rises. < A shrinking force will occur when the temperature falls.

The force of expansion can be calculated for every installation. However, in ge-neral the force is just a fraction of the force which occurs with metal materials.

Suppliers of pipe clamps and brackets know the properties of the materials and offer a range of solutions.

● Pipe channels may be used to increase the stability of the pipe. The expansion is reduced to the same value as steel pipes.

● The strength of the fixed points should be sufficient to compensate the expansion force.

● The specific expansion can be minimised by installing the KELIT ALU composite pipe (d20 – d90), especially on long pipelines.This pipe reduces the expansion by approx. 75%.

Force of heat expansionThe force of linear expansion is differentfor each material. The specific force of heat expansion is calculated according to the following formula:

The force of heat expansion isdependant on the dimension of thepipe and the change in temperaturebut not on the length of piping.

An important factor is the rigidity of thematerial (E-module)

Comparison of the materials:If unhindered K2 PPR pipes willexpand more than metal materialsunder the influence of heat. Theforce of heat expansion, however,is much smaller!

The E-module of PP-R (like any otherplastic) is dependant on the temperature(see graph below)

> Temperature: < E-module< Temperature: > E-module

As the temperature increases the E-moduledecreases.

E-module of PP-R in relation to theoperating temperature tm

Example:Length of piping: l = 50 mTemperature during installation: tv = 20°CMedium temperature: tm = 60°CDifference in temperature: dl = 40°C

10

1000

900

800

700

600

500

400

300

200

180

020 30 40 50 60 70 80

Temperature tm in °C >

E-mod

ule (E

) in N

/mm2

Ft = E · A · α · Δt1000

3130

27,3 x 3,2 Galvanised steel 25 585 N

18 774 N

8 406 N

1 248 N

771 N

426 N

894 N

Dimension Linear expansion Force of expansion(Ft)

26,9 x 2,0 Stainless steel

28 x 1,2 Copper

25 x 3,5 KELIT Alu Composite

25 x 2,9 PVC

25 x 3,5 K2 PPR

25 x 3,5 PEX/VPE

0 100 200 300 400 mm

3. Exposed piping3.1 Preventing expansion bymechanical restraint d20–d50

For aesthetic reasons KELIT ALU pipesare often preferred for exposed pipesbelow d63. Greater stability can beobtained by installing the pipes in steelchannels.

3.2 Expansion loops d 63 –110All changes in the direction of the pipecan be used to accommodate the linearexpansion. In some cases an expansionloop will be necessary.

In order to achieve this stability all of thepipes must be supported by pipe channelsand all of the brackets must be fastenedtightly to the pipe to make them fixedpoints. In addition the channels are fixedto the pipe (e.g. using cable ties) exceptfor the sizes d20, d25 and d32 as thechannels for these sizes are self-locking.This method reduces the linear expansionto the same amount as steel.

The fixed points are arranged so that thepiping is divided into sections and theexpansion force can be guided in thedesired direction. See pages 28 to 31 forthe calculations of the length of theexpansion arm.

Pipe installing K2 PPR1. Installing the pipes in the shaftIn practise the main risers can expand and contract laterally in the shaft between two floors if a fixed point is located next to the pipe that branches off from the main pipe. The distance between two fixed points should not exceed 3 m. Other methods can be used to accommodate expansion such as an expansion arm in the pipe branching off from the riser.

2. Embedding the pipePiping that is embedded in the wall, floor screed etc. … is prevented from linear expansion. The material can absorb the pressure and tensile stress without causing any damage. If the pipes are insulated then the insulation material provides further room for expansion.

Guidelines for distance between pipesupport pointsThe distances between the support points given below (in cm) prevent K2 PPR pipes from sagging when they are filled with water and there are NO pipe channels.

d PN 1O PN 16 PN 20 ALU PN 20 mm 20°C 20°C 60°C 20°C 60°C 20°C 60°C 20 70 75 60 80 65 120 100 25 75 80 70 85 75 130 110 32 90 95 80 100 85 150 130 40 100 105 90 110 95 170 150 50 115 120 100 125 105 180 160 63 130 135 110 140 120 195 180 75 150 160 130 170 150 205 190 90 185 195 150 205 170 215 200 110 195 205 160 215 180 – – 125 205 – – – – – – 160 220 – – – – – –

minimum (mm)2 · Δ l + 150 mm

MS

3332

Pressure test – drinking water systems with drinking water according to ÖNORM EN 806-4 The pressure test with drinking water is a combined leakage / load test and it must be performed for all lines in accordance with the specifications of ÖNORM EN 806-4. Pipes and other piping components are designed for maximum operating pressure (MDP) in accordance with the ÖNORM EN 805 or ÖNORM EN 806 series. However, they must be designed to withstand at least a system operating pressure (MDP) / nominal pressure (PN) of 1000 kPa (10 bar). As the test pressure must be 1.1 x the maximum system operating pressure (in accordance with ÖNORM EN 806-4), the pressure test must be performed with at least 1100 kPa (11 bar) (recommended by KE KELIT 15 bar).

The accuracy of the pressure gauge (positioned at the lowest possible point wherever possible) is to the nearest 0.02 MPa (0.2 bar). Depending on the pipe materials and dimensions, 3 different procedures can be applied in the leakage and load test.

Test procedure A– test time 10 minutes For all metal and multi-layer composite systems For all plastics (e.g. PP, PE, PEX, PB etc.≤ DN 50/OD 63 For all combined systems (metal systems/multi-layer composite systems with plastics) ≤ DN 50/OD 63 The test pressure (1) must be achieved with pumping and maintained for up to 10 minutes; during this time the test pressure must remain constant, and there must be no drop in pressure.

Choice of test method B or C Test procedure B – test time 60 minutes For all plastics (e.g. PP, PE, PEX, PB etc.) > DN 50/OD 63

For all combined systems (metal systems/multi-layer composite systems with plastics) > DN 50/OD 63 The test pressure (1) must be achieved with pumping and maintained for 30 minutes by subsequent pum-ping, then the pressure must be reduced to 50% of the test pressure by draining it; then the drain valve must be closed. During the time of the additional 30 minutes the 50% test pressure must remain con-stant and there must be no drop in pressure. In addition, it is necessary to perform a visual inspec-tion of the connections.

Test procedure C – test time 180 minutes For all plastics (e.g. PP, PE, PEX, PB etc.) > DN 50/OD 63

For all combined systems (metal systems/multi-layer composite systems with plastics) > DN 50/OD 63 The test pressure (1) must be achieved with pumping and maintained for 30 minutes by subsequent pum-ping, then the test pressure must be checked, and after another 30 minutes the pressure must be che-cked again. If after this period the pressure has drop-ped to less than 0.06 MPa (0.6 bar) then the test pressure must be continued with no further pum-ping. The test period is an additional 120 minutes, during which the last recorded test pressure may not drop by more than 0.02 MPa (0.2 bar). In additi-on, it is necessary to perform a visual inspection of the connections.

MD

P

1

1

1,1

1,1

1,0

1,0

0,5

0,5

0

0

0

0 10 20 30 40 50 60

10

min

1

1,11,0

0,5

00 10 20 30 60 120

≤ 0,06 MPa

≤ 0,02 MPa

180

min

min

MD

PM

DP

MD

P

1

1

1,1

1,1

1,0

1,0

0,5

0,5

0

0

0

0 10 20 30 40 50 60

10

min

1

1,11,0

0,5

00 10 20 30 60 120

≤ 0,06 MPa

≤ 0,02 MPa

180

min

min

MD

PM

DP

MD

P

1

1

1,1

1,1

1,0

1,0

0,5

0,5

0

0

0

0 10 20 30 40 50 60

10

min

1

1,11,0

0,5

00 10 20 30 60 120

≤ 0,06 MPa

≤ 0,02 MPa

180

min

min

MD

PM

DP

Pressure testing protocol according to ÖNORM EN 806-4 for K2 PPR-Drinking water systems test medium: drinking water

Client: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contractor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subject: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test section: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipe materials and dimensions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . . . . . System vents:

Temperature compensation: Visual inspection:

Maximum system operating pressure MDP: . . . . . . . . . . Test pressure 1.1 x MDP: . . . . . . . . . . .

Pipes: d 20 . . . . . . . . . . . . m Pipes: d 75 . . . . . . . . . . . . mPipes: d 25 . . . . . . . . . . . . m Pipes: d 90 . . . . . . . . . . . . m Pipes: d 32 . . . . . . . . . . . . . m Pipes: d 110 . . . . . . . . . . . mPipes: d 40 . . . . . . . . . . . . . m Pipes: d 125 . . . . . . . . . . . mPipes: d 50 . . . . . . . . . . . . . m Pipes: d 160 . . . . . . . . . . . mPipes: d 63 . . . . . . . . . . . . . m

Test procedure A – test time 10 minutes

Metal and composite pipe systems – all sizesPlastic systems and combined systems with plastics ≤ DN 50/OD 63Choice of test method B or C

Test procedure B – test time 60 minutes Plastic systems and combined systems with plastics > DN 50/OD 63

Test procedure C – test time 180 minutes Plastic systems and combined systems with plastics > DN 50/OD 63

Notes:• Temperature fluctuations can affect the test pressure!• Each pressure test is a snapshot survey of the actual condition and it cannot guarantee

no installation faults.• Following a successful pressure test, we would recommend the creation of a confirmed test protocol.

Confirmation:

Clerk: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time: from: . . . . . . . . . . . . . . . . to: . . . . . . . . . . . . . . . . . .

Client: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3534

A pressure test with air or inert gases takes place using a two-step procedure consisting of the leak test and the load test. For ≤ DN 50/ OD 63 pipes the leak test can be carried out in 2 ways.

The pressure test with light or inert gases can be carried out bit by bit, and may not replace the final pressure test with drinking water!

The pressure test must be performed with light or inert gases that is / are largely free of oil and dust, and it is suitable for all pipe materials. In buildings with higher hygiene demands (e.g. medical establishments) inert gas must be used for the pressure test.

Due to the compressibility of the medi-um, during a pressure test with light or inert gases no pressure test greater than 300 kPa (3 bar) may be applied, for safety reasons.

Higher test pressures comprise a large safety risk and they do include the test accuracy. The safety of people and goods must be considered during the test.

During a pressure test, division into small line sections ensures a higher test accuracy and the-refore a higher level of safety. A gradual incre-ase in pressure is useful as an additional secu-rity measure.

All pipe openings must be well sealed against the test pressure (with sufficient strength) with plugs or blind flanges.

During a pressure test with light or inert gases, the connection parts of the pipe elements must be accessible and visible. Bleed valves are provi-ded for the safe discharge of the test pressure.

If any leakage is detected, or a drop in pressu-re is noticed, then all connections must be tested for leaks using appropriate bubbling test equip-ment, and the pressure test must be repeated after the leaks have been eliminated.

Two-step pressure test for all pipes ≤ DN 50/OD 63

Consisting of leak test (variant 1 or 2) and load test

Leak test – variant 1 Pressure test 15 kPa (150 mbar) – test time 60 minutes. Display accuracy of the pressure gauge or standpipe to the nearest 0.1 kPa (1 mbar)

Leak test – variant 2 Test pressure 100 kPa (1 bar) – test time 60 minutes. Display accuracy of the pressure gauge to the nearest 5 kPa (50 mbar); in addition, all connection points in the system must be checked for leakage with appropriate bubbling test equipment.

Load testTest pressure 300 kPa (3 bar) – test time 10 minutes. Display accuracy of the pressure gauge to the nearest 10 kPa (100 mbar)

Two-level pressure test for all pipes > DN 50/OD 63

Consisting of leakage test and load test

Leakage testTest pressure 15 kPa (150 mbar) – test time 90 minutes. Display accuracy of the measuring gauge or standpipe to the nearest 0.1 kPa (1 mbar); in addition, all connection points in the system must be checked for leakage with appropriate bubbling test equipment.

Load testTest pressure 100 kPa (1 bar) – test time 10 minutes. Display accuracy of the pressure gauge to the nearest 10 kPa (100 mbar).

Pressure testing protocol according to ÖNORM B 2531 for K2 PPR-Drinking water systems test medium: air or inert gases

Client: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contractor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subject: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test section: . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipe materials and dimensions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient temperature: . . . . . . . . . . . . . . . . . . . . . . . . Temperature compensation:

Maximum system operating pressure MDP: . . . . . Visual inspection:

Two-stage pressure test for all pipes ≤ DN 50/OD 63: consisting of leak test (variant 1 or 2) and load testLeakage test – variant 1 Test pressure 15 kPa (150 mbar) – test time 60 minutes

Leakage test – variant 2 Test pressure 100 kPa (1 bar) – test time 60 minutesIn addition, all component points in the system must be checked for leakage using appropriate bubbling test equipment.

Load test Test pressure 300 kPa (3 bar) – test time 10 minutes

Two-stage pressure test for all pipes > DN 50/OD 63: consisting of Leak test and load test

Leak test Test pressure 15 kPa (150 mbar) – test time 90 minutesIn addition, all component points in the system must be checked for leakage using appropriate bubbling test equipment.

Load test Test pressure 100 kPa (1 bar) – test time 10 minutes

Notes• Followingasuccessfulpressuretest,wewouldrecommendthecreationofa

confirmed test protocol.• InaccordancewithÖNORMEN806-4,apressuretestwithlightorinertgasescannotreplace

a pressure test; it must be performed immediately prior to the activation of the system.

Confirmation

Clerk: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time: from: . . . . . . . . . . . . . . . . . . . . . . . to: . . . . . . . . . . . . . .

Client. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure test – drinking water systems with air or inert gases according to ÖNORM B 2531

3736

Technical rules for drinking water

Assuming that the design and installationhas been done professionally werecommend that the following guidelinesare followed.

Rinsing with water/air mixtureAfter pressure testing the drinking waterpipes must be rinsed. Depending on the size of the installation and how the piping is run the system should be rinsed in sections from the bottom to the top.The compressed air (supplied from cylinders or from compressors) shall be available in sufficient quantity, and quality harmless to health (e.g. oil-free), with an air pressure equal at least the static pressure of the water.Each riser is rinsed in turn and the lengthof piping should not exceed 100 m.ON EN 806-4, table 7, specifies theminimum number of draw-off points thathave to be opened. Under normal circum-stances all draw-off points should be opened. The rinsing time at each draw-off point should be at least 2 minutes.

After the pipe has been rinsed for approx. 2minutes at the last draw-off point all thedraw-off points are closed in the reverseorder to which they were opened.

Sound controlDIN 4109 recommends the followingmeasures:● Use low-sound faucets● Avoid direct contact between pipes

and other sound transmitting bodies when fixing the pipe.

● Avoid high pressures and high flow velocities

● Special measures should be taken for sound sensitive areas

● Cover with sound reducing insulation

ON EN 806-4

Largest nominal diameter of the distributing pipe DN 25 32 40 50 65 80 100

Minimum flow through the completely full distributing pipe I/min 15 25 38 59 100 151 236

Minimum number of draw-off points to be opened DN15 1 2 3 4 6 9 14

Minimum flow and minimum number of draw-off points to be opened for rinsing ata minimum velocity of 0,5 m/so

ÖNORM H 5155 is the standard applied for in-sulating domestic systems. It simplifies and uni-fies the procedures for planning, installing and maintenance of insulation systems.

● The purpose of ÖNORM H 5155 is to spe-cify the insulation thickness required to mi-nimise the transfer of heat from medium to surroundings and vice versa.

● ÖNORM H 5155 applies for the insulation of all components in heating and drinking water systems

● The insulation thickness varies according to the type of installation and its location within the building (e.g. whether the pipes are concealed or located in an intermediate ceiling or in a heated room etc. …)

● Please also follow KE KELIT´s recommenda-tions with regard to comfort considerations and noise insulation.

ÖNORM H 5155 allows a lambda value of 0.036 W/m.K for K2 PPR cold water pipes at an average temperature of 0°C and an external coefficient of heat transfer of 9 W/m2.K

The lambda value of LEXEL-Insulation 0.038 W/m.K at 40°C fulfils the re-quirements of the standard. The LEXEL equivalents are shown below:

Required thickness 4 mm = LX04 LEXEL Insulation

Required thickness 9 mm = LX09 LEXEL Insulation

Required thickness 13 mm = LX13 LEXEL Insulation

Attention should be paid to the laws and stan-dards regarding insulation which are specific to the country where the products are being installed

Excerpt from ÖNORM H 5155, table 6. The DN/OD values are identical to the ones given for the K2 PPR pipes Size DN/OD (outside diameter) Location of the piping

Insulation for cold water systems under ÖNORM H 5155

Dimension DN/OD (outside diameter) 16 20 25 32 40 50 63 75Piping location Minimum insulation thickness (mm)Utility room 13 13 13 13 19 25 25 25Unheated room, exposed 9 9 9 9 13 19 19 19Heated room, exposed 13 13 13 13 19 25 25 25Installation shaft, installation passage;together with heated pipes 13 13 13 13 19 25 25 25

Installation shaft, installation passage; without heated pipes 9 9 9 9 13 19 19 19

Suspended ceiling, double floors, lightweight/ partition walls, flush-mounting, floors (distripution pipes only) 13 13 13 13 19 25 25 25

Flush-mounted installations; floors (storey and individual supply pipes) 4 4 4 4 9 13 13 13

Flush-mounted installations; floors; adjacent to heat-giving cirulating pipes(storey and individual supply pipes)

13 13 13 13 19 25 25 25

3938

7.Avoid using heat tobend the pipes(it is possible to bendthe cold pipe to a

radius of 8 x d). If the pipe has to be heated then only use hot air. Never heatthe pipe with a naked flame!Maximum temperature for bendingthe pipe: 140°C

8.Try to make the jointsfor standard sectionsof piping at the workbench before they areinstalled. This saves time

and increases the security of the system.

9.Once the system hasbeen installed itshould be subjected topressure testing.

You can copy pages 34 to 37 of thecatalogue to make a test report.

10.•Atemperatureof90°C for short periodsof time is NO problemfor K2 PPR. Highertemperatures over lon-

ger periods of time should be avoided. The pipe system is suited for thermal disinfection.•Thegradualorcontinual(max.6months)disinfection of the pipe system with chlorine dioxide, chlorine or ozone is only permitted for the cold water system and after consultati-on with KE KELIT.•Excessiveconcentrationsarenotonlythreatening to health they can also causepremature ageing of pipe systems.•Copperundcopperionshaveadestabi- lising effect and their presence in the system should be avoided.

11.The followingprecautions can bemade to ensure thatthe maximum

operating temperature is not exceeded:•Monitorandregulatesolarenergystorage.•Checktheelectricconnectionstothehotwater storage before the system isoperated.•Werecommendinstallinginthehotwater piping a mixer valve which isregulated by the boiler.

12.In order to qualify forguarantee cover eachinstallation must useK2 PPR system partsonly.

13.In order to install theK2 PPR systemcorrectly a minimalamount of

expenditure is required for tools For yourown security we recommend that you useand maintain the tried and trusted tools.

14.If you are in doubt donot hesitate to consultour technicians.There is not always a

perfect solution but we can always help.

Summary of the instruction guidelines

1.The K2 PPR pipesystem is made ofplastic and needs to betreated carefully to

prevent shocks and impact on the pipeduring transportation, storage andinstallation.

2.Protect the pipes,fittings andcomponents fromlengthy exposure to

direct UV radiation from the sun.The usual time required for storage andinstallation will have no effect on thematerial as it is stabilised against UV raysbut the material is not resistant to long termUV exposure.

3.The welding machinesare regulated tooperate at 260° C.Welding times

are based on an ambient temperatureof 20°C.If the ambient temperature changes thetime required to push the pipe and fittingon to the heating elements (before theheating time begins) may alter slightly.

4.Any corrections to thealignment of pipe andfitting up to amaximum of 5 must

be made during the welding procedure(see pages 12 to 19) for the permissibletime for adjustments). Any later correctionswill damage the joint.

5.Do NOT screw anythreaded pipes or anycast iron fittings intothe female threads of

the metal moulded fittings.Only join to faucets and components withstraight threads. The threaded joint canbe sealed by the usual methods (hemp,paste, tape …).Do not over twist the threads.

6.The expansion ofK2 PPR pipes isclearly defined andmust be accounted for

in the design and installation of the system.

Please refer to pages 28 to 33 regardingthe methods of accommodating theexpansion of exposed piping•Pipechannels(page33)•Expansionloops(pages28to29)

For longer sections of piping the fixedpoints can be located in such a way thatthe system is split into expansion zones.Suppliers of pipe clamps and bracketsoffer a wide range of solutions.

4140

MK00 K2 PPR pipe PN20/SDR 6

MK08 K2 PPR pipe PN16/SDR 7,4

d s di L Weight Vmm mm mm m kg/m l/m20 3,4 13,2 4 0,17 0,1425 4,2 16,6 4 0,27 0,2232 5,4 21,2 4 0,43 0,3540 6,7 26,6 4 0,67 0,5650 8,3 33,4 4 1,04 0,8863 10,5 42,0 4 1,65 1,3975 12,5 50,0 4 2,34 1,9690 15,0 60,0 4 3,36 2,83110 18,3 73,4 4 5,01 4,23

d s di L Weight Vmm mm mm m kg/m l/m20 2,8 14,4 4 0,15 0,1625 3,5 18,0 4 0,23 0,2532 4,4 23,2 4 0,37 0,4240 5,5 29,0 4 0,58 0,6650 6,9 36,2 4 0,90 1,0363 8,6 45,8 4 1,41 1,6575 10,3 54,4 4 2,01 2,3290 12,3 65,4 4 2,87 3,36110 15,1 79,8 4 4,30 5,00160 21,9 116,2 4 9,04 10,60

MK02 K2 PPR pipe PN10/SDR 11

d s di L Weight Vmm mm mm m kg/m l/m20 1,9 16,2 4 0,11 0,2125 2,3 20,4 4 0,17 0,3332 2,9 26,2 4 0,27 0,5440 3,7 32,6 4 0,42 0,8350 4,6 40,8 4 0,66 1,3163 5,8 51,4 4 1,04 2,0775 6,8 61,4 4 1,41 2,9690 8,2 73,6 4 2,11 4,25110 10,0 90,0 4 3,01 6,36160 14,6 130,8 4 6,35 13,44

Product rangeThe K2 PPR pipe system is constantlybeing extended and updated to meet therequirements of the industry.Please refer to the current K2 PPR pricelist for the complete product range.The abbreviated references, e.gMK00 (= PN20 pipe) orMK30 (= tee), simplify the administration.Please refer to the MK numbers when youplace your order.

On request and subject to minimumquantities and capacities we canmanufacture special types of fittings(e.g. 30° elbow).

All K2 PPR polyfusion fittings from d20 to d110 are rated PN16/20 Fittings d160 are rated PN10/16

Please check the price list to see which sizes and pressure ratings are currently available.

4342

MK70 Elbow 45°

MK20 Elbow 90°

MK10 Socket

di z t AD VPmm mm mm mm Pcs20 12 15 29 1025 13 20 36 1032 15 22 46 1040 21 25 53 550 25 26 68 263 32 29 85 175 37 30 101 190 48 34 122 1110 56 37 145 1160 83 48 200 1

di z t AD VPmm mm mm mm Pcs20 11 15 29 1025 16 20 36 1032 20 22 46 1040 27 25 54 550 32 26 68 263 36 29 85 175 41 30 102 190 50 34 122 1110 58 37 145 1160 85 48 200 1

di z t AD BL VPmm mm mm mm mm Pcs20 1,5 15 29 33 1025 1,5 20 36 43 1032 1,5 22 46 51 1040 2,5 25 54 57 550 2,5 26 68 60 263 2,5 29 85 62 175 2,5 30 101 65 190 3 34 121 74 1110 5,5 37 145 85 1160 9 48 200 114 1

MK35 Reducer tee

di di1 z t z1 t1 AD BL VPmm mm mm mm mm mm mm mm Pcs25 20 16 20 16 15 36 68 1032 20 20 22 26 15 46 84 532 25 20 22 22 20 46 84 540 20 27 25 27 15 54 94 540 25 27 25 24 20 54 94 540 32 27 25 26 22 54 94 550 20 32 26 32 15 68 112 250 25 32 26 28 20 68 112 250 32 32 26 30 22 68 112 250 40 32 26 29 27 68 112 263 25 36 29 40 20 85 128 163 32 36 29 36 24 85 128 163 40 36 29 37 27 85 128 163 50 36 29 36 28 85 128 175 32 41 30 42 22 102 142 175 40 41 30 41 27 102 142 175 50 41 30 40 28 102 142 175 63 41 30 39 29 102 142 190 63 50 34 54 29 122 166 190 75 50 34 50 30 122 166 1110 63 58 37 70 29 145 195 1110 75 58 37 68 30 145 195 1110 90 58 37 65 34 145 195 1160 90 74 48 118 34 200 244 1160 110 74 48 121 37 200 244 1

MK30 Equal tee

di z t AD BL VPmm mm mm mm mm Pcs20 11 15 29 52 1025 16 20 36 68 1032 20 22 46 84 540 27 25 54 94 550 32 26 68 112 263 36 29 85 128 175 41 30 102 142 190 50 34 122 166 1110 58 37 145 195 1160 85 48 200 260 1

4544

MK60 End cap

di z t AD BL VPmm mm mm mm mm Pcs20 8 16 29 24 1025 9 21 36 30 1032 11 22 46 36 1040 13 25 53 38 550 17 26 67 43 563 19 30 84 49 575 21 31 100 52 190 26 36 120 62 1110 41 37 145 78 1160 46 48 200 94 1

MK90 Curved pipe

d z AD BL VPmm mm mm mm Pcs20 215 45 430 1025 215 48 430 1032 215 55 430 5

MK11 Male adapter

di AG z t AD BL SW VPmm Inch mm mm mm mm mm Pcs20 1/2" 44 15 45 60 - 1020 3/4" 44 15 45 60 - 1025 1/2" 40 20 45 60 - 1025 3/4" 40 20 45 60 - 1032 3/4" 48 22 60 72 - 532 1" 59 22 60 83 39 540 5/4" 65 25 76 90 46 250 6/4" 68 26 82 92 52 163 2" 80 29 97 107 64 175 21/2" 90 30 123 120 80 190 3" 102 34 152 136 96 1

MK40 Reducer (female/female)

di di1 z t t1 BL AD VPmm mm mm mm mm mm mm Pcs25 20 2 18 16 38 36 1032 20 3 20 16 42 46 1032 25 2 20 18 42 46 1040 20 5 22 16 48 55 540 25 4 22 18 48 55 540 32 3 22 20 48 55 550 20 6 25 16 53 69 250 25 5 25 18 53 69 250 32 4 25 20 53 69 250 40 3 25 22 53 69 263 25 7 29 18 61 87 163 32 6 29 20 61 87 163 40 5 29 22 61 87 163 50 3,5 29 25 61 87 175 32 8 33 20 69 102 175 40 7 33 22 69 102 175 50 6 33 25 69 102 175 63 3 33 29 69 102 190 32 12 37 20 81 123 190 40 11 37 22 81 123 190 50 9,5 37 25 81 123 190 63 7,5 37 29 81 123 190 75 5,5 37 33 81 123 1110 50 14 43 25 96 149 1110 63 12 43 29 96 149 1110 75 10 43 33 96 149 1110 90 8 43 37 96 149 1160 110 16 59 29 120 213 1

zt

BL

z t1

di1diAD

4746

MK23 Elbow adapter 90° (female)

di IG z t zi AD SW VPmm Inch mm mm mm mm mm Pcs20 1/2" 13 15 21 42 - 1025 1/2" 17 20 21 46 - 1025 3/4" 17 20 21 46 - 1032 1" 20 24 38 61 39 5

DO NOT join to any threaded pipes or cast iron fittings!

MK50PF Valve with stem

di z t t1 AD BH VPmm mm mm mm mm mm Pcs20 23 15 46 37 93 125 23 15 46 37 93 132 24 22 48 46 104 140 32 25 50 53 118 150 40 26 45 67 140 163 52 30 58 84 166 1

MK55 Union (plastic – metal)

d AG z t z1 BL SW SW1 VPmm Inch mm mm mm mm mm mm Pcs20 1/2" 42 17 33 75 36 23 525 3/4" 49 20 40 89 46 30 532 1" 55 26 44 99 52 37 340 5/4" 85 50 52 137 66 45 250 6/4" 85 50 58 143 70 55 163 2" 85 50 65 150 86 66 175 2 1/2" 90 50 68 158 108 80 190 3" 90 50 73 163 122 94 1

includes drainage and replaceable EPDM seals!

MK21 Elbow adapter 90° (male)

di AG z t z1 AD SW VPmm Inch mm mm mm mm mm Pcs20 1/2" 13 15 49 42 - 1025 3/4" 17 20 52 46 - 1032 1" 20 22 61 61 39 5

MK13 Female adapter

di IG z t AD BL SW VPmm Inch mm mm mm mm mm Pcs20 1/2" 18 15 45 45 - 1020 3/4" 18 15 45 45 - 1025 1/2" 16 20 45 45 - 1025 3/4" 16 20 45 45 - 1032 3/4" 25 22 60 68 - 532 1" 22 22 60 68 39 540 5/4" 28 25 76 71 48 250 6/4" 30 26 82 71 56 163 2" 38 29 97 86 70 175 2 1/2" 44 30 123 96 88 190 3" 52 34 152 112 102 1DO NOT join to any threaded

pipes or cast iron fittings!

4948

MK18 Backing ring PP-R

di DN z t BL AD VPmm mm mm mm mm Pcs40 32 4 22 26 78 150 40 6 24 30 88 163 50 5 28 33 102 175 65 6 32 38 122 190 80 5 37 42 138 1110 100 5 42 47 158 1160 150 8 48 56 212 1

K19 PP flange with steel insert

d DN di LK d1 Holes BL AD VPmm mm mm mm mm mm mm Pcs40 32 51 100 18 4 16 140 150 40 62 110 18 4 18 150 163 50 78 125 18 4 18 165 175 65 92 145 18 4 18 185 190 80 108 160 18 8 18 200 1110 100 135 180 18 8 18 220 1160 150 178 240 22 8 24 285 1

Sizing according to DIN 2501 PN16

K19A Flange seal set plastic - metal

d Holes VP mm Pcs Pcs 40 4 1 50 4 1 63 4 1 75 4 1 90 8 1 110 8 1 125 8 1 160 8 1

1 set consisting of screws, bolts, washers and EPDM seal.

1 set consisting of screws, bolts, washers and EPDM seal.

K19K Flange seal set plastic - plastic

d Holes VP mm Pcs Pcs 40 4 1 50 4 1 63 4 1 75 4 1 90 8 1 110 8 1 125 8 1 160 8 1

MK57 Union with female thread

d IG z t BL SW VPmm inch mm mm mm mm Pcs20 1" 44 17 53 36 525 5/4" 50 20 60 46 532 6/4" 56 26 67 52 340 2" 87 50 103 66 250 2 1/4" 87 50 103 70 163 2 3/4" 87 50 103 86 175 3 1/4" 93 50 114 108 190 3 3/4" 93 50 115 122 1

MK56 Union (plastic – plastic)

d z t BL SW VPmm mm mm mm mm Pcs20 42 17 84 36 525 49 20 98 46 532 55 26 110 52 340 85 50 170 66 250 85 50 170 70 163 85 50 170 86 175 90 50 180 108 190 90 50 180 122 1

includes drainage and replaceable EPDM seals!

5150

WZ100 Welding set

WZ110 Pipe welding machine

WZ120 Overhead welding machine

Pipe welding machine 230 Volt, 800 WattIncludes case, table clamp and floor rest Pipe cutters d16 – 40 mm.Heating elements: d20 – 32 mm

Heating elements: d20 – 40 mm

Pipe welding machine 230 Volt, 1000 WattIncludes case,heating elements d20–90 or d25–125,Pipe cutters d20–75, d50–140,special gloves and pipe rests.Packaged in transport crate.

Type 1 d20–90 mmType 2 d25–125 mmType 3 d160 mm

For making polyfusion joints in areas that cannotbe accessed with the table welding machine.Can be used for the pipe types MK00, MK02,KE06 and MK08. Includes hand weldingmachine 230 Volt, 1200 Watt, d50 – 110 weldingtools, d16–75 and d50–140 pipe cutters,timer and special gloves. Packaged in transport crate.

Weight of machine: approx. 12 kilos

KELIT tools WZ122 Polyfusion welding tool

d VP mm Pcs 20 1 25 1 32 1 40 1 50 1 63 1 75 1 90 1 110 1 160 1

Heating elements

WZ130 Pipe cutter

WZ135 Wheel pipe cutter

d VP mm Pcs 16–40 1 Replacement blade 1

d VP mm Pcs 20–75 1 50 –140 1 110–160 1Replacement wheel: 20 – 75 1Replacement wheel: 50 – 140 1Replacement wheel: 110 – 160 1

5352

The technical contents in this brochure are for your information and consultation. We are not liable for thecontents. The application and installation of the products should be adapted to the individual requirements of each project. KE KELIT is constantly improving its products a nd retains the right to make technical changes in the course of these improvements. We are not liable for printing and spelling errors.© by KE KELIT, K2 PPR Handbook 09/2015 engl.

5554

Please note that for technical printingreasons the numbers are written accordingto the common practice in the German speaking countries (i.e. the number and the decimals are separated by a comma).

Full technical back-up and support for the K2 PPR-pipe system is provided by KE KELIT

The network of sales partners, subsidiariesand agents is constantly being expanded.Please ask at the Austrian headquartersfor the current status.

KE KELITKe Kelit (M) SDN BHDLot 5, Jalan 23/5Section 2340300 Shah Alam, SelangorMalaysia

Tel. +603 554 26 68 0

ke_kelit@tm.net.my www.kekelit.com

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Member of theAustrian Working GroupPLASTIC PIPE RECYCLING

ARA-Lizenz Nr.9087

KE KELIT Austria

KE KELIT MalaysiaKE KELIT

Ke Kelit (M) SDN BHDLot 5, Jalan 23/5Section 2340300 Shah Alam, SelangorMalaysia

Tel. +603 554 26 68 0

ke_kelit@tm.net.my www.kekelit.com Handbook 2015-2