RAUPANEL System. Installation Guide

Transcription

1 RAUPANEL System Installation Guide

2 Table of Contents 1.0 Introduction System Components RAUPANELs Return Bends Furring Strips /8" RAUPEX O 2 Barrier Pipe Tools Cutting Blade Deburring Tool Additional Tools Product Handling RAUPANELs Storage Cutting Deburring Return Bends and Furring Strips Storage Cutting Material Planning /8" RAUPEX RAUPANEL System Components Installation Job Site Preparation Installation over Suspended Wood Floor Installation over Concrete Slab RAUPANEL System Installation /8" RAUPEX Pipe Installation Wall and Ceiling Installation Suggested Floor Assemblies Repair Procedures Over Suspended Wood Subfloor Over Concrete Slab 17 Appendices 18 A. Sample Room Layout 18 B. RAUPANEL Output Charts 19 C. 3/8" RAUPEX Pressure Loss Tables 22 D. Graph Paper 25

3 1.0 Introduction REHAU s RAUPANEL System is a high performance alternative to poured thermal mass and joist space radiant heating installations. This system is well suited for both new construction and retrofit applications. The benefits of the RAUPANEL system include: Low thermal mass limits setpoint overshoot and results in quicker response times. High thermal conductivity promotes even temperature distribution. Lower water temperatures may be used to achieve desired heat output. The larger inside diameter of 3/8" RAUPEX pipe (as compared to nominal 5/16" pipe) provides superior flow and heat delivery characteristics. Flexible pipe spacing (6" or 8" oncenter) makes the system well suited for a variety of installations, and heat load requirements. Light weight of components (1.3 lb/ft 2 ) minimizes need for structural reinforcement and offers ease of handling on the job site. Compatible with commonly used floor coverings. Can be installed in walls or ceilings for additional heat output. Fig. 1.1: Installation of RAUPANEL system components This guide provides specific instructions on installing RAUPANEL system components as part of a complete radiant heating system. Installers should consult the RAUPEX Radiant Floor Heating Systems Installation Guide for general guidelines on pipe handling, job site preparation (including manifold installation), pipe connections, air and water pressure testing, and system charging and balancing. The radiant heating system design including heat loss calculations, manifold and pipe sizing, circuit location and length recommendations, should be completed prior to installation. REHAU s design software and/or pipe layout drawings may provide many of the required design details. Contact your regional REHAU representative for more information, or visit us online at NA.com. 1

4 2.0 System Components The patented RAUPANEL System consists of a few basic components (aluminum RAUPANELs, wooden return bends, and furring strips) that are designed for quick and easy installation, as well as excellent performance. The system allows for either 6" or 8" on-center pipe spacing as required, to meet radiant panel performance requirements. 2.1 RAUPANELs The aluminum RAUPANEL (Art ) has a custom groove that allows pipe to be easily snapped into place, maintaining excellent thermal contact. No silicone or other filler materials are required. The unique profile of the highly-conductive aluminum RAUPANEL makes it lightweight and responsive, while maintaining strength. 2.2 Return Bends Return bends are available in 6" and 8" oncenter configurations (Art. No PLY, PLY) to allow for maximum flexibility during installation. They are manufactured from construction-grade plywood, and pre-grooved for easy pipe installation. 8" On-center return bends are specially notched to accommodate the RAUPANELs, simplifying system layout. Dimensions: 6" Return Bend (W x L x H): 8" x 48" x 0.625" 8" Return Bend (W x L x H): 9" x 48" x 0.625" 2.4 3/8" RAUPEX O 2 Barrier Pipe The RAUPANEL System is designed to work with 3/8" RAUPEX O 2 Barrier pipe. RAUPEX is a durable, yet flexible pipe with enhanced temperature capability, and longterm strength. RAUPEX meets the requirements of ASTM F 876, F 877, CSA B and PPI TR-3, and is certified to NSF Standard 14. Additionally, RAUPEX O 2 Barrier complies with the strict requirements of DIN Refer to the RAUPEX Heating and Plumbing Systems Catalog for additional information on RAUPEX pipe. Dimensions: (W x L x H) 6" x 72" x 0.625" Fig 2.2: Return bends Fig. 2.1: RAUPANEL 2.3 Furring Strips 2" Furring strips (Art PLY) are available for 8" on-center installations. They provide a convenient fastening surface for a variety of floor coverings and aid in RAUPANEL spacing. Fig. 2.4: 3/8" RAUPEX O 2 Barrier Pipe Dimensions: Furring Strip (W x L x H): 2" x 48" x 0.625" Fig. 2.3: Furring strip 2

5 3.0 Tools 3.1 Cutting Blade For best results, REHAU recommends that installers use a cutting blade that is suitable for cutting both wood and aluminum. The tungsten carbide cutting blade supplied by REHAU (Art ) as part of the RAUPANEL system is ideal for this purpose. Warning: Always wear safety glasses when cutting the RAUPANEL system components 3.2 Deburring Tool REHAU requires that a deburring tool (Art ) be used to eliminate any sharp burrs from the inside of the RAUPANEL pipe groove after field cutting. It is important to protect the pipe from damage during installation and normal operation. The bi-directional blade on REHAU s deburring tool allows it to be used in clockwise and counterclockwise directions. 3.3 Additional tools The following tools are suggested for installation: Power miter saw Jigsaw (for notching system components) Cordless drill with screw driver bit Pneumatic nail gun Router Chalk line Measuring tape Heavy duty vacuum cleaner Uncoiler Appropriate fasteners Router with 1/2" bit Fig. 3.2: Deburring tool Fig. 3.1: Cutting blade 3

6 4.0 Product Handling Refer to the RAUPEX Radiant Floor Heating Systems Installation Guide for general pipe handling guidelines. Work gloves should be worn to protect from cuts or scratches during deburring operation. Always wear safety glasses while cutting the RAUPANEL components. 4.1 RAUPANELs Storage RAUPANELs are shipped in a cardboard box and should be stored in a dry location. To avoid denting or damaging, store RAUPANELs in a location with minimal traffic. Do not stack heavy materials on top of the RAUPANELs Deburring Use the deburring tool to remove sharp burrs on the inside of the RAUPANEL pipe groove after every field cut. Rest the cutting surface of the deburring blade on the edge of the pipe groove at a 45 angle and pull it along the edge to remove all burrs. Fig 3.4: Deburring sharp edges 4.2 Return Bends and Furring Strips Storage Return bends and furring strips are shipped in a cardboard box and should be stored in a dry location. To avoid damaging, store in a location with minimal traffic Cutting Return bends and furring strips are easily cut with the cutting blade. Follow the same procedures as with any regular plywood sheet Cutting To make straight cuts use a miter (or similar) saw with the cutting blade. This blade can be used to cut both aluminum and wood. After the cut has been made, deburr the inside of the RAUPANEL pipe groove. To make notches in the RAUPANEL use a jig saw with a metal blade. Mark the area that needs to be cut and secure the RAUPANEL to a stable work surface. 4

7 5.0 Material Planning A material list specifying the required quantity of RAUPANEL system components and RAUPEX pipe should be completed as part of the radiant panel system design. If the design does not specify the required quantity of RAUPANEL system components, or a quick estimate is required for quotation purposes, the following guidelines may be used. Please note that quantities will vary depending upon the project s required pipe spacing, which must be determined by the design /8" RAUPEX The amount of 3/8" RAUPEX required will vary depending on the pipe spacing, which is dictated by the radiant panel system design. Use the following equations to estimate the required amount of pipe. Note that the equations take into account additional length of circuit tails. 6" On-center: Total Heated Area (ft 2 ) X 2.2 (ft/ft 2 ) = RAUPEX Pipe Requirement (ft) 8" On-center: Total Heated Area (ft 2 ) X 1.7 (ft/ft 2 ) = RAUPEX Pipe Requirement (ft) Example: Assuming a total heated area of 1000 ft 2, the 3/8" RAUPEX pipe requirements would be as follows: 6" On-center: 1,000 ft 2 X 2.2 = 2,200 ft of 3/8" RAUPEX 8" On-center: 1,000 ft 2 X 1.7 = 1,700 ft of 3/8" RAUPEX 5.2 RAUPANEL System Components The required RAUPANEL, return bend and furring strip quantities will depend on the pipe spacing required, area of coverage, and general shape of the heated spaces. The following formulas reflect product ratios that apply to a typical installation (approximately 12.5% return bend coverage). Installations in large or long rooms, may require more RAUPANELs than calculated here. In installations that involve small rooms, the percentage of return bends may be higher. Use the ratios provided as a general guideline and adjust accordingly. RAUPANELs 6" On-center: Total Heated Area (ft 2 ) X (pcs/ft 2 ) = RAUPANEL Requirement (pcs) 8" On-center: Total Heated Area (ft 2 ) X (pcs/ft 2 ) = RAUPANEL Requirement (pcs) Return Bends 6" On-center: Total Heated Area (ft 2 ) X (pcs/ft 2 ) = Return Bend Requirement (pcs) 8" On-center: Total Heated Area (ft 2 ) X (pcs/ft 2 ) = Return Bend Requirement (pcs) Furring Strips 6" On-center: None required 8" On-center: Total Heated Area (ft 2 ) X (pcs/ft 2 ) = Furring Strip Requirement (pcs) Example: Assuming a Total Heated Area of 1,000 ft 2, of which 25% (250 ft 2 ) is to be spaced at 6" on-center, the following component quantities would be required: Total 6" On-center Area 8" On-center Area Heated Area Requirements Requirements Requirements RAUPANELs: 250 x = 73 pcs x = 165 pcs = 238 pcs Return Bends: 250 x = 12 pcs x = 32 pcs = 44 pcs Furring Strips: None Required (0 pcs) x = 246 pcs = 246 pcs 5

8 6.0 Installation 6.1 Job Site Preparation Inspect the condition of the slab or subfloor. It should be structurally sound, flat, and free of debris so that all panels are evenly supported. Correct any height discrepancies before installing RAUPANEL system components. Confirm that the additional floor height due to RAUPANEL system installation has been taken into account. Door moldings, base plates, electrical outlets, etc. may need to be raised. Coordinate with other trades so that any floor penetrations/obstructions can be clearly designated prior to installing the RAUPANEL system components. Note: Other trades must be notified that aluminum RAUPANELs are being used within the floor. Electrical outlets and/or fixtures within the floor must be clearly marked prior to RAUPANEL installation. Aluminum RAUPANELs system components must not be used to provide electrical ground. Fig. 6.1: Completed RAUPANEL system installation Installation over Suspended Wood Subfloor When a suspended subfloor is located above a conditioned (heated) space, the total R-value of insulation below the RAUPANEL system should be 4-5 times greater than the total R-value of the floor structure and coverings above. REHAU recommends a minimum insulation R-value of R-11 below the subfloor when installed over conditioned space. Suspended floors located above an unheated space should use insulation with a minimum value of R-30 below Installation over Concrete Slab Install a PE vapor barrier over the concrete slab. A 3/4" plywood subfloor is optional. Note: RAUPANEL system components should not come in direct contact with concrete. 6

9 6.2 RAUPANEL System Installation Refer to the radiant panel system design to find the number of circuits covering a room or area and the estimated circuit lengths. 3/8" RAUPEX circuits may range from 150 to 250 feet depending on flow and output requirements. Generally, REHAU recommends that circuit lengths (including circuit tails) be kept below 200 feet to help minimize pump size and attain high system efficiencies. When choosing the preferred orientation of the RAUPANEL system components, consider the following factors: RAUPANEL system should be installed perpendicular to direction of hardwood flooring. RAUPANEL system may be installed to minimize the number of return bends required, maximizing the straight runs. RAUPANEL system may be installed perpendicular to direction of joists to add stiffness to the floor. Follow the steps listed below for each individual circuit. 1. Plan circuit tail paths Plan the paths for the circuit tails to the area that they will cover. It may be helpful to mark off the area where the tails will be installed. Tails may be installed by any of the following methods: Run tails on top of the subfloor/slab using furring strips (or scrap wood), or mortar as filler. Pipe should be secured to the subfloor (copper straps may be used). Direct tails under the subfloor by drilling an oblong hole and sleeving the pipe for protection. Subfloor penetration should be wide enough (minimum 1") to accommodate pipe and PE protection sleeve (Art ) and long enough (minimum 3") to allow a smooth bend in the pipe. Secure pipe under subfloor (plastic pipe talons may be used). Use router to cut pipe grooves into 5/8" plywood for the circuit tails. 2. Align and fasten return bends and furring strips Measure and snap a chalk line off the wall to ensure the first line of RAUPANELs line up evenly. When installing panels at 8" on-center, secure a row of furring strips along the chalk line. Align return bends at both ends of the straight run making sure that pipe grooves line up properly. Plywood components may be secured by any of the following methods: Nail or screw plywood return bends and furring strips to the subfloor. A pneumatic nail gun or a drill may be used. Glue plywood components to wood subfloor using wood glue suitable for this purpose. When installing over concrete slab, use masonry fasteners. Tapcon screws or Congrip fasteners are suggested. Fig. 6.2: Circuit tails routed on top of subfloor Fig 6.3: Circuit tails routed below subfloor (note PE sleeving) Fig. 6.4: Furring strips and return bends aligned Fig. 6.5: RAUPANEL System layout (8" on-center). Stagger panels for best results. 7

10 3. Align and fasten RAUPANELs Install RAUPANELs using the furring strips or chalk line for alignment. Stagger them to ensure proper alignment. RAUPANELs should be secured after the entire circuit area has been laid out to allow for adjustment. They may be secured or allowed to float when installed 8" on-center with furring strips. When securing RAUPANELs, fasteners should be positioned at the ends and in the center of each aluminum panel. Secure on both sides, between the outer legs, approximately 0.5" from the edge, using any of the following methods: 6.3 3/8" RAUPEX Pipe Installation 1. Before installing the pipe make sure the channels are free of debris and obstructions. Use a broom or vacuum to clean the pipe grooves. Note that no silicone is required in the pipe groves. 2. Attach RAUPEX pipe to the corresponding supply manifold outlet. If a bend guide is being used, pass the RAUPEX through it before attaching the pipe end to the manifold. 3. If the manifold is mounted in the wall, a portion of the base plate may need to be removed so the RAUPEX can be routed under the drywall. 4. Run the RAUPEX to the circuit area through the pre-determined path (see Section 6.2, Step 1). 5. Snap the RAUPEX into the pipe grooves by stepping it in or by using a rubber mallet. 6. Once the circuit is finished, route RAUPEX pipe back to manifold. Attach the RAUPEX to the return header. If a bend guide is being used, pass the RAUPEX through it before attaching the pipe end to the manifold. Over wood subfloor Nail RAUPANELs using pneumatic nailing gun. Ring shank flat head roofing nails are suggested. Panels may be screwed down using screw gun. Fine threaded drywall screws are suggested. Ensure that screw head is flush with the panel surface. Over concrete slab Use Phillips flat head masonry fasteners. (Tapcon or Congrip, for example) Fig. 6.7: Mounted manifold with base plate removed Fig. 6.6: Using screw gun to secure RAUPANEL to subflooring Fig. 6.8: Inserting RAUPEX into RAUPANEL grooves 8

11 6.4 Wall and Ceiling Installation The RAUPANEL System may also be installed 6" or 8" on-center within walls and/or ceilings. Typically this is done if additional heat is required or desired for a given room or area. Refer to the following steps: 1. Allow sufficient space for the circuit to enter and exit the wall or ceiling. Angle or remove enough of the base plate to allow the RAUPEX to enter the wall under the sheetrock. 2. Mark where the lower edge of the first RAUPANEL will be located, making sure that the panel is level. Secure the first row of RAUPANELs or furring strips, adding a return bend at the end. Make sure pipe grooves align properly. 3. Secure the remaining RAUPANELs, furring strips, and return bends to the wall studs or ceiling joists. 4. If adjacent walls are being covered with the same circuit, notch or drill holes in the corner studs to allow the pipe to bend around the corner. Pipe should be covered with PE protective sleeve in these areas. 5. Generally, it may be advisable to install RAUPANEL within the wall to a height of no more than 48" to minimize the possibility of damage from nailing. Furring strips should be mounted to the studs/joists in the remaining portion of the wall or ceiling not covered by the RAUPANEL system components to provide a flush surface for the wall covering. For installation of RAUPEX pipe follow the instructions in Section 6.3. Fig. 6.8: Circuit transition from floor to wall installation Fig. 6.9: Pipe routing in corner, prior to sleeving 9

12 7.0 Suggested Floor Assemblies The following figures depict a number of typical floor assemblies for installations over suspended wood subfloors or concrete slabs 7.1 Over Concrete Slab 10

13 11

14 12

15 7.2 Over Suspended Subfloor 13

16 14

17 7.3 Wall and Ceiling 15

18 16

19 8.0 Repair Procedures Option 1 Option 2 If the pipe is punctured during installation of the floor covering, or at some other time when the entire circuit cannot be easily removed, it may be necessary to install an EVERLOC repair coupling. The following are suggested repair procedures. 8.1 Over Suspended Wood Subfloor Either of the following methods can be used. 1. Pull the pipe out of the groove and cut it at the point of puncture. 2. Cut the aluminum panel at least 6" in both directions away from the point of puncture. 1. Pull the pipe out of the groove and cut it at the point of puncture. 2. Remove a sufficient section of aluminum panel to allow holes to be drilled through the subfloor and the pipe to be routed underneath. Pipe should be sleeved when passing through the floor penetration. 3. Burrow a 1/4" recess in the subfloor below the location of the coupling to accommodate for the outside diameter of the 3/8" EVERLOC coupling (0.75"). 3. Assemble the coupling below the subfloor. 4. Assemble the coupling and reinstall the RAUPEX pipe into the groove. Fill in the space around the coupling with furring strips or scrap plywood. 4. Fill in the space around the repair with furring strips or scrap plywood. 8.2 Over Concrete Slab 1. Pull the pipe out of the groove and cut it at the point of puncture. 2. Cut the aluminum panel at least 6" in both directions away from the point of puncture. 3. Burrow a 1/4" recess in the concrete below the location of the coupling to accommodate for the outside diameter of the 3/8" EVERLOC coupling (0.75"). Be sure to repair the vapor barrier afterward. 4. Assemble the coupling and reinstall the RAUPEX pipe into the groove. Fill in the space around the coupling with furring strips, scrap plywood, or mortar. 17

20 18 Sample room layout depicts 6" and 8" on-center spacing and other common installation practices. Cut 6" Return Bends to Make 90 Degree Turns 8" On-Center Pipe Spacing 8" Return Bend Route Circuit Tails On Top of Subfloor Route Circuit Tails Under Subfloor 6" Return Bend (Cut) 6" On-Center Pipe Spacing Appendix A Fill in with Scrap Wood or Mortar Stagger Panels Cut Returns for Single U-Bend

21 Appendix B System Output Charts RAUPANEL TM Output - 8" OC Spacing Over Suspended Wood Floor (w/r19) or Concrete Slab R = R = BTU/h/ft R = 1.0 R = 2.0 R = Mean Heating Water Temperature ( o F) 19

22 RAUPANEL TM Output - 6" OC Spacing Over Suspended Wood Floor (w/r19) or Concrete Slab R = 0.25 R = BTU/h/ft R = 1.0 R = 2.0 R = Mean Heating Water Temperature ( o F) 20

23 RAUPANEL TM Wall Output With 1/2" Sheetrock and R-11 Insulation " OC 8" OC 60.0 BTU/h/ft Mean Heating Water Temperature ( o F) 21

24 Appendix C 3/8" RAUPEX Pipe Pressure Loss Tables 100% Water Pressure Loss (ft head for given circuit length) Flow Rate Velocity 100 o F (38 o C) Water 140 o F (60 o C) Water GPM ft/sec 100' 150' 200' 250' 100' 150' 200' 250' Shaded areas indicate high head loss 20% Glycol by Volume Pressure Loss (ft head for given circuit length) Flow Rate Velocity 100o F (38 o C) 20% Glycol solution 140 o F (60 o C) 20% Glycol Solution GPM ft/sec 100' 150' 200' 250' 100' 150' 200' 250' Shaded areas indicate high head loss 22

25 30% Glycol by Volume Pressure Loss (ft head for given circuit length) Flow Rate Velocity 100o F (38 o C) 30% Glycol solution 140 o F (60 o C) 30% Glycol Solution GPM ft/sec 100' 150' 200' 250' 100' 150' 200' 250' Shaded areas indicate high head loss 40% Glycol by Volume Pressure Loss (ft head for given circuit length) Flow Rate Velocity 100o F (38 o C) 40% Glycol solution 140 o F (60 o C) 40% Glycol Solution GPM ft/sec 100' 150' 200' 250' 100' 150' 200' 250' Shaded areas indicate high head loss 23

26 50% Glycol by Volume Pressure Loss (ft head for given circuit length) Flow Rate Velocity 100o F (38 o C) 50% Glycol solution 140 o F (60 o C) 50% Glycol Solution GPM ft/sec 100' 150' 200' 250' 100' 150' 200' 250' Shaded areas indicate high head loss 24

27 Appendix D Use graph paper to document RAUPANEL system layout 25

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