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Variotherm Heating Systems: Variotherm
Installation Guide for Variotherm models including: VBOOK8_EN Vario Comp, VBOOK8_EN, Vario Comp, Comp
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DocumentDocumentDESIGN & INSTALLATION Fl o o rMODULAR FLOOR HEATING 20 mm Modular Floor VBOOK8_EN | 8/2024 wwwvariothermcom This is how it's done ... INS TA LL ATION VIDEO The installation video is no substitute for this planning and installation instructions! 4.6 5 4.7 1 1 PRINCIPLES 4 1.1 Comfort........................................................................... 4 1.2 Energy savings................................................................ 5 1.3 Is it possible to cool a room using the floor? ................. 5 1.4 Description and advantages of the VarioComp.............. 6 22 PRECONDITIONS 8 2.1 Warranty conditions ....................................................... 8 2.2 Information on standards............................................... 8 2.3 Coordination of the floor structure ................................ 8 2.4 Vapour barrier/vapour retarder ..................................... 8 2.5 Rooms............................................................................. 8 2.6 Tools................................................................................ 8 2.7 Movement joints ............................................................. 9 2.8 Humidity.......................................................................... 9 2.9 Transport/storage of goods............................................ 9 2.10 Impact sound insulation ............................................... 9 33 FLOOR STRUCTURE 10 3.1 General ......................................................................... 10 3.2 Usual substructures..................................................... 11 4 4 COMPONENTS & PROCESSING13 4.1 Edge insulation strip .................................................... 13 4.2 PE construction foil ...................................................... 13 4.3 Compact underlay boards ............................................ 14 4.4 VarioComp boards/blank boards.................................. 14 4.5 VarioProFile pipe 11.6x1.5............................................ 16 4.6 VarioManifold / Pressure test....................................... 20 4.7 VarioComp filling compound T7 ................................... 22 5 5 FLOOR COVERING24 5.1 General ......................................................................... 24 5.2 Residual humidity of the VarioComp filling compound 24 5.3 Filling in a glass fibre cloth .......................................... 25 . . . . . . 5.4 Application of an additional floor levelling compound ..... 25 5.5 Rooms exposed to high humidity ...................................... 26 5.6 Tile, stone and ceramic coverings..................................... 27 5.7 Soft floor coverings and synthetic resin floors ................. 27 5.8 Hard floor coverings (parquet, laminate, PVC boards) ..... 28 6 HEATING PRACTICE ................................. 29 6.1 Calculating the heating load ............................................. 29 6.2 Variotherm dimensioning software........................................29 6.3 Heat output .............................................................................30 6.4 Pressure loss..........................................................................32 7 PROTOCOLS................................................ 33 7.1 Leak-tightness test in accordance with EN 1264-4 ...............33 7.2 Functional heating (in compliance with EN 1264-4 or BVF) ..34 7.3 Commissioning.......................................................................34 PRINCIPLES For perfect comfort and optimum energy savings, Variotherm recommends a combination of floor, wall and ceiling heating/cooling system. In general, walls offer the largest exchange area, which is why wall heating/cooling systems ensure that people can easily feel the radiant heat. The Variotherm floor heating system is ideal for all `cold' floors. It is an optimum temperature regulator, creating a pleasant atmosphere. The Variotherm floor heating emits long-wave, infrared radiant heat. Consistent with the body's own heat, similar to the heat of the sun, this type of heat is experienced as particularly pleasant. . Comfort Comfort is not only created through a certain air temperature in the room. The temperature of the surfaces enclosing the room is of equal importance. The felt temperature is roughly consistent with the arithmetic mean of both temperatures. What makes people feel comfortable? People feel comfortable when the following basic `thermal comfort' equation holds: Heat production = heat loss Heating Cooling Ceiling Wall Floor c Which system areas are suitable for which needs? Heat production = heat loss Room enclosure temperature °C 30 Just about 28 still cosy Uncomfortable 26 24 22 Cosy 20 18 16 Uncomfortable 14 12 14 16 18 20 22 24 26 28 Room air temperature °C c Zone of cosiness Approx. 7 % EVAPORATION Sweat gland Approx. 20 % RESPIRATORY AIR Approx. 30 % CONVECTION 37 °C Approx. 40 % RADIATION c Human heat balance Approx. 3 % CONDUCTION 4 | PRINCIPLES In this context, it is important that the heat loss from the human body is as evenly distributed in all directions as possible We feel uncomfortable if too much heat is lost in one particular direction (cold surfaces, draughts) or heat loss is prevented in one direction (hot surfaces or steam-tight, thick clothing) In many cases it is therefore recommendable to install a combination involving the Variotherm wall heating system Consistent heat transfer ensures that temperature layering in the room is kept at a minimum, promoting the general spreading of a pleasant temperature In the case of floor heating, the floor is indeed warmer than the air at head-level Indeed, according to popular wisdom, people stay healthy with a cool head and warm feet' The room temperature can be set lower than with conventional heating systems Radiant heat raises the felt air temperature without affecting your comfort Since the heat is transferred invisibly via the floor, no visible components have to be planned for, such as recesses for heating devices, radiators and pipes These almost unavoidable `subtenants' in expensive living space require a lot of room and are not pleasing to the eye They restrict both the wall and window design and the space where furniture can be positioned Combined floor heating and wall heating systems complement each other perfectly in living spaces They allow for tailor-made heat supply in every room 1.2 Energy savings The right surface heating/cooling system not only gives you optimum comfort, it also saves energy and money The cost of operating a floor heating system can be reduced due to low surface temperatures and hence low heating water temperatures Surface heating/cooling is therefore ideal where low-temperature energy sources are used, such as biomass, heat pumps, condensing boilers and solar collectors The approximate cost savings per 1 K (°C) lower room air temperature are 6 % Low room air temperature also has the physiological advantage of significantly increasing the absorption of oxygen 1.3 Is it possible to cool a room using the floor? Cooling via the floor is possible Real room cooling is only possible in combination with additional areas on the ceiling and/or wall 24 °C 24 °C 23 °C 70 °C 19 °C 19 °C c Discomfort with radiators 21 °C 22 °C 21 °C 21 °C 22 °C c Comfort with floor heating system PRINCIPLES | 5 . Description and advantages of the VarioComp The VarioComp floor heating system is ideally suited for retrofitting a floor heating system. All components of the complete system are perfectly matched: > The specially milled routings of the VarioComp board > The easy to bend VarioProFile pipe with an extremely stable form > The fast-drying VarioComp filling compound > The ideal height for the optional XPS or SILENT underlay board The fast reaction time allows good control of the room temperature even in sunny rooms. The complete system has been checked, tried out in practice and has been awarded with a number of quality certificates. The VarioComp floor heating was subjected to comparison measurements with a screed floor heating system (VarioRoll, pipe spacing: 100 mm, screed covering of the VarioProFile pipe: 40 mm) for 24 hours. The faster heating of the surface of the VarioComp floor heating compared to the screed floor heating system can be clearly seen. The reaction time of the surface temperatures to reduced flow temperature is shorter. This results in: > Better control of the VarioComp floor heating. The surface temperature during heating is greater than that of the screed floor heating system. > More efficient layout of the heating surfaces because lower flow temperatures than those used for other floor heating systems are possible. 20 mm +0 mm -1,5 mm A d vVaa rni to aC go me ps > Construction height just 20 mm > Low weight (25 kg/m ) > Rapid construction progress fast drying times: Ready for covering after just 24 hours > Ideal for renovations > Routing system throughout, allowing pipes to be laid flexibly > High heat output lower flow temperature > Rapid reaction times c System height and tolerances Temperature [°C] 00:01:00 00:35:00 01:09:00 01:43:00 02:17:00 02:51:00 03:25:00 03:59:00 04:33:00 05:07:00 05:41:00 06:15:00 06:49:00 07:23:00 07:57:00 08:31:00 09:05:00 09:39:00 10:13:00 10:47:00 11:21:00 11:55:00 12:29:00 13:03:00 13:37:00 14:11:00 14:45:00 15:19:00 15:53:00 16:27:00 17:01:00 17:35:00 18:09:00 18:43:00 19:17:00 19:51:00 20:25:00 20:59:00 21:33:00 22:07:00 45 40 35 30 25 ~ 2,5 h 20 15 Time [hh:mm:ss] Captions: Flow temperature Mean surface temperature of the VarioComp floor heating (pipe spacing 100 mm) Mean surface temperature of the screed floor heating (pipe spacing 100 mm) Room air temperature 6 | PRINCIPLES 13.370/1 Substrate prepared on site (dry, even and load-bearing) PE construction foil VarioProFile pipe 11.6x1.5 VarioComp board VarioComp filling compound Edge insulation strip with overlap foil Floor covering: Here, you can choose whatever you like: wooden parquet, tiles, stone flooring, laminate or carpet. c VarioComp boards mm (pipe spacing or mm) c VarioProFile pipe . x . c VarioComp filling compound PRINCIPLES | 7 2 PRECONDITIONS 2.1 Warranty conditions If installed or commissioned incorrectly, all claims on the basis of the manufacturer's warranty and guarantee become void This brochure (version dated 8/2024) is intended for authorised qualified personnel and constitutes part of our warranty! All previous versions become invalid upon release of a new version! For the latest version please refer to the QR Code on the title page or wwwvariothermcom Local, geographic and climatic regulations/standards for cooling, heating and electrical installations must be observed! 2.2 Information on standards The validity of the standards referred to in these installation instructions was last checked on 22082024 If necessary, amendments to standards must be checked 2.5 Rooms > The rooms must be cleared out, clean, grease-free, dust-free and dry Residual plaster and mortar must be removed > To prevent the VarioComp filling compound from drying out too quickly, there must be no draughts on the construction site (windows, exterior doors and door frames should be installed) > All trades involved must be informed about the installation of the floor heating, and no other work may be conducted while the heating is being laid in order to ensure that no damage occurs during the subsequent installation work If necessary, a warning sign should be hung up at a suitable place on the construction site Warning signs are available from wwwvariothermcom (Service/Info centre) 2.6 Tools Recommended tools (at the construction site) for the installation work: 2.3 Coordination of the floor structure The following items must be coordinated between the architect, construction manager, installation technician and floor layer: > Horizontal level > Floor structure with: - appropriate strength - the necessary vapour retarders/barriers - the necessary thermal/impact sound insulation > Expansion joints > VarioComp filling compound to be applied by installer, floor layer or construction manager > Floor covering, with heat sensors if necessary Vacuum cleaner Rubber mallet Circular saw or jig saw Agitator Trowel Brush or paintbrush for cleaning 2.4 Vapour barrier/vapour retarder Vapour barriers or vapour retarders need to be included in the floor structure, depending on the installation situation and type of floor covering An agreement must be reached in a coordination meeting between the contractors (construction company, installation technician, etc) as to whether these intermediate layers are necessary Variotherm tools for applying the VarioComp filling compound: Scraper Bucket set VarioComp mixing tool 8 | PRECONDITIONS 2.7 Movement joints Movement joints (eg with edge insulation strips) are required in order to allow for expansion These are to be defined by the architect or planner > Field size max 80 m², lateral length max 12 m Building joints must be continued throughout the entire floor structure up to and including the floor covering > Keep the number of pipe feed-throughs through the movement joints to a minimum 12 m 12 m Examples of the layout of the movement joints --- 12 m 12 m Movement joints are particularly important when it comes to ceramic floor coverings It is crucial that the movement joints run congruently in all layers (compact floor heating and floor covering) See Chapter 45 for details on pipe laying with movement joints elastic joint compound 6-10 mm eg edge insulation strips 2.8 Humidity The maximum air humidity may not exceed 70 % during storage, installation and further processing of the VarioComp boards, and during the construction phase and use of the building Wet plaster and wet screed must be applied and dried before the VarioComp boards are installed The VarioComp boards may be used in rooms up to humidity class W3 as specified in ÖN B 3407 (or W1-I as specified in DIN 18534-1) 2.9 Transport/storage of goods VarioProFile pipe Leave the VarioProFile pipe in the box for as long as possible in order to avoid damage such as dents and scratches This type of damage has a detrimental effect on the creep behaviour In order to prevent damage to the VarioProFile pipe during the construction phase, high-visibility warning signs should be placed at appropriate locations The interaction of the oxygen in the air with UV rays damages the VarioProFile pipes, which should not be stored in the open air At low temperatures ( 5 °C) the VarioProFile pipe should be stored in heated rooms prior to installation VarioComp boards The VarioComp boards are delivered on pallets When storing, ensure that there is sufficient load-bearing capacity at the storage site The VarioComp boards should always be stored flat on an even surface They should be protected from moisture, particularly rain Boards that have become damp for a brief period of time may only be processed after they have dried out completely Always store the VarioComp boards with the routings facing upwards VarioComp filling compound The VarioComp filling compound is delivered in sacks on pallets It must be ensured that they are stored in a dry place and covered in foil until they are used The maximum length of storage is 12 months from the production date (see stamp on the bag) For safety data sheet, go to wwwvariothermcom (Service/Info centre) elastic joint compound eg edge insulation strips break 2.10 Impact sound insulation Particular attention should be paid to impact sound insulation The impact sound improvement values must be specified by the planner or architect and be coordinated with the relevant floor structure as described in Chapter 3 See also chapter 43 for Variotherm SILENT underlay board PRECONDITIONS | 9 FLOOR STRUCTURE . General The VarioComp board is a pure tube carrier and thermal conduction element - and should therefore be regarded as a floor covering and not as a component of the floor structure. Why? The necessary static support, thermal and impact sound insulation and protection against moisture diffusion must already be provided by the construction underneath the VarioComp board. The following items must be coordinated between the architect, construction manager, installation technician and floor layer: > Horizontal level line > Floor structure with appropriate strength, necessary vapour retarders/barriers, necessary thermal insulation/impact sound insulation and expansion joints > VarioComp filling compound to be applied by installer, floor layer or construction manager > Floor covering, with heat sensors if required 1. DRY 2. LEVEL The substrate must be dry, dust and grease free. Maximum residual humidity of the subsurface (CM values): · Untreated concrete: 3.0 % · Cement screed: 2.0 % · Calcium sulphate screed: 0.5 % The required evenness is as follows (ÖNORM DIN 18 202): 3. LOAD-BEARING Measuring point spacing 0.1 m 1 m 4 m 10 m 1 mm 3 mm 9 mm 12 mm Maximim pitch Measuring point spacing Surveyor`s staff Pitch Distance to the walls at least 250 mm 100 × 100 mm The load-bearing capacity specified in the table below must be provided. If there are several concentrated loads, these must be at least 500 mm apart. Caution: The sum of the concentrated loads must not exceed the maximum permissible floor load capacity. Particularly heavy objects (pianos, aquariums, bathtubs) must be given special consideration! Maximum deformation Vm with 100 kg on 100 × 100 mm. Room usage examples in accordance with ÖNORM EN 1991-1-1 Max. concentrated load Qk Category A1: Floors of rooms in residential buildings and houses, wards and hospital rooms (without heavy diagnostic instruments), rooms in hotels and lodgings, kitchens, toilets and rooms with residential-type use in existing buildings Category B1: Office floors in existing buildings 2.0 kN Max. service load qk 2.0 kN/m Max. deformation Vm (with 100 kg on 100 × 100 mm) 1.5 mm Category B2: Office floors in office buildings Category C1: Floors in rooms with tables etc., e. g. classrooms in schools, cafés, restaurants, dining areas, reading rooms, reception rooms, wards and hospital rooms (with heavy diagnostic instruments) 3.0 kN 3.0 kN/m 1.0 mm Category C2: Floors in rooms with fixed seating, e. g. in churches, theatres, cinemas, conference rooms, lecture halls, meeting halls, waiting rooms, train station waiting rooms 4.0 kN 4.0 kN/m Consultation is necessary 10 | FLOOR STRUCTURE 3.2 Usual substructures Screed / Bare slab Wooden beam ceiling Screed: > Test for evenness, and if necessary, even out using levelling compound > Test for dryness Bare slab: > Test for evenness, and if necessary, even out using levelling compound > Building sealant, if required Fill /Dry construction > Check sagging, surface evenness and loadbearing capacity (see e g max deformation Vm, Chapter 31); reinforce construction if required Fill > Loose fill (necessary compaction must be provided!) > Bonded fill (oven dry density 350 kg/m3, compression strength 0405 N/mm2) > Trickle protection sheet, if required Load distribution layer 1 needed! eg > 20 mm dry screed element, processing according to manufacturer's instructions > 2 × 15 mm OSB board, glued and screwed > 2 × 19 mm chipboard (V100), glued and screwed _____________ 1 The load distribution layers are given as examples VarioComp boards, XPS and other insulation boards are not suitable as load distribution layers! FLOOR STRUCTURE | 11 VarioComp boards on thermal/impact sound insulations up to 30 mm thickness The VarioComp board can be laid directly on thermal/impact sound insulations up to an insulation thickness of 30 mm The requirement is for a sufficiently high compressive strength of the underlay boards: Insulation thickness max. 15 mm and compressive stress (at 10 % compression) 150 kPa (15 t/m2) > 5 mm: Variotherm SILENT underlay board, 1 layer > 10 mm: Variotherm SILENT underlay board, 2 layers (staggered) or > 10 mm: Variotherm XPS underlay board, 1 layer > 15 mm: Variotherm XPS+SILENT underlay boards (staggered) << For details see chapter 43 Insulation thickness max. 20 mm and compressive stress (at 10 % compression) 200 kPa (20 t/m2) > Variotherm XPS underlay boards, 2 layers (staggered) Additional product examples: Ardex DS 40 Austrotherm Universalplatte Austrotherm Uniplatte DOW Styrofoam LB-A/LBH-X/RTM-NC-X Gutex Multiplex-top Jackon Jackodur KF 300 Standard GL Jackon Jackoboard DOW Floormate 200-A PCI (BASF) Polysilent PCI (BASF) Pecidur Styrodur 2800C Wedi building board Unifloor Jumpax CP/Heat-Pak Unifloor Heat-Foil Unifloor Redupax/Redupax+ Insulation thickness max. 30 mm and compressive stress (at 10 % compression) 300 kPa (30 t/m2) Product examples: Austrotherm XPS Top 30 Jackon Jackoboard PCI (BASF) Polysilent Unifloor Jumpax CP/Heat-Pak DOW Floormate 500-A Jackon Jackodur KF 300 Standard GL PCI (BASF) Pecidur Wedi Bauplatte DOW Styrofoam LB-A/LBH-X/RTM-NC-X Kingspan GreenGuard GG300 Styrodur 3000 CS/SQ Foamglas T4+ VarioComp boards on thermal/impact sound insulations1 starting from 30 mm thickness For laying on thermal/impact sound insulations1 starting from 30 mm,a load distribution layer2 is additionally needed! eg: > 18 mm OSB board, tongue and groove bonded > 19 mm chipboard (V100), tongue and groove bonded > 25 mm dry screed element, processing according to manufacturer's instructions > 2 × 15 mm OSB board, glued and screwed > 2 × 19 mm chipboard (V100), glued and screwed _____________ 1 The insulation below the load distribution layer must be sufficiently stable for walking, and must be approved for floor constructions by the manufacturer 2 The load distribution layers are given as examples VarioComp boards, XPS and other insulation boards are not suitable as load distribution layers Note: 01 N/mm2 = 100 kN/m² = 100 kPa = 10 t/m2; 1 kN 100 kg 12 | FLOOR STRUCTURE 4 COMPONENTS & PROCESSING 4.1 Edge insulation strip The edge insulation strip must allow a movement of the floor heating of at least 5 mm It is glued along the surrounding walls, as well as on pillars, steps, door frames, columns, shafts, etc using the downwards aligned butyl rubber adhesive strip a before the floor heating is laid The edge insulation strip should extend from the loadbearing substrate (or the lower edge of the uppermost insulation layer) through to the upper edge of the floor cover If this is not possible due to the construction, the edge insulation strip must at least reach from the lower edge of the VarioComp board to the upper edge of the covering The overlap foil of the edge insulation strip is glued to the construction foil laid at a later stage using the applied adhesive strip The protruding remainder of the edge insulation strip is only removed after the floor covering has been completed a 1 2 3 4 1 Edge insulation strip with 2 Overlap foil 3 PE construction foil 4 Load-bearing substrate 4.2 PE construction foil 1 The construction foil acts as a sliding and decoupling layer between the VarioComp board and the substrate If 2 dry screed gypsum fibre board has been applied below the VarioComp board, no construction foil is needed > Before the VarioComp boards are laid, the construction foil is laid underneath covering the entire load-bearing substrate with an overlap of 30 mm and fastened with adhesive tape > The load-bearing substrate (as described in Chapter 3) must be clean, dry and dust-free in order to prevent unevenness between the VarioComp boards later on > In the edge areas, the construction foil is glued underneath to the overlapping foil of the edge insulating strip (self-adhesive strip) 3 4 > Edge insulation strip > Part No: V299 > PKU: 25 m roll 16 rolls in a bag > Weight/PKU: 08 kg > Material: PE foam > 75 mm high, 10 mm thick > Complies with EN 1264-4 > PE construction foil > Part No: V2895 > PKU: 50 m2 roll > Weight/PKU: 51 kg > Thickness 01 mm > Material: recycled PE > Dimension: 1030 mm × 50 m = 515 m² > Usable area: 1000 mm × 50 m = 500 m² (with a 30 mm overlap) > Adhesive tape > Part No: V288 > PKU: 1 pce | Carton with 36 pcs > Weight/PKU: 210 g > Roll: 50 mm × 66 m | COMPONENTS & PROCESSING 13 > VarioComp underlay board XPS > Part No.: V2898 > PKU: 0.75 m board Package with 30 m > Weight/PKU: 250 g > Perfect as thermal insulation > VarioComp underlay board SILENT > Part No.: V2899 > PKU: 0.466 m board Package with 7 m > Weight/PKU: 600 g > Perfect as impact sound insulation . Compact underlay boards As an option, the VarioComp underlay boards can be laid underneath the VarioComp modular floor heating system. They are the ideal supplement between non-insulated substrates (such as even screed) and the compact floor heating system. Technical data Board dimensions Board thickness Maximum board layers (Joint offset 200 mm) Thermal conductivity [] Thermal insulation resistance [R] Impact sound reduction [LW] Edge formation Surface Board material Compression strength or compression stress at 10% compression [CS(10\Y)] Fire resistance as per EN 501-1 XPS 1250 × 600 mm 10 mm 2 0.035 W/mK 0.286 m K/W 14 dB Straight edges Smooth Extruded rigid polystyrene foam (XPS) 200 kPa (20 t/m²) E measured on bare reinforced concrete ceiling SILENT 790 × 590 mm 5 mm 2 0.07 W/mK 0.071 m K/W 17 dB Blunt Smooth Wood fibre insulation board as per EN 13 986 and EN 622-4 150 kPa (15 t/m²) E > VarioComp board > Pipe spacing 100 mm > Part No.: V290 > PKU: 0.6 m board Pallet with 30 m (50 pcs.) > Weight/PKU: 9.6 kg > 1000 × 600 × 18 mm > VarioComp board > Pipe spacing 150 mm > Part No.: V295 > PKU: 0.54 m board Pallet with 27 m (50 pcs.) > Weight/PKU: 9.6 kg > 900 × 600 × 18 mm . VarioComp boards/blank boards VarioComp boards from Variotherm are 18 mm gypsum fibre boards that are certified regarding their ecological properties. They consist of gypsum, cellulose and water, all of which are natural resources. Cellulose is manufactured from 100% waste paper. Different mixtures (types of paper, cardboard) are created, depending on the paper collected in the local region. This can lead to differences in board colour. The VarioComp boards are used to hold the pipes and as a thermally conductive board for pipe spacing of 100 mm or 150 mm (pipe spaces of 150 mm are not recommended for living and barefoot areas!). The blank boards are also 18 mm gypsum fibre boards that are certified regarding their ecological properties, but do not have grooves. They are used instead of VarioComp boards for small, unheated areas, e.g. food cupboards or areas with fixed installations. Lifting, carrying and laying individual VarioComp boards: Lifting, carrying and laying multiple VarioComp boards (5 boards and upwards): > Blank board > Part No.: V021-029 > PKU: 0.6 m board Pallet with 30 m (50 pcs.) > Weight/PKU: 12.6 kg > 1000 × 600 × 18 mm First lower the VarioComp boards onto one edge and then lower them completely. Vertical storage leads to deformation of the boards and damage to the edges. It is possible to transport the boards horizontally inside the building with a lift truck or other board transportation vehicle. 14 | COMPONENTS & PROCESSING > The mean daily relative humidity must not exceed 70 % when laying the VarioComp boards. Wet plaster and wet screed must be applied and dried before the VarioComp boards are installed. > The load-bearing subsurface (as described in Chapter 3) must be clean, dry and dust-free. > The VarioComp boards are laid lengthways or crossways, with an offset of at least 200 mm, edge to edge. Blank boards for small, unheated areas, e.g. food cupboards or areas with fixed installations, instead of VarioComp boards. Small residual surfaces and areas in front of the distribution manifold can be filled with the VarioComp filling compound. << Tip from Variotherm: Align the rows of grooves with approx. 200 mm long pipe pieces! Distribution manifold area Depending on the size of the distribution manifold, a high pipe density possibly cannot be fitted into the VarioComp board anymore. It is therefore recommended to leave out the VarioComp board(s) in this area. It helps to have an aid in levelling the filling compound to the correct level later. Ideally, this aid consists of unused/residual pieces of VarioComp boards or blank boards. The pipes can be affixed to the base using the VarioRail 11.6. Alternatively, you can use a perforated strip (avoid squashing the pipes!) Levelling aid > VarioRail 11.6 > Part No.: V2722 > PKU: 1 m | Carton with 50 × 1 m > Weight/PKU: 100 g > Material: PE > Installation height: 17 mm > Grid spacing: 38.5 mm Scraper Perforated strip << For information on how to apply the VarioComp filling compound, see Chapter 4.7 | COMPONENTS & PROCESSING 15 . VarioProFile pipe . x . Heat stabilized polyethylene (PE) with profiled surface structure Adhesive layer Homogeneous and solid aluminium pipe Adhesive layer Raised-temperature-resistance polyethylene (PE-RT) Advantages > Fully corrosion-free > As light as a plastic pipe > 10-year guarantee with certificate > Optimum creep behaviour > Profiled surface structure guarantees optimum heat transfer (10 % larger surface) > Flexible, easy to bend, extremely stability > Resistant to hot water additives (inhibitors, antifreeze) > Mirror-smooth inner surface less pressure loss no encrustation > High pressure and temperature resistance > 100 % oxygen diffusion-tight > Lower linear coefficient of expansion, lower heat expansion forces > Tested as per EN 21 003 Technical data > Pipe diameter: 11.6 mm > Pipe wall thickness: 1.5 mm > Aluminium pipe thickness: 0.15 mm > Roll length: 100, 300, 500 and 800 m > Water content: 0.058 l/m > Special narrow bending radius (use a suitable bending device): 30 mm > Max. operating temperature [tmax]: 70 °C > Short-term resistant [tmal]: 95 °C > Max. operating pressure [pmax]: 6 bar > Linear expansion coefficient: 2.3 × 10-5 [K-1] > Mean heat conduction coefficient []: 0.44 W/mK > Heat transmission resistance: 0.0034 m K/W Pressure [bar] Creep behaviour 40 30 PB VarioProFile pipe pipe 20 PEX pipe Elongation with 10 m and temperature difference t 25 °C (e. g. 20 °C to 45 °C): 10 0,1 1 10 100 1 000 10 000 100 000 1 000 000 Time [h] 50 years Plastics Pipe material Elongation PEX/VPE PP PB PVC VarioProFile pipe Cu Stainless steel Steel 50.00 mm 42.50 mm 32.50 mm 20.00 mm 5.75 mm 4.20 mm 3.50 mm 2.88 mm Homogeneous plastic pipes produce high stress levels in the device because of their expansion coefficient. The VarioProFile pipe is ideal for use as a surface heating and cooling pipe due to the very small changes in length and thermal expansion force. Metal l 16 | COMPONENTS & PROCESSING Installation The spacing between the pipes during laying depends on the thermal capacity needed for the individual rooms: 100 mm: living spaces and barefoot areas 150 mm: e.g. workshops, halls, office spaces, etc. (not recommended for living spaces and barefoot areas!) Pipe requirement 100 mm pipe spacing 150 mm pipe spacing 10 m/m² 6.7 m/m² Maximum 11.6 mm VarioProFile pipe length per heating circuit 80 m (pay attention to the pump design!) > Do not make any kinks in the pipe! > With a room temperature of over +5 °C, the pipes can be bent manually without pre-warming. > Check that the grooves are clean! Dirt particles prevent flush laying of the pipes and can cause pipe damage. > As pipe length guide, there are marks on every metre on the VarioProFile pipes (e.g. ) > Lay without twisting, and use a pipe uncoiler. > Press the VarioProFile pipe between the routings using the sole of your shoe. When changing direction, guide the pipes around the routings with your thumb. > After the heating circuit is completed, the VarioProFile pipe is returned to the heating manifold, cut off at the appropriate length, calibrated, and connected. Spiral: Uniform distribution of surface temperature as the supply is located next to the return. Meandering: Less uniform distribution of surface temperature, for small, ancillary rooms and peripheral zones. Pipe installation at movement joints For preparation of movement joints, also see chapter 2.7. Edge insulating strip Wall Door frame Expansion joint c Pipe feed-through through the movement joint (no sleeve tube required)) c In the vicinity of the door, the expansion joint is fed through under the door leaf. Variant : Door area fitted with VarioComp board c Variant : Later, only use VarioComp filling compound to fill in the door area. | COMPONENTS & PROCESSING 17 Laying example of a private single-family private house (ground floor) Living room 26.5 m Pipe spacing: 100 mm Peripheral zone in front of glass surfaces Maximum 11.6 mm VarioProFile pipe length per heating circuit 80 m (pay attention to the pump design!) Bedroom 14.2 m Pipe spacing: 100 mm No board. The area is filled in with VarioComp filling compound, see Chapter 4.4. Kitchen 10.3 m Pipe spacing: 100 mm Anteroom (5.2 m ) Pipe spacing: 100 mm (covered with supply lines) Shower/WC 4.1 m Pipe spacing: 100 mm + 2.5 m EasyFlexWall Anteroom (6.8 m ) Pipe spacing: 100 mm Peripheral zone in entrance area ¹ Peripheral zone: Starting in front of a large glass surface or glass doors, a meander pattern layout goes along the glass surface, reaching into the room by about 1 metre. This will lead to a higher surface temperature in front of the glass surfaces (Variotherm comfort tip). Check e. g. Surveyor`s staff 18 | COMPONENTS & PROCESSING Calibrating/pressing the pipe For processing residual pipe lengths or for repairs, the VarioProFile pipes 11.6x1.5 can be permanently and securely connected to each other using a press-fit coupling 11.6x11.6. The press-fit coupling must lie completely at the VarioComp board level. A permanent, secure connection is only guaranteed if original Variotherm system components are used: > VarioProFile pipe 11.6x1.5 > Variotherm calibration and chamfering tool > Variotherm press-fit couplings and Variotherm pressing tool The press-fitting pliers and drive unit must be checked at least once a year for correct operation by REMS or an authorised REMS customer service workshop. > Cold shrinking tape > Part No.: Z1699 > PKU: 1 pce. | Carton with 20 pcs. > Weight/PKU: 990 g > Roll: 50 mm × 15 m > 1 roll is sufficient for approx. 35 press-fit coupling connections (with a 50 % overlap) > Calibration and chamfering tool > Part No.: W042 > PKU: 1 pce. > Weight/PKU: 140 g > For calibrating and chamfering the Variotherm pipes c Chisel out the groove 0 c Calibrate and chamfer the pipe c Push on the press-fit coupling until it reaches the stop c Pressing. The press-fitting jaw must close fully. c Flatten / cut away the guide rings c Insert the pressed press-fit coupling* c For application of the filling compound, see Chapter . *Corrosion prevention measures: The connecting elements are to be protected (after the pressure test) in accordance with EN 1264 and compliance with ÖN H 5155 (e.g. with Z1699 cold shrink tape). The relevant operating instructions for the pressing tools are included with the appliances. > Pipe cutting pliers > Part No.: W037 > PKU: 1 pce. > Weight/PKU: 230 g > For trimming the Variotherm pipes > Replacement blade: W0371 > AkkuPress Mini > Part No.: W019 > PKU: 1 pce. > Weight/PKU: 9.9 kg > Incl. sheet steel box, press-fitting jaws TH16 Mini & TH11.6 Mini, battery charger, 2 batteries > Mini press-fitting jaw TH11.6 > Part No.: W031 > PKU: 1 pce. > Weight/PKU: 1.5 kg > EcoPress > Part No.: W015 > PKU: 1 pce. > Weight/PKU: 9.7 kg > Incl. sheet steel box, press-fitting jaws TH16 & TH11.6 > Press-fitting jaw TH11.6 > Part No.: W025 > PKU: 1 pce. > Weight/PKU: 2.0 kg > Press-fit coupling 11.6x11.6 > Part No.: Z1600 > PKU: 1 pce. > Weight/PKU: 30 g > Press contour: TH(11.6) | COMPONENTS & PROCESSING 19 4.6 VarioManifold / Pressure test Advantages > Plastic manifold with internal air chambers for thermal insulation > Flexible conversion to thermostat operation > Pre-settable flow indicator in the flow (10-160 l/h) according to EN 1264-4, viewing glass can be cleaned > Optimised for low-temperature surface heating/ cooling > Detachable 3-way ball valves on the flow and return > Venting option, flushing option via rotatable fill and drain cocks > Modular construction > Absolutely oxygen-tight > Designation labels > All parts self-sealing, manifold pressure-tested > Variable distance between flow and return bars Pressure test Once all circuits have been connected to the heating/ cooling manifold, the system can be filled downstream of the manifold and pressurised The pipes are to be kept under pressure prior to applying the VarioComp filling compound so that any damage becomes immediately visible (Please see Chapter 71 for the protocol Leak-tightness test) For details regarding the system and heating circuit pipes and the room temperature control please refer to the "DISTRIBUTION and CONTROL" planning and installation instructions 20 | COMPONENTS & PROCESSING Pumped VarioManifold The Pumped VarioManifold allows the integration of a low-temperature surface heating system (2 to 15 heating circuits) in a high-temperature heating system (2-pipe system) with existing circulation pump Pump Microstation The Pump Microstation allows the integration of a low-temperature surface heating system (1 to 2 heating circuits) in a high-temperature heating system (2-pipe system) with existing circulation pump | COMPONENTS & PROCESSING 21 > VarioComp filling compound T7 > Part No.: V291 > PKU: 1 bag 42 bags on pallet > Weight/PKU: 25 kg > Consumption: approx. 6.0 kg/m for V290 (pipe spacing 100 mm), approx. 4.8 kg/m mit V295 (pipe spacing 150 mm) > Special filling compound for filling out the laid VarioComp boards Technical data: Thermal conductivity 10,dry,mat: 0.61 W/(mK) (50 %-Quantil) Diffusion resistance µ: approx. 15 Oven-dry density: 1450 kg/m Heat capacity cp: approx. 1000 J/(kgK) > VarioComp mixing tool > Part No.: W030 > PKU: 1 pce. > Weight/PKU: 715 g > Diameter 120 mm > Drive unit recommendations: 1000 W, 600 min- , Drill chuck 13 mm > For optimum processability of the VarioComp filling compound > Bucket set > Part No.: W028 > PKU: 1 set > Weight/PKU: 1.2 kg > Water bucket for the correct dosage > 30 litre bucket for mixing the VarioComp filling compound . VarioComp filling compound T The VarioComp filling compound is a filling compound developed specially by Variotherm for filling the laid VarioComp boards. It guarantees the best possible thermal transfer of the VarioProFile pipe onto the entire VarioComp board. The VarioComp filling compound is not self-levelling and is therefore evenly distributed and removed using a scraper. Before pouring in the VarioComp filling compound, a pressure test should be carried out for all the relevant heating circuits. Use the log for this purpose (Chapter 7). We recommend to keep the pipes under water pressure while pouring in the VarioComp filling compound. The processing temperature must be at least +5 °C. Manual application of the VarioComp filling compound - Dry - Dust-free - Grease-free 8 L 8 L 8 L 25 kg mmaaxx.. 600 min-1,.522mminin. . Pot life 2030 minutes > Scraper > Part No.: W029 > PKU: 1 pce. > Weight/PKU: 1.0 kg > Scraper width 600 mm > With telescopic shaft > For evenly spreading the Vario- Comp filling compound Scrape off at the level of the boards Pot life 2030 minutes ~~11.,55hh ((ttii = 20 °CC)) ~~22.,55hh ((ttii = 10 °CC)) _____________ In order to prevent shortening of the pot life, empty the bucket completely after every mixing process with a trowel and clean it with a paint brush. >> 22 | COMPONENTS & PROCESSING Machine application of the VarioComp filling compound (recommended for large-scale projects) The VarioComp filling compound can also be applied using a mixing pump. The time-consuming mixing with a bucket is no longer necessary as this is done in the machine. A third person is required for filling the machine with VarioComp filling compound. As an example, Knauf PFT G4 (www.pft.net): > Stator/Rotor D4-3 PIN Twister or D3-5 wf can be used as a mixing pump > Recommended water quantity approx. 612 l/min. > Geka coupling 1"AG/1"IG > Mixing spiral for heavy plaster or similar products (e.g. M-Tec, Inotec, Ülzener-UMS/Putzknecht) Checking the applied VarioComp filling compound As soon as it is possible to walk on the surface, the excess filling compound is removed using a trowel or plastering knife. Note: The top of the VarioProFile pipe is flush with the level of the board surface and can be visible at several points! Knauf PFT G4 © Knauf PFT Checking for evenness The surface of the VarioComp corresponds to ÖNORM DIN 18 202 (table 3, line 3), limits of evenness deviations (see also Chapter 5). Special case: if according to the floor layer the standard tolerances are too high for laying the required floor covering, however, uneven areas can be evened out as follows: SURVEYOR`S STAFF Option 1: Level out with a 2nd layer of VarioComp filling compound (levelling out up to max. 3 mm) If the 1st layer of VarioComp filling compound is not older than 3 hours, a 2nd layer of VarioComp filling compound can be directly applied without a base coat. 10 L If the 1st layer of VarioComp filling compound is older than 3 hours, a 2nd layer of VarioComp filling compound can be applied in combination with a base coat. You may only apply the base coat once the VarioComp filling compound (0.3 % CM) has completely dried out. (See the table in Chapter 5.4 for suitable base coats) Option 2: Levelling out with a calcium sulphate levelling compound 1. Layer of VarioComp filling compound with base coat + calcium sulphate levelling compound. You may only apply the base coat once the VarioComp filling compound (0.3 % CM) has completely dried out. Approx. 0.5 kg/m² will be used. See the table in Chapter 5.4 for examples of base coats and calcium sulphate levelling compounds. | COMPONENTS & PROCESSING 23 FLOOR COVERING . General It is not necessary and not permitted to abrade the surface of the finished VarioComp! > The floor covering used must be suitable for floor heating systems (observe the manufacturer's instructions). > The surface of the VarioComp complies with DIN 18 202 (Table 3 limits for evenness deviations, Row 3). > The tensile bond strength is 1 N/mm > The floor covering should be laid as quickly as possible to avoid any soiling of the surfaces or damage to the pipes. > Floors should have a max. thermal resistance of 0.15 m²K/W. Variotherm recommends: 0.1 m²K/W (incl. underlay/adhesive) Measuring point spacing Surveyor`s staff Pitch Measuring point spacing Max. pitch 0.1 m 2 mm Guidelines for the thermal resistance R [m²K/W] of various floor coverings: Floor covering Tiles Clinker slabs Marble Natural stone slab Linoleum PVC coverings Cork parquet Prefinished parquet floor (2-layer) Prefinished parquet floor (3-layer) Laminate Thin carpet Medium carpet Thick carpet Thickness 8 mm 11 mm 10 mm 12 mm 2,5 mm 2,5 mm 4 mm 10 mm 14 mm 9 mm 6 mm 9 mm 13 mm Thermal resistance R = d/ 0.01 m K/W 0.010.02 m K/W 0.01 m K/W 0.01 m K/W 0.015 m K/W 0.010.02 m K/W 0.05 m K/W 0.050.07 m K/W 0.070.10 m K/W 0.05 m K/W 0.070.11 m K/W 0.110.15 m K/W 0.150.24 . Residual humidity of the VarioComp filling compound The assessment of the readiness for covering is carried out via the calcium carbide method (CM). Before laying the floor covering, the VarioComp filling compound must be dried in accordance with the following table: Floor covering (Take note of the manufacturer's instructions!) Stone & ceramic coverings in a thin bed Wood covering, parquet Linoleum, PVC, vapour tight floor covering (the levelling mass has already been applied in accordance with Chapter 5.4) CM value (remove 100 g of filling compound for measuring) 1.3 % 0.3 % 0.3 % Estimated drying time at ti = 20 °C, max. 50 % relative humidity without baking out 6 days with baking out at tf = 40 °C 24 h 8 days 36 h not possible 48 h _____________ Only serves as a reference value and cannot be used to assess the readiness for covering! At ti = 20 °C, you must wait at least 4 hours after finishing applying the filling compound before beginning the baking out process. 24 | FLOOR COVERING . Filling in a glass fibre cloth > If floor coverings are glued, a mesh must be inserted in the joining areas between the VarioComp boards and the blank boards in the form of glass fibre cloth (4 × 4 mm) and with an overlap of 200 mm (adhesion with e.g. tile adhesive). > For critical floor structures, we recommend that a 4 × 4 mm glass fibre cloth is inserted over the entire area. Glass fibre cloth 4 x 4 mm Finished and sealed-in VarioComp 200 mm Blank boards 200 mm . Application of an additional floor levelling compound In the following cases, the finished VarioComp surface is additionally levelled off using a calcium sulphate floor levelling compound: > With soft floor coverings and artificial resin floors (see Chapter 5.7) > Depressions which exceed the standard tolerances (see Chapter 5.1) or which are too large for the floor covering according to the floor installer > If levelling out is needed You should only start work once the VarioComp filling compound (0.3 % CM) has completely dried out (see also chap. 5.2). Product examples (please observe the relevant manufacturer's instructions!): Brand Mapei Schönox Maxit Fermacell Thomsit Stauf Baumit Ardex Wakol Casea Ball Uzin Sopro Tilemaster Primer ECO PrimT Plus Schönox VD, VD Fix maxit floor 4716 Deep primer R766, R777 D54 Grund Ardex P51 D 3040 casuprim HB Stopgap 1100 Gypsum PE 360 PLUS GD 749 Prime Plus Calcium sulphate floor-levelling compound Planitex Fast / Planitex Pro Schönox APF maxit floor 4095 Self-levelling compound AS1, AS2 GS Nivello Quattro Ardex K22 F A 830 casufloor FS Stopgap P121 NC 105 / NC 110 / NC 112 Turbo / NC 115 Hybrid FSH 561 Anhylevel . . . Primer . Calcium sulphate floor-levelling compound FLOOR COVERING | 25 5.5 Rooms exposed to high humidity For surfaces which are exposed to high levels of humidity, sealing systems must be applied (e g bathrooms with shower trays - W3) The wall construction must be sealed using sealing system and additional sealing tape 60 mm Sealing tape Seam sealing silicone Foam backfill material Subsurface according to chapter 3 Edge insulation strip with welded-on foil Tiles on flexible adhesive and possibly with glass fibre cloth Sealing system (compound seal) VarioComp (incl already dried filling compound) Construction foil << Example: Tiled floor covering exposed of moisture (W2/W3) (More details for tiled covering on VarioComp see chapter 56) Use of primer and sealing system (compound sealing): W1 W2 W3 W4W6 Stress group according to ÖN B 3407 Residential sector: living rooms, corridors, toilets, offices etc Residential sector: kitchen and rooms with similar usage Commercial sector: toilet systems Wall and floor surfaces without drainage (e g bathroom with shower tub higher than 20 mm above floor covering), toilet systems without floor drainage, porch Wall and floor surfaces with drainage (e g shower with flush drain at the same level as the floor), swimming bath area, shower systems, industrial kitchen, balconies, terraces Adhesive mortar with tile coverings Calcium sulphate flexible adhesive mortar Cement flexible adhesive mortar Only cement flexible adhesive mortar Only cement flexible adhesive mortar Primer Not required Required In addition to the sealing system, when recommended by the manufacturer In addition to the sealing system, when recommended by the manufacturer No VarioComp floor heating possible Sealing system Not required Not required Recommended Required Product examples1 of primer and sealing system (compound sealing): Manufacturer Ardex Cimsec PCI (BASF) Schönox Mapei Weber Ceresit Sopro Primer Ardex P51 Gipsgrundierung / Haftbrücke Gisogrund Schönox KH Primer G weberprim 801 CT 17 Primer GD 749 Sealing system Ardex 8 + 9 Dichtflex CL51 / 2K Sealing CL49 Lastogum Schönox HA / 1K DS Premium Mapegum WPS webertec 822 Shower/Bath Sealing Flexible sealing compound FDF 525/527 ___________ 1 Please observe the relevant manufacturer's instructions 26 | FLOOR COVERING 5.6 Tile, stone and ceramic coverings See also the appropriate standards for laying tiles, boards and mosaics > The surface must be dust-free > Sealing systems must be used on surfaces exposed of moisture (see chapter 55) The wall boundaries must be sealed using appropriate sealing tape > A flexible adhesive (S1 classified according to EN 12 004) is used to bond the tiles A primer must be applied if required by the adhesive manufacturer This is particularly the case for flexible cement adhesives > Flexible grouting mortar must be used for grouting > After laying the tiles, boundaries with the walls are additionally sealed with silicone Wall construction 5.7 Soft floor coverings and synthetic resin floors Seam sealing silicone Foam backfill material Subsurface according to chapter 3 Edge insulation strip with welded-on foil Tiles on flexible adhesive and possibly with glass fibre cloth Flexible adhesive VarioComp (incl dried filling compound) Construction foil For soft floor coverings (e g carpet, linoleum) and synthetic resin floors, a calcium sulphate-based floor-levelling compound which has to be provided by the costumer and must be at least 4 mm thick is applied to completed VarioComp (see chapter 54) Caution: Only use synthetic resin floors with low stresses during the hardening process! (Tensile bond strength max 1 N/mm2) Wall construction Edge strip Edge insulation strip with welded-on foil Soft floor covering Subsurface according to chapter 3 Carpet Calcium sulphate floorlevelling compound1, minimum 4 mm (provided by costumer) Primer Soft rear layer VarioComp Linoleum ___________ 1 Please observe the relevant manufacturer's instructions for the required primer or sealant of the VarioComp surface and of the planned floor-levelling compound Product examples see chapter 54 You should only start work once the VarioComp filling compound (03 % CM) has completely dried out FLOOR COVERING | 27 5.8 Hard floor coverings (parquet, laminate, PVC boards) > Lay only floor coverings that are approved by the manufacturer for use with floor heating systems Floors should have a maximum thermal insulation resistance of 015 m2K/W Recommendation from Variotherm 01 m2K/W (incl underlay strip/adhesive) > The differences in thermal output between the glued and floating design are negligible Both versions have approximately the same surface temperatures Note the information provided by the manufacturer! Wall Edge strip Edge joints at least 10 mm e g 3-layer parquet Underlay e g 3-layer parquet Adhesive VarioComp Edge insulation strip with welded-on foil Subsurface acc to chapter 3 FLOATING VERSION (recommended by Variotherm) > Lay laminate, PVC boards or 3-layer parquet floating on an underlay strip suitable for floor heating (max thickness 2 mm) Exception: With floor coverings with an underlay strip already laminated on the underside, no additional underlay strip is required > The edge seam to adjacent components should be at least 10 mm Advantages: Cover easy to replace no risk that the VarioComp will be damaged during dismantling Costs of laying usually lower Disadvantages: Possible joint formation due to material expansion Sanding the parquet may be problematic (springing of the cover) GLUED VERSION: > 2- or 3-layer parquet suitable for floor heating, without gluing the tongue and grooves Gluing of solid/solid wood floors is not permitted! > Maximum flow temperature 40 °C (Maximum temperature limiter required!) > Gluing without base coat, with eg: - Mapei Ultrabond ECO S948 1K - Thomsit P 695 - Ardex Premium AF 480 MS - Weitzer Parkett Profi-SMP glue no 400-EC1 - Sika SikaBond-52 Parquet, SikaBond-54 Parquet or equivalent adhesive (primer according per manufacturer's specifications) Advantages: Almost no joint formation Disadvantages: Parquet difficult to replace - VarioComp could be damaged during dismantling Cost of laying usually higher 28 | FLOOR COVERING 6 HEATING PRACTICE 6.1 Calculating the heating load Along with the respective national annex, the EN 12 831 standard will be used to calculate the heating load for the heated rooms Every room is considered individually For the outside temperature, the locally acquired and standardised outdoor temperature Tne is used c Extract from a heating load calculation 6.2 Variotherm dimensioning software Key values for individual heating circuits (flow/return temperature, the amount of water, pressure loss, number of circuits, allocation of the manifolds etc) can be quickly and easily calculated or determined by entering the heating load into the Variotherm dimensioning software It can be found in our Professional Area at wwwvariothermcom/professional No. Room name G living room kitchen porch bathroom WC B room 1 room 2 room 3 room 4 aisle WC Building project: Simon Sample ZIP: 2544 City: Leobersdorf Date: Processed by: Floor space A [m²] 53,00 17,20 5,00 4,20 2,00 Maximum length of TH or SH L [m] Heating load Q [W] 2860 1021 458 231 134 Supplement heating load Heating load incl. Supplement Room temp. Heating system Suppl. [%] Q+Suppl. [W] 2860 1021 458 231 134 ti [° C] 22 Modular floor heating 20 Modular floor heating 18 Modular floor heating 24 Modular floor heating 20 Modular floor heating 15,00 14,00 17,00 16,00 19,50 3,50 954 878 969 953 1624 273 954 878 969 953 1624 273 20 Modular floor heating 20 Modular floor heating 20 Modular floor heating 20 Modular floor heating 20 Modular floor heating 20 Modular floor heating Floor covering [d/] or pipe covering [mm] 0,075 0,010 0,010 0,010 0,010 Dimensioning temperature tf/tr [° C] 40/30 40/30 40/30 40/30 40/30 0,075 0,075 0,075 0,075 0,010 0,010 40/30 40/30 40/30 40/30 40/30 40/30 Mathematical Dim. Unit Type 51,10 m² 14,60 m² 5,00 m² 3,90 m² 2,00 m² FBHK10 FBHK15 FBHK10 FBHK10 FBHK15 14,50 m² 13,40 m² 14,70 m² 14,50 m² 19,50 m² 3,30 m² FBHK10 FBHK10 FBHK10 FBHK10 FBHK10 FBHK10 No. of circuits 8 2 1 1 1 1 1 3 2 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 Practical Dim. Unit Type 6,62 m² 6,25 m² 5,00 m² 4,20 m² 2,00 m² RA10 RA10 RA10 RA10 RA10 5,00 m² 7,00 m² 5,66 m² 5,33 m² 6,50 m² 3,50 m² RA10 RA10 RA10 RA10 RA10 RA10 Residual FH performance to (Ti=20) [° C] 106 26 17 27 7 27 21 27 32 27 36 26 46 26 152 26 102 26 -6 27 18 27 Supply pipe Supply line length per circuit [m] Pressure loss Flow quantity per circuit [mWC] 0,48 0,83 0,55 0,16 0,05 per circuit [kg/h] 32 45 41 22 15 Distribution manifold number 1 1 1 1 (1) Calculation of pressure loss and flow rate with 2 systems at one heating circuit (see manual): 0,30 29 2 0,74 40 2 0,44 33 2 0,36 31 2 0,86 47 2 0,17 26 2 Summary of the heating systems Amount Unit m² m² m² m² m² m² m² m² m² m² m² m² m² 161,6 m² m² m² m² m² m² m² m m m m m m m m Heating system System wall heating System wall heating Modular wall heating EasyFlex wall heating EasyFlex wall heating EasyFlex ceiling heating EasyFlex ceiling heating Modular ceiling heating Screed floor heating Screed floor heating Screed floor heating Screed floor heating Screed floor heating Modular floor heating Modular floor heating Industrial floor heating Industrial floor heating Industrial floor heating Industrial floor heating Industrial floor heating Skirting heating Skirting heating Skirting heating Skirting heating Trench heating Trench heating Trench heating Trench heating Supply pipe Supply pipe Type SWHK2 SWHK3 MWHK EWHK77 EWHK115 EDKH77 EDKH115 MDKH FBH10 FBH15 FBH20 FBH25 FBH30 FBHK10 FBHK15 FBHS20 FBHS25 FBHS30 FBHS35 FBHS40 HL mini HL Ia HL IIa HL IIIa BKH1 mini BKH1 BKH2 mini BKH2 16x2 11.6x1.5 Pipe / Heating element 1.616 m Summary of pipe length by line Room name living room kitchen porch bathroom WC room 1 room 2 room 3 room 4 aisle WC Ø 20 [m] Ø 16 [m] Total c Variotherm dimensioning software example for heating Ø 11.6 [m] 529,6 125,0 43,5 42,0 20,0 HL18 [m] HLm18 [m] 150,0 140,0 169,8 159,9 195,0 35,0 1609,8 tf/tr Number of Flow Pressure loss heating quantity + 0.1 mWC circuits manifold for manifold [kg/h] [mWC] Distribution manifold 1 40/30 12 424 0,9 Distribution manifold 2 40/30 15 526 1,0 Distribution manifold 3 Distribution manifold 4 Distribution manifold 5 Distribution manifold 6 Distribution manifold 7 Distribution manifold 8 When all distribution manifolds are fed via one pump, the following applies: Total flow quantity: 950 kg/h Maximum pressure loss from distribution manifold incl. 0.1 mWC for max. opened valve 0,96 mWC Summary of the floor heating surface area: Screed floor heating Modular floor heating Industrial floor heating Summary of loads: Total heating load Total installed load 0,0 m² 161,6 m² 0,0 m² 10.355,0 W 10.888,0 W Total filling water: Total filling water 93,7 litre Notes: Manifold notation according to drawing | HEATING PRACTICE 29 . Heat outputs HEAT OUTPUT for a floor covering with a thermal resistance of d/ = 0.01 / 0.05 / 0.075 / 0.10 m K/W 35 Excess temperature = tmH Tr [°C] 30 100 mm 100 mm 100 mm 100 mm 25 150 mm 150 mm 150 mm 20 150 mm Pipe Spacing 150 mm: 15 Not recommended for living rooms or bare-foot areas! 10 5 0 0 10 20 30 Heat output [W/m ] 40 50 24 60 70 26 tmH = mean hot water temperature = tf + tr 2 [°C] Tr = room temperature [°C] tf/tr = flow/return temperature [°C] 80 90 28 100 110 120 130 140 150 160 170 180 30 ... mean surface temperature [°C] at Tr = 20 °C HEAT OUTPUT for a floor covering with a thermal resistance of d/ = 0.12 / 0.14 / 0.16 / 0.18 m K/W 35 Excess temperature = tmH Tr [°C] 30 100 mm 100 mm 100 mm 100 mm 25 150 mm 150 mm 150 mm 20 150 mm Pipe Spacing 150 mm: 15 Not recommended for living rooms or bare-foot areas! 10 tmH = mean hot water temperature = tf + tr 2 [°C] 5 Tr = room temperature [°C] tf/tr = flow/return temperature [°C] 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Heat output [W/m ] 24 26 28 30 ... mean surface temperature [°C] at Tr = 20 °C _____________ Guidelines for the thermal resistance of various floor coverings see chapter . 30 | HEATING PRACTICE Tiles, ceramic and natural stone coverings Thermal resistance d/: 001 m2K/W PS150: Not recommended for living rooms or bare-foot areas! PS100 PS150 100 mm 150 mm tf/tr [°C] 30/20 30/25 35/25 35/28 35/30 375/325 40/30 40/35 45/35 45/40 50/40 50/45 1 Heat output [W/m2] at room temperature Tr TO [°C] tmH [°C] Tr = 15 °C PS100 PS150 Tr = 18 °C PS100 PS150 Tr = 20 °C PS100 PS150 Tr = 22 °C PS100 PS150 Tr = 24 °C PS100 PS150 (at Tr = 20 °C) PS100 PS150 250 55 46 39 32 27 23 16 14 - - 23 22 275 69 58 53 44 41 35 30 25 19 16 24 23 300 83 70 67 56 55 46 44 37 33 28 25 24 315 92 77 75 63 64 53 53 44 41 35 26 25 325 97 82 81 67 69 58 58 49 47 39 26 25 350 111 93 94 79 83 70 72 60 61 51 28 26 350 111 93 94 79 83 70 72 60 61 51 28 26 375 125 105 108 91 97 82 86 72 75 63 29 28 400 139 117 122 103 111 93 100 84 89 75 30 29 425 153 128 136 114 125 105 114 96 103 86 32 30 450 167 140 150 126 139 117 128 107 117 98 33 31 475 181 152 164 138 153 128 142 119 131 110 34 32 Thin parquet floors, laminates and carpets Thermal resistance d/: 0075 m2K/W PS150: Not recommended for living rooms or bare-foot areas! PS100 PS150 100 mm 150 mm tf/tr [°C] 30/20 30/25 35/25 35/28 35/30 375/325 40/30 40/35 45/35 45/40 50/40 50/45 1 Heat output [W/m2] at room temperature Tr TO [°C] tmH [°C] Tr = 15 °C PS100 PS150 Tr = 18 °C PS100 PS150 Tr = 20 °C PS100 PS150 Tr = 22 °C PS100 PS150 Tr = 24 °C PS100 PS150 (at Tr = 20 °C) PS100 PS150 250 44 37 30 26 22 18 13 11 - - 22 22 275 55 47 42 36 33 28 24 20 15 13 23 23 300 66 56 53 45 44 37 35 30 26 22 24 23 315 72 62 59 51 50 43 42 36 33 28 25 24 325 77 66 64 55 55 47 46 39 37 32 25 24 350 88 75 75 64 66 56 57 49 48 41 26 25 350 88 75 75 64 66 56 57 49 48 41 26 25 375 99 85 86 74 77 66 68 58 59 51 27 26 400 110 94 97 83 88 75 79 68 70 60 28 27 425 121 104 108 93 99 85 90 77 81 70 29 28 450 132 113 119 102 110 94 101 87 92 79 30 29 475 143 123 130 112 121 104 112 96 103 89 31 30 tmH = mean hot water temperature = tf + tr 2 [°C] Tr = room temperature [°C] TO = mean surface temperature [°C] tf/tr = flow temperature / return temperature [°C] ___________ 1 The flow temperature must never exceed 50 °C | HEATING PRACTICE 31 Mass flow rate [l/h] . Pressure loss Example: The total pressure loss of a 7.2 m² VarioComp heating surface (one heating circuit) is to be calculated. The desired flow/return temperature is 37.5/32.5 °C, resulting in a heat output of 66 W/m² at a room temperature of 20 °C (thin parquet, d/ = 0.075 m K/W). Calculation of the flow rate from the pressure loss diagram: Q = 475.2 W (66 W/m × 7.2 m ) T = 5 K (tf - tr = 37.5 K - 32.5 K) c = 1.163 Wh/kgK (specific heat capacity of water) m = Q ÷ c ÷ T = 475.2 W ÷ 1.163 Wh/kgK ÷ 5 K = 81.7 kg/h (l/h) The flow rate is therefore 0.4 m/s and the pressure loss is 335 Pa/m Pipe length for 7.2 m heating surface = 72 m (1 m = 10 m pipe at 100 mm pipe spacing) · p for 7.2 m² VarioComp: 335 Pa/m × 72 m = 24 120 Pa (pipe laid ,,endless") 200 Wall roughness = 0.007 mm 100 90 81.7 80 70 60 50 40 30 20 Maximum flow rate per heating circuit of the VarioManifold: 160 l/h 10 [Pa/m] [mWC/m] 0.001 [mbar/m] 0.1 20 0.002 0.2 1030 0.003 0.3 40 50 60 70 80 90 100 200 0.004 0.005 0.006 0.008 0.01 0.02 0.007 0.009 0.4 0.5 0.6 0.7 0.8 0.9 1 2 Pressure loss [Pa/m] 300 335 400 0.03 0.04 500 600 700 800 900 1000 0.05 0.06 0.07 0.08 0.09 0.1 3 4 5 6 7 8 9 10 In case of setting a press-fit coupling for connecting residual lengths of pipe: · p for 1 pce. press-fit coupling 11.6 × 11.6: × /2 × = 7.2 × 500 kg/m³ × (0.4 m/s)² = +576 Pa Press-fit coupling Coefficient of resistance (Zeta) 11.6 × 11.6 7.2 32 | HEATING PRACTICE PROTOCOLS . Leak-tightness test in accordance with EN - The VarioComp floor heating system circuits are to be tested for leak-tightness using a water pressure test before pouring in the VarioComp filling compound. The test pressure should be min. 4 bar and max 6 bar. Due to the initial pipe expansion it may be necessary to re-pump the test pressure. If there is a risk of freezing, appropriate measures should be taken, e. g. use of antifreeze and controlling the building's temperature. The Leak-tightness test can also be carried out with compressed air as an alternative. The test pressure in this case is max. 3 bar. Construction project: _____________________________________________________________________________________ Building owner/Occupant: _________________________________________________________________________________ Client: _________________________________________________________________________________________________ Heating installation technician: ____________________________________________________________________________ Architect: _______________________________________________________________________________________________ Other: _________________________________________________________________________________________________ > Installation completion of the VarioComp boards including connections and piping on: ___________________ > Leak-tightness is carried out with water compressed air > Pressure test started on: ________________ with test pressure of ____ bar > Pressure test completed on: ________________ with test pressure of ____ bar > VarioComp filling compound added. Begun on: _______________ Completed on: _______________ > The system water was treated (e. g. as per ÖNORM H 5195-1) Yes No > Antifreeze was added to the system water Yes No > The VarioComp has been baked out as described in chapter 5.2 with tf/tr = ___ /___ °C: No Yes: 24 h 36 h 48 h ____ h > Floor covering: Tiles Parquet Carpet, linoleum Other ________________________ > Completing the laying work on: ___________________ > Start of heating (max. flow temperature of the VarioComp floor heating tf = 50 °C) on: ___________________ Approval: Building owner/Occupant/Client Construction management/Architect Heating installation technician PROTOCOLS | 33 . Functional heating (in compliance with EN - or BVF ) The functional heating serves as verification and proof of the creation of a defect-free installation for the heating installer and/or drywall builder. The functional heating is only carried out after the VarioComp filling compound has been applied. The VarioComp filling compound must have dried out completely. The maximum calculated flow temperature must be maintained for at least 1 day. Construction project: ____________________________________________________________________________________ Building owner/occupant: ________________________________________________________________________________ Client: _________________________________________________________________________________________________ Heating installer: ________________________________________________________________________________________ Architect: ______________________________________________________________________________________________ Others: ________________________________________________________________________________________________ Preheating of the VarioComp floor heating > Completion work finished: _______________ > Preheating started with constant max. calculated flow temperature: _______________ | tf = _______°C > End of functional heating : _______________ If there is a risk of freezing, appropriate measures should be taken, (e. g. frost protection mode). > The rooms were ventilated without draughts and all windows and external doors closed after switching off the surface heating system: Yes No > Operating state and outdoor temperature on handover: When switched off after the preheating phase, the VarioComp floor heating must be protected against draughts and from cooling down too quickly until it has cooled down completely. Approval: Building owner/Occupant/Client Construction management/Architect Heating installer . Commissioning Please note that the flow temperature (heating water) of the VarioComp floor heating may not exceed tf = 50 °C. The main stop valves at the distributor station, and the heating circuit shut-offs are to be opened. The entire system is to be deaerated thoroughly. The circulation pump may be switched on after deaeration. After commissioning, the VarioComp floor heating system can be considered maintenance-free. (Subject to technical modifications without notice.) ________ BVF = Bundesverband Flächenheizungen und Flächenkühlungen e.V. 34 | PROTOCOLS PROTOCOLS | 35 ENJOY THE COMFORT & SAVE ENERGY That's why our customers love us: Heating and cooling optimised for COMFORT in all rooms! Fast and friendly service, ANSWERS backed up with expertise! Always in tune with the latest technology, INNOVATION guaranteed! Everything CLEAR and SIMPLE, in writing of course! PROFESSIONALISM at all times, from the first contact to the reference list! VARIOTHERM SINCE 1979 Variotherm is an Austrian model plant with hundreds of partners in Austria, Europe and around the world. 13.370/1 VBOOK8_EN | 8/2024 Your Variotherm Partner All rights pertaining to distribution and translation, in whole or in part, including film, radio, television, video recording, Internet, photocopying and reprinting, are reserved. Subject to mistakes and printing errors. Misprints and errors excepted. HEIZSYSTEME GMBH GÜNSELSDORFER STRASSE 3A 2544 LEOBERSDORF AUSTRIA Phone: +43 [0] 22 56 - 648 70-0 office@variotherm.com www.variotherm.com