Dunham-Bush Evo-Lite Style CG User manual

Evo-Lite Style CG Radiant Panels
Installation Instructions
Dunham-Bush Ltd, Downley Road, Havant, Hants PO9 2JD
Document Ref:
Tel: [phone] Email: [e-mail]
224-000-001-A
UK:www.dunham-bush.co.uk Global:www.dunham-bush.com
July 2014
INSTALLER : IT IS IMPORTANT TO LIASE WITH OTHER TRADES
WHEN INSTALLING EVO-LITE RADIANT PANELS
INTRODUCTION
This booklet provides instructions to identify, handle,
install and commission Dunham-Bush Evo-Lite Style
CG radiant panels. The instructions apply to panels
from the standard range only. Please study the
instructions carefully before commencing any
installation work.
IDENTIFICATION
Refer to Diagram 1. On larger or more complex
installations, Dunham-Bush may provide a baseboard
layout (BL) drawing which will show details of each
panel run, dimensions and panel part numbers. If
specified on the order, each panel will be marked with
a unique individual stencil reference, which may also
be shown on the BL drawing.
DESCRIPTION
Evo-Lite Style CG comprises aluminium alloy sheet
panel bonded to an extruded aluminium channel
profile; copper tube (carrying the hot water) is
mechanically located inside the extruded channel with
spring clips. Insulation is fitted to the upper side of the
panel to prevent heat loss upwards from the panel.
Optional accessories for hanging and pipe jointing are
supplied loose.
STANDARD RANGE OF PANELS AND SIZES
Each panel type is available as two tube (2T) or four
tube (4T) variants and are available in nine different
panel types:
EA - standard panel
EB - end panel
EC - connection panel
ED - single (stand-alone) panel
EE - expansion panel
EF - multi-circuit panel
EG - dummy panel
EH - flow connection panel
EJ - return connection panel
Panels are available in the following nominal lengths:
600mm, 900mm, 1000mm, 1200mm, 1500mm,
1800mm, 2000mm, 2100mm, 2400mm, 2500mm,
2700mm and 3000mm
Typical panel designation:
Style CG-4T EC1200
- CG ceiling grid application
- 4T four tube
- EC connection panel
- 1200 nominal length 1200mm
Diagram 1: Evo-Lite Style CG-4T - typical panel run (2T panels similar)
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Diagram 2: Typical panel arrangments (Style CG-4T panels shown - 2T similar)
CONSTRUCTION
Delivery
The purchaser is responsible for off-loading, and must
examine the radiant panels promptly upon receipt.
Any claims for damage will only be accepted if, at the
time of delivery, the consignment note is endorsed
with the details and counter signed by the transport
driver.
Handling
Radiant panels are usually palletised so a fork-lift or
similar will be required for lifting. Individual panels can
usually be handled by one or two persons. Panels
must not be dropped or suffer impact in any
circumstances.
Storage
Radiant panels should be stored in clean, dry indoor
conditions. Packaging should not be removed until the
panel is required for installation (the radiant surface of
each panel is covered in a protective film which should
be removed when installation and commissioning is
complete). Any packaging should only be removed if
damage is suspected at the time of delivery.
Preparation
Evo-Lite Style CG radiant panels are intended for
horizontal installation within a standard 600mm ceiling
grid ;
hence it is important to liase with other trades to
co-ordinate installation
. Provision must be made for
proper fixings ; the ceiling, soffit or structure must be
suitable to accept proposed fixings such as expanding
anchors, drop rods, lindaptors etc. Refer to Table 1 for
panel masses.
Access is recommended for maintenance i.e. pipe
connections. Ceiling tiles, builders work etc should be
removable with sufficient clearance. Evo-Lite should
be free to expand during normal operation.
Warning
Some components may have sharp edges. Care must
be taken when handling the product and protective
gloves should be worn.
Nominal panel length (mm)
600
900
1000
1200
1500
1800
2000
2100
2400
2500
2700
3000
Mass of panel 2T (kg)
3.1
4.7
5.2
6.2
7.8
9.4
10.4
10.9
12.5
13.0
14.0
15.6
Mass of panel 4T (kg)
4.3
6.4
7.1
8.5
10.7
12.8
14.2
14.9
17.1
17.8
19.2
21.3
Table 1 : Masses of Evo-Lite Style CG radiant panels
N.B. Style CG panels have a nominal installed mass of approximately 10kg/m²
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Diagram 3: Typical section detail for installation; Style CG-4T shown - 2T similar
Diagram 4: Suspension point locations for Evo-Lite Style CG
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INSTALLATION
General
Refer to the layout (BL) drawing for panel
arrangement. Panels can be installed before or after a
ceiling is installed. When two or more panels are to be
installed in a run, then pipework is interconnected
using 15mm straight couplings or expansion hoses
provided.
Fitting
1. Prepare suitable fixings to accept the radiant
panels. Refer to Diagrams 3 and 4 for fixing
positions.
2. Suspend the panel and level with the
suspended ceiling grid. Note that panels can be
suspended by one of the following options
(refer to Diagram 4.)
Drops rods fixed directly to the panel
Suspension wires directly to the panel
Directly onto the ceiling grid
3. If the panel is to be suspended directly by the
ceiling grid then additional support should be
provided by safety wires, fitted on diagonally
opposite corners.
4. If two or more panels are to be installed in a run
then fit the pipe couplings to the first panel.
Suspend the second panel level to the first
panel and engage the pipes of both panels into
the couplings, using compression nuts and
olives. Check that all panels are located
correctly and in a straight line before tightening
joints. Tighten all joints by hand then tighten
further approximately 1¼ turns. Fit the panel
joint strip using panel joint clips and M5 nuts
provided (Refer to Diagram 6).
5. Expansion panels should be fitted every 6m of
straight panel run, and are supplied with
expansion hoses fitted in place of the straight
couplings. Note that the hoses will require
pre-bending prior to fitting. (Refer to Diagram 7)
6. Ensure that panels are interconnected correctly.
EC, EH and EJ panels are positioned at the
connection end (flow and return) of panel run,
whereas EB panels are positioned at the
opposite end. EA and EE panels are used at
intermediate positions. ED panels are single
(stand-alone) panels. (Refer to Diagram 2).
7. Refer to Pipework Connections for connecting
the panels to the mains.
8. Refit the insulation and leave the protective film
on the radiating surface until installation and
commissioning is complete.
Pipework connections
1. Connection to the mains is made via EC, ED,
EH and EJ panels. Panels have Ø15mm copper
tube tails formed upwards for connection from
above. Flow and return connections are
interchangeable.
2. The installer must provide suitable fittings to
connect the panels. Flexible hoses are
recommended to allow for rapid installation
and flexibility.
3. Local isolating and regulating valves are
recommended, as well as drains, vents
and strainers.
Diagram 5 : Evo-Lite Style CG-2T panel - ED type
50mm thick foil encapsulated insulation
OD15mm copper tube
Aluminium panel
Extruded aluminium channel
Spring clip
Flow and return connections
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Diagram 6: Installation detail of Evo-Lite Style CG - standard joint
Diagram 7: Installation detail of Evo-Lite Style CG - expansion joint
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COMMISSIONING
1. Check the fastness of all fixings. Ensure that the
insulation is fitted correctly and that the radiating
surface is not damaged.
2. Purge the air from the system using air vents in
the mains.
3. Check pipe connections for leaks.
Refer to Table 2 for test and working pressures.
4. Balance the water flow rate through the panel to
accepted practice to achieve the specified flow rate.
5. Leave this document and any layout drawings with the
end-user
Maximum cold test pressure
12 bar gauge
Maximum working pressure at 120°C
6 bar gauge
Table 2 : Recommended test and working pressures
Diagram 8: Standard joint detail for Evo-Lite Style CG
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GENERAL GUIDANCE
1. Preparation
Planning and preparation of ceiling openings to
is important; openings should be uniform,
straight and free from all obstructions prior to
panel installation. It is essential to co-ordinate
all installation works with other trades.
2. Layout
Panel runs should be set out on a layout plan.
Radiant panels should be concentrated in areas
of highest heat loss i.e. around the outside
perimeter of the room, particularly, near
windows. This will counteract disproportionately
high heat losses. Single or dual circuit runs
should be considered- see Water flow rates
and Hydraulic Resistances below.
4. Maximum mounting height
There is no maximum mounting height for
Evo-Lite. However, when mounting heights
exceed 4m, the heat load should be adjusted to
allow additional losses of radiant heat incident
on walls, and stratification of air which absorbs
some heat by convection.
5. Minimum mounting height
There is no minimum mounting height for
Evo-Lite. For comfort and safety the following
rule of thumb can be applied:-
All Styles
LTHW - minimum mounting height 2.4m
MTHW - minimum mounting height 3.0m
Contact Dunham-Bush for further information
on mounting heights and comfort conditions.
5. Expansion joints
Expansion joints should be fitted every 6m in a
straight panel run.
6. Panel runs
Refer to Diagram 2 for typical arrangements in
a panel run. Dunham-Bush will prepare
complete baseboard layout drawings for
approval, which can be used to co-ordinate
materials and installation on site.
7. Water flow rates
To ensure rated heat outputs are achieved,
water velocity in the tube should be such the
water flow is turbulent. This maximises heat-
transfer from the water, through the tube and to
the radiating surface. Water flow rates should
also be limited to inhibit noise and erosion and
high pressure drops. Water velocities should
ideally be between 0.3 - 1.0m/s.
8. Hydraulic resistances
Evo-Lite utilises 15mm OD copper tube to
transport hot water.To calculate the total
pressure drop, determine the water flow rate :-
Water flow = Q
rate (kg/s) Cpx ΔT
Q = total heat output (kW)
Cp= specific heat capacity of water
(kJ/kgK); approx. 4.187
ΔT = water temperature drop
Obtain the hydraulic resistance from the graph
below. Note that the water flow rate should be
halved if dual circuit panel runs are used (i.e.
type EH and EJ panels). N.B. circuit length
applies for one circuit only
9. Applications
Evo-Lite Style CG is designed to fit into
conventional 'lay-in' tile ceiling grids; panel
dimensions have been optimised so that panel
edges are concealed by standard ceiling grid
T-bars - typically 15mm or 24mm. For other
types of ceiling, Style FS or Style CS panels
may be more appropriate. Style WS panels
are designed for vertical wall surface
applications. Contact Dunham-Bush for details.
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MAINTENANCE
Dunham-Bush Evo-Lite radiant panels are essentially maintenance free, with no moving parts. Panel surfaces can
be washed with mild cleaner or detergent followed by rinsing. Strong, abrasive or mechanical cleaning should not
be used. If panels or accessories become damaged, they can be replaced after isolating, draining and
disconnecting from pipework or adjacent panels.
SPARES/SERVICE
PLEASE WRITE THE DETAILS OF RADIANT PANELS HERE.
These details will be required when ordering spares for your Dunham-Bush radiant panels
STYLE AND No. OF TUBES
BL DRAWING OR ORDER No.
DATE OF INSTALLATION
Spare parts/service – Please contact our office, contact information shown below.
Manufacturer reserves the right to change any product specification without notice.
Dunham-Bush Ltd, Downley Road, Havant, Hants, PO9 2JD
Sales and Technical Support
Spare Parts and Service
Tel: [phone] Fax: [phone]
Tel: [phone] Fax: [phone]
Email: [e-mail]
Email: [e-mail]
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