Therma - Rad Draft.pdf - Hurlcon Heating

INSTALLATION AND OPERATING INSTRUCTIONS I INSTALLATION AND OPERATING INSTRUCTIONS
Therma-Rad
Panel Radiators
INSTALLATION AND
OPERATING INSTRUCTIONS
Melbourne: 03 9554 2275 Gold Coast: 07 5552 2600 Perth: 08 9350 2600
Sydney: 02 9853 2100 Townsville: 07 4750 3100 sales@hurlconheating.com.au
Brisbane: 07 3308 5400 Adelaide: 08 8152 7600 www.hurlconheating.com.au
3/08/2011 1

INDEX
1 - Introduction........................................................................................3
2 - General Advice..................................................................................3
3 - Technical Specifications....................................................................3
4 - Sizes & Types available ....................................................................4
5 - Calculating Water flow.......................................................................5
6 - Heat Correction Factors ....................................................................5
7 - Pressure Loss....................................................................................6
8 - Packing..............................................................................................6
9 - Panel Dimensions .............................................................................7
10 - Installation Details ...........................................................................7
11 - Positioning of wall brackets .............................................................8
12 - Methods of Plumbing.......................................................................9
13 - Problem Solving ............................................................................10
14 - Water Treatment............................................................................10
15 - Warranty........................................................................................10
Therma-Rad Panel Radiators 2

1 - INTRODUCTION
This brochure has been compiled to give our customers complete technical information on selecting, installing and
commissioning Therma-Rad Steel Panel Radiators. Therma-Rad radiators are produced on the most modern
automated radiator manufacturing equipment. The Therma-Rad radiators are manufactured to ISO 9001 Quality
Management System and are certified to comply with the following international standards EN 442, BS EN ISO
9001:2000, NFP 52 - 011 & - 012. Therma-Rad radiators have the convector fins welded to the waterways for
maximum heat transfer. All the radiators are tested to 13 bar pressure to ensure that the completed product is fault
free before leaving the factory. The Therma-Rad radiators are fully cleaned, prime coated and electro statically
powder coated before packing.
2 - GENERAL ADVICE
1. The radiator outputs in this catalogue are quoted with the standard conditions of water temperatures of 90 o
C flow and 70 o C return with an ambient air temperature of 20 o C. The radiators can be used at different
temperatures but their heat output will vary accordingly. Please refer to page 6 for further details.
2. Therma-Rad radiators are designed to be installed in a sealed system only. Never drain the water in the
heating system unless absolutely necessary, add water only if needed. Each time you add water or
change the water in the heating system, corrosion occurs and the life of the radiator will decrease.
Therma-Rad radiators can be used indefinitely without changing the water in the system. Refer also to
section 14.
3. The pipe work should be pressure tested to eliminate any leaks but DO NOT use MAINS PRESSURE if
the radiators are connected.
4. Use only OVENTROP or approved valves both on the flow and return side of each radiator. The manual or
thermostatic valves should be placed on the inlet side with the lockshield valve for flow control on the
outlet side. The use of thermostatic valves will provide more comfort and economy.
5. Keep the packing on the radiator until the installation is completed to prevent any unwanted scratches or
damage to the radiator.
6. Use the air vent in one of the top connections to eliminate all the air from the radiator.
7. The normal system pressure for a closed vented sealed system is between 1 - 2 Bars when cold.
3 - TECHNICAL SPECIFICATIONS
All Hurlcon Therma-Rad radiators are manufactured to the following standards.
Steel quality ST 12.03 DIN 1543
Panel gauge
1.20 mm cold rolled steel
Convector fins
0.45 mm cold rolled steel
Top & side covers
0.75 mm cold rolled steel
Test pressure
13 BAR minimum
Working pressure
10 BAR maximum
Connections
Standard radiator 4 places -1/2” BSP
Compact valve radiator 6 places -1/2” BSP
Paint specification Epoxy-polyester Powder RAL 9016
Accessories supplied with each Therma-Rad
Screws and plastic wall plugs
Wall hangers
Blanking plug G 1/2''
Airvent plug G 1/2''
Side panels (mounted onto the panel radiator)
Grills (mounted onto the panel radiator)
Therma-Rad Panel Radiators 3

4 - SIZES & TYPES AVAILABLE
Available radiators range from 400mm wide to 3000mm long in 100 mm steps.
Heights of 200, 300, 400, 500, 600, 700, 900, are available.
All are available as Types 10, 11, 21, 22, 33. Refer to drawings page 7. See page 11 for complete size and
output table.
NOTE. Hurlcon has a wide range of sizes in stock however check the availability with your nearest Hurlcon sales
office prior to commencing installation as delivery of special orders can be up to 10 -12 weeks.
Technical Data
Radiator Height
Radiator Type *
Heat output in
Watts per m
Water content in
litres per m
Weight in
kg per m
200
300
400
500
600
700
900
11 592 1.1 7.9
21 790 2.1 11.3
22 1108 2.1 15.8
33 1622 3.2 17.7
11 742 1.7 9.7
21 1150 3.4 15
22 1437 3.4 18.7
33 2085 5.1 27.6
11 966 2.1 13.1
21 1440 4.2 22.9
22 1803 4.2 31.2
33 2638 6.3 36.5
11 1158 2.5 16.3
21 1730 5 25
22 2157 5.0 31.2
33 3164 7.5 46.0
11 1356 2.9 19.4
21 1970 5.8 30.7
22 2485 5.8 37.4
33 3638 8.7 55.3
11 1540 3.3 22.5
21 2230 6.6 33.9
22 2800 6.6 43.5
33 4078 9.9 64.4
11 1919 4.1 28.6
21 2750 8.2 43.4
22 3458 8.2 55.8
33 4967 12.3 82.9
Therma-Rad Panel Radiators 4

5 - CALCULATING WATER FLOW
To ascertain water flow requirement to a panel radiator the following information must be known.
- Output required from the radiator.
- Temperature difference between Flow and Return (∆T).
Then Water in flow l/s can be calculated by the formula
Flow in l/s = output kW
∆T x 4.18
Example
Required output of 2.0 kW
Boiler capacity - flow 80 o C return 70 o C thus ∆T = 10
The calculation is
Required Flow = 2.0
10 x 4.18 = 0.048 l/s ( x 3600 = 172.8 l/hr )
6 – HEAT CORRECTION FACTORS
For selection of the Panel size.
The Therma-Rad radiator heat outputs vary according to the difference between the room air temperature and the
average of the flow and return water temperatures (called mean water temperature). The data supplied is based
on 90/70 o C water temperatures and 20 o C ambient air temperature C f = 1
Flow Room
Correction Factor C f
water Temp Return water Temperature o C
Temp
o C 40 45 50 55 60 65 70 75
24 1.97 1.71 1.53 1.38 1.27 1.17 1.10 1.03
22 1.81 1.59 1.43 1.31 1.20 1.12 1.05 0.99
90 o C 20 1.68 1.49 1.35 1.24 1.14 1.07 1.00 0.95
18 1.56 1.40 1.27 1.17 1.09 1.02 0.96 0.91
15 1.41 1.28 1.18 1.09 1.02 0.95 0.90 0.86
24 2.10 1.82 1.62 1.46 1.34 1.24 1.16 1.09
22 1.92 1.69 1.52 1.38 1.27 1.18 1.11 1.05
85 o C 20 1.78 1.58 1.42 1.30 1.21 1.12 1.06 1.00
18 1.65 1.48 1.34 1.24 1.15 1.07 1.01 0.96
15 1.49 1.35 1.24 1.14 1.07 1.00 0.95 0.90
24 2.24 1.94 1.72 1.56 1.42 1.32 1.24 1.16
22 2.05 1.80 1.61 1.46 1.35 1.25 1.18 1.11
80 o C 20 1.89 1.67 1.51 1.38 1.27 1.19 1.12 1.06
18 1.75 1.57 1.42 1.31 1.21 1.13 1.07 1.01
15 1.58 1.42 1.30 1.21 1.12 1.06 1.00 0.95
24 2.41 2.08 1.85 1.66 1.52 1.41 1.32
22 2.20 2.20 1.72 1.56 1.43 1.34 1.25
75 o C 20 2.02 2.02 1.61 1.47 1.35 1.27 1.19
18 1.87 1.87 1.51 1.38 1.28 1.20 1.13
15 1.67 1.67 1.38 1.27 1.19 1.12 1.06
24 2.61 2.25 1.99 1.79 1.64 1.52
22 2.37 2.07 1.85 1.67 1.54 1.43
70 o C 20 2.17 1.91 1.72 1.57 1.45 1.35
18 2.00 1.78 1.61 1.47 1.37 1.28
15 1.79 1.61 1.47 1.35 1.27 1.19
24 2.85 2.44 2.15 1.94
22 2.58 2.24 1.99 1.81
65 o C 20 2.35 2.07 1.85 1.69
18 2.15 1.91 1.73 1.59
15 1.91 1.72 1.57 1.45
24 3.14 2.68 2.36
22 2.82 2.45 2.18
60 o C 20 2.56 2.24 2.02
18 2.34 2.07 1.87
15 2.03 1.85 1.69
Example.
Required 2.0 kW heating
Conditions
Flow temp 80 oC
Return temp 70 oC
Ambient air 22 oC
From the chart
Cf = 1.18
Corrected Radiator
2 kW x 1.18 = 2.36 kW
std output required.
Select the radiator size of
600 / 22 / 1000
with 2.49 kW std output
being closest to the panel
output required.
1. Outputs increase by approximately 2 % when top grilles are not fitted.
2. Correction factor for other temperature conditions available on request.
Therma-Rad Panel Radiators 5

7 - PRESSURE LOSS
The pressure loss through a radiator and valves are relatively low but can be calculated by the following formulae.
For a Therma-Rad panel radiator with OVENTROP valves the calculations are as follows:-
For type 11 panels P 11 = 164
For type 22 panels P 22 = 97
Thus for the example of a 2 kW heat output and with a calculated water flow of 172 l/h (from section 5), the
pressure loss through the panel will be:-
Pressure loss P r = P X X (water flow l/h) 2
For a type 11 panel
Pressure loss = 164 x (172) 2
10,000 x 1,000
10,000 x 1,000
= 0.49 kPa
For a type 22 panel
Pressure loss = 97 x (172) 2 = 0.29 kPa
10,000 x 1,000
Add to this the pressure loss through the valves to obtain the total loss per radiator.
Pressure loss for a standard OVENTROP radiator valve set is
P v = (36 x flow l/s / K v ) 2
= kPa pressure loss.
K v = 1.1 for standard OVENTROP valve set
Thus for our example 2.0 kW radiator, the pressure loss for the valves with a water flow of 0.04 l/s is as follows
P v = (36 x 0.048 / 1.1 ) 2
= 2.47 kPa pressure loss.
Total loss through radiator = P r + P v = P t kPa = 0.29 + 2.47 = 2.75 kPa
8 - PACKING
1. In order to protect the Therma-Rad radiator and avoid damage from external effects, all four corners of the
radiator are protected with thick cardboard.
2. To protect against dirt etc. the radiators are shrink wrapped in heavy plastic. This heavy-duty protection
minimises the risk of damage in the delivery and installation phase.
3. It is recommended that the wrapping should be kept on the radiator until on all construction work is
completed.
Therma-Rad Panel Radiators 6

9 - PANEL DIMENSIONS
Types and basic sizes - cover panels & grilles fitted to types 11, 21, 22 & 33 (not shown).
50 50 67 100 160
30/10 55/35 78/56 90/70 90/70
Type 10 Type 11 Type 21 Type 22 Type 33
10 - INSTALLATION DETAILS
A method of installation.
1. Determine the size and position of the radiator to be installed in the room.
2. Determine the height above the floor for the radiator (usually between 90 and 150 mm). Check the height
of the skirting board to clear the radiator mounting bracket and the radiator.
3. Locate & drill the four mounting holes according to the details below.
4. Fix the brackets in place with the appropriate fixing screws and level the brackets.
5. Cut away the packing around the four ½” BSP connections point and fit the air bleed plug to a top corner
and the valve unions and plug according to the plumbing requirements. Refer page 9.
6. It is wise to check a sample radiator for dimensions before committing the pipe work. This allows for
varying valve fittings and bracket location.
7. Determine the position of the pipe entries through the floor or wall. Drill oversize holes to allow for
alignment variations and expansion movement.
8. Fit the radiator to the wall brackets using the plastic inserts on the brackets. Leave the outer packing on to
protect the paint finish during the installation phase.
9. Install the radiator valves and plumb to suit. DO NOT water test with MAINS PRESSURE water.
10. When the installation is complete, fill the system, check for leaks, and eliminate all air from the system.
11. Commission and run the boiler to heat the water.
12. Balance the system using the lockshield valves to give proportional flow to all radiators.
13. Re-check for air in the system and the circulator is running quietly.
Therma-Rad Panel Radiators 7

11 – POSITIONING OF WALL BRACKETS
Standard radiator.
L
Type 11 = 115
All others = 100
Concealed
brackets
25
60m
m
- 85
Radiator Height H
H
25 43
60m
m
- 85
Centre Line
of Valves
90 -150 mm
TYPE 10,11 TYPE 21,22,33
35 or 55 70 or 90
Compact valve radiator.
Intergrated
Compact valve
L
Type 11 = 115
All others = 100
Concealed
brackets
25
60m
m
- 85
Radiator Height H
H
60m
m
- 85
30
Centre Line of
Valves
90 -150 mm
Return
50
Pipe centres
Flow
TYPE 10,11 TYPE 21,22,33
35 or 55 70 or 90
All panels 1800mm and longer come with 3 rd central bracket
Therma-Rad Panel Radiators 8

12 - METHODS OF PLUMBING
- With the four ½” connections, fit the control valve (manual or thermostatic), lockshields and air bleeds.
The connections may be on the same side for the smaller radiator or opposite sides for longer radiators to
ensure good water distribution.
- An air bleed plug must always be located at the top of the radiator.
Typical Methods of Plumbing a Standard 4 Port Radiator
Typical Method of Plumbing a Compact Valve 6 Port Radiator
Integrated valve
Notes
Air bleed plug MUST be in one of the top connections of the radiator
Radiator must be installed level and vertical.
Therma-Rad Panel Radiators 9

13 - PROBLEM SOLVING
1. A panel radiator needs a continuous flow of hot water to work effectively.
2. If the radiator is hot at the bottom but cold at the top - bleed the air out.
3. If the radiator flow pipe is hot and the return cold - increase the flow of water by re-balancing the system.
4. If the radiator or the pipe work is noisy, check for air in the system. Switch the circulator off and allow the
air to settle to the top of the radiators. Then bleed the radiators, top up water if necessary.
5. A radiator will be hot only at maximum heat output. A warm radiator indicates that the boiler has switched
off or the thermostatic valve, if fitted, has adjusted the output down to suit the required room conditions.
It is wise to provide an external drain at the lowest point of the pipe work in the event that the system has
to be drained for maintenance or modification.
14 - WATER TREATMENT
- There is a basic need to treat the water contained in all heating systems that have steel panel radiators.
- There will always be some corrosion in a steel panel radiator system even though the system is closed.
- The water in a closed system will promote corrosion unless the initial charge of water is correctly treated.
- Open vented systems in particular should be treated, as open vented systems are not completely sealed
off from the atmosphere. It is essential to provide a tank open to the atmosphere if proper venting and
expansion of the system is to be achieved.
- The same tank that is used to fill the system provides the capacity for the storage of water that has
expanded when heated. When the system cools down, this same water is drawn back into the system
taking with it a small quantity of dissolved oxygen.
- Even without any leakages from the system, there will be evaporation losses from the surface of the tank
depending on the ambient temperature.
- In practice the development of corrosion in a system reduces the transfer of heat through the formation of
black iron oxide sludge. This corrosion process causes noises from the boiler and circulator eventuating in
the premature failure of the radiators, circulator and boiler.
- For the above reasons, it suggested that the system is thoroughly flushed through at the time of
installation.
- The system should then be filled with a stable water treatment solution that does not require continuous
topping up. For example RAD-PROTEX. Please refer to our technical department.
15 - WARRANTY
ThermaRad panel radiators are guaranteed for 10 years against defects in material or workmanship.
Warranty includes rework or replacement of the radiator (parts only).
The products must be installed and used according to accepted plumbing practices, like BS5449.
Failure to do so will void the guarantee.
The below items must also be followed or else the warranty may be voided:
1. ThermaRad panel radiators should be used in closed heating systems. Never use in open circuit (steam,
thermal spring , boiled water or tap water)
2. After the installation, the system should be tested by an expertised personnel. Otherwise, damage may
occur in the place of installation.
3. Please ensure that the connection elements are free of any dirt and burr after the installation. If necessary,
flush the system to get rid of particles before testing or using the system.
4. Do not use the radiators in humid environment (swimming pool, sauna bath, green house)
5. Do not overtighten the stoppers, airvents or valves, otherwise the connection threads could be damaged.
6. Keep the packaging on the radiator even after installing the radiator until all construction work is finished.
The packaging will prevent scratches and damage on the radiator surface or paint.
7. Maximum working pressure of the radiators is 10 bars.
8. When filling the radiators for the first time, heating system controls should be closed and the system
should be set to right pressure.
9. Never empty the water in heating system. Add water when needed. Each time you add or change water to
your heating system, corrosion occurs and its life time will decrease.
10. Please take cautions against freezing risk.
11. Use an anti-corrosion agent in the system if the water is very aggressive or acidic.
12. Avoid dropping or flexing (bending) the radiators when carrying or transporting it.
13. Please do not use corrosive or abrasive agents to clean your radiator.
14. Do not place more than 20 kgs onto the radiator so as to avoid the brackets coming out of the wall.
15. This warranty shall not apply to any radiators that have been subject to accident, negligence, alteration,
abuse or misuse.
Therma-Rad Panel Radiators 10

Height 200 300 400 500 600 700 900
Types 11 22 33 11 22 33 11 22 33 11 22 33 11 22 33 11 22 33 11 22 33
w/m 540 1100 1500 742 1437 2085 966 1803 2638 1158 2157 3164 1356 2485 3638 1540 2800 4078 1919 3458 4967
400 0.22 0.44 0.60 0.30 0.57 0.83 0.39 0.72 1.06 0.46 0.86 1.27 0.54 0.99 1.46 0.62 1.12 1.63 0.77 1.38 1.99
500 0.27 0.55 0.75 0.37 0.72 1.04 0.48 0.90 1.32 0.58 1.08 1.58 0.68 1.24 1.82 0.77 1.40 2.04 0.96 1.73 2.48
600 0.32 0.66 0.90 0.45 0.86 1.25 0.58 1.08 1.58 0.69 1.29 1.90 0.81 1.49 2.18 0.92 1.68 2.45 1.15 2.07 2.98
700 0.38 0.77 1.05 0.52 1.01 1.46 0.68 1.26 1.85 0.81 1.51 2.21 0.95 1.74 2.55 1.08 1.96 2.85 1.34 2.42 3.48
800 0.43 0.88 1.20 0.59 1.15 1.67 0.77 1.44 2.11 0.93 1.73 2.53 1.08 1.99 2.91 1.23 2.24 3.26 1.54 2.77 3.97
900 0.49 0.99 1.35 0.67 1.29 1.88 0.87 1.62 2.37 1.04 1.94 2.85 1.22 2.24 3.27 1.39 2.52 3.67 1.73 3.11 4.47
1000 0.54 1.10 1.50 0.74 1.44 2.09 0.97 1.80 2.64 1.16 2.16 3.16 1.36 2.49 3.64 1.54 2.80 4.08 1.92 3.46 4.97
1100 0.59 1.21 1.65 0.82 1.58 2.29 1.06 1.98 2.90 1.27 2.37 3.48 1.49 2.73 4.00 1.69 3.08 4.49 2.11 3.80 5.46
1200 0.65 1.32 1.80 0.89 1.72 2.50 1.16 2.16 3.17 1.39 2.59 3.80 1.63 2.98 4.37 1.85 3.36 4.89 2.30 4.15 5.96
1300 0.70 1.43 1.95 0.96 1.87 2.71 1.26 2.34 3.43 1.51 2.80 4.11 1.76 3.23 4.73 2.00 3.64 5.30 2.49 4.50 6.46
1400 0.76 1.54 2.10 1.04 2.01 2.92 1.35 2.52 3.69 1.62 3.02 4.43 1.90 3.48 5.09 2.16 3.92 5.71 2.69 4.84 6.95
1500 0.81 1.65 2.25 1.11 2.16 3.13 1.45 2.70 3.96 1.74 3.24 4.75 2.03 3.73 5.46 2.31 4.20 6.12 2.88 5.19 7.45
1600 0.86 1.76 2.40 1.19 2.30 3.34 1.55 2.88 4.22 1.85 3.45 5.06 2.17 3.98 5.82 2.46 4.48 6.52 3.07 5.53 7.95
1700 0.92 1.87 2.55 1.26 2.44 3.54 1.64 3.07 4.48 1.97 3.67 5.38 2.31 4.22 6.18 2.62 4.76 6.93 3.26 5.88 8.44
1800 0.97 1.98 2.70 1.34 2.59 3.75 1.74 3.25 4.75 2.08 3.88 5.70 2.44 4.47 6.55 2.77 5.04 7.34 3.45 6.22 8.94
1900 1.03 2.09 2.85 1.41 2.73 3.96 1.84 3.43 5.01 2.20 4.10 6.01 2.58 4.72 6.91 2.93 5.32 7.75 3.65 6.57 9.44
2000 1.08 2.20 3.00 1.48 2.87 4.17 1.93 3.61 5.28 2.32 4.31 6.33 2.71 4.97 7.28 3.08 5.60 8.16 3.84 6.92 9.93
2100 1.13 2.31 3.15 1.56 3.02 4.38 2.03 3.79 5.54 2.43 4.53 6.64 2.85 5.22 7.64 3.23 5.88 8.56 4.03 7.26 10.43
2200 1.19 2.42 3.30 1.63 3.16 4.59 2.13 3.97 5.80 2.55 4.75 6.96 2.98 5.47 8.00 3.39 6.16 8.97 4.22 7.61 10.93
2300 1.24 2.53 3.45 1.71 3.31 4.80 2.22 4.15 6.07 2.66 4.96 7.28 3.12 5.72 8.37 3.54 6.44 9.38 4.41 7.95 11.42
2400 1.30 2.64 3.60 1.78 3.45 5.00 2.32 4.33 6.33 2.78 5.18 7.59 3.25 5.96 8.73 3.70 6.72 9.79 4.61 8.30 11.92
2500 1.35 2.75 3.75 1.86 3.59 5.21 2.42 4.51 6.60 2.90 5.39 7.91 3.39 6.21 9.10 3.85 7.00 10.20 4.80 8.65 12.42
2600 1.40 2.86 3.90 1.93 3.74 5.42 2.51 4.69 6.86 3.01 5.61 8.23 3.53 6.46 9.46 4.00 7.28 10.60 4.99 8.99 12.91
2700 1.46 2.97 4.05 2.00 3.88 5.63 2.61 4.87 7.12 3.13 5.82 8.54 3.66 6.71 9.82 4.16 7.56 11.01 5.18 9.34 13.41
2800 1.51 3.08 4.20 2.08 4.02 5.84 2.70 5.05 7.39 3.24 6.04 8.86 3.80 6.96 10.19 4.31 7.84 11.42 5.37 9.68 13.91
2900 1.57 3.19 4.35 2.15 4.17 6.05 2.80 5.23 7.65 3.36 6.26 9.18 3.93 7.21 10.55 4.47 8.12 11.83 5.57 10.03 14.40
3000 1.62 3.30 4.50 2.23 4.31 6.26 2.90 5.41 7.91 3.47 6.47 9.49 4.07 7.46 10.91 4.62 8.40 12.23 5.76 10.37 14.90
3/08/2011 11

INSTALLATION AND OPERATING INSTRUCTIONS I INSTALLATION AND OPERATING INSTRUCTIONS
HURLCON HEATING Pty. Limited. A.B.N. 97 007 284 504
www.hurlconheating.com.au email: sales@hurlconheating.com.au
Information and specifications subject to change without notice.
Victoria: New South Wales: Queensland: South Australia: Western Australia: Gold Coast: Townsville:
Ph: (03) 9554 2275 Ph: (02) 9853 2100 Ph: (07) 3308 5400 Ph: (08) 8152 7600 Ph: (08) 9350 2600 Ph: (07) 5552 2600 Ph: (07) 4750 3100
Fax: (03) 9554 2272 Fax: (02) 98532170 Fax: (07) 3308 5470 Fax: (08) 8152 7670 Fax: (08) 9350 2670 Fax: (07) 5552 2670 Fax: (07) 4750 3170
3/08/2011 12