How to make a heating register from a profile pipe with your own hands. Schemes and drawing for connecting home-made heating registers
Do-it-yourself heating register
Calculation of parameters and drawing
The first stage in the manufacture of a heating register with your own hands is design. It is clear that it is impossible to make a heating register normally by eye. Therefore, it is necessary to carry out a number of additional calculations, based on which it will be possible to select the optimal heat exchanger. When designing heating registers, there are many factors to consider:
- power;
- construction;
- installation methods.
Before you make heating registers with your own hands, you need to understand what it is heater, which means that it must warm up a certain room. Its heat transfer should correspond to the situation, but do not put a heat exchanger in the entire wall in a small room. One meter should account for 100 to 200 kilowatts, depending on the region. There is a formula for calculating the heat transfer of heating registers. It includes the following values:
- heat exchanger length in meters;
- internal section in meters;
- thermal conductivity coefficient of metal;
- delta of supply and return temperatures;
- number "P".
To determine the heat transfer, you need to multiply all the components of the calculation. Of course, each of the above values can be determined separately from this formula. So, knowing the quadrature of the room, you can determine what dimensions the structure should have. Often, home-made registers for heating are made from improvised materials, so it is not possible to choose some parameters. We have to customize the entire structure to the existing characteristics, while not forgetting the functionality of the heat exchanger.
When calculating the length of the heat exchanger, it must be remembered that the value obtained indicates the total length of the pipes.
For example, according to the formula, a value of five meters was obtained. This means that both one five-meter pipe along the perimeter and several segments are suitable for heating, the sum of the lengths of which will be the same five meters. The bottom line is that the heat exchange area is preserved.
There are two methods for placing the main (thick) pipes:
- horizontally;
- vertically.
In principle, there is no difference in manufacturing. If you take a horizontal structure and rotate it 90 degrees clockwise, you get a vertical heat exchanger. This will make a difference when installed on a loop.
That's the whole difference between vertical and horizontal register
In addition, the heating registers are fastened with special jumpers. There may be one or two such jumpers. Also, the connection of horizontal sections can be carried out by couplings of the same diameter, which are welded into the end. These are the so-called serpentine registers. You can choose any method of assembling a heating register from pipes with your own hands, the main thing is that you have enough skills to execute it.
In order not to complicate the manufacturing process of the register, we will use a scheme for connecting horizontal sections with two nozzles. Heating register, drawing:
Heating register drawing
For work we need:
- three identical pipe sections;
- four connecting pipes;
- six plugs.
The distance between the pipes of the heating register can be large, but not less. Moreover, if pipes of large diameter are used, the distance between them is determined by the formula: diameter x 1.5. This distance is optimal. The next step is welding.
The assembly of individual structural elements together is carried out by welding the metal. This can be done in any way convenient for you. How to weld a heating register? In fact, it all depends on what kind of welding machine you have:
- electric arc (manual, semi-automatic);
- gas.
The most widespread are electric arc manual welding machines, as they are the cheapest and simplest. Such an apparatus can both connect metal parts and cut them. On large parts, you need to cut holes for the nozzles. This should be done near the edge, stepping back one diameter of the pipe. There will be four holes on the middle section, two on the first and outer sections.
Holes for connecting pipes
After that, on a flat horizontal surface, we lay out all the elements in one structure and make tacks at the base of the nozzles. You need to make either two tacks along the equator of the pipe, or three evenly around the entire circumference, as in the Mercedes badge. If the location of the tacks is incorrect, then the part may lead during welding. After making sure that the geometry of the register is correct, you can proceed to welding.
During operation in the melting bath, it is necessary to maintain high temperature, and distribute the molten metal. The electrode must constantly move along a certain trajectory. How to weld a heating register, the simplest electrode movement trajectories:
- left - right (herringbone);
- forward - backward (with an influx).
The most important moment is the formation of the root of the seam on the tack and the exit from the tack. The process is carried out with a break, as the welder needs to change the position of the electrode. Although with proper skill you can cook without interruption. After the seam has cooled, you need to knock down the sludge with a hammer. So, it remains only to weld the ends with plugs, which must first be cut out of metal of the same thickness.
By the way, for the production of registers, you need to take steel of at least three millimeters.
As a result, we got a blank, in which holes for supply and return, as well as an air vent, will be cut in the future. The air vent, the same Mayevsky crane, removes air pockets that reduce the efficiency of the heat exchanger. You can also read more about . Connecting the registers to the heating system is the last stage, after which it is possible to carry out a hydraulic test and put the equipment into operation.
In addition, this blank can be used for the manufacture of a register with an electric heating element. A hole for the heating element is cut out in the lower end, and a expansion tank open type.
Heating register connection diagrams
Setting the heating register to kotrur
Now that the heat exchanger is ready, you need to install the heating register on the circuit. Like a conventional battery, it can be connected in many ways, while the supply must always be higher than the return. About we wrote in one of the previous articles. Installation of branch pipes to the heating register is carried out:
- on one end;
- at different ends.
The last scheme for connecting heating registers is called diagonal and is more preferable. When we know where the supply and return will be, we can make holes in the ends for threaded couplings. Fittings connecting the heat exchanger to the circuit will then be screwed to these couplings. An air vent is welded on the opposite side from the supply. It may be at the end, but it is better that the valve is at the top.
Before installing the heating registers, remember that it has a fairly large weight, even without a coolant, and filled with water even more so. Therefore, it is necessary to provide reliable fasteners. The heat exchanger is placed on the floor or hung on the wall. It is better, of course, to make legs and put it on the floor, additionally fixing it with fasteners to the wall. Do not forget that from the surface of the heat exchanger to the walls and floor should be about 25 centimeters.
Another recommendation concerns the location of the heat exchanger. As you may have noticed in apartments, the battery is always under the window. On the one hand, it heats the cold air emanating from the glass, and on the other hand, it heats the outer wall. That is, you should try to install registers along the walls that are in contact with the street.
Heating appliances are the basis of any heating system. In industrial, production and warehouse premises, heating registers have long been used - installations that are smooth-walled pipes welded together. AT recent times they have received wide demand among private traders. The registers contain significantly more coolant inside than in classic radiators, thanks to which they radiate heat longer.
Main classification
The registers offered by the market can be divided into two types:
- Coil (S-shaped)
- Sectional
Coil (S-shaped)
Serpentine registers, consisting of several sections, are widely used. The latter are interconnected by arcs, in which the diameter is commensurate with the sectional one. It turns out a pipe of a continuous configuration, for which the entire surface is working. The efficiency of the installations is very high.
For the manufacture of coil registers, a smooth-walled steel pipe with a high carbon content is used. The areas where the narrowing occurs are eliminated, due to which the hydraulic resistance inside is significantly reduced. There are also models on the market made of low-alloy or stainless steel, cast iron.
Sectional
The most popular among private owners are sectional heating registers, consisting of pipes closed with plugs connected to each other. The coolant is passed through the upper pipe, at the end of which it flows into the next one - and so on until the exit.
To increase the heat transfer coefficient, the transition for the coolant between the pipes is made as close to the edge as possible. Plugs between pipes come in one of two types: elliptical or flat. The inlet pipe is made for flange, thread or welding.
Sectional heating registers are equipped with a threaded fitting, through which a vent for accumulated air masses is mounted. The diameter of the main horizontal pipes varies and varies from 25 mm to 40 cm (in household appliances - up to 16 cm). The transition is carried out by branch pipes of a smaller section. Another feature of the installations is that the maximum pressure inside should not exceed 1 MPa.
Heating register subtypes
In addition to their own configuration, heating registers can be divided into subtypes according to the following criteria:
- Location options
- Production material
Location options
Depending on the location of the heating registers, they are divided into two categories:
- Portable (with heating element)
- Stationary
Portable or mobile device does not require binding to a specific place and, as a rule, they operate from a 220 V electrical network. Inside there are heating elements with a power of 1.6 to 6 kW, which heat the coolant. Similar devices are used in garages, construction sites, cottages, etc.
Stationary registers are located in a specific place, like heating radiators, and require connection to the boiler. The latter will heat up the coolant and force it to circulate through the heater.
Production material
Depending on the material of manufacture, heating registers are of the following types:
- Steel
- Aluminum
- Cast iron
Steel registers are the most common. They are connected to the heating system with threaded connections or by welding. Products are characterized by high heat transfer coefficient and reasonable cost.
The small specific weight of aluminum registers, resistance to corrosion, lack of seams and high heat transfer rates determined the demand for such products among buyers. They are made by the method of monolithic casting. A significant disadvantage is the high cost.
Cast iron radiators are connected to the heating system by means of a monolithic flange connection. Affordable cost and easy installation are the main advantages of the products. However, they are less inert analogues, therefore, they warm up longer.
How to count the number of edges
Before purchasing a heating register, special attention must be paid to the diameter of the pipe. Experts recommend choosing installations with a diameter of 3-4 cm for the home, but not more than 8 cm. The main reason for this decision is that a household heating boiler is not able to give out the amount of heat that would be enough for high-quality heating of large surfaces.
Read more about radiators
When making a calculation, one should take into account the length of one fin of the register and the heat transfer per each meter of it. For example, a product 1 m long with an internal section of 6 cm allows you to heat about 1 square.
Having counted the required number of ribs, rounding is done up. At certain conditions the resulting value can be increased by 20-50%. These include:
- A large number of window openings, doors in the room
- Small wall thickness
- Poor room insulation
How to set the heating register
Each owner can install a heating register without involving a master in the work. To simplify assembly operations, it is first necessary to prepare each of the elements of the heating system according to the project.
One of the main requirements is a high-quality connection of the register with pipelines. It must withstand the maximum allowable load - 10 MPa. If docking is done by welding, you need to monitor the quality of the seams.
It is necessary to have heating registers closer to the floor surface. The larger the diameter of the main pipe, the less resistance there will be for the circulating coolant.
The efficiency of the device depends on a large number of factors, including the heating area, which is directly proportional to the length and diameter of the pipes. The most common in everyday life are models with the following characteristics:
- Recommended pipe diameter– from 25 to 160 mm
- Connecting jumpers for sectional models - from 30 mm
- Distance between the main pipes - from 50 mm
- Max pressure– 10 MPa
- Material– high carbon steel
We make a register with our own hands
Anyone who knows how to work with a welding machine is able to make a heating register on their own. A simple design can be filled with antifreeze or oil.
Introductory video for making
To make a heater with your own hands, it is recommended to follow the instructions:
In portable structures, it is necessary to install a heating element with a power of 1.5 to 6 W, which will operate from a conventional outlet. If the system is powered by a heating boiler, the efficiency of the registers can be increased by installing a powerful circulation pump.
Main advantages
Among the many advantages of heating registers, it should be noted:
In custody
Of course, heating registers are replacing classic heating radiators. In private houses, they can be found in rooms with more aggressive conditions (toilet, bathroom, periodically unheated rooms, etc.). For good master It will not be difficult to make such a device yourself.
In private houses there are always several utility or technical rooms where the requirements for the interior are low. But they still need to be heated, and in order not to spend money on the purchase of modern radiators, a steel register welded from pipes can be installed there. And, although everyone has seen such simple heating devices with their own eyes, not everyone knows their device. This material is to help those homeowners who want to independently manufacture, install and connect heating registers to their system.
Heating register device
Despite the fact that such heaters are considered obsolete and are not very attractive appearance, they continue to be widely used in a variety of areas, for example:
- for heating industrial premises of industrial enterprises;
- as an autonomous heater in garages;
- as a water heating element built into a brick oven.
Note. The furnace register of smooth heating pipes is calculated and manufactured depending on the capacity and design of the furnace.
By design, heating devices are distinguished by 2 types: sectional and in the form of a coil. In the first case, the role of section 1 is played by each horizontal pipe, the coolant flow through them is provided by vertical jumpers. They are made of pipes of smaller diameter in order to create artificial resistance to flow and increase heat transfer from each section. The pipes from which the sectional heating register is made are plugged at the ends, and the coolant is supplied according to the “top-down” scheme.
The design of the heater in the form of a coil is clear from its name. Here, the diameters do not narrow, the water flows freely through the entire device, changing direction several times. The heat transfer of this register is lower than that of a sectional one, but the hydraulic resistance is less and it is somewhat easier to manufacture.
Advice. It is preferable to make sectional heaters for utility rooms or garages, where uniform heating and comfortable air temperature are important. It is better to install coils as standby heaters at the very end of a two-pipe system. There they work remarkably because of their low resistance.
Registers for heating are welded from smooth pipes of round and rectangular cross section. However, the generally accepted design is ordinary round pipes made of low-carbon steel such as St3, St10 and even St0. If the battery is designed to work with steam system, then they take steel St20. Rectangular sections are not recommended, they are washed worse by convective air flow, which means that they will give off less heat. For garage heating, autonomous registers are made, filled with antifreeze or transformer oil, and an electric heating element is built into the lower section from the end.
Advantages and disadvantages
Before undertaking the manufacture of heating registers, it is necessary to evaluate all the pros and cons of these heaters, so as not to be deceived in expectations later. So, first about the advantages:
- low cost and ease of manufacture;
- low hydraulic resistance: thanks to this, the heater can be used in the "tail" of any system;
- reliability and durability: a register welded from ordinary pipes with high quality will easily last at least 20 years;
- resistance to pressure drops and water hammer;
- smooth surface facilitates easy removal of dust when cleaning rooms.
Unfortunately, a do-it-yourself heating register also has a lot of drawbacks. The main one is low heat transfer with a significant mass of the device. That is, in order to ensure a comfortable temperature in a medium-sized room, the register must have a decent size. Here is a simple example taken from the technical literature. If the temperature difference between the coolant and the room is 65 ºС (DT), a register welded from 4 DN32 pipes 1 m long will give out only 453 W, and from 4 DN100 pipes - 855 W. It turns out that, based on heat transfer per 1 m of length, any panel or sectional radiator is at least twice as powerful.
Note. The presented data were determined experimentally at a high coolant flow rate of 300 kg/h.
Other negative aspects of smooth-tube registers are not so critical, although they are significant:
- holds a large volume of water: the disadvantage does not play a big role if there are 1-2 pieces for the entire system of such heating devices;
- during operation, it is very difficult to increase or decrease the power of registers from smooth pipes. You can not do without dismantling and welding machine;
- subject to corrosion and require periodic maintenance with painting;
- have an unpresentable appearance: the defect is reparable, if necessary, the heater is hidden behind a decorative screen.
After analyzing the advantages and disadvantages of smooth-tube devices, we can conclude that their scope in private housing construction is very limited. As already mentioned, the registers can be used for heating various rooms with low requirements for comfort and interior.
When selecting materials, it is necessary to resolve the question - what diameters of pipes to take and what should be their total length. All these parameters are arbitrary, you can make a heater from any pipes, and take its length convenient for placement in the room. But in order to supply the required amount of heat, it is necessary to provide a sufficient heat exchange area. To do this, it is recommended to perform an approximate calculation of the register by surface area.
To make such a calculation is quite simple. It is necessary to calculate the area of the outer surface of all sections in m2 and multiply the resulting value by 330 W. Proposing this method, we proceed from the statement that 1 m2 of the surface of the register will give off 330 W of heat at a coolant temperature of 60 ºС, and indoor air - 18 ºС.
Advice. You can not do manual calculations, but use a simple program in EXEL and then correctly weld the register according to the exact parameters. In one click, you can download the program from the link: http://al-vo.ru/wp-content/uploads/2014/02/teplootdacha-registra-otopleniya.xls.
For a person with skills in welding, it will not be difficult to independently weld the register according to the available drawings. It is necessary to prepare and cut pipes into sections and jumpers, cut out plugs from a steel sheet. The assembly sequence is arbitrary; after welding, the heater should be checked for tightness. When manufacturing and installing registers, consider the following recommendations:
- you should not take pipes with too thin or thick walls: the former will cool faster and last less, while the latter will warm up for a long time and are difficult to adjust;
- do not forget to build a Mayevsky crane into the end of the upper section to release air;
- when welding coils, a rotary section can be made from two finished elbows if it is not possible to use a pipe bender;
- put a tap at the coolant inlet, a valve at the outlet;
- remember that the installation of the registers is carried out with an imperceptible bias towards the connection of the supply pipe. Then Mayevsky's crane will be at the highest point.
Conclusion
Smooth-tube registers cannot be considered a relic of the past, since they attract with their cheapness and are still successfully used in various situations. But the system of a private house should not be loaded with such heating devices, the volume of heated water will then increase many times, which will affect energy consumption in a big way.
One of important elements any heating system, without which its functioning is impossible, are heating devices. To date, the market offers a huge range of radiators for every taste and wealth. And, despite the existing variety of forms and high efficiency modern models, a special place in the line of such products is occupied by heating registers.
Structurally, such heaters are parallel smooth-walled pipes with a diameter of at least 32 mm, interconnected by short transverse jumpers.
I would like to note that the registers were widely used in times of total shortage, when traditional radiators, even if they were not of high quality, could be purchased with difficulty. However, such devices should not be underestimated: in some cases they can be more effective than many modern heaters and batteries.
In most cases, this type of device is used for heating technical (garages, utility rooms, warehouses, etc.) and industrial buildings. But it is not uncommon to find them in autonomous heating schemes for private houses.
Figure 1 - An example of a heating system with registers
Advantages and disadvantages of heating registers
The main advantages of these devices, first of all, are the simplicity of design (they can be designed and manufactured by hand), increased strength (resistance to pressure and temperature drops, independence from the quality and type of coolant) and a long period of trouble-free operation, subject to compliance with installation quality.
Not to mention other advantages:
- configuration variability;
- high degree of heat transfer;
- the possibility of heating rooms with a large area with relatively compact dimensions of the devices;
- longer cooling (this is due to the presence of a large volume of coolant in the devices);
- ease of care;
- relatively low price.
Despite these advantages, in terms of comparative efficiency, heating registers are still inferior to traditional radiators, which is associated with a smaller total heat transfer area. But this drawback can be eliminated by modifying the basic design of the devices, for example, by increasing the number of horizontally arranged elements or by welding additional metal parts to them, for example, vertical plates.
Existing types of heating registers
All the existing variety of such devices can be classified into three groups.
By design features:
- sectional - are made in the form of one or more parallel pipes with plugs at the ends and interconnected by branch pipes, through which the coolant completely fills the device;
Figure 2 - Option sectional register
- serpentine (S-shaped) - in such models, horizontally located elements are connected to each other by means of arc-shaped elements of the same diameter, made of the same materials; as a result, such heating registers have a solid design, which leads to greater thermal efficiency due to an increase in the heat transfer area and reliability due to the absence of sections of variable cross section.
Figure 3 - Option coil heating register
By type of material:
- cast iron - they are distinguished by high strength, durability, but have a large mass, which complicates the installation process; the connection of cast-iron registers to the heating system is carried out by means of flanges: one is welded to the pipeline, the second (monolithic) is included in the design of the device;
- aluminum - the demand for this type of device is due to a rather attractive appearance, low weight, a good indicator of heat transfer; in such heaters there are no welds and joints; the main disadvantage is the high cost;
It must be taken into account that aluminum registers are sensitive to the quality of the coolant, therefore, under conditions central heating they should be used with caution.
- steel - the design of such models has a fairly large number of welds; connection to the heating system is also made by welding; therefore, the reliability and duration of the service life will mainly depend on the quality of the installation work.
By installation method:
- mobile (mobile) - such devices are similar in principle to electric heaters, the main difference is only in the size of the devices; they are usually used for temporary heating of premises in which finishing work is being carried out, or construction houses (trailers) for workers;
- stationary - such devices are part of the heating system and are installed in buildings on an ongoing basis.
Features of the design of heating registers and possible schemes for connecting to pipelines
As noted above, heating registers are made sectional or S-shaped from pipes with a diameter of 32-200 mm. At the same time, the number of elements, their location and shape may vary depending on the required power of the device.
Figure 4 - Exemplary options design heating registers
To increase the power of the registers, one should not strive to use elements of a large diameter, because. such an approach can lead to a loss of boiler performance or the need to purchase more powerful equipment, which is not always advisable.
For the manufacture of such devices, as a rule, smooth-walled pipes are used, but the use of profile metal is also allowed. Necessary condition at the same time, the type of material (cast iron, steel), the rules for working with it and compliance with the requirements for welding will be taken into account.
When doing the register with your own hands, it is not recommended to place the elements too close to each other, because. this will affect heat dissipation. The optimal distance is 50 mm more than the diameter of the pipes.
Regardless of the design, any model has inlet-outlet pipes for connection with pipelines for the supply and removal of coolant, a fitting for installing an air vent. In sectional devices, plugs are also mandatory elements, which can be elliptical (custom-made) or flat, as well as connecting pipes (it is recommended to place them closer to the ends of the pipes).
Heating registers can be operated both in single-pipe and in two-pipe systems. To connect such devices to heat supply schemes, you can use the following options:
- diagonal;
- lateral;
Figure 5 - Diagonal and lateral connection of registers to the heating system
- lower (it is more expedient to use this scheme for small dimensions of the device or a small number of horizontal elements).
Figure 6 - Scheme of the lower connection of the register
Installation of registers in the heating system
First of all, it should be noted that the assembly of such heating devices can be carried out both in the factory and directly at the facility. In the latter case, the heating registers are delivered as separate elements.
When using models that have threaded connections, the process of their installation in the heating system will not differ in any way from the installation of radiators. If the design of the devices does not provide for a thread, welding will be required.
It should be borne in mind that, unlike radiators, the registers should be installed at a slight slope (0.05%) towards the movement of the coolant.
DIY heating registers
Before proceeding with the manufacture of heating devices of this type, it is necessary to make an accurate calculation of them, namely:
Approved by an expert
Heating devices are an indispensable element of any water heating system. They are usually the most expensive part. A good opportunity for savings can be the use of homemade radiators. They are made from smooth steel pipes round section or from profile pipes. The latter option is somewhat more expensive, but allows you to reduce the depth of the device and get a more aesthetic appearance.
Usage profile pipe for the manufacture of heating registers has a number of features. Getting started with your own hands or deciding to buy a "homemade", you need to carefully weigh the pros and cons. Studying the basic rules by which heating registers are made from a profile pipe will help to avoid mistakes when independent work and will make it possible to make a competent choice of the necessary parameters.
Heaters in the form of registers are a structure of several vertical or horizontal pipelines interconnected by means of jumpers. In this case, the connecting elements can have a different shape and size. They are classified according to their location.
The structure of the register
For the manufacture of heating registers, smooth carbon steel pipes with a round section, as well as square and rectangular ones, are used. Their combined use is possible. good materials registers can also be stainless and galvanized steel, aluminum, copper, brass, but they are much more expensive and more difficult to handle with your own hands.
The simplest in execution are heating registers made of a steel profile pipe. They can be performed in two main configurations: sectional type and serpentine (S-shaped).
In a sectional type register, several sections of profiled rolled metal with plugged ends are arranged in parallel and connected to each other by round tubes of a smaller cross section. Jumpers provide filling of rows of the device with heat carrier from two sides at the same time. At the same time, the closer the adapter pipes are installed to the edge, the higher the heat transfer of the device.
In the serpentine register, the liquid passes in an S-shape through the rows of shaped pipes, gradually cooling down. To give the structure rigidity, additional deaf jumpers are used. Horizontal rows are connected in pairs by a snake using tubes of a smaller section, as in sectional models, or segments of the main profile. The latter option is preferable because of the smaller hydraulic resistance and more heat transfer.
Connecting pipes are made with thread or for welding. Most effective option connection of the heater is a diagram from top to bottom. For low models and in the case of forced circulation of the coolant, entry and exit from below may be justified.
The design of the register necessarily provides for a Mayevsky crane or an automatic air vent. It is located at the end of the top row on a threaded fitting to enable replacement. A prerequisite for installation is the observance of a slope of 0.05% in the direction of the movement of the coolant.
Registers are both stationary and portable. The former work as elements common system heating, the latter perform the task of local heating. The heat source for a separate mobile register is a heating element with a power of 1.5-6 W, built into the housing.
Important! The distance between the rows of the register significantly affects the heat transfer. The closer the pipes are to each other, the greater their mutual influence, which reduces the efficiency of the device. It is recommended to place the rows at a distance not less than the height of the profile pipe, increased by 50 mm.
In addition to large horizontal registers, small vertical models are also in demand. With careful work, you can get home-made cheap radiators from shaped pipes, almost as good as modern sectional radiators in terms of aesthetics.
In some cases, steel registers may be good addition to the heaters already installed in the room. Despite lower heat dissipation than similarly sized radiators, their use may be more appropriate due to their lower cost.
High vertical registers are very convenient for high rooms or near high window openings. They can successfully fit into the interiors of rooms with unusual design solutions. With a little experimenting with color and shape, you can get a creative decoration from simple heating devices.
Advantages and disadvantages of a profile pipe
Most often, heating registers are made from smooth round-section water and gas pipes. They are cheaper, have better hydraulic characteristics for transporting the coolant, greater tensile strength with a small wall thickness. What caused the use of profile pipes for the manufacture of registers?
Heating radiators made of rolled metal of square and rectangular cross section have a number of important advantages:
- compactness of the device in depth;
- the ability to give an attractive appearance;
- surface area is greater than round pipe the same height;
- additional opportunities for creative design of non-standard premises;
- relatively easy to make with your own hands, do not spin during operation;
- can be made from pipe scraps left after construction work.
However, there are also disadvantages:
- the profile pipe is not intended for liquid transportation;
- lower resistance to water hammer and high pressure;
- Welds are longer than comparable round tube registers, increasing the chance of leakage and reducing the overall reliability of the instrument.
Thus, before making a decision on the advisability of using registers from shaped pipes, it is necessary to evaluate all possible options, carefully analyze the operating conditions and requirements that heating devices must meet in each case.
Choice of options
The parameters of the heating register are determined on the basis of the required heat output. The most accurate values are given by a detailed thermotechnical calculation of heat losses through building envelopes, but since it is rather laborious, we will consider alternative options.
Very approximately for a typical insulated room with a height of not more than 3 m, 1 kW of heat output per 10 m 2 can be taken. More accurate values can be determined from the table below, depending on the quality of thermal insulation and the volume of the room.
Heat dissipation 1 m.p. profile pipe is determined by the formula:
Q=K F ∆t,
K- heat transfer coefficient, W / (m 2 0 C), for single pipe K= 11.3 W/( m 2 0 С);
F is the surface area of the pipe, m 2, F \u003d 2 (a+b) l,
where a and b are the dimensions of the sides of the cross section, and l- pipe length, respectively, m;
∆t- temperature difference, 0 C, ∆t \u003d 0.5 (t 1 + t 2) - t to,
where t1 and t2– temperature of the coolant at the inlet and outlet of the device; t to- the temperature in the room.
The required pipe length is calculated by dividing the required heat output by the heat output of 1 m of pipe. The number of rows is determined with rounding up and is determined by the availability of free space and the configuration of the room. For the obtained number, the value of heat transfer is specified taking into account the mutual irradiation of pipes using a reduction factor of 0.9 for each row.
The length of the register can be taken constructively, taking into account the characteristics of the room and the location of the equipment. For example, if there is a large window, then it is desirable that the length of the threads be no less than the size of the window, creating a wide thermal curtain for cold air.
Advice! In some cases, it makes sense to take the length of the register across the entire width of the room. This will ensure the most uniform heating of the room. For objects such as greenhouses, this is especially important.
The section of the profile pipe is taken either on the basis of the available material, or is selected by trial calculations and finding the optimal combination of the section and length of the rows of the heating register. The most commonly used pipes are 60 * 40, 60 * 60 and 80 * 60 with a wall thickness of 3 mm. Large sections are not desirable, since an increased volume of coolant will create an additional load on the boiler.
On a note: Don't skimp on wall thickness. The thicker the wall of the pipe, the longer the heater will last. It will be able to withstand large pressure surges and is more resistant to corrosion.
Based on the calculations, the final selection of the parameters of the heating register is carried out and a drawing is drawn up. According to the accepted sizes ordered heating device or do-it-yourself register production.
Making registers with your own hands
Steel registers are fairly simple in construction and do not require much skill to build. Almost anyone with experience with a welding machine can make home-made heating radiators from a profile pipe. Unlike round ones, they are easy to fix in place, which makes it easier to carry out welding work.
Necessary materials and tools
Before starting work, you need to stock up on everything you need. Let us consider in detail what is required for the simplest three-row register.
Materials:
- Profile pipe in accordance with the design parameters. Dimensions can be from 30x30x3 to 80x80x3 mm.
- Round pipe with the same wall thickness with a diameter of 25 or 32 mm, depending on the section of the profile pipe.
- Steel sheet 3 mm thick.
- Branch pipes with external or internal thread in accordance with the diameter and type of connection - 2 pcs.
- Steel coupling with an internal thread with a diameter of 15 mm and a Mayevsky crane.
Tools:
- Welding machine.
- Drill.
- Bulgarian.
- A hammer.
- Marker or metal rod.
- Roulette.
Material preparation:
- The profile pipe is cut into pieces of the required length in accordance with the drawing.
- The round pipe is cut into 4 pieces of 10 cm.
- 6 plugs are cut out of sheet metal in accordance with the size and shape of the profile pipe. They should be 3-5 mm smaller than the pipe section. This will neatly hide the weld in the gap.
- The pipes are laid on a flat horizontal surface strictly parallel at a distance of 10 cm. Two wooden beams can be used for support. The ends are set in one line. Marks are made for holes at a distance of about 5-10 cm from the edge.
- Using a cutter or drill, the marked holes are cut in accordance with the diameter of the jumpers.
Work order
- The jumpers are fixed in place and tacked by welding at 2-3 points.
- Having placed the structure vertically, the jumpers are finally welded. It is recommended that you first make a thin seam at a low current, which will allow you to fill the gaps well. Next, a thick main seam is performed at increased current.
- The internal space of the register is cleaned from metal debris and slag.
- Plugs are applied, tacked and welded to the ends of the profile pipes.
- Welds are processed. The protruding parts are knocked down with a hammer, then each seam is cleaned with a grinder.
- Holes in the register are drilled depending on the selected connection scheme. At the same time, it is better to place them not in the center of the ends, but slightly higher or lower.
- Connecting pipes are welded to the holes.
- The seams are cleaned and all holes except one are muffled. The register is filled with pressurized water and the welding quality is checked. Seams must withstand pressure up to 13 atm.
- The outer surface is cleaned, degreased and painted with heat-resistant paint.
- A fitting is welded to the top row and a Mayevsky crane is installed.
Sometimes supports are welded to the register, but devices without them are more versatile. If necessary, you can always use the stand, but the weight is less and the possibility of mounting on the wall remains.
Conclusion
Homemade radiators from a profile pipe are well suited for heating large rooms. It is convenient to use mains-powered devices at objects of periodic use: construction sites, garages, workshops, cottages. Stationary registers are used in production shops, greenhouses, warehouses and other technical facilities.
They have a fairly simple design, which ensures relative ease of manufacture. This allows you to make steel registers with your own hands, which gives significant cost savings. If you wish, you can be more sophisticated and create analogues of modern design models, which can become not only effective sources of heat, but also an interior decoration.