Bayerteq Thermal Cycling Unit – TCU Series (Temperature Cycling Tester)
- Advanced multi-station thermal cycling unit for assessing temperature cycling resistance in hot and cold pressurized piping systems
- Full compliance with ISO 19893, ISO 10508, ASTM F1335-98, DVGW W 534, DVGW W 542, DVGW W 543, and EN 12293
- Supports 1 to 6 independent test stations accommodating pipe diameters up to Ø 110 mm
- Controlled temperature range from 20 °C to 95 °C with tight temperature uniformity (<1 °C) and dual hot/cold tank architecture
- Adjustable pressure ratings from 4.0 to 12.0 bar (optional up to 16.0 bar) with ±0.5 bar regulation precision
- High-capacity circulation pumps up to 18 m³/h @ 12 bar; optional pre-stress loading system with digital load cells
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The thermal cycling unit (TCU Series) developed by Bayerteq is an advanced materials testing apparatus designed to evaluate the thermal fatigue resistance, joint integrity, and long-term mechanical stability of thermoplastic pipes and fittings subjected to alternating hot and cold water cycles under sustained internal pressure. Engineered in strict compliance with international standards including ISO 19893, ISO 10508, and ASTM F1335-98, this system serves as the definitive certification tool for potable water, plumbing, and heating distribution networks.
Plumbing networks conveying pressurized hot and cold water experience continuous thermal expansion and contraction cycles that generate severe stresses at pipe-to-fitting joints. The Bayerteq thermal cycling unit reproduces real-world operational service conditions by alternating pressurized hot water (up to 95 °C) and cold water (down to 20 °C) through test specimens across thousands of predefined cycles while monitoring for leaks, joint disconnection, and structural degradation.
Thermal Cycling Unit System Architecture & Station Capabilities
The TCU is designed around a high-efficiency modular platform delivering flexible testing options:
- Multi-Station Configuration (1 to 6 Stations): Accommodates up to 6 individual pipe assembly lines simultaneously. Each station allows independent selection of cycle duration, flow rate, and pressure levels to suit different pipe dimensions up to Ø 110 mm.
- Dual Independent Tank Architecture: Features separate insulated stainless steel hot and cold water storage tanks. The hot tank utilizes heavy-duty electric heating elements, while the cold tank is cooled via a dedicated chiller and high-efficiency plate heat exchanger.
- High-Flow Pressure Pumping System: Equipped with industrial multi-stage pumps delivering flow rates up to 18 m³/h at pressures up to 12.0 bar (or 16.0 bar optional), maintaining consistent fluid velocity through all test loops.
- Optional Pre-Stress Tensile Loading: Integrated mechanical tension frames equipped with calibrated load cells apply defined tensile pre-stress loads to pipe specimens during thermal cycling, satisfying specialized DVGW and EN qualification criteria.
Every Bayerteq thermal cycling unit features fully automated water replenishment, digital pressure regulation with ±0.5 bar accuracy, lockable test chamber enclosures, and emergency stop protection for 24/7 unmonitored endurance testing.
Bayerteq TCU Series – Technical Specifications
| Parameter | Specification Details |
|---|---|
| Applicable Standards | ISO 19893, ISO 10508, ASTM F1335-98, DVGW W 534, DVGW W 542, DVGW W 543, EN 12293 |
| Number of Test Stations | 1 to 6 individual, independently controllable test stations |
| Specimen Diameter Range | Up to Ø 110 mm (Custom clamping adapters available for larger dimensions) |
| Operating Pressure Range | 4.0 bar to 12.0 bar (Standard) / 4.0 bar to 16.0 bar (Extended High-Pressure Option) |
| Pressure Control Accuracy | ±0.5 bar throughout cycling transitions |
| Pumping Capacity Rate | Up to 18 m³/h @ 12 bar (Independent circulation and booster pumps per circuit) |
| Temperature Range | 20 °C to 95 °C |
| Cold Water Control Accuracy | ±2.0 °C |
| Hot Water Control Accuracy | ±1.0 °C |
| Temperature Uniformity | < 1.0 °C within test volume |
| Cycle Configuration | Freely programmable dwell times, transition speeds, flow rates, and pressure curves per station |
| Thermal Reservoirs | Dual stainless steel tanks; heating tank with electric immersion heaters; cooling tank with external chiller & plate heat exchanger |
| Water Management | Automatic water replenishment and liquid level sensors with dry-run heater interlocks |
| Optional Pre-Stress Unit | Tensile pre-stress loading system with precision load cells and mechanical clamping |
| Safety & Enclosure | Fully enclosed test bay with lockable transparent safety doors, emergency stop, leak detection tray |
Key Operational & Engineering Advantages
Independent Multi-Station Testing
Operates 1 to 6 stations concurrently with individual cycle profiles, flow settings, and pressures, maximizing laboratory throughput and flexibility.
Dual Hot & Cold Tank Separation
Independent stainless steel reservoirs for heating and chilling eliminate thermal contamination and enable sharp, fast temperature cycle transitions.
High-Volume Circulation Pumps
Industrial multi-stage pumps delivering up to 18 m³/h at 12 bar ensure strict adherence to standardized water flow velocities per ISO 19893.
Optional Tensile Pre-Stress System
Integrated load cells apply tensile loading along the pipe axis during thermal cycling, meeting demanding DVGW W 534 and European test standards.
Automatic Water Level Regulation
Automated replenishment circuits maintain proper tank levels at all times, with integrated dry-run cutoff switches to safeguard heating elements.
Comprehensive Operator Safety
Lockable test enclosure doors prevent accidental contact with hot pressurized pipes, backed by safety interlocks and immediate emergency stop controls.
System Architecture & Optional Add-ons
1. Station Expansion Modules
Modular station configurations from 1 to 6 lines, customizable to specific laboratory footprint and testing volume demands.
2. Pre-Stress Tensile Loading Kits
Mechanical tension frames with digital load cells to apply continuous axial pre-stress forces on pipe specimens during thermal cycling.
3. Digital Flow Measurement & Control
High-precision digital flow meters per station for continuous velocity logging and automated proportional flow regulation.
4. External Water Chiller System
Dedicated industrial water chiller unit coupled with stainless steel plate heat exchangers for rapid cold-water stabilization at 20 °C.
Industry Standards & Practical Applications
The Bayerteq thermal cycling unit is essential for quality assurance laboratories, certification bodies, and pipe manufacturing facilities:
- Potable Water & Plumbing Systems (ISO 10508 / ISO 19893): Verification of multilayer composite pipes (PE-RT/Al/PE-RT, PEX/Al/PEX) and polyolefin piping systems under cyclic thermal and pressure stress.
- Radiator & Underfloor Heating Networks: Long-term thermal durability qualification of hot-water heating conduits subjected to alternating operational heating cycles.
- Mechanical Fittings & Joint Qualification (DVGW W 534): Testing the tightness and pull-out resistance of press-fittings, push-fit joints, and compression fittings during 2,500 or 5,000 thermal cycles.
- Multilayer Pipe Certification (DVGW W 542 & W 543): Verification of adhesive layer integrity and barrier performance under alternating hot (95 °C) and cold (20 °C) cycles.
- Composite Pipe Evaluation (ASTM F1335-98): Establishing classification parameters and fatigue life margins for pressure-rated composite plumbing systems.