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PDF Content Summary: Contents HYDAC INTERNATIONAL User Manual Brazed Plate Heat Exchanger HYDAC HEX Sxxx 1.Working Principle3 2. Application 3 3. Advantage4 4.Design Condition for Copper Brazed PHE4 5.Specification & BPHE Dimension4 6.Standardized Connections5 7.Installation Guide6 8. Anti-Freezing Protection Methods for BPHE7 9.Soldering Instructions 10.Cleaning 11 Warning 12. Warranty Terms9 13.Label and Marking10 Please note: Before proceeding with installation and operation read entire manual carefully. Failure to do so can cause injury or property damage. When receiving heat exchangers, any claims for damage or shortage in shipment must be filed immediately against the transportalion company by the consignee. The heat exchangers may have some sharp edges so exercise caution when handling. Provided that it is used and maintained in accordance with the generally accepted codes of good practice and the recommendations of the User manual, meets the essential safety and health requirements of the Pressure Equipment Directive 97/23/EC. 3. Advantage 5. Specification & BPHE Dimension HYDAC BPHE provides many great advantages: - Highly thermal efficiency - Compact size and less weight - High working pressure - High thermal resistances and high operating temperature - Lower cost for the same performances - Lower pressure drop and high corrosion resistance - No gaskets, no leakages - Easy installation, easy replacement, less maintenance - Durability L1 L2 W1 W2 Weight Thickness Area Volume Max No. Type mm mm mm mm kg (H) mm Myplate Liter/Channel of plate HEX S400) 194 154 80 40 10.8+0.050N 10.0+2.25N | 0.0117 | 0.025 60 HEX S500 311 278 7340 0.84+0.07N | 10.0+2.30N 0.01946 0.040 60 HEX 5610 306 250 10650 1.5+0.135N 100+2.40N 0.0255 0.055 100 HEX S510304 250 124 70 1.6+0.150N 10.0+2.40N 0.0300 0.065 100 HEX S615 522 466 106 50 3.1+0.220N 10.0+2.40N 0.0475 0.095 | 120 HEX S715 504 444 124 64 3.5+0 240N | 10.0+2.40N 0.0533 0.107 120 HEX S722 613 519 186 92 7.12+0.41N | 14.0+2.40N 10.094461 0.206 1140 HEX $522 528 456246 1747.2+0.520N 11.5+2.40N0.1099 0.232 | 160 HEX 5210 527 430 245 148 8.5+0.490N 11.5+2 85N 0.1036 0,289 160 4.Design Condition for Copper Brazed PHE 0) Working Temperalure Range A1 B2 Max Allowable | Test Pressure Pressure (PT) (PS) Type TOP HEX S400/S500 / 5610/ S510 / S615/57151 S722/S522 30 Bar 45 Bar -160-200°C HEX S210 16 Bar B1 23 Bar 1. Working Principle 2. Application HYDAC Brazed Plate Heat Exchanger (BPHE) consists of chevron plates of acid-resistant stainless steel. Every other plate is reversed so the ridges of the herringbone pattern intersect one another on adjacent plates forming a lattice on contact points. When these points are vacuum brazed together, two separate systems of channels for two media flow in counter-current are formed. The lattice structure causes vigorous turbulence, thus, ensuring maximum heat transfer, HYDAC BPHE can be used for various medias: - All type of refrigerants; ammonia will be used for nickel brazed. - Organic solvents - Water - Oil - Various brine solutions (glycol mixtures, CaCl2, alcohols etc) The BPHE is a highly efficient, corrosion-resistant and pressure resistant heat exchanger. The standard BPHE is designed to meet 30 bar, 200°C, and the largest-size handles a maximum flow capacity of 900 liter/min. HYDAC BPHE can be used: - Heat pumps - Industrial chiller; plastic machines, welding machines, hydraulic presses (oil), and compressor oil cooling Air conditioning - Refrigeration - Air dryer - Water cooler; drinking water or process water for various industries - Temperature holding for storage tanks - Heat recovery including heat recycling from hot steam - Indoor heating including floor heating Refrigerant applications, BPHE function as: - Evaporators - Condensers Super-heaters for gas Desuper-heaters for gas Subcoolers for condensate - Economizers - Intercoolers - Oil coolers 6. Standardized Connections 7. Installation Guide ** Connections for fluid applications are threaded connectors. *Connections for refrigerant units are soldered/sweat connectors, Illustration of 1: General purpose of BPHE 2 : Types of fluid applied 3: Arrangements of fluids directions Threaded Connections PTINPTIGD -Male PTINPT/GB-Female 3/4 1 2 ' 2-1/2' 3" (1723/4'1 1-14" 1-12 2" 2-/2" % od Type 1/2 HEX S4001 HEX S500X HEX S6101 HEX S5101 HEX S615 HEX S715 HEX S722 HEX S522 HEX S2101 22: 41 ** X X X 1 Soldered Connections 5/8" ID 16.15 7/8" 10 22.36eim 1-/8" 1-3/8" 1-5/8". ID 28.80mm J1D 35 25mm 10 41.50mm X Application Fluid 1 Fluid 2 Fluid 3 Type 1/2" ID 12.90mm HEX 5400 * HEX S500 X HEX 5610 HEX S5101 HEX S6151 HEX S7151 HEX S722 HEX S522 HEX S210 Evaporator (single refrigerant) Evaporator (dual refrigeranl) Refrigerant A2A1 Refrigerant 1 A2A1 Chiller water B2-B1 Chiller water B2-B1 Refrigerant 2 C2-01 Condenser Heating, Cooling Refrigerant | Cooling water A1-A2 B1-B2 Cold water Hot waler A2A1 B2-B1 Cooling water A1 A2 B1-B2 Oil Oil cooler Refrigerant A2-A1 Air Dryer (Refrigerant) Air&Oil cooling (Air compressor) Air D2–(D1)+(82) --B1Separator-C1-C2 Cooling water D26D1(B2)-1 C1-C2 Air Oil A2-A1 Soldered Connections Threaded Connections 8. Anti-Freezing Protection Methods for BPHE! *Always install your BPHE vertically, especially for a refrigerant system, in order to be secured and keep less volume of water below the connector. * In order to achieve high thermal efficiency and high heat transfer rates, BPHE is better to be installed in counter flow direction. When BPHE works as an Evaporator, the two-phased (liquid an gas) refrigerant enters the evaporator at the bottom left connector and the single-phased (gas) refrigerant leaves the evaporator from the top left connector after heat transferring. The water enters at the top right connector and leaves from the bottom right. In the case of evaporator, heat is transferred from water to refrigerant and both fluids are in counter flow direction, *When BPHE works as a condenser, the single-phased (gas) refrigerant enters the condenser at top left connector and the single-phased (liquid) refrigerant leaves the condenser from the bottom left connector The water enters the condenser at bottom right and leaves the condenser from top right. In the case of condenser, heat is transferred from refrigerant to water and both fluids are in counter flow direction. -Any formation of freezing oricing will damage BPHE and the refrigeration system. The following methods will prevent BPHE from freezing up -Use brine (e.g. glycol) when evaporation temperature is close to the freezing point. -Low working pressure will cause low evaporation temperature. Ir the evaporation temperature is below 00, it will cause the water to freeze up. As a result, evaporator is being expanded and finally cracked open especially the bottom portion of the PHE. Since bottom portion has the lowest temperature. -To start the refrigeration system, always starting with the water pump for a few minutes, and then starting the compressor. To stop the system, always stopping with the compressor, and then stopping the water pump. (1) Low Pressure Cut-off Switch (LP) A low-pressure cut-off switch shall be installed and the value shall be set properly. When the actual evaporation pressure is lower than the setting value, the compressor will be cut off automatically. (2) Low Temperature Thermostat (LT) The function of thermostat is to prevent evaporation temperature going under 0°C. If evaporation temperature is always above 0C; than water has no chance to freeze up and expand. (3) Water Temperature Sensor Installation of an Anti-freezing temperature sensor near the water outlet is another method to prevent the water from freezing up. The setting temperature is suggested at 4°C for buffering purpose. (4) Water Flow Switch Installation of a water flow switch in the water circuit can prevent possible BPHE freeze-up due to low water flow rate, Usually, low water flow rate may cause by malfunction of water pump, leaking pipes, pipe blockage due to pipe contamination or dirty filter. *Mounting suggestions: There are four different ways to mount the BPHE: (a)Bottom support (b) Sheet metal bracket, (c) Crossbar& bolts, (d) Stud bolts (a) (b) (C) (d) -All items should be supported independently. -Do not apply excessive forces to the fittings. -Except for small in sized HYDAC HEX $400, brazed PHE cannot fasten directly to the fittings/piping. -Using flexible hoses or vibration dampers to reduce pulsation, shock or vibrations those are caused by the operating system. 12. Warranty Terms 13. Label and Marking Free of charge if what defects are caused by manufacturing material or manufacturing workmanship. - Warranty period is 12 months after exit factory delivery or else, by contract with the purchaser. A1 TOP B2 HYDAC brazed plate heat exchanger Type: - Exceptions are: (1) The failure or malfunction of BPHE is caused by improper or negligent usage of BPHE. (2) Malfunctions from Freezing or icing, flood, fire, or any natural disaster, or accident, (3) Damages cause by improper or faulty installation, or product exposed to corrosive elements harmful to the structure. Max. working temperature: 200 °C Max. working pressure: bar Test pressure: bar 4. A1B21 OTO CE A2 HYDAC B1 Manufactured by KHT Taiwan For tracking purposes, model name and serial number will be embossed on the plate of the front cover below the two upper connectors of the BPHE. 9. Soldering Instruction 11. Warning Cleaning and degreasing the surface of copper pipes and PHE connectors before soldering is important. To avoid the inside of copper pipes and BPHE from Oxidation, protect the inside with N,-gas. Put the BPHE on a flat surface and wrap a wet rag around the connectors to protect the BPHE from excessive heatino. Use a 40-45% silver alloy soldering rod to weld the copper pipe into the connector at a max. of 800°C. After soldering, clean and dry the connection and BPHE. 10. Cleaning Cleaning of fouled plate heat exchangers is important Back flushing will remove most of the soft debris that is blocked the inside. The solution used by back flushing shall be weak acid with concentration less than 5%, for example citric acid. If acidity is too high, the copper and stainless steel, which is Inside the PHE, might be etched or corroded. Before restarting the system, flush the plate heat exchanger with large amounts of fresh water to purge any remaining acid solution. - Fluid that is explosive, extremely flammable, highly toxicant, highly corrosive, hazardous or etc. Cannot apply to BPHE. Examples are ammonia, nitric acid. sulfuric acid, etc. When unknown quality of water is applied to BPHE. filter and strainer should be place at the water inlet of BPHE to filter out the dirt or large particles, Mesh size of around 20 is suitable for most cases. Blockage of evaporator due to dirt or large particles will reduce the flow rate of water then the water will freeze up, consequently might cause the crack of the BPHE. Chlorinated water. seawater, etc. are not suitable for BPHE because it will corrode and damage the BPHE. For example, swimming pool water - Solution which applied to BPHE shall have PH value range between 6 - 8. Ground water with high sulfuric compound, sulfuric acid, low PH value, may cause gradual copper corrosion and damage the BPHE in a few years, Rubber ring always mounts or adheres the bottom edge of the BPHE in order to protect the hand and wrist against the sharp metal edges. If the rubber ring is not a required part of your order, watch out for the sharp metal edge. - When moving BPHE, always wear gloves and pay attention to the sharp edges around the bottom of BPHE. Some BPHE comes with rubber strips that covers the sharp edge of the BPHE but some does not. It all depends on your request. Weak Acid EC DECLARATION OF CONFORMITY According to the following EC Directive -Pressure Equipment Directive: 97/23/EC Brazed Plate Heat Exchangers (BPHE) Type: Pressure Bearing Material: Steel 304 (ASTM A240 or JIS G4304/G4305) Steel 316 (ASTM A240 or JIS G4304/G4305) Provided that it is used and maintained in accordance with the generally accepted codes of good practice and the recommendations of the User Manual, this device meets the essential safety and health requirements of the Pressure Equipment Directive, To prevent the most specific risks of this device, the safety and compliance with the essential requirements of the Direclive have been applied. The design, fabrication, inspection and testing should comply with: ASME Boiler and Pressure Vessel Code Section VI, and EN 14276-1 Pressure equipment for refrigerating system and heat pumps, Part 1: Vessels - General requirement. Brazing Procedure Reference: EN 14276-1, Annex B, and ASME Section X Head Office HYDAC INTERNATIONAL GMBH Industriegebiet 66280 Sulzbach/ Saar Germany For the procedure of EC conformity assessment, the manufacturer cliooses Module Dl for the complete serials of products, which covers the Category I. I at present, and are used for Fluids in Group 2 of pressure vessel equipnient Notificd Body is DET NORSKE VERITAS and the Identification number is 0575 Tel.: +49 (0)6897/509-01 Fax: +49 (0) 6897/509-577 E-Mail: email@example.com Internet: hydac.com
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