Brazed Plate Heat Exchangers - Xylem Inc.

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INSTRUCTION MANUALINSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.Brazed Plate HeatExchangers

Table of ContentsIntroduction and Safety . 2Introduction. .2Safety .2Safety terminology and symbols .2User Safety .3Product warranty .4Product Description .5General description . .5Installation .6Piping arrangement . .6Soldering instructions . .7Connection max. torque . .7Mounting max. torque . 8Operation .9Startup and shutdown procedures . .9Maintenance .10Cleaning procedures . .10Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual1

Introduction and SafetyINTRODUCTIONThe purpose of this manual is to provide necessary information d this manual carefully before installing and using the product.Improper use of the product can cause personal injury and damages toproperty and may void the warranty.NOTICE:Save this manual for future reference, and keep it readily available at thelocation of the unit.SAFETYWARNING:-The operator must be aware of safety precautions to prevent physical injury.-Operating, installing, or maintaining the unit in any way that is not covered inthis manual could cause death, serious injury, or damage to the equipment.This includes any modification to the equipment or use of parts not providedby Xylem. If there is a question regarding the intended use of the equipment,please contact a Xylem representative before proceeding.-Do not change the service application without the approval of an authorizedXylem representative.CAUTION:You must observe the instructions contained in this manual. Failure to do socould result in physical injury, damage, or delays.Terminology and symbolsIt is extremely important that you read, understand, and follow the safetymessages and regulations carefully before handling the product. They arepublished to help prevent these hazards:-Personal accidents and health problems-Damage to the product-Product malfunctionBrazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual2

Hazard levelsDANGER:A hazardous situation which, if not, avoided, will result in death or serious injuryWARNING:A hazardous situation which, if not, avoided, could result in death or serious injuryCAUTION:A hazardous situation which, if not, avoided, could result in minor or moderateinjuryNOTICE:-A potential situation which, if not avoided, could result in undesirable conditions-A practice not related to personal injuryHazard categoriesHazard categories can either fall under hazard levels or let specific symbolsreplace the ordinary hazard level symbols.These are examples of other categories that can occur. They fall under theordinary hazard levels and may use complementing symbols:-Crush hazard-Cutting hazard-Arc flash hazardUSER SAFETYGeneral safety rulesApplicable general safety rules:-Always keep the work area clean.-Pay attention to the risks presented by gas and vapors in work area.-Avoid all electrical dangers and pay attention to the risks of electric shock or arcflash hazards.-Always bear in mind the risk of drowning, electrical accidents, and burn injuries.Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual3

Safety equipmentUse safety equipment according to the company regulations. Use this safetyequipment within the work area:-Hard hat-Safety goggles, preferably with side shields-Protective shoes-Protective gloves-Gas mask-Hearing protection-First-aid kit-Safety devicesNOTICE:Never operate a unit unless safety devices are installed. Also see specificinformation about safety devices in other chapters of this manual.This product can expose you to Hexavalent Chromium, which is known tothe state of California to cause cancer and birth defects and otherreproductive harm. For more info go to: www.P65Warnings.ca.govPRODUCT WARRANTYCoverageXylem undertakes to remedy defects in products from Xylem under theseconditions:-The faults are due to defects in design, materials, or workmanship.-The faults are reported to a local sales and service representative within thewarranty period.-The product is used only under the conditions that are described in this manual.-All service and repair work that is done by Xylem authorized personnel.-Genuine Xylem parts are used.LimitationsWarranty does not cover defects caused by:-Deficient maintenance-Improper installation-Modifications or changes to the product and installation that are made withoutconsulting a Xylem authorized representative-Incorrectly executed repair work-Normal wear and tearXylem assumes no liability for the following situations:-Bodily injury-Material damages-Economic lossesBrazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual4

Warranty claimXylem products are high quality products with expected reliable operation and longlife. However, should the need for a warranty claim arise, contact your local salesrepresentative or the manufacturer.Product DescriptionGENERAL DESCRIPTIONBrazed plate heat exchangers consist of thin corrugated stainless steel platesbetween a thicker frame plate and pressure plate that are vacuum brazed togetherto form a durable, integral piece that can withstand both high pressure andtemperature.The corrugated plate design provides very high heat transfer coefficients resulting ina smaller surface area and compact design.Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual5

InstallationWARNING:Many heat exchangers circulate fluids which are irritating or dangerous tothe human system. These fluids could cause problems if bolted orthreaded joints are not maintained in a leak tight condition at operatingpressures, temperatures, an no flow, ambient conditions.CAUTION:Even if fluids are not irritating or dangerous, a leak could cause a slipperysituation on the floor below.CAUTION:Since one fluid in the heat exchanger is at a higher temperature, any leaksmay cause burns.CAUTION:Brazed plate heat exchangers have exposed sharp metal surfaces.Protective gloves are recommended during handling.1. Upon receipt of the exchanger, inspect for shipping damage, especially to the connections. Ifdamage is extensive, notify the carrier immediately. Finally, check the heat exchanger againstproper drawings and spec sheets to make sure everything is as expected.2. Before piping up, inspect all openings in the heat exchanger for foreign material. Remove all plugsand shipping covers immediately prior to installing. Make sure it is thoroughly cleaned to removeall preservation materials, if any were used, unless the material is soluble in the system fluid.3. For single phase fluids, the heat exchanger can be mounted in any orientation that is convenientand should be piped in a counter current, parallel flow arrangement. For two phase fluids, the heatexchanger should be mounted vertically and piped as shown in Figure 1 and Table 1. Connectionsmay be either on the front or back of the exchanger.Liquid to LiquidGeneralHot InletHot OutletCold InletCold OutletF1/B1F4/B4F3/B3F2/B2Snow Melt/ Radiant Floor/Domestic/ PoolBoiler SupplyF1/B1Boiler ReturnF4/B4Process SupplyF3/B3Process ReturnF2/B2RefrigerationEvaporatorRefrig. InletRefrig. OutletH2O inletH2O outletF4/B4F1/B1F2/B2F3/B3CondenserRefrig. InletRefrig. OutletH2O inletH2O outletF1/B1F4/B4F3/B3F2/B2FIGURE 1TABLE 1Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual6

4. Provide air vent valves for the heat exchanger so that it can be purged to prevent or relieve vaporor gas binding.5. Install proper relief valves and temperature alarms to insure the heat exchanger isn’t subject toconditions beyond the intended design.6. Don not weld or braze brackets or attachments directly to body of heat exchanger.7. For soldering type connections braze with minimum 45% silver solder and at a maximum 1200 F.For welded type connections use TIG or MIG welding. Avoid overheating. A wet cloth or ragshould be placed around the base of the connection. A nitrogen purge should be used to avoidinternal oxidation. Braze or weld with exchanger in the vertical position.8. The nozzle connections are designed for normal torque force and damage may occur if overtightened. The use of pipe sealant materials compatible with the system fluids is recommended forthreaded type connections. Connection load limits should be observed and are shown in Figure 2,Table 2, and Table 3.435 psig Standard DesignModelT (lbs)F (lbs)Mb (in-lbs)Mv (in-lbs)400, 40528361150328636410, 411, 412458913755401416415458913755401416422, 423, 4246247230026004373432, 433, 434,435ConsultFactoryConsultFactoryTABLE 2150 psig Pressure DesignTFModelT (lbs)F (lbs)Mb (in-lbs)Mv (in-lbs)Mb4002001002020028013027300Mv410, 411,412FIGURE 2TABLE 3Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual7

9. For units with integral mounting tabs ensure unit is fully supported in place prior to tightening thesupport tab bolts. Do not use the support tab bolts to pull the unit into position. Ensure the correctnumber and size of bolts for the unit type is used to bolt the unit into place. Bolt unit into placeusing the maximum torque values in Table 4.10. For units supplied with mounting studs use Table 5 for maximum torque values. Damage mayoccur if studs are over tightened. Unit should be fully supported in place prior to tightening thestuds. Do not use the studs to pull the unit into position.11. Units with integral mounting tabs can be mounted using U-bolts or a customer supplied/fabricatedbracket.12. Units with mounting studs can be mounted using a customer supplied/fabricated bracket.Mounting Tab Bolt Maximum Tightening ForceGrade 8 Clean Lubricated Bolts#Unit TypeBolts40024054410, 411, 412, 4152422, 423, 4244Bolt SizeTorque lb-ft¼” - 20¼” – 203/8” – 16½” - 13882460TABLE 4Mounting Stud Maximum Torque ValuesGrade * Clean Lubricated BoltsStud Size1/4”-20Torque lb-ft83/8”-16241/2”-1330TABLE 5Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual8

OperationWARNING:A heat exchanger is a pressure vessel designed for operation at certainspecific limits of pressure and temperature. The cooling or process system,which includes the heat exchanger, must be safeguarded with safety valvesand controls so that these heat exchanger design conditions are notexceeded. All operating personnel should be made aware of these specificdesign pressures and temperatures prior to start-up.1. Insure the entire system is clean prior to start-up to prevent plugging of passages with debris. Theuse of strainers or settling tanks in pipelines leading to the heat exchanger is recommended. Therecommended strainer size is 20-24 mesh.2. Start operating gradually. See Table 6 for suggested start-up and shut-down procedures for mostapplications. If in doubt, consult the nearest Xylem Heat Transfer representative for specificinstructions.3. Do not operate the heat exchanger under pressure and/or temperature conditions in excess of thespecified design limits shown on the nameplate attached to the heat exchanger.4. Drain all fluids when shutting down to eliminate possible freeze-up and/or corrosion issues.Type ofFluidRelativeTemperatureType wnProcedureShut down bothfluids gradually atthe same time.LiquidHotLiquidColdStart both fluidsgradually at thesame time.GasHotLiquidColdStart cold fluid firstthen hot fluid.Shut down hot fluidgradually then coldfluid.Shut down coldfluid first then hotfluid.Shut down coldfluid first then hotfluid.CondensingGasHotLiquidColdStart hot fluid firstthen slowly startcold fluid. Avoidtemperatureshock.Liquid orGasHotVaporizingLiquidColdStart hot fluid firstthen cold fluid.TABLE 6Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual9

Xylemwww.xylem.com/standardxchangeStandard Xchange is a trademark of Xylem Inc. or oneof its subsidiaries. 2018 Xylem Inc.Brazed Plate IOMSeptember 2018

Brazed Plate Heat Exchangers Installation, Operation, and Maintenance Manual 9 WARNING: A heat exchanger is a pressure vessel designed for operation at certain specific limits of pressure and temperature. The cooling or process system, which includes the heat

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